Professional Documents
Culture Documents
CSP 900rmm 2 - I1r34p
CSP 900rmm 2 - I1r34p
FILING INSTRUCTIONS:
1. Before you put this revision in the manual, make sure the manual contains all the revisions
from before. Look at the last revision List of Effective Pages.
Do not put this revision in the manual, if the manual does not contain all the
CAUTION revisions from before.
2. To include this revision in the manual, remove old pages and put in new pages as shown below.
3. This revision includes all the Temporary Revisions since last revision. It is permitted to put this
revision in the manual if Temporary Revisions were not put in.
Transmittal
Page 1
320000 601 and 602 . . . . . . . . . . . . 601 and 602
1 and 2 . . . . . . . . . . . . . . . . 1 and 2 611 thru 618 . . . . . . . . . . . . 611 thru 618
101/(102 blank) . . . . . . . . . 101 and 102 801 thru 810 . . . . . . . . . . . . 801 thru 810
401 thru 411/(412 blank) . 401 thru 416 Chapter 63
601 thru 610 . . . . . . . . . . . . 601 thru 612 i thru x . . . . . . . . . . . . . . . . . i thru x
801 and 802 . . . . . . . . . . . . 801 and 802
631000
Chapter 53 401 thru 409/(410 blank) . 401 thru 412
i thru xii . . . . . . . . . . . . . . . . i thru xii 601 thru 608 . . . . . . . . . . . . 601 thru 610
532000 801 thru 804 . . . . . . . . . . . . 801 thru 804
201 and 202 . . . . . . . . . . . . 201 and 202
Chapter 64
534000 i and ii . . . . . . . . . . . . . . . . . i and ii
201 thru 220 . . . . . . . . . . . . 201 thru 222
643000
535500 401 thru 416 . . . . . . . . . . . . 401 thru 420
405 and 406 . . . . . . . . . . . . 405 and 406
601 and 602 . . . . . . . . . . . . 601 and 602 Chapter 67
801 thru 804 . . . . . . . . . . . . 801 thru 804 671000
Chapter 62 603 thru 606 . . . . . . . . . . . . 603 thru 606
i thru viii . . . . . . . . . . . . . . . . i thru x 623 and 624 . . . . . . . . . . . . 623 and 624
620000 672000
101/(102 blank) . . . . . . . . . 101 and 102 437 and 438 . . . . . . . . . . . . 437 and 438
621000 607 and 608 . . . . . . . . . . . . 607 and 608
401 thru 406 . . . . . . . . . . . . 401 thru 410 617 and 618 . . . . . . . . . . . . 617 and 618
601 thru 608 . . . . . . . . . . . . 601 thru 612 Chapter 71
801 and 802 . . . . . . . . . . . . 801 and 802 i thru vi . . . . . . . . . . . . . . . . . i thru vi
622000 712000
411 thru 424 . . . . . . . . . . . . 411 thru 426 None . . . . . . . . . . . . . . . . . . 801 thru 804
Transmittal
Page 2
Rotorcraft
900 Series
MD Explorerr
(MDHI Model MD900r)
Cover/Title Page
MD Helicopters Inc.
4555 East McDowell Road
Mesa, Arizona 852159734
RESTRICTED USE
MDHI provides this manual for use by owners, operators and maintainers of MDHI
products and authorized parts. Use by STC or PMA applicants or holders as
documentation to support their certificates is not an authorized use of this manual and
is prohibited. MDHI takes no responsibility for customer's use of parts manufactured
under an STC or PMA when this manual is used as documentation with the Federal
Aviation Administration to justify the STC or PMA. Use of unauthorized parts on
MDHI products will void the MDHI warranty offered to the customer on components
and may void the warranty on the helicopter.
MD Helicopters Inc.
4555 East McDowell Road
Mesa, Arizona 852159734
MD HELICOPTER, INC.
TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
This manual has been prepared and distributed by the Technical Publications Department and is
intended for use by personnel responsible for the maintenance of MDHI Helicopters. Periodic revision
of this manual will be made to incorporate the latest information. If, in the opinion of the reader, any
information has been omitted or requires clarification, please direct your comments to this office via
this form (or a duplicate). An endeavor will be made to include such information in future revisions.
MD Helicopters, Inc.
Bldg 615 M/S G048
4555 East McDowell Road
Mesa, AZ 852159734
Telephone: (800) 3108539
Technical Publications Changes: (480) 3466212; FAX: (480) 3466809
Technical Publications Order Desk: (480) 3466372, FAX: (480) 3466821
Date:
Originator:
Address:
EMail:
Manual Title: Page Number(s):
Chapter Title: Paragraph Number(s):
ATA Section Number: Step Number(s):
Issue Date:
Figure Number(s):
Revision No. and Date:
Table Number(s):
Remarks / Instructions:
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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Revision 34
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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LOEP Revision 34
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Rotorcraft Maintenance Manual
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
CSP900RMM2
Front Matter
Cover/Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover/Title Page
CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Change Request
TR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record of Temporary Revisions
LOEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Effective Pages
Aircraft General
Chapter 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
Chapter 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Airworthiness Limitations
Chapter 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continued Airworthiness Inspections
Chapter 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and Areas
Chapter 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting and Jacking
Chapter 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leveling/Weight and Balance
Chapter 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing
Chapter 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking and Mooring
Chapter 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Placards 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 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AntiTorque Assembly
Chapter 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flight Controls
Powerplant
Chapter 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powerplant
Chapter 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Bleed Air
Chapter 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Controls
Chapter 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Exhaust
Chapter 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil
CSP900RMM3
Electrical
Chapter 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicators, Recording Systems, and Navigation
Chapter 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Power
Chapter 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Avionics
Chapter 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring
Page i
Contents Revision 29
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
01 Introduction 25 Equipment/Furnishings
010000 Introduction 251000 Crew Compartment Interior
252000 Cabin Compartment Interior
04 Airworthiness Limitations
255000 Baggage Compartment Interior
040000 Airworthiness Limitations Trim
05 Continued Airworthiness Inspections 255500 Cargo Hook System
Page ii
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page iii
Contents Revision 6
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page iv
Revision 19 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Chapter
INTRODUCTION
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
TABLE OF CONTENTS
Para/Figure/Table Title Page
01-00-00 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Aircraft Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. 900 CONFIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. 902 CONFIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Engine Conversion Modification from PW206A or PW206E to PW207E . . . . . . . 2
3. Helicopter Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. MD Explorer Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. Rotorcraft Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Rotorcraft Flight Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Standard Practices Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. Illustrated 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
11. MDHI Publications Revisions and Reissues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Reissue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
12. Service Bulletins and Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
13. Application of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A. Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Service and Operations Report Form 853 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Maintenance and Operational Test Instructions and Precautions . . . . . . . . . . . . . . 201
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01 Contents Revision 29
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
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Revision 29 01 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
010000
Introduction
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
INTRODUCTION
DESCRIPTION AND OPERATION
1. Introduction A. 900 CONFIG
The MD Explorer (Model MD900) is a light The 900 CONFIG designates Model MD900
twin engine helicopter, provided by MD serial numbers 90000010 thru 90000051. The
Helicopters, Inc. (MDHI). The rotorcraft is 900 CONFIG is the MD900 as originally type
certified by the Federal Aviation Administra certificated.
tion under FAA Type Certificate Number
B. 902 CONFIG
H19NM. The helicopter is designed to carry
seven people, in addition to the pilot, or it can The 902 CONFIG designation started at
be fitted for internal payloads and/or for MD900 serial number 90000052 and subse
jettisonable external payloads quent. The 902 CONFIG incorporates changes
to the original MD900 to meet the require
2. Aircraft Configuration ments of FAR Part 27 Appendix C Category A.
The major changes for the 902 CONFIG are
The Model MD900 has two main production as follows:
configurations. The configurations are
designated as the 900 CONFIG and the 902 Fuel System -The 902 CONFIG fuel system
CONFIG These designations are used incorporates a longitudinal baffle in the fuel
throughout the publications applicable to the tank to provide separate left and right fuel
MD900 to indicate where the two configura supplies. The crossfeed system is removed and
tions are different. Where the two configura a fuel transfer system installed. Vapor
tions are identical, no configuration is speci shrouding is added to fuel feed system above
fied. the upper deck.
The Model MD900 helicopter is approved for Fuel Quantity -The 902 CONFIG fuel
Pratt and Whitney engines; two (2) PW206A, quantity has a separate low level light for the
or two (2) PW206E, or two (2) PW207E. left and right side of the fuel cell.
The 900 CONFIG can have the following Powerplant - The 902 CONFIG uses the
engine models installed; Pratt & Whitney 206E or 207E engine.
- PW206A engines, Pedal Anticipator -The 902 CONFIG has a
- PW206E engines, pedal anticipator. This signals the EEC of an
- PW207E engines. impending load demand increase caused by an
increase of the anti-torque fan pitch.
The 902 CONFIG can have the following
engine models installed; NACA Inlet -(National Advisory Committee
- PW206E engines, for Aeronautics). The 902 CONFIG has an
- PW207E engines. additional engine air inlet forward of the
existing inlet designated the NACA Inlet. The
Each engine model requires a specific NACA inlet is of the submerged duct design as
Electronic Engine Control (EEC) and Inte developed by NACA.
grated Instrument Display System (IIDS).
To determine which IIDS and EEC are Anti-Torque Fan Tip Seal -An improved
necessary for each engine model, reference profile tip seal is installed on the 902 CON
CSP-900IPL-4, Section 76-00-00. FIG.
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01-00-00 Revision 26
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Any eligible MD900 helicopter with PW206A 900 CONFIG Fuel tank with 902 CONFIG
or PW206E Engines configuration, once Engine fuel supply lines.
converted, meets the MD900 with PW207E
Engines configuration Type Design. Fuel boost pump outlet fitting installed.
Completion of the conversion is not a helicop Fuel crossfeed system and the associated
ter model change and does not affect the fuel tank pump outlet check valves are
applicability of previously issued Airworthi removed (use 902 CONFIG).
ness Directives.
XFEED switch and XFEED circuit breaker
MDHI is the only maintenance facility are removed.
permitted to perform the conversion.
Left FUEL low tic mark on the IIDS does
Helicopters converted to the MD900 with not operate (#1 fuel quantity sensor is not
PW207E Engines configuration will use the installed).
existing MD900 Maintenance Publications in
addition to the appropriate Rotorcraft Flight Engine combustor wet fuel drain line ( and
Manual listed in Directives and Related fuel catch-can option) are not installed (use
Manufacturers Publications (Ref. Table 201). PW207E).
The maintenance, troubleshooting and PW207E Engine feed hose, engine feed hose
inspection procedures contained in the existing shrouding, and engine FMU shrouding (use
MD900 Maintenance Publications, 902 CONFIG).
CSP-900RMM-2 and CSP-900RMM-3, are
not affected by this conversion. The manuals Fuel system electrical (use 902 CONFIG).
already contain the various configuration
differences identified with 900 CONFIG or 902 902 CONFIG - PW207E Engine conversion
CONFIG for the airframe items and PW206A,
PW206E OR PW207E for engine configuration - For Category A helicopters (S/N 0052 thru
differences. The Illustrated Parts List 0076, 0079, 0080) 902 CONFIG with PW206E
CSP-900IPL-4 also reflects the differences. engines converted to PW207E engines, there is
no difference between the converted helicopter
Existing MD900 Service Letters and Technical and the production 902 CONFIG with
Bulletins are still applicable for the helicopter, PW207E engines. The converted helicopter is
as required. New Service Bulletins and ADs maintained as a 902 CONFIG with PW207E
for the MD900 are applicable, as required. engines.
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Rotorcraft Maintenance Manual
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01-00-00 Revision 14
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
PW207E CONFIG Lines and valves from the cyclic, collective, upper flight controls, anti-
fuel cell to engine deck are shrouded and tied. torque controls, and a vertical stabilizer
This allows for isolation of fuel leaks from the control system.
airframe and cabin. Excess fuel that is not
burned in the combustion chamber drains back Reference the KFC 900 AFCS Installation
into the fuel cell. Manual for flight control rigging of aircraft
equipped with the KFC 900 Autopilot.
Powertrain - The powertrain is mounted on
the transmission deck. The powertrain consists Environmental Control System - The
of the transmission, drive, lubrication, rotor environmental control system provides fresh
brake, and fire detection subsystems. The air, heated and cooled air for crew and
powertrain system transfers engine torque passenger comfort. The system also provides
loads to operate the Main Rotor, NOTAR, for windscreen defogging.
and Hydraulic Systems. The powertrain
system is driven by both engines or can be Electrical System - The electrical system is
driven by one engine. designed to provide the necessary electrical
power to operate and control the systems
during ground and air operations. The
Rotor System - The rotor system consists of
electrical system consists of the battery power,
the rotor hub, pitchcases, and rotor blades.
external power, DC power generation, DC
The rotor system is a five bladed fully-articu
power distribution, and lighting subsystems.
lated rotor hub located over the helicopters
center of gravity. It is mounted on the static
Instrument System - The instrument
support mast structure and receives mechani
system consists of Independent Instruments,
cal input from the rotor drive shaft. The rotor
such as airspeed, altimeter and magnetic
provides lift and helicopter lateral and
compass and the Integrated Instruments
longitudinal control. Lead-lag blade move
Display System (IIDS).
ments are dampened by elastomeric dampers.
Pitch of the blades is controlled through the
Avionics System - The avionics system
hydraulically boosted flight controls.
consists of autoflight, communications, and
navigation subsystems.
NOTAR Anti-Torque Control - The
anti-torque system provides yaw control and
4. MD Explorer Publications
stabilized helicopter rotor torque in the yaw
axis during hover and flight. The system Principle publications for the MD Explorer are
consists of an air inlet duct, enclosed articu the Rotorcraft Maintenance Manual (RMM),
lated fan driven by the transmission, air Rotorcraft Flight Manual (RFM), Illustrated
circulation control tailboom, two vertical Parts List (IPL), Standard Practices Manual
stabilizers and a direct jet thruster. (SPM), Component Maintenance Manual
(CMM), Shipping Manual, Service Bulletins,
Hydraulic System - The hydraulic system is Technical Bulletins, Service Letters and
a dual path system. Dual circuit servo-actua Ground Based Maintenance Computer
tors connect the collective and cyclic cockpit (GBMC) users guide.
controls to the upper flight controls. A single
circuit dual path servoactuator connects the The maintenance practices and procedures
anti-torque controls to the NOTAR fan and contained in MD-900 publications, are to be
direct jet thruster control linkages. The used for the MD-900 helicopter only. Study
hydraulic system components have sufficient the contents to get an understanding of the
strength to withstand combinations of loads arrangement and use of the manuals before
resulting from hydraulic pressure, vibration, working on the aircraft.
temperature variations and torque.
Operators and maintenance personnel must
Flight Controls and Rigging - The helicop refer to the current publications index for a
ter may be equipped with either right hand or complete listing of all maintenance informa
left hand control configurations consisting of tion available.
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
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01-00-00 Revision 14
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
VERTICAL
STABILIZER
HORIZONTAL
POWERPLANT STABILIZER
(ENGINE
RIGHT HAND)
UPPER COWLING
AND FAIRINGS
POWERPLANT
POWERTRAIN (ENGINE LEFT HAND)
CABIN DOOR
TAILBOOM
ASSEMBLY
FUSELAGE STRUCTURE
ASSEMBLY NOTAR
ANTI-TORQUE
CONTROL
COCKPIT
DOOR
BAGGAGE
COMPARTMENT
DOOR
ANTI-TORQUE
FUEL SYSTEM FAN ASSEMBLY
COCKPIT
DOOR
CABIN DOOR
LANDING GEAR
FLIGHT ASSEMBLY
CONTROLS 9G01-001A
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6. ATA Numbering System and Format The uniform number system established by
ATA-100 is used. This number system
(Ref. Figure 2) supplies a procedure for dividing material into
chapter, section, subject and page. The number
The MDHI Maintenance Manual and related is composed of three elements, which have two
MDHI manuals are prepared in general numbers each. The chapter and section
compliance with Air Transport Association elements (subassembly 10, 20, 30, etc.) are
Specification for Manufacturers' Technical normally established by ATA-100. Subject/
Data, ATA-100. Unit element numbers are assigned by MDHI.
1ST ELEMENT 2ND ELEMENT 3RD ELEMENT
62 10 10
CHAPTER/SYSTEM SUBJECT/UNIT
MAIN ROTOR SYSTEM MAIN ROTOR BLADE
ASSEMBLY
SECTION/SUB-ASSEMBLY
MAIN ROTOR 9G01-002A
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INTRODUCTION
MAINTENANCE PRACTICES
1. Maintenance and Operational Test 5. Maintenance Information Requests
Instructions and Precautions
Address all questions regarding the MD
All helicopter maintenance must obey all Explorer maintenance to the MDHI Field
instructions and precautions as follows. Service Representative assigned to the
geographical area in which the helicopter is
2. Pilots Flight Manual operated. If a Field Service Representative is
not in the area, contact:
If helicopter operation is necessary during or
after maintenance tests, you must obey all MD Helicopters, Inc.
instructions and limits given in the applicable Field Service Department
Rotorcraft Flight Manual and all applicable 4555 E. McDowell Road,
Optional Equipment Supplements. (Ref. Bldg. M615/G048
Table 201, Directives and Related Publica Mesa, Arizona 85215-9734
tions)
If the part you think is unserviceable is
3. Operational Tests supplied by a different company; e.g., engine,
starter-generator, fuel cells, landing gear
After maintenance, modification, removal, damper, and etc., contact the part manufactur
installation, inspection, test, cleaning, er directly (Ref. Table 201, Directives and
painting, or repair; the affected parts, assem Related Publications).
blies, installations, or systems must be
examined and an operational test must be 6. Torque Values
done before release of the helicopter for flight.
Torque values are identified in the task, the
4. Inspections Standard Practices Manual, or the illustration.
Inspection procedures and wear tolerances, A. Standard Hardware Torque Values
will be supplied in the applicable chapter text.
You must do the inspections shown in Chapter Standard hardware torque values are not
05, Continued Airworthiness. identified in the task or illustration. An
example of a standard torque is: Torque screw
Inspections in this manual are inspections for (5). Item (5) in the illustration will not show a
cracks, corrosion, distortion, components torque value. For a detailed list of standard
installed correctly, other defects, or damage. torque values (Ref. CSP-SPM Section
20-10-00, Table 202).
Inspections of fuel and oil system hoses, tubes,
and fittings include inspection for corrosion, B. Special Hardware Torque Values
leakage, and distortion.
(Ref. Figure 201)
NOTE: If more than permitted limits are found,
contact MDHI Field Service Department for Special hardware torque values are identified
instructions. in the task or are shown in the illustration. An
example of a special torque would be: Torque
Replace components that show damage or clamp (1) 10-20 in-lb (1.13-2.26 Nwm) or
wear more than permitted, or that cause item (1) in the illustration will show the
incorrect operation or security of an assembly. special torque in a box pointing to item (1).
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Vendor Publications
Battery
Saft Operating and Maintenance Manual 23861
phone: 2292452838, 275782
www.saftbatteries.com
Engine
Pratt & Whitney Canada Maintenance Manual 3038324
phone: 4506779411 (PW206A , PW206E, PW207E)
Rotor Brake
BF Goodrich Aerospace Component Maintenance Manual with BFG 419669
phone: 9374402130 Illustrated Parts List 632230 BFG 1331005
StarterGenerator
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NOTES:
(1) Publication must be kept and treated as part of the primary information file for the MD Explorer.
(2) Publication must be kept and treated as part of the information file for the MD Explorer Autopilot System.
(3) Including any associated RFM supplements that are ship specific.
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ENGINE OIL HIGH TEMPERATURE CAUTION ANNUNCIATOR ENG OIL HI TEMP CAUTION
(YELLOW)
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 ENG OIL LOW PRESS CAUTION
(YELLOW)
ENGINE OIL LOW PRESSURE WARNING ANNUNCIATOR (RED) ENG OIL LOW PRESS WARNING
GENERATOR HIGH LOAD CAUTION ANNUNCIATOR (YELLOW) GEN HI LOAD CAUTION
GENERATOR %LOAD DIGITAL DISPLAY (WHITE) GEN %LOAD DD
GENERATOR OUT CAUTION ANNUNCIATOR (YELLOW) GEN OUT CAUTION
NG HIGH WARNING ANNUNCIATOR (RED) NG HI WARNING
NG HIGH CAUTION ANNUNCIATOR (YELLOW) NG HI CAUTION
ENGINE GAS TURBINE RPM%, NG DIGITAL DISPLAY (WHITE) NG DD
NG LOW WARNING ANNUNCIATOR (RED) NG LOW WARNING
TRANSMISSION AREA FIRE WARNING ANNUNCIATOR (RED) XSMN FIRE WARNING
TRANSMISSION CHIPS CAUTION ANNUNCIATOR (YELLOW) XSMN CHIPS CAUTION
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TRANSMISSION LOW OIL TEMPERATURE CAUTION XSMN LOW OIL TEMP CAUTION
ANNUNCIATOR (YELLOW)
TRANSMISSION HIGH OIL PRESSURE WARNING ANNUNCIATOR XSMN HI OIL PRESS WARNING
(RED)
TRANSMISSION HIGH OIL PRESSURE CAUTION ANNUNCIATOR XSMN HI OIL PRESS CAUTION
(YELLOW)
TRANSMISSION OIL PRESSURE DIGITAL DISPLAY in %PSI XSMN OIL PRESS %PSI DD
(WHITE)
TRANSMISSION LOW OIL PRESSURE CAUTION ANNUNCIATOR XSMN LOW OIL PRESS CAUTION
(YELLOW)
TRANSMISSION LOW OIL PRESSURE WARNING ANNUNCIATOR XSMN LOW OIL PRESS WARNING
(RED)
FUEL WARNING TICK MARKS (RED) LH INDICATES LH FUEL WARNING TICK MARKS (902
WARNING AND RH INDICATES RH WARNING CONFIG)
LOW FUEL PRESSURE CAUTION ANNUNCIATORS (YELLOW) LOW FUEL PRESS CAUTION
CAUTIONS/WARNINGS CLUSTER CAUTION/WARNING CLUSTER
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Chapter
AIRWORTHINESS
LIMITATIONS
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
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ROTORCRAFT MAINTENANCE MANUAL
Section
040000
Airworthiness
Limitations
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
AIRWORTHINESS LIMITATIONS
DESCRIPTION AND OPERATION
1. Approval of Airworthiness Limitations specify maintenance required under 43.16
and [91.403] of the Federal Aviation Regula
The Airworthiness Limitations are Federal tions (FARs) unless an alternative program
Aviation Administration (FAA) approved and has been FAA approved.
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Rotorcraft Maintenance Manual
TR09002,
Chapter 040000
27 January 2010
(Published in
TR09006)
Page 4
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Rotorcraft Maintenance Manual
AIRWORTHINESS LIMITATIONS
MAINTENANCE PRACTICES
1. General serial number and current helicopter hours
must be recorded in the Log Book for the
The Airworthiness Limitations Schedule helicopter. The remaining number of useful life
specifies the mandatory replacement times for hours for the component with the life limit
life-limited components on the MDHI Model denotes the subsequent time at which the item
900 helicopters. must be removed from the helicopter.
At the listed life-limit hours, components or If a component with a life limit is part of an
assemblies must be removed from the helicop assembly, the assembly must be removed from
ter and permanently retired from service. the helicopter when the remaining number of
useful life hours for the component with the
At the listed inspection interval, the compo
life limit expires. The assembly may be
nents or assemblies must be inspected in
overhauled and restored to maximum number
accordance with the Rotorcraft Maintenance
of hours of useful life by installing new life
Manual (RMM) or applicable manufacturers'
limited components plus all other parts
maintenance manual.
specified in the overhaul instructions (refer to
2. Mandatory Replacement Time Component Maintenance Manual (CMM).)
The mandatory replacement time or life limit Components with a life-limit removed at
of a component of the helicopter is the as retirement are to be destroyed or conspicuous
signed maximum number of allowable ly marked to prevent inadvertent return to
operating hours. Certain assemblies and service.
components on the helicopter have a hourly 3. Airworthiness Limitations Schedule
life limit established by MDHI and approved
by FAA. The number of hours assigned to The schedule contained on the following pages
different components varies according to tabulates the mandatory replacement require
engineering fatigue tests, part experience, etc. ments.
For example, a component with an assigned
life of 1000 hours, may accumulate 1000 hours The first column of the schedule denotes to
of operation in service. Upon completion of the which model of helicopter the mandatory
1000 hours of operation, useful life of the replacement is applicable.
component is ended. The components listed in The second column contains the component
this section must be removed from the description.
helicopter at the number of hours indicated.
The third column denotes the associated
When a component with a life limit or an component part number.
assembly that incorporates a component with
a life limit is installed on a new or used The fourth column denotes the applicable life
helicopter, the nomenclature, part number, limit of the component.
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900R1441004101 10,000
900 Coupling, Fan Shaft NOTAR 900R2444002101 10,000
900R2444003101 10,000
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NOTES:
(1) Lifelimited components interchanged between models or configurations must be restricted to the lowest
service life indicated for the models or configurations affected. Lifelimited components removed at
retirement are to be either overhauled, or placed in controlled storage until the life is extended, or
destroyed or conspicuously marked to prevent inadvertent return to service. Parts are applicable only on
models under which a service life is listed.
(2) Hours listed are flight hours unless otherwise noted.
(3) Interim life; life extension in progress (ref. FAA lifelimit data, Rev. BC).
(4) Ref. applicable manufacturer publications for mandatory component replacement requirements.
(5) Special inspections required at 50hour and 100hour intervals. Refer to MDHI Service Bulletin
SB900001R5 or later, and to Section 052010 for inspection requirements.
(6) Special inspections required at 100hour and 1000hour intervals. Ref. Section 052010.
(7) Special inspection required every 500hours. Ref. Section 052010.
(8) 500N53115 TensionTorsion Straps previously installed on MD900 helicopters are lifelimited to 2,500
hours when installed on MD500N series helicopters.
(9) After 2,000 hours, the life of the Elastomeric Damping Spring is On Condition but requires performance
of a Special inspection every 100 hours thereafter until deterioration is sufficient to retire assembly. Ref.
Section 052010.
(10) Special inspection required every 1,000hours or 6 months, whichever comes first. Ref. Section 052010.
(11) Aircraft Equipped with Autopilots
The 900C3010004107 trim actuator assembly must be overhauled every 5000 hours.
Aircraft not Equipped with Autopilots
The trim actuator assembly is not considered flight critical.
(12) Life of damper may use 30,000 landings instead of 5,000 hours if aircraft logs landings. Operators who
have not logged landings can apply 6 landings per hour to determine life of part.
(13) Life limit is from date of manufacture stamped on the cartridge.
(14) Inspection required at 5,000 hours and at each subsequent 2,500 hours. Ref. Section 052010.
(15) Special inspection required every 50hours. Ref. Section 052010.
(16) Special inspections required at 100hour and 300hour intervals. Ref. Section 052010.
(17) Service life shown for the basic (no dash number) part numbers apply to all dash numbered versions
unless otherwise indicated.
(18) Part number 900R1103002101 is part of 900R1103001109.
Part number 900R1103003101 is part of 900R1103001111.
Part number 900R1103004101 is part of 900R1103001113.
Part number 900R1103005101 is part of 900R1103001115.
(19) Special inspections required at 1200hour and subsequent 300hour intervals. Ref. Section 052010.
(20) Special inspection required every 1,000 hours. Ref. Section 052010.
(21) The tensiontorsion straps have a 5 year calendar life that starts the day the package is opened (ref.
Section 643000). If the date the package was opened is unknown, the 5year calendar life is based on
the manufacturing cure date.
For straps installed before 06 March 2008 on Model MD900 helicopters serial numbers 900000008 thru
900000123, the initial calendar replacement is based on the cure date on the strap. Refer to Table 2 to
find the expiration date.
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ROTORCRAFT MAINTENANCE MANUAL
Chapter
CONTINUED AIRWORTHINESS
INSPECTIONS
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
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ROTORCRAFT MAINTENANCE MANUAL
Section
050000
Continued
Airworthiness
Inspections
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
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A. Records of Aircraft Inspections (1). Metal parts (all metal parts, bodies, or
casings of units in systems and in
Aviation regulatory agencies require pilots, electrical, instrument, and radio
mechanics, owners and operators to know and installations, ducting, tubing, rods, and
to keep records of aircraft inspections and bellcranks) do an inspection for:
repairs. This includes, but is not limited to:
(a). Cleanliness, external signs of dam
Airworthiness directives, age, leaks, overheating, discharge, or
fluid contamination.
Service notices,
(b). Obstruction of drainage or vent
Scheduled inspection records, and holes.
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ROTORCRAFT MAINTENANCE MANUAL
(c). Correct seating and sealing of (e). Attachments, end connections, and
fairings and serviceability of fasten locking devices are correctly
ers. attached.
(d). Components, fasteners, and connec (4). Electrical components (circuit protec
tions are correctly attached. tion devices, wiring, connectors, plugs,
motors, generators, actuators, relays,
(e). Distortion, dents, scores, chafing, solenoids, and contactors) do an
pulled or missing fasteners, rivets, inspection for:
bolts, or screws.
(a). Cleanliness, obvious damage, corro
(f). Signs of cracks or wear. sion, that components and connec
tions are correctly attached.
(g). Separation of bond.
(b). If protective covers are required to be
(h). Failure of welds or spot welds.
removed, check for cleanliness,
(i). Deterioration of protective treatment scoring, pitting or burning of con
and corrosion. tacts, brushes for condition, and that
exposed contacts are correctly
(2). Composite, rubber, fabric, fiberglass, attached.
and plastic parts (coverings, ducting,
flexible hoses, flexible mountings, seals, (c). Overheating.
insulation of electrical cables, windows, (d). Fluid contamination.
etc.) do an inspection for:
NOTE: For detailed wiring inspection criteria,
(a). Cleanliness, cracks, cuts, chafing, refer to CSP-SPM, Section 20-60-00.
kinking, twisting, crushing, or
contraction (sufficient free length). (5). Wire harnesses do an inspection for:
(b). Damage, delamination, or deteriora (a). Routing, contact with structure,
tion. proper support and protection.
(c). Crazing. (b). Strain at termination points, free
movement of shock-mounted or
(d). Loss of flexibility (other than fabric hinged equipment and proper slack
covered component). for equipment installation and
maintenance.
(e). Overheating.
(6). Inside fuel cell areas do an inspec
(f). Fluid saturation.
tion for:
(3). Control system components do an
(a). Leaks, cleanliness, foreign objects,
inspection for:
cracks.
(a). Correct alignment, no binding. (b). Components for general condition
(b). Distortion, signs of bowing, scoring, and are correctly attached.
chafing, fraying, kinking, signs of (c). Plumbing, and wiring for security,
wear, flattening, cracks, or loose and general condition.
fasteners.
(7). Markings, labels, and placards do an
(c). Deterioration of protective treatment inspection for:
or corrosion.
(a). Legibility.
(d). Electrical bonding correctly posi
tioned, undamaged, and applied. (b). Correctly attached.
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Section
051000
Continued
Airworthiness
Component
Overhaul
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Neither the assignment of an overhaul life to The third column (Part Number) is the
an assembly or component nor failure to applicable assembly or component part
assign a life constitutes a guarantee of any number.
kind. The only guarantees are those included
in the warranty applicable to the helicopter The fourth column (Hours) is the applicable
and any assembly or component warranty that serviceable life before overhaul.
is included in the Purchase Agreement for the
helicopter or the assembly or component. The fifth column (RMM Section) is the
applicable section of the RMM that has the
2. Overhaul Schedule procedure and requirements for overhaul of
the assembly or component. In some
Table 201 tabulates the overhaul require instances in which there is no applicable
ments for components and assemblies with RMM section, reference to other documenta
finite overhaul lives. tion or a note will appear.
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NOTES:
(1) Limitedlife components interchanged between models or configurations must be restricted to the lowest
service life indicated for the models or configurations affected. Limitedlife components removed at
retirement are to be destroyed or conspicuously marked to prevent inadvertent return to service. Parts are
applicable only on models under which a service life is listed.
(2) Refer to Section 040000 for lifelimited parts.
(3) Refer to related manufacturer publications for component overhaul requirements (ref. Section 010000).
(4) 2,500hour 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.
(5) Dual servoactuators must be overhauled by Goodrich Actuation Systems. Send dual servoactuator to
Goodrich Actuation Systems, Repair Module, 13 Avenue de IEguillette, BP 7186 (F95056
CergyPontoise Cedex), F95310 SaintOuen IAumone, France.
(6) Swashplate angular contact ball bearing requires inspection and regrease at 2000 hours or 5 years, from
original Airworthiness Certificate issuance date or last regrease, whichever comes first. Bearing must be
returned to MDHI for servicing.
(7) Return transmission to MDHI.
(8) Hours listed are flight hours unless otherwise noted.
(9) Ref. Overhaul Parts List, Rev. D.
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Section
052000
Continued
Airworthiness
Scheduled
Inspection
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
The Special Inspection schedules (ref. Section NOTE: Review and do the one-year special in
05-20-10) contain additional hourly and spections in conjunction with the Area In
calendar inspection requirements. The Special spections in the ASIP.
Inspections (Hourly and Calender) must be
complied with at the specified interval from Routine Inspection A Routine Inspection
the previous inspection or initial issuance date is to be done at one hundred (100) hour
of Airworthiness Certificate for the aircraft. intervals as part of the ASIP.
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The third column refers to the applicable performance of the specified inspection.
section of the RMM for the specified
requirements and procedures for that
inspection. All completed inspection schedules must be
kept as a permanent part of the helicopter
The fourth column is for verification of the records.
9G05-002
1. NOSE SECTION AND COCKPIT 5. POWERPLANT
2. CABIN COMPARTMENT 6. BAGGAGE COMPARTMENT
3. UPPER TRANSMISSION DECK 7. TAILBOOM AND EMPENNAGE
4. MAIN ROTOR
Figure 1. Inspection Areas
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Section
052010
Continued
Airworthiness
Special Inspections
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
50 Hour
Main Rotor: Flexbeam Inspection (PN 900R1103001109 and 111) [Ref. Note (1)]
900 Do the Flexbeam Inspection. Examine main rotor flexbeam for 622000
cracks, delamination, and defects. It is not necessary to remove the
pitchcase or use a borescope.
Main Rotor: Centering Bearing Inspection [Ref. Note (1)]
900 Do the 50Hour Inspection for the Centering Bearing Assemblies. 622000
Examine main rotor centering bearings for cracks and defects.
100 Hour
Main Rotor: Flexbeam Inspection (PN 900R1103001109 and 111) [Ref. Note (1)]
900 Do the Flexbeam Inspection. Examine main rotor flexbeam for 622000
cracks, delamination, and defects. It is necessary to remove
pitchcase or use a borescope.
Main Rotor: Flexbeam Inspection (PN 900R1103001113 and 115) [Ref. Note (1)]
900 Do the Flexbeam Inspection. Examine main rotor flexbeam for 622000
cracks, delamination, and defects. It is not necessary to remove
pitchcase or use a borescope.
Main Rotor:
900 Do the 100Hour Inspection of the Main Rotor Hub Assembly . 622000
900 Do the Main Rotor Blade Abrasion Strip Inspection. 621000
Powerplant:
900 Deleted. Moved to Section 052020, Airframe Periodic Inspection.
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100 Hour
Transmission and Drive System:
900 Do a check of the main rotor drive plate nut torque at the initial 631000
helicopter 100hour inspection. Refer to Main Rotor Drive Plate Nut
Torque Check.
900 Deleted. Moved to 1000 Hour Special Inspection.
900 Do the transmission Chip Detector Test. 632000
AntiTorque Assembly:
900 Do the AntiTorque Drive Shaft Inspection. Examine fan drive shaft 631000
for damage or defects.
900 Examine antitorque fan blades for damage and defects. Refer to 643000
Table 601. Fan Blade Damage Limits.
900 Examine counterweights on pitch horn for correct installation. Refer 643000
to AntiTorque Fan Component Inspection.
900 Examine fan hub sleeves for damage. Refer to AntiTorque Fan 643000
Component Inspection and Table 602. Fan Hub Damage Limits.
Landing Gear:
900 Examine skid tube abrasion strips for wear and correct installation. 320000
Refer to Skid Tube Assembly Inspection.
900 If ground handling wheels have been attached to Station 203 320000
forward ground handling attachment pins: and
Examine skid tube upper surface between the aft ground handling CSPSPM
wheel attach pins. Refer to Skid Tube Assembly Inspection and do 209000
a Fluorescent Penetrant Inspection.
VSCS:
900 Do the VSCS Operational Test or VSCS Check. 672000
or
Rotorcraft
Flight Manual
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100 Hour
Hydraulic System:
900 Do the Hydraulic System Operational Test (Aircraft Ground Run) or 290000
Hydraulic System Check (ref. the appropriate Rotorcraft Flight and
Manual). Rotorcraft
Flight Manual
Fuel:
900 Do the Fuel Cell Longitudinal Baffle Integrity Test (902 CONFIG). 280000
Do the Fuel Transfer System Functional Test (902 CONFIG).
300 Hour
Transmission and Drive System: 3Micron Lubrication Pump Filter Replacement
[Ref. Note (2)]
900 Remove and replace 3micron transmission lubrication pump filter 632100
assembly (ref. procedures of Lubrication Pump Filter Assembly
Removal or Installation).
Transmission and Drive System: Main Rotor Drive Shaft, Drive Plate and Static Mast
Inspection (Yearly or 300 hours whichever occurs first)
900 Do the Drive Plate Inspection and Main Rotor Drive Shaft 631000
Inspection. 633000
Remove, inspect, and regrease main rotor drive shaft and drive
plate.
Examine internal static mast in accordance with instructions of Main
Rotor Static Mast Inspection.
Main Rotor:
900 Do the Gap Check of the Blade Retention Bolts (103 and 105). 621000
900 Do the Inspection of the Upper Hub Flange. 622000
Fuel:
900 If supplemental fuel system is installed: CSPSPM
Examine the AUX FUEL XMIT circuit breaker, circuit breaker lugs
and electrical termination connections for the correct installation.
Flight Controls:
900 Do a Trim Servo PN 900C3010004107 Electronic Stop Test 671000
Verification and Replacement (Longitudinal and Lateral Trim
Actuators).
Starter/Generators:
900 Do a starter/generator bench inspection. (6)
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300 Hour
Tailboom: Tailboom External and Internal Inspection
(Yearly or 300 hours whichever occurs first)
900 Examine the control cable attach bracket for cracks, corrosion, and 534000
condition.
400 Hour
900 Do the Main Rotor Hub Assembly Upper Bearing Inspection. 622000
500 Hour
900 Examine lower damper cap assemblies for condition and proper 622000
installation, in accordance with instructions in Main Rotor Hub
Assembly Inspection.
600 Hour
Antitorque Installation:
900 Examine the fan pitch bearing, in accordance with instructions in 643000
AntiTorque Fan and Pitch Control Component Inspection Pitch
Control Inspection.
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600 Hour
Transmission and Drive System: Transmission Oil Replacement
(Yearly or 600 hours whichever occurs first)
1000 Hour
900 Do the Eddy Current Inspection of the Main Rotor Upper Hub 622000
Assembly.
Main Rotor: Drive Ring (Yearly or 1,000 hours whichever occurs first)
900 Examine Drive Ring in accordance with instructions in Main Rotor 622000
Hub Assembly Inspection.
1200 Hour
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2000 Hour
Empennage: Elastomeric Damping Spring Condition [Ref. Note (5)]
900 Do the Elastomeric Damper Condition Test. 535500
900 Examine upper and lower endplates: 535500
Exterior surfaces for apparent defects and general condition
Attachment hardware for security
For improper movement (wiggle).
NOTES:
(1) Ref. Section 040000 for part number applicability.
(2) If 3micron filter has been replaced in the last 150 hours, change 3micron filter at the next 300hour
interval.
(3) The 75micron filter can be cleaned a maximum of four (4) times. Maximum filter life cannot be more
than 1200 hours or 24 months.
(4) This inspection is to maintain the continued airworthiness of the MD900 airframe after the demonstrated
life limit has been reached.
(5) After 2000 hours, the life of the elastomeric damping 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 010000).
(7) After 1200 hours, the TensionTorsion Strap Inspection is required at 300hour intervals until the life
limits of the tensiontorsion straps are reached.
(8) If not done before, do the VSCS Actuator Regrease Procedure at the next scheduled inspection. But no
later than the next 100 hours.
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DAILY
Rotorcraft
900 During operation in a corrosive environment, do a rinse of the CSPSPM
rotorcraft (ref. the instructions in Rotorcraft Rinse). 202000
14 DAY
Rotorcraft
900 During operation in a corrosive environment, do a wash of the CSPSPM
rotorcraft (ref. the instructions in Rotorcraft Wash). 202000
6 MONTH
Main Rotor: Support, Droop Stop
900 Examine the droop stop support (ref. the instructions in Main Rotor 622000
Hub Assembly Inspection).
1 YEAR (Do a the 1 YEAR requirements in conjunction with the Area Inspections in the ASIP)
Environmental Control System: AirConditioning Compressor Reduction Gearbox
Servicing (Yearly or 600 hours whichever occurs first)
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1 YEAR (Do a the 1 YEAR requirements in conjunction with the Area Inspections in the ASIP)
Fuel System: Fuel Vent System Inspection
900 Do the Fuel Vent System Inspection. Examine fuel vent system 280000
components and interconnecting lines for condition and proper
installation.
Fuel System: Vapor Shroud System Inspection
900 Do the Vapor Shroud Box, Cover Assembly and Vapor Shroud Hose 280000
Inspection. Examine vapor shroud boxes, cover assemblies, and
interconnecting hoses for condition and proper installation.
Landing Gear: Landing Gear Cross Tube Inspection
900 Do the Forward Crosstube Inspection and Aft Crosstube 320000
Inspection. Make sure that forward and aft cross tube spread is
within allowable maximum limits.
Fuselage: Cabin Door Latch Mechanism Rigging Verification
900 Do the Cabin Door Latch Mechanism Rigging Verification 520000
Fuselage: Fuselage Internal Structure Inspection
900 Examine cockpit floor substructure and installation for distortion, 532000
corrosion, apparent defects, and security of attachment hardware:
Examine plough beams and attachment components.
Examine FS 106.00 bulkhead assembly and attachment
components.
Examine FS 130.00 bulkhead assembly and attachment
components.
Examine crew seat fittings and attachment components.
900 Examine FS 155.50 frame assembly and installation for distortion, 532000
corrosion, apparent defects, and security of attachment hardware.
900 Examine AFrame assembly and installation for distortion, corrosion, 533000
apparent defects, and security of attachment hardware:
Examine vertical leg and center beam components.
Examine forward mast fitting assemblies.
900 Examine outboard side of keel beam assemblies: 532000
For cracks, delamination, and apparent defects. and
CSPSPM
Attached ribs and components for correct installation and 209000
attachment of hardware.
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1 YEAR (Do a the 1 YEAR requirements in conjunction with the Area Inspections in the ASIP)
Pitot Static System: Pitot Static Moisture Drain
900 Examine roof structure and installation for distortion, corrosion, 533000
apparent defects, and security of attachment hardware:
Examine forward, mid, and aft deck structure longerons.
intercostals, channels and frames.
Examine flight controls support components.
Examine roof beam installation components.
900 Examine FS 230.50 bulkhead assembly and installation for distortion, 533000
corrosion, apparent defects, and security of attachment hardware.
Transmission and Drive System: Main Rotor Drive Shaft and Drive Plate Inspection
(Yearly or 300 hours whichever occurs first)
900 Remove, examine, and regrease main rotor drive shaft and drive 631000
plate.
Do the Main Rotor Drive Shaft Inspection.
Do the Main Rotor Drive Shaft Removal and Installation.
Do the Drive Plate Inspection.
Do the Main Rotor Drive Plate Removal and Installation.
900 Clean or replace transmission 75micron oil filter (ref. the instructions 632100
in Lubrication Pump Filter Assembly Removal and Installation).
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1 YEAR (Do a the 1 YEAR requirements in conjunction with the Area Inspections in the ASIP)
Main Rotor: Drive Ring (Yearly or 1,000 hours whichever occurs first)
900 Examine drive ring (ref. the instructions in Main Rotor Hub Assembly 622000
Inspection).
900 Examine lower damper cap assemblies for condition and correct 622000
installation (ref. the instructions in Main Rotor Hub Assembly
Inspection).
Flight Controls: Rotor Flight Controls
900 Do the Rotor Flight Controls Rigging Check. 671000
Fire Protection: Container Weight Verification
900 Do the Weight Verification Of Fire Bottle. 262020
Remove and weigh fire extinguisher containers.
2 YEAR
Fire Protection System: Bridgewire Resistance Test
900 Do the Discharge Cartridge Bridgewire Resistances Test. 262020
Main Rotor: Main Rotor Hub Bearing Grease Replacement
900 Replace main rotor hub upper and lower bearing grease (ref. the 622000
instructions in Upper Seal, Upper Hub Assembly and Lower Seal,
Upper Hub Assembly).
5 YEAR
Fire Protection: Hydrostatic Testing of Fire Extinguisher Containers
900 Do a hydrostatic testing of fire extinguisher containers. 262020
NOTES:
(1) The 75micron filter can be cleaned a maximum of four (4) times. Maximum filter life cannot be more than
1200 hours or 24 months.
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Equipment / Furnishings
Cargo Hook Installation: Cargo Hook System Inspections and Tests
900 Do these inspections and tests when a cargo hook is installed: 255500
After installation of the cargo hook system, do a Cargo Hook
System Functional Test.
Before each use, do these inspections and test:
General Inspection,
Cargo Hook Inspection,
Cable (Wire Rope) Inspection, and a
Cargo Hook System Operational Test.
Main Rotor
Main Rotor: Blade Retention Bolt Torque Check
900 After a main rotor blade and blade retention bolt installation, do a 621000
Blade Retention Bolt Torque Check at these intervals:
After first flight.
Every 4 to 10 hours of flight operation after the firstflight check
until:
(101) The bolt torque is not less than 800 inlb (90.4 Nm).
(103) The closing force has not changed more than 10 percent
of the recorded final installation force and is not less than 65 lbf
(29.5 kgf).
(105) The closing torque has not changed more than 10
percent of the recorded final installation torque and is not less
than 350 inlb (39.5 Nm).
Main Rotor: Main Rotor Drive Plate Nut Torque Check
900 Do a Main Rotor Drive Plate Nut Torque Check at these intervals: 631000
After first flight.
Every 4 to 10 hours of flight operation until there is no loss of
torque.
During the next 100hour inspection after an installation.
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ROTORCRAFT MAINTENANCE MANUAL
Section
052020
Airframe Periodic
Inspection Program
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
CONTINUED AIRWORTHINESS
AIRFRAME PERIODIC INSPECTION
1. Introduction Powerplant - Area 5 (ref. Table 205)
The rotorcraft is divided into 7 different Baggage compartment - Area 6 (ref.
inspection areas. The airframe periodic Table 206)
inspection includes inspections for these 7
areas and the landing gear (ref. Figure 201), Tailboom and empennage - Area 7 (ref.
and general and final requirements: Table 207)
Nose section and cockpit - Area 1 (ref. Final inspections (ref. Table 209)
Table 202) Make a copy of each table for your inspection
Cabin compartment - Area 2 (ref. records. Put your initials on the record after
Table 203) successful completion of each task. At the end
of each table is a signature block for certifica
Upper transmission deck and main rotor - tion of each airframe periodic inspection and
Areas 3 and 4 (ref. Table 204) continued airworthiness.
9G05-001
1. NOSE SECTION AND COCKPIT 5. POWERPLANT
2. CABIN COMPARTMENT 6. BAGGAGE COMPARTMENT
3. UPPER TRANSMISSION DECK 7. TAILBOOM AND EMPENNAGE
4. MAIN ROTOR 8. LANDING GEAR
Figure 201. Inspection Areas
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Signature
Date
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Rotorcraft Maintenance Manual
Table 202. Airframe Periodic Inspection Area 1, Nose Section and Cockpit (Cont.)
Fuselage
900 Examine cockpit windscreens for condition, security, and damage. 531000
900 Examine area fuselage exterior panels, and structure that is in view 531000
for damage, deterioration, and distortion. 532000
900 Examine cockpit floor panels for damage, condition, and attach 532000
hardware for correct installation and security.
Equipment / Furnishings
900 Examine crew compartment for loose equipment and correct stowage 251000
of fire extinguisher, first aid kit, and other auxiliary equipment. 256000
262010
900 Examine crew seats and floor attach fittings for condition and security 251000
of attach hardware. Do a check of the crew seat adjustment for
correct operation.
900 Examine crew restraints for condition and security of attachment to 251000
seats. Do a check of the belt adjusters, buckles, and inertia reels for
correct operation.
900 Examine crew compartment interior trim for condition and security of 251000
attachment.
Doors
900 Examine left and right crew doors: 520000
For condition and damage
Door seals for condition and damage
Attach hardware and components for damage and security.
900 Do a check of crew door latch mechanisms for correct operation. 520000
900 Examine crew door windows and seals for condition, damage, and 520000
correct installation.
Flight Controls
900 Examine collective, cyclic, and antitorque flight controls brackets, 671000
bellcranks, links and control rods located under the cockpit floor, and 671020
in the controls closet for condition, indication of interference, correct 672000
installation, and control rod bolts installed in the correct direction.
Engine Controls
900 Examine mechanical engine control interconnect cables, detent 760000
modules, and area control cables for condition and correct
installation.
900 Do the Engine Controls Operational Test. 760000
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Table 202. Airframe Periodic Inspection Area 1, Nose Section and Cockpit (Cont.)
Fuel System
900 Do the Fuel ShutOff Valve Operational Test. 280000
900 Do the Crossfeed ShutOff Valve Operational Test (900 CONFIG). 280000
Fire Protection
If optional bleed air leak detection system is installed:
900 Examine detection control units and electrical connections for 261020
condition and security.
Instruments
900 Remove glare shield and top panel, and visually inspect: 950000
Glare shield and top panel for condition and damage 951000
952000
Installation of electrical wiring and instrument connections for and
condition, damage, and correct installation CSPSPM
Installation of pitotstatic tubing and connections for condition, 206000
damage, and correct installation.
900 Examine instrument panel and console structure for condition, 532000
damage, and security of attach hardware. 950000
900 Examine instruments for proper markings, condition, correct 951000
operation, and security. 952000
900 Examine area electrical wiring installation in forward section of 960000
console and installation of forward interconnect panel. and
CSPSPM
206000
900 Examine installation of console installed control panels and avionics 960000
equipment for correct markings, condition, and security.
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Table 202. Airframe Periodic Inspection Area 1, Nose Section and Cockpit (Cont.)
Electrical Power
900 Do the Exterior Lighting System Operational Test and Interior 964000
Lighting System Operational Test.
900 Examine nose area electrical wiring and electrical component 980000,
installation for condition, support, and security of attach hardware. and
CSPSPM,
206000
If battery is installed in the nose:
900 Examine battery installation: 961000
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.
900 Examine external power box or external power relay for condition, 960000
correct installation, wiring condition, and electrical connections.
Signature
Date
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Fuselage
900 Examine area fuselage exterior panels, and structure that is in view 532000
for damage, deterioration, and distortion. 533000
900 Examine cabin floor panels for condition, damage, and attach 532000
hardware for correct installation and security.
Equipment / Furnishings
900 Examine cabin compartments for loose equipment and correct N/A
stowage of auxiliary equipment.
900 Examine cabin seats and attach fittings for condition and security of 252000
attach hardware.
900 Examine seat belts for condition and security of attachment to seats. 252000
Do a check of belt adjustors and buckles for correct operation.
900 Examine cabin compartment interior trim for condition and security. 252000
Doors
900 Examine left and right cabin doors: 520000
For condition and damage
Door seals for condition and damage
Attach hardware and components for condition, damage, and
security.
900 Do a check for correct operation of: 520000
Cabin door latch mechanisms
Cabin door rollers.
900 Examine cabin door windows and attach seals for condition, damage, 520000
and correct installation.
Flight Controls
900 Examine area collective, cyclic, and antitorque flight controls 671000
brackets, bellcranks, links and control rods for condition, indication of 672000
interference, correct installation, and control rod bolts installed in the
correct direction.
900 Examine directional control servoactuator for correct installation, 672000
condition, too much fluid leakage, and security of connections.
900 Examine area hydraulic system tubes and flexible hoses for security 290000
of connections, support, condition, and security of attach hardware.
Engine Controls
900 Examine area mechanical engine control cables for condition and 760000
correct installation.
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Fuel System
900 Do the Fuel Cell Leak Check/Pressure Test Method 1 or 2. 280000
Fire Protection
If optional bleed air leak detection system is installed:
900 Examine detection cable and cable attachments for condition and 261010
security.
Electrical Power
900 Examine area electrical wiring and electrical component installation 980000
for condition, support, and security of attach hardware.
Signature
Date
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Table 204. Airframe Periodic Inspection Areas 3 and 4, Main Rotor and Upper Transmission
Deck (Cont.)
Fuselage
900 Examine area fuselage exterior panels, exterior surfaces of upper 533000
deck fairings and cowls, and structure that is in view for damage,
deterioration, and distortion.
Main Rotor
900 Examine for fluid on deck (except drain pans) indicating leakage.
900 Examine input drive shafts and NOTAR drive shaft: 631000
Flexible diaphragms and attach flanges for cracks, corrosion, and
damage
Attach hardware for security.
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Table 204. Airframe Periodic Inspection Areas 3 and 4, Main Rotor and Upper Transmission
Deck (Cont.)
Powerplant
900 Examine forward left and right engine tubes for fluid leaks, condition, 717000
and security of connections and supports. 790000
900 Examine left and right forward engine firewall to plenum seals for 716000
condition and security of fire seal clamp.
900 Examine left and right forward engine mounts for damage, condition, 712000
indication of failure, and security of attach hardware.
If optional generator cooling modification is installed:
900 Do the Generator Cooling Duct and Screen Inspection. 716000
Flight Controls
900 Examine collective, cyclic, and antitorque flight controls brackets, 671000
bellcranks, links and control rods located on the upper deck for 672000
condition, indication of interference, correct installation, and control
rod bolts installed in correct direction.
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Table 204. Airframe Periodic Inspection Areas 3 and 4, Main Rotor and Upper Transmission
Deck (Cont.)
Engine Controls
900 Examine mechanical linkage to FMU for condition, correct installation, 760000
and security of attach hardware.
900 Examine mechanical engine control boxes, control cables, and 760000
adapter plates for condition and correct installation.
NACA Inlet
900 Examine NACA inlet for condition and security. 716000
if Inlet Particle Separator is installed:
900 Examine NACA inlet: 716000
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.
Fuel System
900 Examine left and right engine fuel feed hoses for leaks, indication of 280000
failure, condition, and security of connections to engines.
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Table 204. Airframe Periodic Inspection Areas 3 and 4, Main Rotor and Upper Transmission
Deck (Cont.)
Fire Protection
900 Examine area engine deck mounted fire/overheat detection system 261020
detection cable, grommets, brackets, and cable connectors for
condition and security.
900 Examine detection control units (installed in Area 6) and electrical 261020
connections for condition and security.
Hydraulic System
900 Examine hydraulic system tubes, flexible hoses, and pump case drain 290000
hoses for leaks, indication of failure, security of connections, support,
and security of attach hardware.
900 Examine System 1 / System 2 manifold/reservoir for leaks, condition, 290000
security. Do a check for correct fluid levels.
900 Examine System 1 / System 2 hydraulic pumps and pump case 290000
drains for leaks, condition, and security of installation.
900 Examine ground support equipment (GSE) panel and interconnecting 290000
tubes for leaks, condition, security of tube connections, support, and
security of attached hardware.
If optional hand pump is installed:
900 Examine hand pump for leaks, condition, and security of installation. 290000
900 Examine interconnecting tubes for leaks, indication of failure, security 290000
of connections, support, and security of attach hardware.
Electrical Power
900 Examine area electrical wiring and electrical component installation 980000
for condition, support, and security of attached hardware.
Airframe Periodic Inspection Certification Area 3 and 4, Main Rotor and Upper Transmission
Deck
I certify that this aircraft has been inspected in accordance with Airframe Periodic Inspection requirements and
is determined to be in an airworthy condition.
Signature
Date
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Fuselage
900 Examine fuselage exterior panels, exterior surfaces of upper deck 533000
fairings and cowls, and structure that is in view for damage,
deterioration, and distortion.
Powerplant
900 Examine left and right inlet panels for condition and security of attach 716000
hardware.
900 Examine left and right engine tubes for fluid leaks, condition, and 717000
security of connections and supports. 790000
900 Examine left and right, aft engine firewall to plenum seals for 710000
condition and security of fire seal clamp.
900 Examine left and right aft engine mounts for condition, indication of 712000
failure, and security of attach hardware.
900 Do the Engine NP Overspeed Test Procedure in the applicable Rotorcraft
Rotorcraft Flight Manual. Flight Manual
If optional inlet particle separator system is installed:
900 Examine left and right engine inlet air particle separator panels for 716000
impact damage, condition, and security of attach hardware.
900 Examine left and right bypass doors and installations for condition 716000
and security of attach hardware.
900 Do the Inlet Plenum Inspection and Inlet Particle Separator 716000
Functional Test.
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Fire Protection
900 Examine area engine deck mounted fire/overheat detection system 261020
detection cable, grommets, brackets, and cable connectors for
condition and security.
If optional fire extinguishing system is installed:
900 Examine fire extinguishing system engine compartment distribution 262000
tubes and supports for condition and security.
Electrical Power
900 Examine area electrical wiring and electrical component installation 980000
for condition, support, and security of attach hardware.
Signature
Date
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Rotorcraft Maintenance Manual
Fuselage
900 Examine area fuselage exterior panels, and structure that is in view 532000
for damage, deterioration, and distortion.
900 Examine baggage floor panels for damage, condition, and attach 532000
hardware for correct installation and security.
Equipment/Furnishings
900 Examine baggage compartment interior trim for condition and security 255000
of attach hardware.
Door
900 Examine baggage door: 520000
For condition
Door seals for condition and damage
Attachment hardware and components for condition and security.
900 Do a check of baggage door latch mechanism for correct operation. 520000
AntiTorque Assembly
900 Examine antitorque fan: 643000
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.
900 Examine felt metal seal: 643000
Correct fan blade tip clearance
Felt seal for indication of FOD damage.
900 Examine NOTAR drive shaft: 631000
Flexible diaphragms and attach flanges for cracks, corrosion, and
other damage
Attachment hardware for security.
NOTE: Examine with a small mirror through counterweight arm clear-
ance holes in fan hub.
Flight Controls
900 Examine antitorque flight controls brackets, bellcranks, links and 672000
control rods for condition, indication of interference, correct
installation, and rod end bolts installed in the correct direction.
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Rotorcraft Maintenance Manual
Signature
Date
Page 216
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Rotorcraft Maintenance Manual
Table 207. Airframe Periodic Inspection Area 7, Tailboom and Empennage (Cont.)
Fuselage
900 Examine exterior surface of tailboom, fuselage attach frame, and 534000
empennage attach frames for damage, condition, and security of
attach hardware.
900 Examine horizontal stabilizer: 535500
Exterior surfaces for damage and condition
Attach frames for damage, condition, and security of attach
hardware
Elastomeric damping spring for damage, condition, and security of
attach hardware.
If horizontal damping spring component time is 2000 hours or greater:
900 Do the Elastomeric Damping Spring Condition Verification Test. 535500
900 Examine upper and lower endplates: 535500
Exterior surfaces for damage and condition
Attach hardware for security
For incorrect movement (wiggle).
900 Examine tailboom bumper for deformity, condition, and security. 534000
Flight Controls
900 Examine VSCS actuators, mounting brackets, control rods, and 672000
endplate cranks for condition, indication of interference, correct
installation, and rod end bolts installed in the correct direction.
900 Examine thruster and thruster components: 672000
Thruster sector, control pulleys, drum, cable, cable ends,
turnbuckles, brackets, and attach hardware for condition, correct
installation, corrosion, pitting, wear and security
Do a check for correct thruster cable tension, use tensiometer
Rotating cone and bearing race (on inside surface) for condition
Control bearings for freedom of rotation, outer races for wear (flat
spots), and security.
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Table 207. Airframe Periodic Inspection Area 7, Tailboom and Empennage (Cont.)
Signature
Date
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Rotorcraft Maintenance Manual
Signature
Date
Page 219
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Rotorcraft Maintenance Manual
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
Signature
Date
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ROTORCRAFT MAINTENANCE MANUAL
Section
052050
Airframe Segmented
Inspection Program
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
900 Make sure you comply with component mandatory retirement, refer to 040000
Airworthiness Limitation Schedule and make entries in the Rotorcraft
Log Book.
900 Make sure you comply with component overhaul, refer to Overhaul 051000
Schedule and make entries in the Rotorcraft Log Book.
900 Make sure you comply with applicable Special Inspections (Hourly 052010
and Calendar) and make entries in the Rotorcraft Log Book.
900 Make sure you comply with all applicable Airworthiness Directives N/A
and service bulletins and make entries in the Rotorcraft Log Book.
900 Make sure all placards and markings are installed. 110000
900 Remove trim panels, covers, and access panels as necessary. 060000
Cockpit
900 Do an electrical function check of navigation, strobe, landing, 964000
instrument, utility, and universal lights.
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900 Examine the doors and access panels for correct installation and 532000
condition.
900 Examine the main rotor flexbeams for cracks, delamination, and 622000
damage.
900 Examine the main rotor centering bearings for cracks and condition. 622000
900 Examine the main rotor blades and attach pins for correct installatin 621000
and condition.
900 Examine the for grease leaks around main rotor and swashplate 620000
bearings.
900 Examine the upper controls for correct installation and condition. 623000
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900 Examine the input drive shaft for correct installation and broken or 631000
missing torque stripes.
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900 Examine the horizontal stabilizer for correct installation and condition. 535500
900 Examine the horizontal endplates for correct installation and 535500
condition.
900 Do an inspection of rotating cone for correct installation and freedom 672000
of movement. Remove rotating cone and do an inspection as follows:
Thruster sector, 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.
Left Side Fuselage
900 Examine the rotorcraft exterior for correct installation and condition, 530000
loose or missing rivets, cracks, tears, and punctures.
900 Examine the doors and access panels for correct installation and 532000
condition.
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Signature
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900 Inspect cockpit floor panels for damage, condition, and attach 532000
hardware for correct installation and security.
900 Inspect cockpit windscreens for condition, security, and damage. 531000
Equipment/Furnishings
900 Inspect crew seats and floor attach fittings for condition and security 251000
of attach hardware. Do a check of the crew seat adjustment for
correct operation.
900 Inspect crew restraints for condition and security of attachment to 251000
seats. Do a check of the belt adjusters, buckles, and inertia reels for
correct operation.
900 Inspect crew compartment interior trim for condition and security of 251000
attachment.
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900 Inspect crew door windows and seals for condition, damage, and 520000
correct installation.
Flight Controls
900 Inspect collective, cyclic, and antitorque flight controls brackets, 671000,
bellcranks, links and control rods located under the cockpit floor, and Section 1.,
in the controls closet for condition, indication of interference, correct Parts A., D.,
installation, and control rod bolts installed in the correct direction. & E.;
672000
Engine Controls
900 Inspect mechanical engine control interconnect cables, detent 760000
modules, and area control cables for condition and correct
installation.
Environmental Control System
900 Inspect crew gaspers for correct operation and installation. 212000
If optional heat/defog system is installed:
900 Inspect heat/defog system: 214000
valve for condition and security
ejector and ducts for condition and security.
900 Do a check of crew heater control cable for correct operation. 214000
Fire Protection
If optional heat/defog system is installed:
900 Inspect detection control units and electrical connections for condition 261020
and security.
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900 Inspect instruments for correct markings, condition, correct operation, 951000
and security. 952000
900 Inspect installation of console installed control panels and avionics 960000
equipment for correct markings, condition, and security.
Electrical Power
900 Inspect nose area electrical wiring installation and installation of 980000
electrical panels for condition, security, support, and security of CSPSPM
hardware. 206000
If battery is installed in the nose:
900 Inspect battery installation 961000
battery case and cover for condition, and damage, and installation
hardware for correct installation
vent tubes for condition and correct installation
power connection and temperature sensor connection for condition
and security.
900 Inspect external power box or external power relay for condition, 960000
correct installation, and security of wiring and electrical connections.
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Helicopter must not be moved or flown unless cockpit floor, cabin floor and bag-
CAUTION gage floor panels are securely installed. These are stressed panels.
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.
Signature
Date
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INSPECTION 2 CABIN
900 Inspect cabin floor panels for condition, damage, and attach hardware 532000
for correct installation and security.
Electrical Power
900 Inspect area electrical wiring and electrical component installation for 980000
condition, support, and security of attach hardware.
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900 Inspect cabin compartment interior trim for condition and security. 252000
900 Inspect seat belts for condition and security of attachment to seats. 252000
Do a check of belt adjustors and buckles for correct operation.
Doors
900 Inspect cabin door windows and attach seals for condition, damage, 520000
and correct installation.
Flight Controls
900 Inspect area collective, cyclic, and antitorque flight controls brackets, 671000,
bellcranks, links and control rods for condition, indication of Section 1.,
interference, correct installation, and control rod bolts installed in the Parts B., D.,
correct direction. & E.;
672000
Engine Controls
900 Inspect area mechanical engine control cables for condition and 760000
correct installation.
900 Inspect cabin gaspers for correct operation and installation. 212000
900 Do a check of cabin heater control cable for correct operation. 214000
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Fuel System
900 Do the fuel cell leak/pressure test 280000
Touchup all damaged paint as necessary.
Helicopter must not be moved or flown unless cockpit floor, cabin floor and bag-
CAUTION gage floor panels are securely installed. These are stressed panels.
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.
Signature
Date
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Table 204. Inspection 3 Main Rotor and Upper Transmission Deck (Area 3 and 4)
General
900 Fully clean helicopter as necessary before you start inspection. CSPSPM
202000
900 Examine the aircraft maintenance records for aircraft discrepancies N/A
and correct as necessary.
900 Make sure you comply with component mandatory retirement, refer to 040000
Airworthiness Limitation Schedule and make entries in Log Book.
900 Make sure you comply with component overhaul, refer to Overhaul 051000
Schedule and make entries in Log Book.
900 Make sure you comply with all applicable Airworthiness Directives N/A
and service bulletins and make entries in Log Book.
900 Make sure all placards and markings are installed. 110000
900 Remove trim panels, covers, and access panels as necessary. 060000
Fuselage
900 Examine the area fuselage exterior panels, exterior surfaces of upper 531000
deck fairings and cowls, and structure that is in view for damage, 532000
deterioration, and distortion. 533000
Main Rotor
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Table 204. Inspection 3 Main Rotor and Upper Transmission Deck (Area 3 and 4) (Cont.)
900 Inspect exterior of transmission for condition and security of attached 632000
components.
900 Inspect exterior of oil cooler blower, oil cooler, interconnect, and 632100
cooling exhaust ducts:
for damage, condition and security of attach hardware
inlet and outlet screens and interior of inlet and exhaust ducts for
FOD.
Flight Controls
900 Examine collective, cyclic, and antitorque flight controls brackets, 671000,
bellcranks, links and control rods located on the upper deck for Section 1.,
condition, indication of interference, correct installation, and make Parts C., G.,
sure the control rod bolts are installed in the correct direction. & H.;
672000
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Table 204. Inspection 3 Main Rotor and Upper Transmission Deck (Area 3 and 4) (Cont.)
900 Inspect Ground Support Equipment (GSE) panel and interconnecting 290000
tubes for leaks, condition, security of tube connections, support, and
security of attach hardware.
If optional hand pump is installed:
900 Inspect hand pump for leaks, condition, and security of installation. 290000
900 Inspect interconnecting tubes for leaks, indication of failure, security 290000
of connections, support, and security of attach hardware.
Powerplant
900 Inspect forward left and right engine tubes for fluid leaks, condition, 717000
and security of connections and supports. 790000
900 Inspect left and right forward engine firewall to plenum seals for 710000
condition and security of fireseal clamp.
900 Inspect left and right forward engine mounts for damage, condition, 712000
indication of failure, and security of attach hardware.
900 Inspect mechanical linkage to FMU for condition, correct installation, 760000
and security of attach hardware.
900 Inspect mechanical engine control boxes, control cables, and adapter 760000
plates for condition and correct installation.
NACA Inlet
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Table 204. Inspection 3 Main Rotor and Upper Transmission Deck (Area 3 and 4) (Cont.)
Electrical Power
900 Inspect area electrical wiring and electrical component installation for 980000
condition, support, and security of attach hardware.
Signature
Date
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Signature
Date
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INSPECTION 5 POWERPLANT
General
900 Fully clean helicopter as necessary before you start inspection. CSPSPM
202000
900 Make sure you comply with component mandatory retirement, refer to 040000
Airworthiness Limitation Schedule and make entries in Log Book.
900 Make sure you comply with component overhaul, refer to Overhaul 051000
Schedule and make entries in Log Book.
900 Make sure you comply with all applicable Airworthiness Directives N/A
and service bulletins and make entries in Log Book.
900 Make sure all placards and markings are installed. 110000
900 Remove trim panels, covers, and access panels as necessary. 060000
Fuselage
900 Inspect fuselage exterior panels, exterior surfaces of upper deck 533000
fairings and cowls, and structure that is in view for damage,
deterioration, and distortion.
Fire Protection
900 Inspect area engine deck mounted fire/overheat detection system 261020
detection cable, grommets, brackets, and cable connectors for
condition and security.
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900 Inspect left and right inlet panels for condition and security of attach 716000
hardware.
900 Inspect left and right engine tubes for fluid leaks, condition, and 717000
security of connections and supports. 790000
900 Inspect left and right, aft engine firewall to plenum seals for condition 710000
and security of fireseal clamp.
900 Inspect left and right aft engine mounts for condition, indication of 712000
failure, and security of attach hardware.
900 Inspect left and right engine inlet air particle separator panels for 716000
impact damage, condition, and security of attach hardware.
900 Inspect left and right bypass doors and installations for condition and 716000
security of attach hardware.
900 Do the Inlet Plenum Inspection and Inlet Particle Separator 716000
Functional Test.
900 Inspect bleed air closure plates on engines for correct installation and 750000
security of attach hardware.
900 Inspect bleed air fittings on engines for correct installation and 750000
security of attach hardware.
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Signature
Date
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900 Inspect baggage floor panels for damage, condition, and attach 532000
hardware for correct installation and security.
Equipment/Furnishings
900 Inspect baggage compartment interior trim for condition and security 255000
of attach hardware.
Door
900 Inspect baggage door: 520000
condition
door seals for condition and damage
attach hardware and components for condition and security.
900 Do a check of baggage door latch mechanism for correct operation. 520000
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Fire Protection
If optional heat/defog system is installed:
900 Inspect area detection cable and cable attachments for condition and 261010
security of installation.
900 Inspect fire bottle discharge and crossflow tubes for condition and 262000
security of end connections.
Fuel System
900 Do the Fuel Supply Vapor Shroud Leak Check/Pressure Test. 280000
If optional fuel drain catch cans are installed:
900 Inspect fuel drain catch cans for condition and security. 717000
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900 Inspect electrical load center for correct installation, security, and 960000
correct installation of electrical wiring and connections.
900 Inspect strobe power supply for condition and security. 964000
900 Inspect area electrical wiring and electrical component installation for 980000
condition, support, and security of hardware.
If optional aft battery installation is installed:
900 Inspect battery installation (Aft Installation): 961000
battery case 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.
900 Inspect external power box or external power relay for condition, 960000
correct installation, and security of wiring and electrical connections.
Touchup all damaged paint as necessary.
Helicopter must not be moved or flown unless cockpit floor, cabin floor and bag-
CAUTION gage floor panels are securely installed. These are stressed panels.
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.
Signature
Date
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INSPECTION 7 TAIL
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Signature
Date
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ROTORCRAFT MAINTENANCE MANUAL
Section
055000
Continued
Airworthiness
Unscheduled
Inspection
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
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NOTE: The overspeed is recorded in the excee The third column (Ref. RMM Section) shows,
dance log data from the IIDS. if applicable, the manual or section that has
the specific inspection or procedure.
6. Lightning Strike
When you think there has been a lightning The fourth column (Initial) is for personnel
strike on the helicopter, speak to the Field to show they have done the necessary
Service Department at MDHI, Mesa, Arizona. inspection or procedure.
Telephone 1-800-388-3378 or (480)
346-6387. DATAFAX: (480) 346-6813 for All completed inspection schedules must be
inspections and maintenance procedures you kept as a permanent part of the helicopter
need to do. records.
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900 Examine passenger compartment and passenger seats for loose 252000
assemblies or parts.
900 Examine landing gear skids for damage and permanent deformation 320000
that is more than the permitted limits.
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Level I Initial inspection after a suspected hard landing. If no damage or deformation is found after these
inspections, no additional inspection is necessary. If damage and/or deformation is found during the these
inspections, do the Level II hardlanding conditional inspections (ref. Table 202).
Ref. RMM
Model Requirement Section Initial
Fuselage
900 Examine upper deck fairings and cowlings: 533000
Examine for correct alignment and obvious damage
Examine installation of fasteners
900 Examine upper deck skin panels (transmission and engine bays) for 533000
deformation and buckling.
900 Examine upper deck mast fittings and adjacent area for damage or 533000
deformation.
900 Examine upper deck engine mount fittings and adjacent area for 533000
damage or deformation.
900 Examine underside of fuselage for signs of contact with the ground. 532000
900 Examine tailboom for damage: 534000
Examine lower surface for signs of contact with the ground
Examine upper surface for signs of rotor blade strike
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Level I Initial inspection after a suspected hard landing. If no damage or deformation is found after these
inspections, no additional inspection is necessary. If damage and/or deformation is found during the these
inspections, do the Level II hardlanding conditional inspections (ref. Table 202).
Ref. RMM
Model Requirement Section Initial
Main Rotor
900 Examine rotor blades: 621000
Examine blade tips for damage and signs of blade strike
Examine length of blade for blade skin buckling, cracks, and
indications delamination
900 Examine droop stop rollers and striker plates for damage and for 622000
signs of hard contact.
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Level I Initial inspection after a suspected hard landing. If no damage or deformation is found after these
inspections, no additional inspection is necessary. If damage and/or deformation is found during the these
inspections, do the Level II hardlanding conditional inspections (ref. Table 202).
Ref. RMM
Model Requirement Section Initial
Flight Controls
900 Examine upper deck flight controls and rotating controls for obvious 671000
damage, deformation, and installation.
900 Do an operational test to make sure the controls move correctly. 671000
900 Examine the thruster cables, thruster cable support bracket, thruster 672000
control rod, and thruster control sector assembly for correct
installation, damage, and deformation.
900 Examine thruster for obvious damage or signs of contact with the 672000
ground.
900 Examine thruster stationary track and rotating cone followers for 672000
damage and deformation.
900 Do an operational test to make sure the directional controls and 672000
rotating cone move correctly.
Powerplant
900 Refer to related manufacturers publications for engine 010000
maintenance/inspection requirements.
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Level I Initial inspection after a suspected hard landing. If no damage or deformation is found after these
inspections, no additional inspection is necessary. If damage and/or deformation is found during the these
inspections, do the Level II hardlanding conditional inspections (ref. Table 202).
Ref. RMM
Model Requirement Section Initial
After Inspection
Touchup all damaged paint and exterior markings, as necessary.
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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900 Do the cabin Seat Energy Absorption System (EAS) Inspection. 252000
900 Examine passenger restraints as follows: 252000
Examine for damage and make sure they are correctly attached
Do the Seat Restraint System Operational Test
Fire Protection
If fire extinguishing system is installed
900 Examine fire bottles as follows: 262000
Examine fire bottles for damage
Examine brackets for damage and deformation
Make sure fasteners are tight.
900 Examine tubes as follows: 262000
Examine for damage and deformation
Make sure connections are tight
Examine for indication of leakage.
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Level II The Level II inspection is necessary if damage and/or deformation was found when you did the Hard
Landing Level I inspection.
NOTE: Some inspection items in the inspection that follows are directly related to specified types of damage
found during the Hard Landing, Level I, Conditional Inspection. Inspection items related to specified types of
damage are identified.
Ref. RMM
Model Necessary Inspection Section Initial
Fuel System
Hydraulic System
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Level II The Level II inspection is necessary if damage and/or deformation was found when you did the Hard
Landing Level I inspection.
NOTE: Some inspection items in the inspection that follows are directly related to specified types of damage
found during the Hard Landing, Level I, Conditional Inspection. Inspection items related to specified types of
damage are identified.
Ref. RMM
Model Necessary Inspection Section Initial
Landing Gear
If permanent deformation of one or both landing gear cross tubes is more than permitted limits
If permanent deformation of one or both landing gear cross tubes has occurred
900 If removed cross tube shows no permanent deformation more than 320000
permitted limits:
Examine for an indication it touched fuselage fittings and saddles
Examine forward fitting spacer and damper holes for damage and
deformation
If you do not see damage, do a fluorescent penetrant or dye CSPSPM
penetrant inspection of cross tube. 209000
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Level II The Level II inspection is necessary if damage and/or deformation was found when you did the Hard
Landing Level I inspection.
NOTE: Some inspection items in the inspection that follows are directly related to specified types of damage
found during the Hard Landing, Level I, Conditional Inspection. Inspection items related to specified types of
damage are identified.
Ref. RMM
Model Necessary Inspection Section Initial
Landing Gear (Cont.)
Fuselage
900 Examine cockpit floor substructure and lower section of forward 531000
bulkhead as follows:
Examine composite components for cracks and delamination
Examine metal components for damage and deformation
Examine bonded or riveted joints for separation.
900 Examine baggage floor substructure and aft part of cross tube box for 532000
damage, separation of bonded or riveted joints, and deformation of
metal components:
Examine composite components for cracks and delamination
Examine metal components for damage and deformation
Examine bonded or riveted joints for separation.
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Level II The Level II inspection is necessary if damage and/or deformation was found when you did the Hard
Landing Level I inspection.
NOTE: Some inspection items in the inspection that follows are directly related to specified types of damage
found during the Hard Landing, Level I, Conditional Inspection. Inspection items related to specified types of
damage are identified.
Ref. RMM
Model Necessary Inspection Section Initial
Fuselage (Cont.)
900 Examine tailboom frame and adjacent structure for damage and 532000
deformation.
900 Examine landing gear fuselage fittings and adjacent structure as 532000
follows:
Examine components for damage and deformation
Examine riveted joints for separation
Make sure torque stripe across aft fuselage fitting and adjacent
structure is not broken.
900 Examine keel beams, fuel cell support ribs and adjacent structure, 532000
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.
If upper deck fairings and cowlings, upper deck, static mast deck fittings and/or engine mount deck
fitting shows damage or deformation
900 Examine upper deck fairings, cowlings, and fittings as follows: 533000
Make sure parts are correctly aligned
Examine latches and latch strikers for damage and deformation
Examine composite components for cracks and delamination
Examine flanges of composite components for cracks or damaged
fastener holes
Examine metal components for damage and deformation
Examine flanges of metal components for deformation and
damaged fastener holes
Examine bonded or riveted joints for separation.
900 Examine engine air inlet plenums and installation points as follows: 533000
Examine components for damage and deformation
Examine bolted or riveted joints for separation.
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Level II The Level II inspection is necessary if damage and/or deformation was found when you did the Hard
Landing Level I inspection.
NOTE: Some inspection items in the inspection that follows are directly related to specified types of damage
found during the Hard Landing, Level I, Conditional Inspection. Inspection items related to specified types of
damage are identified.
Ref. RMM
Model Necessary Inspection Section Initial
Fuselage (Cont.)
If upper deck fairings and cowlings, upper deck, static mast deck fittings and/or engine mount deck
fitting shows damage or deformation
900 Examine upper deck mast fittings and installation points: 533000
Examine fittings for damage and deformation
Examine riveted joints for separation
Main Rotor
If main rotor blades or main rotor hub shows damage
900 Do the Main Rotor Sudden Stoppage, Conditional Inspection. 055000
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Level II The Level II inspection is necessary if damage and/or deformation was found when you did the Hard
Landing Level I inspection.
NOTE: Some inspection items in the inspection that follows are directly related to specified types of damage
found during the Hard Landing, Level I, Conditional Inspection. Inspection items related to specified types of
damage are identified.
Ref. RMM
Model Necessary Inspection Section Initial
Transmission and Drive System
If main rotor blades or main rotor hub shows damage; and/or transmission input, and/or antitorque
drive shaft shows damage or an indication of movement at flanges
AntiTorque Assembly
If fan blades show damage and/or an indication of contact with felt seal
900 Do the AntiTorque Fan Sudden Stoppage, Conditional Inspection. 055000
Flight Controls
900 Remove access covers and examine all upper deck linkages, 671000
bellcranks, control rods, and support brackets as follows:
Examine for damage and deformation
Make sure rod end bearings and hardware is correctly attached
Make sure linkages, bellcranks, and control rods move freely.
900 Remove cockpit access covers and floor panels. Examine all 671000
linkages, bellcranks, control rods, and support brackets:
Examine for damage and deformation
Make sure rod end bearings and hardware are correctly attached
Make sure linkages, bellcranks, and control rods move freely.
Powerplant
900 Refer to related manufacturers publications for necessary engine 010000
maintenance/inspection.
900 Examine left and right engine firewall seals for damage. 710000
900 Make sure left and right engine firewall seals are correctly attached. 710000
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Level II The Level II inspection is necessary if damage and/or deformation was found when you did the Hard
Landing Level I inspection.
NOTE: Some inspection items in the inspection that follows are directly related to specified types of damage
found during the Hard Landing, Level I, Conditional Inspection. Inspection items related to specified types of
damage are identified.
Ref. RMM
Model Necessary Inspection Section Initial
Powerplant Controls
900 Do the Engine Controls Operational Test. 760000
After Hard Landing Level II Inspection
Touchup all damaged paint, external marks and placards, as necessary.
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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900 Remove hydraulic pump assemblies and examine hydraulic pump 290000
drive spline for damage or deformation.
Fuselage
900 Examine upper deck fairings and cowlings for damage. 533000
900 Examine upper deck mast fittings and adjacent structure for damage 533000
and deformation.
900 Examine upper deck engine mount fittings and adjacent structure for 533000
damage and deformation.
900 Examine upper deck skin panels (transmission and engine bays) for 533000
deformation and buckling.
900 Examine upper deck substructure for damage, deformation, and 533000
separation of riveted joints.
Main Rotor
900 Remove and examine main rotor dampers for damage and 622000
delamination of elastomer.
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AntiTorque Assembly
900 Remove antitorque inlet duct assembly (F2, ref. Section 060000) 640000
and examine fan support and adjacent structure for damage and
deformation.
900 Remove antitorque inspection door (F9, ref. Section 060000) and 640000
examine fan assembly blades for damage and signs of contact with
felt seal.
If antitorque fan blades show damage or signs of contact with felt seal
900 Do a conditional inspection in accordance with Unscheduled 055000
Maintenance, Conditional Schedule, Sudden Stoppage, AntiTorque
Fan.
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Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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Ref. RMM
Model Requirement Section Initial
Fuselage
900 Remove and examine antitorque fan inlet screen assembly for 533000
damage or deformation.
900 Examine antitorque fan mounting frames and adjacent structural 532000
components for deformation and separation of riveted joints.
900 Examine fan support for impact damage, deformation, and correct 532000
installation.
900 Remove and examine antitorque fan drive shaft assembly: 631000
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
If antitorque fan drive shaft shows signs of movement at flanges and/or damage which makes the
component unserviceable
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AntiTorque Assembly
900 Remove and examine fan assembly access panels for FOD damage: 640000
Examine antitorque inlet duct assembly (F2) 060000
Examine center body fairing assembly (F3)
Examine lower center diffuser (F7)
Examine lower duct assembly (F8)
Examine lower section of stator assembly
900 Examine inlet assembly (F4): 640000
Examine for impact damage 060000
Examine overlap joint at inlet assembly (F4) and upper inlet duct
assembly (T240) for correct positioning and installation
900 Examine upper duct assembly (F5), upper center diffuser (F6), and 640000
upper section of stator assembly for FOD damage and correct 060000
installation.
900 Remove and examine fan drive coupling: 640000
Examine flange for damage, deformation, and elongation of
fastener holes
Examine spline for damage and deformation
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Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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Table 205. Overtorque Up to 110% (average input), Conditional Inspection Both Engines
Operative
Ref. RMM
Model Requirement Section Initial
Comply with the requirements of the applicable Transmission and Drive System
CAUTION Overtorque Inspection in addition to these requirements.
Fuselage
900 Examine antitorque fan support for deformation and installation. 532000
900 Examine upper deck mast fittings and adjacent structure for obvious 533000
damage and looseness.
900 Examine upper deck engine mount fittings and adjacent structure for 533000
obvious damage and looseness.
Main Rotor
900 Examine main rotor blades: 621000
Examine skin for buckling and cracks
Examine for signs of skin delamination
900 Examine main rotor hub assembly: 622000
Examine upper and lower main rotor hub assemblies for cracks
and deformation
Examine installation of fasteners
900 Examine truss struts: 632000
Examine for obvious damage and installation
Examine for fasteners for looseness
900 Examine drive link assembly: 672000
Examine for damage and deformation
Examine for loose components and fasteners
Make sure there is correct freedom of movement
900 Examine swashplate assembly: 622000
Examine for obvious damage
Examine links for obvious damage and installation
Make sure there is correct freedom of movement of rotating and
stationary swashplate subassemblies
Make sure the links have the correct freedom of movement
Make sure there is correct freedom of movement of swashplate
assembly on static mast
AntiTorque Assembly
900 Examine blades of antitorque fan assembly for damage and 643000
indications of contact with felt seal.
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Table 205. Overtorque Up to 110% (average input), Conditional Inspection Both Engines
Operative (Cont.)
Powerplant
900 Refer to related manufacturers publications for engine 010000
maintenance/inspection requirements.
NOTE: Engine Overtorque is a separate exceedance recorded by the
IIDS. This record will be in engine torque%
900 Examine LH and RH engine mounts 712000
Examine for damage and deformation
Examine for loose fasteners
After Inspection
Touchup all damaged paint and exterior markings, as necessary.
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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Table 206. Overtorque Above 110% (Average Input), Conditional Inspection Both Engines
Operative
Comply with the requirements of the applicable Transmission and Drive System
CAUTION Overtorque Inspection in addition to these requirements.
Fuselage
900 Examine upper deck mast fittings and adjacent structure for damage 533000
and deformation.
900 Examine upper deck engine mount fittings and adjacent structure for 533000
damage and deformation.
900 Examine upper deck skin panels (transmission and engine bays) for 533000
deformation and buckling
900 Examine upper deck substructure for damage, deformation, and 533000
separation of riveted joints.
900 Examine antitorque fan mounting frames and adjacent structural 532000
components for deformation and separation of riveted joints.
900 Examine fan support for damage, deformation, and loose fasteners. 532000
Main Rotor
900 Remove and examine main rotor blades: 621000
Examine skin for buckling and cracks
Examine for signs of skin delamination
Examine bosses for cracks and delamination
Examine flanged bushings for damage and installation
Examine retention bolts for damage or deformation
900 Remove and examine pitch links: 622000
Examine for damage and deformation
Examine bearings for damage and installation
Examine fasteners for damage or deformation
900 Remove and examine damper caps: 622000
Examine for damage and deformation
Examine fasteners for damage or deformation
Examine pitchcase fastener holes for damage
900 Remove and examine main rotor dampers for damage and 622000
delamination of elastomer.
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Table 206. Overtorque Above 110% (Average Input), Conditional Inspection Both Engines
Operative (Cont.)
AntiTorque Assembly
900 Remove and examine fan drive coupling: 640000
Examine flange for damage, deformation, and elongation of
fastener holes
Examine spline for damage and deformation
900 Examine mating drive coupling spline on fan support assembly for 640000
damage and deformation.
900 Examine fan assembly blades for damage and/or signs of contact 640000
with felt seal.
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 with felt seal
900 Do a conditional inspection in accordance with Unscheduled, 055000
Conditional Inspection, Sudden Stoppage, AntiTorque Fan.
Flight Controls
900 Examine hydraulic servo actuators: 671000
Examine for too much leakage
Examine piston rods for damage or deformation
Examine for loose fasteners
900 Remove applicable covers and examine all upper deck linkages, 671000
bellcranks, control rods, and support brackets:
Examine for damage and deformation
Examine for loose rod end bearings and fasteners
Make sure there is correct freedom of movement of linkages,
bellcranks, and control rods
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Table 206. Overtorque Above 110% (Average Input), Conditional Inspection Both Engines
Operative (Cont.)
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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Table 207. Transmission and Drive System Overtorque, Conditional Inspection, Single Engine
Operation
125 to 139%
900 Log time above transmission input exceedance threshold as provided N/A
by the IIDS in the Rotorcraft Log Book (S1 value).
140 to 150%
900 Log time above transmission input exceedance threshold as provided N/A
by the IIDS in the Rotorcraft Log Book (S1 value).
900 Examine transmission acoustic isolators for condition and installation. 632000
900 Examine transmission fasteners for condition and looseness. Make 632000
sure the torque is correct.
Above 150%
900 Replace input drive shaft and all fasteners. 631000
900 Replace transmission assembly. 632000
After Inspection
Touchup all damaged paint and exterior markings, as necessary.
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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Table 208. Transmission and Drive System Overtorque (900 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential
CAUTION
Each engine overtorque exceedance shall be evaluated as a single engine overtorque.
The combined engine overtorque shall be evaluated as an average of the two engine overtorques.
NOTE: If IIDS shows time above multiple thresholds, make sure which ones are actual exceedances. If more
than one, record longest one as S1 time in Rotorcraft Log Book.
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Table 208. Transmission and Drive System Overtorque (900 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)
900 Examine main rotor drive shaft and drive plate for cracked or broken 631000
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
900 Replace hardware that attaches main rotor drive plate. 631000
900 Magnetic particle examine main rotor drive plate for cracks or related CSPSPM
damage. If found replace:
Main rotor drive plate
Main rotor drive plate cover and fasteners
Transmission assembly
All eight segmented acoustic isolators
Hardware that attaches transmission
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Table 208. Transmission and Drive System Overtorque (900 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)
900 Examine input drive shaft assemblies and fasteners for condition and 631000
installation. Make sure the torque is correct.
900 Examine main rotor drive shaft and drive plate spline teeth for 631000
cracked or broken spline teeth. If found replace transmission
assembly and all eight segmented acoustic isolators.
900 Replace main rotor drive shaft, drive plate, drive plate cover, and 631000
related fasteners.
900 Remove and examine antitorque fan drive shaft, do not disassemble 631000
drive shaft assembly:
Examine coupling to shaft interface for damage or cracking.
Examine fastener holes for corrosion, elongation, and fretting.
Replace if a discrepancy is found.
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Table 208. Transmission and Drive System Overtorque (900 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)
900 Remove and examine antitorque fan drive shaft, do not disassemble 631000
drive shaft assembly:
Examine coupling to shaft interface for damage or cracking.
Examine fastener holes for corrosion, elongation, and fretting.
Replace if a discrepancy is found.
900 Examine antitorque fan input flange for corrosion, hole elongation, 643000
and fretting. Replace if a discrepancy is found.
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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Table 209. Transmission and Drive System Overtorque (902 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential
CAUTION
Each engine overtorque exceedance must be evaluated as a single engine overtorque.
The combined engine overtorque must be evaluated as an average of the two engine overtorques.
Pedal position in percent must be used to determine main rotor overtorque inspection requirements.
If pedal position at time of exceedance is not recorded, 900 CONFIG Transmission and Drive System
Overtorque inspection schedule must be used on 902 CONFIG rotorcraft.
NOTE: If IIDS shows time above multiple thresholds, make sure which ones are actual exceedances. If more
than one, record longest one as S1 time in the Rotorcraft Log Book.
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Table 209. Transmission and Drive System Overtorque (902 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)
900 If recorded pedal position is greater than 30%, examine main rotor 631000
drive shaft PN 900D2436530101
900 If recorded pedal position is greater than 30%, replace main rotor 631000
drive plate fasteners.
900 If recorded pedal position is greater than 30%, examine main rotor 631000
drive shaft and drive plate for cracked or broken spline 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
Averaged Input 126 to 135%
900 Record time above transmission input exceedance threshold as given N/A
by the IIDS in the Rotorcraft Log Book (T1 value).
900 Examine antitorque fan coupling for condition and installation. 643000
900 Examine transmission antitorque output coupling for condition and 632000
installation.
900 Examine input drive shaft assemblies and fasteners for condition and 631000
installation. Make sure the torque is correct.
900 If recorded pedal position is greater than 25%, replace main rotor 631000
drive shaft, if not PN 900D2436530101.
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Table 209. Transmission and Drive System Overtorque (902 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)
900 If recorded pedal position is greater than 25%, examine main rotor 631000
drive shaft and drive plate for cracked or broken spline 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
900 If recorded pedal position is greater than 25%, examine main rotor 631000
drive shaft PN 900D2436530101
900 If recorded pedal position is greater than 25%, magnetic particle 631000
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
900 If recorded pedal position is greater than 25%, examine drive plate 631000
for:
Fastener hole elongation
Material displacement at or around fastener holes
Pitting or fretting around fastener holes
Corrosion
Replace if a discrepancy is found
900 If recorded pedal position is greater than 25%, replace drive plate 631000
fasteners.
900 Examine input drive shaft assemblies and fasteners for condition and 631000
installation. Make sure the torque is correct.
900 Record time above transmission input exceedance threshold as given N/A
by the IIDS in the Rotorcraft Log Book (T1 value).
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Table 209. Transmission and Drive System Overtorque (902 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)
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Table 209. Transmission and Drive System Overtorque (902 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)
900 If recorded pedal position is greater than 20%, examine drive plate 631000
for:
Fastener hole elongation
Material displacement at or around fastener holes
Pitting or fretting around fastener holes
Corrosion
Replace if a discrepancy is found.
900 If recorded pedal position is greater than 20%, replace drive plate 631000
fasteners.
900 If recorded pedal position is greater than 45% and less than 80%, 631000
examine main rotor drive shaft and drive plate splines. If splines are
cracked or broken, replace:
Transmission assembly
All eight segmented acoustic isolators
900 If recorded pedal position is greater than 45% and less than 80%, 631000
replace:
Main rotor drive shaft
Main rotor drive plate
Main rotor drive plate cover
Main rotor drive plate and cover fasteners
900 If not replaced by single engine torque value, examine input drive 631000
shaft assemblies and fasteners for condition and installation. Make
sure the torque is correct.
900 Remove and examine antitorque fan drive shaft, do not disassemble 631000
drive shaft assembly:
Examine coupling to shaft interface for damage or cracking.
Examine fastener holes for corrosion, elongation, and fretting.
Replace if a discrepancy is found.
900 Examine antitorque fan input flange for corrosion, hole elongation, 643000
and fretting. Replace if a discrepancy is found.
900 Replace transmission, all acoustic isolators, and related fasteners. 632000
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Table 209. Transmission and Drive System Overtorque (902 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)
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Table 209. Transmission and Drive System Overtorque (902 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)
900 Remove and examine antitorque fan drive shaft, do not disassemble 631000
drive shaft assembly:
Examine coupling to shaft interface for damage or cracking.
Examine fastener holes for corrosion, elongation, and fretting.
Replace if a discrepancy is found.
900 Examine antitorque fan input flange for corrosion, hole elongation, 643000
and fretting. Replace if a discrepancy is found.
900 Replace transmission, all acoustic isolators, and related fasteners. 632000
900 Examine main rotor drive shaft and drive plate for cracked or broken 631000
spline teeth. If found replace:
Main rotor drive plate
Main rotor drive shaft
Main rotor drive plate cover and fasteners
900 Do a magnetic particle inspection of the main rotor drive plate for 631000
cracks or related damage. If found replace:
Main rotor drive plate
Main rotor drive plate cover and fasteners
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Table 209. Transmission and Drive System Overtorque (902 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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Table 210. Transmission and Drive System Overtorque, Conditional Inspection. Both Engines
Operative, Greater Than 8% Engine Torque Differential
CAUTION
For each single input fault, do the requirements of Table 207, Transmission and Drive System
Overtorque, Conditional Inspection Single Engine Operation.
Do the averaged input portion of the applicable Both Engines Operative Overtorque
Inspection (ref. Table 208 900 CONFIG and Table 209 902 CONFIG).
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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Table 211. Main Rotor Overspeed, 109 to 110% NR, Power Off, Conditional Inspection
900 Examine main rotor dampers (via inboard ends of pitch cases) for 622000
signs of damage and/or delamination of elastomer.
900 Examine centering bearings (via inboard ends of pitch cases) for 622000
signs of damage and/or delamination of elastomer.
900 Examine drive link assembly and adjacent components and fasteners: 672000
Examine for obvious damage and deformation, and make sure
there is correct freedom of movement
Examine fasteners for proper installation and looseness
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Table 211. Main Rotor Overspeed, 109 to 110% NR, Power Off, Conditional Inspection (Cont.)
After Inspection
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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Table 212. Main Rotor Overspeed, 106 to 110% NR, Power On, Conditional Inspection
900 Examine upper deck engine mount fittings and adjacent structure for 533000
damage and deformation.
900 Examine upper deck skin panels (transmission and engine bays) for 533000
deformation and buckling.
900 Examine upper deck substructure for damage, deformation, and 533000
separation of riveted joints.
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Table 212. Main Rotor Overspeed, 106 to 110% NR, Power On, Conditional Inspection (Cont.)
900 Examine main rotor dampers (via inboard ends of pitch cases) for 622000
signs of damage and/or delamination of elastomer.
900 Examine drive link assembly and adjacent components and 672000
fasteners:
Examine for obvious damage and deformation, and make sure
there is correct freedom of movement
Examine fasteners for correct installation and looseness
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Table 212. Main Rotor Overspeed, 106 to 110% NR, Power On, Conditional Inspection (Cont.)
AntiTorque Assembly
900 Examine fan assembly blades for damage and/or signs of contact 640000
with felt seal.
Powerplant
After Inspection
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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Table 212. Main Rotor Overspeed, 106 to 110% NR, Power On, Conditional Inspection (Cont.)
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Table 213. Main Rotor Overspeed, 111 to 114% NR, Power Off, Conditional Inspection
Ref. RMM
Model Requirement Section Initial
Main Rotor
900 Remove damper caps and examine main rotor dampers for damage 622000
and delamination of elastomer.
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Table 213. Main Rotor Overspeed, 111 to 114% NR, Power Off, Conditional Inspection (Cont.)
AntiTorque Assembly
900 Examine fan assembly blades for damage and/or signs of contact 640000
with felt seal.
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Table 213. Main Rotor Overspeed, 111 to 114% NR, Power Off, Conditional Inspection (Cont.)
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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 filler caps are correctly
installed and are not loose.
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Table 214. Main Rotor Overspeed, 111 to 114% NR, Power On, Conditional Inspection
Ref. RMM
Model Requirement Section Initial
Hydraulic
900 Remove hydraulic pump assemblies and examine hydraulic pump 290000
drive spline for damage or deformation.
Fuselage
900 Examine upper deck fairings and cowlings for damage. 533000
900 Examine upper deck mast fittings and adjacent structure for damage 533000
and deformation.
900 Examine upper deck engine mount fittings and adjacent structure for 533000
damage and deformation.
900 Examine upper deck skin panels (transmission and engine bays) for 533000
deformation and buckling.
900 Examine upper deck substructure for damage, deformation, and 533000
separation of riveted joints.
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Rotorcraft Maintenance Manual
Table 214. Main Rotor Overspeed, 111 to 114% NR, Power On, Conditional Inspection (Cont.)
900 Remove damper caps and examine main rotor dampers for damage 622000
and delamination of elastomer.
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Rotorcraft Maintenance Manual
Table 214. Main Rotor Overspeed, 111 to 114% NR, Power On, Conditional Inspection (Cont.)
Page 261
05-50-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Table 214. Main Rotor Overspeed, 111 to 114% NR, Power On, Conditional Inspection (Cont.)
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
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Rotorcraft Maintenance Manual
Table 215. Main Rotor Overspeed, Over 114% NR, Power Off, Conditional Inspection
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05-50-00 Revision 34
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
Table 216. Main Rotor Overspeed, Over 114% NR, Power On, Conditional Inspection
Page 265
05-50-00 Revision 34
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Rotorcraft Maintenance Manual
Page 266
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Rotorcraft Maintenance Manual
Table 217. Main Rotor High Vibration During Startup or Shutdown At 35 To 40% NR
Page 267
05-50-00 Revision 34
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Rotorcraft Maintenance Manual
Page 268
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Rotorcraft Maintenance Manual
Chapter
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
06 Contents Revision 27
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ROTORCRAFT MAINTENANCE MANUAL
Page ii
Revision 27 06 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
060000
Dimensions and
Areas
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 201
06-00-00 Original
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Rotorcraft Maintenance Manual
Page 202
Original 06-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
33.83 ft
(10.34 m)
DIAMETER
5.33 ft 9.33 ft
(1.62 m) (2.84 m)
5.91 ft
(1.80 m) 40.583 ft
(12.37 m)
12.0 ft
(3.66 m)
9.17 ft
(2.79 m)
10.91 ft
(3.32 m)
34.08 ft
7.33 ft (10.39 m)
(2.23 m) 1.25 ft
(0.38 m) 9G06-006D
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Rotorcraft Maintenance Manual
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480
60 60
40 40
20 20
- 20 - 20
- 40 - 40
- 60 - 60
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460
5 0
STA 199.25
60 40 20 0 - 20 - 40 - 60
WL 207.97
220 220 220
140
WL 159
140
ROOF DECK
120 120 120
60 60 60
3 16
STA 155.5 STA 230.5
FRAME FRAME
BL 8.5 BL 24
BEAM BEAM
9G06-007C
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Rotorcraft Maintenance Manual
9G06-014
1. NOSE AND COCKPIT 4. MAIN ROTOR
2. CABIN 5. POWERPLANT (FORWARD FIRESEAL AND AFT)
3. UPPER TRANSMISSION DECK (FORWARD FIRESEAL 6. BAGGAGE
AND FORWARD) 7. TAIL (TAILBOOM ATTACH AND AFT)
Figure 203. Inspection Areas
Page 205
06-00-00 Revision 27
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
1/4
TURN
1/4
TURN
PUSH TO PUSH TO
UNLOCK LOCK
PULL TO RELEASE
DOOR PINS
BOLT
LATCH
UNLOCK-ONE ACTION LOCK-TWO ACTIONS
1 PUSH
HOOK-1
PULL
2 PULL
LIFT PUSH-2
PULL OFF
HERE
LIFT
HERE
9G06-008
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Rotorcraft Maintenance Manual
N80
N82
N106
9G06-001A
Page 207
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Rotorcraft Maintenance Manual
L220 L260
L210 L270
L155
L262
L166
L109 L210
L240
L107 L170 L211 NACA INLET
INSTALLATION
9G06 002B
Page 208
Revision 18 06-00-00
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Rotorcraft Maintenance Manual
L220 Inlet Panel Assembly, Inlet, Engine Compressor 25 Fastener Sleeve Bolt G
LH (Engine Air)
Page 209
06-00-00 Revision 13
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
R270 R155
R107
R166
R210
NACA INLET R211
INSTALLATION
R185 R158 R128 R109
9G06-003A
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Rotorcraft Maintenance Manual
Page 211
06-00-00 Revision 18
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
T292
TR218
T240
T155 T220 TL218
9G06-009A
TL218 Oil Dipstick Hand Engine Oil Level and Filler 1 Hinge Q
Hold, LH 2 Camlock E
TR218 Oil Dipstick Hand Engine Oil Level and Filler 1 Hinge Q
Hold, RH 2 Camlock E
T240 Upper Inlet Duct Fan Driveshaft, Air Inlet To Fan 19 Screw L
Assembly 24 Bolt M
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Rotorcraft Maintenance Manual
B178
B142 B230
9G06-005
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06-00-00 Original
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Rotorcraft Maintenance Manual
S6
SR7 SR5 SL7
SL5 S4
SR3
SR1
SL1 S2 SL3
SR8
WITHOUT THRUSTER EXTENSION
SL8
9G06-004B
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Rotorcraft Maintenance Manual
Page 215
06-00-00 Revision 29
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
AR129
A235
AR145
AL138
AL230
AL129
AL155
A160 AL165 A170 A217 AL250
9G06-010A
Defuel the helicopter before you remove floor panels AL155, AR155, AL165, AR165,
CAUTION AL230, AR230, and A235. Damage to the structure can occur if you remove these
panels with fuel in the helicopter.
A217 Cabin Floor Aft Panel Fuel Cell Aft Vent Rollover 75 Screw L
Assembly Valves
AL155 Cabin Floor Left Left Forward Fuel Vent Valve, 12 Screw L
Forward Access Fuel Cell
Cover
AL165 Cabin Floor Left Fuel Cell Frangible Valve, Wire 76 Screw L
Outboard Panel Harness
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Rotorcraft Maintenance Manual
AL250 Baggage Floor Left Fuel Tee Fittings, Fuel Pressure 25 Screw L
Outboard Panel Switch Drain Tubing, Fuel Hose 4 Bolt M
Shrouds, Fuel Catch Can
AR129 Cockpit Outboard Fire Overheat Bleed Air Leak 34 Screw L
Right Floor Panel Control, Wire Harness, RH 1 Bolt M
Static Port
AR138 Cockpit Floor Right Flight Control Tubes, 35 Screw L
Access Panel Bellcranks, Throttle Cables
AR230 Cabin Floor Right Aft Right Aft Fuel Vent Valve, Fuel 13 Screw L
Access Cover Cell
AR250 Baggage Floor Right Fuel Tee Fittings, Fuel Pressure 25 Screw L
Outboard Panel Switch Drain Tubing, Fuel Hose 4 Bolt M
Shrouds, ECS Tubing, Strobe
Power Supply, Fuel Catch Can
Page 217
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
PR120
PL120
9G06-012A
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Rotorcraft Maintenance Manual
F4
F5
F3 REF. STATOR
F6
F7
F9
REF. FAN SUPPORT AND
HOUSING
F8
F1 F2
9G06-013A
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
Chapter
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
07 Contents Revision 25
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Rotorcraft Maintenance Manual
Page ii
Revision 25 07 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
071000
Lifting and Jacking
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 201
07-10-00 Revision 13
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
B. Component Hoisting
NOTES:
(Ref. Figure 201)
(1) Examine aircraft weight and balance record
The approximate weights for large components per current Rotorcraft Flight Manual
that may require hoisting are listed in (Ref. Section 01-00-00, Table 201) for
Approximate Hoisting Weights (Ref. current weight.
Table 201).
Table 201. Approximate Hoisting Weights
Component 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)
3
4
1 2
(5 PL)
9G07-002A
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Rotorcraft Maintenance Manual
C. Helicopter Jacking NOTE: Use of the forward jack pad grease plate
allows the jack to adjust to the change in the
(Ref. Figure 202) longitudinal dimension. Use of the grease
plate is only required if you intend to change
the attitude of the aircraft.
Consumable Materials
Oil, Lubricating (C106)
(Ref. CSPSPM)
Item Nomenclature
C106 Oil, Lubricating
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07-10-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
8 9
1 1
5
REF. 8
3 2
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Rotorcraft Maintenance Manual
Chapter
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
08 Contents Revision 32
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Rotorcraft Maintenance Manual
Page ii
Revision 32 08 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
081000
Weight and Balance
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(Ref. Figure 202 and Figure 203) (11). Record on Surplus and Missing Equip
ment Form.
NOTE: Weigh helicopter without fuel.
(12). Record the total weight, arms, and
(1). Connect helicopter to electrical ground moments on the Actual Weight and
(Ref. Section 10-10-00). Balance Form.
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08-10-00 Revision 32
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(1). Install the two aft jack pad (T201-1) (10). Lower helicopter until the three
and forward jack pad (T201-2) (Ref. helicopter jack (T202) or load cells are
Section 07-10-00). clear of the two aft jack pad (T201-1)
and forward jack pad (T201-2).
(2). Put a helicopter jack (T202) on forward
jack pad grease plate (T206) below
forward jack pad (T201-2). (11). Make sure helicopter weigh system
(T204) has an indication of 0000.
(3). Put a helicopter jack (T202) below each
aft jack pad (T201-1).
(12). If helicopter weigh system (T204) does
(4). Install helicopter weigh system (T204) not have an indication of 0000, record
as follows: the indication and subtract the values
from the weight recorded in step (9).
(a). If you use platform scales, put a
platform scale below each helicopter
jack (T202). (13). Calculate helicopter weight and balance
from the recorded data.
(b). If you use load cells, attach a load
cell to the top of each helicopter jack
(T202). (14). If it is necessary to weigh the helicopter
again, do steps (5). thru (13). again.
(c). Connect the wires between the
indication unit and the platform (15). Disconnect the wires from between the
scales or load cells. indication unit and the platform scales
(5). Set helicopter weigh system (T204) ON or load cells.
and adjust to an indication of 0000.
(16). Remove the three helicopter jack (T202)
Jacking and forward jack pad grease plate
(T206) from below the helicopter.
Page 202
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Rotorcraft Maintenance Manual
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480
60 60
40 40
20 20
20 20
40 40
60 60
220 220
200 200
180 180
160
140
120 120
100 100
WL 106
FLOOR 80 80
60 60
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480
9G08-001B
Page 203
08-10-00 Revision 32
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Weighed by J. Doe
EMPTY FULL
FUEL X
OIL, ENGINE LH X
OIL, ENGINE RH X
OIL, TRANSMISSION X
HYDRAULIC FLUID X
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480
5 0
220 220
200 200
180 180
160 160
140
120 120
WL 106
FLOOR 100 100
80 80
60 60
LONGITU LONGITU
AVE. SCALE TARE OR NET LATERAL LATERAL
DINAL DINAL
WEIGHING POINT READING CALIB. CORR. WEIGHT ARM MOMENT
ARM MOMENT
LBS LBS LBS IN IN-LBS
IN IN-LBS
Forward (NOTE 1) 869.7 0.0 869.7 154.1 0.0 133929 -8066
Aft Right 1289.5 0.0 1289.5 233.0 23.3 300454 29981
Aft Left 887.5 0.0 887.5 233.0 -23.3 206788 -20634
TOTAL (AS WEIGHED) 3046.7 210.4 0.4 641170 1280
Less : Surplus Weight (See Table 1) -1.8 189.4 -10.4 -346 19
Plus: Missing Required Equipment (See Table 1) 222.6 198.0 0.0 44071 0
NOTE 1: ON SOME HELICOPTERS MDHI USES A SPECIAL FORWARD JACK PAD AT FS 154.0 AND LATERAL 9.3. ON OTHER
HELICOPTERS MDHI USES LATERAL 0.0.
NOTE 2: IN LEVEL ATTITUDE, MAIN ROTOR MAST IS TILTED 5 DEGREES FORWARD.
Page 204
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Rotorcraft Maintenance Manual
9G08-003A
Page 205
08-10-00 Revision 7
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
9G08-004A
Page 206
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
9G08008
Page 207
08-10-00 Revision 32
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Rotorcraft Maintenance Manual
Page 208
Revision 32 08-10-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
082000
Leveling
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
LEVELING
MAINTENANCE PRACTICES
1. Helicopter Leveling (2). Locate keyhole slot (2) in upper aft left
hand cabin door beam (4).
Provisions are made in the design for a
leveling target on the cabin floor, allowing for (3). Attach plumb bob line (5) to keyhole
leveling the helicopter with a plumb bob. A slot (2).
corresponding ceiling location for suspension of (4). Remove left cabin carpet (Ref. Section
a plumb bob relates to the floor leveling 25-20-00) from floor area (1).
marks.
(5). Locate unpainted rivet (3) for plumb
The target is a rivet head located under the bob (5) alignment.
carpet, near the aft left hand cabin door pillar.
Airframe structure damage can
CAUTION occur if stress panels are not in
A. Plumb Bob Leveling
place before jacking.
(Ref. Figure 201) (6). Ensure all stress panels are installed
(Ref. Section 06-00-00).
Special Tools Jacking
(Ref. CSPSPM)
Item Nomenclature
T201 Jack Pad Kit
T202 Helicopter Jack
(7). Jack helicopter (Ref. Section 07-10-00).
T205 Plumb Bob
(8). Adjust jacks (T202) until plumb bob is
in alignment with the leveling target
(1). Remove closeout panel, covering upper (3) (rivet head). This ensures aircraft
aft left hand cabin door beam (4) (Ref. attitude is 0 degrees both longitudinally
Section 25-20-00). and laterally.
Page 201
08-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
2 (NOTE 2)
FS 215.425
5 BL 26.757
WL 155.025
3
1 (NOTE)
Page 202
Original 08-20-00
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Rotorcraft Maintenance Manual
Chapter
TOWING
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
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
Page i
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Rotorcraft Maintenance Manual
Page ii
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
090000
Towing
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
TOWING
MAINTENANCE PRACTICES
1. Towing Requirements (3). Attach ground handling wheel set
(T101) (3) to attach points (2) on skid
The requirement to ground transport the MD tubes (1).
Explorer on prepared surfaces is met by means
of skid mounted ground handling wheels. (4). Hold tail up while lowering ground
handling wheel set (T101) (3).
The ground handling wheel set (3) consists of (5). Jack hydraulic ram, which forces
two each, dual wheel assemblies, which wheels down and skids up.
support a fully equipped MD Explorer approxi
mately three inches above the ground. (6). When the jack is extended, a mechani
cal safety latch automatically snaps
The ground handling wheel set (3) is used for into position, to prevent the wheels
moving the MD Explorer by hand and for from going up in the event of loss of
towing. The wheels are manually lowered with hydraulic pressure.
a detachable jack handle, and are held in the
Lead Lag Loads
down position by a mechanical lock. The CAUTION
ground handling wheel set is equipped with a
tow bar attach fitting. (7). Excessive lead-lag load applied to the
main rotor blades during ground
At regular intervals examine tire pressure and handling can result in damage to the
repack wheel bearings (Ref. Section damper assembly.
32-40-00).
Airframe structure damage can
A. Helicopter Manual Moving
CAUTION occur if stress panels are not in
place before moving helicopter.
(Ref. Figure 201)
(8). Ensure all stress panels are installed
(Ref. Section 06-00-00).
Special Tools
When ground handling helicop
(Ref. CSPSPM) CAUTION ter do not lift main rotor blades
Item Nomenclature
to clear objects. The main rotor should be ro
T101 Ground Handling Wheel Set tated to clear objects.
(9). Ensure cyclic stick is centered and do
NOTE: The ground handling wheel set (T101) not exceed the maximum up limits for
attaches at four points, two inboard and two the main rotor hub flexbeam during
outboard, on the skid assemblies. ground handling, maintenance and
pre-flight operations.
(1). A handle assembly is strapped to the
Do not move the rotor blade tip
skid tubes and extends out, to pull the CAUTION up more than 4.0 ft. (1.22 m)
wheels to and from the helicopter.
when the rotor is not in operation. And do
not move the flexbeam up more than 1.0 in.
(2). Position ground handling wheel set (2.54 cm) at the blade attach point. Dam
(T101) (3) over skid tubes (1) and roll age to the flexbeam can occur.
ground handling wheel set (3) forward.
(10). Manually move helicopter on ground
NOTE: The wheel set can be installed in either handling wheel set (3) by balancing
direction, depending on jack handle posi tailboom and pushing on rear fuselage
tion. portion of airframe.
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Rotorcraft Maintenance Manual
The towbar (5) is equipped with caster wheels (9). Allow inside wheel to turn (not pivot)
and is designed for use with the ground while helicopter is being turned.
handling wheel set (T101) (3) and allows the (10). Detach tow bar (T102) (5) from power
helicopter to be moved by one person. unit.
The towbar (5) does not interfere with equip (11). Release ratchet handles on tow bar (5),
ment that may be hung under the helicopter before ground handling wheel set
(T101) is lowered completely.
(1). Raise helicopter up with ground
(12). Detach nylon straps under skid tube
handling wheel set (T101) (3).
assembly (1).
(2). Position caster wheels on tow bar C. Helicopter Transport
(T102) (5) to straddle over front skid
tube assembly (1). (Ref. Figure 201)
Page 202
Original 09-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Do not move the rotor blade tip When ground handling helicop
CAUTION up more than 4.0 ft. (1.22 m) CAUTION ter do not lift main rotor blades
when the rotor is not in operation. And do to clear objects. The main rotor should be ro
not move the flexbeam up more than 1.0 in. tated to clear objects.
(2.54 cm) at the blade attach point. Dam
age to the flexbeam can occur.
(5). Ensure cyclic stick is centered and do
(3). Attach safety hold-down straps on not exceed the maximum up limits for
heli-porter (4) to skid tube assembly the main rotor hub flexbeam during
(1). ground handling, maintenance and
Do not tow helicopter at speeds pre-flight operations.
CAUTION over 5 mph. A safe minimum
turning radius is approximately 20 feet.
(6). Attach heli-porter (4) hook-up to a tow
(4). Release heli-porter (4) hand brake. vehicle.
5
1
VIEW ROTATED
3
2
4
VIEW ROTATED
9G09001A
1. SKID TUBE ASSEMBLY 4. HELIPORTER (T103)
2. GROUND HANDLING ATTACH POINTS 5. TOW BAR (T102)
3. GROUND HANDLING WHEEL SET (T101)
Figure 201. Helicopter Towing and Ground Handling
Chapter
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
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Rotorcraft Maintenance Manual
Page ii
Revision 25 10 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
101000
Parking and Storage
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
When ground handling helicop (1). Park helicopter into the prevailing wind
CAUTION ter do not lift main rotor blades and secure in accordance with normal
to clear objects. The main rotor should be ro parking conditions.
tated to clear objects.
(2). Statically ground helicopter (Ref.
Section 10-10-00).
(2). Ensure cyclic stick is centered and do
not exceed the maximum up limits for 2. Ground Service Connections
the main rotor hub flexbeam during
ground handling, maintenance and Ground service connections are located on the
pre-flight operations. right hand side of the fuselage below and
forward the pilot's door.
(3). Position helicopter in desired parking
area by taxiing or towing helicopter A. External Power Receptacle
(Ref. Section 09-00-00). (Ref. Figure 201)
(4). Allow helicopter to rest on landing gear The ground power receptacle (3) is 28 volts
skid tubes. DC.
Page 201
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(2). To ground helicopter, install clamp and (3). Maintain full fuel cell to reduce con
grounding stud (2) into grounding jack densation in the cell (Ref. Section
(1). 12-00-00).
When ground handling helicop
(3). To remove ground from helicopter, CAUTION ter do not lift main rotor blades
remove grounding jack (1) from clamp to clear objects. The main rotor should be ro
and grounding stud (2). tated to clear objects.
(4). Ensure cyclic stick is centered and do
not exceed the maximum up limits for
3 the main rotor hub flexbeam during
1
ground handling, maintenance and
4 pre-flight operations.
3
D
(5). Store helicopter in hangar, if space
UN HE
O
R R
E
allows.
G
4. Flyable Storage
Flyable storage will maintain a stored MD
Explorer in an operable condition. If daily use
2 9G10-003A is impractical, the following procedures will
1. GROUNDING JACK
2. CLAMP AND GROUNDING STUD (T110)
keep the helicopter in flyable condition. At
3. GROUND POWER RECEPTACLE regular intervals inspect helicopter. Date and
4. FUEL FILLER PORT type of storage must be recorded in helicopter
records.
Figure 201. Ground Service Connections
A. General Procedures
3. Helicopter Storage (1). Corrosion control depends on control of
The following provides procedures to place the moisture. One method is ventilation, to
MD Explorer in storage. allow circulation of dry air through the
helicopter. Use fans or blowers, when
Protective covers serve as shields to prevent available.
entry of blowing dust, water, freezing rain, FOD
snow and/or foreign objects into the helicopter WARNING
during ground storage.
(2). Ensure drain holes are free of debris
A. Environmental Conditions and kept open during storage period.
Existing environmental conditions and (3). Perform pre-flight inspection per
facilities must be taken into account when the current Rotorcraft Flight Manual
helicopter is placed in storage. Conditions (Ref. Section 01-00-00, Table 201).
Page 202
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Rotorcraft Maintenance Manual
B. Preparation For Flyable Storage (h). Record date engine was placed in
flyable storage in helicopter records.
(Ref. Figure 202)
(3). Hydraulic System
Special Tools (a). Service hydraulic system, to prevent
(Ref. CSPSPM) contamination or degradation (Ref.
Item Nomenclature Section 29-00-00).
T2008 Engine Area Cover (4). Fuel System
T108 Blade Tiedown
(a). Drain water from fuel cell per
T107 Pitot Cover
current Rotorcraft Flight Manual
T106 Upper Deck Cover (Ref. Section 01-00-00, Table 201).
(b). Fill fuel cells to full capacity (Ref.
(1). Drive System Section 12-00-00).
(a). Service drive system to prevent (5). Airframe
contamination or degradation (Ref.
Section 12-00-00, Transmission and (a). Open window air vents. Position air
Rotor Drive System). vents downward.
Tiedown rotor blades, whenever
(2). Engines CAUTION helicopter is parked, to prevent
(a). Clean and preserve engines in rotor damage from blade flapping as a result
accordance to manufacturers Engine of air turbulence from other aircraft or wind
Manual (Ref. Section 01-00-00). gusts. The maximum blade tie down load is
when the blade tip just begins to deflect
(b). Service engines, to prevent contami downward.
nation or degradation (Ref. Section
12-00-00). (b). Secure main rotor blades with blade
tiedowns (1) (Ref. Section 10-20-00).
NOTE: Run-up can be omitted if helicopter
was recently operated. (c). Install pitot cover (2) and upper deck
cover (3) (Ref. Section 10-20-00).
Airframe structure damage can
CAUTION occur if stress panels are not in
(d). Close doors (Ref. Section 06-00-00).
place before run-up. (e). Statically ground helicopter (Ref.
Section 10-10-00).
(c). Ensure all stress panels are installed
(Ref. Section 06-00-00). C. Maintenance During Flyable Storage
(d). Perform engine run-up, at least once (1). Perform pre-flight inspection, at least
every five days per current Rotorcraft once every seven days per current
Flight Manual (Ref. Section Rotorcraft Flight Manual (Ref. Section
01-00-00, Table 201). 01-00-00, Table 201).
(e). After engine run-up, service all (2). Inspect helicopter and treat for corro
helicopter systems to prevent con sion control (Ref. CSP-SPM).
tamination or degradation (Ref. (3). Inspect static ground wires, blade
Section 12-00-00). tiedowns and mooring devices at
regular intervals.
(f). Operate engines until oil tempera
ture is in normal operating range (4). Inspect tiedowns immediately after
and battery is fully charged (Ref. winds exceeding 45 knots.
RFM).
(5). Enter type of storage and date helicop
(g). Install engine area cover (4) (Ref. ter was placed in storage, in helicopter
Section 10-20-00). records.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Consumable Materials
(7). Remove battery (Ref. Section
(Ref. CSPSPM) 96-10-00) and store in waxed paper
Item Nomenclature and a wood crate.
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(4). Check fuel, oil and hydraulic lines for (7). Airframe
leakage.
(a). Open window air vents. Position air
(5). Service helicopter in accordance with vents downward.
Servicing (Ref. Section 12-00-00).
(b). Close and secure all cowlings, panels,
(6). Ensure all bolts, washers, nuts etc. covers and doors (Ref. Section
which are removed during disassembly, 06-00-00).
are coated with a light coat of corrosion
preventive (Ref. CSP-SPM). (c). Install pitot cover (2) and upper deck
cover (3) (Ref. Section 10-20-00).
(7). Record type and date of storage in
helicopter records. (d). Statically ground helicopter (Ref.
Section 10-10-00).
C. Preservation for Intermediate Storage
D. Maintenance During Intermediate
(Ref. Figure 202)
Storage
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10-10-00 Revision 25
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
5
6
3 4 6
2
9G10-001
1. BLADE TIEDOWN (T108) 4. ENGINE AREA COVER (T2008)
2. PITOT COVER (T107) 5. AFT MOORING TIEDOWNS (T104)
3. UPPER DECK COVER (T106) 6. FORWARD MOORING TIEDOWNS (T105)
Figure 202. Helicopter Blade Tiedowns and Covers
Page 206
Original 10-10-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
102000
Mooring
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
MOORING
MAINTENANCE PRACTICES
1. Mooring Helicopter (3). Secure helicopter to ramp tiedowns
using aft mooring tiedowns (1) and
Protective covers and tiedowns are furnished forward mooring tiedowns (2).
as loose equipment, and are used for mooring
the helicopter. (4). If a paved ramp with tiedown rings are
not available, park helicopter (Ref.
Section 10-10-00), on an unpaved
Special Tools parking area, headed in the direction
(Ref. CSPSPM) from which highest forecast winds are
Item Nomenclature expected.
T104 Aft Mooring Tiedowns
(5). Secure helicopter using aft mooring
T105 Forward Mooring Tiedowns
tiedowns (1) and forward mooring
T2008 Engine Area Cover tiedowns (2).
T107 Pitot Cover
Tiedown rotor blades, whenever
CAUTION helicopter is parked, to prevent
A. High Wind Conditions Helicopter rotor damage from blade flapping as a result
Mooring of air turbulence from other aircraft or wind
gusts. The maximum blade tie down load is
(Ref. Figure 201) when the blade tip just begins to deflect
downward.
When severe storm conditions or wind
velocities higher than 75 knots are forecast, (6). Remove main rotor blades, if possible
helicopter should be hangared or evacuated to (Ref. Section 62-10-00).
a safe area. If the helicopter must be parked in
the open during high winds, comply with the (7). Fill fuel cell, if possible (Ref. Section
following. 12-00-00).
Structural damage can occur (8). Install engine area cover (3), pitot cover
CAUTION from flying objects during high (4), (Ref. Section 10-00-00).
wind conditions. Helicopter should be han (9). Ensure all switches are in the OFF
gared or evacuated to a safe weather area position and external power is discon
when wind conditions above 75 knots are nected.
expected.
(10). Close and secure all doors, windows
(1). If a paved ramp with tiedown rings is and access panels (Ref. Section
available, park helicopter (Ref. Section 06-00-00).
10-10-00), on landing gear skids,
headed in direction from which highest (11). After winds subside, inspect helicopter
forecast winds are expected. carefully for damage which may have
been inflicted by flying objects.
When ground handling helicop
CAUTION ter do not lift main rotor blades 2. Covers and Tiedowns
to clear objects. The main rotor should be ro
tated to clear objects. A requirement exists to shield the MD
Explorer from inclement weather conditions
(2). Ensure cyclic stick is centered and do and other outside environmental factors, that
not exceed the maximum up limits for could cause FOD damage during parking,
the main rotor hub flexbeam during mooring and storage. The covers described are
ground handling, maintenance and weather resistant, light weight and conform to
pre-flight operations. the helicopter contours.
Page 201
10-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(1). Two aft mooring tiedown straps (1) will (Ref. Figure 201)
come off the aft fitting.
Special Tools
(2). Two separate forward mooring tie (Ref. CSPSPM)
downs (2) attach to the forward fuse Item Nomenclature
lage. T106 Upper Deck Cover
(Ref. Figure 201) (1). Attach upper deck cover (6), at forward
corners to snap-head screws placed in
existing screw holes on lower edge of
Special Tools particle separator inlet.
(Ref. CSPSPM)
Item Nomenclature
(2). Attach upper deck cover (6), at rear
corners with similar snaps, or with a
T108 Blade Tiedown strap going underneath the tailboom
where it meets the fuselage.
Page 202
Original 10-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
1
2
3 2
6
9G10004
1. AFT MOORING TIEDOWNS (T104) 4. PITOT COVER (T107)
2. FORWARD MOORING TIEDOWNS (T105) 5. BLADE TIEDOWN (T108)
3. ENGINE AREA COVER (T2008) 6. UPPER DECK COVER (T106)
Figure 201. Helicopter Covers and Mooring Tiedowns
D. NOTAR Boom Cover E. NOTAR Thruster Cover
(Ref. Figure 202)
(Ref. Figure 202)
Special Tools
(Ref. CSPSPM)
Special Tools Item Nomenclature
(Ref. CSPSPM)
Item Nomenclature T2010 NOTAR Thruster Cover
Page 203
10-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Special Tools (1). Position cover (5) over top of rotor hub.
(Ref. CSPSPM)
Item Nomenclature
T109 Bubble Cover Canopy
(2). Attach cover (5) with buckles under
each blade.
(1). The cover (4), attaches at four points. (Ref. Figure 202)
(3). Attach upper rear corners to snap-head T2008 Engine Area Cover
screws placed in existing screw holes on
lower edge of particle separator inlet.
(4). Attach straps at lower rear corners to The MD Explorer engine area cover (6) is
rear struts. similar and does the same job as the upper
deck cover, except that it also encloses the
(5). Tighten special rope in top and bottom main rotor. The cover weighs approximately
hems, to insure against wind chaffing. five pounds (2 kg).
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Original 10-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
5 6 2
3 7
4
9G10002
1. NOTAR BOOM COVER (T2009) 5. ROTOR HUB COVER (T2007)
2. NOTAR THRUSTER COVER (T2010) 6. ENGINE AREA COVER (T2008)
3. PITOT COVER (T107) 7. BLADE COVERS (T2011)
4. BUBBLE COVER CANOPY (T109) 8. COLD WEATHER BLADE COVERS (T2012)
Figure 202. Helicopter Protective Covers
Section
103000
Return To Service
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
RETURN TO SERVICE
MAINTENANCE PRACTICES
1. Return to Service B. Short Term Storage Depreservation and
Activation
Perform the following tasks for depreservation
and activation to return the MD Explorer to Special Tools
service. (Ref. CSPSPM)
Item Nomenclature
T2008 Engine Area Cover
A. Flyable Storage Depreservation and T108 Blade Tiedown
Activation T107 Pitot Cover
T106 Upper Deck Cover
Special Tools
(Ref. CSPSPM) (1). Remove protective covers (T2008, T107
Item Nomenclature and T106) stow in designated location.
T2008 Engine Area Cover (2). Open all doors and ventilate helicopter
(Ref. Section 06-00-00).
T107 Pitot Cover
T106 Upper Deck Cover (3). Remove tiedowns (T108) and stow with
other covers.
T108 Blade Tiedown
(4). Service and connect battery (Ref.
Section 96-00-00).
(1). Remove protective covers (T2008, T107 (5). Clean main rotor assembly (Ref.
and T106) stow in designated location. CSP-SPM, Section 20-20-00).
(6). Check fuel system for presence of water
(2). Clean helicopter as necessary (Ref. and drain as necessary.
CSP-SPM, Section 20-20-00).
(7). Fill fuel cell as necessary with approved
fuel (Ref. Section 12-00-00).
(3). Open all doors and ventilate helicopter
(8). Clean and service hydraulic system in
(Ref. Section 06-00-00).
accordance with (Ref. Section
29-00-00).
(4). Remove blade tiedowns (T108) and (9). Clean and depreserve engine in
stow with other covers. accordance with manufacturers Engine
Manual (Ref. Section 01-00-00).
(5). Clean and depreserve engine in (10). Clean helicopter as necessary (Ref.
accordance with manufacturers Engine Section 20-20-00).
Manual (Ref. Section 01-00-00).
(11). Ensure all removed components have
been reinstalled. Check helicopter
(6). Record date helicopter was prepared for records for components that have been
service in helicopter records. removed or disconnected. Check for
subsequent installation.
(7). Remove static ground wire installed for (12). Ensure systems have been properly
storage. depreserved and serviced before any
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10-30-00 Revision 17
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
system or component operational test is (7). Transmission oil and lubrication pump
performed, refer to appropriate ATA filter assembly are to be replaced for
Chapter. aircraft that have been in storage in
excess of a year without operation (Ref.
(13). Remove static ground wire installed for Section 63-21-00).
storage.
(8). Install main rotor blades (Ref. Section
(14). Record date helicopter was prepared for 62-10-00).
service in helicopter records.
(9). Check fuel system for presence of water
C. Intermediate Storage Depreservation and and drain as necessary.
Activation
(10). Fill fuel cell as necessary with approved
Special Tools fuel (Ref. Section 12-00-00).
(Ref. CSPSPM)
(11). Clean and service hydraulic system in
Item Nomenclature
accordance with (Ref. Section
T2008 Engine Area Cover 29-00-00).
T108 Blade Tiedown
T107 Pitot Cover
(12). Clean helicopter as necessary (Ref.
CSP-SPM, Section 20-20-00).
T106 Upper Deck Cover
(13). Ensure all removed components have
been reinstalled. Check helicopter
(1). Remove engine area cover (T2008),
records for components that have been
pitot cover (T107) and upper deck cover
removed or disconnected. Check for
(T106). Stow in designated location.
subsequent installation.
(2). Open all doors and ventilate helicopter
(14). Ensure systems have been properly
(Ref. Section 06-00-00).
depreserved and serviced before any
(3). Remove blade tiedowns (T108) and system or component operational test is
stow with other covers. performed, refer to appropriate ATA
Chapter.
(4). Remove battery from storage and
install serviceable battery (Ref. Section (15). Remove static ground wire installed for
96-10-00). storage.
(5). Clean main rotor assembly (Rev (16). Record date helicopter was prepared for
CSP-SPM,. Section 20-20-00). service in helicopter records.
(6). Clean and service hydraulic system in (17). Perform preflight check (Ref.
accordance with (Ref. Section CSP-900RFM-1 900 CONFIG or
29-00-00). CSP-902RFM-1 902 CONFIG).
Page 202
Revision 1 10-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Chapter
PLACARDS AND
MARKINGS
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
11 Contents Revision 26
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page ii
Revision 26 11 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
110000
Placards and
Markings
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 201
11-00-00 Revision 26
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
2. Decals and Placard (3). Where a decal is applied over a skin lap
(one skin overlapping another), the
A. Decal and Placard Application decal must be cut so that it lies flat and
makes a positive bond.
Consumable Materials
(Ref. CSPSPM) Adhesive, Epoxy (C407)
Item Nomenclature
C407 Adhesive, Epoxy
C411 Adhesive, Epoxy
C420 Solvent, Cleaning
Adhesive, Epoxy (C411)
Page 202
Revision 26 11-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
28 (NOTE 4) 20 (NOTE 1)
24 (NOTE 1)
25 10
9 (NOTE 1) 23 ( NOTE 4 ) (NOTE 1)
11
26 (NOTE 1)
4 (NOTE 2)
B A
C
C
B A
12
23 ( NOTES 4 AND 5 ) 19 1 7
(NOTE 1) 18 (NOTE 1) (NOTE 2)
2 23
(NOTE 1) 3 14 6 (NOTE 1)
(NOTE 3) (NOTES 1 AND 2)
23
15 17 (NOTE 1)
FS 13
295.095 FS
233.000 16 17
15
21
16 15 16
17 13 17
8 (NOTE 2)
5 (NOTE 1)
WL
147.000
FS
400.000 A-A
BL
22 (NOTE 1) 0.000
C-C
NOTES:
1. MINIMUM EXTERIOR DECAL INSTALLATION
2. LEFT HAND SHOWN, RIGHT HAND TYPICAL 14
14 (NOTE 1)
3. WITH FUEL SYSTEM RANGE EXTENDER INSTALLED (NOTE 1) 14
4. WITH SUPPLEMENTAL FUEL SYSTEM INSTALLED 14
(NOTE 1) (NOTE 1) 9G11-001-1E
5. ALTERNATE LOCATION B-B
Page 203
11-00-00 Revision 26
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
THRU THRU
THRU THRU
1. FUEL FILL LOCATION
SAFELOCK
SAFELOCK
KEY
key
LOCK
lock SLAM
SLAM
SAFELOCK
OPEN
key
lock
SLAM
9. NO PUSH INFORMATION
8. PUSH INFORMATION 11. EXTERIOR COCKPIT
DOOR (LEFT SIDE)
9G11-001-2G
Page 204
Revision 26 11-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
MCD ON NELL
HELICO PTER SYSTEMS
MESA, AZ .
MO DEL NO .
SERIAL N O.
TYPE CERT NO .
PR OD CER T NO .
CAUTION
DISCONNECT ELECTRICAL WIRING
BEFORE REMOVING BOOM
24. EXTERIOR CABIN DOOR 25. EXTERIOR CABIN DOOR 26. FUEL CAP DECAL
INSTRUCTION (RIGHT SIDE) INSTRUCTION (LEFT SIDE)
(ORIGINAL CONFIGURATION (ORIGINAL CONFIGURATION
LATCH MECHANISM) LATCH MECHANISM)
9G11-001-3
Page 205
11-00-00 Revision 26
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
B B
E
E
6
A 4
G
A
E-E
D G C
B-B
D C
5
2 1 14 15
D-D
11
12
13
0.25 IN.
3 10 ( 6.35 MM )
A-A 1.23 IN.
7 ( 31.24 MM )
WITH SUPPLEMENTAL FUEL
SYSTEM INSTALLED
9 G-G 9G11-002-1G
C-C
Page 206
Revision 26 11-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
3. INFORMATION-AIRCRAFT LIMITATIONS
9G11-002-2E
Page 207
11-00-00 Revision 26
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
4
1
RIGHT SHOWN
LEFT OPPOSITE
1 2 3
. . .
9G11-008-1A
Page 208
Revision 26 11-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
6
3
7
4
.
EARLY CONFIGURATION
4
.
CURRENT CONFIGURATION
4
5
5
.
7
6 .
.
9G110082
Page 209
11-00-00 Revision 26
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
A A B
B
C C
FS D
230.50
WL
106.00
FS A-A FS
155.50 155.50
4
FS
230.50
RBL LBL 2
19.99 19.99
FS
248.00
3 B-B
E-E FS
155.50 6 5 FS 5
5 130.50
3 .3
3.8
E E
5
(TOP OF DECAL)
5 5
.3
D-D
5 C-C 5 5
9G11-003-1B
Page 210
Revision 26 11-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
CAUTION
CAUTION DO NOT CONNECT OR
(GCU) VOLTAGE REGULATION DISCONNECT UNIT WHILE
CONSULT MAINTENANCE MANUAL GENERATOR IS IN MOTION
FOR PROPER ADJUSTMENT WITHOUT OPENING GCU AND
GENERATOR FIELD
3. CAUTION, VOLTAGE REGULATION CIRCUIT BREAKERS
4. CAUTION-ELECTRICAL CONNECT/DISCONNECT
5. ACCESS PANEL
6. FUEL ACCESS DOOR
9G11-003-2
Page 211
11-00-00 Revision 26
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
A
A
B
1
C
C
B
WL
160.00
FS
155.50
B-B 6 (NOTE)
2 (NOTE) 8
1
1
A- A
FS
C-C 155.50
6 (NOTE) 7 (NOTE)
5
Page 212
Revision 26 11-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
THIS COVER RETAINS SPRING LOADED SERVICE DRIVE PLATE SPLINE AIRCRAFT MUST BE PROPERLY GROUNDED
DRIVE SHAFT. SEE MAINTENANCE AND BATTERY DISCONNECTED
MANUAL FOR REMOVAL PROCEDURE WITH GREASE CONFORMING TO PRIOR TO SERVICING
SYNTECH 3913-G1
4. CAUTION-SPRING LOADED DRIVE SHAFT 5. SERVICE DRIVE PLATE SPLINE 6. CAUTION-BATTERY DISCONNECT
HYDRAULIC SERVICING
WARNING FLUID: MIL-H-83282
MAX RATED SUPPLY
PRESSURE: 1000 PSI (6,895 kPa)
FAILURE TO PROPERLY INSTALL,ALIGN MAX FLOW RATE: 2.2 GPM (0.14 L/S)
AND TORQUE,FUEL,OIL AND AIR TUBES MAX RETURN PRESSURE: 60 PSI (414 kPa)
AND FITTINGS COULD RESULT IN AN
ENGINE FAILURE.REFER TO THE APPLI SEE FLIGHT MANUAL AND LOG BOOK
CABLE MANUAL FOR PROPER INSTAL
ATION AND TORQUE PROCEDURES FOR ADDITIONAL INFORMATION
8. HYDRAULIC SERVICING
7. DECAL
9G11-004-2B
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11-00-00 Revision 26
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
900H7801501103
9G11006A
9G11-007
Figure 207. Main Rotor Pitch Case Decal (Part of Main Rotor Installation)
Page 214
Revision 26 11-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
9G11-005
Figure 208. Transmission and Drive Service Decal (Part of Transmission and Drive System)
Page 215
11-00-00 Revision 26
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
1 2
3 LOOKING INBOARD
RIGHT SIDE OF COCKPIT
FOOT HEATER
COCKPIT HEAT/DEFOG
PULL FOR HEAT PULL FOR HEAT
1. CABIN HEAT
9G11-009
Page 216
Revision 26 11-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Chapter
SERVICING
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
12-00-00 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Description And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Servicing Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1.Servicing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Environmental Control System (ECS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Air-Conditioning (AC) Servicing Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. AC System Servicing (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.AC Compressor Servicing Ports (EARLY CONFIG) . . . . . . . . . . . . . . 202
C. R-134A AC System Servicing (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202.AC Servicing Ports (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . 204
D. Drain the AC Compressor Reduction Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203.Compressor Reduction Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
E. Fill the AC Compressor Reduction Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204.Ground 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 at the Sump Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
C. Defuel the Supplemental Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 207.Hydraulic System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4. Hydraulic System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
A. Service the Hydraulic System with Hand Pump (Optional) . . . . . . . . . . . . . . . . . . 213
B. Service the Hydraulic System with Ground Support Equipment (GSE) Cart . . 213
Figure 208.Servicing of the Landing Gear Damper . . . . . . . . . . . . . . . . . . . . . . . . . 215
5. Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
A. Fill the Landing Gear Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
6. Transmission and Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
A. Main Transmission Oil Fill/Add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Figure 209.Main Transmission Oil Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
B. Drain the Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Page i
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ROTORCRAFT MAINTENANCE MANUAL
Page ii
Revision 34 12 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
120000
Servicing
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
SERVICING
DESCRIPTION AND OPERATION
1. Description The locations of servicing points are shown in
Figure 1.
(Ref. Figure 1)
The servicing materials and capacities are
shown in Table 1.
Instructions and information for complete
servicing of the rotorcraft are provided in this Refer to directive and related manufacturer
section. Servicing includes replenishment of publications (ref. Section 01-00-00) for
fuel, changing or replenishment of oil, and servicing requirements for the engine fuel and
other such maintenance functions. oil filters, and rotorcraft battery.
11
1
2
3 12
9
6
10
14
6
7
5
13
15 5
4
9G12-002E
1. ECS AIRCONDITIONER REFRIGERANT 9. TRANSMISSION & DRIVE SYSTEM MAIN
EARLY CONFIG SHOWN TRANSMISSION LUBRICATING OIL
2. ECS AIRCONDITIONER SYSTEM OIL 10. ROTOR BRAKE MASTER CYLINDER HYDRAULIC
3. ECS COMPRESSOR REDUCTION GEARBOX OIL FLUID
4. FUEL SYSTEM FUEL 11. POWERPLANT ENGINE LUBRICATING OIL
5. HYDRAULIC SYSTEM GSE PANEL 12. POWERPLANT ENGINE WASH SOLUTION
6. HYDRAULIC SYSTEM MANIFOLD/RESERVOIR 13. POWERPLANT FUEL CATCH CAN (PW206A/E ONLY)
HYDRAULIC FLUID 14. ROTOR BRAKE CALIPER SPRAY LUBE
7. HYDRAULIC SYSTEM OPTIONAL HAND PUMP 15. WINDSCREEN WASHER (OPTIONAL) RESERVOIR
RESERVOIR HYDRAULIC FLUID FLUID
8. LANDING GEAR DAMPER FLUID
Figure 1. Servicing Points
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Rotorcraft Maintenance Manual
Fuel System
Hydraulic System
5 Hydraulic Fluid C112 Hydraulic Fluid (7) 2.2 Quarts 2.1 Liters
7 Optional Hand Pump C112 Hydraulic Fluid (7) 1.2 Quarts 1.1 Liters
Reservoir Hydraulic
Fluid
Landing Gear
8 Damper Fluid C105 Hydraulic Fluid MILH5606 2.3 Fluid 70.0 Cubic
Ounces Centimeters
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Rotorcraft Maintenance Manual
9 Main Transmission C106 (8) Lubrication Oil (3) (8) 10.0 9.5 Liters
Lubrication Oil Quarts
C122 (9) Lubrication Oil Mobil SHC 626 10.0 9.5 Liters
(9) Quarts
Rotor Brake
10 Hydraulic Fluid C112 Hydraulic Fluid (7) 1.2 Pints 0.6 Liters
Powerplant
11 Engine Lubrication (10) Lubrication Oil (2) (11) 1.3 Gallons 5.1 Liters
Oil (11)
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Windscreen
NOTES:
(1) For the applicable product manufacturer(s) CAUTIONs and WARNINGs (ref. CSPSPM).
(2) Applicable specification in accordance with related manufacturers publications.
(3) MILPRF23699 lubrication oil supercedes MILL23699 type oil.
(4) Usable fuel for main fuel cell 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) (PostTB900030) Total additional fuel with supplemental fuel cell installed.
(7) MILPRF83282 hydraulic fluid supercedes MILH83282 type fluid.
(8) MILPRF23699 is used only in transmission assemblies 900D1400004 and 900D1400005. Do not blend
with other oils.
(9) MOBIL SHC 626 is used only in transmission assembly 900D1400006101. Do not blend with other oils.
(10) MDHI Rotorcraft Maintenance Manual Consumable Item No. Not Applicable (N/A).
(11) Do not mix oil brands or types.
(12) Drain fuel catch can (Pratt&Whitney 206A and 206E Only) (ref. Section 120000, Maintenance
Practices).
(13) Distilled or deionized water for operations above 32F (0C). Distilled or deionized water with a 50 percent,
by volume, mixture of isopropyl alcohol for operations equal to or below 32F (0C).
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Rotorcraft Maintenance Manual
SERVICING
MAINTENANCE PRACTICES
1. Environmental Control System (ECS) (3). Before servicing, all grease, oil, or other
foreign material must be cleaned from
A. AirConditioning (AC) Servicing the exterior surfaces of components.
Precautions
(4). Do not let unwanted materials (dirt,
Failure to follow air-condi sand, contamination) or moisture get in
WARNING tioning system servicing the system.
precautions can result in injury to per (5). The receiver dehydrator must be
sonnel and/or damage to rotorcraft. replaced each time the AC system is
opened.
Failure to follow the servicing
CAUTION procedures can have an effect on B. AC System Servicing (EARLY CONFIG)
the rotorcraft warranty. (Ref. Figure 201)
Oil, Daphne Hermetic (R12) (C116)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C116 Oil, Daphne Hermetic (R12)
C806 Refrigerant, R12
Oil, Daphne Hermetic (R134A) (C117)
Special Tools
(Ref. CSPSPM)
Item Nomenclature
Do not mix daphne hermetic oil T701 Refrigerant Recovery and Recycling
CAUTION (C116) and daphne hermetic oil
Station
(C117). Damage to the system can occur.
T702 Electronic Leak Detector
Refrigerant, R12 (C806)
Make sure the personnel that
CAUTION maintain and service the air-
conditioning system have the necessary
education and experience. The system has
complex and specialized components that
Refrigerant, R-134A (C815) require specific knowledge.
Failure to comply with
CAUTION manufacturers recovery and re
cycling station servicing requirements and
management of refrigerants, can result in
Do not mix R12 refrigerant damage to the air-conditioning system.
CAUTION (C806) and R-134A refrigerant
(C815). Damage to the system can occur. NOTE: Obey all government and local regula
tions with you fill and evacuate the AC sys
(1). Make sure of the System R number tems with refrigerant substances.
before AC system servicing. (1). Remove Access Panel R210 (ref. Section
53-30-00).
(2). Always fill refrigerant vapor into
high-pressure (discharge) side of (2). Remove caps (1, 2) from service ports
system. (Schrader valve) on compressor.
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
NOTE: Do not add more than 5.5 oz (160 cc) Use only a qualified mechanic or
total. CAUTION pilot to start and operate the en
gines.
Oil, Daphne Hermetic (R134A) (C117)
(19). Start the right engine (ref. applicable
RFM).
Rotor Blades
(a). For a R-134A refrigerant system, (20). Set the AC/VENT switch to COOL
add the quantity of refrigerant oil LOW position on the UTILITY PAN
removed in Step (4).(a). then add 2.0 EL.
to 3.0 oz (60 to 90 cc) of daphne
hermetic oil (C117). (a). If the AC compressor does not
operate, refer to the Fault Isolation
NOTE: Do not add more than 5.5 oz (160 cc) Troubleshooting Table 101 (ref.
total. Section 21-50-00).
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Rotorcraft Maintenance Manual
(29). If necessary, install right aft station Make sure the personnel that
230.00 bulkhead baggage compartment CAUTION maintain and service the air-
interior trim panels (ref. Section conditioning system have the necessary
25-50-00). education and experience. The system has
complex and specialized components that
require specific knowledge.
C. R134A AC System Servicing (CURRENT
CONFIG) Failure to comply with
CAUTION manufacturers recovery and re
cycling station servicing requirements and
(Ref. Figure 202) management of refrigerants, can result in
damage to the air-conditioning system.
Consumable Materials NOTE: Obey all government and local regula
(Ref. CSPSPM) tions with you fill and evacuate the AC sys
Item Nomenclature tems with refrigerant substances.
C117 Oil, Daphne Hermetic (R134A) (1). Remove Access Panel L155 to get
access to the AC service ports (ref.
C815 Refrigerant, R134A
Section 53-30-00).
(2). Remove caps (1 and 2) from service
ports (Schrader valve) on inlet and
Special Tools outlet tubes.
(Ref. CSPSPM)
Item Nomenclature (3). Service air conditioning with a refriger
ant recovery and recycling station
T701 Refrigerant Recovery and Recycling (T701). Refer to related manufacturers'
Station publications for recovery and recycling
T702 Electronic Leak Detector station operation instruction information.
(4). Pull a vacuum of approximate 29.50 to
29.90 inHg of vacuum for 30 min
utes.
(a). Measure quantity of oil removed.
(5). The system must be able to maintain
and hold 29.20 to 29.90 inHg of
vacuum for 30 minutes without
noticeable change in vacuum reading
after pump has been turned off.
(a). If the AC system keeps a vacuum for
30 minutes, go to Step (11).
1
2 (b). If the AC system does not keep a
vacuum for 30 minutes, go to Step
(6).
CURRENT CONFIGURATION (6). Remove Access Panel L210 (ref. Section
53-30-00).
LEFT FORWARD TRANSMISSION DECK SHOWN
9G12-015
1. LOW PRESSURE INLET LINE CAP (REF. IPL, 215000, (7). Remove Access Panel T155 to get
FIG. 2) access to the evaporator (ref. Section
2. HIGH PRESSURE OUT LINE CAP 53-30-00).
Figure 202. AC Servicing Ports (CURRENT (8). Remove Access Panel R210 (ref. Section
CONFIG) 53-30-00).
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
(21). Let the refrigerant in the AC high- (24). If necessary, install Access Panel T155
pressure and low-pressure subsystems (ref. Section 53-30-00).
equalize.
(25). If necessary, install Access Panel L210
(ref. Section 53-30-00).
(22). Disconnect refrigerant recovery and
(26). Install Access Panel L155.
recycling station (T701).
(27). If necessary, install Access Panel R210
(ref. Section 53-30-00).
(23). Install caps (1, 2) from service ports
(Schrader valve) on inlet and outlet (28). If necessary, install Access Panel L155
tubes. (ref. Section 53-30-00).
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D. Drain the AC Compressor Reduction (5). Let lubricating oil (C106) drain into
Gearbox container.
(Ref. Figure 203) (6). Install new packing (7) on drain plug
(6).
Consumable Materials (7). Install drain plug (6) with packing (7)
(Ref. CSPSPM) in compressor (1).
Item Nomenclature
C702 Lockwire (8). Safety drain plug (6) with new lockwire
(C702).
(9). Close Access Panel R210 (ref. Section
06-00-00).
3 1
2 4 5 E. Fill the AC Compressor Reduction
Gearbox
(Ref. Figure 203)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C106 Oil, Lubricating
C702 Lockwire
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1, 4, 5
6
2 1
9G12-018
1. MAIN FUEL CELL GROUND PORT 5. SUPPLEMENTARY FUEL CELL OPTIONAL GROUND
2. MAIN FUEL CELL GRAVITY FILL PORT PORT
3. SUPPLEMENTARY FUEL CELL GRAVITY FILL PORT 6. GROUNDING STRAP
4. SUPPLEMENTARY FUEL CELL GROUND PORT
Figure 204. Ground Ports for Fuel Servicing
2. Fuel (4). At least one fully-charged 50 lb (23
kg) CO2 fire extinguisher must be
A. Fuel System Servicing Precautions available near the work area.
Failure to follow fuel system (5). The fuel vehicle must be parked 20 feet
WARNING servicing precautions can (6 meters) minimum from the
result in injury to personnel and/or rotorcraft during the fuel operation.
damage to the rotorcraft.
(6). Ground the fuel vehicle if possible.
(1). Only approved personnel can fuel the
rotorcraft. (7). Ground the rotorcraft before the start
of the fuel system servicing (ref.
(2). Clothing that makes static electricity Figure 204).
cannot be used by personnel.
(8). All rotorcraft electrical power must be
(3). Open flames and smoking are not OFF, unless you receive other instruc
permitted in the refueling area. tions from MDHI.
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Rotorcraft Maintenance Manual
152 - GAL
156 - GAL
SLOT
4
9G12016
NOTE: The main fuel tank is located below the NOTE: The lanyard must be correctly attached
cabin compartment floor. Its capacity is to make sure the check valve is fully open.
1014 lb (460 kg) (149.0 US gallons (564 li
ters)). Aviation Turbine Fuel
Fuel helicopter with correct fuel
CAUTION as soon as possible after landing
to prevent moisture condensation. Con
densation can have an effect on rotorcraft
performance. Keep the fuel nozzle free of un
CAUTION wanted material. Contamina
(1). Ground the fuel nozzle or fuel vehicle to tion can damage the fuel system and have
ground port (4) or another bare metal an effect on rotorcraft performance.
surface.
(2). Remove filler cap (2). (4). Slowly fill the main fuel tank.
NOTE: There is an optional locking fuel cap (5). Install filler cap (2).
that can be installed on the gravity fill port.
A key is necessary to lock or open the fuel (6). Remove the fuel nozzle and ground(s)
cap. from the rotorcraft.
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4 (OPTIONAL LOCATION)
3
9G12017
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Rotorcraft Maintenance Manual
3. Defuel the Fuel System (b). Drain the remaining fuel at the sump
drain (ref. Procedure 3.B.).
NOTE: The main fuel tank system can be de
fueled at the gravity filler port or the sump (6). Remove the hose from gravity fill port.
drain. But the gravity filler port method
(7). Install filler cap (2).
cannot completely drain all of the fuel from
the main tank. The sump drain procedure (8). If the fuel cell is to stay empty for more
must be done after the gravity filler port than 5 days, do the fuel cell preserva
procedure to completely empty the fuel tion procedure (ref. Section 10-10-00).
tank.
B. Defuel the Main Fuel Cell at the Sump
A. Defuel the Main Fuel Cell at the Gravity Drain
Fill Port
Obey all fuel system servic
WARNING ing precautions.
Special Tools
(Ref. CSPSPM) NOTE: Two fuel sump drain valves are located
Item Nomenclature on the bottom centered on the sump plate.
The valves are spring-loaded, normally
T804 Fuel Suction Pump Kit
closed, poppet drain valves. The valves open
T8041 Fuel Suction Pump Hose Set by pushing the control cable internal plung
er attached to fuel drain valve.
Obey all fuel system servic (1). Make sure the rotorcraft is as level as
WARNING ing precautions. possible.
(1). Ground the rotorcraft (ref. Figure 204). (2). Open access panels B178 and R185 (ref.
Section 06-00-00).
(2). Remove filler cap (2).
(3). Place a suitable container under fuel
NOTE: There is an optional locking fuel cap drain valves.
that can be installed on the gravity fill port.
Aviation Turbine Fuel
A key is necessary to lock or open the fuel
cap.
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Rotorcraft Maintenance Manual
Obey all fuel system servic (6). After all fuel has drained from supple
WARNING ing precautions. mental fuel tank, replace packing and
install plug.
Aviation Turbine Fuel
(a). Torque plug (ref. CSP-SPM).
4
MINIMUM
OIL LEVEL
1
3
HAND PUMP
FLUID TEMP
FLUID TEMP -40C 95C
-40C 95C FULL
F
F U
6 FULL
U L
L L
L REFILL
R REFILL
R E
5 E F
F I EMPTY
I L
L L VIEW LOOKING DOWN
L EMPTY
MANIFOLD / RESERVOIR
EARLY CONFIG MANIFOLD / RESERVOIR
CURRENT CONFIG 9G12-005B
1. HAND PUMP FLUID LEVEL SIGHT GAUGE (REF. IPL, 4. PUMP HANDLE
290000, FIG. 4) 5. MANIFOLD/RESERVOIR FLUID LEVEL SIGHT GAUGE
2. HAND PUMP RESERVOIR COVER (REF. IPL, 290000, FIG. 2)
3. SELECTOR VALVE LEVER 6. MANIFOLD/RESERVOIR BLEED VALVE
Figure 207. Hydraulic System Servicing
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Rotorcraft Maintenance Manual
4. Hydraulic System Servicing (5). Close access panels L155 and R155 (ref.
Section 06-00-00).
A. Service the Hydraulic System with Hand
Pump (Optional) B. Service the Hydraulic System with
Ground Support Equipment (GSE) Cart
(Ref. Figure 207)
(Ref. Figure 207)
Consumable Materials
(Ref. CSPSPM) Consumable Materials
Item Nomenclature (Ref. CSPSPM)
Item Nomenclature
C112 Hydraulic Fluid
C112 Hydraulic Fluid
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Rotorcraft Maintenance Manual
Carefully adjust the hydraulic NOTE: During the bleed of the hydraulic sys
CAUTION pressure. Damage to the rotor tem, make sure the hydraulic fluid (C112)
craft hydraulic system can occur. level does not go below the REFILL line of
the fluid level sight gauge on the manifold/
(f). Set the pressure of hydraulic mule reservoir.
(T2001) to 500 psig (3448 kPa)
maximum. (d). Reduce the system pressure to 50
psig (345 kPa).
Do not make full or sudden
CAUTION movements of the main rotor (e). Open manifold/reservoir bleed valve
flight controls with the external hydraulic (6).
power applied to rotorcraft. The main rotor
flexbeams cannot accommodate full control (f). Examine hydraulic fluid (C112)
excursions (combinations of full collective through the flex tubing at the BL
and full cyclic movements) without centrifu port.
gal force.
(g). Let hydraulic fluid (C112) flow until
(g). Apply pressure to the rotorcraft there are no air bubbles.
hydraulic system.
(h). Close bleed valve (6).
(h). Monitor the fluid level at sight gauge
(5) while cycling flight controls. (i). Loosen the hose connections at the
(i). After you get to the correct fluid pump pilot ports.
level, stop cycling the flight controls. (j). Examine the discharge hydraulic
(j). Stop the pressure at hydraulic mule fluid (C112) for air bubbles.
(T2001).
(k). Let hydraulic fluid (C112) flow until
(k). Stop hydraulic mule (T2001). there are no air bubbles.
(4). Bleed the hydraulic system: (l). Torque the hose connections.
(a). Connect hydraulic mule (T2001) (m). Stop the pressure from hydraulic
return line to return port on the mule (T2001).
same GSE panel to which the hy
draulic mule pressure line is con (n). Stop hydraulic mule (T2001).
nected.
(5). Disconnect hydraulic mule lines from
(b). Apply 500 psig (3448 kPa) to the GSE panel.
hydraulic system with hydraulic
mule (T2001). (6). Install panel port covers.
(c). Cycle all hydraulic actuators at least (7). Remove flex tubing from manifold BL
15 cycles as you simultaneously port fitting and reconnect drain tube.
turn the main rotor head five times
minimum in the direction of normal (8). Close access panels L155 and R155 (ref.
blade travel. Section 06-00-00).
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5 4
REF. 4
3
FULL
RED
GREEN
9G12-001A
1. DAMPER (REF. IPL, 320000, FIG. 2) 4. RESERVOIR LEVEL INDICATOR
2. FILL PORT 5. FIRST NOTCH
3. BLEED VALVE
Figure 208. Servicing of the Landing Gear Damper
5. Landing Gear Hydraulic Fluid (C105)
A. Fill the Landing Gear Damper
(Ref. Figure 208)
(3). Fill the reservoir of damper (1) with
Consumable Materials hydraulic fluid (C105) in reservoir.
(Ref. CSPSPM)
Item Nomenclature (4). Open bleed valve (3) slightly.
C105 Hydraulic Fluid (5). Let hydraulic fluid (C105) bleed out
until there are no air bubbles in the
flow.
Special Tools (6). Close bleed valve (3).
(Ref. CSPSPM)
Item Nomenclature (7). Continue to fill the reservoir with
hydraulic fluid (C105) until the reser
T111 Fluid Service Unit voir level indicator (4) shows completely
full (all green).
The damper (1) must be in the (8). Remove fluid service unit (T111) from
CAUTION vertical position. If the damper fill port (2).
is not in the correct position, servicing can
not be done correctly. (9). Install cap on fill port (2).
NOTE: It is not necessary to remove damper (1) (10). Open bleed valve (3) slightly.
from the rotorcraft for servicing. (11). Drain hydraulic fluid (C105) from bleed
valve (3) until the red of fluid level
(1). Remove the cap from fill port (2). indicator (4) reaches first notch (5).
(2). Attach hydraulic fluid service unit NOTE: The servicing of the damper is correct
(T111) of 50 psi (minimum) to fill port when reservoir level indicator (4) is green
(2). with a very thin wedge of red seen to first
notch (5).
NOTE: Use a standard 37 female flared fitting
to connect to fill port (2). (12). Close bleed valve (3).
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6. Transmission and Drive System Do not put too much oil in trans
CAUTION mission. A too full transmission
A. Main Transmission Oil Fill/Add can cause very high pressure fluctuations.
Oil, Lubricating (C122)
(Ref. Figure 209) Oil, Lubricating (C106)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature (3). Add the correct lubricating oil to
C106 Oil, Lubricating transmission.
C122 Oil, Lubricating (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).
3 B. Drain the Main Transmission
(Ref. Figure 209)
Special Tools
2 (Ref. CSPSPM)
Item Nomenclature
1
T307 HeliLock Drain Attachment
4
(3). Put open end of heli-lock drain attach
9G12-004 ment (T307) (1) in an applicable
1. HELILOCK DRAIN ATTACHMENT container.
2. CHIP DETECTOR HOUSING (REF. IPL, 633000, FIG.
1) Oil, Lubricating (C122)
3. FILLER CAP (REF. IPL, 620000, FIG. 2) Oil, Lubricating (C106)
4. SIGHT GAGE (REF. IPL, 633000, FIG. 1)
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SCREW
FAN BEARING WASHER
WASHER
WING NUT
GREASE TOOL
PART A
GREASE TOOL
PART B
GREASE FITTINGS
9G12-014
(2). Carefully remove both seals from (5). Purge bearing with grease (C104) or
bearing. aircraft grease (C107) until clean grease
protrudes from all four holes in Part A of
(3). Inspect seals for damage. grease tool.
(a). No damage permitted. (6). Remove anti-torque bearing grease tool
(T604).
(4). Install bearing between grease tool
Part A and Part B, with a 4-inch 10-24 (7). Hand rotate bearing to purge excess
threaded bolt, washers, and wing nut. grease.
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Make sure seals are serviceable. (4). Install filler cap (1).
CAUTION If new seals are required, seals
and bearings must come from the same ven (5). Close Access Panel R155 (ref. Section
dor. 06-00-00).
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature LUBRICATE
2
LUBRICATE
9G12-011
1. FILLER CAP (REF. IPL 632200, FIG. 1) 9G12-012
2. SIGHT GLASS
Figure 212. Rotor Brake Caliper Servicing
Figure 211. Rotor Brake Master Cylinder
Servicing
(1). Open Access Panel L210 or R210 (ref.
(1). Open Access Panel R155 (ref. Section Section 06-00-00).
06-00-00). Lubricant, Spray (C120)
NOTE: The rotor brake reservoir is located on
the top forward deck.
(2). Remove filler cap (1).
Do not allow lubricant to con
Hydraulic Fluid (C112) CAUTION tact brake disk or brake pad.
(2). Lubricate areas shown in Figure 212
with spray lubricant (C120).
(3). Fill reservoir to top of sight glass (2) (3). Close Access Panel L210 or R210 (ref.
with hydraulic fluid (C112). Section 06-00-00).
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(b). Safety with lockwire (C702). (2). Remove engine oil filler cap.
B. Engine Oil System Filling/Replenishing (3). Refill engine oil tank with lubricating
oil (C106).
(Ref. Figure 213)
(4). Install and lock engine oil filler cap.
Consumable Materials
(a). Place dipstick in gearbox.
(Ref. CSPSPM)
Item Nomenclature (b). Make sure dipstick off-set of cap is in
C106 Oil, Lubricating line with off-set hole of gearbox oil
filler tube.
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MAXIMUM ALLOWABLE
OIL LEVEL
MINUMUM ALLOWABLE
OIL LEVEL
2
CHIP
DETECTOR
OIL FILTER
IMPENDING
VIEW LOOKING AFT BYPASS INDICATOR
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Rotorcraft Maintenance Manual
Special Tools
(Ref. CSPSPM)
LEFT SIDE SHOWN
Item Nomenclature
VIEW LOOKING INBOARD T406 Compressor Wash Rig
T4061 Adapter
NOTE:
At or above 365F (25C) use drinking qual
ity water for desalination wash.
Below 365F (25C) use rinsing solution
1 (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).
2 CAUTION
Use correct rinsing solution mixture.
9G12-010A
1. FUEL CATCH CAN (REF. IPL, 717000, FIG. 2)
Engine temperature must be below 65_C
2. CATCH CAN DRAIN VALVE (150_F).
Figure 214. Fuel Catch Can To prevent damage, turn off inlet particle
separator and heat/defog shutoff valves.
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Special Tools
(Ref. CSPSPM) 9G12-003A
Item Nomenclature
Figure 215. Engine Wash Panel
T406 Compressor Wash Rig
T4061 Adapter (1). Fill compressor wash rig (T406) with
cleaning solution and water or rinse
solution.
NOTE: (2). Pressurize tanks to 60 to 82 psi (414
Prepare cleaning solution (ref. P&WC to 565 kPa).
Maintenance Manual, Directives and Re
lated Manufacturers' Publications, Sec (3). Open Access Panel R210 (ref. Section
tion 01-00-00). 06-00-00).
At or above 365F (25C) use drinking qual (4). Connect engine compressor wash rig
ity water for the rinse. (T406) to engine wash panel with
adapter (T406-1).
Below 365F (25C) use a rinse solution (ref.
P&WC Maintenance Manual, Directives Obey the starter limits (ref. ap
CAUTION plicable RFM). Damage to the
and Related Manufacturer Publications,
Section 01-00-00). starter can occur.
The cleaning and rinse solution pressure (5). Dry-motor the engine (ref. applicable
must be 60 to 82 psi (414 to 565 kPa). RFM).
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(6). When NG reaches 5%, inject cleaning (12). Do this procedure on the other engine.
solution into engine inlet.
(13). Close Access Panel R210 (ref. Section
(7). Turn starter OFF after 30 seconds. 06-00-00).
(8). Close valve for cleaning solution when Obey the starter limits (ref. ap
CAUTION plicable RFM). Damage to the
NG decreases to 5%.
starter can occur.
(9). Let the cleaning solution soak for 10
minutes. (14). Operate the engines at idle for at one
minute minimum to dry the engines
Obey the starter limits (ref. ap (ref. applicable RFM).
CAUTION plicable RFM). Damage to the
starter can occur. 8. Rotorcraft
(10). Dry-motor the engine (ref. applicable A. Operation in a Corrosive Environment
RFM).
NOTE: A corrosive environment is an atmo
(a). When NG reaches 5%, inject solution sphere with high levels of abrasive dust,
into engine inlet. acidic or high-mineral-content soils, agri
cultural agents, extreme temperatures, in
(b). Inject the remaining solution. dustrial air pollution, or salt water vapor.
(c). If the water/methanol mixture was (1). Do the Rotorcraft Rinse Procedure
used, motor the engine for 30 se every day (ref. CSP-SPM, Section
conds minimum to dry the engine 20-20-00).
and remove flammable fumes.
(2). Do the Rotorcraft Wash Procedure
(11). Disconnect adapter (T406-1) from the every 14 days (ref. CSP-SPM, Section
engine wash panel. 20-20-00).
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9G12-013A
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Rotorcraft Maintenance Manual
Chapter
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
18 Contents Revision 34
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Rotorcraft Maintenance Manual
Page ii
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
180000
Vibration and Noise
Analysis
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
BMS software in the IIDS records the vibra Loose blade attach bolts or other associated
tion data and provides recommended adjust hardware.
ments for correcting imbalance condition in Loss of a fan blade is not yet predictable but
both the main rotor and the anti-torque fan the fan support structure is designed to handle
assembly. the resulting out of balance condition. The
BMS will detect anti-torque fan ``out of
A. Main Rotor Vibration Monitoring balance conditions. Maintainers will use this
as an indication to correct fan balance reduc
(Ref. Figure 1) ing vibration to an acceptable level of (0.15
IPS or less). Attempts should be made to
Typical causes for main rotor vibrations are: balance the assembly to the optimal balance of
(0.05 IPS).
Mass Imbalance (weight distribution) caused
by normal wear of rotor system components or C. Transmission and Drive System Vibration
blade replacement. Monitoring
(Ref. Figure 1)
Aerodynamic Forces caused by slight
differences in rotor blade airfoil shapes, blade Future enhancements to the BMS will include
twist, or erosion. monitoring transmission and drive system
components and engines.
The main rotor vibration sensor provides a
vibration level signal to the IIDS. BMS D. Vibration Trend Monitoring
software in the IIDS uses this data to deter The critical components of the main rotor
mine if the main rotor vibration levels are out system and anti-torque system are designed
of tolerance. to be replaced ``on condition. Warning of
abnormal conditions in these components will
BMS software also provides recommended be provided by three indications:
changes to pitch case weights, blade tabs or
pitch change links to bring the main rotor (1). BMS vibration monitoring trends,
vibration levels within tolerance. These
recommendations are based on information (2). Normal periodic inspections,
stored in the IIDS related to blade tab (3). Perceptible unusual vibrations at the
position, main rotor blade hub weights pilot's station.
installed, and pitch case weights installed.
The BMS can be the most sensitive of these
Typically, the BMS will be able to provide indications giving a warning in advance of the
balance corrections that will bring the other detection methods. Typically the BMS
vibration levels into tolerance within two sensors will be able to detect changes in
flights if the starting vibration level is no vibrations before they become apparent to the
greater than 0.5 IPS (Inches Per Second). pilot.
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Rotorcraft Maintenance Manual
The BMS captures vibration data and stores it This information can be used by maintainers
in a log to use in detecting changes in vibra to isolate failed or failing components.
tion levels over a period of time (trending).
Vibration trend monitoring of the main rotor
and anti-torque systems can provide an early
warning of system component progressive
failures.
IIDS UNIT
BALANCE MONITORING
ROTOR VERTICAL ROTOR VERT VIB POWER
VIBRATION
SENSOR
ROTOR VERT VIB SIGNAL
ROTOR
AZIMUTH ROTOR AZIMUTH SIGNAL
SENSOR
NOTAR
AZIMUTH NOTAR AZIMUTH SIGNAL
SENSOR
9G18-001A
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Rotorcraft Maintenance Manual
Erratic balance readings. Incorrect azimuth to sensor Verify azimuth sensor gap. 643000
gap.
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Rotorcraft Maintenance Manual
NOTE: Blade tracking targets must be (5). Repeat steps (3). and (4). to install
installed in the correct sequence. Blade blade tracking targets (6) numbered
number one is located above nose of helicop two, three, four and five on each rotor
ter when swashplate interrupter is above blade, in sequence opposite the direc
azimuth sensor. Blades number 2, 3, 4, and tion the rotor turns.
5 are numbered in sequence opposite the di
rection the rotor turns.
DIRECTION
ROTOR TURNS BLADE 3
BLADE 2
BLADE 4
BLADE 1
BLADE 5 2
5
3 INBOARD VIEW OF TAB
6
9G18-003B
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Rotorcraft Maintenance Manual
B. Main Rotor Ground Track Adjustment C. Main Rotor Hover Track Adjustment
Rotor Vibrations Rotor Vibrations
WARNING WARNING
(1). Install main rotor blade tracking
targets. (1). Install main rotor blade tracking
targets.
(2). Start one engine, refer to current
Rotorcraft Flight Manual (Ref. Section (2). Start and hover aircraft, refer to
01-00-00, Table 201). current Rotorcraft Flight Manual (Ref.
(3). Set main rotor RPM to 65% NR. Section 01-00-00, Table 201).
(4). Press MENU on IIDS key panel (Ref. (3). Press MENU on IIDS key panel (Ref.
CSP-900RMM-3, Section 95-30-00). CSP-900RMM-3, Section 95-30-00).
(5). Use the key to select BALANCE
(4). Use the key to select BALANCE
MONITOR from first level menu and
MONITOR from first level menu and
press ENT.
press ENT.
(6). Use the key to select MAIN ROTOR
TRACK from second level menu and (5). Use the key to select MAIN ROTOR
press ENT. Display changes to: FLASH TRACK from second level menu and
STROBE BLD SPREAD <ON> press ENT. Display changes to: FLASH
STROBE BLD SPREAD <ON>
(7). Point strobe light at main rotor blade
tips and press trigger. Record vertical (6). Point strobe light at main rotor blade
position of each rotor blade tracking tip. tips and press trigger. Record vertical
NOTE: Move strobe light in a ``W'' pattern while position of each rotor blade tracking tip.
pointed at blade tip path in front of aircraft
to find reflective blade tracking targets. NOTE: Move strobe light in a ``W'' pattern while
pointed at blade tip path in front of aircraft
(8). Calculate adjustments necessary to to find reflective blade tracking targets.
correct blade track. Track must be
within 1 in. (2.54cm). (7). Calculate adjustments necessary to
(9). Make pitch change link adjustment. correct blade track. Track must be
within 1 in. (2.54 cm).
(10). Repeat steps (2). thru (8). with main
rotor RPM set to 100% NR. (8). Make pitch change link adjustment.
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Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
9G18-004
C702 Lockwire 1. PITCH CHANGE LINK
2. ROD END
3. NUTS
4. BARREL
(1). Remove and discard lockwire from nuts
(3). Loosen nuts. Figure 202. Pitch Change Link Adjustment
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F. Main Rotor Blade Tab Adjustment (2). Install trim tab gauge (2) on main rotor
blade (3) at trim tab.
(Ref. Figure 203)
(3). Install tab bending tool (4) on trim tab.
Special Tools NOTE: Trim tab is very sensitive. Only small
(Ref. CSPSPM) amounts of force are necessary to bend tab.
Item Nomenclature One mil is equal to 0.001 inch.
T902 Main Rotor Blade Tab Bending Tool (4). Bend tab up or down as necessary. Do
not bend tab more than 0.085 in.
(0.215 mm) from ``0.
(1). Install calibration plate (1) in trim tab
gauge (2). Adjust dial indicator (T902)to (5). Remove tab bending tool (T902) and
read ``0. trim tab gauge. Record changes.
2
3
4
9G18-006
1. CALIBRATION PLATE 3. MAIN ROTOR BLADE
2. TRIM TAB GAUGE 4. ROTOR BLADE TRIM TAB BENDING TOOL
Figure 203. Main Rotor Blade Tab Adjustment
G. Main Rotor Balance (On Ground) (3). Do the ground balance part of Balance
Display Measurement Menu procedure
Rotor Vibrations (Ref. CSP-900RMM-3, Section
WARNING 95-30-00). Record results.
(4). Do the Main Rotor Solutions Options
(1). Start aircraft, refer to current Rotor Menu procedure (Ref. CSP-900RMM-3,
craft Flight Manual (Ref. Section Section 95-30-00) to find necessary
01-00-00, Table 201). adjustments to get correct balance.
(5). Make balance adjustments.
(2). Do the Collect M/R Data Run XX Menu
procedure (Ref. CSP-900RMM-3, (6). Repeat steps (1). through (4). until
Section 95-30-00). balance is 0.3 IPS or less.
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H. Main Rotor Balance (In Flight) Blade number one is located above nose of
helicopter when swashplate interrupter is
Rotor Vibrations above azimuth sensor. Blades number 2,
WARNING 3, 4, and 5 are numbered in sequence op
posite the direction the rotor turns.
(1). Start aircraft, refer to current Rotor
craft Flight Manual (Ref. Section (1). Find main rotor blade indicated by
01-00-00, Table 201). Main Rotor Solutions Options Menu
procedure (Ref. CSP-900RMM-3,
(2). Do the Collect M/R Data Run XX Menu Section 95-30-00)
procedure (Ref. CSP-900RMM-3, NOTE: Balance weights are approximately
Section 95-30-00). 13.6 grams each. No more than 13 balance
weights (approximately 177 grams) can be
(3). Do the complete Balance Display
installed on each pitch case.
Measurement Menu procedure (Ref.
CSP-900RMM-3, Section 95-30-00). (2). Find the correct quantity of weight to
Record results. add or remove.
(4). Do the Main Rotor Solutions Options (3). Remove sealant from bolts (6), washers
Menu procedure (Ref. CSP-900RMM-3, (7), and bonding jumpers (8).
Section 95-30-00) to find necessary (4). Remove bolts (6), washers (7), bonding
adjustments to get correct balance. jumpers (8), and weights (3) (if instaled).
(5). Make balance adjustments. (5). Prepare surface for electrical bond (Ref.
CSP-SPM).
(6). Repeat steps (1). through (4). until
NOTE:
balance is 0.2 IPS or less.
Change bolt length as necessary when
I. Pitch Case Weight Adjustment you add or remove weights.
(Recommended Location) If weights were not installed before, you
must use a different part number bolt
(Ref. Figure 204) when you install weights (Ref.
CSP-900IPL-4).
Consumable Materials (6). Install balance weights, bonding
(Ref. CSPSPM) jumpers, washers, and bolts. Torque
Item Nomenclature bolts 20-25 in-lb (2.26-2.82 Nwm) and
C229 Sealant, Conductive safety with lockwire (C702).
C702 Lockwire (7). Test bolts for class S electrical bond
(Ref. CSP-SPM.
NOTE: Sealant, Conductive (C229)
Pitch case weight location is the recom
mended location for main rotor balance
adjustments.
Hub weight location is an alternative (8). Environmentally seal bolts, washers,
location and can be used along with the and bonding jumpers, use sealant
pitch case location. (C229) (Ref CSP-SPM).
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J. Hub Weight Adjustment (Alternative (2). Find the correct quantity of weight to
Location) add or remove.
(Ref. Figure 204) (3). Remove nuts (5),washers (2), balance
weights (3) (if installed), screws (1), and
NOTE:
washers (2).
Pitch case weight location is the recom
mended location for main rotor balance NOTE:
adjustments.
No more than 8 each 900R2101024-101
Hub weight location is an alternative or 16 each 900R2101024-103 balance
location and can be used along with the weights (approximately 218 grams) can
pitch case location. be installed at each hub weight location.
Blade number one is located above nose of Install the same quantity of balance
helicopter when swashplate interrupter is weights on top and bottom of hub plate.
above azimuth sensor. Blades number 2,
3, 4, and 5 are numbered in sequence op Change screw length as necessary when
posite the direction the rotor turns. you add or remove weights.
(1). Find main rotor blade indicated by (4). Install balance weights, screws,
Main Rotor Solutions Options Menu washers, and nuts. Torque nuts 20-25
procedure (Ref. CSP-900RMM-3, in-lb (2.26-2.82 Nwm) and safety
Section 95-30-00) screws with lockwire (C702).
6 6
7
7
8
8
1
3 1
2
3
5 2
4
2
4
9G18-007A
1. SCREW 5. HUB PLATE
2. WASHER 6. BOLT
3. BALANCE WEIGHT 7. WASHER
4. NUT 8. BONDING JUMPER
Figure 204. Main Rotor Balance Adjustment
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2. AntiTorque Fan Assembly Balance (3). Do the NOTAR Balance Collect Data
Menu procedure (Ref. CSP-900RMM-3,
A. AntiTorque Fan Balance Using Balance Section 95-30-00)
Monitoring System (BMS) in IIDS
Rotor Vibrations (4). Do the Display NOTAR Measure
WARNING ments Menu procedure (Ref.
CSP-900RMM-3, Section 95-30-00).
(1). Start one engine, refer to current
Rotorcraft Flight Manual (Ref. Section NOTE: No more than 0.15 IPS fan balance is
01-00-00, Table 201). permitted.
(2). Set main rotor RPM to 100% for two
minutes. (5). Do the NOTAR Balance Solutions
Menu procedure (Ref. CSP-900RMM-3,
NOTE: Section 95-30-00). If necessary, record
Make sure directional control pedals are recommended balance adjustment.
set to approximately one inch forward
right pedal to get minimum fan pitch be NOTE: Try to balance the fan to (0.05 IPS).
fore you do this procedure.
You can also look at the torque indication (6). If necessary, change anti-torque fan
on the IIDS and move directional control balance weight.
pedals to get the lowest torque indication.
This will give you an accurate indication (7). If necessary, do steps (1). thru (6).
the fan is at minimum pitch. again.
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Table 201. AntiTorque Fan Recommended (c). Install nut. Torque nut.
Balance Weights (5). Install lower diffuser and duct (Ref.
Thick I.D. O.D. Weight Section 53-00-00).
Part Number (in.) (in.) (in.) (Grams)
(6). Install baggage compartment closeout
AN960KD416L 0.016 0.265 0.500 0.103 panels and soft insulation panels (Ref
Section 25-50-00).
AN960416L 0.032 0.265 0.500 0.572
AN960KD416 0.063 0.265 0.500 0.407
AN960C416 0.063 0.265 0.500 1.144
HS306325L 0.016 0.263 0.528 0.121
HS306225L 0.016 0.263 0.528 0.339
HS306325 0.032 0.263 0.528 0.241
HS306225 0.032 0.263 0.528 0.667
HS306325H 0.063 0.263 0.528 0.482
HS306225H 0.063 0.263 0.528 1.355
HS306326L 0.016 0.263 0.619 0.181
HS306226L 0.016 0.263 0.619 0.507
HS306326 0.032 0.263 0.619 0.361
HS306226 0.032 0.263 0.619 1.015
HS306326H 0.063 0.263 0.619 0.723
HS306226H 0.063 0.263 0.619 2.029
HS306327L 0.016 0.263 0.800 0.329
HS306227L 0.016 0.263 0.800 0.922
HS306327 0.032 0.263 0.800 0.657
HS306227 0.032 0.263 0.800 1.844
HS306327H 0.063 0.263 0.800 1.314
HS306227H 0.063 0.263 0.800 3.689
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12 13
2
11 1
3
10 2
9 3
1
8 4
7 5
6
BALANCE STUD ASSEMBLY
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3. Main Rotor Autorotation RPM (3). Record main rotor RPM and density
altitude.
A. Autorotation RPM Adjustment
(4). Refer to autorotation RPM chart in
(Ref. Figure 206) Figure 206 for correct rotor RPM.
NOTE:
Rotor Vibrations
WARNING To increase autorotation RPM, lengthen
pitch change links (decrease blade pitch).
(1). Operate aircraft at an altitude suffi To decrease autorotation RPM, shorten
cient for doing an autorotation, refer to pitch change links (increase blade pitch).
current applicable Rotorcraft Flight
Manual (Ref. Section 01-00-00, If you turn pitch link barrel one flat, you
Table 201). will change rotor RPM by approximately
0.6%.
(2). Do the autorotation at a stabilized (5). If autorotation RPM is not within
airspeed of 70 KIAS with collective range, adjust all pitch change links
stick full down. equally as shown on autorotation RPM
chart.
NOTE: If aircraft is at or near gross weight lim
it and there is high density altitude, it is (6). When autorotation RPM is correct, do
possible the procedure can not be done with the hover and forward flight balance
collective stick full down. Refer to note on procedures to make sure rotor vibration
Sheet 2 of Figure 206 for alternative collec levels are 0.2 IPS or less (Ref. Main
tive position at higher gross weights. Rotor Balance (In Flight)).
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18000
EXAMPLE:
ROTORCRAFT WEIGHT: 4920 LBS.
DENSITY ALTITUDE: 500 FT.
16000 *MAIN ROTOR RPM FOR THIS WEIGHT AND DENSITY
ALTITUDE SHOULD BE SET BETWEEN 101% AND 102% NR
WITH COLLECTIVE CONTROL LEVER FULL DOWN.
14000
12000
DENSITY ALTITUDE - FT
10000
8000
6000
4000
EXAMPLE DENSITY
ALTITUDE: 2000
500 FEET
-2000
88 90 92 94 96 98 100 102 104 106 108
89 91 93 95 97 99 101 103 105 107
*
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18000
EXAMPLE:
ROTORCRAFT WEIGHT: 5860 LBS.
DENSITY ALTITUDE: 500 FT.
14000
DENSITY ALTITUDE - FT
12000
10000
8000
6000
4000
EXAMPLE DENSITY
ALTITUDE:
500 FEET 2000
108
107
0
106
105
-2000
88 90 92 94 96 98 100 102 104
89 91 93 95 97 99 101 103
PERCENT NR *
9G18-002-2A
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Chapter
ENVIRONMENTAL
CONTROL SYSTEM
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
21 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page ii
Revision 34 21 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page iii
21 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page iv
Revision 34 21 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page v
21 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page vi
Revision 34 21 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page vii
21 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page viii
Revision 34 21 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page ix
21 Contents Revision 34
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ROTORCRAFT MAINTENANCE MANUAL
Page x
Revision 34 21 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
212000
Vent System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
VENT SYSTEM
DESCRIPTION AND OPERATION
1. Vent System switch controls the vent fan and air condition
ing. VENT LOW provides vent air at a low
The vent system introduces outside air into setting. VENT HIGH provides air at a high
the cabin and crew compartment. Air enters setting, selected from the center console utility
through an air inlet duct above the transmis panel assembly.
sion deck. Air is routed into a water separator
to remove moisture (rain), while maintaining a D. Air Supply Plenum
constant air flow. A two speed vent fan, located
on the transmission deck is used to induce The air supply plenum distributes the air flow
airflow. Air enters the cockpit and cabin area from the inlet duct and vent fan to the air
through a plenum, air ducts and gasper ducts. The air supply plenum is constructed of
assemblies. composite fiberglass.
E. Air Ducts
2. Vent System Components
Air ducts route air directly to the gasper
A. Inlet Duct assemblies from the air supply plenum. The
air ducts are constructed of silicon rubber
An inlet duct is attached to the right side of coated woven fiberglass, with a nylon heli-coil
the forward swashplate fairing assembly. An reinforcement.
inlet hole measuring five inches in diameter is
covered with an air scoop and screen to allow F. Crew Station Gasper Assemblies
outside air in for the air vent system.
Four crew station gasper assemblies allow air
B. Water Separator to be directed into the cockpit. The gasper
assemblies are constructed of aluminum and
The water separator is located immediately are capable of delivering a flow volume of 20
downstream from the inlet duct. Outside air cubic feet per minute. The gasper assemblies
enters the water separator. Moisture (rain) utilize an inner cylindrical disc that allows air
entering the water separator with fresh air is to discharge at adjustable volume rates. A
centrifugally extracted to the bottom of the finger rotation of the assembly will alternate
water separator when the air makes a 180 the gasper assembly's cylindrical disc to
degree turn and flows into a vent fan. Water is change air flow discharge volume.
drained from the separator when a rubber
check valve opens into on the transmission G. Passenger Gasper Assemblies
deck.
Passenger gasper assemblies are located at six
C. Vent Fan various locations in the passenger compart
ment ceiling. Gasper assemblies are
The vent fan is used to initiate and sustain air constructed of aluminum and are capable of
flow at 180 cubic feet per minute. The fan is a delivering air at a flow volume of 20 cubic feet
two speed vane axial type with an aluminum per minute. Gasper assemblies utilize an inner
impeller. The fan is powered by a 28 vdc cylindrical disc to discharge air at adjustable
brushless motor. The vent fan is mounted at volume rates. A finger rotation of the assembly
fuselage station 185.5 on the right side of the will alternate the gasper assembly's cylindrical
transmission deck. A five position AC/VENT disc to change the air flow discharge volume.
Page 1
21-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
AIR DUCTING
GASPER ASSY
COCKPIT BULKHEAD
PLENUM ASSY
FRESH AIR INLET
AIR DUCTING
GASPER ASSY
OVERHEAD WATER SEPARATOR
CREW STATION GASPER ASSY
COCKPIT
FLEXIBLE GASPER ASSY
SERIAL NUMBERS 0039-SUBSEQUENT PASSENGER
AIR DUCTING
COMPARTMENT
VENT FAN
FLEXIBLE
AIR DUCTING AIR DUCTING
AIR DUCTING
DUCT ASSY
ROOF DECK FLEXIBLE
AIR DUCTING AIR DUCTING
VENT AIR SUPPLY GASPER ASSY
GASPER ASSY
GASPER ASSY OVERHEAD PLENUM PASSENGER
CREW STATION
CREW STATION COMPARTMENT
GASPER ASSY PASSENGER
COMPARTMENT
AIR DUCTING
DOOR PILLAR PLENUM
GASPER ASSY
CREW STATION
9G21012B
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Original 21-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
VENT SYSTEM
FAULT ISOLATION
1. Vent System Troubleshooting Troubleshooting tables should be used with
system schematics, electrical wiring diagrams,
serviceability checks and other detailed
(Ref. Figure 101) procedures in this and other chapters of the
manual.
The following troubleshooting procedures are a Comprehensive wiring diagrams are available
brief summary of vent system faults which in the Rotorcraft Maintenance Manual
may be encountered (Ref. Table 101). 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 Replace or reset VENT EVAP 206000
(CB18) Open. circuit breaker (CB18) as
required.
Faulty AC/VENT switch. Remove and replace vent 960000
switch.
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Rotorcraft Maintenance Manual
K100
A620 POWER RELAY
ELECTRICAL LOAD CENTER A413
B2 B1
RECIRCULATING FAN
W123 W306
A606 CB18
UTILITY CONTROL PANEL VENT/EVAP J8 P381 P513 J1
A2 A1
28VDC C A 28VDC
S3 W124
AC/VENT SWITCH
J1 P117 P374 J2 X1 D SPEED CONTROL
COOL HI
1 X2
2 A 22 B PWR GND
COOL LO J3 P377 J155 P155
CA1 3 OFF E PWR GND
4 VENT LO 21 20 F
E
5 VENT HI GS400
1 COOL HI A612
2 COOL LO FWD INTERCONNECT
CA2 3 OFF PANEL
4 VENT LO
W123
5 P172 J1 J1 P171
VENT HI
C 43 10
COOL HI D
1
2 COOL LO
CA3
3 OFF
4 VENT LO
5
VENT HI
E E GS104-D
E H E GS106-J
9G21025A
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Rotorcraft Maintenance Manual
VENT SYSTEM
MAINTENANCE PRACTICES
1. Vent System (10). Inspect electrical connector for corro
sion. Verify fan for two-speed opera
(Ref. Figure 201) tion.
A. Vent System Inspection (11). Inspect air plenum duct assemblies for
(1). Open right forward access door assem cracks, tears, deterioration, deforma
bly R155 and transmission access door tion and security. Repair or replace as
assembly R210 (Ref. Section 06-00-00). required.
(2). Remove cabin compartment interior (12). Inspect distribution flexible ducts for
roof panels (Ref. Section 25-20-00). cuts, deterioration and collapsed nylon
coiled supports. Repair or replace as
(3). Inspect air scoop for cracks. Repair or required.
replace as required.
(13). Inspect door pillar plenum duct for
(4). Inspect inlet air screen for cracked and cracks. Repair or replace as required.
broken wire mesh. Inspect for obstruc
tion, corrosion and security. Repair or (14). Inspect crew compartment gasper
replace as required. assemblies for cracks, cylindrical disc,
cap and ball socket for freedom of
(5). Inspect inlet duct for cracks, deforma operation. Repair or replace as re
tion, and security. Repair or replace as quired.
required.
(15). Inspect cabin compartment gasper
(6). Inspect water separator for cleanness,
assemblies for cracks, cylindrical disc,
cracks, corrosion and security. Inspect
cap and ball socket for freedom of
welds at mounting brackets for cracks.
operation. Repair or replace as re
Repair or replace as required.
quired.
(7). Inspect water separator rubber drain
check valve for deterioration. Repair or (16). Install cabin compartment interior roof
replace as required. panels (Ref. Section 25-20-00).
(8). Inspect fan assembly for cleanness. (17). Close right-hand forward access door
assembly R155 and transmission access
(9). Inspect fan mounting brackets for door assembly R210 (Ref. Section
cracks. Repair or replace as required. 06-00-00).
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Rotorcraft Maintenance Manual
9
13
9
9
14 2
9 15
5
4 6
10 14 3
11 9
9 5
7 6
10
6
12
11
12
9G21028B
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Rotorcraft Maintenance Manual
Page 203
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Rotorcraft Maintenance Manual
9
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature 4
5
(1). Clean and prepare vent recirculating 6
fan mounting bracket for electrical
1
bonding (Ref. CSP-SPM, Section
7
20-50-00).
(2). Install recirculating fan (4) in mounting
3
bracket (7 and 8) with screws (5) and
washers (6). Torque screws (5). 9G21011
1. CLAMP, BAND TYPE
Sealing Compound (C205) 2. FLEXIBLE DUCTTOWATER SEPARATOR
3. DUCT ASSEMBLY ROOF DECK
4. RECIRCULATING FAN
5. SCREW
6. WASHER
7. FAN MOUNTING BRACKET FWD
(3). Remove old sealant and clean faying 8. FAN MOUNTING BRACKET AFT
9. ELECTRICAL CONNECTOR (P513)
surfaces. Apply sealing compound
(C205) to cover faying surfaces between Figure 203. Recirculating Fan
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Rotorcraft Maintenance Manual
7
9 2
1
10
6
5
8
3
7
1
5 7
6
4 9G21009
1. CLAMP, BAND TYPE 6. FLEXIBLE DUCTTOGASPER ASSEMBLY
2. FLEXIBLE DUCT, AFT CABIN 7. GASPER ASSEMBLY PLENUM CAP
3. FLEXIBLE DUCT, FWD CABIN 8. DUCT ASSEMBLY, ROOF DECK
4. PLENUM ASSEMBLY, AIR SUPPLY DUCT 9. SCREW
5. CLAMP, BAND TYPE 10. WASHER
Figure 204. Vent Air Supply Plenum Assembly
4. Vent Air Supply Plenum Assembly (3). Remove hose clamps (1) and disconnect
flexible ducts (2 and 3) from vent air
supply assembly (4).
A. Vent Air Supply Plenum Assembly
Removal (4). Remove clamps (5) and disconnect
plenum assembly flexible ducts (6) from
(Ref. Figure 204) gasper assembly plenum caps (7).
(5). Remove sealant from fasteners on roof
(1). Open left forward access door assembly deck duct assembly (8). Remove screws
L155 (Ref. Section 06-00-00). (9) and washers (10) from roof deck
duct assembly.
(2). Remove cabin compartment interior (6). Remove plenum assembly air supply (4)
roof panels (Ref. Section 25-20-00). from ceiling structure.
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
2
11 10
18
(2 PL)
16
15 12
17 (2 PL) 13
14
(6 PL)
8
3 4
6
7 9
5 9G21013
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Rotorcraft Maintenance Manual
Page 208
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
214000
Heat / Defog System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Engine Bleed Air Check Valve - Prevents C. Heat Flow Control Valve
reverse flow of bleed air. The heat flow control valve is a stainless steel
Flow Control Shutoff Valve - Provides crew single ball valve. The valve is located on the
member control of bleed air to the heat/defog aft cabin heat ejector. The valve is activated
system. mechanically for controlling the flow of bleed
air entering into the aft cabin heater ejector.
Heat Flow Control Valve - Controls the flow
of bleed air to the aft cabin heater ejector. D. Heater Control Cable
The heater control cable is located in the aft
Heater Control Cable - Mechanically
passenger compartment. The cable is a push
controls heat flow control valve position.
pull cable constructed of stainless steel. The
Aft Cabin Heater Ejector - Mixes bleed air cable adjusts the heat flow control valve.
with ambient cabin air and releases the mixed
E. Aft Cabin Heat Ejector
air to the cabin compartment.
The aft cabin heater ejector is located in the
Heat/Defog Bleed Air Lines - Routes bleed
aft passenger compartment. The ejector acts
air to the flow control valves.
like a flow divider mixing inside ambient cabin
Heat/Defog Valve - Controls the flow of bleed air with hot engine bleed air to produce heated
air to the heat/defog ejector. cabin air.
Heat/Defog Control Cable - Controls heat F. Heat / Defog Bleed Air Tubes
defog valve position. The heat/defog bleed air tubes are stainless
Heat/Defog Ejector - Mixes ambient cockpit steel tubes that route bleed air throughout the
air with bleed air. heat/defog subsystem. The tubes route bleed
air to the heat flow control valve, heat/defog
Defog Manifolds - Releases heated air to the valve, and foot heater valves.
wind screens for defog purposes.
G. Heat / Defog Valve
Foot Heater Valve - Releases heated air to
the crew compartment. The heat/defog valve is a stainless steel ball
valve located at the lower left cockpit fuselage
Foot Heater Control Cable - Controls foot section. The valve is mechanically activated to
heater valve position. route bleed air into the heat/defog ejector for
Page 1
21-40-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
distribution to the defog manifold and foot heat/defog ejector to the heat/defog manifolds
heater valves. and foot heaters.
I. Heat / Defog Ejector The foot heater control cables are push pull
stainless steel cables. The two control cables
The heat/defog ejector is located below the are located under the instrument panel. Each
crew compartment floor near the aircraft foot heater control cable operates a butterfly
centerline. The ejector acts like a flow divider valve, which allows the pilot/copilot to adjust
mixing inside ambient air with hot engine heated air outflow.
bleed air to produce heated crew/defog air. M. Foot Heater Valves
J. Plenum Heat / Defog Hoses The foot heater valves are mounted on the side
of the forward battery compartment, directed
The plenum heat/defog hoses are flexible towards the pilots feet. The foot heater valves
silicon rubber coated woven fiberglass hose are constructed of composite material with an
with a nylon helical reinforcement. Located in internal aluminum butterfly disc. The foot
the lower left and right cockpit fuselage heater valve allows for a varying amount of
section, the hoses route bleed air from the heated air to blow onto the pilot/copilot feet.
Page 2
Revision 13 21-40-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
ENGINE BLEED
AIR HOSES
ENGINE BLEED
AIR CHECK VALVE
FLOW CONTROL
SHUTOFF VALVE
FLEXIBLE HEATER
CONTROL CABLE
FOOT HEATER
CONTROL CABLE
FOOT HEATER
VALVE
HEAT/DEFOG
CONTROL CABLE
9G21016A
Page 3
21-40-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
CHECK
VALVES
ENGINE ENGINE
PASSENGER COMPARTMENT
FLOW CONTROL
VALVE
STARTUP
LOCK OUT
PILOT HEAT
EJECTOR
FOOT
HEATER
FOOT HEATER
CONTROL VALVE
CREW STATION 9G21022
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Rotorcraft Maintenance Manual
Page 101
21-40-00 Revision 24
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
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
valve through the IIDS.
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Original 21-40-00
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Rotorcraft Maintenance Manual
A B C D 92 E GS102-K
N P R S
W123 A2
IIDS
TB4-5 J1 P171
P102 J2
J K L M 19 34 HEAT/DEFOG INSTALLED
A606 W124
UTILITY CONTROL PANEL
P172 J6
J1 P117 P104 J4
J 22 7 ZJ HEAT ON/OFF
S2
CAB HEAT
SWITCH
1 OFF
2
A699
3 ON FLOW CONTROL SHUTOFF
W124 W311
A601 900 CONFIG VALVE
OFF CIRCUIT BREAKER PANEL J520 P520
4
TB302-2
5 CB12 J2 P128 (WHITE WIRE)
BLD AIR A C
6 HEAT
28VDC 13 B
OVRD 5A
C
(BLUE WIRE)
D D
K E
B E GS104-C F
A601 902 CONFIG
CIRCUIT BREAKER PANEL
CB36 J2 P128
BLD AIR
HEAT
R. DC BUS 13
5A
9G21023B
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Rotorcraft Maintenance Manual
9G21-033
Page 104
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
HEAT/DEFOG SYSTEM
REMOVAL/INSTALLATION
1. Heat/Defog Ejector B. Heat/Defog Ejector Installation
(Ref. Figure 401)
A. Heat/Defog Ejector Removal
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Rotorcraft Maintenance Manual
Page 402
Original 21-40-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(1). Open landing light window panel N82, (3). Upper threaded area to be approxi
nose access panel N106 and bottom mately two inch above mounting
center access panel assembly B142 bracket. Tighten jam nuts by hand. Do
(Ref. Section 06-00-00). not torque jam nuts at this time.
(2). Remove cotter pin (1), washers (2) and (4). Insert cable through hole in cockpit
clevis pin (4) and disconnect heat/defog floor and through bulkhead web.
control cable (3) from heat/defog valve (5). Loosely install jam nuts and washers
(5). on opposite end lower threaded area of
(3). Remove jam nut (8) and washer (9) control cable on forward side of bulk
from lower threaded area of heat/defog head web.
control cable. (6). Connect control cable to heat/defog
(4). Remove jam nut (8) and washer (9) valve with clevis pin, washers and
from upper and lower threaded areas cotter pin.
and remove control cable from cable (7). Adjust cable linkage as required to
mounting bracket (10) and pull cable ensure proper valve closure. Adjust
through bulkhead web, cockpit floor cable so that heat/defog valve arm
and mounting bracket. contacts stop in both the fully closed
B. Heat/Defog Control Cable Installation and open position. Torque jam nuts.
(Ref. Figure 401) (8). Close landing light window panel N82,
nose access panel N106 and bottom
(1). Install jam nut and washer on upper center access panel B142 (Ref. Section
heat/defog control cable. 06-00-00).
Page 403
21-40-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
15
16
6
8
15
900 CONFIG 9
11
12 10
13
14
95-110 in-lb
7 8
10.7-12.4 Nm
5
11
9
460-500 in-lb
57.96-56.48 Nm 22 (2 PL)
AN FLARED FITTINGS
902 CONFIG
95-110 in-lb 9
20 10.7-12.4 Nm 8
18
21
18 in-lb 19
2.0 Nm
1 2
3
15
5
4 16
900 CONFIG
6
17
15
9G21017B
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
NOTE: This task is typical for left or right De NOTE: This task is typical for left or right Foot
fog Manifold installation. Heater Valve installation.
(1). Install defog manifold with nuts, (1). Install foot heater valve in heat/defog
washer, and screw. Torque nuts. plenum to outlet hose. Install hose
(2). Install nuts and washers on mounting clamp. Torque hose clamp.
stud. Torque nut.
(2). Install screws and washers through
Sealing Compound (C205) bracket into foot heater valve. Torque
screws.
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Rotorcraft Maintenance Manual
13
14
1
18 in-lb 15
9 2.0 Nm
95-110 in-lb 13
10.7-12.4 Nm 14
16 8
18 in-lb 11
3 2.0 Nm
10
2 12
9G21014
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Rotorcraft Maintenance Manual
(3). Remove guard (32) from lower ejector (1). Install screws and washers through
screen. Guard is attached with hook fuselage frame into ejector mounting
and pile tape. bracket. Torque screws. Position ejector
as far inboard as possible.
(4). Remove screws (19), washers (20),
ejector screen (17) and ejector gasket (2). Install screw washer spacers and
(18) from interior panel. Two places. cushioned support clamp to cabin heat
ejector and composite standoff.
(5). Remove cabin interior trim panel (3). 900 CONFIG - Install threadless
adjacent to ejector outlet (Ref. Section flexible coupling seal with cup facing
25-20-00). tube end (Ref. Section 21-40-00).
NOTE: Avoid damage to insulation during re (4). 900 CONFIG - Install spacer fitting,
moval if possible. Reuse foam on installa connecting cabin heat ejector to heating
tion. system flow control valve with retainer
and flexible coupling assembly.
(6). Remove and discard tape (7,) and
(5). 902 CONFIG - Install coupling nut,
remove insulation (6) from connections
connecting cabin heat ejector to heating
(8).
system flow control valve. Torque nut.
(7). Remove screw (30), washer (26), spacer NOTE: Wrap tube connections with insulation
(31), cushioned support clamp (27) from and tape. Overlap the existing insulation on
aft cabin heat ejector (22) and compos tube and line assemblies one inch.
ite standoff (29).
(6). Install insulation (6) over tube connec
(8). 900 CONFIG - Disconnect flexible tions and wrap with tape (7).
coupling assembly (8) and retainer (9) (7). Position ejector gaskets, between
from heating system flow control valve ejector outlets and interior trim and
(5) and aft cabin heat ejector (22). install ejector screen, screws and
washers through interior trim panel
(9). 900 CONFIG - Retain spacer fitting into ejector. Torque screws.
(11), remove and discard seals (10) from
cabin heat ejector. (8). Install cabin compartment right side
wall interior trim insulation panel
(10). 902 CONFIG - Disconnect coupling adjacent to ejector outlet (Ref. Section
nut (33) from heating system flow 25-20-00).
control valve (5) and aft cabin heat (9). Install baggage compartment interior
ejector (22). trim insulation panels (Ref. Section
25-50-00).
(11). Remove screws (12) and washers (13)
from fuselage frame and remove aft (10). Install cabin seats assembly, if applica
cabin heat ejector. ble (Ref. Section 25-20-00).
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Rotorcraft Maintenance Manual
8. Heating System Flow Control Valve Single (2). Put flow control valve in its installed
Ball position.
A. Heating System Flow Control Valve (3). 900 CONFIG - Install flexible coupling
Single Ball Removal assemblies, spacers, and retainers on
flow control valve.
(Ref. Figure 403)
(4). 902 CONFIG - Connect coupling nuts
(1). If necessary, remove cabin seats to flow control valve. Torque nuts.
assembly (Ref. Chapter 25-20-00). NOTE: Wrap tube connections with insulation
(2). Remove right aft cabin compartment and tape. Overlap insulation on tube and
interior trim insulation panel adjacent line assemblies one inch.
to aft cabin heat ejector outlet (Ref. (5). Install insulation on tube connections
Section 25-20-00). and wrap with tape.
(3). Remove cotter pin (1), washers (2), and (6). Connect control cable to flow control
clevis pin (3). valve with clevis pin, washers, and
cotter pin.
NOTE: If possible, prevent damage to insula
tion. You can use insulation again. (7). If necessary, adjust cable until flow
control valve arm touches stop in both
(4). Remove and discard tape (7) and the fully closed and fully open position.
remove insulation (6) from tube
connections. (8). Install right cabin compartment
interior trim panel adjacent to aft cabin
(5). 900 CONFIG - Disconnect flexible heat ejector outlet (Ref. Section
coupling assemblies (8) and retainers 25-20-00).
(9) from flow control valve (5). Remove (9). Install cabin seats assembly, if applica
flow control valve. ble (Ref. Section 25-20-00).
(6). 900 CONFIG - Keep spacer fitting(s) 9. Flexible Heater Control Cable Assembly
(11). Remove and discard seals (10).
A. Flexible Heater Control Cable
(7). 902 CONFIG - Disconnect coupling Assembly Removal
nuts (33) from flow control valve (5).
Remove flow control valve. (Ref. Figure 403)
(1). If necessary, remove cabin seats
B. Heating System Flow Control Valve
assembly (Ref. Section 25-20-00).
Single Ball Installation
(2). Remove cabin compartment interior
(Ref. Figure 403) trim insulation panel adjacent to
ejector outlet and cabin heat control
Consumable Materials cover plate (Ref. Section 06-00-00.
(Ref. CSPSPM) (3). Remove cotter pin (1), washers (2), and
Item Nomenclature clevis pin (3).
C801 Foam (900 CONFIG)
(4). Remove nuts (23), washers (24), angle
C709 Tape, Adhesive (900 CONFIG)
(37), and handle (34).
C610 Rubber, Expanded (902 CONFIG)
C710 Tape, Glass Fabric (902 CONFIG) (5). Remove cable plug (35) and washer
(16).
(6). Remove sealing compound from nut
(1). 900 CONFIG - Install threadless
(36) and washer (16).
flexible coupling seal on flow control
valve and tube assemblies (Ref. (7). Pull control cable (4) down and remove
Threadless Flexible Coupling Seal nut (36) and washer (16). Remove
Installation). control cable.
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Rotorcraft Maintenance Manual
(4). Install nut and washer on control cable (10). Install cabin compartment interior trim
top end, put control cable through panel adjacent to ejector outlet and
handle and install washer and nut. cabin heat control cover plate.
(5). Adjust nuts until center of handle is (11). If necessary, install cabin seats assemb
0.39 in. (9.91 mm) from end of cable. ly (Ref. Section 25-20-00).
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21-40-00 Revision 28
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
3
29
2
27 34
0.39 IN
(9.91 mm)
8 35
26
REF 4 30
23 (2 PL) 31
24 (2 PL)
23 (2 PL)
5 36 24 (2 PL)
16
2
1 8 13 12
4
29 15
28
16
27 14
26 22
25 17
10 20
19
6
32
7
8
18
21
33 (2 PL)
9
11
10
Figure 403. Cabin Heat Ejector, Single Ball Flow Control Valve, Flexible Heater Control Cable
Page 410
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Rotorcraft Maintenance Manual
10. Engine Bleed Air Check Valve (900 Compound, Anti-Seize (C220)
CONFIG)
A. Engine Bleed Air Check Valve Removal
(Ref. Figure 404)
NOTE: This task is typical for left or right en (2). Apply anti-seize compound (C220) to
gine. bleed air fitting and install check valve.
(1). Open L260 or R260 (Ref. Section Torque check valve 500-600 in-lb
06-00-00). (56.5-67.8 Nwm).
(2). Disconnect hose assembly (4) or (5) (3). Apply anti-seize compound (C220)to
from check valve (2). check valve and connect hose to check
(3). Remove check valve (2). valve. Torque coupling nut 500-600
(4). Remove boss seal (3). in-lb (56.5-67.8 Nwm).
B. Engine Bleed Air Check Valve Installation (4). Close L260 or R260 engine cowl (Ref.
(Ref. Figure 404) Section 06-00-00).
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C220 Compound, AntiSeize
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21-40-00 Revision 28
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
11. Flow Control Shutoff Valve Assembly (900 B. Flow Control Shutoff Valve Assembly
CONFIG) Installation
A. Flow Control Shutoff Valve Assembly (Ref. Figure 404)
Removal
(1). Install flexible coupling seals (Ref.
(Ref. Figure 404) Threadless Flexible Coupling Seal
(1). Open R260 (Ref. Section 06-00-00). Installation).
(2). Disconnect electrical connector P520 (2). Put shutoff valve in its installed
(16). position.
(3). Disconnect flexible couplings (13) and (3). Install flexible coupling assemblies,
retainers (12) from shutoff valve (17). spacers, and retainers on shutoff valve.
Remove shutoff valve.
(4). Connect electrical connector P520.
(4). Keep spacer fittings (14). Remove and
discard seals (15). (5). Close R260 (Ref. Section 06-00-00).
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
12. Valve To Deck Tube Assembly (900 B. Valve to Deck Tube Assembly Installation
CONFIG)
(Ref. Figure 404)
(1). Open right engine cowl assembly R260 (1). Install new gaskets on top and bottom
(Ref. Section 06-00-00). of engine deck between deck assembly
and tube flanges.
(a). Install bolts in tube assembly flange
(2). Remove baggage compartment interior
through engine deck and flange of
trim roof insulation panel (Ref. Section
tube assembly. Torque bolts.
25-50-00).
Sealing Compound (C211)
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Rotorcraft Maintenance Manual
4
9
2 10
11 500 - 600 in-lb
56.5 - 67.8 Nm
8
1 3 5
7
18 6
22
14
21 15 17
36 - 46 in-lb
4.0 - 5.2 Nm
14 9G21027B
15
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Rotorcraft Maintenance Manual
13. Engine Bleed Air Check Valve (902 (3). Apply anti-seize compound (C220) to
CONFIG) check valve and connect hose to check
valve. Torque coupling nut 500-600
A. Engine Bleed Air Check Valve Removal in-lb (56.5-67.8 Nwm).
(Ref. Figure 405)
(4). Close L260 or R260 (Ref. Section
NOTE: This task is typical for left or right engi 06-00-00).
ne.
14. Flow Control Shutoff Valve Assembly (902
(1). Open L260 or R260 (Ref. Section
CONFIG)
06-00-00).
(2). Disconnect hose (4) or (5). A. Flow Control Shutoff Valve Assembly
Removal
(3). Remove check valve (2).
(Ref. Figure 405)
(4). Remove boss seal (3).
B. Engine Bleed Air Check Valve Installation (1). Open R260 (Ref. Section 06-00-00).
(1). Install boss seal. (1). Put shutoff valve in its installed
position.
Compound, Anti-Seize (C220)
(2). Connect coupling nuts to shutoff valve.
Torque coupling nuts 500-600 in-lb
(56.5-67.8 Nwm).
(2). Apply anti-seize compound (C220) to (3). Connect electrical connector P520.
bleed air fitting and install check valve.
Torque check valve. (4). Close R260 (Ref. Section 06-00-00).
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Rotorcraft Maintenance Manual
15. Valve To Deck Tube Assembly (902 (6). Remove tube (15).
CONFIG)
B. Valve to Deck Tube Assembly Installation
A. Valve to Deck Tube Assembly Removal
(Ref. Figure 405)
(Ref. Figure 405)
(1). Install tube on valve and bulkhead
(1). Open R260 (Ref. Section 06-00-00). union.
(2). Remove right aft station 230.00 (2). Connect coupling nuts. Torque coupling
bulkhead baggage compartment nuts 500-600 in-lb (56.5-67.8 Nwm).
interior trim insulation panels (Ref. (3). Install clamp.
Section 25-50-00).
(4). Install right aft station 230.00 bulk
(3). Remove baggage compartment interior head baggage compartment interior
trim roof insulation panel (Ref. Section trim insulation panels (Ref. Section
25-50-00). 25-50-00).
(4). Remove clamp from tube (15). (5). Install baggage compartment interior
trim roof insulation panel (Ref. Section
(5). Disconnect coupling nuts (18) from 25-50-00).
shutoff valve (13) and bulkhead union
(16). (6). Close R260 (Ref. Section 06-00-00).
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Rotorcraft Maintenance Manual
INBOARD FIREWALL
ASSEMBLY
4 REF
14
FS
251.31
12 13
RH FIREWALL
15
ENGINE DECK
16
10 7 REF
500 - 600 in-lb
4 56.5 - 67.8 Nm 500 - 600 in-lb
VIEW LOOKING INBOARD
19 56.5 - 67.8 Nm
RH SIDE
20 350 - 400 in-lb
21 7 11
39.53 - 45.18 Nm
17 5
9
460 - 500 in-lb 11
51.96 - 56.48 Nm
FS 3
6
248.97
BL
10 0.00 2
RBL
11.78
8
500 - 600 in-lb
500 - 600 in-lb 1
2 56.5 - 67.8 Nm
56.5 - 67.8 Nm 3 1
Figure 405. Engine Bleed Air Check Valve / Flow Control Shutoff Valve (902 CONFIG)
Page 417
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
4
1
9G21032
1. SEAL ASSEMBLY TOOL 4. SEAL REFORMING TOOL ASSEMBLY
2. SEAL ASSEMBLY TOOL BODY 5. SEAL ASSEMBLY FOR FLEXIBLE COUPLING
3. SEAL ASSEMBLY TOOL SLEEVE
Figure 406. Threadless Flexible Coupling Seal Replacement (900 CONFIG)
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
NOTES:
1. APPLY ANTI-SEIZE COMPOUND MIL-T-8348
TO BULKHEAD FITTING.
27
6
4
2 17
18
AN UNION CONNECTION
19
TYPICAL INSTALLATION
20
(21 PL NOTE 3, 4, ROTATED)
902 CONFIG
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
18 17
13 19 12
20
18
19 (2 PL)
20
17
21
12 21
NOTE 3 NOTE 2
TYPICAL INSTALLATION OF INSULATION
AND TAPE AT TUBE CONNECTION
24 (2 PL)
25
23 (2 PL)
NOTE 2
12
900 CONFIG
NOTE 1, 3 12
13
902 CONFIG
12 21
13
12
STA.230.50 13 902 CONFIG
NOTE 3
26
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
HEAT/DEFOG SYSTEM
INSPECTION/TEST
1. Heat/Defog System Inspection through to tube. Inspect for indication
of an air leak. If necessary, repair or
(Ref. Figure 601) replace.
A. Heat/Defog System Bleed Air (3). Inspect Sta. 230.03 tube insulation and
Engine/Firewall Inspection (Area 5) tape for tears and cuts that are through
(1). Open L260 and R260 (Ref. Section to tube. Inspect for indication1 of an air
06-00-00). leak. If necessary, repair or replace.
(2). Inspect engine bleed air check valve for (4). Inspect tubes for condition. If necessary,
condition and security. If necessary, repair or replace.
repair or replace.
(5). Install right aft station 230.00 bulk
(3). Inspect hose between right and left head baggage compartment interior
engine bleed air valve and firewall trim insulation panels (Ref. Section
fittings for condition. If necessary, 25-50-00).
repair or replace.
C. Under Floor Tube Assemblies Inspection
(4). Inspect bleed air firewall fittings for (Area 1 and 2)
cracks and indication of an air leak at
firewall gasket. If necessary, repair or (1). Remove AR165, AR138, and AR129
replace. (Ref. Section 06-00-00).
(5). Inspect bleed air flow control shutoff (2). Inspect tube inside/outside shields and
valve for security and condition. oxygen hose clamps for security. If
Electrical connector for corrosion. If necessary, repair or replace.
necessary, repair or replace. (3). Inspect tube insulation and tape for
(6). Inspect check valve to deck tube for tears and cuts that are through to tube.
condition, cracks, and indication of an Inspect for indication of an air leak. If
air leak. If necessary, repair or replace. necessary, repair or replace.
(7). Close L260 and R260 (Ref. Section (4). Install AR165, AR138, and AR129 (Ref.
06-00-00). Section 06-00-00).
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
E. Aft Cabin Heat Ejector Inspection (Area 2) (3). Inspect ejector for security. If necessary,
repair or replace.
(1). Remove cabin compartment interior
trim insulation panel adjacent to (4). Inspect control cable for kinks, crushed
ejector outlet (Ref. Section 25-20-00). sleeve and corrosion. Inspect for galling
and indication of wear. If necessary,
(2). Inspect tube between flow control valve repair or replace.
and heat ejector insulation and tape for
tears and cuts that are through to tube. (5). Close N82, N106, and B142 (Ref.
If necessary, repair or replace. Section 06-00-00).
H. Heat/Defog Valve Inspection (Area 1)
(3). Inspect ejector bypass valve door for
easy movement. (1). Inspect valve housing for loose connec
tions at mating surfaces. If necessary,
(4). Inspect ejector for cracks. No damage repair or replace.
permitted.
(2). Inspect valve for security and indica
(5). Install cabin compartment interior trim tion of an air leak. If necessary, repair
insulation panel adjacent to ejector or replace.
outlet (Ref. Section 25-20-00).
(3). Check valve for full open and close
F. Flow Control Single Ball Valve Inspection positions and make sure it touches
(Area 2) stops. If necessary, adjust cable.
(1). Remove cabin compartment interior I. Rubber Ducts and Hoses Inspection
trim insulation panel adjacent to (Area 1)
ejector outlet (Ref. Section 25-20-00).
(1). Inspect rubber hoses and ducts for cuts,
(2). Inspect flow control valve housing for tears, and indication of deterioration. If
loose connections at mating surfaces. If necessary, repair or replace.
necessary, repair or replace. (2). Inspect for security of attach hardware.
If necessary, repair or replace.
(3). Inspect flow control valve for security,
condition, and indication of an air leak. J. Defog Manifold Inspection (Area 1)
If necessary, repair or replace.
(1). Inspect manifold for cracks and dela
(4). Operate check valve full open and close mination. If necessary, repair or
and make sure it touches stops. If replace.
necessary, adjust control cable.
(2). Inspect manifold attach hardware for
(5). Install cabin compartment interior security. If necessary, repair or replace.
panel adjacent to ejector outlet (Ref.
K. Foot Heater Valves Inspection (Area 1)
Section 25-20-00).
(1). Inspect valve and attach brackets for
G. Heat/Defog Ejector Inspection (Area 1) cracks. If necessary, repair or replace.
(1). Open N82, N106, and B142 (Ref. (2). Inspect control cable for easy operation.
Section 06-00-00). If necessary, repair or replace.
(2). Inspect ejector for cracks and separa (3). Inspect attach hardware for security. If
tion. No damage allowed. necessary, repair or replace.
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Rotorcraft Maintenance Manual
10
13
14
15 12 11
16
17 8
1 3
1
2
6
2
5
4
9G21026A
1. HEAT DEFOG MANIFOLD 10. MAIN BLEED AIR FIREWALL FITTING
2. FOOT HEATER VALVE 11. LH ENGINE BLEED AIR CHECK VALVE
3. FOOT HEATER CONTROL CABLE 12. ENGINE BLEED AIR TUBES
4. HEAT/DEFOG EJECTOR 13. RH ENGINE BLEED AIR CHECK VALVE
5. HEATER/DEFOG VALVE (FLOW CONTROL) 14. FLOW CONTROL SHUTOFF VALVE
6. HEATER/DEFOG CONTROL CABLE 15. ENGINE DECK FITTING
7. BLEED AIR TUBE 16. FLEXIBLE HEATER CONTROL CABLE
8. AFT CABIN HEAT EJECTOR 17. HEATING SYSTEM FLOW CONTROL VALVE SINGLE
9. UNION PERMASWEDGE FITTING (900 CONFIG) BALL
Figure 601. Heat/Defog System
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Rotorcraft Maintenance Manual
2
15 (7 PL)
8
Figure 602. Engine Bleed Air Check Valve / Flow Control Shutoff Valve
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Rotorcraft Maintenance Manual
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
2. Heat/Defog System Leak Check flow rate. Air flow rate must be less
Functional Test than 2.0 cfm (56.6 L/m).
(Ref. Figure 601, Figure 602, and Figure 603) (11). If the air flow rate is more than 2.0 cfm
(56.6 L/m), continue functional test as
follows:
Consumable Materials
(Ref. CSPSPM) (a). check all tube connections and
Item Nomenclature fittings above the engine deck for
C809 Leak Detector, Liquid leaks.
C220 Compound, AntiSeize (b). Apply liquid leak detector (C809) to
the flow control shutoff valve,
firewall fittings, main bleed air
Special Tools fitting, and tube and hose connectors.
(Ref. CSPSPM) (c). Make sure there are no air leaks
Item Nomenclature around the flow control shutoff valve,
Air Flow Measurement Test Set (Ref. firewall fittings, main bleed air
Figure 603) fitting, and tube and hose connectors.
(d). If necessary, repair air leaks.
(1). Open L260 and R260 (Ref. Section
06-00-00). (12). If air flow rate is less than 2.0 cfm
(56.6 L/m), continue functional test as
(2). Remove right aft station 230.00 follows:
bulkhead baggage compartment
(a). Set POWER switch on ELEC
interior trim insulation panels (Ref.
TRICAL MASTER panel to BAT/
Section 25-50-00).
EXT.
(3). Remove AR165, AR138, and AR129 (b). Set HEAT switch on utility panel to
(Ref. Section 06-00-00). OVRD.
(4). Disconnect hose (5) and install AN (c). Air flow rate must be less than 4.0
806J-12 plug in coupling nut (Ref. cfm (113.2 L/m).
Figure 602).
(13). If air flow rate is more than 4.0 cfm
(5). Disconnect hose (4) and install (113.2 L/m), continue functional test as
AN919-18J reducer in coupling nut follows:
(Ref. Figure 602).
(a). Check all tube connections and
(6). Set HEAT switch on utility panel to fittings for leaks.
OFF.
(b). Apply liquid leak detector (C809) to
(7). Make sure cabin flow control valve and tube connectors and fittings.
crew compartment heat/defog valve are
(c). Make sure there are no air leaks at
closed.
tube connections and fittings.
(8). Connect a test fixture as shown in (d). If necessary, repair air leaks.
Figure 603.
(14). If air flow is less than 4.0 cfm (113.2
(9). Apply regulated shop air 90-110 psig L/m), continue functional test as
(620.5-758.5 kPa) to air supply follows:
adapter.
(a). Manually operate flow control valve
(10). With a constant pressure of 90-110 to make sure aft cabin heat ejector
psig (620.5-758.5 kPa), check the air control cable is adjusted correctly.
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Rotorcraft Maintenance Manual
(b). Manually operate heat/defog valve to (19). Connect hose to check valve. Torque
make sure heat/defog control cable is coupling nut 500-600 in-lb (56.5-67.8
adjusted correctly. Check air flow to Nwm).
heat/defog manifold.
(20). Remove plug from left engine hose.
(c). Operate foot heater control cables, (21). Apply anti-seize compound (C220) to
check air flow to foot heaters. left engine check valve.
(15). Set HEAT switch on utility panel to (22). Connect hose to check valve. Torque
OFF. coupling nut 500-600 in-lb (56.5-67.8
Nwm).
(16). Set POWER switch on ELECTRICAL
MASTER panel to OFF. (23). Close L260 and R260 (Ref. Section
06-00-00).
(17). Remove reducer from right engine hose.
(24). Install right aft station 230.00 bulk
Compound, Anti-Seize (C220) head baggage compartment interior
trim insulation panels (Ref. Section
25-50-00).
(25). Install cabin floor access panels AR165,
outboard floor panel AR129 and cockpit
(18). Apply anti-seize compound (C220) to floor panel AR138 (Ref. Section
right engine check valve. 53-20-00).
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Rotorcraft Maintenance Manual
AIR SUPPLY
ADAPTER
PRESSURE
GAUGE SHOP AIR
FEMALE QUICK CONNECT SUPPLY
AIR FLOW
CONTROL VALVE
AIR FLOW
METER
Page 608
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
215000
Air Conditioning
System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 2
Revision 8 21-50-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
The valve is a spray nozzle. It is in operation The duct assembly lets the air move through
at the same time as the compressor. The valve the air conditioning ducts to cool the crew and
adjusts for temperature to control the liquid passenger compartment.
refrigerant flow into the evaporator.
P. Three Way Valve
M. Evaporator Assembly
The three way valve is next to the evaporator
The evaporator assembly is in a housing that fan.
attaches to the air plenum duct.
The three way valve is a butterfly disc valve.
The evaporator supplies a heat exchange for The three way valve lets cabin recirculated air,
the cabin air to cool. The internal chamber of outside fresh air, or both into the air condition
the evaporator lets the low pressure liquid ing system.
refrigerant expand into a low temperature gas.
Q. ThreeWay Valve Control Cable
When the AC/VENT rotary switch is set to
COOL HIGH or COOL LOW the evaporator The three-way valve control cable is above the
fan energizes. The fan then recirculates the right pilot seat.
cabin air or fresh air through the evaporator.
The three-way valve opens to let warm cabin The three-way valve control cable is a push
air or fresh air go into the fresh air vent pull cable. The three-way valve control cable
system ducts. The low pressure gas in the operates the three way valve. The pilot can set
evaporator cools the air that flows over the the cable position for outside fresh air, cabin
evaporator. recirculated air, or both.
Page 3
21-50-00 Revision 8
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
RECEIVER COMPRESSOR
WATER SEPARATOR DEHYDRATOR
3-WAY VALVE
CONTROL CABLE AIR PLENUM LOW PRESSURE
DUCT GAUGE SWITCH
EVAPORATOR
FAN
THERMOSTATIC
SWITCH
EVAPORATOR
LINES AND
TUBING
CONDENSER SCOOP
Page 4
Revision 8 21-50-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
COMPRESSOR
RH CONDENSER
WATER SEPERATOR
HIGH PRESSURE
GUAGE SWITCH
3-WAY VALVE LOW PRESSURE SWITCH
DUCT ASSEMBLY
RECIEVER
3-WAY VALVE DEHYDRATOR
3-WAY VALVE
CONTROL CABLE THERMOSTATIC
SWITCH AIR PLENUM
DUCT
EVAPORATOR
FAN
EVAPORATOR LINES AND
TUBING
SERVICING SIGHTGLASS
PORTS
9G21_040
Figure 2. Air Conditioning System CURRENT CONFIG
Page 5
21-50-00 Revision 8
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
CABIN/PASSENGER COMPARTMENT
AIR OUTLET
6 PLACES
HIGH PRESSURE
SWITCH
RECEIVER/
DRYER
THERMAL
EXPANSION
VALVE EVAPORATOR
3 - WAY
VALVE
WATER RAM AIR IN
SEPARATOR
FAN
THERMOSTATIC
CONDENSER
SWITCH OVERBOARD DRAIN
OVERBOARD
OVERBOARD
DRAIN
CONDENSER
FANS
COMPRESSOR ASSEMBLY
LOW PRESSURE
SWITCH
CREW/PILOT COMPARTMENT
RECIRCULATING
AIR INLET LOW PRESSURE LIQUID
AIR OUTLET FROM CABIN
HIGH PRESSURE GAS
4 PLACES
LOW PRESSURE GAS
9G21-020A
Page 6
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
CABIN/PASSENGER COMPARTMENT
AIR OUTLET
6 PLACES
HIGH PRESSURE
SWITCH
THERMAL RECEIVER/
EXPANSION DRYER
VALVE
EVAPORATOR
3 - WAY
VALVE
WATER RAM
SEPARATOR AIR IN
FAN
CONDENSER
SWITCH
OVERBOARD
OVERBOARD
DRAIN
LH COOLING
BLOWER
RH COOLING CONDENSER
BLOWER
OVERBOARD
COMPRESSOR
ASSEMBLY
LOW PRESSURE SWITCH
CREW/PILOT COMPARTMENT
HIGH PRESSURE LIQUID
RECIRCULATING
AIR INLET LOW PRESSURE LIQUID
FROM CABIN
AIR OUTLET HIGH PRESSURE GAS
4 PLACES
9G21-039
AIRCONDITIONING SYSTEM
FAULT ISOLATION
1. AirConditioning System Troubleshooting Troubleshooting tables are used with system
schematics, electrical wiring diagrams,
(Ref. Figure 101 thru Figure 103) serviceable checks, and also refer to other
procedures in this manual.
The troubleshooting procedures in Table 101 Wiring diagrams are available in the Rotor
are air-conditioning system faults which craft Maintenance Manual CSP-900RMM-3
possibly can occur. (ref. Section 98-40-00).
Table 101. AirConditioning System Troubleshooting
Fault Probable Cause Corrective Action Ref. Section
Air Condition does not Circuit breaker COMP Replace or reset COMP circuit 960000
operate when the COOL (CB17) open. breaker (CB17) as necessary.
LOW or COOL HI selection
is made on the Utility Control Defective air condition Replace the relay. 960000
disable relay K75.
Panel during normal engine
operation. Open wire between relay Do a test on the wires for a 206000
(See Note 1) K75X2 and P104ZF serviceable condition. Make
(on the IIDS). repairs as necessary.
Defective compressor Replace the compressor. 215000
solenoid.
Defective time delay relay Replace the time delay relay. 960000
K73/4.
System pressure is low. Service the air conditioning 120000
system.
A leak in the air conditioning 120000
system. Repair as necessary.
Defective low pressure Replace the low pressure 215000
switch. switch.
System pressure is high. Defective thermostatic 215000
expansion valve (TXV).
Replace the valve.
Condenser is dirty, clean as 215000
necessary. Remove blockage
from the air inlet as necessary.
EARLY CONFIG 215000
Condenser fans do not operate.
Repair or replace as necessary.
Defective IIDS. Replace the IIDS. 953000
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Rotorcraft Maintenance Manual
Suction line or low pressure Defective thermostatic Replace the Thermostatic 215000
line has ice on the other side expansion valve (TXV). Expansion Valve (TXV).
of the thermal bulb position.
Evaporator has frost on it. Flooded evaporator. Replace the Thermostatic 215000
Incorrect adjustment on Expansion Valve (TXV)
expansion valve (TXV).
Evaporator has ice on it. Defective thermostatic Replace thermostatic switch. 215000
switch.
NOTES:
(1) The IIDS automatically deenergizes the airconditioning system if there is an engine failure while
inflight. The message AC DISABLE will show on the alpha/numeric display. The electrical ground to the
air condition disable relay (K75) will be removed through the IIDS. It is necessary for the two engines to
be fully operational while inflight for the airconditioning system to operate.
(2) The Aircraft On Ground relay (AOG) lets a single (right) engine operate the airconditioning service and
other maintenance (ref. Section 953000).
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1
7
6
3 4
9
5
10
13
14
12
11
17
17
16 8
15
2
9G21029B
1. 3WAY VALVE CONTROL CABLE 10. AIR PLENUM
2. 3WAY VALVE 11. LINES AND TUBING
3. 3WAY VALVE DUCT ASSEMBLY 12. EVAPORATOR
4. WATER SEPARATOR 13. EVAPORATOR FAN
5. HIGH PRESSURE GAUGE SWITCH 14. THERMOSTATIC SWITCH
6. RECEIVER DEHYDRATOR 15. CONDENSER
7. COMPRESSOR 16. CONSENDER FAN
8. UNIVERSAL BULKHEAD FITTING 17. EMI FILTERS
9. LOW PRESSURE GAUGE SWITCH
Figure 101. AirConditioning System (Vapor Cycle Cooling System) EARLY CONFIG
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Rotorcraft Maintenance Manual
14 7
4
5
8
3
12
11
13 10
15
9G21_041
1. 3WAY VALVE CONTROL CABLE 9. AIR PLENUM
2. 3WAY VALVE 10. LINES AND TUBING
3. 3WAY VALVE DUCT ASSEMBLY 11. EVAPORATOR
4. WATER SEPARATOR 12. EVAPORATOR FAN
5. HIGH PRESSURE GAUGE SWITCH 13. THERMOSTATIC SWITCH
6. RECEIVER DEHYDRATOR 14. CONDENSER
7. COMPRESSOR 15. SIGHT GLASS
8. LOW PRESSURE GAUGE SWITCH
Figure 102. AirConditioning System (Vapor Cycle Cooling System) CURRENT CONFIG
Page 104
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Rotorcraft Maintenance Manual
A620
ELECTRICAL LOAD CENTER
K7-5
AIR COND CB17 CB19
DISABLE RELAY COMP EVAP
A2 J8 P381
A3 28VDC
IIDS W123 A2 28VDC A
A1 5A 20A
J4 P104 X1
A606 CB18
UTILITY CONTROL PANEL P377 J3 X2 VENT/EVAP
AIR COND ZF
S3 V 28VDC
DISABLE C
AC/VENT 20A
SWITCH J3 P377
P117 W124 P374 J2
COOL HI J1 S
1 W
2 COOL LO A 22
CA1
3 OFF
4 VENT LO R
K7-3/4
TIME DELAY 2.0 SEC RELAY
A3
A2 A1
1 COOL HI T
X1
2 COOL LO
X2
CA2 3 OFF
TB1-3
4 VENT LO
A E J N T U
5
VENT HI J5 P379
C L
COOL HI K8-3/4
CB56 CONDENSER FAN 1 RELAY
D CNDSR FAN 1
1
B3 B2
2 COOL LO 28VDC
15A B1
CA3 A3
3 OFF A2
X1 EARLY
4 VENT LO A1 CONFIG
5 VENT HI TB1-3
X2
B F K P W
21
M
K8-1/2
CB26 CONDENSER FAN 2 RELAY
GS104-D CNDSR FAN 2 B3
E E B2
28VDC
15A B1
A3
E H E A2
A1
GS106-J X1
X2
A612
FWD INTERCONNECT PANEL
P172 J1 J1 P171
43 10 A
9G210241B
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A404
EVAPORATOR FAN
W123 K100 W305
P381 POWER RELAY P516 J1
B2 B1
A B 28V DC
A2 A1
C A 28V DC
COMPRESSOR
R C SOLENOID
W305-SP1 S302
THERMOSTATIC
T D
PS2 PS1 SWITCH
HIGH PRESSURE LOW PRESSURE
SWITCH SWITCH A
P502 P503
C C
U E B B
B
A A
W125
P379 TB301
L A B
A411
W304
A680 CONDENSER FAN
FAN EMI FILTER #1
P501 J1
9G210242C
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9G21-034
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AIRCONDITIONING SYSTEM
REMOVAL / INSTALLATION
1. Compressor Assembly (4). Install the engine accessory drive cover
and gasket.
A. Compressor Assembly Removal
(a). Torque the nuts.
(Ref. Figure 401)
C. Compress Assembly Installation
The receiver dehydrator must
CAUTION be replaced each time the com (Ref. Figure 401)
pressor is removed, or the air-conditioning
(AC) system is opened. An early failure of Consumable Materials
the compressor can occur. (Ref. CSPSPM)
(1). Open Access Panel R210 (ref. Section Item Nomenclature
06-00-00). C106 Oil, Lubricating
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(c). Do the Hose and Tube Internal (a). Torque the fitting of inlet hose (3)
Cleaning procedure (ref. CSP-SPM, 460 to 500 in-lb (51.97 to 56.49
Section 20-20-00). Nm).
6 7
2
8
9
1
5 4
9G21008B
1. AC COMPRESSOR (REF. IPL, 215000, FIG. 3) 6. NUT
2. OUTLET HOSE (HIGHPRESSURE) 7. WASHER
3. INLET HOSE (LOWPRESSURE) 8. PACKING
4. DRAIN HOSE (COMPRESSOR DRAIN) 9. PACKING
5. ELECTRICAL CONNECTOR SP1
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16
14
12
14 12
1
1 (REF)
7 15
8
2 (REF)
2
3
4
5
6
10 9 10
11
DECK (REF)
6 5 155.50 BULKHEAD (REF) 9G21030B
1. 3WAY VALVE DUCT 9. WASHER
2. 3WAY VALVE CABLE 10. JAM NUT
3. SPLIT GROMMET 11. CABLE BRACKET
4. CABLE HANDLE BRACKET 12. VBAND CLAMP
5. WASHER 13. EVAPORATOR FAN
6. SCREW 14. BAND CLAMP
7. WASHER 15. BULKHEADTOVALVE DUCT
8. COTTER PIN 16. SEPARATORTO VALVE DUCT
Figure 402. Removal and Installation of ThreeWay Valve Cable and Duct
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2. ThreeWay Valve Cable (7). Connect cable (2) washers (7), and new
cotter pin (8).
A. ThreeWay Valve Cable Removal
(8). Adjust linkage of cable (2) to get full
(Ref. Figure 402) travel of duct (1).
(1). Open Access Panel R155 (ref. Section (9). Torque jam nuts (10) 270 to 300 in-lb
06-00-00). (30.50 to 33.90 Nm).
(2). Remove cotter pin (8), washers (7), and Sealing Compound (C205)
end of cable (2) from duct (1).
(7). Carefully remove sealant from split 3. ThreeWay Valve Duct Assembly
grommet (3).
A. ThreeWay Valve Duct Assembly
(8). Move cable (2) aft from bracket (4) to Removal
remove.
(Ref. Figure 402)
B. ThreeWay Valve Cable Installation
(1). Open Access Panel R155 (ref. Section
(Ref. Figure 402) 06-00-00).
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10
5
3
5 8
4 3
5
3
3
3
1
VIEW ROTATED
2
9G21021C
1. EVAPORATOR FAN (REF. IPL, 215000, FIG. 1 AND 6. SCREW
FIG. 2) 7. FLEXIBLE DUCT
2. WASHER 8. ELECTRICAL CONNECTOR P516
3. WASHER 9. VBAND CLAMP
4. SCREW 10. 3WAY VALVE DUCT
5. SCREW
Figure 403. Removal and Installation of the Evaporator Fan
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(1). Remove Access Panel T155 (ref. Section (2). Install washers (2) between the upper
53-30-00). deck and evaporator fan (1).
(2). Remove V-band clamp (9) and duct NOTE: Only install washers (2) with the -101
(10). evaporator fan.
(3). Disconnect Electrical Connector P516 (3). Install evaporator fan (1) with washers
(8). (3) and screws (4, 5).
(4). Carefully remove sealant from the (a). Torque screws (4, 5) 20 to 25 in-lb
bottom of evaporator fan (1) and upper (2.26 to 2.82 Nm).
deck.
Sealing Compound (C205)
(5). Remove screws (6) and washers (3) to
disconnect flexible duct (7) from
evaporator fan (1).
(6). Remove screws (4, 5) and washers (3).
(4). Environmentally seal screws (4, 5),
(7). Remove evaporator fan (1). washers (3), and mating surfaces with
(8). Remove washers (2). sealing compound (C205) (ref. CSP-
SPM, Section 20-50-00).
NOTE: Washers (2) are only installed with the
-101 evaporator fan. (5). Attach flexible duct (7) to evaporator
fan (1) with screws (6) and washers (3).
B. Evaporator Fan Installation
(a). Torque screws (6) 20 to 25 in-lb
(Ref. Figure 403) (2.26 to 2.82 Nm).
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21 (REF)
21
25
26
22 8 (REF)
1 2 3 9 (REF)
4
1 (REF)
5
23 (10 PL)
24 (10 PL)
VIEW ROTATED
6
16 7
20 (NOTE 1) 15
17 (6 PL) 12
18 (6 PL) 13 (10 PL) 11
19 (6 PL) 14 (10 PL) 8 (3 PL)
(NOTE 2) 10 9 (3 PL)
1 (REF)
NOTE 3
4.20-4.80 INCH
41 (2 PL) (103.7-121.9 MM)
40 (2 PL)
15 (REF)
27 29 42
22 (REF)
4 (REF) 28 VIEW ROTATED
LOOKING UP 40 (2 PL)
30
31 39 (2 PL)
33
5 (REF)
6 (REF)
34
38 32
37
35
12 (REF) 36
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. 9G21051
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(1). Remove Access Panel T155 (ref. Section (4). Install washers (18), screws (17), and
53-30-00). nuts (19) (if installed).
NOTE: If the rotorcraft uses nuts (19), install
(2). Remove band clamp (2).
screws (17) with heads on aft side of outlet
(3). Disconnect duct (3) from outlet shroud shroud (1).
(1). (a). Torque nuts (19) or screws (17) 20 to
(4). Remove nuts (19) (if installed), washers 25 in-lb (2.26 to 2.82 Nm).
(18), and screws (17). Sealing Compound (C205)
(5). Remove screws (23) and washers (24).
(6). Remove outlet shroud (1) and gasket
(11).
(5). Apply sealing compound (C205) to
B. Outlet Shroud Installation mating surfaces, washers (24), and
screws (23).
(Ref. Figure 404)
(6). Install Access Panel T155 (ref. Section
53-30-00).
Consumable Materials
(Ref. CSPSPM) 6. Evaporator Assembly (EARLY CONFIG)
Item Nomenclature
A. Evaporator Removal
C205 Sealing Compound
(Ref. Figure 404)
(1). Install gasket (11), outlet shroud (1), (1). Evacuate AC system (ref. Section
washers (24), and screws (23). 12-00-00).
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(2). Remove outlet shroud (1) (ref. Proce (a). Torque adapter (5) 230 to 260 in-lb
dure 5.A.). (25.99 to 29.38 Nm).
(3). Remove glass fabric tape (C710) (37) (7). Connect tube (6) to adapter (5).
and rubber (C610) (36) from sense
(a). Torque the captive nut of tube (6) 230
element (35) and forward end of tube
to 260 in-lb (25.99 to 29.38 Nm).
(7).
(8). Put sense element (35) against tube (7)
(4). Loosen band clamp (34) and remove
at the 3 or 9 o'clock position, no more
sense element (35) from tube (7).
than 12 inch (305 mm) along tube (7)
(5). Disconnect tube (7). from its connection to evaporator (15).
(6). Remove union (12). NOTE: Do not put rubber between sense ele
ment (35) and tube (7).
(7). Disconnect tube (6).
(9). Put rubber (C610) around sense
(8). Remove adapter (5). element (35) and full length of tube (7).
(9). Remove screws (13) and washers (14). (10). Wind glass fabric tape (C710) on rubber
(C610).
(10). Remove evaporator (15) and gasket
(11). (11). Install outlet shroud (1).
(4). Install union (12) in the outlet of (3). Disconnect sense tube (33).
evaporator (15). (4). Remove nut (38), screw (29), and
(a). Torque union (12) 460 to 500 in-lb washer (28).
(51.97 to 56.49 Nm). (5). Remove expansion valve (4) and clamp
(5). Connect tube (7) to union (12). (32).
B. Expansion Valve Installation
(a). Torque captive nut of tube (7) 460 to
500 in-lb (51.97 to 56.49 Nm). (Ref. Figure 404)
NOTE: Make sure washer (30) and strainer (1). Put expansion valve (4) and clamp (32)
(31) are installed in expansion valve. in position.
(6). Install adapter (5). (2). Connect evaporator inlet port (27).
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1 (REF)
38 (2 PL)
39 (4 PL)
NOTE 3 40 (2 PL)
19
41
0.22-0.28 INCH
(5.6-7.1 MM)
VIEW ROTATED
LOOKING DOWN 2.68-2.74 INCH
(68.1-69.6 MM)
22
18 3
13
23 5
2
19 4
24
20 (10 PL)
21 (10 PL)
12 (REF)
14 (6 PL)
15 (6 PL)
26
28
4 (REF) 25
27
1 6 (4 PL)
29 7 (4 PL)
30 12 8
9
10 (10 PL)
5 (REF) 11 (10 PL)
32 24 (REF)
33
37 31
36
34
NOTES: 35
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. 9G21050
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12. Evaporator Inlet Shroud (CURRENT (4). Install Access Panel T155 (ref. Section
CONFIG) 53-30-00).
(3). Disconnect duct (18) from inlet shroud (2). Remove inlet shroud (23) (ref. Proce
(23). dure 12.A.).
(4). Remove screws (20) and washers (21). (3). Remove glass fabric tape (C710) (36)
and rubber (C610) (35) from sense
(5). Remove inlet shroud (23) and gasket element (34) and forward end of tube
(13). (25).
(1). Install gasket (13), inlet shroud (23), (6). Remove union (9).
washers (21), and screws (20).
(7). Disconnect tube (24).
(a). Torque screws (20).
(8). Remove inlet adapter (5).
(2). Connect duct (18) to inlet shroud (23). (9). Remove screws (10) and washers (11).
(3). Install band clamp (22). (10). Remove evaporator (12) and gasket (8).
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(6). Make sure washer (29) and strainer (Ref. Figure 405)
(30) are installed in expansion valve
(4). Consumable Materials
(Ref. CSPSPM)
(7). Install adapter (5). Item Nomenclature
(a). Torque adapter (5) 230 to 260 in-lb C205 Sealing Compound
(25.99 to 29.38 Nm).
(8). Connect tube (24) to adapter (5). (1). Install outlet shroud (1), washers (7),
and screws (6).
(a). Torque the captive nut of tube (24) (a). Torque screws (6) 20 to 25 in-lb
230 to 260 in-lb (25.99 to 29.38 (2.26 to 2.82 Nm).
Nm).
Sealing Compound (C205)
(9). Put sense element (34) against tube
(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). (2). Apply sealing compound (C205) to
mating surfaces, washers (7), and
(10). Put rubber (C610) (35) around sense screws (6).
element (34) and the full length of tube
(25). (3). Install screws (14) and washers (15).
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(a). Torque screws (14) 20 to 25 in-lb (3). Carefully straighten the temperature
(2.26 to 2.82 Nm). probe as you pull it through grommet
(41).
(4). Apply sealing compound (C205) to
mating surfaces, washers (7, 15), and (4). Remove thermostatic switch (19).
screws (6, 14).
B. Thermostatic Switch Installation
(5). Connect duct (18) to outlet shroud (1).
(Ref. Figure 405)
(6). Install band clamp (22).
(1). Install thermostatic switch (19) with
(7). Install evaporator (12) (ref. Procedure screws (38), washers (39), and nuts
13.B.). (40).
15. Thermostatic Switch (CURRENT CONFIG) (a). Torque nuts (40) 20 to 25 in-lb (2.26
to 2.82 Nm).
A. Thermostatic Switch Removal
(2). Carefully pull the temperature probe
(Ref. Figure 405) thru grommet (41).
(1). Remove outlet shroud (1) (ref. Proce (3). Carefully bend the temperature probe
dure 14.A.). as shown (ref. Figure 405, Detail A).
(2). Remove nuts (40), screws (38), and (4). Install outlet shroud (1) (ref. Procedure
washers (39). 14.B.).
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A411 J1 1
A412 J1
3 (P500)
2
10 4 (P501)
7
6
5
9 18
8
17
21
22
16
15
TUB (REF)
13
12
11 24
12
11
23
14
19
20
9G21-049
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16. Condenser Fan (EARLY CONFIG) (a). Torque screws (6) 20 to 25 in-lb
(2.26 to 2.82 Nm).
A. Condenser Fan Removal
(2). Install condenser fans (1) (ref. Proce
(Ref. Figure 406) dure 16.B., Condenser Fan Installa
(1). Remove Access Panel A235 (ref. Section tion).
53-20-00). 18. Condenser (EARLY CONFIG)
(2). Disconnect Electrical Connector P500 A. Condenser Removal
or P501 (3, 4).
(Ref. Figure 406)
(3). Remove V-band clamp (2).
(1). Evacuate AC system (ref. Section
(4). Remove condenser fan (1). 12-00-00).
B. Condenser Fan Installation (2). Remove condenser transition duct (7)
(Ref. Figure 406) (ref. Procedure 17.A., Condenser
Transition Duct Removal).
(1). Install condenser fan (1) with V-band
clamp (2). (3). Disconnect tubes (13, 14) from unions
(12).
NOTE: As necessary, turn condenser fans (1) to
align with electrical connectors (3). (4). Remove unions (12) and packings (11).
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(4). Connect tubes (13, 14) to unions (12). Sealing Compound (C205)
19. Condenser Inlet Screen (EARLY CONFIG) (2). Remove screws (24) and washers (23).
A. Inlet Screen Removal (3). Remove frame (22) and exit screen (21).
B. Exit Screen Installation
(Ref. Figure 406)
(Ref. Figure 406)
(1). Remove condenser (10) (ref. Procedure
18.A., Condenser Removal).
Consumable Materials
(Ref. CSPSPM)
(2). Remove screws (20) and washers (19). Item Nomenclature
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1 (NOTE)
5 REF.
5
2
7
6
3 (3 PL)
4 (3 PL)
(NOTE)
8
9 (4 PL) VIEW ROTATED
10 (4 PL)
(NOTE)
17
11
12
13
12 14 (5 PL)
13 15 (5 PL)
17
16
16
14 (5 PL) 15 (5 PL)
NOTE:
ONE ADDITIONAL WASHER CAN BE ADDED UNDER BOLT HEAD FOR CLEARANCE. 9G21043A
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(10). Remove condenser (6) and inlet cooling (7). Test the condenser for a Class H
duct (11). electrical bond (ref. CSP-SPM, Section
20-50-00).
(11). Remove bolt (1), washer (2), and
condenser (6). Sealant, Fuel Resistant (C216)
B. Condenser Installation
(Ref. Figure 407)
(8). Environmentally seal bolts (15) and
Consumable Materials electrical bond jumper (17) with sealant
(Ref. CSPSPM) (C216) (ref. CSP-SPM, Section
Item Nomenclature 20-50-00).
C211 Sealing Compound, Corrosion Inhibitive (9). Connect inlet tube (7) and outlet tube
C216 Sealant, Fuel Resistant (8).
(a). Torque captive nuts of tubes (7, 8)
NOTE: This task is typical for the left or right 230 to 260 in-lb (25.99 to 29.38
condensers. Nm).
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29
14 (2 PL) 1
15 (2 PL)
2
3
30 REF.
30 1
28 (2 PL) 31
TYPICAL 3 PL
27 2
26 REF.
3
26
22 REF. 21
23 (4 PL)
24 (4 PL) 1
24 19
25 22 20
14
15 8 8
16 8 3
1
18 2 4
17
13
12
1
11 2
11 5
EARLY CONFIG
3
8 2 4
1
4 8 1
5 2 TYPICAL
10
2 8
3
9 6
1
4
3 8
2
1
4
3 7
8 (2 PL)
TYPICAL
2
2 5
9G210061A
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(2). Put receiver dehydrator (1) with clamps (3). Remove screws (10), washers (9), nuts
(2) on bracket (12). (11), and bracket (12).
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Consumable Materials
(Ref. CSPSPM) (3). Environmentally seal between the
Item Nomenclature edges of bracket (12) and the upper
C205 Sealing Compound deck with sealing compound (C205) (ref.
CSP-SPM, Section 20-50-00).
(1). Put bracket (12) in position on the (4). Environmentally seal screws (10) and
upper deck. washers (9) with sealing compound
(2). Attach bracket (12) with washers (9), (C205) (ref. CSP-SPM, Section
screws (10), and nuts (11). 20-50-00).
(a). Torque screws (10) 20 to 25 in-lb (5). Install receiver dehydrator (1) (ref.
(2.26 to 2.82 Nm). Procedure 22.B.).
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29
14 (2 PL) 1
15 (2 PL)
2
3
30 REF.
30 1
28 (2 PL) 31
TYPICAL 3 PL
27 2
26 REF.
3
26
22 REF. 21
23 (4 PL)
24 (4 PL) 1
24 19
25 22 20
14
15 8 8
16 8 3
1
18 2 4
17
13
12
1
11 2
11 5
EARLY CONFIG
3
8 2 4
1
4 8 1
5 2 TYPICAL
10
2 8
3
9 6
1
4
3 8
2
1
4
3 7
8 (2 PL)
TYPICAL
2
2 5
9G210061A
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66 50 26 REF.
67 45 REF. 34 REF.
32
14 (2 PL)
49
15 (2 PL)
33
68 34
CURRENT CONFIG
36 51 52
8 37 (4 PL)
38 (4 PL) 52
17
14 43 38 (4 PL) 53
39 (4 PL)
42
54
40 53
13 LOW PRESSURE
41
15 (2 PL) 55 SWITCH
61
57
61 58
57 59
58 60
59 56
60 57
58
59
60
56
57
58
59
60 VIEW ROTATED
62 62
63 (3 PL) 63 (3 PL)
64 (2 PL) 64 (2 PL)
VIEW ROTATED 65 9G210062A
65
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(6). Close Access Panel R210 (ref. Section (4). Remove nut (5), screw (3), washers (2),
06-00-00). and loop clamp (4).
25. HighPressure Switch (5). Remove screws (57), washers (59), loop
clamps (56 and 58), nuts (60), and inlet
A. HighPressure Switch Removal hose (29 or 32).
(Ref. Figure 409) B. Inlet Hose Installation
(1). Open Access Panel R210 (ref. Section (Ref. Figure 409)
06-00-00).
(1). Connect inlet hose (29 or 32).
(2). Evacuate AC system (ref. Section (2). Install washers (2, 59), screws (3, 57),
12-00-00). loop clamps (4, 56, 58), and nuts (5, 60).
(3). Disconnect Electrical Connector P502 (a). Torque nuts.
(66).
(3). Torque the captive nuts of inlet hose
(4). Remove high-pressure switch (67). 460 to 500 in-lb (51.97 to 56.49 Nm).
B. HighPressure Switch Installation The receiver dehydrator must
CAUTION be replaced each time the com
(Ref. Figure 409) pressor is removed, or the AC system is
(1). Install high-pressure switch (67). opened. An early failure of the compressor
can occur.
(a). Torque the nut of tee 230 to 260
in-lb (25.99 to 29.38 Nm). (4). Remove and replace the receiver
dehydrator (ref. Procedure 22.).
(2). Connect Electrical Connector P502
(5). Service AC system (ref. Section
(66).
12-00-00).
The receiver dehydrator must
CAUTION be replaced each time the com
(6). Close Access Panel R210 (ref. Section
06-00-00).
pressor is removed, or the AC system is
opened. An early failure of the compressor 27. Compressor Outlet Hose
can occur.
A. Outlet Hose Removal
(3). Remove and replace the receiver
dehydrator (ref. Procedure 22.). (Ref. Figure 409)
(4). Service AC system (ref. Section (1). Disconnect outlet hose (31 or 50).
12-00-00). (2). Remove screws (57), washers (59),
(5). Close Access Panel R210 (ref. Section clamps (61 and 58), nuts (60), and inlet
06-00-00). hose (29 or 32).
B. Outlet Hose Installation
26. Compressor Inlet Hose
(Ref. Figure 409)
A. Inlet Hose Removal
(1). Connect outlet hose (31 or 50).
(Ref. Figure 409)
(2). Install clamps, screws, washers, and
(1). Open Access Panel R210 (ref. Section nuts.
06-00-00).
(a). Torque nuts.
(2). Evacuate AC system (ref. Section
12-00-00). (3). Torque the captive nuts of outlet hose
(31 or 50) 230 to 260 in-lb (25.99 to
(3). Disconnect inlet hose (29 or 32). 29.37 Nm).
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The receiver dehydrator must (6). Install access panels L155 and L210
CAUTION be replaced each time the com (ref. Section 53-30-00).
pressor is removed, or the AC system is
opened. An early failure of the compressor C. HighPressure Switch to MidSection
can occur. Tube Removal
(Ref. Figure 409)
(4). Remove and replace the receiver
dehydrator (ref. Procedure 22.). (1). Remove access panels L155, L210, and
R210 (ref. Section 53-30-00).
(5). Service AC system (ref. Section
12-00-00). (2). Evacuate AC system (ref. Section
12-00-00).
(6). Close Access Panel R210 (ref. Section
06-00-00). (3). Disconnect tube (19) from union (8) and
tee (68).
28. HighPressure Tubes (EARLY CONFIG)
(4). Remove nuts (5), screws (3), washers
A. MidSection To Evaporator Tube (2), clamps (1), and tube (19).
Removal
D. HighPressure Switch to MidSection
(Ref. Figure 409) Tube Installation
(1). Remove access panels L155 and L210 (Ref. Figure 409)
(ref. Section 53-30-00). (1). Connect tube to union and tee.
(2). Evacuate AC system (ref. Section (2). Install clamps, screws, washers, and
12-00-00). nuts.
(3). Disconnect tube (16) from adapter (14) (a). Torque nuts.
and union (8).
(3). Torque tube nuts 230 to 260 in-lb
(4). Remove nuts (5), screws (3), washers (25.99 to 29.37 Nm).
(2), clamps (1), and tube (16).
The receiver dehydrator must
CAUTION
B. MidSection To Evaporator Tube be replaced each time the com
Installation pressor is removed, or the AC system is
opened. An early failure of the compressor
(Ref. Figure 409) can occur.
(1). Connect tube to adapter and union. (4). Remove and replace the receiver
dehydrator (ref. Procedure 22.).
(2). Install clamps, screws, washers, and
nuts. (5). Service AC system (ref. Section
12-00-00).
(a). Torque nuts.
(6). Install access panels L155, L210, and
(3). Torque tube nuts 230 to 260 in-lb R210 (ref. Section 53-30-00).
(25.99 to 29.37 Nm).
E. Receiver Dehydrator to HighPressure
The receiver dehydrator must Switch Tube Removal
CAUTION be replaced each time the com
pressor is removed, or the AC system is (Ref. Figure 409)
opened. An early failure of the compressor (1). Remove Access Panel R210 (ref. Section
can occur. 53-30-00).
(4). Remove and replace the receiver (2). Evacuate AC system (ref. Section
dehydrator (ref. Procedure 22.). 12-00-00).
(5). Service AC system (ref. Section (3). Remove tube (22) from tee (68) and
12-00-00). receiver dehydrator (26).
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F. Receiver Dehydrator to HighPressure (3). Torque hose nuts 230 to 260 in-lb
Switch Tube Installation (25.99 to 29.37 Nm).
(Ref. Figure 409) (4). Service AC system (ref. Section
12-00-00).
The receiver dehydrator must
CAUTION be replaced each time the com (5). Install Access Panel R210 (ref. Section
pressor is removed, or the AC system is 53-30-00).
opened. An early failure of the compressor
I. Baggage Closet to Deck Tube Removal
can occur.
(Ref. Figure 409)
(1). Remove and replace the receiver
dehydrator (ref. Procedure 22.). (1). Remove baggage compartment roof
insulation as necessary (ref. Section
(2). Connect tube to tee and receiver 25-00-00).
dehydrator.
(2). Remove baggage compartment right
(3). Torque tube nuts 230 to 260 in-lb insulation and closeout panel (ref.
(25.99 to 29.37 Nm). Section 25-00-00).
(4). Service AC system (ref. Section (3). Evacuate AC system (ref. Section
12-00-00). 12-00-00).
(5). Install Access Panel R210 (ref. Section (4). Disconnect tube (20) from elbow (65)
53-30-00). and union (8).
G. Receiver Dehydrator to Deck Hose (5). Remove screw (3), washer (2), and
Removal clamp (1). Remove tube (20).
(1). Remove Access Panel R210 (ref. Section (Ref. Figure 409)
53-30-00).
(1). Connect tube to elbow and union.
(2). Evacuate AC system (ref. Section (2). Install clamp, screw, and washer.
12-00-00). Torque screw.
(3). Disconnect hose (30) from receiver (3). Torque tube nuts 230 to 260 in-lb
dehydrator (26) and elbow (65). (25.99 to 29.37 Nm).
(4). Remove hose (30). The receiver dehydrator must
CAUTION be replaced each time the com
H. Receiver Dehydrator to Deck Hose pressor is removed, or the AC system is
Installation opened. An early failure of the compressor
(Ref. Figure 409) can occur.
(4). Remove and replace the receiver
The receiver dehydrator must
CAUTION be replaced each time the com dehydrator (ref. Procedure 22.).
pressor is removed, or the AC system is (5). Service AC system (ref. Section
opened. An early failure of the compressor 12-00-00).
can occur.
(6). Install baggage compartment right
(1). Remove and replace the receiver closeout panel and insulation (ref.
dehydrator (ref. Procedure 22.). Section 25-00-00).
(2). Connect hose to receiver dehydrator (7). Install baggage compartment roof
and elbow. insulation (ref. Section 25-00-00).
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K. Deck to Baggage Closet Tube Removal (2). Remove baggage compartment roof
insulation as necessary (ref. Section
(Ref. Figure 409) 25-00-00).
(1). Remove baggage compartment roof (3). Evacuate AC system (ref. Section
insulation as necessary (ref. Section 12-00-00).
25-00-00).
(4). Disconnect tube (20 or 21) from elbow
(2). Remove baggage compartment right (65).
insulation and closeout panel (ref.
Section 25-00-00). (5). Disconnect hose (30 or 31) from elbow
(65).
(3). Evacuate AC system (ref. Section (6). Remove nut (62), elbow (65), and
12-00-00). washers (63, 64).
(4). Disconnect tube (21) from elbow (65) N. Upper Deck Elbow Installation
and union (8).
(Ref. Figure 409)
(5). Remove screw (3), washer (2), clamp
(1), and tube (21). NOTE: Installation of upper deck elbow is typi
cal.
L. Deck to Baggage Closet Tube Installation
(1). Install washers (64) and two washers
(Ref. Figure 409) (63) on elbow.
(1). Connect tube to elbow and union. (2). Install elbow, washer (63), and nut.
(2). Install clamp, screw, and washer. (3). Torque nut 230 to 260 in-lb (25.99 to
29.37 Nm).
(a). Torque screw. (4). Connect tube and hose.
(3). Torque the captive nuts of tube 230 to (5). Torque tube and hose nuts 230 to 260
260 in-lb (25.99 to 29.37 Nm). in-lb (25.99 to 29.37 Nm).
The receiver dehydrator must The receiver dehydrator must
CAUTION be replaced each time the com CAUTION be replaced each time the com
pressor is removed, or the AC system is pressor is removed, or the AC system is
opened. An early failure of the compressor opened. An early failure of the compressor
can occur. can occur.
(4). Remove and replace the receiver (6). Remove and replace the receiver
dehydrator (ref. Procedure 22.). dehydrator (ref. Procedure 22.).
(5). Service AC system (ref. Section (7). Service AC system (ref. Section
12-00-00). 12-00-00).
(6). Install baggage compartment right (8). Install baggage compartment roof
closeout panel and insulation (ref. insulation (ref. Section 25-00-00).
Section 25-00-00). O. Baggage Closet Tube Removal
(7). Install baggage compartment roof (Ref. Figure 409)
insulation (ref. Section 25-00-00).
NOTE: Removal of forward or aft baggage clos
M. Upper Deck Elbow Removal et tube is the same.
(Ref. Figure 409) (1). Remove baggage compartment right
insulation and closeout panel (ref.
NOTE: Removal of upper deck elbow is typical. Section 25-00-00).
(1). Remove Access Panel R210 (ref. Section (2). Evacuate AC system (ref. Section
53-30-00). 12-00-00).
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(3). Disconnect tube (11) from unions (8). The receiver dehydrator must
CAUTION be replaced each time the com
(4). Remove screw (3), washer (2), and pressor is removed, or the AC system is
clamp (1). Remove tube (11). opened. An early failure of the compressor
can occur.
P. Baggage Closet Tube Installation
(3). Remove and replace the receiver
(Ref. Figure 409) dehydrator (ref. Procedure 22.).
NOTE: Installation of forward or aft baggage (4). Service AC system (ref. Section
closet tube is the same. 12-00-00).
(1). Connect tube to unions. (5). Install baggage compartment right
outboard floor panel (ref. Section
(2). Install clamp, screw, and washer. 53-20-00).
(a). Torque screw. S. Floor to Keel Beam Tube Removal
(3). Torque tube nuts 230 to 260 in-lb (Ref. Figure 409)
(25.99 to 29.37 Nm). (1). Remove baggage compartment right
The receiver dehydrator must outboard floor panel (ref. Section
CAUTION be replaced each time the com 53-20-00).
pressor is removed, or the AC system is (2). Evacuate AC system (ref. Section
opened. An early failure of the compressor 12-00-00).
can occur.
(3). Disconnect tube (10) from unions (8).
(4). Remove and replace the receiver
dehydrator (ref. Procedure 22.). (4). Remove tube (10)
(5). Service AC system (ref. Section T. Floor to Keel Beam Tube Installation
12-00-00). (Ref. Figure 409)
(6). Install baggage compartment right (1). Connect tube (10) to unions (8).
closeout panel and insulation (ref.
Section 25-00-00). (a). Torque tube nuts 230 to 260 in-lb
(25.99 to 29.37 Nm).
Q. Keel Beam to Floor Tube Removal
The receiver dehydrator must
CAUTION be replaced each time the com
(Ref. Figure 409)
pressor is removed, or the AC system is
(1). Remove baggage compartment right opened. An early failure of the compressor
outboard floor panel (ref. Section can occur.
53-20-00).
(2). Remove and replace the receiver
(2). Evacuate AC system (ref. Section dehydrator (ref. Procedure 22.).
12-00-00). (3). Service AC system (ref. Section
(3). Disconnect tube (9) from unions (8). 12-00-00).
Remove tube (9) (4). Install baggage compartment right
outboard floor panel (ref. Section
R. Keel Beam to Floor Tube Installation
53-20-00).
(Ref. Figure 409) U. Condenser to Keel Beam Tube Removal
(1). Connect tube to unions. (Ref. Figure 409)
(2). Torque tube nuts 230 to 260 in-lb (1). Remove baggage compartment floor
(25.99 to 29.37 Nm). center panel (ref. Section 53-20-00).
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(2). Evacuate AC system (ref. Section (4). Service AC system (ref. Section
12-00-00). 12-00-00).
(3). Disconnect tube (7) from unions (8). (5). Install baggage compartment floor
center panel (ref. Section 53-20-00).
(4). Remove tube (7)
29. HighPressure Tubes (CURRENT
V. Condenser to Keel Beam Tube CONFIG)
Installation
A. Evaporator to Sight Glass Tube Removal
(1). Connect tube to unions.
(Ref. Figure 409)
(2). Torque the captive nuts of tube 230 to
260 in-lb (25.99 to 29.37 Nm). (1). Remove Access Panel L155 (ref. Section
53-30-00).
The receiver dehydrator must
CAUTION be replaced each time the com (2). Evacuate AC system (ref. Section
pressor is removed, or the AC system is 12-00-00).
opened. An early failure of the compressor
(3). Remove tube (42) from sight glass (41)
can occur.
and adapter (14).
(3). Remove and replace the receiver B. Evaporator to Sight Glass Tube
dehydrator (ref. Procedure 22.). Installation
(4). Service AC system (ref. Section (Ref. Figure 409)
12-00-00).
(1). Install tube (42) between sight glass
(5). Install baggage compartment floor (41) and adapter (14).
center panel (ref. Section 53-20-00).
(a). Torque the captive nuts of tube (42)
W. Keel Beam to Condenser Tube Removal 230 to 260 in-lb (25.99 to 29.37
Nm).
(Ref. Figure 409)
The receiver dehydrator must
(1). Remove baggage compartment floor CAUTION be replaced each time the com
center panel (ref. Section 53-20-00).
pressor is removed, or the AC system is
(2). Evacuate AC system (ref. Section opened. An early failure of the compressor
12-00-00). can occur.
(3). Remove tube (6) from unions (8). (2). Remove and replace receiver dehydra
tor (26) (ref. Procedure 22.).
X. Keel Beam to Condenser Tube
Installation (3). Service AC system (ref. Section
12-00-00).
(Ref. Figure 409)
(4). Install Access Panel L155 (ref. Section
(1). Connect tube to unions. 53-30-00).
(2). Torque tube nuts 230 to 260 in-lb C. Sight Glass Removal
(25.99 to 29.37 Nm). (Ref. Figure 409)
The receiver dehydrator must
CAUTION be replaced each time the com
(1). Remove Access Panel L155 (ref. Section
53-30-00).
pressor is removed, or the AC system is
opened. An early failure of the compressor (2). Evacuate AC system (ref. Section
can occur. 12-00-00).
(3). Remove and replace the receiver (3). Disconnect tube (42) and tube (43) from
dehydrator (ref. Procedure 22.). sight glass (41).
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(2). Evacuate AC system (ref. Section (a). Torque captive nuts of tube (46) 230
12-00-00). to 260 in-lb (25.99 to 29.38 Nm).
(3). Remove tube (45) from tee (68) and LH The receiver dehydrator must
condenser (69). CAUTION be replaced each time the com
(4). Remove screws (3), washers (2), clamps pressor is removed, or the AC system is
opened. An early failure of the compressor
(1), and tube (45).
can occur.
P. Left Condenser to HighPressure Switch
Tube Installation (2). Remove and replace receiver dehydra
tor (26) (ref. Procedure 22.).
(Ref. Figure 409)
(3). Service AC system (ref. Section
(1). Install tube (45) between tee (68) and 12-00-00).
LH condenser (69).
(2). Install clamps (1), screws (3), and (4). Install Access Panel R210 (ref. Section
washers (2). 53-30-00).
(3). Torque captive nuts of tube 230 to 260 (Ref. Figure 409)
in-lb (25.99 to 29.38 Nm).
(1). Remove Access Panel R210 (ref. Section
The receiver dehydrator must 53-30-00).
CAUTION be replaced each time the com
pressor is removed, or the AC system is (2). Evacuate AC system (ref. Section
opened. An early failure of the compressor 12-00-00).
can occur.
(3). Remove tube (49) from tee (47) and RH
(4). Remove and replace receiver dehydra
condenser.
tor (26) (ref. Procedure 22.).
(5). Service AC system (ref. Section T. Tee to Right Condenser Tube Installation
12-00-00).
(Ref. Figure 409)
(6). Install access panels L210 and R210
(ref. Section 53-30-00). (1). Install tube (49) between tee (47) and
RH condenser.
Q. HighPressure Switch to Tee Tube
Removal (a). Torque the captive nuts of tube (49)
230 to 260 in-lb (25.99 to 29.38
(Ref. Figure 409) Nm).
(1). Remove Access Panel R210 (ref. Section
The receiver dehydrator must
53-30-00). CAUTION be replaced each time the com
(2). Evacuate AC system (ref. Section pressor is removed, or the AC system is
12-00-00). opened. An early failure of the compressor
can occur.
(3). Remove tube (46) from tee (68) and tee
(47). (2). Remove and replace receiver dehydra
tor (26) (ref. Procedure 22.).
R. HighPressure Switch to Tee Tube
Installation
(3). Service AC system (ref. Section
(Ref. Figure 409) 12-00-00).
(1). Connect high-pressure switch to tee (4). Install Access Panel R210 (ref. Section
tube (46) to tees (47, 68). 53-30-00).
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1 (REF)
2 (REF)
3 (REF)
4 (REF)
5
16
17 6
7
8
9
5 (REF)
10
15
15 16 (REF) 6 (REF)
9 16 (REF) 6 (REF) 10
10
9
11
13 13
11
12 11
12 14
9G21047
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30. LowPressure Lines (EARLY CONFIG) (4). Attach clamp (10) to bracket (13) with
screw (9), washer (11), and nut (12).
A. ECS MidSection to LowPressure
Switch Tube Removal (a). Torque screw (9) 20 to 25 in-lb (2.26
to 2.82 Nm).
(Ref. Figure 410)
(5). Attach clamps (10, 15) to bracket (13)
(1). Remove the access panels L155, L210, with screw (9), washer (11), and nut
and R210 (ref. Section 53-30-00). (12).
(2). Evacuate AC system (ref. Section (a). Torque screw (9) 20 to 25 in-lb (2.26
12-00-00). to 2.82 Nm).
(6). Torque both captive nuts of tube (5) 460
(3). Disconnect tube (5) from union (7) and to 500 in-lb (51.97 to 56.49 Nm).
tee (4).
The receiver dehydrator must
(4). Remove nuts (12), screws (9), washers CAUTION be replaced each time the com
(11), and clamps (10). pressor is removed, or the AC system is
opened. An early failure of the compressor
(5). Remove tube (5). can occur.
B. ECS MidSection to LowPressure (7). Remove and replace receiver dehydra
Switch Tube Installation tor (2) (ref. Procedure 22.).
(Ref. Figure 410) (8). Service AC system (ref. Section
12-00-00).
Consumable Materials (9). Install access panels L155, L210, and
(Ref. CSPSPM) R210 (ref. Section 53-30-00).
Item Nomenclature
C. ECS Evaporator To MidSection Tube
C610 Rubber, Expanded
Removal
C710 Tape, Glass Fabric
(Ref. Figure 410)
(1). If tube (5) is a replacement, do these (1). Remove access panels L155 and L210
steps: (ref. Section 53-30-00).
(a). Wind rubber (C610) on surface of (2). Evacuate AC system (ref. Section
tube (5). 12-00-00).
(3). Remove glass fabric tape (C710) and
(b). Wind glass fabric tape (C710) on rubber (C610) from forward 12 inch
rubber (C610). (305 mm) of tube (6).
(2). Connect tube (5) to union (7) and tee (4). Disconnect tube (6) from unions (7).
(4).
(5). Remove nuts (12), screws (9), washers
(3). Install clamps (10) on tube (5). (11), and clamps (10).
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(6). Remove tube (6). (3). Connect tube (6) to unions (7).
(7). If necessary, remove union (7) and
(4). Install clamps (10) on tube (6).
packing (8) from evaporator (17).
(a). Discard packing (8). (5). Attach clamps (10, 15) to bracket (13)
with washer (11) and screw (9).
D. ECS Evaporator To MidSection Tube
Installation
(a). Torque screw (9) 20 to 25 in-lb (2.26
(Ref. Figure 410) to 2.82 Nm).
(c). Torque union (7) 460 to 500 in-lb The receiver dehydrator must
(51.97 to 56.49 Nm). CAUTION be replaced each time the com
pressor is removed, or the AC system is
(2). If tube (6) is a replacement, do these
opened. An early failure of the compressor
steps:
can occur.
(a). Wind rubber (C610) on surface of
tube (6) from 12 inch (305 mm) aft (10). Remove and replace receiver dehydra
of forward end to aft end. tor (2) (ref. Procedure 22.).
(b). Wind glass fabric tape (C710) on
(11). Service AC system (ref. Section
rubber (C610).
12-00-00).
NOTE: Do not put glass fabric tape (C710) on
forward 1.00 inch (25.4 mm) of rubber (12). Install access panels L155 and L210
(C610). (ref. Section 53-30-00).
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1 (REF)
2 (REF)
6
4 (REF)
5 (REF)
3 (REF)
17 (REF)
7 8
18
8
9
10
12
6 (REF)
11
6 (REF)
11
10
12
14
12
13
15
16
17 (REF) 7 (REF) 16
11 10 12 17 (REF) 7 (REF)
11
10
12
14
15 12
13
9G21048
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31. LowPressure Lines (CURRENT CONFIG) (4). Attach clamp (11) to bracket (14) with
screw (10), washers (12), and nut (13).
A. ECS MidSection to LowPressure
Switch Tube Removal (a). Torque screw (10) 20 to 25 in-lb
(2.26 to 2.82 Nm).
(Ref. Figure 411)
(5). Attach clamp (11) to bracket (15) with
(1). Remove the access panels L155, L210, washer (12), and screw (10).
and R210 (ref. Section 53-30-00).
(a). Torque screw (10) 20 to 25 in-lb
(2). Evacuate AC system (ref. Section (2.26 to 2.82 Nm).
12-00-00).
(6). Torque both captive nuts of tube (6) 460
(3). Disconnect tube (6) from union (8) and to 500 in-lb (51.97 to 56.49 Nm).
tee (4). The receiver dehydrator must
CAUTION be replaced each time the com
(4). Remove nuts (13), screws (10), washers
(12), and clamps (11). pressor is removed, or the AC system is
opened. An early failure of the compressor
(5). Remove tube (6). can occur.
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(6). Remove tube (7). (3). Connect tube (7) to unions (8).
(7). If necessary, remove union (8) and (4). Install clamps (11) on tube (7)
packing (9) from evaporator (18).
(a). Discard packing (9). (5). Attach clamps (11, 16) to bracket (15)
with washer (12) and screw (10).
D. ECS Evaporator To MidSection Tube
Installation (a). Torque screw (10) 20 to 25 in-lb
(Ref. Figure 411) (2.26 to 2.82 Nm).
(b). Install union (8) with packing (9) on (9). Wind glass fabric tape (C710) on rubber
evaporator (18). (C610).
(c). Torque union (8) 460 to 500 in-lb
The receiver dehydrator must
(51.97 to 56.49 Nm). CAUTION be replaced each time the com
(2). If tube (7) is a replacement, do these pressor is removed, or the AC system is
steps: opened. An early failure of the compressor
can occur.
(a). Wind rubber (C610) on surface of
tube (7) from 12 inch (305 mm) aft (10). Remove and replace receiver dehydra
of forward end to aft end. tor (4) (ref. Procedure 22.).
(b). Wind glass fabric tape (C710) on
rubber (C610). (11). Service AC system (ref. Section
12-00-00).
NOTE: Do not put glass fabric tape (C710) on
forward 1.00 inch (25.4 mm) of rubber (12). Install access panels L155 and L210
(C610). (ref. Section 53-30-00).
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(1). Inspect receiver dehydrator for service (2). Inspect for cracks and corrosion. None
able condition. Repair or replace as permitted.
necessary.
(3). Inspect for loose or missing hardware.
(2). Inspect receiver dehydrator for corro Repair or replace as necessary.
sion. None permitted. (4). Inspect V-band clamp for security.
Repair or replace as necessary.
(3). Inspect fittings for evidence of leakage.
None permitted. G. Three Way Valve Duct Assembly
Inspection
C. Evaporator Assembly Inspection
(1). Inspect three way valve for serviceable
(1). Inspect evaporator for damage of condition and for freedom of operation.
evaporator fins and tubes. None Repair or replace as necessary.
permitted.
(2). Inspect for loose or missing hardware.
(2). Inspect for cracks at mount flange. Repair or replace as necessary.
None permitted.
(3). Inspect for cracks, deformation and
(3). Inspect fan shroud for cracks, deforma deterioration. None permitted.
tion and deterioration. None permitted. H. Three Way Valve Control Cable
Inspection
(4). Inspect for loose or missing hardware.
Repair or replace as necessary. (1). Inspect control cable for serviceable
condition and freedom of operation.
D. High Pressure Switch Inspection Repair or replace as necessary.
(1). Inspect high pressure switch for (2). Inspect for loose or missing hardware.
corrosion. None permitted. Repair or replace as necessary.
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I. Line and Tube Assemblies Inspection (4). Inspect attach fitting for evidence of
leakage.
(1). Inspect low pressure line for serviceable
condition of insulation material from (a). If leakage has occurred evacuate
evaporator to low pressure switch. No system.
damage permitted. (b). Remove, repair or replace leaking or
non-serviceable fittings.
(2). Inspect lines, tubes and fittings for
evidence of leakage and serviceable (c). Service air conditioning system
condition. (Ref. Section 12-00-00).
K. Condenser Fan Inspection
(a). If leakage has occurred evacuate (EARLY CONFIG)
system.
(1). Inspect condenser fan for visible
(b). Remove, repair or replace leaking or corrosion. No damage permitted.
non-serviceable condition lines,
tubes and fittings. (2). Inspect for loose or missing hardware.
Repair or replace as necessary.
(c). Service air conditioning system (3). Inspect fan shroud for cracks, deforma
(Ref. Section 12-00-00). tion and deterioration. No damage
permitted.
(3). Inspect for loose or missing attachment
support hardware. Repair or replace as (4). Verify condenser fan operation.
necessary. L. Condenser Scoop
(EARLY CONFIG)
J. Condenser Assembly Inspection
(1). Inspect condenser scoop for cracks.
(1). Inspect condenser for damage at mount None permitted.
flange. None permitted.
(2). Inspect condenser scoop for loose or
missing attachment hardware. Repair
(2). Inspect for cracks. None permitted. or replace as necessary.
(3). Inspect for loose or missing hardware. (3). Inspect for deformation and deteriora
Repair or replace as necessary. tion. Repair or replace as necessary.
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Rotorcraft Maintenance Manual
Chapter
EQUIPMENT /
FURNISHINGS
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
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CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
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MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
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CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
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MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
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CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
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MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page vii
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CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
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CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page x
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MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Section
251000
Crew Compartment
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page 1
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Rotorcraft Maintenance Manual
RESTRAINT
SYSTEM
ATTENUATION
TUBES
9G25001
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Rotorcraft Maintenance Manual
TOP PANEL
ROOF PANEL
CENTER
BEAM COVER
HOOK TAPE
HOOK TAPE
COAT HOOK
TOP PANEL
ASSEMBLY
LIGHT ASSEMBLIES
CENTER BEAM
COVER
COAT
CLOSET PANEL
HOOK
ASSEMBLIES
INTERIOR
DOOR PANEL
LOWER
PANEL
ASSEMBLY
SIDE PANEL
ASSEMBLY
CARPET PANEL
CARPET
TRAPPING
CARPET STRIP
PANEL
HOOK TAPE
CARPET TRAPPING
STRIP 9G25002A
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Rotorcraft Maintenance Manual
4. Adjustment Rail Assembly, Crew Seat (4). Remove nuts (20), washers (19) and
bolts (18) attaching inertia reel (11) and
A. Adjustment Rail Assembly Removal shoulder harness (10) to seat back
assembly (42).
(Ref. Figure 401)
(5). Remove seat pan assembly (39) (Ref.
(1). Remove crew seat assembly (4). Section 25-10-00).
(2). Remove forward rail stops (1) with pull (6). Remove nuts (7), washers (8 and 14),
up cables (12) attached. bushings (15) and screws (17) attaching
side tubes (25) to seat back assembly
(3). Remove aft rail stops (13). (42).
(4). Disengage lock system assembly (47) (7). Remove nuts (7), washers (8 and 29)
from adjustment rail assemblies (2) by and bolts (30) attaching diagonal
moving adjustment lever (3) under supports (44) to fixed fitting assemblies
front of seat pan assembly (39). (32).
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(5). Install seat pan assembly (39) (Ref. (3). Install screws (37), washers (33) and
Section 25-10-00). nuts (20) attaching harness locking
handle assembly (38) to seat pan
(6). Install bolts (18), washers (19) and nuts assembly (39).
(20) attaching inertia reel (11) and
shoulder harness (10) to seat back (42). (4). Install screws (36), washers (33) and
nuts (20) attaching lock system assem
(7). Install adjustment rail assemblies (2) bly (47) to seat pan (39).
(Ref. Section 25-10-00). (5). Install seat pan (41) cushion (Ref.
(8). Install back rest cushion (40) (Ref. Section 25-10-00).
Section 25-10-00). (6). Install crew seat assembly (4) in
aircraft.
(9). Install crew seat assembly (4) in
aircraft. 7. Upright Support Assembly
A. Upright Support Assembly Removal
6. Seat Pan Assembly
(Ref. Figure 401)
A. Seat Pan Assembly Removal (1). Remove crew seat assembly (4).
(Ref. Figure 401) (2). Remove seat back assembly (42) (Ref.
Section 25-10-00).
(1). Remove crew seat assembly (4).
(3). Remove and discard cotter pin (26).
(2). Remove seat pan (41) cushion (Ref. Remove nut (27), washers (8 and 51)
Section 25-10-00). and bolt (31) attaching upright support
assembly (43), tie tube assembly (50)
(3). Remove nuts (7), washers (8 and 14), and forward roller assembly (49) to
bushings (24) and screws (17) attaching forward rail holder (46).
side tubes (25) to seat pan assembly
(39). B. Upright Support Assembly Installation
(Ref. Figure 401)
(4). Remove nuts (20), washers (33) and
screws (37) attaching harness locking (1). Install bolt (31), washers (8 and 51) and
handle assembly (38) to seat pan (39). nut (27) attaching upright support
assembly (43), tie tube assembly (50)
(5). Remove nuts (20), washers (33) and and forward roller assembly (49) to
screws (36) attaching lock system forward rail holder (46). Install new
assembly (47) to seat pan (39). cotter pin (26).
(6). Remove nuts (7), washers (8 and 22), (2). Install seat back assembly (42) (Ref.
bushings (23) and bolts (21) attaching Section 25-10-00).
seat pan (39) to seat back assembly (3). Install crew seat assembly (4) in
(42). aircraft.
(7). Remove seat pan (39). 8. Cable Roller
B. Seat Pan Assembly Installation A. Cable Roller Removal
(Ref. Figure 401)
(Ref. Figure 401)
(1). Remove crew seat assembly (4).
(1). Install bolts (21), bushings (23), (2). Remove forward rail stop (1) with pull
washers (8 and 22) and nuts (7) up cable (12) attached.
attaching seat pan assembly (39) to
seat back assembly (42). (3). Remove and discard cotter pin (26).
Remove nut (27), washers (8 and 51)
(2). Install screws (17), bushings (24), and bolt (31) attaching upright support
washers (8 and 14) and nuts (7) assembly (43), tie tube assembly (50)
attaching side tubes (25) to seat pan and forward roller assembly (49) to
(39). forward rail holder (46).
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Rotorcraft Maintenance Manual
(4). Remove and discard cotter pin (52). (2). Install aft rail holder assembly (45)
Remove washer (33) and straight pin (Ref. Section 25-10-00).
(53) that hold cable roller (35) in (3). Install screws (36), washers (33) and
support assembly (43). new nuts (20) attaching lock system
(5). Remove roller (35). assembly (47) to seat pan assembly
(39).
B. Cable Roller Installation (4). Install crew seat assembly (4) in
aircraft.
(Ref. Figure 401)
10. Diagonal Support
(1). Install cable roller (35) in upright
support assembly (43) with straight pin A. Diagonal Support Removal
(53), washer (33) and new cotter pin (Ref. Figure 401)
(52).
(1). Remove crew seat assembly (4).
(2). Route pull up cable (12) through rollers (2). Remove and discard cotter pin (26).
(35) and forward roller assembly (49). Remove nut (27), washers (8 and 29)
and bolt (28) attaching lower end of
(3). Install bolt (31), washers (8 and 51) and diagonal support (44), tie tube assem
nut (27) attaching upright support bly (50) and aft roller assembly (48) to
assembly (43), tie tube assembly (50) aft rail holder assembly (45).
and forward roller assembly (49) to
forward rail holder (46). Install new (3). Remove nut (7), washers (8 and 29) and
cotter pin (26). bolt (30) attaching upper end of
diagonal support (44) to fixed fitting
(4). Install forward rail stop (1) with pull up assembly (32).
cable (12) attached. (4). Remove support (44).
(5). Install crew seat assembly (4) in B. Diagonal Support Installation
aircraft.
(Ref. Figure 401)
9. Lock System Assembly (1). Install bolt (30), washers (8 and 29) and
nut (7) attaching upper end of diagonal
A. Lock System Assembly Removal support (44) to fixed fitting assembly
(32).
(Ref. Figure 401)
(2). Install bolt (28), washers (8 and 29) and
(1). Remove crew seat assembly (4). nut (27) attaching lower end of diagonal
support (44), tie tube assembly (50) and
(2). Remove and discard nuts (20). Remove aft roller assembly (48) to aft rail
washers (33) and screws (36) attaching holder assembly (45). Install new cotter
lock system assembly (47) to seat pan pin (26).
assembly (39).
(3). Install crew seat assembly (4) in
(3). Remove aft rail holder assembly (45) aircraft.
(Ref. Section 25-10-00). 11. Aft Rail Holder Assembly
(4). Remove and discard nuts (20). Remove A. Aft Rail Holder Assembly Removal
washers (33) and bolts (18) attaching
(Ref. Figure 401)
lock system (47) to aft rail holder (45).
(1). Remove crew seat assembly (4).
B. Lock System Assembly Installation
(2). Remove and discard cotter pin (26).
(Ref. Figure 401) Remove nut (27), washers (8 and 29)
and bolt (28) attaching lower end of
(1). Install bolts (18), washers (33) and new diagonal support (44), tie tube assem
nuts (20) attaching lock system assem bly (50) and aft roller assembly (48) to
bly (47) to aft rail holder assembly (45). aft rail holder assembly (45).
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Rotorcraft Maintenance Manual
(3). Disengage lock system assembly (47) B. Forward Rail Holder Installation
from seat adjustment rails (2) by
moving adjustment lever (3) under (Ref. Figure 401)
front of seat pan assembly (39).
(1). Align forward roller assembly (49) in
(4). Remove rail holder assembly (45). upright support assembly (43) and
route pull up cable (12) around roller
assembly (49).
(5). Remove nuts (20), washers (33) and
bolts (18) attaching lock system (47) to (2). Install bolt (31), washers (8 and 51) and
aft rail holder (45). nut (27) attaching support assembly
(43), tie tube assembly (50) and forward
B. Aft Rail Holder Assembly Installation roller assembly (49) to forward rail
holder (46). Install new cotter pin (26).
(Ref. Figure 401)
(3). Install forward rail stop (1) with pull up
(1). Install bolts (18), washers (33) and nuts cable (12) attached.
(20) attaching lock system assembly
(47) to aft rail holder assembly (45). (4). Install crew seat assembly (4) in
aircraft.
(2). Retract lock system (47) by moving
adjustment lever (3) under front of seat 13. Forward Roller Assembly
pan assembly (39).
A. Forward Roller Assembly Removal
(3). Slide aft rail holder assembly (45) onto (Ref. Figure 401)
adjustment rail assembly (2).
(1). Remove crew seat assembly (4).
(4). Install bolt (28), washers (8 and 29) and
nut (27) attaching lower end of diagonal (2). Remove forward rail stop (1) with pull
support (44), tie tube assembly (50) and up cable (12) attached.
aft roller assembly (48) to aft rail
holder (45). Install new cotter pin (26). (3). Remove and discard cotter pin (26).
Remove nut (27), washers (8 and 51)
(5). Install crew seat assembly (4) in and bolt (31) attaching upright support
aircraft. assembly (43), tie tube assembly (50)
and forward roller assembly (49) to
forward rail holder (46).
12. Forward Rail Holder
(4). Remove forward roller (49).
A. Forward Rail Holder Removal
B. Forward Roller Assembly Installation
(Ref. Figure 401)
(Ref. Figure 401)
(1). Remove crew seat assembly (4).
(1). Align forward roller assembly (49) in
upright support assembly (43) and
(2). Remove forward rail stop (1) with pull
route pull up cable (12) around roller
up cable (12) attached.
assembly (49).
(3). Remove and discard cotter pin (26). (2). Install bolt (31), washers (8 and 51) and
Remove nut (27), washers (8 and 51) nut (27) attaching support assembly
and bolt (31) attaching upright support (43), tie tube assembly (50) and forward
assembly (43), tie tube assembly (50) roller assembly (49) to forward rail
and forward roller assembly (49) to holder (46). Install new cotter pin (26).
forward rail holder (46).
(3). Install forward rail stop (1) with pull up
(4). Remove forward rail holder (46). cable (12) attached.
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Rotorcraft Maintenance Manual
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(4). Install new cotter pins (26). (5). Slide attenuation tube (54) up and out
of fixed fitting assembly (32).
(5). Install crew seat assembly (4) in
aircraft. NOTE: When removing bolts (34), tension
springs (55) will fall down inside of upright
17. Attenuation Tube support assemblies (43).
A. Attenuation Tube Removal (6). Remove nuts (20), washers (33) and
bolts (34) attaching fitting assemblies
(Ref. Figure 401) (32) to upright support assemblies (43).
(1). Remove crew seat assembly (4). (7). Slide seat back assembly (42) and
fitting assemblies (32) up and off of
(2). Remove nut (7), washer (8) and bolt support assembly (43).
(56) that attaches attenuation tube (54)
to seat back assembly (42). (8). Remove fitting assembly (32).
(3). Slide attenuation tube (54) up and out B. Fixed Fitting Assembly Installation
of fixed fitting assembly (32). (Ref. Figure 401)
B. Attenuation Tube Installation (1). Slide seat back assembly (42) and fixed
fitting assemblies (32) down onto
(Ref. Figure 401) upright support assembly (43).
(1). Slide attenuation tube (54) down and NOTE: Tension springs (55) and pull up cables
into fixed fitting assembly (32). (12) will have to be lowered down inside of
upright support assembly (43) to line up
(2). Install bolt (56), washer (8) and nut (7)
with fixed fitting assemblies (32) before
attaching attenuation tube (54) to seat
installing bolts (34).
back assembly (42).
(2). Align loop of tension springs (55) with
(3). Install crew seat assembly (4). fitting assemblies (32) and install bolts
(34), washers (33) and nuts (20)
18. Fixed Fitting Assembly attaching fitting assemblies (32) to
A. Fixed Fitting Assembly Removal support assembly (43).
(3). Slide attenuation tubes (54) down and
(Ref. Figure 401)
into fixed fitting assemblies (32).
(1). Remove crew seat assembly (4). (4). Install bolts (56), washers (8) and nuts
(2). Remove forward rail stops (1). (7) attaching attenuation tubes (54) to
seat back assembly (42).
(3). Remove nuts (7), washers (8 and 29) (5). Install bolts (30), washers (8 and 29)
and bolts (30) attaching upper end of and nuts (7) attaching upper end of
diagonal supports (44) to fixed fitting
diagonal supports (44) to fixed fitting
assemblies (32).
assemblies (32).
(4). Remove nuts (7), washers (8) and bolts (6). Install forward rail stops (1).
(56) that attach attenuation tubes (54)
to seat back assembly (42). (7). Install crew seat assembly (4).
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Rotorcraft Maintenance Manual
10
42
40
7
8
14
15
20 (4 17
PL)
20 19 (4 41
33 PL)
55 34 1811(4
PL)
4 7
25 8
54 7 29
8 30
14 44
12 REF 16
15
17 43
32 7
8 39
56
7 7 7
8 43 8 8
3 22 14 14
23 24 16
20 (2 PL) 21 44 REF 17
33 (2 PL) VIEW LOOKING 2 48 15
36 (2 PL OUTBOARD 9
50 26
47
52 27
35 8
20 (2 PL) 53 13
54 29
33 (4 PL)
12 28
37 (2 PL
38
1 45
5 (6 PL)
6 (6 PL)
26
2 46 27
49 8
51
31
20 20
33 47 33
18 18
9G25007A
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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27. Top Panel Assembly Left Hand (2). Press panel (15) surface against hook
tape fasteners to attach.
A. Top Panel Removal
30. Main Covers, Center Beam, LH and RH
(Ref. Figure 402)
A. Main Covers, Center Beam Removal
(1). Disengage captive fasteners that attach
LH top panel (12) to frame. (Ref. Figure 402)
(2). Remove panel (12). (1). Disengage captive fasteners that attach
center beam main covers (14) to frame.
B. Top Panel Installation
(2). Remove main covers (14).
(Ref. Figure 402)
B. Main Covers, Center Beam Installation
(1). Align LH top panel (12) with frame (Ref. Figure 402)
holes.
(1). Align center beam main covers (14)
(2). Engage captive fasteners attaching with frame holes.
panel (12) to frame.
(2). Engage captive fasteners attaching
28. Lower Panel, Right Hand main covers (14).
A. Lower Panel, Right Hand Removal 31. Forward Cover, Center Beam
(Ref. Figure 402) A. Forward Cover, Center Beam Removal
(1). Disengage captive fasteners that attach (Ref. Figure 402)
RH lower panel (13) to frame.
(1). Remove screws (16) and washers (8)
(2). Remove lower panel (13). that attach center beam forward cover
(17) to center beam.
B. Lower Panel, Right Hand Installation
(2). Remove cover (17).
(Ref. Figure 402)
B. Forward Cover, Center Beam Installation
(1). Align RH lower panel (13) with frame
(Ref. Figure 402)
holes.
(1). Align center beam forward cover (17)
(2). Engage captive fasteners attaching with mounting holes in center beam.
panel (13) to frame.
(2). Install screws (16) and washers (8)
29. Side Panel attaching forward cover (17).
A. Side Panel Removal 32. Top Panel Assembly Right Hand
(Ref. Figure 402) A. Top Panel Removal
NOTE: Left and right side panels are typical. (Ref. Figure 402)
(1). Separate hook tape fasteners by pulling (1). Disengage captive fasteners that attach
side panel (15) away from mounting RH top panel (18) to frame.
surface. (2). Remove panel (18).
(2). Remove panel (15). B. Top Panel Installation
B. Side Panel Installation (Ref. Figure 402)
(Ref. Figure 402) (1). Align RH top panel (18) with frame
mounting holes.
(1). Align side panel (15) and hook tape
fasteners with mating surface hook (2). Engage captive fasteners attaching
tape attachments. panel (18).
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33. Roof Panel (2). Remove screws (26 and 27) that attach
interior door handle (25) and remove
A. Roof Panel Removal handle.
(1). Carefully separate hook tape fasteners (4). Remove panel (24).
that attach roof panel (19) to airframe.
B. Door Panel Installation
(2). Remove panel (19).
(Ref. Figure 402)
B. Roof Panel Installation
(1). Align door panel (24) with cockpit door
(Ref. Figure 402) assembly and install washers (30),
screws (29) and decorative caps (28).
(1). Align hook tape fasteners on roof panel
(2). Install interior door handle (25) and
(19) with mating frame fasteners.
attach with screws (26 and 27).
(2). Press panel (19) surface against hook (3). Install cockpit door assembly (Ref.
tape fasteners to attach. Section 52-00-00).
34. InFill Panel 36. Support, Headset Jack
A. InFill Panel Removal A. Support, Headset Jack Removal
(Ref. Figure 402) (Ref. Figure 402)
(1). Remove screws (16) and washers (8) (1). Remove LH center beam main cover
that attach in-fill panel (23) to frame. (14), Ref. Section 25-10-00).
(2). Remove panel (23). (2). Remove screws (20) and washers (21)
that attach headset jack support (22) to
B. InFill Panel Installation center beam.
(2). Install screws (16) and washers (8) B. Support, Headset Jack Installation
attaching panel (23).
(Ref. Figure 402)
35. Door Panel, Cockpit (1). Attach connector and jack receptacles
to headset jack support (22).
A. Door Panel Removal
(2). Align support (22) with mounting holes
(Ref. Figure 402) in center beam.
NOTE: Left and right side door panels are typi (3). Install screws (20) and washers (21)
cal. attaching support (22) to center beam.
(1). Remove cockpit door assembly (Ref. (4). Install LH center beam main cover (14)
Section 52-00-00). (Ref. Section 25-10-00).
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22 20
21 2
5 14
(EACH SIDE) 12 1
19
23
18
19
8
(12 PL) 12 (REF)
16 3
(12 PL) 14
(EACH SIDE)
24 15
6
26
17 27 11
28 13
(7 PL) 29
30 25
10
7 (7 PL)
8
9G25008A
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CREW COMPARTMENT
INSPECTION/TEST
1. Crew Compartment Adhesive Paste, Acrylic (C422)
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
MAIN
TUBE
SEAT
FRAME
FIXED FITTING
0.1 IN
(2.54 mm)
CREW
SEAT
SPACER
25
9G25025
(c). Inertia reel for damage, wear, and (d). Belts for cuts, nicks, tears, or other
smooth operation as follows: damage. No damage permitted.
1). Make sure harness strap can not (e). Do a check for correct operation of
be pulled out of inertia reel when buckles, latch and release. No defects
fully extended. permitted.
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D. Trim Inspection (Area 1) NOTE: Repairs are not recommended when the
center of the damage is less than 1.97 in.
Consumable Materials
(50 mm) from a fastener or 3.15 in. (80
(Ref. CSPSPM)
mm) from edge of panel.
Item Nomenclature (b). Repair holes or impact damage on
C714 Tape, Adhesive, Clear composite honeycomb panels. Maxi
C422 Adhesive Paste, Acrylic mum repair dimension, 1.57 in. (40
C812 Filler Compound mm).
(2). Examine panels and fuselage structure (2). Make sure position lock pin mechanism
for missing or loose hook and loop tape releases.
fasteners. If loose, bond with adhesive
paste (C422). (3). Hold lock mechanism unlocked and
move seat forward-up and aft-down.
(3). Make sure interior lights are service Make sure seat moves smoothly
able and electrical connections have no through full travel.
damage. No damage permitted.
(4). Move seat forward-up and aft-down
(4). Examine carpet for cuts, tears, correct and release lock mechanism at each
installation, or other unserviceable lock position. Make sure seat locks in
conditions. all positions and lock pins fully engage.
(5). Examine composite or laminated panels F. Seat Restraint System Operational Test
for correct installation and condition.
(1). Latch lap belt and shoulder harness.
(6). Examine panels for dents, scratches,
Make sure latch mechanism operates
and impact damage.
correctly. Make sure straps do not
NOTE: Repairs are not recommended for disengage from buckle unless released
scratches or dents which are less than 1.2 by buckle operation.
in. (30.5 mm) from a fastener or 1.97 in.
(50 mm) from edge of panel. (2). Move manual control handle forward to
the manual lock position. Make sure
(a). Repair scratches or dents with filler straps lock. Do again at one other
compound (C812). position.
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ROTORCRAFT MAINTENANCE MANUAL
Section
252000
Cabin Compartment
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page 1
25-20-00 Original
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Rotorcraft Maintenance Manual
ATTENUATION
THREE-POINT TUBES
RESTRAINT SYSTEM
FOUR-POINT
RESTRAINT SYSTEM
9G25018A
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Rotorcraft Maintenance Manual
PSU AFT
CLOSEOUT PANEL
PSU FWD
AREA LIGHT
FWD ROOF PANEL
THRESHOLD
CABIN CARPET
CABIN FLOOR
9G250031B
Page 3
25-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
WINDOW REVEAL
TRAPPING STRIP
PULL HANDLE
DOOR PANEL
AFT BULKHEAD
SIDEWALL PANEL PANEL
SIDEWALL PANEL
BAGGAGE
CLOSEOUT
PANEL
9G250032A
Page 4
Original 25-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
CLOSEOUT
PANELS
ROOF PANELS
CLOSEOUT VENT GASPER
PANEL
CLOSEOUT
PANELS
THRESHOLD AREA LIGHT
VENT GASPER
THRESHOLD
CARPET
FLOOR
STRUCTURE HOOK
DOOR STRUCTURE TAPE
TRAPPING STRIP
PULL HANDLE
SIDE PANEL
AFT BULKHEAD
PANEL
HEAT VENT
FWD BULKHEAD
PANEL 9G25004B
Restraint system does not Malfunction of buckle Replace harness assembly. 252000
lock or release properly. mechanism.
1. Cabin Seat Assembly (2). Install bolts (8), bushings (12), washers
(5 and 11) and nuts (4) attaching
A. Cabin Seat Assembly Removal shoulder restraint harness (13) to seat
tubes.
(Ref. Figure 401)
(3). Torque nuts.
(1). Depress spring loaded collar to disen
gage BROWNLINE fittings (1) on each 3. Cabin Seat Fabric Assembly
end of attenuation tube (2) to release A. Cabin Seat Fabric Removal
cabin seat assembly (2).
(Ref. Figure 402)
(2). Remove seat assembly (2).
(1). Remove cabin seat assembly from
B. Cabin Seat Assembly Installation aircraft.
(1). Align cabin seat assembly (2) with seat (3). Remove existing seat fabric assembly
anchor plates (3). (1).
B. Cabin Seat Fabric Installation
(2). Depress spring loaded collar to engage
BROWNLINE fittings (1) on each end (Ref. Figure 402)
of cabin seat assembly (2) and insert
into mating roof and floor anchor plates (1). Install cabin seat fabric assembly (1)
(3) to secure. Floor attachments should around seat pan (4) and secure to seat
be secured first, and then ceiling back frame.
fittings. NOTE: Tension seat fabric to seat pan per the
following steps.
(3). Ensure fitting collars have fully and
properly engaged mating base attach (2). Make a bowline knot (2) (Ref. stage 1)
ments. on one of cord (3) ends.
Page 401
25-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
13
3
1
2
5 8
12 FOUR-
5 POINT
RESTRAINT
11 1
4 1
HARDWARE PATTERN
TYPICAL 3
9
10 9
13 6
4
7 5
HARDWARE PATTERN
TYPICAL
13
9G25010C
1. BROWNLINE FITTING 8. BOLT
2. ATTENUATION TUBE/SEAT ASSEMBLY 9. WASHER
3. ANCHOR PLATES 10. WASHER
4. NUT 11. WASHER
5. WASHER 12. BUSHING
6. BOLT 13. RESTRAINT HARNESS
7. BUSHING
Figure 401. Cabin Seats/Restraint System
Page 402
Revision 12 25-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(1). Disengage captive fasteners that attach NOTE: Both right and left sides are typical, un
wall panel (19), if applicable. less specified.
(2). Carefully separate hook tape fasteners (1). Remove screws (1) that attach carpet
by pulling panel (19) away from thresholds (2) to floor.
mounting surface. (2). Pull cabin carpet (3) up from hook tape
B. Wall Panel Installation fasteners to remove.
B. Cabin Carpet Installation
(Ref. Figure 403)
(Ref. Figure 403)
(1). Align wall panel (19) and hook tape
fasteners with mating surface hook (1). Press cabin carpet (3) down onto hook
tape attachments. Press surfaces tape fasteners.
together to secure.
(2). Install screws (1) to attach carpet
(2). Engage captive fasteners, if applicable. thresholds (2) and carpet (3) to floor.
Page 403
25-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
8. Forward and Aft Roof Panels (3). Install hardware securing roof panel to
(Commercial and Business) support structure.
A. Forward and Aft Roof Panels Removal 10. Area Light, Cabin Roof
(Ref. Figure 403) A. Area Light Removal
(1). Remove hardware that secures roof (Ref. Figure 403)
panels (6) to support structure.
(1). Remove screws (8 and 22) that attach
(2). Disengage pull pins (4) and guide pins area light (10) to light support unit (9)
(5) that hold forward and aft roof and light support plate (21).
panels (6) to adjacent passenger service
(2). Disconnect electrical connection from
units (PSU) (7) and interior perimeter
light (10) and remove.
support structures.
B. Area Light Installation
(3). Remove roof panels (6).
(Ref. Figure 403)
B. Forward and Aft Roof Panels Installation
(1). Install electrical connection to area
(Ref. Figure 403) light (10).
(1). Align forward and aft roof panels (6) (2). Install screws (8 and 22) attaching light
with adjacent passenger service units (10) to light support unit (9) and light
(PSU) (7) and interior perimeter support plate (21).
support structures.
11. Light Support Plate
(2). Engage pull pins (4) and guide pins (5)
to secure panels (6) in place. A. Light Support Plate Removal
(3). Install hardware securing roof panels to (Ref. Figure 403)
support structure.
(1). Remove screws (8 and 22) that attach
9. Center Roof Panel (Commercial and area light (10) to light support unit (9)
Business) and light support plate (21).
(2). Remove pull pins (4) and guide pins (5) B. Light Support Plate Installation
that hold center roof panel (6) between (Ref. Figure 403)
passenger service units (PSU) (7) and
interior perimeter support structures. (1). Prepare surface for electrical bond (Ref.
CSP-SPM).
(3). Remove roof panel (6).
(2). Install screws (11) and washers (12)
B. Center Roof Panel Installation attaching light support plate (21) to
roof mounting surface.
(1). Align center roof panel (6) with adja
cent passenger service units (PSU) (7) (3). Install electrical connection to area
and interior perimeter support struc light (10).
tures.
(4). Install screws (8 and 22) attaching light
(2). Install pull pins (4) and guide pins (5) (10) to light support unit (9) and light
to secure panel (6) in place. support plate (21).
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Rotorcraft Maintenance Manual
Page 405
25-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 406
Original 25-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
23
23
14
12 (43 PL) 14
21 14
11 (43 PL) 7
13
7 12
9 21
6
12
22
10 6
18 11
8 6
2 12
1 4 5 11
20
3
17
12
15
25
24
16
19
25 25
19
25
9G25009B
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25-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
18. Cabin Carpet (Utility) (3). Install screws (4) and washers (5)
securing vent gasper closeouts (6) to
A. Cabin Carpet Removal roof support brackets.
(Ref. Figure 404)
20. Area Light, Cabin Roof
(1). Remove screws (1) that attach carpet
thresholds (2) to floor. A. Area Light Removal
(2). Pull cabin carpet (3) up from hook tape (Ref. Figure 404)
fasteners to remove.
(1). Remove screws (9 and 10) that attach
B. Cabin Carpet Installation area light (11) to light support plate
(12).
(1). Press cabin carpet (3) down onto hook
tape fasteners. (2). Disconnect electrical connection from
light (11) to remove.
(2). Install screws (1) to attach carpet
thresholds (2) and carpet (3) to floor. B. Area Light Installation
19. Roof Panel (Utility) (1). Install electrical connection to area
A. Roof Panel Removal light (11).
(Ref. Figure 404) (2). Install screws (9 and 10) attaching light
(11) to light support plate (12).
(1). Remove screws (4) and washers (5) that
attach vent gasper closeouts (6) to roof 21. Light Support Plate
support brackets.
A. Light Support Plate Removal
(2). Disengage hardware that attaches roof
panel (7) to closeout panels (8). (Ref. Figure 404)
(3). Remove roof panel (7) by pulling down
(1). Remove roof panel (7) (Ref. Section
from hook tape fasteners. 25-20-00).
B. Roof Panel Installation
(2). Remove screws (9 and 10) that attach
(1). Align roof panel (7) with hook tape area light (11) to light support plate
fasteners in closeout panels (8) and (12).
press together to secure.
(3). Remove screws (4) and washers (5) that
(2). Engage hardware that attaches roof attach light support plate (12) to
panel (7) to closeout panels (8). support brackets.
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
B. Light Support Plate Installation (2). Install light support plate (12) (Ref.
Section 25-20-00).
(1). Prepare surface for electrical bond (Ref.
CSP-SPM). (3). Install roof panel (7) (Ref. Section
(2). Install screws (4) and washers (5) 25-20-00).
securing light support plate (12) to
support brackets. 23. Door Panel and Trapping Strip
(3). Install screws (9 and 10) securing area
A. Door Panel and Trapping Strip Removal
light (11) to light support plate (12).
(4). Install roof panel (7) (Ref. Section (Ref. Figure 404)
25-20-00).
(1). Remove screws (4) that attach trapping
22. Closeout Panels strip (16) to door frame (18).
A. Closeout Panels Removal
(2). Remove screws (14) and washers (15)
(Ref. Figure 404) that attach lower door panel (17) to
door frame (18).
(1). Remove roof panel (7) (Ref. Section
25-20-00). (3). Remove door panel (17) and trapping
(2). Remove light support plate (12) (Ref. strip (16).
Section 25-20-00).
B. Door Panel and Trapping Strip
(3). Remove screws (4) and washers (5) that Installation
attach closeout panels (8) to roof
support structure. (1). Install screws (14) and washers (15)
B. Closeout Panels Installation attaching lower door panel (17) to door
frame (18).
(1). Install screws (4) and washers (5)
attaching closeout panels (8) to roof (2). Install screws (4) attaching trapping
support structure. strip (16) to door frame (18).
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25-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
12 8
7
8 5 (4 PL)
4 (4 PL)
5 (45 PL)
5 (4 PL) 6
4 (45 PL) 4
4 (4 PL) 11 5
1 (9 PL) 2 8
6 9 (2 PL) 10 (2 PL)
2
3
18
16
4 (5 PL)
18 17
14
15
19
13
13
13
13
9G25015A
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
CABIN COMPARTMENT
INSPECTION/TEST
1. Cabin Compartment (6). Examine seat fabric for tears, cuts, or
other damage.
A. Seat Inspection (Area 2)
(a). The maximum permitted separation
(1). Examine cabin seats for correct instal at fabric seams, 0.875 in. (22.23
lation and condition. mm) (across seam) and a width of 1
(2). Examine quick disconnect mechanism in. (25.4 mm) (along seam).
on cabin seat main tubes for correct
operation and damage. (7). Examine seat support straps for wear,
cuts, or tears. None permitted.
(a). Make sure they engage and lock into
anchors when seat is installed. B. Seat Energy Absorption System (EAS)
Maximum play permitted at upper Inspection
and lower attach points, 0.020 in.
(Ref. Figure 601)
(0.508 mm).
(b). Examine roof and floor anchors for (1). Measure the clearance between the
correct installation and condition. fixed fitting and sliding fitting on the
Maximum scratch and gouge depth main tube on the two sides of each
permitted, 0.012 in. (0.305 mm). cabin seat. Maximum clearance
permitted, 0.1 in. (2.54 mm)
(3). Examine Energy Absorption System
(EAS) aluminum tubes for condition. C. Seat Restraint System Inspection
No deformation or cracks are permitted. (Area 2)
No damage through external coating is
(1). Examine restraint system for correct
permitted.
installation and operation as follows:
(a). Make sure aluminum tube is aligned
with seat main tube. (a). Belt adjust mechanism for correct
operation and condition. No damage
(b). Examine plastic cap that attaches permitted.
EAS aluminum tube to seat main
tube. Damage to cap can be an (b). Area of belt that goes through adjust
indication EAS aluminum tube is mechanism for wear. No damage to
deformed or damaged. No damage or belt permitted.
deformation permitted.
(c). Belts for cuts, nicks, tears, or other
(4). Repair corrosion to a maximum depth damage. No damage permitted.
of 0.010 in. (0.254 mm) (Ref. CSP-
SPM). (d). Do a check for correct operation of
buckles, latch and release. No defects
(5). Make sure seat fabric is clean. permitted.
Page 601
25-20-00 Revision 33
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
0.1 IN
FIXED FITTING (2.54 mm)
ASSEMBLY
SLIDING FITTING
9G25026
Page 602
Revision 33 25-20-00
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
D. Trim Inspection (Area 2) (3). Make sure interior lights are service
able and electrical connections have no
damage. No damage permitted.
Consumable Materials
(Ref. CSPSPM) (4). Examine carpet for cuts, tears, correct
Item Nomenclature installation, or other unserviceable
conditions.
C422 Adhesive Paste, Acrylic
C714 Tape, Adhesive, Clear (5). If installed, examine overhead passen
ger service units for correct operation
and damage. No damage permitted.
(1). Examine soft insulation panels or hard
wall panels for condition and wear. (a). Make sure air vent gaspers move
freely and are not clogged.
(a). Make sure panels are clean and have (b). Do a operational check of each light.
no stains, tears, or corrosion on metal
components. For procedures to clean (6). Make sure you can read the placards
(Ref. CSP-SPM). and decals.
(7). Make sure placards and decals are
NOTE: Repair minor damage to panels, use correctly installed.
clear adhesive tape (C714).
E. Seat Operational Test
Adhesive Paste, Acrylic (C422)
(1). Make sure seats fold up into their
stowed position and attach with strap.
F. Seat Restraint System Operational Test
(1). Latch lap belt and shoulder harness.
(2). Examine panels and fuselage structure Make sure latch mechanism operates
for missing or loose hook and loop tape correctly. Make sure straps do not
fasteners. If loose, bond with adhesive disengage from buckle unless released
paste (C422). by buckle operation.
Page 603
25-20-00 Revision 33
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page 604
Revision 33 25-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
255000
Baggage
Compartment
Interior Trim
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
25-50-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
HOOK TAPE
HOOK
TAPE
HOOK
TAPE
THRESHOLD
CARPET
HOOK
TAPE
HOOK
TAPE
HOOK
TAPE HOOK
HOOK TAPE
TAPE
HOOK
TAPE 9G250051A
Page 2
Original 25-50-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
NOTE
LIGHT ASSEMBLY
INTERIOR
NOTE DOOR PANEL
DOOR LATCHING
MECHANISM
HOOK TAPE
BAGGAGE DOOR
ASSEMBLY
HOOK TAPE
PANEL ASSEMBLY
INTERIOR
SOFT PANEL
(1). Align closeout panel (2) with mounting (4). Remove nuts (17) and washers (14)
surfaces. that attach mounting bracket (16).
Page 401
25-50-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 402
Revision 3 25-50-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
17
13
14 12 14
9
ROTATED
13
14
15
16
14 13
11
10 NOTE
19
18
1
1
5
4
6 8
20
Page 403
25-50-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 404
Original 25-50-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C422 Adhesive Paste, Acrylic
C714 Tape, Adhesive, Clear (2). Inspect panels and fuselage structure
for missing or loose hook tape fasteners.
If loose, reattach to structure with
(1). Inspect baggage area soft insulation adhesive paste (C422).
panels for general condition and wear.
(a). Verify that insulation panels are (3). Inspect carpeting for cuts, tears,
clean and free from discoloration, security or other unserviceable condi
stains, tears or corrosion on metallic tions. Repair as necessary.
components. For cleaning procedures
(Ref. CSP-SPM). (4). Verify that interior light is serviceable
NOTE: Minor repairs may be made to these and electrical connections are free from
panels to prevent continuing degradation by damage or deterioration.
using clear adhesive tape (C714) to cover
the damaged area and draw a tear or hole (5). Inspect placards and decals for security
closed. and legibility.
Section
255500
Cargo Hook System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
25-55-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
QUICK
RELEASE PIN QUICK RELEASE PIN
(SEE NOTE) (SEE NOTE)
PIN LINK LINK ASSEMBLY
LINK
ASSEMBLY CABLE CABLE
FORWARD
PIN LINK
fwd saddle clamp
LH FWD LANDING
RH AFT LANDING GEAR FITTING
GEAR FITTING
RH FWD LANDING
GEAR FITTING
CYCLIC STICK
CARGO HOOK SERVICE LOOP
MECHANICAL
RELEASE LEVER
LOAD BEAM
LOAD INDICATOR
ELECTRICAL CONNECTOR MANUAL RELEASE
ELECTRICAL RELEASE CABLE CONNECTION
CONNECTOR
MANUAL CARGO HOOK
RELEASE
ELECTRIC CARGO
HOOK RELEASE
cyclic grip rotated 9G25014C
Page 2
Revision 34 25-55-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 101
25-55-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 102
Revision 25 25-55-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(2). Disconnect cargo hook electrical (4). Tighten nuts and install new cotter
connector (1), load indicator electrical pins.
connector (2) and mechanical release
control cable connector (3). (5). Install cable clamps (21) attaching
connector lines (1, 2 and 3) to cargo
(3). Remove quick release pins (4) from Fwd hook cable (6).
and Aft pin links (5). D. Cargo Hook System Installation
(4). Remove pin links (5) that attach cargo (Ref. Figure 401)
hook cables (6) and cargo hook (7) to
landing gear saddle clamp assemblies Power Off
(8)
(Ref. Figure 401) (1). Align cargo hook cable attach hardware
with landing gear saddle clamp assem
(1). Remove cable clamps (21) that attach blies (8) and install pin links (5).
connector lines (1, 2 and 3) to cargo
hook cable (6). (2). Install quick release pins (4) into Fwd
and Aft pin links (5).
(2). Remove and discard cotter pins (9).
Remove nuts (10), washers (11) and (3). Connect cargo hook electrical connector
bolts (12) that attach clevis' (13) to (1), load indicator electrical connector
hook connector (14). (2) and mechanical release control cable
connector (3).
(3). Remove and discard cotter pin (17).
(4). Restore power to aircraft (Ref. Section
Remove nut (18), washer (19) and bolt
96-00-00).
(16) that attach load cell (20) to cargo
hook (7). (5). Verify cargo hook Vne card is installed
in aircraft (Ref. Section 11-00-00).
(4). Remove and discard cotter pin (17).
Remove nut (18), washer (19) and bolt (6). Perform Set Cargo Hook (Load Cell)
(15) that attach load cell (20) to hook Calibration Code Menu (Ref.
connector (14). CSP-900RMM-3, Section 95-30-00).
Page 401
25-55-00 Revision 10
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
MAX WORKING
LOAD 2200 LB
CARGO HOOK PLACARD
(IF INSTALLED REF. SB900-073)
8
4
8
5
1
13 (2 PL) 9 (2 PL)
11 (2 PL)
10 (2 PL)
7
19 17
3
18 2
12 (2 PL) 21
14
15
20 17
18
19 note: ENSURE QUICK RELEASE
16 PIN HEAD FACES ``UP''
AFTER INSTALLATION
9G25012B
Page 402
Revision 25 25-55-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
2. Cargo Hook Cockpit, Mechanical Release 3. Cargo Hook Cockpit, Mechanical Release
Cable Assembly Bracket
NOTE: Pilot or copilot cargo hook mechanical A. Cargo Hook Cockpit, Mechanical Release
release cable attachments are the same ex Bracket Removal
cept for routing through fuselage.
(Ref. Figure 402)
A. Cargo Hook Cockpit, Mechanical Release
(1). Remove cargo hook cockpit mechanical
Cable Assembly Removal release cable assembly handle (1).
(Ref. Figure 402) (2). Remove jam nut (4) and washer (5) that
attach cable assembly (3) to cargo hook
(1). Remove cargo hook cockpit mechanical cockpit mechanical release bracket (2).
release cable assembly handle (1).
(3). Remove nut (8) that attaches bracket
(2). Remove jam nut (4) and washer (5) that (2) to cyclic tube.
attach cable assembly (3) to cargo hook
cockpit mechanical release bracket (2). (4). Remove bracket (2).
(3). Remove tiedown straps (12). B. Cargo Hook Cockpit, Mechanical Release
Bracket Installation
(4). Remove nuts (9), washers (6 and 7) and
bolts (10) that attach loop clamps (11) (Ref. Figure 402)
to cable support clips (13).
(1). Install cargo hook cockpit mechanical
(5). Disconnect cable assembly (3) attach release bracket (2) and attach with nut
point at the fuselage doubler (14). (8). Torque nut.
(2). Install jam nut (4) and washer (5)
(6). Remove cable assembly (3) from under
attaching cargo hook cockpit mechani
floor fuselage routing.
cal release cable assembly (3) to
B. Cargo Hook Cockpit, Mechanical Release bracket (2).
Cable Assembly Installation (3). Install cable assembly handle (1).
(Ref. Figure 402) 4. Cable Support Clip
(1). Route cargo hook mechanical release A. Cable Support Clip Removal
cable assembly (3) under floor and
secure through loop clamps (11). (Ref. Figure 402)
(2). Install bolts (10), washers (6 and 7), (1). Remove nuts (9), washers (6 and 7) and
and nuts (9) attaching loop clamps to bolts (10) that attach loop clamps (11)
cable support clips (13). Torque nuts. and cable support clips (13) to the
plough beam.
(3). Connect cable assembly (3) at the
fuselage doubler (14). (2). Separate loop clamps (11) from clips
(13) and remove.
(4). Attach cable assembly (3) to cargo hook
B. Cable Support Clip Installation
cockpit mechanical release bracket (2)
by installing washer (5) and jam nut (Ref. Figure 402)
(4).
(1). Join loop clamps (11) and cable support
(5). Install cargo hook cockpit mechanical clips (13).
release cable assembly handle (1).
(2). Install bolts (10), washers (6 and 7) and
(6). Secure cable assembly (3) with tiedown nuts (9) attaching loop clamps (11) and
straps (12). clips (13) to plough beam. Torque nuts.
Page 403
25-55-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
1
2
3 5
3 2
12 8
12
4
11
10
13
14
6
13
PILOT'S SIDE SHOWN
COPILOT'S SIDE SIMILAR
9G25013
1. HANDLE 8. NUT
2. BRACKET 9. NUT
3. CABLE ASSEMBLY 10. BOLT
4. JAM NUT 11. LOOP CLAMP
5. WASHER 12. TIEDOWN STRAP
6. WASHER 13. CABLE SUPPORT CLIP
7. WASHER 14. FUSELAGE DOUBLER
Figure 402. Cargo Hook Mechanical Release
Page 404
Original 25-55-00
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Rotorcraft Maintenance Manual
Page 405
25-55-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
RBL
0.51
13
FS
155
3 P600
J600
9
1
7 10
5
11
4 12
2 (20 PL) 9G25-021A
1. DOUBLER 8. WASHER
2. RIVET 9. NUT
3. WIRE HARNESS W314 10. SHORTING PLUG
4. ELECTRICAL RELEASE CONNECTOR 11. SHORTING PLUG
5. LOAD INDICATOR CONNECTOR 12. DUST CAP
6. MECHANICAL RELEASE CONNECTOR 13. DUMMY RECEPTACLE
7. SCREW
Figure 403. Wire Harness W314, Cargo Hook
Page 406
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Rotorcraft Maintenance Manual
Page 601
25-55-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
LUG
9G25-024
Page 602
Revision 34 25-55-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
C. Inspection for the Aft LH and Aft RH CSP-SPM, Section 20-40-00, Paint
Saddle Assemblies Removal Chemical).
(Ref. Figure 601) (4). Examine lug to saddle radius area with
a 10X magnification glass for cracks.
(1). Remove aft crosstube cover assembly.
(a). No cracks permitted.
(2). Examine the lugs of aft LH and RH (5). Touch up lug to saddle radius area of
saddles to make sure they are not bent. aft LH and aft RH saddles.
(a). Bent lugs not permitted. (a). Apply a chemical coating (ref.
CSP-SPM, Section 20-40-00,
Make sure that paint stripper Aluminum Alloy, Surface Touch-up
CAUTION does not contaminate bushing or Treatment).
insert of aft LH and RH saddles.
(b). Apply primer and paint to match
(3). Remove paint from lug to saddle radius original (ref. CSP-SPM, Section
area of aft LH and aft RH saddles (ref. 20-30-00).
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Rotorcraft Maintenance Manual
DIM. D
DIM. B
DIM. C
9G2502
Page 604
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Rotorcraft Maintenance Manual
D. Cable (Wire Rope) Inspection (1). Make sure the CARGO HOOK/HOOK
circuit breaker is pressed to full in the
(Ref. Figure 602). (closed) position.
(1). Examine wire rope for: (2). Make sure the manual release knob on
(a). Dirt, grit, and foreign objects. the left side of the hook assembly is
serviceable without a load attached.
1). If there is contamination, clean the
wire rope. NOTE: This test must be done with the roto
rcraft operated in a low hover position, be
(b). Pitting and corrosion. cause the cargo hook hangs below the land
ing gear skid tubes.
1). No pitting or corrosion permitted.
Make sure that the load beam
(c). Frayed, split, and broken wires. CAUTION on the cargo hook is engaged in
the locked position before a load is attached.
1). No frayed, split, or broken wires
permitted. (3). Attach a load in the cargo hook load
(d). Stretched eyelets. beam and keeper.
1). No stretched eyelets permitted. (4). When the weight is suspended, and the
selection is made on the IIDS panel
(2). Remove cargo hook system (ref. Section menu for HOOK WT., the load indica
25-55-00, Removal/Installation). tion must read HOOK WT. xxxx LBS
on the alphanumeric display.
(3). Measure the length of forward LH and
RH wire ropes (Dimension D). The cargo hook must stay
WARNING closed as it moves through
(a). Dimension D must be 47.125 to all positions of extreme travel (for
47.375 inch (119.698 to 120.333 ward, aft, and side-to-side).
cm).
(5). With a lead line attached to the cargo
(b). If the measurement is not within the hook, with the ground personnel a safe
specified length, replace the wire distance from the rotorcraft, pull aft,
rope. downward, forward, and side-to-side
(4). Measure the length of aft LH (Dimen with an approximate 30 degree angle of
sion B) and RH (Dimension C) wire displacement on the hung load.
ropes.
(6). Activate electrical release on the
(a). Dimension C must be 37.195 to command station cyclic control grip to
37.445 inch (94.475 to 95.110 cm). release hung load.
(b). Dimension B must be 37.195 to (a). The load beam must release the
37.445 inch (94.475 to 95.110 cm). attached load.
(c). If the measurement is not within the (7). After the aircraft has landed, reattach
specified length, replace the wire load on hook.
rope.
(8). Return to low hover to test mechanical
2. Cargo Hook System Tests release lever.
A. Cargo Hook System Functional Test (9). With the aircraft in a low hover
position, activate mechanical release
NOTE: Do the functional test procedure when handle to release hung load.
the cargo hook system is first installed on
the aircraft and after replacement or over (a). The load beam must release the
haul of the hook system. attached load.
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Rotorcraft Maintenance Manual
B. Cargo Hook System Operational Test (3). Make sure the manual release knob on
the left side of the hook assembly is
NOTE: Do the operational test procedure when operational without a load attached.
it is necessary to make sure that the cargo (4). On ELECTRICAL MASTER panel,
hook system release mechanisms operate set POWER switch to BAT/EXT
correctly. position.
(1). Make sure the CARGO HOOK/HOOK (5). Activate electrical release on the
circuit breaker is pressed to full in command station cyclic control grip to
(closed) position. do a check of the release mechanism at
the cargo hook.
(2). Make sure installation and security of (6). Activate mechanical release handle on
mechanical release cable, electrical the command station cyclic control stick
release and load indication wire to do a check of the release mechanism
harness and connectors. at the cargo hook.
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Rotorcraft Maintenance Manual
Section
256000
Emergency
Equipment
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
EMERGENCY EQUIPMENT
DESCRIPTION AND OPERATION
1. Emergency First Aid Kit B. First Aid Kit Contents
Periodically check kit contents to ensure an
A. First Aid Kit adequate supply of medical items. Purchase
individual items locally.
The Emergency First Aid Kit uses a plastic Kit contents include a direction sheet and the
case that meets Federal Aviation Regulation following eight packaged items: adhesive and
(FAR) 27.8530 requirements for fire protection. plain bandage compresses, iodine, swabs,
The case has a 129 cubic inch capacity (3.00 x ammonia inhalants, burn ointment, tourni
5.00 x 8.62 inches) and weighs 1.3 pounds quet, forceps, and scissors. The contents of the
maximum. The case assembly includes a kit meet or exceed the requirements of Federal
handle and a snap fastener. Aviation Authority (FAA) Specification 121,
Appendix A for aircraft with a passenger
The case is opened by off-setting the snap capacity of seven persons or less.
fastener with a counterclockwise movement of
To purchase a replacement kit, contact: The
the thumb and forefinger.
Boeing Company (formerly - McDonnell
Douglas Helicopter Systems)
The kit is located in the right hand side wall 5000 East McDowell Road, Mesa, AZ 85215
stowage pocket of the baggage area. Attn.: New Parts Sales.
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.
Section
256010
Rescue Hoist
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
EMERGENCY EQUIPMENT
DESCRIPTION AND OPERATION
1. Rescue Hoist Variable Speed Controller is a highly efficient
speed control which incorporates the latest
A. Description (PWM) Pulse Width Modulated speed control
techniques. Hoist speed control is accom
The Rescue Hoist System provides a means for plished by a speed command applied to the
lowering and raising personnel from an controller from either the variable speed
airborne helicopter. Operation is from either operator control or the constant speed priority
the crew station or pilot station. The system is override pilots control switch.
comprised of a Hoist Assembly, Pendant
Control Assembly, Electronic Variable Speed Internal power MOSFET switching elements
Controller; interconnection Electrical Control control the amount of average DC voltage
Pendant Cable, and a Pilot Display Assembly. applied to the hoist motor. The greater the
deflection of the thumbwheel on the hoist
Hoist Assembly is a multiple layered type operators Pendant Control Assembly, the
drum design with a cable capacity of 245 feet greater average DC voltage applied to the
of 3/16 dia. 19 x 7 const. (Spin Resistant motor, hence, faster hoisting speeds.
type). Reduction gearing is the planetary type.
Drive train includes a fail-safe mechanically The Controller Assembly being greater than
actuated load brake. Hoist is driven with a 28 95% efficient dissipates minimal power. A heat
VDC electric motor, which includes a totally sink on the side of the controller is used to
enclosed fan cooling and an integral motor remove heat from the controller and installa
brake. tion must be either horizontal with heat sink
facing up or vertical. The controller incorpo
Limit switches are directly coupled to the hoist rates digital electronics which process the hoist
drum to control cable fully extended and limit switch information and limits the hoist
intermediate cable positions (hook approach to speed if an intermediate switch is actuated
aircraft and approach to cable fully-extended and inhibits further hoist movement if a stop
switch). A cable fully retracted switch is built switch is actuated.
into the cable level-wind nut assembly to Controller's digital electronics control the
assure proper homing of the hook when hoist priority of the control inputs from the hoist
is not in service. Redundant switches are used operator or the pilot control. The pilot has
and the mechanical mounting techniques complete priority over the hoist operator and
employed ensure fail-safe operation. the hoist is automatically set to the 600 lb
mode. Pilot's command is fixed-speed with
In the operation of the hoist, the cable rate is
automatic slow downs and stops when the
automatically slowed to a safe speed whenever cable extremes are reached.
the hoist is operated in the cable zone con
trolled by the fail-safe redundant intermediate The controller processes cable position
switch. information from the hoist. Position informa
tion is absolute and will continue to provide
The Hoist also incorporates a cable payout cable position information if power is inter
potentiometer driven by the output of the limit rupted. Cable position information is processed
switch drive mechanism and provides a signal and digitally transmitted to hoist operator's
(proportional to the length in feet of cable control display and pilot's display assembly.
extending from the hoist) to the cable payout
display on the control pendant. Cable payout information is for reference only
and should not be used for helicopter position
A cycle (events) counter is included which is information. The cable payout cannot account
operated by a magnetically actuated reed for cable stretch due to hook loads, therefore,
switch to count drum revolutions. Divide this there is a tolerance at the full-in or full-out of
number by 334 to determine full hoist cycles. plus or minus 3 feet.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
The controller assembly incorporates the electrical connector for interfacing with the
following safety features: Controller.
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Rotorcraft Maintenance Manual
may be operated with loads up to 600 lbs at be selected until the present load is removed
speeds up to 100 feet per minute. from the cable.
An over temperature sensing switch is
With load selection switch actuated to select embedded in the winding of the electric motor
at a temperature critical location. Prolonged
hoist operation in the 250 lb capacity, opera
operation of the hoist system under high
tion at the hoist control with loads applied to
temperature ambients exceeding design limits
hoist cable exceeding 250 lbs will cause the will result in triggering the over motor
motor warning light to flash and in this mode warning light. Critical over temperature
(250 lb selection), the hoist control circuitry conditions within the motor winding results in
will automatically shift and latch the hoist actuation of the sensor which controls the
system to operate in the 600 lb mode. The motor warning light. The motor warning light
hoist system will stay latched in the 600 lb remains illuminated until the motor cools or
mode and the motor warning light will main power to the controller is switched off.
continue to flash until the system is reset by Hoisting operation must be completed at the
switching the load select switch to the 600 lb earliest moment after motor warning light is
mode. Hoist operation can continue in the 600 illuminated, prolonged operation of equipment
lb mode and the high speed mode should not will result in motor damage.
EMERGENCY EQUIPMENT
MAINTENANCE PRACTICES
1. Rescue Hoist Installation Ensure no load is attached to
CAUTION hoist without strut assembly
(23) in position and secured at upper and
A. Install Hoist, Support And Strut
lower points.
(3). Attach support assemblies (9 and 10) (9). Wet install bushings (28) into support
and control box support (11) to bracket tube (4), use epoxy primer (C318).
assemblies (1 and 2) with bolt (14) and
washers (13). (10). Slide support tube (4) onto fitting
assemblies (35) and (36). Secure with
washers (18) and quick release pins
(4). Attach controller assembly (16) to (29).
control box support (11) with bolts (15)
and washers (7). Safety with lockwire (11). Attach upper end of strut assembly (23)
(C702). to lower attach point of aft bracket
assembly (2) with bolt (27), washer (25)
(5). Attach hoist assembly (22) to upper and lock nut (26).
attach points of bracket assemblies (1
and 2) with bolts (17), washers (18) and (12). Attach harness connector P8 to hoist
lock nuts (19). assembly (22) and connector P2 to
controller assembly (16).
(6). Attach hoist assembly (22) to lower (13). Attach connectors P524, P525 and
attach points of bracket assemblies (1 P526 from hoist wire harness to aircraft
and 2) with bolts (20), washers (7) and connectors J524, J525, and J536. (Ref
lock nuts (21). CSP-900RMM-3, 98-30-00)
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
5 (4 PL) REF 2
7 (4 PL) 6 (3 PL)
7 (3 PL)
8 (3 PL) 2
3 9 (2 PL) 27
22 25 X2
1 15 (4 PL) 26
7 (4 PL)
14 (2 PL)
13 (2 PL)
16
11
4
10 (2 PL) 18
20 (2 PL) 42 ( 2 PL )
7 (2 PL X2) 40 (2 PL X 2 )
12 (4 PL) 39 ( 2 PL )
21 (2 PL)
13 (4 PL)
37 ( 4 PL ) 23
38 ( 4 PL )
40 ( 4 PL X 2 ) 29
28
29
18 36
28
FS
230.5
35
REF 22
32 23
33
34
24 LOWER STRUT
FITTING
31 17 (2 PL)
18 (2 PL X2)
19 (2 PL)
30
9K25014A
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Rotorcraft Maintenance Manual
B. Assist Handel Installation (4). Secure aft clamp (42) to support tube
(4) 19.3 inched from end of support tube
(Ref. Figure 1) (measured along bottom of support tube
to bottom edge of clamp) using bolts
(1). Install fowrard clamp (41) 18 inches (37), washers (39), and nuts (38).
from end of support tube (4) (measured
C. Fairing Installation
along bottom of support tube to bottom
edge of clamp) using bolts (37), washers (Ref. Figure 2)
(39), and nuts (38).
(1). Attach upper fairing (1) to support
(2). Install handle (43) into forward clamp assemblies (2 and 3) and clip assem
(41) using bolt (40), washers (39), and blies (4, 5, 6 and 7) using screws (8) and
nut (38). washers (9).
(2). Attach lower fairing (10) to support
NOTE: Adjust aft clamp (42) position to pre assemblies (2 and 3), clip assemblies (4,
vent binding occuring between clamp and 5, 6 and 7) and upper fairing (1) using
support tube (4). screws (8) and washers (9).
(3). Install aft clamp (42) on handle (43) (3). Attach end cap assembly (11) to upper
using bolt (40), washers (39) and nut and lower fairings (1 and 10) using
(38). screws (8) and washers (9).
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Rotorcraft Maintenance Manual
11
1
3
3 2
9
2
9
8
10
M25023
A
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Rotorcraft Maintenance Manual
INBD
3 1.00
4 (7 PL)
.75 AFT
1.00
1 .75
2
RH LANDING GEAR SKID TUBE
VIEW LOOKING DOWN
M25015
Consumable Materials
(4). Tighten straps (6) to remove slack
(Ref. CSPSPM)
without pulling float guard (1) out of
Item Nomenclature
position. Tie wrap excess as required to
secure loose straps (6).
C207 Sealing Compound, Fuel Resistant
(5). Secure skid guard (9) in place with
clamps (10).
NOTE: This installation is only done when the
aircraft is configured with both Rescue Sealing Compound (C207)
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). (6). Fillet seal around all clamps (10) with
sealing compound (C207).
(2). Remove original (hoist) skid guard and
replace with (hoist/float) skid guard (9). (7). Locate decals (11) as shown.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
INBD
6 (4 PL)
11 (2 PL)
RH SIDE, VIEW LOOKING DOWN FWD
A
3
A 1 2
9 UP
10 (6 PL)
REF 1
REF 6
REF 2
4
5
UP
INBD
7
SECTION A-A 9K25-029
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Rotorcraft Maintenance Manual
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(2). Remove clamps (4) and guard (1). (1). Remove tie wraps as required and
G. Float Guard Removal remove straps (6).
(Ref. Figure 4). (2). Position and secure mating surfaces of
NOTE: This installation is only done when the Velcro (hook) (4) on cover (2) to velcro
aircraft is configured with both Rescue (pile) (5) area on float bag (2).
Hoist and Air Cruiser Emergency Floats to
gether.
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Rotorcraft Maintenance Manual
SERVICING
MAINTENANCE PRACTICES
1. Servicing Instructions NOTE: With the fairings installed, a flash light
and mirror are required to verify the fluid
A. Hoist Fluid Servicing level through the sight gauge.
(Ref. Figure 1). (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
9K25004A
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
RESCUE HOIST
INSPECTION / TEST
1. Rescue Hoist (9). Verify cable is lowered and CABLE
PAYOUT display registers correct
A. Hoist System Inspection reading.
(1). Inspect attaching components for A drag load of approximately 20
security of installation. CAUTION pounds must be applied to the
cable when hoisting to prevent cable from
(2). Inspect entire system for damage, becoming loose and fouling drum. Apply
deformations, cracks and excessive drag load with gloved hand or use a clean
wear. heavy cloth to protect hand and cable.
(3). Inspect cable and hoist assembly for (10). On collective control module, hold
condition. HOIST switch in UP position until
cable returns to original position.
(4). Inspect electrical connections for
Do not allow the payout of cable
condition and security of installation. CAUTION to be retarded. If cable is pre
(5). Replace any damaged or questionable vented from paying out, cable will loosen on
components. drum and foul drum. Cable tension rollers
are use to provide positive constant tension
B. Electrical System Functional Test between cable and drum.
(1). Apply external power to helicopter (Ref. (11). On pendant, lower cable using payout
CSP-900RMM-3, Section 96-00-00). direction/speed control thumbwheel
switch.
(2). On ELECTRICAL MASTER panel,
set POWER switch to BAT/EXT (12). Verify cable is lowered and cable payout
position. display on pendant registers correct
reading.
(3). On ELECTRICAL MASTER panel, A drag load of approximately 20
set R GEN switch to ON position. CAUTION pounds must be applied to the
(4). On electrical load center, verify HOIST cable when hoisting to prevent cable from
PWR and HOIST CUT circuit break becoming loose and fouling drum. Apply
ers are closed. drag load with gloved hand or use a clean
heavy cloth to protect hand and cable.
(5). On instrument panel, set HOIST (13). On pendant, raise cable using payout
switch to ON position. direction/speed control thumbwheel
(6). Verify hoist power on light is illumi switch to original position.
nated. (14). On pendant, set load mode select to
600 LB.
(7). On pendant, set load mode select to
250 LB. (15). Repeat steps (8). thru (13).
(16). On instrument panel, set HOIST
Do not allow the payout of cable
CAUTION to be retarded. If cable is pre switch to OFF position.
vented from paying out, cable will loosen on (17). On ELECTRICAL MASTER panel,
drum and foul drum. Cable tension rollers set R GEN switch to OFF position.
are use to provide positive constant tension (18). On ELECTRICAL MASTER panel,
between cable and drum. set POWER switch to OFF position.
(8). On collective control module, hold (19). Remove external power from helicopter
HOIST switch in DN position for a few (Ref. CSP-900RMM-3, Section
seconds. 96-00-00).
Section
257000
Hinged Avionics
Shelf
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
25-70-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
AVIONICS CLIP
AFT OUTBOARD
BRACKET
SHELF CHANNEL
SUPPORT ASSEMBLY
INTERCOSTAL
SHELF ANGLE
HINGE HALF
Page 2
Original 25-70-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 201
25-70-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
2 1
3 2
10
5 1
1
2
1 2
1 2
8 10
2
3
7 1
4
2
2
7 3 9G25011
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Original 25-70-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(2). Inspect shelf and attaching brackets for (3). Verify that shelf assembly and avionics
cracks, corrosion or any other type of shelf channel meet electrical bonding
damage or deformation. Scratches or requirements (Ref. CSP-SPM).
Chapter
FIRE PROTECTION
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
26 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page ii
Revision 34 26 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page iii
26 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page iv
Revision 34 26 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
261010
Overheat Bleed Air
Leak Detection
(Heat/Defog) System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
26-10-10 Revision 4
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
OVERHEAT HEAT/DEFOG
CONTROL BLEED AIR LINE
OVERHEAT DETECTION
CABLE
DETECTION CABLE
RUBBER GROMMET
9G26001
Page 2
Revision 4 26-10-10
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Fault in overheat Bleed air Circuit breaker BLD AIR Set or reset circuit breaker. 960000
leak detection (See Notes). LEAK CB 6 not set on
Electrical Load Center.
Faulty circuit breaker. Replace circuit breaker. 960000
Detector cable center Test detector cable. 261000
conductor high resistance.
NOTES:
(1) The overheat bleed air leak detection system is automatically self tested by the Integrated Instrument
Display System (IIDS) when electrical power is applied. Additionally if a manual test is required, a built in
fault detection circuit wired into a press to test DISP key located on the IIDS front panel may be used. By
depressing and holding the DISP key 3 to 5 seconds all liquid crystal display (LCD) illuminate. When the
DISP key is released a 1 second flash of the CAB HEAT WARNING indicates a normal functional
system. ACFTFALT=4 No flash of the CAB HEAT WARNING indicates a fault in the overheat bleed air
leak detection system.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
A669
BLEED AIR LEAK
DETECTOR CONTROL W309
FDL4
J1 P160 J478 P1
BLEED AIR LEAK
DETECTION CABLE
LOOP A D A
A612
J161 P2 LOOP FWD INTERCONNECT PANEL
A2
W122
LOOP B H B IIDS
P172 J6 TB3-8 J3 P170 P105 J5
W124
TEST K 63 A B C D 76 ZN DETECTOR TEST
25K .25W
EXTERNAL CALIBRATION RTN B
R1 J3
CALIBRATION RESISTOR E P103
PWR GND J E
28VDC PWR G
9G26011B
Figure 101. Overheat Bleed Air Leak Detection System Wiring Diagram
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Rotorcraft Maintenance Manual
Page 201
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
2. Overheat Bleed Air Leak Detection Cable B. Overheat Bleed Air Leak Detection Cable
(Heat/Defog) Installation
(Ref. Figure 201) Do not exceed minimum bend
CAUTION radius 0.750 inch (19.05 mm).
Consumable Materials (1). Install detection cable from baggage
(Ref. CSPSPM) compartment through FS 230.5
Item Nomenclature bulkhead and holes in each structure to
C701 Lockwire
FS 155.5 bulkhead.
NOTE: Cable does not need to be in contact
with bleed air line.
A. Overheat, Bleed Air Leak Detection Cable
Removal (2). Wrap detection cable 3 turns around
horizontal length of bleed air line.
(1). Remove right crew seat from cockpit
(Ref. Section 25-10-00). (3). Wrap cable 31/2 turns around vertical
length of bleed air line.
(2). Remove cabin seats from cabin
compartment if applicable (Ref. Section (4). Install mounting nuts on cable ends
25-20-00). and torque nuts. Safety nuts with
lockwire (C701).
(3). Remove interior trim and insulation
(5). Install rubber grommets along cable.
panels from aft right side FS 230.5
Secure cable to bleed air line with
bulkhead (Ref. Section 25-50-00).
tiedown straps at grommets.
(4). Remove carpet from cabin floor panels, (6). Attach electrical connector P1 to
if applicable (Ref. Section 25-20-00). forward cable end connection. Torque
connector. and safety with lockwire
(5). Remove cockpit access panels AR129
(C701).
and AR138 (Ref. Section 06-00-00).
(7). Attach electrical connector P2 to aft
(6). Remove cabin floor panels; A160, cable end connection. Torque connector
AR165, AL165, A170, and A217(Ref. and safety with lockwire (C701).
Section 06-00-00).
(8). Install baggage compartment floor
(7). Remove baggage floor panels A235 and panels AR250 and A235 (Ref. Section
AR250 (Ref. Section 06-00-00). 06-00-00).
(8). Detach electrical connector P1 (1) from (9). Install cabin floor panels A160, AR165,
forward bleed air leak detection cable AL165, A170, and A217 (Ref. Section
(5) end connection. 06-00-00).
(9). Detach electrical connector P2 (2) from (10). Install cockpit floor panels AR129 and
aft cable end connection. AR138 (Ref. Section 06-00-00).
(10). Cut and discard lockwire and remove (11). Install carpet in cabin, if applicable (Ref
mounting nuts (6) from cable ends. Section 25-20-00).
Remove cable ends from bulkheads. (12). Install insulation and interior trim
panels on aft right side FS 230.5
(11). Cut and discard tie down straps (8) bulkhead (Ref. Section 25-50-00).
securing cable to bleed air line.
(13). Install cabin seats in cabin compart
(12). Remove and retain rubber grommets ment, if applicable (Ref. Section
(7) from fire detection cable. 25-10-00).
(13). Carefully unwrap fire detection cable (14). Install right crew seat in cockpit (Ref.
from bleed air line and remove cable. Section 25-10-00).
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Rotorcraft Maintenance Manual
5.43
(13.79 cm)
43.43
(110.3 cm)
9
3
70-80 in-lb
7.9-9.0 Nm
6 4
65-75 in-lb
7.3-8.5 Nm
2
1
65-75 in-lb 5
LOOKING
7.3-8.5 Nm
FORWARD
6
8 7 70-80 in-lb
7.9-9.0 Nm 5.06
(12.85 cm)
5 9
1.33
11.46 (3.38 cm)
(29.11 cm) 2.42
8.58 (6.15 cm) 9.38
(21.79 cm) 11.86 35.60 17.63 (23.83 cm)
(30.12 cm) (90.42 cm) (44.78 cm)
LOOKING OUTBOARD
RIGHT SIDE
9G26013
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
3. Overheat Bleed Air Leak Detection (4). Install cockpit floor panels AR138 and
Control AR129 (Ref. Section 06-00-00).
(Ref. Figure 202) (5). Install right crew seat in cockpit (Ref.
Section 25-10-00).
A. Overheat Bleed Air Leak Detection
Control Removal STA. 155.0 BKHD
3 2 1 (4 PL) 4 (4 PL)
(1). Remove right crew seat in cockpit (Ref.
Section 25-10-00).
(2). Remove cockpit floor panels AR129 and
AR138 (Ref. Section 06-00-00).
(3). Detach electrical connector P160 (3)
from bleed air leak detection control (2).
(4). Remove screws (1) from bleed air leak
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).
9G26002
(2). Install bleed air leak detection control 1. SCREW
onto bulkhead with spacers and screws. 2. BLEED AIR LEAK DETECTION CONTROL
3. ELECTRICAL CONNECTOR (P160)
Torque screws. 4. SPACER
(3). Attach electrical connector P160 to Figure 202. Overheat Bleed Air Leak
bleed air leak detection control. Detection Control
Page 204
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Rotorcraft Maintenance Manual
Section
261020
Deck and Engine
Area Fire/Overheat
Detection System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
26-10-20 Revision 4
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 2
Original 26-10-20
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 101
26-10-20 Revision 4
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Table 101. Deck and Engine Area Fire/Overheat Detection System Troubleshooting (Cont.)
Fault Probable Cause Corrective Action Ref. Section
SENSFALT=12 On IIDS Faulty fire/overheat Remove and replace 261020
alpha/numerical display. (See detection control unit. fire/overheat detection control
Notes) unit
NOTES:
(1) The Fire/overheat detection system is automatically self tested by the Integrated Instrument Display
System (IIDS) when electrical power is applied. Additionally if a manual test is required, a built in fault
detection circuit wired into a press to test DISP key located on the IIDS front panel may be used. By
depressing and holding the DISP key 3 to 5 seconds all liquid crystal display (LCD) illuminate. When the
DISP key is released a 1 second flash from each (FIRE) WARNING 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 system.
A2 A602
ELECTRICAL LOAD CENTER
IIDS
W123 W124
J2 P102 P377 J3 J2 P374
T T T T T
XMSN FIRE 58 M 14
XMSN FIRE FAULT 59 N 15
XMSN TEST 60 P 16
A105
A601 902 CONFIG FIRE/OVERHEAT
CIRCUIT BREAKER PANEL CONTROL
A601 900 CONFIG
CB4 (TRANSMISSION DECK)
CIRCUIT BREAKER PANEL
XMS J2 P128
BAT 5A N CB3 W124
2 P370 J1
BUS FIRE XMSN FIRE T
L. ESS BUS
J2 P128 C FIRE
FDL1 BAT 5A 2 F FAULT
FIRE DETECTION CABLE BUS K TEST
(TRANSMISSION DECK)
P2 J475 W124 G 28VDC
LOOP B H LOOP B
GS304-F E A CHASSIS GROUND
P1 J477
GS306-K E J PWR GND
A D LOOP A
B EXTERNAL CALIBRATION
RTN
E CALIBRATION RESISTOR
9G26009B
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Rotorcraft Maintenance Manual
A103
A2 A602 FIRE/OVERHEAT
ELECTRICAL LOAD CENTER
IIDS CONTROL (LH ENGINE)
W122 W124
P376 J4 J2 P374 P371 J1
J3 P103
T T T T T T
L ENG FIRE 64 C 8 C FIRE
L ENG FIRE FAULT 65 E 9 F FAULT
L ENG TEST 66 P 10 K TEST
G 28VDC
W123 GS302-B
J2 P102 P377 J3
T T T T E A CHASSIS GROUND
T
R ENG FIRE 64 9 11 B EXTERNAL CALIBRATION RTN
R ENG FIRE FAULT 65 10 12 E CALIBRATION RESISTOR
R ENG TEST 66 11 13 E J PWR GND
GS304-E
D LOOP A
P375 J1
H LOOP B
A601 900 CONFIG 17
26
CIRCUIT BREAKER PANEL W125
FDL3
FIRE DETECTION CABLE
A102
CB4 FIRE/OVERHEAT
L. ENG FIRE (LH ENGINE)
P379 J5 J6 P376 W124 CONTROL (RH ENGINE)
P2 J473
J1 P131
A H E P372 J1
5A 1 T
C FIRE
LOOP
P1 J479 F FAULT
BAT BUS K TEST
B J M
GS302-D E A CHASSIS GROUND
CB5 GS306-H E J PWR GND
R. ENG FIRE B EXTERNAL CALIBRATION RTN
J2 P128 W124
E CALIBRATION RESISTOR
5A 1 G 28VDC
FDL2 D LOOP A
FIRE DETECTION CABLE H LOOP B
(RH ENGINE) P1 J476 W124
A601 902 CONFIG
A
CIRCUIT BREAKER PANEL
CB21 LOOP P2 J474
L. ENG FIRE
J1 P131 B
5A 1
CB3
R. ENG FIRE
J2 P128
5A 1
L. ESS BUS
9G26010B
(Ref. Figure 201, Figure 202, and Figure 203) Special Tools
(Ref. CSPSPM)
A. Deck and Engine Fire/Overheat Detection Item Nomenclature
Inspection
T1002 MilliOhm Meter
T1012 Megohmmeter, Digital/Analog
(1). Remove engine cowl assembly L260 or
R260 (Ref. Section 06-00-00).
(1). Detach connectors at both ends of cable.
(2). Inspect fire detection control units for
security. (2). Verify the cable contact pin is centered
in the connector. No physical damage
(3). Inspect fire detection cable connectors allowed.
for security. (3). Inspect for corrosion or foreign objects.
None allowed.
(4). Inspect sensor portion of cable for
chafing. 0.006 in (0.152 mm) maximum (4). Using milli-ohm meter (T1002)
depth allowed. measure the resistance from the center
pin on one end to the center pin on the
(5). Inspect fire detection cable for breaks. other end.
Replace cable assembly if broken. Maximum resistance 4.25 ohm for
engine detection cable.
(6). Inspect quick release clamps for
security, quick release mechanism for Maximum resistance 8.05 ohm for
latching and locking. Repair or replace transmission detection cable.
as required. (5). Using megohmmeter (T1012) measure
the resistance from the center pin to
(7). Inspect for damaged or broken Z the outer sheath (center pin negative).
brackets. Repair or replace as required.
Use 100 Vdc test voltage.
(8). Inspect detection cable for missing, Test at ambient temperature of 70 F
deteriorated, and secure rubber (21.1 C) to 80 F (26.7 C).
grommets. Repair of replace as re
quired. Minimum resistance 1.7 Mohm.
(6). Replace faulty cable.
(9). Install engine cowling assembly L260
or R260 (Ref. Section 06-00-00). (7). Attach connectors at both ends of cable
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(5). Careful remove fire detection cable (6). Attach electrical connector J475 and
from upper deck. J477 to fire detection cable connectors.
Torque connectors and safety with
(6). Remove and retain rubber grommets lockwire (C701).
(3) from cable. (7). Install aft swashplate fairing assembly
T220 (Ref. Section 06-00-00).
(7). Remove unserviceable quick release
clamps. Remove screws (4), washers (5), (8). Install L210 and R210 transmission
and nuts (6). access doors (Ref. Section 06-00-00).
Page 202
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Rotorcraft Maintenance Manual
4
70 -90 in-lb 2
65 -75 in-lb 10 10 5
8 7.9 - 10.2 Nm
7.3 - 8.5 Nm
3
65 -75 in-lb
9
7.3 - 8.5 Nm 11
10 10 12
7
6
9G26004A
1. DECK FIRE/OVERHEAT DETECTION CABLE 7. Z BRACKET
2. QUICK RELEASE CLAMP 8. ELECTRICAL CONNECTOR (J475)
3. RUBBER FIRE DETECTOR GROMMET 9. ELECTRICAL CONNECTOR (J477)
4. SCREW 10. CONNECTOR MOUNTING NUTS
5. WASHER 11. ELECTRICAL CONNECTOR (J475 FDL P2)
6. NUT 12. ELECTRICAL CONNECTOR (J477 FDL P1)
Figure 201. Deck Fire/Overheat Detection Cable
Page 203
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(5). Remove and retain grommets (12) from (6). Apply fillet of sealing compound (C215)
cable. to cable mounting nuts on engine side
of firewall.
(6). Remove unserviceable quick release
clamps, remove screws (7), washers (8), (7). Install engine cowling assembly L260
and nuts (9). or R260 (Ref. Section 06-00-00).
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Revision 4 26-10-20
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Rotorcraft Maintenance Manual
70 -90 in-lb
65 -75 in-lb 1 6 6 7.9 - 10.2 Nm
7.3 - 8.5 Nm 4
J473 J474 J373 J374
LEFT RIGHT LEFT RIGHT
65 -75 in-lb 2
7.3 - 8.5 Nm 5
7 J479 J476 J379 J376
LEFT RIGHT LEFT RIGHT
8 11
12
3
10 6 6
9 13
9G26016A
1. ELECTRICAL CONNECTOR (RIGHT ENGINE J474) 8. WASHER
2. ELECTRICAL CONNECTOR (RIGHT ENGINE J476) 9. NUT
3. RIGHT ENGINE DETECTION CABLE 10. LEFT ENGINE DETECTION CABLE
4. ELECTRICAL CONNECTOR (LEFT ENGINE J473) 11. QUICK RELEASE CLAMP
5. ELECTRICAL CONNECTOR (LEFT ENGINE J479) 12. FIRE DETECTOR RUBBER GROMMET
6. MOUNTING NUT 13. ZBRACKET
7. SCREW
Figure 202. Engine Fire/Overheat Detection Cable (Typical)
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26-10-20 Revision 4
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
4. Deck and Engine Fire/Overheat Control (4). Remove screws (5) and washers (6), and
(Typical) remove control from bracket assembly
(4).
(Ref. Figure 203) B. Fire/Overheat Control Unit Installation
4
NOTE: THE UPPER DECK AND ENGINES FIRE/OVERHEAT DETECTION CIRCUITS 5
ARE CONNECTOR DEPENDANT AND ARE NOT CONTROL UNIT INDEPENDENT 6
9G26003A
1. RIGHT ENGINE FIRE/OVERHEAT CONTROL (P372) 4. MOUNTING BRACKET ASSEMBLY
2. TRANS. DECK FIRE/OVERHEAT CONTROL (P370) 5. SCREW
3. LEFT ENGINE FIRE/OVERHEAT CONTROL (P371) 6. WASHER
Figure 203. Deck and Engine Fire/Overheat Control Units
Page 206
Revision 4 26-10-20
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
261030
Smoke Detection
System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
5 1
4 9g26-022
1. SMOKE DETECTOR (REF. IPL, 261030, FIG. 1) 4. A652 AUDIO SELECT PANEL (REF. IPL, 970000, FIG.
2. WIRING HARNESS (NOT SHOWN) 1)
3. A620 ELECTRICAL LOAD CENTER (REF. IPL, 5. A675 AUDIO INTERCON ASSEMBLY
960001, FIG. 1)
Figure 201. Smoke Detector System
Page 201
26-10-30 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
A804
SMOKE DETECTOR
J1 P852
P852
SP1
CHASSIS GND D W47A22 EMI 3 E GS302-K
A620
ELEC LOAD CENTER
SMOKE DETECTOR FIRE HRD
P378 J4 CB31 CB32
S
A652
AUDIO SELECT PANEL
R
P 20-21-050 P501 J1
N 11 ALERT #1
W49B22 EMI 3
9G26-020
2. Smoke Detector Removal and Installation (2). Remove nuts (5) and washers (4) from
(Ref. Figure 203) studs (3).
A. Removal
(1). Disconnect Electrical Connector P852. (3). Remove smoke detector (2).
Page 202
Revision 34 26-10-30
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
P852
5
3
4
BAGGAGE COMPARTMENT
DOOR OPENING
9G26-021
Page 203
26-10-30 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 204
Revision 34 26-10-30
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
262010
Emergency Fire
Extinguisher
(Hand Held)
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
C. Emergency Fire Extinguisher (2). Remove screws (3), washers (4) and
Removal/Installation bracket (2).
(Ref. Figure 201) (3). Install bracket (2) with screws (3) and
washers (4).
(1). Unfasten clasps on the fire extinguisher
bracket (2) and remove fire extinguish (4). Hang extinguisher (1) on bracket (2)
er (1). and secure with clasps.
Page 201
26-20-10 Revision 21
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 202
Revision 19 26-20-10
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
4
3
9G26-017
Page 203
26-20-10 Revision 19
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
3 4
4
7
5
5
6
7 5
9G26-019
Figure 202. Cabin Mounted Emergency Fire Extinguisher, Right Hand Shown (Left Hand
Typical)
1. CABIN MOUNTED BRACKET 5. WASHER
2. FIRE EXTINGUISHER BRACKET 6. SELFLOCKING NUT
3. 14 OZ FIRE EXTINGUISHER 7. SCREW
4. BONDED STUD
Page 204
Revision 19 26-20-10
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Rotorcraft Maintenance Manual
Section
262020
Fire Extinguisher
System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
26-20-20 Revision 4
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
PRESSURE GAUGE
FILLER PORT
(RED PORT)
PRIMARY
CARTRIDGE (BLUE PORT)
ALTERNATE
CARTRIDGE
DISTRIBUTION TUBE
LEFT SIDE
DISTRIBUTION TUBE
RIGHT SIDE
REF
ENGINE DECK
DISCHARGE
TUBE
REF
FIRE BOTTLE
ENGINE DECK
ASSEMBLY
DISCHARGE
TUBE
OUTLET
PORT
CROSS FLOW OUTLET
TUBES PORT 9G26007
Page 2
Revision 4 26-20-20
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Fire bottle gauge indicates Faulty wiring. Test and repair wiring (1). 980000
below 250 psig (1724 kPa),
Faulty gauge. Replace fire bottle. 262020
TANK PRESS LO not
displayed on IIDS. Faulty IIDS. Replace IIDS. 953000
Cartridge did not discharge FUEL SHUTOFF valve Check FUEL SHUTOFF valve 960000
extinguishing agent. switch not positioned to position.
OFF.
Circuit breaker FIRE HRD Set or reset circuit breaker 960000
not set.
Faulty FIRE HRD circuit Replace circuit breaker. 960000
breaker.
Faulty wiring. Test and repair wiring (1). 980000
Faulty PRI/ALT select Replace switch. 960000
switch.
Faulty FUEL SHUTOFF Replace switch. 960000
valve switch.
Faulty discharge cartridge. Replace discharge cartridge. 262020
ACFTFALT=12, IIDS sensor Faulty wiring. Test and repair wiring (1). 980000
fault for TANK PRESS LO.
Faulty gauge. Replace fire bottle. 262000
Faulty IIDS. Replace IIDS. 953000
NOTES:
(1) Disconnect electrical connectors from discharge cartridge, and install shunt plug covers before trouble
shooting wiring faults.
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26-20-20 Revision 4
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
A604 A704
ENGINE/FUEL CONTROL PANEL RH FIRE BOTTLE
S6 P509 J2
L FUEL SHUTOFF 28VDC
SWITCH A ALTERNATE LEFT
RTN
1 CLOSED B CARTRIDGE
2
3 OPEN
P508 J1
4 SELECT 28VDC
5 A PRIMARY RIGHT
RTN
6 OFF B CARTRIDGE
A620
ELECTRICAL LOAD CENTER
W125 P512 J3
S7
CB32
R FUEL SHUTOFF C
J1 P130 FIRE HRD PRESSURE
SWITCH P375 J1 A
2 1 CLOSED SENSOR
3 OPEN A 24 5A BAT
BUS
4 SELECT
5
6 OFF
A705
W125 W307 LH FIRE BOTTLE
S8
BOTTLE DISCHARGE J302 P302 P507 J1
SWITCH 3 PRI 28VDC
B 1 A PRIMARY LEFT
2 OFF RTN B
1 ALT GS301-C E 2 CARTRIDGE
C 3
6 PRI GS303-E E 4
5 D 5
OFF P510 J2
4 ALT GS305-A E 6
Y 7 A 28VDC ALTERNATE
RIGHT
GS307-A E 8 B RTN
CARTRIDGE
A2 A612
IIDS W122 FWD INTERCONNECT PANEL
J5 P105 P170 J3 J2 P173 P511 J3
PRESSURE LO P302-SP1
TANK PRESS LO Z 10 22 9 A
PRESSURE
P302-SP2 SENSOR
RTN
E 10 C
GS301-A
9G26008A
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Rotorcraft Maintenance Manual
(9). Inspect crossflow tube assemblies for (12). Close baggage compartment door L262
dents, scratches and unserviceable (Ref. Section 06-00-00).
condition. Maximum allowed dent
depth depth 0.015 in (0.381 mm) or (13). Install engine cowl assemblies L260
scratch depth 0.0035 in (0.0889 mm). and R260 (Ref. Section 06-00-00).
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26-20-20 Revision 4
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
2. Discharge Cartridge Bridgewire (8). Install shunt plug cover onto discharge
Resistances Test cartridge.
(Ref. Figure 201) (9). Remove discharge cartridge from
discharge cartridge safety chamber
Special Tools (T2026).
(Ref. CSPSPM)
(10). Install discharge cartridge into fire
Item Nomenclature
bottle.
T1003 Digital Multimeter, Portable
T1006 Shunt Plug Cover
T2026 Chamber, Safety
11/02
(1). Install wire from discharge cartridge
safety chamber (T2026) to ground.
SHUNT PLUG COVER
(2). Attach technician ground strap to Manufacture
Date CARTRIDGE
discharge cartridge safety chamber
(T2026) and test ground.
A
(3). Remove discharge cartridge from fire
bottle with shunt plug cover installed.
1.00 0.10 OHMS
Test meter which passes more
CAUTION than 50 milliamperes current B
may damage discharge cartridge, reducing
cartridge life. Higher current may cause dis CARTRIDGE
SCHEMATIC
charge cartridge to detonate.
Fire Extinguisher
9G26-014A
(5). Thread discharge cartridge, with shunt (1). Verify manufacture date stamped on
plug cover installed, into discharge discharge cartridges ( Ref. Figure 201).
cartridge safety chamber (T2026).
(2). Remove discharge cartridges that have
(6). Remove shunt plug cover (T1006). reached service life limit (Ref. Chapter
04).
(7). Using digital multimeter (T1003)
measure discharge cartridge bridgewire (3). Return expired discharge cartridges to
resistance (Pin A to Pin B) 0.90-1.10 Mass Systems, Inc. or an approved
ohms. Replace cartridge if required. service-repair facility.
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Rotorcraft Maintenance Manual
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(1). Be shunted with a conductive rubber (a). Detach connectors P508 from (red
shunt plug (Mass Systems, Inc. port) primary discharge cartridge (9),
PN 306212) or wire across exposed P509 (blue port) alternate discharge
terminal shorted to discharge cartridge cartridge (10), and pressure gage
connector case. P512 (11).
(2). Be packed properly in a suitable (b). Install (T1006) shunt plug covers to
container. The container markings and primary and alternate discharge
shipping documents must comply with cartridges.
the requirements (DOT). (c). Disconnect crossflow tube assemblies
NOTE: The explosive charge in each discharge (12 and 4) and right side discharge
cartridge is approximately 0.4 grams. tube assembly (13).
(4). Remove screws (18) and washers (19)
6. Fire Bottle Assembly from fire bottle mounting support (24)
(Ref. Figure 202) or (25) and remove fire bottle assembly.
B. Fire Bottle Assembly Installation
Consumable Materials Fire Extinguisher
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire
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Revision 27 26-20-20
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature (1). Install discharge cartridge into fire
C702 Lockwire bottle discharge outlet port. Torque
cartridge 90-100 in lb (10.16-11.29
Special Tools
N m) and safety with lockwire (C702).
(Ref. CSPSPM) (2). Remove shunt plug cover (T1006).
Item Nomenclature
(3). For installation of fire extinguisher
T1006 Shunt Plug Cover discharge cartridge in position:
(a). Left primary, attach connector P507
A. Discharge Cartridge Removal to red port (6).
(b). Left alternate, remove attach P510
(1). Remove electrical load center (Ref.
to blue port (7).
CSP-900RMM-3, Section 96-00-00).
(c). Right primary, attach connector P508
Fire Extinguisher to red port (14).
(d). Right alternate, attach P509 to blue
port (15).
(4). Install electrical load center (Ref.
(2). For removal of fire extinguisher CSP-900RMM-3, Section 96-00-00).
discharge cartridge in position: 8. Discharge Tube Assembly
(a). Left primary, detach connector P507 (Ref. Figure 202)
(1) from red port (6). A. Discharge Tube Assembly Removal
(b). Left alternate, detach P510 (2) from NOTE: This task is typical for left and right
blue port (7). Discharge Tube Assembly removal.
(1). Remove electrical load center (Ref.
(c). Right primary, detach connector
CSP-900RMM-3, Section 96-00-00).
P508 (9) from red port (14).
(2). Disconnect discharge tube assembly (5)
(d). Right alternate, detach P509 (10) or (13) connector nuts from deck fitting
from blue port (15). (30) or (31) and fire bottle discharge
port fitting (6) or (14) and remove
(3). Install shunt plug cover (T1006) onto discharge tube assembly.
discharge cartridge.
B. Discharge Tube Assembly Installation
(4). Cut lock wire from discharge cartridge NOTE: This task is typical for left and right
and remove cartridge from fire bottle. Discharge Tube Assembly installation.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(1). Install discharge tube assembly (3). Loosen distribution tube assembly
connector nuts to deck fitting and fire connector nut (17) to deck fitting (30) or
bottle discharge port fitting. Torque (31) and remove distribution tube.
nuts (Ref. CSP-SPM).
B. Distribution Tube Assembly Installation
(2). Install electrical load center (Ref.
CSP-900RMM-3, Section 96-00-00). NOTE: This task is typical for left and right
Distribution Tube Assembly installation.
9. Distribution Tube Assembly
(Ref. Figure 202) (1). Install distribution tube assembly onto
deck fitting.
A. Distribution Tube Assembly Removal
(2). Install upper and lower support clamps,
NOTE: This task is typical for left and right screws, washers, and nuts. Torque nuts
Distribution Tube Assembly removal. (Ref. CSP-SPM).
(1). Remove engine cowl assemblies L260 or
R260 (Ref. Section 06-00-00). (3). Torque distribution tube assembly
connector nut (Ref. CSP-SPM).
(2). Remove screws (20), washers (21), and
nuts (22) from upper and lower support (4). Install engine cowl assemblies L260 or
clamps (23) and remove clamps. R260 (Ref. Section 06-00-00).
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Rotorcraft Maintenance Manual
8 16
15 3 6
1
10
11
LOOKING AFT 24 (RH)
20
21 25 (LH)
22
23
20
21
26 22
23
27
18 (3 PL)
20 20 19 (3 PL)
21 21
22 22
23 23
29
30 17 (2 PL) 28
LOOKING FORWARD
28
32 31
13
7
14
5 4
12 9
2
9G26-015
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Rotorcraft Maintenance Manual
Page 208
Revision 4 26-20-20
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Chapter
FUEL SYSTEM
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
28 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page ii
Revision 34 28 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page iii
28 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page iv
Revision 34 28 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page v
28 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page vi
Revision 34 28 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page vii
28 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page viii
Revision 34 28 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
280000
Fuel System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
FUEL SYSTEM
DESCRIPTION AND OPERATION
1. Fuel System A. Fuel Cell
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
trapped between the cell and the helicopter D. Fuel Sump Drain Valves
structure. The liner ribs route leaking fuel for
drainage through fuselage drain holes. Two fuel sump drain valves are located on the
fuel cell sump plate. The sump plate is
B. Fuel Vents centered on the bottom forward portion of the
fuel cell. The drain valves are spring loaded,
Two forward and two aft vent/rollover valves normally closed, poppet drain valves. The
are located on the top side of the fuel cell and valves are actuated by push cables to evacuate
vent fuel to the atmosphere. The single fuel from the fuel cell. Fuel exits the fuselage
vent/rollover valves are located at the forward through drain hoses.
right corner and the aft left corner of the fuel
cell. The dual vent/rollover valves are located E. Fuel Quantity Probes
at the forward left corner and rear right corner
of the fuel cell. The dual vent/rollover valves The fuel quantity probes are powered by
are attached to standpipes, which prevent any 24-28 vdc current and consist of two capaci
fuel from draining overboard. Each single tance type sensor probes bolted to the fuel cell
vent/rollover valve is connected by hoses and sump plate. The forward and aft gauging
tubes to a dual vent/rollover valve. probes output signals are processed by the
Integrated Instrument Display System (IIDS)
Each vent/rollover valve is a normally open to illuminate the fuel quantity bar graph and
poppet type float valve. The valve automatical digital readout on the IIDS display.
ly closes to prevent fuel loss through the vent
system. It's primary purpose is to allow the The aft gauging probe has an independently
fuel cell to vent to the atmosphere. It's powered 24 to 28 Vdc fuel low level detector
secondary function is to close when the (thermistor). The fuel low warning indicator on
helicopter is outside of an 855 pitch or roll the IIDS illuminates when the low level
angle. The valve also closes when fuel levels in warning detector is activated (900 CONFIG -
the fuel cell reach the float. 97 to 117 lb (44.0 to 53.1 kg) of fuel remain
ing) (902 CONFIG - 97 to 127 lb (44.0 to
Flame arrestors are located in the outlet of 57.6 kg) of fuel remaining).
each standpipe to prevent any potential flames
from reaching the vent/rollover valves and fuel (900 CONFIG - PW207E) The left FUEL
cell. low level warning tic mark on the IIDS does
not operate for aircraft upgraded from
C. Gravity Filler Port Fueling/Defueling PW206A to PW207E engines.
Refueling and defueling is through a gravity The fuel quantity bar graph on the IIDS
filler port located on the right side of the displays the fuel quantity status, fuel low
fuselage at the forward section of the fuel cell. caution bars, and fuel low warning bar. The
A check valve attaches to the filler neck fuel quantity bars (green) indicate fuel in 50
fitting. The filler neck fitting is secured to the pound increments. The fuel low caution bars
fuselage. The check valve is located within the (yellow) indicate fuel in 150 lb (68.0 kg)
fuel cell. The valve opens when the fuel cap is increments and illuminate when fuel quantity
removed by pulling a lanyard for refueling and is 151 to 300 lb (68.5 to 136.1 kg). The fuel
defueling operations. The valve closes when low warning bar (red) illuminates when fuel
the fuel cap is secured to the filler neck fitting quantity is 150 lb (68.0 kg). The digital
preventing fuel leakage. readout displays pounds of available fuel in a
numeric value.
An optional range extender filler port
increases fuel capacity by 12 US gallons (45.4 902 CONFIG - The forward fuel probe also
liters) by allowing the fuel cell to fill complete has a low level sensor. The forward fuel probe
ly. low fuel warning indicates low fuel in the left
fuel cell cavity. The aft fuel probe low fuel
(902 CONFIG) The lanyard attached to the indicator is for the right cavity. The IIDS
fuel cap also opens a flapper valve in the display will identify the warning as left or
longitudinal baffle to decrease refueling time. right low fuel.
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Rotorcraft Maintenance Manual
Page 3
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
When tensile, shear, or bending loads are interrupt motor power and illuminate a valve
applied to the fuel supply line connectors and position indicator lamp on the IIDS display.
fittings, the frangible valve section breaks,
allowing the two halves of the coupling to Fuel Crossfeed Valve (900 CONFIG -
separate and seal the fuel passages. Once the PW206A) The fuel crossfeed/shutoff valve is a
frangible valve closure has occurred, a detent 28 vdc, two position motor actuated valve. The
moves into position and prevents the valve valve is normally closed, and is controlled by a
from reopening. An indicator is visible around pilot activated switch on the fuel system
the frangible connector when the valve is control panel. The valve has 2 limit switches
closed. that stop the travel and 2 position indicator
switches that complete an electrical circuit to
The fuel supply lines from the fuel cell to the illuminate a valve position light on the IIDS
main transmission deck are shrouded and display. The valve allows both engines to be
connected to a drain line to vent leaking fuel. fueled by the same or alternate booster pump.
In the event of a failed booster pump, the
C. Fuel Pressure Switch crossfeed valve is opened allowing the operat
The fuel pressure switch is a diaphragm type ing booster pump to supply fuel to both
normally closed switch. engines. The valve consists of an actuator and
valve body. The valve body consists of an
When measured fuel pressure is less than 3 aluminum alloy body, an aluminum alloy ball,
psig, the switch closes sending a signal to the support fittings, thermal relief assembly, seals,
IIDS display. The fuel flow bar indicator mounting bracket and associated hardware.
segments illuminate when fuel pressure is 3
psig or less. The actuator consists of an electric motor, gear
train, electrical magnetic interference (EMI)
D. Fuel Shutoff / Crossfeed filtering, limit switches, and electrical connec
tor. The limit switches are positioned near
Fuel Shutoff Valves - The engine fuel each end of the actuator's rotational travel to
shutoff valves are used to perform emergency interrupt motor power and illuminate a valve
shut down of the engines. The fuel shutoff position indicator lamp on the IIDS display.
valve is a 28 vdc, two position motor actuated
valve. The valve is normally open, and is The fuel flow bar indicator on the IIDS display
controlled by a pilot activated switch on the illuminates crossfeed valve positions. The
fuel system control panel. The valve has 2 crossfeed valve is shown in the open position
limit switches that stop the travel and 2 when the bar of the crossfeed indicator
position indicator switches that complete an segment is illuminated. Each of the valve
electrical circuit to illuminate a valve position indicator segments will flash when the valve is
light on the IIDS display. The fuel flow bar in between an open or closed position.
indicator on the IIDS display illuminates
shutoff valve positions. Each engine shutoff The fuel shutoff/crossfeed valves are shrouded
valve is shown in the open position when the and connected to the shrouded fuel supply
upper bar of each shutoff valve indicator lines to vent leaking fuel.
segment is not illuminated. The upper bar of E. Fuel Transfer System (902 CONFIG)
each indicator segment is illuminated when
the valve is closed. The fuel transfer system is designed to
equalize the fuel in the left and right fuel
The valve consists of an actuator and valve cavities and minimize unusable fuel.
body. The valve body consists of an aluminum
alloy body, aluminum alloy ball, support When either electric booster pump is operat
fittings, thermal relief assembly, seals, ing, fuel is pumped through a jet pump in the
mounting bracket and associated hardware. opposite fuel cell cavity. The jet pump draws
The actuator consists of an electric motor, gear fuel from the sump through a pickup and the
train, electrical magnetic interference (EMI) fuel is ejected on the other side of the longitu
filtering, limit switches, and electrical connec dinal baffle. For example, when the left
tor. The limit switches are positioned near booster pump is operating, fuel is transferred
each end of the actuator's rotational travel to to the left fuel cell cavity.
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
FUEL SHUT-OFF
VALVE (2 PL)
RIGHT ENGINE
FEED TUBE ASSY LEFT ENGINE
FEED TUBE ASSY
DUAL VENT/ROLLOVER
VALVE (2 PL)
SINGLE VENT/ROLLOVER
VALVE (2 PL)
AFT FUEL
PROBE
FUEL
FILLER
TEE FITTING
(2 PL)
GRAVITY SELF SEALING
FILL PORT FRANGIBLE VALVE (2 PL)
FUEL NOTE
CELL
HOSE ASSY
RIGHT
SUMP DRAIN
CONTROLS (2 PL) FUEL BOOSTER HOSE ASSY
FWD FUEL PUMP (2 PL) LEFT
PROBE
FUEL CROSSFEED
SHUT-OFF VALVE ASSY
NOTE:
FUEL CROSSFEED SYSTEM REMOVED ON 900 CONFIG HELICOPTERS CONVERTED TO PW207E ENGINES.
9G28-002C
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
ENGINE DECK
FRANGIBLE VALVE (2 PL)
FUEL SHUTOFF
VALVE (2 PL)
RIGHT ENGINE
FEED TUBE ASSY
LEFT ENGINE
FEED TUBE ASSY
DUAL VENT/
ROLLOVER VALVE
SINGLE VENT/ROLLOVER
VALVE ( 2 PL)
SELF SEALING
FUEL FILLER
FRANGIBLE VALVE
(2 PL)
TEE FITTING
(2 PL)
FUEL CELL AFT FUEL PROBE
SUMP DRAIN
CONTROLS (2 PL) FUEL BOOSTER
PUMP (2 PL)
FORWARD FUEL PROBE JET PUMP (2 PL)
9G28-048
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Original 28-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
TO FWD RH M M M
VENT SYS TO AFT LH
VENT SYS
RH FUEL
FUEL CELL
FEED SYS VENT ROLLOVER
BAFFLE (2 PL)
VALVE (4 PL)
NOTES:
1. FUEL CROSSFEED SYSTEM REMOVED ON 900 CONFIG HELICOPTERS CONVERTED TO PW207E ENGINES.
2. FMU SHROUD BOX INSTALLED ON 900 CONFIG HELICOPTERS CONVERTED TO PW207E ENGINES.
9G28-001A
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28-00-00 Revision 14
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
RIGHT LEFT
ENGINE ENGINE
FUEL METERING UNIT (FMU) ENGINE DECK FRANGIBLE
SHROUD BOX (2 PL) CONNECTOR (2 PL)
FUEL BOOST
PUMP (2 PL) CENTER BAFFLE
9G28-049
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Original 28-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
FUEL SYSTEM
FAULT ISOLATION
1. Fuel System Troubleshooting The troubleshooting tables should be used
with the simplified system schematics,
electrical wiring diagrams, serv nability checks
(Ref. Figure 101 thru Figure 106) and other detailed procedures in this and other
chapters of the manual.
The following troubleshooting procedures are a Comprehensive wiring diagrams are available
brief summary of fuel system faults which may in the Rotorcraft Maintenance Manual
be encountered (Ref. Table 101). CSP-900RMM-3 (Ref. Section 98-40-00).
Table 101. Fuel System Troubleshooting
Fault Probable Cause Corrective Action Ref. Section
LOW OR NO FUEL
PRESSURE (900 CONFIG)
FUEL low fuel pressure Set CROSSFEED valve
caution segments illuminated switch to ON (open) position
on IIDS panel with boost ON. and turn opposite side
booster pump ON;
If low fuel pressure remains Replace fuel pressure switch. 280000
illuminated:
Faulty fuel pressure switch.
Disconnected or ruptured Verify fuel supply lines security 280000
fuel supply line in fuel cell. and condition. Repair or
replace parts as required.
Faulty wiring between fuel Test and repair wiring. 206000
pressure switch and IIDS.
FUEL low fuel pressure Troubleshoot fuel crossfeed Replace fuel crossfeed system 280000
caution segments illuminated system valve and hose. valve or hose.
on IIDS panel with boost ON.
If low fuel pressure light
goes off:
Faulty fuel booster pump. Replace fuel booster pump 280000
cannister.
Faulty fuel booster pump Test and repair wiring. 206000
wiring.
Contaminated fuel. Perform Contaminated Fuel 280000
Cell Procedure.
Fuel cell frangible valve Check frangible valve indicators 280000
closed off fuel supply. for closure.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 102
Revision 24 28-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
FUEL QUANTITY
INDICATION ERRORS
FUEL low level warning(s) Faulty fuel quantity Remove, test, calibrate or 280000
illuminated with known transmitter probes. replace fuel quantity probes.
quantity above 160 lbs in
cruise or 220 lbs in hover. Faulty fuel transfer system. Perform Fuel Transfer System 280000
(902 CONFIG) Operational Test
Repair faulty component.
Contaminated fuel. Perform the Contaminated Fuel 280000
Cell Procedure.
FUEL low level warning(s) Faulty aft fuel quantity Remove, test, calibrate or 280000
illuminated with known probe. replace aft fuel quantity probe.
quantity above 300 lbs. (900 Thermistor not set to a
CONFIG) proper level on fuel quantity
probe.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
SENSFALT=4 On IIDS Faulty forward (left) fuel Replace forward (left) fuel 280000
alpha/numerical display. quantity probe. (Out of range probe.
high or low.)
Faulty wiring circuit between Test and repair wiring circuit. 206000
fuel quantity probe and IIDS. 280000
SENSFALT=5 On IIDS Faulty aft (right) fuel quantity Replace aft (right) fuel probe. 280000
alpha/numerical display. probe.
Faulty wiring circuit between Test and repair wiring circuit. 206000
fuel quantity probe and IIDS. 280000
FUEL quantity LB digital Loose or faulty wiring or Inspect, test and repair wiring. 206000
display readout does not connections on fuel quantity
match actual known fuel transmitter probes.
quantity.
Faulty forward or aft (left or Remove, test, calibrate or 280000
right) fuel quantity replace forward and aft (left
transmitter probe and right) fuel quantity
transmitter probes.
Incorrect fuel calibration Enter correct factors, if known, 280000
factors in IIDS or perform fuel calibration.
FUEL quantity LB digital Faulty forward or aft (left or Remove, test, calibrate and 280000
display readout not right) fuel quantity repair or replace transmitter
illuminated with approximate- transmitter probe. Refer to probe.
ly half of known FUEL IIDS alphanumeric fault
quantity segments shown. display.
FUEL quantity segment bars Loose or faulty IIDS battery Test and repair wiring. 206000
not illuminated on IIDS with bus voltage sensor wiring. 280000
FUEL quantity LB digital
display showing correct Battery voltage low, below Refer to IIDS alphanumerical 961000
known fuel quantity. 19.0 volts. fault display.
Do not attempt an engine
start with battery.
Page 104
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
A2 A612 A115
IIDS FWD INTERCONNECT PANEL LH FUEL PRESSURE SWITCH
W122 W125
J5 P105 P170 J3 J2 P173 P351 J1
LEFT FUEL PRESS LOW Y 5 16 A
GS305-J E B
A114
W123 RH FUEL PRESSURE SWITCH
W124
J4 P104 P171 J1 J6 P172 P350 J1
RIGHT FUEL PRESS LOW X 5 15 A
GS306-J E B
9G28-030A
A620 A604
ELECTRICAL LOAD CENTER ENGINE/FUEL CONTROL PANEL
S5 A112
W124 W128 RH FUEL BOOST PUMP
CB4 W124 R FUEL BOOST
R BST PMP J2 P124 P122 J122
J6 P378 P124 J2 SWITCH
3 ON
2 W B1 +
10A C Z GS131 E -
1 OFF
S3 W125 W127
A111
CB5 W125 L FUEL BOOST LH FUEL BOOST PUMP
L BST PMP J5 P379 P130 J1 SWITCH J1 P130 P119 J119
3 ON
2 W B1 +
10A C Z
GS130 E -
1 OFF
9G28-029A
Page 105
28-00-00 Revision 24
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
+ BLACK
- WHITE
FUSE
A612
FWD INTERCONNECT
A2 PANEL A107
IIDS AFT FUEL PROBE
W122 W124 W128
J3 P103 P122 J122
P170 J3 J6 P172 J223 P1
P P P
P P P P P
FUEL PROBE AFT HI 23 25 25 A1 D FUEL PROBE AFT HI
FUEL PROBE AFT LO 24 26 26 A2 C FUEL PROBE AFT LO
A8
J1 P131 A8
6 A4 P P A 28VDC
GS105-G E A5 B PWR RTN
CB14
A620 FUEL PROBE
J2 P128 P122 J122
ELECTRICAL LOAD CENTER W124
P
5A 9 A4
CB1
FUEL LOW
J2 P374 GS106-G E A5
W124 P
5A 6 A6
GS106-H E A7
9G28-027A
Figure 104. Fuel Quantity Gauging Probes Wiring Diagram (900 CONFIG)
Page 106
Original 28-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
A612
FWD INTERCONNECT
A2 PANEL A104
IIDS RIGHT FUEL PROBE
W122 W124 W128
J3 P103 P122 J122
P170 J3 J6 P172 J223 P1
P P P
P P P P P
FUEL PROBE RIGHT HI 23 25 25 A1 D FUEL PROBE RIGHT HI
FUEL PROBE RIGHT LO 24 26 26 A2 C FUEL PROBE RIGHT LO
E
A8
RIGHT FUEL
RIGHT FUEL 62 28 28 A3 H LOW DISCRETE
LOW DISCRETE P A 28VDC
J2 P102 W123 W125 B PWR RTN
P171 J1 J2 P173 P
P P P F LOW FUEL 28VDC
P P
FUEL PROBE LEFT HI 23 23 23 G 28 VDC RTN
FUEL PROBE LEFT LO 24 24 24
J5 P105 P170 J3
W122
LEFT FUEL LOW V 1 14
DISCRETE
A107
W127 LEFT FUEL PROBE
P119 J119 J222 P1
P P
A601 A1 4 FUEL PROBE LEFT HI
CIRCUIT BREAKER PANEL A2 3 FUEL PROBE LEFT LO
5
J1 P131 A8 8 LEFT FUEL LOW
DISCRETE
6 A4 P 1 28VDC IN
GS105-G E A5 2 28 VDC RTN
CB22
FUEL PROBE J2 P128 A3
A6 6 LOW FUEL 28 VDC IN
5A 9
LH ESS BUS GS104-F E A7 7 28 VDC RTN
9G28-057B
Figure 105. Fuel Quantity Gauging Probes Wiring Diagram (902 CONFIG)
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
A104 A107
FWD FUEL PROBE AFT FUEL PROBE
P1 P1
0.2 - 5.0V DIFFERENTIAL FUEL 0.2 - 5.0V DIFFERENTIAL FUEL
HI D HI D
LO QUANTITY SIGNAL QUANTITY SIGNAL
C P LO C
E R E P
O R
28VDC B 100 mA LOW LEVEL DISCRETE O
A H
PWR RTN E A 28VDC B
B
PWR RTN E
B
LOW FUEL 28 VDC
LOW LEVEL F
DETECTOR PWR RTN
G
9G28-034A
9G28-059A
Page 108
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
A604 A119
A601 ENGINE/FUEL CONTROL PANEL FUEL SHUTOFF VALVE
CIRCUIT BREAKER PANEL
S4 (CROSSFEED)
CB8
XFD VLV W125 FUEL CROSSFEED W125 P355 J1
SWITCH 1 J1 P130
J1 P131 P130 J1 CLOSED
G A
2
5A 3 E
OPEN
F H
3 W126
GS303-C E F
M
GS305-K E D
GS307-H E G
C
SH2 A
E
A117
LH FUEL SHUTOFF VALVE
CB7 S6
L FUEL BOOST W125 P353 J1
L FUEL VLV
SWITCH 1 CLOSED
U A
2
5A 4 X
OPEN
V H
3
4 GS301-B E F
5 SEL
M
GS303-A E D
6
GS303-B E G
E
SH2 B
C
A116
S7 RH FUEL SHUTOFF VALVE
CB12 W124 R FUEL BOOST
R FUEL VLV J2 P124 W124 P352 J1
J2 SWITCH
P129 P124 J2 1 CLOSED
U A
2
5A 5 X 3 OPEN
V H
E Y E 4 SEL
GS302-E E F
GS100-K 5 M
GS302-F E D
6
GS304-C E G
E
SH2 C
C
9G28-028-1A
Figure 108. Fuel ShutOff and Crossfeed Valve Wiring Diagram (900 CONFIG PW206A)
(Sheet 1 of 2)
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
A2 A612
IIDS FWD INTERCONNECT PANEL
W122 W125
J5 P105 P170 J3 J2 P173
FUEL XFEED VALVE CLOSED V 1 14 A SH1
FUEL XFEED VALVE OPEN U 2 15
J6 P172
13 C SH1
14
9G28-028-2A
Figure 108. Fuel ShutOff and Crossfeed Valve Wiring Diagram (900 CONFIG PW206A)
(Sheet 2 of 2)
Page 110
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
A601 A604
CIRCUIT BREAKER PANEL ENGINE/FUEL CONTROL PANEL
W125
A117
LH FUEL SHUTOFF VALVE
CB7 S6 W125
L FUEL SHUTOFF J1 P130 P353 J1
L FUEL VLV P130 J1
J1 P131 SWITCH 1 CLOSED
U A
2
5A 4 X
OPEN
V H
3
4 GS301-B E F
5 SEL
M
GS303-A E D
6
GS303-B E G
E
SH2 B
C
A116
S7 RH FUEL SHUTOFF VALVE
CB12 W124 R FUEL SHUTOFF
R FUEL VLV J2 P124 W124 P352 J1
J2 P128 SWITCH
P124 J2 1 CLOSED
U A
2
5A 5 X 3 OPEN
V H
E Y E 4 SEL
GS302-E E F
GS100-K 5 M
GS302-F E D
6
GS304-C E G
E
SH2 A
C
9G28-060-1A
Figure 109. Fuel ShutOff Valve Wiring Diagram (902 CONFIG, 900 CONFIG PW207E)
(Sheet 1 of 2)
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
A2 A612
IIDS FWD INTERCONNECT PANEL
W122 W125
J5 P105 P170 J3 J2 P173
W124
J6 P172
13 A SH1
14
9G28-060-2
Figure 109. Fuel ShutOff Valve Wiring Diagram (902 CONFIG, 900 CONFIG PW207E)
(Sheet 2 of 2)
Figure 110. Fuel ShutOff Valves / Crossfeed Valve Wiring Schematic (Typical)
Page 112
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
FUEL SYSTEM
MAINTENANCE PRACTICES
1. Fuel Cell (3). Remove cabin seats, if applicable
(Ref. 25-20-00, Cabin Seat Assembly
A. General Removal).
(4). Remove carpet, if applicable (Ref.
CAUTION 25-20-00, Cabin Carpet Removal).
AMFUEL cells removed from service (5). Remove cabin floor panels AL165,
must not be left dry for more than 10 AR165 and A170 (Ref. 53-20-00, Cabin
days. Do not allow the cell to be in direct Floor Outboard Panel Removal and
sunlight for extended periods. Apply Cabin Floor Center Panel Removal).
SAE10 oil as a plasticizing agent. The cell
liner will lose pliability if left dry for ex (6). Remove fuel cell access covers (Ref.
tended periods. Subsequent flexing may 28-00-00, Fuel Cell Access Cover
cause material to crack. Removal).
Fuel cells are susceptible to fungus (7). Remove check valves and jet pumps
growth after contact with contaminated (Ref. 28-00-00, Fuel Cell Removal).
fuel. Fungus trapped in the fuel filters in
dicates fuel tank contamination. Remove, (8). Remove fuel transfer in-line check
inspect, clean or replace filter elements valves in accordance with instructions
per applicable Pratt & Whitney Mainte in Fuel Cell Removal
nance Manual. (Ref. 28-00-00)
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(12). Flush out the jet pump supply tubes. (23). Inspect fuel supply hose clamps for
security and deterioration. Repair or
(13). Flush out engine fuel supply lines. replace as required.
(14). Clean fuel booster pump inlet screens. (24). Inspect fuel quantity probes for
security.
CAUTION The orange umbrella shaped (25). Inspect the engine fuel filter elements
check valves are easily damaged. No dam (Ref. Pratt & Whitney Maintenance
age to the umbrella check valves is allowed. Manual). Replace as required.
(26). Install fuel transfer in-line check
(15). On the fuel booster pump, ensure the valves in accordance with instructions
holes under the two orange umbrella in Fuel Cell Removal (Ref. 28-00-00)
check valves are not clogged.
(27). Install fuel cell access covers (Ref.
(a). Clean if clogged. It may be necessary 28-00-00, Fuel Cell Access Cover
to replace the booster pump if the Installation).
holes cannot be unclogged.
(28). Install cabin floor panels AL165,
Alcohol, Isopropyl (C419) AR165 and A170 (Ref. 53-20-00, Cabin
Floor Outboard Panel Installation and
Cabin Floor Center Panel Installation).
(29). Perform fuel cell check/pressure test
(Ref. 28-00-00, Fuel Cell Check/Pres
(16). Clean all internal fuel cell surfaces with sure Test).
lint free cloth moistened with isopropyl
(30). Add 10 gallons (38 Liters) of fuel to
alcohol to remove foreign object
helicopter (Ref. 12-00-00, Main Fuel
contamination. Air dry for 15 minutes.
Tank Fueling). Wait one hour after
(17). Install jet pumps and check valves (Ref. fueling before you proceed.
28-00-00, Fuel Cell Installation). (31). Check for fuel contamination.
(18). Inspect fuel cell baffles for security and (a). Obtain fuel samples from both fuel
flapper valve for freedom of movement. sump drains and examine samples
for evidence of contamination.
(19). Inspect fuel cell baffle lacing cord for
fraying or loose fibers. Replace if (b). If evidence of fuel contamination is
required. found, repeat Contaminated Fuel
Cell Procedures until no contamina
(20). Inspect fuel cell longitudinal baffle for tion exists.
debonding where the metal baffle
(32). Install carpet, if applicable (Ref.
connects to the rubber. None allowed.
25-20-00, Cabin Carpet Installation).
(21). Inspect fuel cell frangible valves for (33). Install cabin seats, if applicable (Ref.
security. 25-20-00, Cabin Seat Assembly
Installation).
(22). Inspect fuel supply hoses for deteriora
tion, collapsed or kinked hoses. No (34). Fuel helicopter (Ref. 12-00-00, Main
damage allowed. Fuel Tank Fueling).
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Rotorcraft Maintenance Manual
(5). Remove cabin floor panels AL165, (17). Inspect fuel quantity probes for
AR165 and A170 (Ref. 53-20-00, Cabin security.
Floor Outboard Panel Removal and
(18). Inspect the engine fuel filter elements
Cabin Floor Center Panel Removal).
(Ref. Pratt & Whitney Maintenance
(6). Remove fuel cell access covers (Ref. Manual). Replace as required.
28-00-00, Fuel Cell Access Cover (19). Install fuel cell access covers (Ref.
Removal). 28-00-00, Fuel Cell Access Cover
(7). Flush out engine fuel supply lines. Installation).
(20). Install cabin floor panels AL165,
(8). Clean fuel booster pump inlet screens. AR165 and A170 (Ref. 53-20-00, Cabin
Floor Outboard Panel Installation and
CAUTION The orange umbrella shaped Cabin Floor Center Panel Installation).
check valves are easily damaged. No dam (21). Perform fuel cell check/pressure test
age to the umbrella check valves is allowed. (Ref. 28-00-00, Fuel Cell Check/Pres
sure Test).
(9). On the fuel booster pump, ensure the
holes under the two orange umbrella (22). Add 10 gallons (38 Liters) of fuel to
check valves are not clogged. helicopter (Ref. 12-00-00, Main Fuel
Tank Fueling). Wait one hour after
(a). Clean if clogged. It may be necessary fueling before you proceed.
to replace the booster pump if the
holes cannot be unclogged. (23). Check for fuel contamination.
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Rotorcraft Maintenance Manual
(a). Obtain fuel samples from both fuel (24). Install carpet, if applicable (Ref.
sump drains and examine samples 25-20-00, Cabin Carpet Installation).
for evidence of contamination.
(25). Install cabin seats, if applicable (Ref.
25-20-00, Cabin Seat Assembly
(b). If evidence of fuel contamination is Installation).
found, repeat Contaminated Fuel
Cell Procedures until no contamina (26). Fuel helicopter (Ref. 12-00-00, Main
tion exists. Fuel Tank Fueling).
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FUEL SYSTEM
REMOVAL/INSTALLATION
1. Fuel Cell (12). Remove bolts (26) and washers (27).
A. Fuel Cell Removal (13). Remove sealant from bolt heads (23).
(Ref. Figure 401) (14). Remove bolts (23) and washers (24).
(15). Remove and discard o-ring (25).
Consumable Materials
(Ref. CSPSPM) (16). Disconnect booster pump wire har
Item Nomenclature nesses (10, Figure 403) as follows:
C707 Tape, Pressure Sensitive (a). Remove screw (16) from left booster
pump and disconnect A111 (Q12D16)
wire positive (+) terminal.
Aviation Turbine Fuel
(b). Remove screw (16) from right booster
pump and disconnect A112 (Q13C16)
wire positive (+) terminal.
(c). Remove screw (17) from left booster
(1). Defuel helicopter (Ref. Section pump, push up on shut-off lever arm.
12-00-00). Remove A111 (Q35A16N) and
(2). If necessary, remove cabin seats (Ref. (Q35B16) wire from negative (-)
Section 25-20-00). terminal.
(3). If necessary, remove carpet (Ref. (d). Remove screw (17) from right booster
Section 25-20-00). pump, push up on shut-off lever arm.
Remove A112 (Q36A16N) and
(4). Remove panels AL155, AR155, A160, (Q36B16) wire from negative (-)
AL165, AR165, A170, A217, AL230, terminal.
and AR230 (Ref. Section 53-20-00).
(17). Disconnect forward and aft fuel sump
(5). Remove panel B178 (Ref. Section drain valve controls.
06-00-00).
(18). Remove bolts (28) and washers (29).
System Contamination
CAUTION CAUTION
(6). Remove fuel cell access covers. Do not fold fuel cell in temperatures less
than 50 F (10 C).
(7). Remove forward and aft fuel quantity
probes. Do not use fuel cell metal fittings to lift or
move fuel cell. Damage to the barrier that
(8). Remove left and right fuel cell frangible you can not see can occur.
valves.
(19). Carefully remove fuel cell (1).
(9). Remove single and dual vent/rollover
NOTE: If fuel cell is to be replaced, do the steps
valves. that follow:
(10). Remove fuel filler neck flexible coupling (20). Remove fuel sump drain valves.
(8, Figure 407) and remove and discard
o-rings (7). (21). Remove fill port check valve.
(11). Remove sealant from bolt heads (26, (22). Remove screws (19), washers (20), and
Figure 401). clamps (21) from left and right inner
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Rotorcraft Maintenance Manual
(g). Install tubes on jet pumps. Torque (15). Install flexible coupling (8).
tube nuts.
(6). Install fill port check valve. (16). Install fuel cell frangible valves.
(13). Environmentally seal bolt heads and (21). Fully examine inner side of fuel cell for
washers, use sealing compound (C207) unwanted material before you install
(Ref. CSP-SPM). fuel cell cover.
Grease (C109)
NOTE: If new fuel cell is new, do the fuel cell
baffle lacing cord deflection inspection. This
inspection is not necessary if same fuel cell
is installed and baffle lacing cords have not
moved.
(14). Lubricate new o-rings (7, Figure 407)
with grease (C109) and install on fuel
cell filler neck and gravity filler neck. (22). Install fuel cell access cover.
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(23). Install panels AL155, AR155, A160, (26). Do the fuel quantity indicating system
AL165, AR165, A170, A217, AL230, functional test.
and AR230 (Ref. Section 53-20-00).
(27). If necessary, install carpet (Ref. Section
(24). Install panel B178 (Ref. Section
25-20-00).
06-00-00).
(25). Do the fuel cell leak check/pressure (28). If necessary, install cabin seats (Ref.
test. Section 25-20-00).
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Rotorcraft Maintenance Manual
16
15
16
14
18
1 17
3 11 11
5 10
7
17
NOTE
13
6
12
12
NOTE:
FUEL CROSSFEED SYSTEM REMOVED ON 900 CONFIG HELICOPTERS CONVERTED TO PW207E ENGINES. 9G28-022-1C
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Rotorcraft Maintenance Manual
16
15
16
14
18
17
1
2
3 11
11
12
(2 PL)
10
4
5
6
17
7
9G28-022-2A
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23
25
24
21
27 20
19
REF 22
FUSELAGE
29
28
29
28
30
30
G28-022-3
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2. Fuel Cell Access Cover (1). Prepare access cover surface for
electrical bonding (Ref. CSP-SPM).
A. Fuel Cell Access Cover Removal
Grease (C109)
(Ref. Figure 402)
Aviation Turbine Fuel
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A. Centrifugal Fuel Booster Pump Removal (a). PW206A Remove fuel supply check
valve (3) and packing (4). Discard
(Ref. Figure 403) packing.
NOTE: This task is typical for left and right (b). PW206E/PW207E Remove union
centrifugal fuel booster pump removal. (22) and packing (4). Discard pack
ing.
Aviation Turbine Fuel
(c). Remove reducer bushing (5) and
packing (6). Discard packing.
(11). 902 CONFIG - Remove fittings from
booster pump outlet as follows:
(1). Defuel helicopter (Ref. Section
12-00-00). (a). Disconnect tube (28).
(2). If necessary, remove cabin seats (Ref. (b). Remove nut (26), adapter (27), tee
Section 25-20-00). (24), reducer (25), and packing (4).
Discard packing.
(3). If necessary, remove carpet (Ref.
Section 25-20-00. (12). Remove and discard lockwire. Remove
bleeder/drain plug (14) and packing
(4). Remove cabin floor panels AL165, (13). Discard packing. Drain fuel into
AR165, A170 (Ref. Section 53-20-00). an applicable container.
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Rotorcraft Maintenance Manual
(13). Remove bolt (7 or 21) and washer (8). Finish Enamel, Black (C303)
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(a). Connect A111 (Q12D16) wire to left (d). Install reducer and tube nut. Torque
booster pump positive (+) terminal. tube nut 230-260 in-lb (26-29.4
A112 (Q13C16) wire to right booster Nwm).
pump positive (+) terminal and
install (short) straight slot screw. (e). Connect tube. Torque tube nut 50-65
in-lb (5.65-7.34 Nwm).
(b). Connect A111 (Q35A16N) and
(Q35B16) wire to left booster pump (13). Connect fuel hose. Torque fuel supply
negative (-) terminal. A112 hose nut 230-260 in-lb (26-29.4 Nwm).
(Q36A16N) and (Q36B16) wire to (14). Install forward fuel cell access cover
right booster pump negative (-) (Ref. Section 28-00-00).
terminal. Install hex head screw,
push up on shut-off lever arm so (15). Install cabin floor panels AL165,
screw will turn freely. Torque screw. AR165, A170 (Ref. Section 53-20-00).
(11). 900 CONFIG - Install fittings in (16). Do the fuel cell leak check/pressure
booster pump as follows: test.
(a). Lubricate packing with grease (C109) (17). Install sump access panel B178 (Ref.
and install on reducer bushing. Section 06-00-00).
(b). Install reducer bushing. Torque (18). Fuel helicopter (Ref. Section 12-00-00).
reducer bushing 380-405 in-lb
(42.9-45.8 Nwm). (19). Do the fuel booster pump operational
test.
(c). (PW206A) Lubricate packing with
grease (C109) and install on fuel (20). If necessary, install carpet (Ref. Section
supply system check valve. 25-20-00).
(d). (PW206A) Install check valve. (21). If necessary, install cabin seats (Ref.
Torque check valve 280-305 in-lb Section 25-20-00).
(31.6-34.5 Nwm).
C. Centrifugal Fuel Booster Pump Umbrella
(e). (PW206E/PW207E) Lubricate Shaped Check Valve Removal
packing with grease (C109) and
install on union. NOTE: You can only change the umbrella
shaped check valve in the fuel booster pump
(f). (PW206E/PW207E) Install union. cartridge housing.
Torque union 280-305 in-lb
(31.6-34.5 Nwm). (1). Remove fuel booster pump.
(12). 902 CONFIG - Install fittings in (2). Remove fuel booster pump cartridge.
booster pump as follows: (3). Remove check valve (23).
(a). Lubricate packing with grease (C109) D. Centrifugal Fuel Booster Pump Umbrella
and install on reducer. Shaped Check Valve Installation
(b). Install reducer. Torque reducer (1). Install check valve.
380-405 in-lb (42.9-45.8 Nwm).
(2). Install fuel booster pump cartridge.
(c). Install tee. Torque tee 230-260 in-lb
(26-29.4 Nwm). (3). Install fuel booster pump.
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26 24
27
28
1
22 25
3
902 CONFIG
900 CONFIG WITH
206E OR 207E ENGINES 5
4
23
2
8
8
6 13 10
7
10
9 10 11
12
16
15
14 17 BOTTOM VIEW
SERIAL NUMBER
33 AND SUBSEQUENT 19
18
8 (3 PL) 8
20 (3 PL) 8 (4 PL) 21
15 (4 PL)
9G28-012C
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Consumable Materials
(4). Remove and discard lockwire securing
(Ref. CSPSPM)
bleeder/drain plug (7, Ref. Figure 404)
Item Nomenclature
from bottom of pump cartridge (2).
Remove and discard O-ring (6).
C802 Cloth, NonLint
(5). Remove Spirolox retaining ring (5) from
bottom of fuel pump.
(b). Remove (long) Allen drive shoulder NOTE: This task is typical for LH and RH Cen
screw (17). While applying upward trifugal Fuel Booster Pump Cartridge
pressure to the shut-off lever arm to installation.
prevent binding of the Allen drive
shoulder screw, remove: Consumable Materials
A111 (Q35A16N) and (Q35B16) wire (Ref. CSPSPM)
from left booster pump negative (-) Item Nomenclature
terminal.
A112 (Q36A16N) and (Q36B16) wire C109 Grease
from right booster pump negative (-) C702 Lockwire
terminal.
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(7). Secure bleeder/drain plug (7) with (12). Install sump access panel assembly
lockwire (C702). B178 (Ref. Section 06-00-00).
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1
BOTTOM VIEW
2
3 9
5 4
8
7 9G28-013A
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B. Forward Fuel Gauging Probe Installation (12). Install cabin seats, if applicable (Ref.
Section 25-20-00).
(Ref. Figure 405)
6. Aft Fuel Gauging Probe
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
A. Aft Fuel Gauging Probe Removal
C109 Grease
(Ref. Figure 405)
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Consumable Materials
(Ref. CSPSPM) 2
Item Nomenclature
10
C109 Grease 1
11
(1). Prepare probe surface for electrical
bonding (Ref. CSP-SPM).
Grease (C109)
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19 (2 PL) 14 (4 PL)
20 (2 PL) 15 (4 PL)
21 (2 PL) 22 (2 PL) 16 (4 PL)
18 (2 PL)
17 (4 PL)
4 (2 PL)
2
23 (2 PL)
25 (2 PL)
26 (2 PL)
27 (X2 2 PL)
28 (2 PL)
1 24 (2 PL)
11 (2 PL)
12 (X2 2 PL)
13 (X2 2 PL)
3 (2 PL)
5 (2 PL)
6 (2 PL)
7 (2 PL)
8 (2 PL)
9 (2 PL)
10 (2 PL) 9G28-050
1. FORWARD (LEFT SIDE) FUEL GAUGING PROBE 15. BOLT
2. AFT (RIGHT SIDE) FUEL GAUGING PROBE 16. SPACER
3. FUEL BOOSTER PUMP 17. WASHER
4. HOSE ASSEMBLY, BOOSTER TO FUEL CELL OUTLET 18. CHECK VALVE
5. TEE 19. PACKING
6. PACKING 20. BUSHING
7. REDUCER 21. PACKING
8. PACKING 22. JET PUMP
9. REDUCER 23. TUBE ASSEMBLY, BOOSTER TO JET PUMP
10. TUBE NUT 24. TUBE ASSEMBLY, JET PUMP TO OUTLET
11. BRACKET ASSEMBLY 25. CLAMP
12. BOLT 26. BOLT
13. WASHER 27. WASHER
14. CLAMP 28. NUT
Figure 406. Fuel Pump, Gauging, and Transfer Systems (902 CONFIG)
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7. Gravity Fill Port Filler Neck (1). Prepare filler neck surface for electrical
bonding (Ref. CSP-SPM).
A. Gravity Fill Port Filler Neck Removal
Sealant, Conductive (C229)
(Ref. Figure 407)
Aviation Turbine Fuel
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
8. Fuel Fill Port Check Valve Assembly (1). Prepare fill port check valve assembly
and fuel cell fitting faying surfaces for
A. Fuel Fill Port Check Valve Assembly electrical bonding (Ref. CSP-SPM).
Removal
Grease (C109)
(Ref. Figure 407)
Aviation Turbine Fuel
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4 10
16 12 14
13
11 902 CONFIG
2
6
7
8 9
15
9G28-037 LOOKING INBD RIGHT SIDE
1. FUEL FILLER CAP 9. FUEL CELL FITTING
2. LANYARD 10. ORING
3. BOLT 11. ORING
4. WASHER 12. WASHER
5. FILLER NECK FLANGE 13. NUT
6. GRAVITY FILLER NECK 14. CHECK VALVE ASSEMBLY
7. ORING 15. CENTER BAFFLE CHECK VALVE (902 CONFIG)
8. FLEXIBLE COUPLING 16. RETAINER, PACKING BACKUP
Figure 407. Gravity Fill Port Filler Neck and Check Valve
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System Contamination
CAUTION (3). Install bolts (3) and washers (4)
(3). Remove bolts (3) and washers (4) from through range extender flange (6), fuel
range extender flange (6) and remove filler neck flange (5) and aircraft outer
range extender. skin. Torque bolts.
B. Range Extender Installation
(4). Connect filler cap lanyard (2) to check
(Ref. Figure 408) valve lanyard and install filler cap (1).
Consumable Materials
(Ref. CSPSPM)
(5). Perform fuel cell leak check/pressure
Item Nomenclature
test (Ref. Section 28-00-00).
C229 Sealant, Conductive
(6). Fuel helicopter (Ref. Section 12-00-00).
1 5
2
3
4
9G28-047
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10. Single Port Fuel Vent Float/Rollover Valve B. Single Port Fuel Vent Float/Rollover
Valve Installation
A. Single Port Fuel Vent Float/Rollover
Valve Removal (Ref. Figure 409)
(Ref. Figure 409) NOTE: This task is typical for LH aft and RH
forward Single Port Fuel Vent Float/Rol
NOTE: This task is typical for LH aft and RH lover Valve installation, except where noted.
forward Single Port Fuel Vent Float/Rol
lover Valve removal, except where noted.
Consumable Materials
Aviation Turbine Fuel (Ref. CSPSPM)
Item Nomenclature
C109 Grease
C206 Sealing Compound
C702 Lockwire
(1). Defuel helicopter (Ref. Section
12-00-00).
(1). Prepare single port float/rollover valve
(2). Remove cabin seats, if applicable (Ref. surface for electrical bonding (Ref.
Section 25-20-00). CSP-SPM).
(3). Remove carpet, if applicable (Ref.
Grease (C109)
Section 25-20-00).
(6). Disconnect electrical bonding jumpers. (3). Position float/rollover valve on fuel cell.
(a). If removing right forward single port (4). Connect electrical bonding jumpers.
float/rollover valve, remove bolt (1)
and washer (2) and disconnect (a). If installing right forward single port
electrical bonding jumpers (3) from float/rollover valve, connect electrical
float/rollover valve. bonding jumpers (3) with bolt (1) and
washer (2) and install at inboard
(b). If removing left aft single port position.
float/rollover valve, remove and
discard lockwire from bolt (1) and (b). If installing left aft single port
plug (4). Remove bolt (1) and washer float/rollover valve, connect electrical
(2) and disconnect electrical bonding bonding jumpers (3) with bolt (1) and
jumpers (3) from float/ rollover valve. washer (2) and install at inboard
position. Torque bolt and safety to
System Contamination plug (4) with lockwire (C702).
CAUTION
(7). Remove remaining bolts (5) and washer (5). Install remaining bolts (5) and washer
(6) attaching float/rollover valve (8) to (6) attaching float/rollover valve to fuel
fuel cell. cell. Torque bolts.
(8). Remove float/rollover valve and discard (6). Perform electrical bond testing (Ref.
O-ring (9). CSP-SPM).
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Sealing Compound (C206) (9). Install cabin floor panels AR155 and
AL230 (Ref. Section 53-20-00).(Ref.
Section 53-20-00).
(10). Perform fuel cell leak check/pressure
test (Ref. Section 28-00-00).
(7). Apply sealing compound (C206) to bolts (11). Install carpet, if applicable (Ref. Section
(Ref. CSP-SPM). 25-20-00).
(12). Install cabin seats, if applicable (Ref.
(8). Install fuel vent hose (7) on float/rol Section 25-20-00).
lover valve (8). Secure vent hose with
lockwire (C702). (13). Fuel helicopter (Ref. Section 12-00-00).
1 7 5
4
1
5 8
6 2
2
3
6
9 8
9
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(c). Disconnect transition duct from (6). Perform electrical bond testing (Ref.
float/rollover valve and elbow duct CSP-SPM).
(10) and remove from bulkhead. (7). Connect aft right or early type forward
left float/rollover valve.
(7). Remove bolt (1) and washer (2) and
disconnect electrical bonding jumpers (a). Connect fuel vent hoses (5) to aft
(3) from float/rollover valve (8). float/rollover valve vent tube (4).
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(b). Secure fuel vent hoses with lockwire NOTE: If necessary, float/rollover valve bolts
(C702). can be loosened to allow transition duct
installation. Retorque bolts after installa
(8). Connect later type forward left float/ tion.
rollover valve.
Sealing Compound (C206) (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
Adhesion Promoter (C242) aircraft.
(a). Install fuel vent hose (5) on float/ (10). Install cabin floor panels AL155 and
rollover valve. AR230 (Ref. Section 53-20-00).
(b). Clean residual sealing compound (11). Perform fuel cell leak check/pressure
from transition duct (11), elbow duct test (Ref. Section 28-00-00).
(10), float/rollover valve (8), and
grommet (12) faying surfaces as (12). Install carpet, if applicable (Ref. Section
required. Use cleaner (C432). 25-20-00).
(c). Lightly abrade faying surfaces. Use
scouring pad (C817). (13). Install cabin seats, if applicable (Ref.
Section 25-20-00).
(d). Apply adhesion promoter (C242) to
faying surfaces and allow to dry. (14). Fuel helicopter (Ref. Section 12-00-00).
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1
2
6 3
7
11
5
12
5
8
10
FORWARD-LEFT SIDE 9
12
S/N 0033-SUBS AND PRIOR AFT-RIGHT SIDE
BY MODIFICATION AND EARLY MODEL
FORWARD-LEFT SIDE
9G28-020B
1. BOLT 7. WASHER
2. WASHER 8. DUAL VENT/ROLLOVER VALVE
3. ELECTRICAL BONDING JUMPER 9. ORING
4. VENT TUBE ASSEMBLY 10. ELBOW DUCT
5. VENT HOSE 11. TRANSITION DUCT
6. BOLT 12. EDGE GROMMET
Figure 410. Dual Port Fuel Vent Float/Rollover Valve
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12. Fuel Vent System Components (c). Disconnect elbow duct from transi
tion duct and fuel vent hose and
A. Fuel Vent Components Removal remove from bulkhead.
(Ref. Figure 411) B. Fuel Vent Components Installation
NOTE: This task is typical for Fuel Vent Sys (Ref. Figure 411)
tem Components removal.
NOTE: This task is typical for Fuel Vent Sys
Helicopter must be defueled be tem Components installation.
CAUTION fore floor panels A160, A170,
and/or A217 or both AL165 and AR165 are Consumable Materials
removed. Structural damage can occur if (Ref. CSPSPM)
any of these panels are removed with fuel in Item Nomenclature
the helicopter.
C206 Sealing Compound
(1). Remove cabin floor panels AL155, C242 Adhesion Promoter
AR155, A160, AL165, AR165, A170, C432 Cleaner
A217, AL230, AR230 (Ref. Section C702 Lockwire
53-20-00) as required.
C817 Pad, Scouring, Cellulose/Nylon
Aviation Turbine Fuel
(1). Prepare fuel vent component surfaces
for electrical bonding (Ref. CSP-SPM).
(2). Install interconnect tube assemblies,
(2). Remove and discard lockwire and standpipe assemblies, and flame
disconnect fuel vent hoses from fuel arrestors, as required with bonding
vent float/rollover valve vent tubes, jumpers and remove bonding clamps,
interconnect tube assemblies, standpipe cushioned support clamps, and attach
assemblies, and flame arrestors, as ing hardware, as required. Torque
required. hardware as required.
Sealing Compound (C206)
CAUTION
Residual Fluids
System Contamination
(3). Apply sealing compound (C206) to
(3). Disconnect bonding jumpers and completely cover bonding clamp and
remove bonding clamps, cushioned hardware on aft flame arrestor.
support clamps, and attaching hard
ware, as required, to remove intercon (4). Connect fuel vent hoses to float/rollover
nect tube assemblies, standpipe valve vent tubes, interconnect tube
assemblies, and flame arrestors, as assemblies, standpipe assemblies, and
required. flame arrestors, as required. Secure
with two to three turns of lockwire
(4). S/N 0033-subs - Remove forward left (C702).
vent ducts as required.
(5). S/N 0033-subs - Install forward left
(a). Remove sealing compound from vent ducts as required.
transition duct, elbow duct and
grommets. (a). Clean residual sealing compound
from transition duct, elbow duct,
(b). Disconnect transition duct from float/rollover valve, and grommets
float/rollover valve and elbow duct faying surfaces as required. Use
and remove from bulkhead. cleaner (C432).
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(b). Lightly abrade faying surfaces. Use (f). Install transition duct and grommet
scouring pad (C817). through bulkhead, and connect to
float/rollover valve and elbow duct.
(c). Apply adhesion promoter (C242) to Allow sealing compound to cure
faying surfaces and allow to dry. before fueling aircraft.
NOTE: If necessary, float/rollover valve bolts
can be loosened to allow transition duct (6). Install cabin floor panels AL155,
installation. Retorque bolts after installa AR155, A160, AL165, AR165, A170,
tion. A217, AL230, AR230 (Ref. Section
53-20-00) as required.
(d). Apply sealing compound (C206) to
faying surfaces. (7). Perform fuel cell leak check/pressure
(e). Install elbow duct and grommet test (Ref. Section 28-00-00).
through bulkhead. Connect fuel vent
to elbow duct. Secure with lockwire (8). Fuel helicopter if necessary (Ref.
(C702). Section 12-00-00).
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9 8
10
5
4
17
8
11
12
3 5
5 19
6
1
1
18
2
18
1
16
20
5
21 3
19
15
22
14
13
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13. Fuel Sump Drain Valve (2). Install fuel drain valve in fuel cell.
Torque drain valve.
A. Fuel Sump Drain Valve Removal
(Ref. Figure 412) (3). Insert forward drain control cable
assembly (3) or aft drain control cable
NOTE: This task is typical for LH and RH Fuel assembly (4) into drain valve. Install
Sump Drain Valve removal. bolt (7) washer (6) and clamp (5).
Torque bolt.
Aviation Turbine Fuel
(4). Install rubber tubing (C608) (10) on
drain valve and secure with lockwire
(C702).
(1). Defuel helicopter (Ref. Section (5). Install sump access panel assembly
12-00-00). B178 (Ref. Section 06-00-00).
(2). Remove sump access panel assembly
B178 (Ref. Section 06-00-00). (6). Fuel helicopter (Ref. Section 12-00-00).
(3). Remove and discard lockwire and (7). Visually check for leaks.
remove rubber tubing (C608) (10) from
fuel drain valve (9).
14. Fuel Sump Drain Valve Control Assembly
(4). Remove bolt (7), washer (6), and clamp (Fwd and Aft)
(5) retaining forward drain control
cable assembly (3) or aft drain control A. Fuel Sump Drain Valve Control Assembly
cable assembly (4). Remove cable end Removal
from fuel drain valve (9).
(Ref. Figure 412)
(5). Remove drain valve (9) from fuel cell
and discard O-ring (8).
NOTE: This task is typical for forward and aft
B. Fuel Sump Drain Valve Installation Fuel Sump Drain Valve Control Cable re
moval.
(Ref. Figure 412)
(1). Remove sump access panel assembly
NOTE: This task is typical for LH and RH Fuel
B178 and open fuel drain access panel
Sump Drain Valve installation.
R185 (Ref. Section 06-00-00).
Consumable Materials (2). Remove bolt (7), washer (6), and clamp
(Ref. CSPSPM) (5) retaining forward drain control
Item Nomenclature cable assembly (3) or aft drain control
C109 Grease cable assembly (4).
C702 Lockwire
C608 Rubber Tubing (3). Remove control cable assembly plunger
from fuel drain valve (9).
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B. Fuel Sump Drain Valve Control Assembly assembly (3) and aft drain control cable
Installation assembly (4). Torque bolt.
2
(REF. FUSELAGE
STRUCTURE
1
1 8
9 9
2 8
5
3
6 6
7
7
10 10
9G28-017
1. SCREW 6. WASHER
2. WASHER 7. BOLT
3. FWD CONTROL CABLE ASSEMBLY 8. ORING
4. AFT CONTROL CABLE ASSEMBLY 9. DRAIN VALVE
5. CLAMP 10. RUBBER TUBING (C608)
Figure 412. Fwd and Aft Fuel Sump Drain Valve and Drain Valve Control Assembly
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15. Fuel Cell Frangible Valve (10). Remove bolts (7) and washers (8)
attaching vapor shroud to keel beam
A. Fuel Cell Frangible Valve Removal and fuel cell.
(Ref. Figure 413) NOTE: During removal of frangible valve, take
precaution to retain gasket (14) between
NOTE: This task is typical for LH and RH Fuel fuel cell outlet fitting and keel beam.
Cell Frangible Valve removal.
(11). Remove vapor shroud (1) and spacer
Aviation Turbine Fuel (11) from frangible valve (3) hose
assembly.
(12). Disconnect fuel hose assembly (12)
ratchet end connector from frangible
valve (3) inside fuel cell. Pull back on
(1). Defuel helicopter (Ref. Section end to disengage ratchet, then unscrew.
12-00-00).
(13). Remove bolts (9) and washers (10)
(2). Remove cabin seats, if applicable (Ref. attaching frangible valve (3) to fuel cell.
Section 25-20-00). Remove frangible valve from inside of
fuel cell and discard O-ring (13).
(3). Remove carpet, if applicable (Ref.
Section 25-20-00). B. Fuel Cell Frangible Valve Installation
(4). Remove cabin floor panels; AL165, (Ref. Figure 413)
AR165, A170, A217, AL230, AR230,
A235, AL250 and AR250 as required
NOTE: This task is typical for LH and RH Fuel
(Ref. Section 53-20-00). Cell Frangible Valve installation.
Consumable Materials
CAUTION
(Ref. CSPSPM)
Residual Fluids Item Nomenclature
System Contamination C109 Grease
C205 Sealing Compound
(5). Remove aft fuel cell access cover (Ref. C606 Rubber Tubing
Section 28-00-00). C702 Lockwire
(6). Remove and discard lockwire securing
fuel line vapor shroud (1). Disconnect (1). Prepare frangible valve surface for
vapor shroud hose from fuel intercon electrical bonding (Ref. CSP-SPM).
nect tee fitting vapor shroud box (2).
Grease (C109)
(7). Disconnect nut on frangible valve (3)
hose assembly from fuel interconnect
tee fitting (4).
(8). Remove and discard lockwire and
(2). Lubricate O-ring (13) with grease
remove drain tubing connector (5) and
(C109) and install on frangible valve (3)
rubber tubing (C606) (6) from vapor
hose assembly.
shroud.
(3). Install frangible valve in fuel cell with
(9). On earlier serial number helicopters, hose through fuel cell.
sealing compound is applied. Carefully
remove sealing compound from fasten (4). Install fitting gasket (14) between fuel
ers and flange surfaces of frangible cell fitting and keel beam and install
valve flange junction with keel beam frangible valve hose assembly through
(Ref. CSP-SPM). keel beam.
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(5). Install bolts (9) and washers (10) (10). Connect frangible valve (3) hose
attaching frangible valve to fuel cell. assembly to fuel interconnect tee fitting
Torque bolts. (4). Torque hose nut.
Sealing Compound (C205) (16). Perform fuel supply vapor shroud leak
check/pressure test (Ref. Section
28-00-00).
(17). Install carpet, if applicable (Ref. Section
25-20-00).
(9). Apply sealing compound (C205) to (18). Install cabin seats, if applicable (Ref.
faying surfaces of vapor shroud and Section 25-20-00).
keel beam and heads of bolts (Ref.
CSP-SPM). (19). Fuel helicopter (Ref. Section 12-00-00).
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2
902 CONFIG
HAND 9
TIGHTEN 10 11 3
12 4
14
5
8
7
6
9G28-011
1. FUEL LINE VAPOR SHROUD 8. WASHER
2. VAPOR SHROUD BOX 9. BOLT
3. FRANGIBLE VALVE HOSE ASSEMBLY 10. WASHER
4. INTERCONNECT TEE FITTING 11. VAPOR SHROUD SPACER
5. DRAIN TUBING CONNECTOR 12. FUEL HOSE ASSEMBLY
6. RUBBER TUBING (C606) 13. ORING
7. BOLT 14. GASKET
Figure 413. Fuel Cell Frangible Valve
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16. Fuel Interconnect Tee Fitting (10). Remove bolts (3) and washers (4)
attaching fuel interconnect tee fitting
A. Fuel Interconnect Tee Fitting Removal (10) to vapor shroud box (9). Remove
(Ref. Figure 414) fuel interconnect tee fitting.
B. Fuel Interconnect Tee Fitting Installation
NOTE: This task is typical for LH and RH Fuel
Interconnect Tee Fitting removal. (Ref. Figure 414)
Aviation Turbine Fuel NOTE: This task is typical for LH and RH Fuel
Interconnect Tee Fitting installation.
Consumable Materials
(Ref. CSPSPM)
(1). Defuel helicopter (Ref. Section Item Nomenclature
12-00-00). C109 Grease
(2). Open baggage compartment door L262 C230 Sealant, Electrically Conductive
(Ref. Section 06-00-00). C702 Lockwire
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(8). 902 CONFIG - Install tube fitting cap 17. Fuel Pressure Switch Assembly
(18). Torque tube fitting cap. Install
shroud box cap (17) and secure with A. Fuel Pressure Switch Assembly Removal
lockwire (C702). (Ref. Figure 414)
(9). Lubricate O-ring (11) lightly with NOTE: This task is typical for LH and RH Fuel
grease (C109) and install on fuel Pressure Switch removal.
pressure switch assembly (12).
Aviation Turbine Fuel
(10). Install fuel pressure switch assembly
(12) in fuel interconnect tee fitting (10).
Torque fuel pressure switch.
(11). Prepare vapor shroud box (9), vapor (1). Defuel helicopter (Ref. Section
shroud box cover assembly (2) surfaces 12-00-00).
for electrical bonding (Ref. CSP-SPM). (2). Open baggage compartment door L262
(Ref. Section 06-00-00).
Sealant, Electrically Conductive (C230)
(3). Remove baggage compartment floor
panels A235, AL250, AR250 as re
quired (Ref. Section 53-20-00).
(4). Remove and discard lockwire and
(12). Apply sealant (C230) to faying surfaces detach connector (1) from fuel pressure
between vapor shroud box cover and switch assembly (12).
vapor shroud box and install vapor (5). Remove bolts (14) and washers (13)
shroud box cover assembly (2) with from fuel interconnect vapor shroud
bolts (14) and washers (13). Torque cover assembly (2) and let cover hang
bolts. from wire bundle.
(13). Attach connector (1) and safety with
lockwire (C702). CAUTION
Residual Fluids
(14). Install cabin and baggage compartment
floor panels AL165, AR165, A170, System Contamination
A217, AL230, AR230, A235, AL250 as (6). Remove pressure switch assembly (12)
required (Ref. Section 53-20-00). with vapor shroud box cover (2) from
fuel interconnect tee fitting (10) and
(15). Perform fuel cell leak check/pressure discard O-ring (11).
test (Ref. Section 28-00-00).
(7). Remove silicone from back of connector.
(16). Perform fuel supply vapor shroud leak
Note color code and pin location
check/pressure test (Ref. Section CAUTION of wires when removing and
28-00-00).
install in same order to prevent switch mal
function.
(17). Close baggage compartment door L262
(Ref. Section 06-00-00). (8). Remove electrical pins from connector
with extraction tool (Ref. CSP-SPM,
(18). Fuel helicopter (Ref. Section 12-00-00). Section 20-60-00).
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18 5
17
2
3 15 1
4
8 902 CONFIG
13 14
11 12
10
95 - 105 in-lb
7 9 10.7 - 11.9 Nm
16
9G28-010
1. CONNECTOR (P350 RH, P351 LH) 10. FUEL INTERCONNECT TEE FITTING
2. VAPOR SHROUD BOX COVER ASSEMBLY 11. ORING
3. BOLT 12. FUEL PRESSURE SWITCH ASSEMBLY
4. WASHER 13. WASHER
5. TUBE ASSEMBLY 14. BOLT
6. FUEL HOSE 15. CONNECTOR JAM NUT
7. FUEL HOSE FRANGIBLE VALVE 16. RUBBER TUBING (C606)
8. FRANGIBLE VALVE 17. SHROUD BOX CAP
9. VAPOR SHROUD BOX ASSEMBLY 18. TUBE FITTING CAP
Figure 414. Fuel Interconnect Tee Fitting and Fuel Pressure Switch
18. Fuel ShutOff Valve Assembly (3). Remove left Electronic Engine Control
(EEC) (Ref. Section 76-00-00).
A. Fuel ShutOff Valve Assembly Removal
(4). Lower or remove left hand hinged
(Ref. Figure 415) avionics shelf (Ref. Section 25-70-00).
NOTE: This task is typical for LH and RH Fuel (5). Remove and discard lockwire and
Shut-Off Valve Assembly removal. detach connector (1) from fuel shut-off
valve assembly (8).
Aviation Turbine Fuel
(6). Remove bolts (2) and washers (3)
attaching vapor shroud cover assembly
(4) to vapor shroud box (5). Let cover
hang from wire bundle.
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vapor shroud box (5) and remove fuel Fluorosilicone Compound (C222)
shut-off valve assembly with vapor
shroud cover (4).
NOTE: This task is typical for LH and RH Fuel (4). Install fuel shut-off valve assembly (8)
Shut-Off Valve Assembly installation. in vapor shroud box (5) with bolts (9)
and washers (10). Torque bolts.
(5). Connect tube assemblies (6 and 7) to
Consumable Materials fittings on fuel shut-off valve assembly
(Ref. CSPSPM) (8). Torque tube nuts.
Item Nomenclature
(6). Prepare vapor shroud box (5) and vapor
C222 Fluorosilicone Compound shroud box cover (4) surface for electri
C230 Sealant, Electrically Conductive cal bonding (Ref. CSP-SPM).
C702 Lockwire (7). Apply sealant (C230) to faying surfaces
C818 Sleeve, Protective, Expandable and between vapor shroud box cover and
Insulating vapor shroud box and install vapor
shroud box cover assembly (4) with
C819 Insulation Sleeving, Electrical, Heat
bolts (2) and washers (3). Torque bolts.
Shrinkable
(8). Attach connector (1) to fuel shut-off
valve assembly and safety with lock
(1). Install valve wires in connector. wire (C702).
(9). Perform fuel shut-off valve operational
(a). Install expandable sleeving (C818) test (Ref. Section 28-00-00).
over wires.
(10). Perform fuel booster pump operational
test (Ref. Section 28-00-00) and check
(b). Install heat shrinkable sleeving for fuel leakage.
(C819) on wires and shrink over
electrical pin splices. NOTE: Allow sealant (C230) to fully cure prior
to pressure test.
(c). Install electrical pins in connector (11). Perform fuel supply vapor shroud leak
with insertion tool (Ref. CSP-SPM, check/pressure test (Ref. Section
Section 20-60-00). 28-00-00).
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(12). Install left hand hinged avionics shelf 19. Crossfeed Fuel ShutOff Valve (900
(Ref. Section 25-70-00). CONFIG)
A. Crossfeed Fuel ShutOff Valve Assembly
(13). Install Electronic Engine Control (EEC) Removal
(Ref. Section 76-00-00). (Ref. Figure 416)
Aviation Turbine Fuel
(14). Install baggage compartment interior
trim roof insulation panel (Ref. Section
25-50-00).
6 Residual Fluids
9G28-021 System Contamination
1. CONNECTOR (P353)
2. BOLT (6). Disconnect hose assemblies (6 and 7)
3. WASHER
from fittings on crossfeed fuel shut-off
4. VAPOR SHROUD COVER ASSEMBLY
5. VAPOR SHROUD BOX ASSEMBLY valve assembly (9).
6. TUBE ASSEMBLY
7. TUBE ASSEMBLY (7). Remove bolts (4) and washers (5)
8. FUEL SHUTOFF VALVE ASSEMBLY attaching crossfeed fuel shut-off valve
9. BOLT assembly to vapor shroud box (10) and
10. WASHER remove crossfeed fuel shut-off valve
11. CONNECTOR JAM NUT
assembly.
Figure 415. Fuel ShutOff Valve Assembly (8). Remove silicone from back of connector.
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Note color code and pin location Sealant, Electrically Conductive (C230)
CAUTION of wires when removing and
install in same order to prevent valve mal
function.
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11 CAUTION
9
7
Residual Fluids
10
8 System Contamination
(4). 900CONFIG - Disconnect male
9G28-009 ratcheting fitting of engine fuel feed
1. CONNECTOR (P355) hose (1) from frangible valve (2) fitting.
2. BOLT Pull back on end to disengage ratchet,
3. WASHER then unscrew.
4. BOLT
5. WASHER (5). 902 CONFIG - Disconnect engine fuel
6. HOSE ASSEMBLY
7. HOSE ASSEMBLY
feed hose.
8. VAPOR BOX COVER ASSEMBLY
9. FUEL SHUT OFF CROSSFEED VALVE ASSEMBLY
(a). Remove and discard lockwire from
10. VAPOR SHROUD BOX ASSEMBLY engine fuel feed hose vapor shroud
11. CONNECTOR JAM NUT hose. Disconnect engine fuel feed
Figure 416. Crossfeed Fuel ShutOff Valve hose vapor shroud hose.
(900 CONFIG) (b). Remove and discard lockwire from
engine fuel feed hose nut. Disconnect
20. Engine Deck Frangible Valve engine fuel feed hose from frangible
A. Engine Deck Frangible Valve Removal valve.
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(b). Connect engine fuel feed hose vapor (10). 900CONFIG - Close transmission
shroud hose and secure with lockwire access door assembly L210 or R210
(C702). (Ref. Section 06-00-00).
(6). Perform fuel booster pump operational (11). 902 CONFIG - Close lower transmis
test (Ref. Section 28-00-00) and check sion access door assembly L210 or R210
for fuel leakage. (Ref. Section 06-00-00).
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7 HAND
1 TIGHTEN HAND
1
TIGHTEN
8 7
2
8 2
6
3
3
5 (REF. FUSELAGE 6 5
4 STRUCTURE)
RIGHT HAND LEFT HAND 4
(REF. FUSELAGE
STRUCTURE)
9G28-007A
1. MALE RATCHETING FITTING 6. FUEL TUBE/LINES
2. ENGINE DECK FRANGIBLE VALVE 7. BOLT
3. VAPOR SHROUD COVER ASSEMBLY 8. WASHER
4. BOLTS 9. ORING
5. WASHER
Figure 417. Engine Deck Frangible Valves (900 CONFIG)
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21. Engine Fuel Feed Hose (f). Remove and discard lockwire from
vapor shroud hose (4). Disconnect
A. Engine Fuel Feed Hose Removal vapor shroud hose.
(c). Remove and discard lockwire and (1). 900 CONFIG - Install engine fuel feed
disconnect fuel feed hose assembly hose.
from engine driven fuel pump elbow
fitting. (a). Connect fuel feed hose (1) to engine
driven fuel pump elbow fitting.
(2). 902 CONFIG - Remove engine fuel Torque fuel feed hose nut and safety
feed hose. with lockwire (C702).
(a). Open upper and lower transmission (b). Connect engine fuel hose (1) male
access door assembly L210 or R210 ratcheting fitting to frangible valve
(Ref. Section 06-00-00). fitting (2). Torque fitting hand tight.
Ratchets on hose and valve must be
(b). Remove aft swashplate fairing fully engaged.
assembly (Ref. Section 53-30-00).
(c). Perform fuel booster pump operation
al test (Ref. Section 28-00-00) and
(c). Remove screws attaching FMU vapor
check for fuel leakage.
shroud box (5) to FMU connector.
(d). Close transmission access door
(d). Remove and discard lockwire and assembly L210 or R210 (Ref. Section
disconnect vapor shroud duct from 06-00-00).
top of FMU vapor shroud box.
(2). 902 CONFIG - Install engine fuel feed
(e). Open FMU vapor shroud box. hose.
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(a). Install spacers on fuel feed hose (3) (f). Perform fuel booster pump operation
al test (Ref. Section 28-00-00) and
Sealing Compound (C207) check for fuel leakage.
(g). Connect vapor shroud hose and
secure with lockwire (C702).
(h). Close FMU vapor shroud box (5).
(b). Apply a fillet of sealing compound (i). Install screws attaching FMU fuel
(C207) at junction of spacer and hose. shroud box to FMU connector.
Ensure that sealing compound does
not block holes in spacer. (j). Connect vapor shroud duct to top of
FMU vapor shroud box. Secure vapor
(c). Install vapor shroud hose (4) over shroud duct with lockwire (C702).
fuel feed hose and spacers.
(k). Perform fuel supply vapor shroud
(d). Connect upper end of fuel feed hose leak check/pressure test (Ref. Section
to engine driven fuel pump elbow 28-00-00).
fitting. Torque fuel feed hose nut. (l). Install aft swashplate fairing assem
bly (Ref. Section 53-30-00).
(e). Connect lower end of fuel feed hose to
frangible valve fitting. Torque fuel (m). Close upper and lower transmission
feed hose nut and safety with lock access door assembly L210 or R210
wire (C702). (Ref. Section 06-00-00).
5
LEFT ENGINE
LOOKING INBOARD
2
902 CONFIG
3
4
902 CONFIG
9G28-044A
1. ENGINE FUEL FEED HOSE ASSEMBLY (900 CONFIG) 4. ENGINE FUEL FEED VAPOR SHROUD HOSE (902
2. ENGINE DECK FRANGIBLE VALVE CONFIG)
3. ENGINE FUEL FEED HOSE ASSEMBLY (902 CONFIG) 5. FMU FUEL SHROUD BOX (902 CONFIG)
Figure 418. Engine Fuel Feed Hose
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22. Fuel Supply Tubes, Hoses and Shrouds (a). Remove and discard lockwire.
Disconnect LH or RH vapor shroud
A. Fuel Supply Tubes, Hoses and Shrouds hose (1, 2), from LH or RH fuel
Removal interconnect tee fitting vapor shroud
(Ref. Figure 419) box (3, 4), and LH or RH fuel shut-
off valve vapor shroud box (5, 6).
NOTE: This task is typical for LH and RH fuel
supply tube, hoses, and shrouds. (b). Pull vapor shroud hose back and
disconnect upper end of LH or RH
Aviation Turbine Fuel 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
CAUTION (9, 10).
(d). Remove pan head bolt (13),washers
Residual Fluids
(14) and nut (15) and remove cush
System Contamination ioned support clamp (16). Remove
engine feed tube assembly with
(1). Defuel helicopter if necessary (Ref.
vapor shroud hose.
Section 12-00-00).
NOTE: Note location of spacers on tube assem
(2). Gain access to components, as required.
bly before removal. Replace spacers in same
(a). Open baggage compartment door location upon installation.
L262 (Ref. Section 06-00-00). (e). Slide LH or RH vapor shroud hose (1,
(b). Remove baggage compartment roof 2) off of engine feed tube assembly
panels (Ref. Section 25-50-00). and remove vapor shroud spacers
(17) from tube assembly.
(c). Remove Electronic Engine Control
(EEC) (Ref. Section 76-00-00). B. Fuel Supply Tubes, Hoses and Shrouds
Installation
(d). Remove hinged avionics shelf (Ref.
Section 25-70-00). (Ref. Figure 419)
(e). Remove electrical load center (Ref. NOTE: This task is typical for LH and RH fuel
CSP-900RMM-3, Section 96-00-00). supply tube, hoses and shrouds.
(c). RH tee fitting vapor shroud box (4). NOTE: Orient spacer slot down on horizontal
runs or aft on vertical runs. Ref. Figure 420
(d). RH fuel shut-off valve vapor shroud for spacer locations.
box (6).
(a). Install spacers (17) on LH or RH
(4). Remove fuel supply tube. engine feed tube assembly (7, 8).
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NOTE: Note location of spacers on hose assem (e). Connect LH or RH fuel supply hose
bly before removal. Replace spacers in same assembly (23, 24) to crossfeed
location upon installation. shut-off valve (20). Torque hose
fittings (Ref. CSP-SPM).
(f). Slide LH or RH vapor shroud hose
(21, 22) off of LH or RH hose assem (f). Connect LH or RH vapor shroud hose
bly (23, 24) and remove vapor shroud (21, 22) to crossfeed shut-off valve
spacers (17) from hose assembly. vapor shroud box (11) and LH or RH
interconnect tee fitting vapor shroud
box (3, 4). Secure vapor shroud hose
B. Lower Fuel Supply Hoses and Shrouds
with lockwire (C702).
Installation
(g). Install cushioned support clamp (16)
(Ref. Figure 419) around fuel supply vapor shroud hose
at location of center spacer with bolt
NOTE: This task is typical for LH and RH low (25), washers (14) and nut (15).
er fuel supply hoses and shrouds. Torque nut (Ref. CSP-SPM).
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(2). Prepare vapor shroud box and vapor (2). Open baggage compartment door L262.
shroud box cover surface for electrical (Ref. Section 06-00-00).
bonding (Ref. CSP-SPM).
(3). Remove baggage compartment floor
Sealant, Electrically Conductive (C230) panels A235, AR250, AL250 (Ref.
Section 53-20-00).
(4). Remove supplemental fuel tank (Ref.
Section 28-10-00)
(5). Remove forward supplemental fuel
(3). Apply sealant (C230) to faying surfaces tank foam supports (Ref. Section
between vapor shroud box cover and 28-10-00).
vapor shroud box and install vapor
(6). Remove lower fuel supply hose.
shroud box cover assembly with bolts
(19) and washers (18). Torque bolts. (a). Remove vapor shroud box cover
assemblies from LH or RH intercon
(4). Perform fuel cell leak check/pressure nect tee fitting (Ref. Section
test (Ref. Section 28-00-00). 28-00-00).
(5). Perform fuel supply vapor shroud leak (b). Remove and discard lockwire.
check/pressure test (Ref. Section Disconnect LH or RH vapor shroud
28-00-00). hose (21, 22) from LH or RH inter
connect tee fitting vapor shroud box
(6). Install baggage compartment floor (3, 4).
panels A235, AR250, AL250 (Ref.
(c). Remove sealant from vapor shroud at
Section 06-00-00).
keel beam.
(7). Close baggage compartment door L262
(Ref. Section 06-00-00). CAUTION
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B. Lower Fuel Supply Hoses and Shrouds, (g). Install cushioned support clamp (16)
Supplemental Fuel System, Installation around fuel supply vapor shroud hose
at location of center spacer with bolt
(Ref. Figure 419) (25), washers (14) and nut (15).
Torque nut (Ref. CSP-SPM).
NOTE: This task is typical for LH and RH low
er fuel supply hoses and shrouds. Sealing Compound (C205)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C207 Sealing Compound, Fuel Resistant (h). Install modified grommet (29) into
C205 Sealing Compound
end of vapor shroud with shroud
positioned onto hose end fitting.
C230 Sealant, Electrically Conductive Install wet with sealing compound
C702 Lockwire (C205). Secure grommet with strap
(28).
(1). Install lower fuel supply hose. (2). Seal vapor shroud hose at keel beam
with sealing compound (C205). Ensure
NOTE: Orient spacer slot down on horizontal opening is entirely closed to provide a
runs or aft on vertical runs. vapor tight seal.
(a). Install spacers (17) on LH or RH fuel (3). Prepare vapor shroud box and vapor
supply hose assembly (23, 24). Ref. shroud box cover surface for electrical
Figure 420 for spacer locations. bonding (Ref. CSP-SPM).
Sealing Compound (C207) Sealant, Electrically Conductive (C230)
(b). Apply a fillet of sealing compound (4). Apply sealant (C230) to faying surfaces
(C207) at junction of spacer and hose. between vapor shroud box cover and
Ensure that sealing compound does vapor shroud box and install vapor
not block holes in spacer. shroud box cover assembly with bolts
(19) and washers (18). Torque bolts
(c). Slide LH or RH vapor shroud hose
(Ref. CSP-SPM).
(21, 22) over LH or RH hose assem
bly (23, 24) and spacers (17). (5). Perform supplemental fuel tank leak
check/pressure test (Ref. Section
(d). Install LH or RH fuel supply hose
28-10-00).
assembly (23, 24) and connect to LH
or RH interconnect tee fitting (9, 10). (6). Perform fuel supply vapor shroud leak
Torque hose fitting (Ref. CSP-SPM). check/pressure test (Ref. Section
28-00-00).
(e). Connect LH or RH fuel supply hose
assembly (23, 24) to crossfeed (7). Install baggage compartment floor
shut-off valve (20). Torque hose panels A235, AR250, AL250 (Ref.
fitting (Ref. CSP-SPM). Section 06-00-00).
(f). Connect LH or RH vapor shroud hose (8). Close baggage compartment door L262
(21, 22) to LH or RH interconnect tee (Ref. Section 06-00-00).
fitting vapor shroud box (3, 4).
Secure vapor shroud hose with (9). Fuel supplemental fuel tank (Ref.
lockwire (C702). Section 12-00-00).
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Rotorcraft Maintenance Manual
19
18
12
5 7 (LH)
8 (RH)
17
2 1 15
14
4 13
14
16
24 22
21
7 (LH)
8 (RH)
23
11 3
18 19
20
9 (LH)
19 10 (RH)
18
900 CONFIG - PW206A
25
14
15
16
17
23
23
14
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Rotorcraft Maintenance Manual
902 CONFIG,
900 CONFIG - PW206E
900 CONFIG - PW207E
27
26
9G28-025-2A
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Rotorcraft Maintenance Manual
28 (2 PL) 29 (2 PL)
(NOTE 5)
30
(NOTE 1)
32
33 (2 PL)
34
(NOTE 2)
(NOTE 1)
31
(NOTE 3)
4)
(NOTE 1)
(NOTE 1)
(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. 9G28-025-3
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
WL
WL 146.560
147.003
2.3 2.3
2.3 6.3
WL WL
147.000 146.560
2.30 2.30
25.50 25.50
10.7 13.3
WL WL
101.000 101.000
LOOKING FWD
9G28-040-1
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Rotorcraft Maintenance Manual
2.3 1.8
WL
101.000
3.2
LOOKING UP 2.3
LOOKING FORWARD
9G28-040-2
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature (3). Clean components with isopropyl
T20144 Manometer alcohol (C419).
C419 Alcohol, Isopropyl (4). Inspect components for contamination.
None allowed.
C103 Lubricant
(5). Inspect poppet for damage. None
allowed.
A. Disassembly (6). Inspect the surfaces that the O-ring
and static seal seat against for damage.
(Ref. Figure 421). None allowed.
B. Assembly
NOTE:
(1). Wipe clean the surfaces that the O-ring
You must have an overhaul kit to perform and static seal seat against on poppet
this procedure (Ref. CSP-900IPL-4). and end cap.
Use care when you remove the end cap Lubricant (C103)
from the housing, the poppet is spring
loaded.
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Rotorcraft Maintenance Manual
(6). Install spring into housing. (4). Check for air leakage. None allowed.
(7). Install poppet into housing.
(5). Connect the manometer (T2014-4)
(8). Install end cap into housing. between the pressure source and the
(9). Torque end cap 144 in-lb (16.27 Nwm). end cap (2).
(3). Submerge check valve in isopropyl (8). If the check valve did not open, discard.
alcohol (C419) or suitable fluid.
INLET PORT
6
5
OUTLET PORT
9g28-078
1. HOUSING 4. POPPET
2. END CAP 5. ORING
3. SPRING 6. STATIC SEAL
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3
9G28-080
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FUEL SYSTEM
INSPECTION / TEST
1. General Inspections for the Fuel Cell (a). Repair or replace components as
necessary.
A. Fuel Cell Inspection Fuselage Bottom
(7). Open Access Panel R185 (ref. Section
(1). Examine the gravity fill port filler neck: 06-00-00).
(a). Examine cap for missing or damaged (8). Do a check of the drain valve control
seal. cable for correct operation and freedom
of movement.
(b). Remove the filler cap.
(9). Examine the sump drain valves for
(c). Operate the fuel/defuel valve. leakage.
(d). Make sure the operation of fuel/de (a). No leakage of fuel from the sump
fuel valve is correct. drain valves is permitted for 5
minutes after the controls have been
(e). Examine lanyard for security. released.
(2). Examine the fuel vent fairings for (10). Examine the installation of the drain
damage. valve control cable clamps.
(a). Examine the fuel vent fairings for air (a). Repair or replace components as
flow blockage. necessary.
(b). Repair or replace as required. (11). Close Access Panel R185 (ref. Section
06-00-00).
(3). Remove Access Panel B178 (ref. Section
06-00-00). (12). Install Access Panel B178 (ref. Section
06-00-00).
(a). Examine the exterior of fuselage
beneath the fuel cell for indications of B. Fuel Cell Inspection Fuselage Cavity
fuel leakage.
NOTE: There is no definite minimum or maxi
(b). No leaks permitted. mum service life of the fuel cell. The best in
surance for trouble-free service is the prop
(c). Repair or replace components as er installation of the cell. Do periodic
required. inspections to find indications of fuel vent
system failure or leakage.
(4). Examine the installation of the fuel
booster pump. Aviation Turbine Fuel
(a). Repair or replace components as
necessary.
(5). Examine the fuel booster pump electri
Do the Fuel Cell Leak Check/Pressure
cal leads for condition and connectors
Test to find leaks in the fuel system. If the
for corrosion and installation.
pressure test does not find leakage, a
(a). Repair or replace components as visual inspection is not required.
necessary. Do a fuel cell cavity visual inspection
when floor panels are removed for other
(6). Examine the fuel quantity probe maintenance.
electrical connector for serviceable
condition, bent or broken pins, frayed or (1). Defuel the rotorcraft (ref. Section
broken wires. 12-00-00).
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(9). Install the carpet, if applicable (ref. (5). Examine the fuel cell access covers for
Section 25-20-00). evidence of fuel leakage and the
electrical bonding jumper for corrosion
(10). Install the cabin seats, if applicable and installation.
(ref. Section 25-20-00). (a). Repair or replace components as
necessary.
C. Fuel Cell Inspection Internal
(6). Remove the fuel cell access covers (ref.
NOTE: There is no definite minimum or maxi Section 28-00-00).
mum service life of the fuel cell. The best in (7). Examine the installation of the fuel cell
surance for trouble-free service is the prop baffles.
er installation of the cell. Do periodic
inspections to find indications of fuel vent (8). Make sure the flapper valves move
system failure or leakage. freely.
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(9). Examine the fuel cell longitudinal AL230, and AR230 (ref. Section
baffle for separation where the metal 53-20-00).
baffle connects to the rubber.
NOTE:
(a). No separation is permitted.
Use installation tool (T801) through hole
(10). Inspect the installation of the fuel cell in the cabin floor panel to lift the top of
frangible valves. the fuel cell for installation of screws to
support the fuel cell to floor panel. Install
(a). Repair or replace components as the vapor seal plug in the floor panel hole
necessary. (ref. Section 53-20-00).
(11). Inspect the fuel supply hoses for As an alternate method use high-grade
deterioration, collapsed or kinked steel all thread rods with large surface
hoses. flat washers and nuts. Insert threaded
rods through the cabin floor panel and
(a). No damage is permitted. threaded hole in the fuel access panel.
(12). Examine the the fuel supply hose Place large surface flat washers over the
clamps for installation and deteriora floor panel and threaded rods. With nuts
tion. installed on threaded rods, turn the nuts
down evenly until the fuel cell is located
(a). Repair or replace components as in the correct position to the cabin floor
necessary. panel.
(13). Examine the installation of the fuel (16). Do the Fuel Cell Leak Check/Pressure
quantity probes. Test (ref. Procedure 4.).
(a). Repair or replace components as
necessary. (17). Fuel the rotorcraft (ref. Section
12-00-00)
(14). Install the fuel cell access covers (ref.
Section 28-00-00, Removal/Installa (18). Install the carpet, if applicable (ref.
tion) Section 25-20-00).
(15). Install access panels AL155, AR155, (19). Install the cabin seats, if applicable
A160, AL165, AR165, A170, A217, (ref. Section 25-20-00).
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2. Inspections for the Fuel Vent System (b). Examine the hose connections for
cracks, cuts, tears, punctures, and
NOTE: There is no definite minimum or maxi collapsed hoses.
mum service life of the fuel vent system. The
best insurance for trouble-free service is the (c). Examine the installation of the
correct installation of the fuel vent system. clamps.
Do periodic inspections to find indications of (d). No damage is permitted.
fuel vent system failure or leakage.
(e). Repair or replace components as
A. Inspection of the Fuel Vent System necessary.
Aviation Turbine Fuel (6). Do an inspection of the forward and aft
standpipe vent tubes and flame
arrestors:
(a). Examine the fuel vent tubes for
cracks, dents, nicks, and corrosion.
NOTE:
(b). Examine the hose connections for
Do a Fuel Cell Leak Check/Pressure Test cracks, cuts, tears, punctures, and
to determine if there are leaks in the fuel collapsed hoses.
system. If the pressure test does not indi
cate leakage, a visual inspection is not (c). Examine the installation of the
necessary. clamps.
Do a visual inspection of fuel vent compo (d). No damage is permitted.
nents when floor panels are removed for
other maintenance. (e). Repair or replace components as
necessary.
(1). Remove the cabin seats, if applicable
(7). Examine the fuel vent float/rollover
(ref. Section 25-20-00).
valves for serviceable condition,
installation, leakage, and corrosion.
(2). Remove the carpet, if applicable (ref.
Section 25-20-00). (a). No damage is permitted.
The rotorcraft must be defueled (b). Repair or replace components as
CAUTION before access panels AL155, necessary.
AR155, AL165, AR165, AL230, and AR230
are removed. Structural damage can occur if (8). Inspect electrical bonding jumpers and
both of these panels are removed with fuel clamps for corrosion, damage, and
in the rotorcraft. installation.
(a). No damage is permitted.
(3). Remove access panels AL155, AR155,
A160, AL165, AR165, A217, AL230, (b). Repair or replace components as
and AR230 (ref. Section 53-20-00). necessary.
(4). Remove interior trim panels station 155 (9). Install access panels AL155, AR155,
left forward bulkhead as required (ref. A160, AL165, AR165, A217, AL230,
Section 25-10-00) and interior trim and AR230 (ref. Section 53-20-00).
panel aft bulkhead station 230.0 right
(10). Install the interior trim panels (ref.
side as required (ref. Section
Section 25-10-00).
25-20-00).
(11). Install the carpet, if applicable (ref.
(5). Do an inspection of the fuel vent tubes: Section 25-20-00).
(a). Examine the fuel vent tubes for (12). Install the cabin seats, if applicable
cracks, dents, nicks, and corrosion. (ref. Section 25-20-00).
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3. Inspections for the Fuel Supply System (e). Close Access Panel L210 or R210
(ref. Section 06-00-00).
A. Inspection of the Engine Fuel Feed Hose
B. Inspection of the Vapor Shroud Box,
Aviation Turbine Fuel Cover Assembly and Vapor Shroud Hose
Aviation Turbine Fuel
(a). Open Access Panel L210 or R210 (ref. (4). Examine the vapor shroud hoses for
Section 06-00-00). cracks, deterioration, deformation, and
installation.
(b). Inspect vapor shroud hose for cracks,
deterioration, deformation, and (a). No damage is permitted.
installation.
(5). Inspect the installation of the vapor
shroud hoses.
1). Repair or replace components as
necessary. (a). Repair or replace components as
necessary.
(c). Inspect FMU shroud box for cracks
and the installation of the latches. (6). (Pre-TB900-003) Install access panels
AL165, AR165, A235, AL250, and
1). Repair or replace components as AR250 (ref. Section 53-20-00).
necessary.
(Post-TB900-003) Install access
(d). Inspect the drain hose for cuts, panels L211 and R211 (ref. Section
chafes, and installation. 06-00-00).
1). Repair or replace components as (7). Close Access Door L262 (ref. Section
necessary. 06-00-00).
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Rotorcraft Maintenance Manual
TAPE OR PLUG
OPENINGS
TAPE OR PLUG
OPENINGS
28 INCH
(71.12 CM)
56 INCH
(142.24 CM)
TAPE OR
PLUG 0 INCH
OPENING (0.00 CM)
MANOMETER
ADAPTER PLUG REGULATED
OUTLET VALVE
TO PRESSURE
ADAPTER PLUG MANOMETER GAUGE
SUPPLY
AIR IN
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4. Fuel Cell Leak Check/Pressure Tests (3). Make sure that all fuel lines have been
connected.
NOTE: Test method 1 or 2 are equally satisfac
tory. The operator can select which test to (4). Make sure there is no damage to the
do. fuel system components.
A. Fuel Cell Leak Check/Pressure Test The FUEL SHUTOFF valve
Method 1 CAUTION switch arms the fire extinguish
ing system. Make sure BOTTLE DIS
NOTE: It will be necessary to partially remove CHARGE switch is set in the OFF position.
the cabin floor if you do Method 1.
(5). Make sure that the LH and RH engine
(Ref. Figure 601)
fuel shut-off valves are in the
Aviation Turbine Fuel CLOSED position on the FUEL
SYSTEM control panel.
(6). Make sure the fuel filler cap is tight.
(7). Plug, cap, or tape shut the aft fuel vent
system outlet (vent fairing).
Consumable Materials
(Ref. CSPSPM) (8). Remove Access Panel AL230 (ref.
Item Nomenclature Section 53-20-00).
C702 Lockwire
(9). Remove AN814-8DL plug from the
C809 Leak Detector, Liquid auxiliary fuel port on the left aft fuel cell
vent fitting.
(1). Clean all grease, oil, and foreign (13). If new fuel cell is installed, slowly apply
material from the interior and exterior 2.0 psig (13.8 kPa) clean filtered
surfaces of components before you begin regulated air pressure to get 56 inch
this test. (142.24 cm) of water as measured on
manometer (T2014-4) to the port.
The helicopter must be drained
CAUTION of all fuel before a functional (a). Hold for 10 minutes as a precaution
leak test can be done. ary measure.
NOTE: When this test is done to satisfy the in NOTE: This will let air trapped between the fuel
spection requirements, it is not necessary to cell and the helicopter structure to escape and
completely defuel the helicopter. The fuel also let the cell adjust to the contour of the
level cannot be more than 600 lb (272 kg). cell cavity.
(2). Defuel and drain fuel cell sump of all (b). Release the air pressure slowly and
fuel (ref. Section 12-00-00). repeat if necessary.
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(14). Slowly apply 2.0 psig (13.8 kPa) of (e). Remove the interior trim panels of
clean, filtered, regulated air pressure to Station 155 left forward bulkhead as
get 56 inch (142.24 cm) of water to required (ref. Section 25-10-00).
the fuel cell as measured on manometer
(T2014-4). (f). Remove the interior trim panel aft of
the bulkhead Station 230.0 right side
(15). Make sure the air pressure inside does as required (ref. Section 25-20-00).
not fall more than 0.125 psig (0.86
kPa) or 3.5 inch (8.89 cm) of water (g). Do a test of the fuel vent connections.
after 15 minutes as measured with
manometer (T2014-4). (h). Remove access panels AL138 and
AL129 (ref. Section 53-20-00).
(16). If the test is successful, slowly release
the air pressure from the fuel cell. (i). Do a test of the fuel vent connections.
(17). Remove adapter from auxiliary fuel (j). Remove access panels AL155,
port. AR155, AL230, and AR230 (ref.
Section 53-20-00).
(18). Install AN814-8DL plug.
(k). Do a test of float/ rollover valves and
(a). Torque plug. vent connections.
(b). Safety plug with lockwire (C702). NOTE: If an air-conditioning condenser exit
(19). Remove plug, cap, or tape from the screen is installed, use for access instead of
forward and aft fuel vent system outlet baggage compartment floor removal. Leave
(vent fairing). one screw loosely attached to prevent screen
from falling inside.
(20). Install removed panels (ref. Section
53-20-00). (l). Remove Access Panel A235 (ref.
Section 53-20-00).
Do not attempt to remove
WARNING access panels with air pres (m). Do a test of the vent connections and
sure applied. This can cause serious in vapor shroud system and fuel supply
jury to personnel and damage to the fu system, if necessary.
selage structure.
(n). Do the vapor shroud press test.
(21). If leakage is more than the permitted
amount, apply liquid leak detector 1). If necessary, correct leaks in vapor
(C809) to areas you think have leaks. shroud system.
NOTE: If helicopter is partially fueled, inspect 2). Put caps on the vapor shroud
area for fuel leakage instead of air bubbles. system.
Follow this sequence to find leaks in the
most accessible areas first. Do a test of each 3). Do a test of the fuel system again.
area one after the other to find the leak.
4). If there are no leaks, then the
(a). Open Access Panel R185 (ref. Section problem is in fuel supply system.
06-00-00).
5). Take the caps off the vapor shroud
(b). Do a test of the fuel drain valves. system.
(c). Remove Access Panel B178 (ref. 6). Make sure of the leakage.
Section 06-00-00).
(o). Remove Access Panel AR165 (ref.
(d). Do a test of the fuel pumps, fuel Section 53-20-00).
gauging probes, and fuel drain
valves. (p). Do a test of the filler neck area.
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The rotorcraft must be defueled (b). Do the fuel cell leak check/pressure
CAUTION before access panels A160, test again.
A170, and/or A217 or both AL165 and
AR165 are removed. Structural damage can (25). If the test is successful, slowly release
occur if one of these panels is removed with the air pressure from the fuel cell.
fuel in the rotorcraft.
(26). Remove adapter from auxiliary fuel
(22). Remove access panels A160, A170, and port.
A217 (ref. Section 53-20-00).
(23). Leakage must be at fuel cell covers or (27). Install AN814-8DL plug.
fuel cell itself.
(a). Torque plug.
Make sure access panels A160,
CAUTION A170, and A217 are installed
(b). Safety plug with lockwire (C702).
before you apply air pressure.
(24). Examine all fittings and components (28). Remove plug, cap, or tape from the
for leaks. forward and aft fuel vent system outlet
(vent fairing).
(a). Tighten loose fittings, replace dam
aged seals or components as neces (29). Install removed panels (ref. Section
sary. 53-20-00).
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TAPE OR PLUG
OPENINGS
28 INCH
(71.12 CM)
56 INCH
(142.24 CM)
0 INCH
(0.00 CM)
MANOMETER
REGULATED
OUTLET VALVE PRESSURE
GAUGE
TO
MANOMETER
SUPPLY
AIR IN
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NOTE: When this test is done to satisfy the in (13). If test is successful, slowly release air
spection requirements, it is not necessary to pressure from fuel cell.
completely defuel the rotorcraft. The fuel
level cannot be more than 600 lb (272 kg). (14). Disconnect test equipment.
(3). Make sure all the fuel lines are correct (15). Remove plug, cap, or tape from the aft
ly connected. fuel vent system outlet (vent fairing).
(4). Make sure there is no damage to the (16). Install removed panels (ref Section
fuel system components. 53-20-00).
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(j). Remove access panels AL155, (20). Leakage must be at fuel cell covers or
AR155, AL230, and AR230 (ref. fuel cell itself.
Section 53-20-00). (21). Examine all fittings and components
(k). Do a test of float/ rollover valves and for leaks.
vent connections. (a). Tighten loose fittings and replace
damaged seals or components as
(l). Remove Access Panel A235 (ref.
necessary.
Section 53-20-00).
(b). Do the fuel cell leak check/pressure
NOTE: If an air-conditioning condenser exit test again.
screen is installed, use the exit screen for ac
cess instead of Access Panel A235. Leave (22). If the test is successful, slowly release
one screw loosely installed. the air pressure from the fuel cell.
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Rotorcraft Maintenance Manual
CAP, PLUG OR
CLAMP SHUT
CAP, PLUG OR
CLAMP SHUT
CAP, PLUG OR
CLAMP SHUT
APPLY AIR
PRESSURE
CAP, PLUG OR
CLAMP SHUT
9G28-035-1
Figure 603. Fuel Supply Vapor Shroud Leak Check / Pressure Test (900 CONFIG) (Sheet 1 of 2)
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Rotorcraft Maintenance Manual
2
1
1 REF
4 3
5
LH SHOWN RH OPPOSITE
9P28-035-2
Figure 603. Fuel Supply Vapor Shroud Leak Check / Pressure Test (900 CONFIG) (Sheet 2 of 2)
5. Fuel Supply Vapor Shroud Leak The rotorcraft must be defueled
Check/Pressure Test CAUTION before both access panels AL165
and AR165 are removed. Structural damage
A. Fuel Supply Vapor Shroud Leak can occur if both of these panels are re
Check/Pressure Test (900 CONFIG) moved with fuel in the rotorcraft. Panel
AL165 or AR165 can be removed individual
(Ref. Figure 603) ly without a defuel of the rotorcraft.
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Page 617
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Rotorcraft Maintenance Manual
APPLY AIR
PRESSURE
CAP, PLUG OR
CLAMP SHUT
CAP, PLUG OR
CLAMP SHUT
APPLY AIR
PRESSURE
CAP, PLUG OR
CLAMP SHUT
APPLY AIR
PRESSURE
CAP, PLUG OR
CLAMP SHUT
APPLY AIR
PRESSURE
9G28-054A
Figure 604. Fuel Supply Vapor Shroud Leak Check/Pressure Test (902 CONFIG)
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C. Fuel Supply Vapor Shroud Leak (5). Disconnect the left or right vapor
Check/Pressure Test (902 CONFIG) shroud drain hose (0.250 in ID rubber
hose) from the engine drain hose tee
(Ref. Figure 604) fitting.
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6. Operational Tests for the Fuel System 2). Make sure the CROSSFEED
switch (900 CONFIG) is set to
A. Operation Test of the Fuel System OFF.
(Ref. Figure 605, Figure 606, and Figure 607) 3). Make sure the L BOOST switch is
set to OFF.
(1). Check fuel quantity probe operation.
4). Make sure the R BOOST switch is
(a). On the ELECTRICAL MASTER set to OFF.
panel, set the POWER switch to
(b). On the IIDS display observe:
BAT/EXT.
1). Right engine fuel pressure seg
(b). On the IIDS display observe: ments (white) are not illuminated.
1). FUEL quantity segments (green) 2). Left engine fuel pressure segments
are illuminated with fuel quantity (white) are not illuminated.
greater than 250 lbs.
3). Right engine fuel shutoff valve
2). FUEL quantity LB digital display segments (yellow) are illuminated.
read out of fuel quantity is illumi
4). Left engine fuel shutoff valve
nated and approximately matches
segments (yellow) are illuminated.
FUEL quantity segments.
5). Right engine low fuel pressure
3). FUEL low level caution segments caution segments (yellow) are not
(yellow) illuminated indicates illuminated.
approximately 150-300 lbs fuel
remaining. 6). Left engine low fuel pressure
caution segments (yellow) are not
4). FUEL low level warning segments illuminated.
and tick marks (red) illuminated
indicates approximately 150 lbs 7). Crossfeed valve segment (white)
fuel or less remaining. not illuminated (900 CONFIG).
(c). On the FUEL SYSTEM panel:
Do not operate booster pumps
CAUTION dry. A minimum of 141 to 151 1). Set the RIGHT guarded FUEL
lb. (22 to 24 US gal / 82.0 to 88.0 L) of fuel SHUTOFF switch to ON.
must be in fuel cell.
2). Set the LEFT guarded FUEL
(2). Do a check of left and right booster SHUTOFF switch to ON.
pump operation, left and right fuel (d). On the IIDS display observe:
shutoff valve operation, crossfeed valve
operation (900 CONFIG), and light 1). Right engine low fuel pressure
segment integrities on IIDS panel: caution alternating offset segments
(white-yellow) are illuminated.
The FUEL SHUTOFF valve
CAUTION switch arms the fire extinguish 2). Left engine low fuel pressure
ing system. Make sure BOTTLE DIS caution alternating offset segments
CHARGE switch is set in OFF position. (white-yellow) are illuminated.
(e). On the FUEL SYSTEM panel, set
NOTE: If fire extinguishing system is NOT the L BOOST switch to ON.
installed, disregard caution relating to fire
bottle discharge in operational test. (f). On IIDS display observe that the left
engine fuel pressure segments
(a). On the FUEL SYSTEM panel: (white) are illuminated.
1). Make sure the FUEL SHUTOFF, (g). (900 CONFIG) - On the FUEL
BOTTLE DISCHARGE switch is SYSTEM panel, set CROSSFEED
set to OFF. switch to ON.
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Rotorcraft Maintenance Manual
(h). (900 CONFIG) - On the IIDS (k). On the FUEL SYSTEM panel:
display observe:
1). (900 CONFIG) - Set the CROSS
1). Right engine fuel pressure seg FEED switch to OFF..
ments (white) are illuminated.
2). Set the L BOOST switch to ON.
2). Crossfeed valve segment (white) is
illuminated.
(l). On the IIDS display observe:
3). Left engine fuel pressure segments
(white) are illuminated. 1). Left engine fuel pressure segments
(white) are illuminated.
(i). On FUEL SYSTEM panel:
2). (900 CONFIG) - Crossfeed valve
1). Set the L BOOST switch to OFF. segment (white) is not illuminated.
2). Set the R BOOST switch to ON. 3). Right engine fuel pressure seg
ments (white) are illuminated.
(j). On the IIDS display observe:
(m). On the FUEL SYSTEM panel:
1). Left engine fuel pressure segments
(white) are illuminated.
1). Set the L BOOST switch to OFF..
2). (900 CONFIG) - Crossfeed valve
segment (white) is illuminated. 2). Set the R BOOST switch to OFF..
3). Right engine fuel pressure seg (3). On the ELECTRICAL MASTER
ments (white) are illuminated. panel, set the POWER switch to OFF.
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BAGGAGE FUEL
%LOAD %LOAD DOOR
GEN GEN 1 HYD 2
FUEL QUANTITY
SEGMENTS
NG NG
IIDS
LOW FUEL CAUTION
SEGMENT
LB C LOW FUEL (YELLOW)
WARNING
OAT TICK (RED)
LOW FUEL WARNING
SEGMENT (RED)
YELLOW
WHITE
RED
GREEN
LB
FUEL QUANTITY DIGITAL
DISPLAY (WHITE)
Figure 606. 900 CONFIG Fuel System IIDS Secondary Panel Display
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Rotorcraft Maintenance Manual
(NOTE )
FUEL (NOTE )
BAGGAGE FUEL
%LOAD %LOAD DOOR
GEN GEN 1 HYD 2
FUEL QUANTITY
SEGMENTS
IIDS LOW FUEL CAUTION
SEGMENT
NG NG (YELLOW)
LB
OAT
C LEFT LOW FUEL
WARNING TICK (RED) RIGHT LOW FUEL
WARNING TICK (RED)
LOW FUEL WARNING
SEGMENT (RED)
YELLOW
WHITE RED
GREEN
LB
FUEL QUANTITY DIGITAL
DISPLAY (WHITE)
B. NORMAL FUEL FLOW WITH IMPENDING ENGINE FUEL FILTERS BY-PASS D. LOW FUEL PRESSURE LEFT BOOSTER PUMP WITH NORMAL
FUEL PRESSURE ON RIGHT BOOSTER PUMP
NOTE: THE LIGHT SEGMENT BAR(S) WILL FLASH ON THE IIDS PANEL WHEN THE VALVE
IS IN TRANSIT BETWEEN THE OPEN AND CLOSED POSITION. 9G28-058
Figure 607. 902 CONFIG Fuel System IIDS Secondary Panel Display
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7. Operational Tests for the Fuel Distribution (b). Set the L BOOST switch to ON.
System
(c). The booster pump must operate
(Ref. Figure 605, Figure 606, and Figure 607) audibly.
A. Operational Test of the Fuel Booster (5). Make sure that the left engine low fuel
Pump pressure (yellow) segments on the IIDS
display are not illuminated.
NOTE:
NOTE: A row of white segments indicate nor
This test is typical for the LH and RH fuel mal fuel pressure and alternating white and
booster pump. Instructions are written yellow offset segments indicate low fuel
for LH fuel booster pump. pressure.
If the fire-extinguishing system is not
installed, disregard caution relating to (6). On the FUEL SYSTEM panel:
bottle discharge in operational test. (a). Set the L BOOST switch to OFF.
Do not operate booster pump (b). Make sure the left engine low fuel
CAUTION dry. A minimum of 141 to 151 lb pressure (yellow) segments on the
(22 to 24 US gal / 83.0 to 90.0 L) of fuel IIDS display are illuminated.
must be in fuel cell.
(7). (900 CONFIG) - Set the CROSS
(1). On the ELECTRICAL MASTER FEED switch to ON and set the R
panel, set the POWER switch to BOOST switch to ON.
BAT/EXT.
(a). The booster pump must operate
The FUEL SHUTOFF valve audibly.
CAUTION switch arms the fire-extin
guishing system. Make sure the BOTTLE (b). Make sure the left and right engine
DISCHARGE switch is in the OFF posi low fuel pressure (yellow) segments
tion. on the IIDS display are not illumi
nated.
(2). On the FUEL SYSTEM panel, set the
BOTTLE DISCHARGE switch to (8). (900 CONFIG) - On the FUEL
OFF. SYSTEM panel:
(3). On the FUEL SYSTEM panel: (a). Set the R BOOST switch and the
CROSS FEED switch to OFF.
(a). Make sure the LEFT and RIGHT
(b). Make sure the left and right engine
FUEL SHUTOFF switches are both
low fuel pressure (yellow) segments
OFF.
on the IIDS display are illuminated.
(b). Make sure the L BOOST and R (9). Set the LEFT guarded FUEL SHUT
BOOST switches are OFF. OFF switch to LEFT OFF.
(c). (900 CONFIG) - Make sure the (10). On ELECTRICAL MASTER panel,
CROSS FEED switch is OFF. set POWER switch to OFF.
CAUTION
Make sure that throttle twist B. Operational Test of the Fuel ShutOff
grips are in NORMAL position Valve
and the ENGINE CONTROL switches are
in the OFF position to prevent accidental NOTE:
engine start or fire. This test is typical for LH and RH shut-
off valve.
(4). On the FUEL SYSTEM panel:
If the fire-extinguishing system is not
(a). Set the LEFT guarded FUEL installed, disregard caution relating to
SHUTOFF switch to ON. bottle discharge in operational test.
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8. Functional Tests for the Fuel Quantity (6). Use helicopter jack (T202) to jack
Indication System rotorcraft evenly to get a 5 nose down
simulated flight attitude on the
A. Functional Test of the Fuel Quantity inclinometer scale placed longitudinally
Indication System on the cabin floor, and level laterally
NOTE: This procedure calibrates the fuel quan across the cabin floor.
tity system when the fuel cell or fuel probes
have been replaced. (7). Stabilize the rotorcraft with wooden
blocks under landing gear skid tubes as
(Ref. Figure 605, Figure 606, and Figure 607) required.
Aviation Turbine Fuel (8). For rotorcraft that are defueled, add to
the fuel cell 2.60 US gal (9.84 L) as
measured from a calibrated fuel truck
metering system.
(2). Remove the filler cap and secure the 1). Find the fuel density for one gallon
lanyard in the slot provided in the filler based on type of fuel and the
cap adapter. temperature of the fuel measured
with a thermometer (T807) (ref.
(3). Defuel and drain fuel cell sump of all Figure 608).
fuel with aircraft at a normal ground
attitude (ref. Section 12-00-00). 2). Multiply the required gallons of
(4). Install jack pad kit (T201) on aft fuel by the fuel density to get
landing gear crosstube saddle assem required weight of fuel in pounds.
blies (ref. Section 07-10-00).
3). Weigh out this much fuel with
(5). Locate inclinometer (T203) on cabin scale (T808).
floor longitudinal axis between stations
155.00 and 213.00. 4). Add weighed fuel to fuel cell.
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TEMPERATURE, DEGREES C
-51 -40 -28 -17 -6 +4 +16 +27 +38 +49
958.51 8.0
JP-5
777.98 6.5 JET A, JET A-1, JP-8
EXAMPLE:
USE A THERMOMETER TO MEASURE THE
TEMPERATURE OF 1 U.S. GALLON (3.785
LITER) OF FUEL, EXAMPLE 80F (27C).
JP-4 INTERSECT THE 80F (27C) AND JET-A
MIL-T-5624 FUEL.
718.13 6.0 AT THE LEFT OF THE CHART, IDENTIFY
THE CORRESPONDING SPECIFIC WEIGHT,
IN THIS EXAMPLE 6.71 SPECIFIC WEIGHT.
6.71 X 2.6 U.S. GALLONS = 17.45 LBS OF
JET-A FUEL AT 80F (27C).
6.71 X 2.83 U.S. GALLONS = 18.99 LBS OF
JET-A FUEL AT 80F (27C).
658.29 5.5
-60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
TEMPERATURE, DEGREES F 9G28-033
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(d). Use the IIDS up arrow key or down (18). Alternate Method:
arrow key to select DO CALIBRA
TION menu item. (a). Calculate fuel to be added by weight.
(e). Press the IIDS ENT key for more (b). Add an additional 18 US gal (68.137
than 4 seconds to bring up the DO L) to the fuel cell.
CALIBRATION third level menu.
(19). Make sure the FUEL low level warning
(f). The IIDS will display message: tick marks (red) indicators are not
illuminated.
AIRCRAFT READY ?
CRUISE ATTITUDE ? (20). Return the aircraft to normal ground
attitude (3 nose up).
(g). Press the IIDS ENT key for more
than 4 seconds to command calibra (21). Fuel the aircraft with an additional
tions. 128.2 US gal (485.28 L) of fuel from a
calibrated fuel truck metering system
(h). The IIDS will display calibration (ref. Section 12-00-00).
codes:
(22). Make sure the IIDS FUEL quantity
FWD FUEL CAL XXX LB is within:
AFT FUEL CAL XXX
Jet A, Jet A-1, JP-8: 932 to 1050 lb
(i). Record the fuel probe calibration (423 to 476 kg)
codes in the Rotorcraft Log Book for
future reference. JP-5: 939 to 1059 lb
(426 to 480 kg)
NOTE: Whenever the IIDS is replaced, the fuel
calibration codes must be re-entered into JP-4: 877 to 989 lb
the SET CAL CODE menu of the installed (398 to 449 kg)
IIDS (ref. CSP-900RMM-3, Section
95-30-00). (23). Alternative Method:
(j). Press the IIDS REC key to save the NOTE: This alternative method more accurate
calibration codes. ly finds that the indication falls within the
required +6% allowable error of actual fuel
(k). Press the IIDS CLR key to exit out
weight at full fuel.
of the menu.
(l). Set the POWER switch on ELEC (a). Find the actual fuel density in lb/gal
TRICAL MASTER panel to OFF for (kg/L) with a hydrometer.
10 seconds minimum. (b). Multiply the fuel density value by
NOTE: This will initialize the IIDS memory for 146.2 US gallons (553.4 L) (total
the calibration codes. usable fuel capacity) to find actual
usable fuel quantity in pounds
(16). Set the POWER switch on ELEC (kilograms).
TRICAL MASTER panel to BATT/
EXT. (c). The IIDS fuel quantity indication
must be within +6% of this value.
(17). Add an additional 18 US gal (68.137 L)
to the fuel cell as measured from a (24). On ELECTRICAL MASTER panel,
calibrated fuel truck metering system. set POWER switch to OFF.
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9. Tests for the Fuel Cell (5). Make sure the right FUEL low level
warning tick mark (red) indicator is
A. Integrity Test of the Longitudinal Baffle of illuminated.
the Fuel Cell (902 CONFIG)
(6). Make sure the left FUEL low level
warning tick mark (red) indicator is not
Aviation Turbine Fuel illuminated.
(7). Fuel must remain on left side of fuel
cell for 30 minutes without bleeding to
the right side.
(1). Make sure there is 60.0 US gal / 408.0 (a). Make sure the right FUEL low level
lb (227 L / 185 kg) of fuel in fuel cell warning tick mark (red) indicator
continues to be illuminated.
(2). Drain right side of fuel cell from RH (b). Make sure the left FUEL low level
fuel sump drain valve (forward drain warning tick mark (red) indicator is
valve control cable) into suitable not illuminated.
container.
(8). Set POWER switch on ELECTRICAL
(3). Apply 24 to 28 Vdc external power to MASTER panel to OFF.
aircraft.
(9). If longitudinal baffle integrity is not
kept, defuel the rotorcraft (ref. Section
(4). Make sure the IIDS and FUEL 12-00-00) and repair fuel cell (ref.
PROBE circuit breakers on ESSEN Manufacturer CMM, Section 01-00-00,
TIAL BUS panel and FUEL LOW or Section 28-00-00).
(900 CONFIG) or RH FUEL LOW and
LH FUEL LOW (902 CONFIG) circuit (10). If longitudinal baffle integrity is kept,
breakers on ELECTRICAL LOAD fuel the rotorcraft (ref. Section
CENTER panel are activated. 12-00-00).
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Rotorcraft Maintenance Manual
A
STRAIGHT EDGE
1.5 TO 1.7 INCH (38 TO 43 MM) 1.5 TO 1.7 INCH (38 TO 43 MM)
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TOP
CORD 5 CORD 4
GROMMET (TYP)
AFT HANGER (TYP) FOR
BAFFLE WARD
0.25 TO 0.50 INCH
BAFFLE (6.4 TO 12.7 MM)
OPTIONAL
CORD 1 CENTER
END POINT BAFFLE
CORD
GROMMET (TYP)
CORD 2
AFT BAFFLE
AND CORD 5
CORD 1
CORD 3 FORWARD BAFFLE
AND CORD 4
9g28-062A
Figure 610. Fuel Cell Baffles and Cord Routing (902 CONFIG)
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HANGER (TYP)
BOWLINE KNOT
TIGHTEN
TIGHTEN TIE
HALF-HITCH
KNOT
GROMMET (TYP)
9g28-081
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11. Operational Tests for the Fuel Transfer (8). Install the filler cap (ref. Section
System (902 CONFIG) 12-00-00).
NOTE: The Normal Ground Attitude or the (9). Make sure the IIDS fuel quantity
Normal Cruise Attitude task can be done in display is between 173 and 213 lb
support of the Periodic Inspection or the (78.5 and 96.6 kg).
Segmented Inspection. (10). Make sure the right low fuel warning
A. Normal Ground Attitude (3 Degrees Nose tick mark is not illuminated.
Up, 0 Degrees Roll) The step that follows will arm
CAUTION the fire-extinguishing system.
Aviation Turbine Fuel
(11). Set the left and right FUEL SHUT
OFF switches on FUEL SYSTEM
control panel to OFF.
NOTE: The operational ability of the transfer
system can be found with a flow rate measu
Special Tools
rement. This can be done by a time check of
(Ref. CSPSPM) the transfer of a known quantity of fuel.
Item Nomenclature
Stopwatch or Timer (12). Set the L BOOST switch on the FUEL
SYSTEM control panel to ON.
NOTE: The helicopter position must be on (13). Start the stopwatch or timer.
stable and level ground before you do this (14). The IIDS fuel quantity indication must
test. decrease.
(1). Attach the rotorcraft to an approved (15). Wait for the right low fuel warning tick
electrical ground (ref. Section mark to illuminate.
10-10-00).
(16). Immediately set the L BOOST switch
(2). Apply 24 to 28 Vdc external power to to OFF.
the rotorcraft (ref. Section 96-00-00). (17). Stop the stopwatch or timer.
(3). Make sure the IIDS, L BST PMP, R (18). The recorded time must be less than 10
BST PMP, RH FUEL LOW, and LH minutes.
FUEL LOW circuit breakers on the
ELECTRICAL LOAD CENTER panel (19). Set the R BOOST switch on the FUEL
are activated. SYSTEM control panel to ON.
(4). Make sure the IIDS, FUEL VLV R, (20). Start the stopwatch or timer.
FUEL VLV L, and FUEL PROBE (21). The IIDS fuel quantity indication must
circuit breakers on the ESSENTIAL increase.
BUS panel are activated.
(22). Wait for the left low fuel warning tick
(5). Set the POWER switch on ELEC mark to illuminate.
TRICAL MASTER panel to BATT/
EXT. (23). Immediately set the R BOOST switch
to OFF.
(6). Remove the filler cap and secure the
lanyard in the slot provided in the filler (24). Stop the stopwatch or timer.
cap adapter. (25). The recorded time must be less than 10
minutes.
(7). Defuel the rotorcraft until the left red
low fuel warning tick mark illuminates (26). Set the POWER switch on the ELEC
(ref. Section 12-00-00). TRICAL MASTER panel to OFF.
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Rotorcraft Maintenance Manual
(27). Remove the 24 to 28 Vdc external (7). Make sure the IIDS, L BST PMP, R
power from the rotorcraft (ref. Section BST PMP, RH FUEL LOW, and LH
96-00-00). FUEL LOW, circuit breakers on the
ELECTRICAL LOAD CENTER panel
(28). Disconnect the electrical ground (ref. are activated.
Section 10-10-00).
(8). Make sure the IIDS, FUEL VLV R,
B. Normal Cruise Attitude (5 Degrees Nose FUEL VLV L, and FUEL PROBE
Down, 0 Degrees Roll) circuit breakers on the ESSENTIAL
BUS panel are activated.
Aviation Turbine Fuel (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 warning tick mark
Special Tools illuminates (ref. Section 12-00-00).
(Ref. CSPSPM) (11). Add 11.8 US gal (44.7 L) to the fuel
Item Nomenclature cell through the filler neck as measured
T201 Jack Pad Kit from a calibrated fuel truck metering
T202 Helicopter Jack system.
T203 Inclinometer (12). Install the filler cap (ref. Section
N/A Stopwatch or Timer 12-00-00).
The step that follows will arm
CAUTION the fire-extinguishing system.
NOTE: The helicopter position must be on
stable and level ground before you do this (13). Set the left and right FUEL SHUT
test. OFF switches on the FUEL SYSTEM
control panel to OFF.
(1). Attach the rotorcraft to an approved
electrical ground (ref. Section NOTE: The operational ability of the transfer
10-10-00). system can be found with a flow rate measu
rement. This can be done by a time check of
(2). Install jack pad kit (T201) on aft the transfer of a known quantity of fuel.
landing gear crosstube saddle assem
(14). Set the L BOOST switch on the FUEL
blies (ref. Section 07-10-00).
SYSTEM control panel to ON.
(3). Locate inclinometer (T203) on cabin (15). Start the stopwatch or timer.
floor longitudinal axis between stations
155.00 and 213.00. (16). The IIDS fuel quantity indication must
decrease.
(4). Use helicopter jack (T202) to jack the (17). Wait for the right low fuel warning tick
rotorcraft evenly to get a 5 nose down mark to illuminate.
ground attitude on the inclinometer
scale placed longitudinally on the cabin (18). Immediately set the L BOOST switch
floor, and level laterally across the to OFF.
cabin floor.
(19). Stop the stopwatch or timer.
(5). As necessary, stabilize the rotorcraft (20). The recorded time must be less than 6
with wooden blocks under the landing minutes.
gear skid tubes.
(21). Remove the filler cap and secure the
(6). Apply 24 to 28Vdc external power to lanyard in the slot provided in the filler
rotorcraft (ref. Section 96-00-00). cap adapter.
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(27). Wait for left low fuel warning tick mark (33). Remove helicopter from wooden blocks
to illuminate. and jacks (ref. Section 07-10-00).
(28). Immediately set the R BOOST switch (34). Disconnect the electrical ground (ref.
to OFF. Section 10-10-00).
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12. Functional Tests for the Low Fuel Light (5). Set the POWER switch on the ELEC
TRICAL MASTER panel to BATT/
A. Functional Test of the Low Fuel Light (900 EXT.
CONFIG)
Aviation Turbine Fuel (6). Defuel and drain the fuel cell sump of
all fuel with the rotorcraft at a normal
ground attitude (ref. Section 12-00-00).
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FUEL SYSTEM
REPAIRS
1. Fuel Cell (a). Repairs can be done with approved
room temperature adhesives recom
A. General mended by the fuel cell manufactur
The fuel cell is an assembly constructed of er.
nitrile-coated woven nylon fabric inner-liner
(b). No patch is required unless the fabric
and outer-ply layers with an impervious,
in the adjacent area is torn, cut, or
0.002-inch-thick (0.05-mm-thick), nylon film
has holes through the cell layers.
barrier membrane put between the layers.
Since fuel cell repair materials, techniques, (2). Cord damage must have an applicable
and procedures can be changed or deleted by patch applied.
the fuel cell manufacturer without notice, B. InnerLiner/OuterPly Damage
MDHI cannot guarantee that the repair
procedures are up-to-date, complete, or (1). Inner-liner/outer-ply repairs that
technically accurate. require the use of cements, patches
Customers that do fuel cell repairs can order and/or vulcanization are:
manuals from the fuel cell manufacturer (a). Loose or open splice/lap seams.
before they start a repair task:
(b). Blisters or delaminations.
American Fuel Cells & Coated Fabrics Co.
(Amfuel, CAGE 05476) (c). Loose reinforcements or accessory
PO Box 887 601 Firestone Drive parts.
Magnolia, AR 71753 (USA)
Telephone: 870-234-3381 (d). Loose fitting flange.
Website: http://amfuel.com/
(e). Loose patches.
2. Fuel Cell Repair
C. Damage Limitations
Amfuel construction materials,
CAUTION repair methods and require (1). Fuel cells with these conditions must be
ments, supplies, and materials are not com returned to the manufacturer for
patible or interchangeable with other fuel inspection to find if the fuel cell can be
cell manufacturers. repaired:
A. Scuff Mark, Chafing, or Snag Damage (a). Inner-liner nylon barrier damage.
(1). Scuff marks, chafing, or snag damage (b). Holes through a cell wall or fitting
on one of the two inner-liner layer or flange.
outer-ply layer (example: layer miss
ing, exposed cord not-damaged) and (c). Replacement of fitting assemblies.
adjacent area can be buffed, cleaned,
have a layer of cement applied, and be (d). Indications of activation or chemical
air-dried for 8 hours. reactions (self-sealing cells).
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Section
281000
Supplemental Fuel
System (Option)
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(Ref. Figure 1) The shut off valve allows fuel transfer when
the main fuel tank quantity is less than
The area within the boattail tub, aft of FS ninety-four U.S. gallons (355.83 liters) and
230.5, between the LH and RH keel beams, inhibits transfer when the main tank fuel
and under the baggage floor is sealed to quantity is greater than one hundred and
provide a fuel and vapor tight fuel cell cavity. eleven U.S. gallons (420.18 liters).
Blocks of rigid closed cell foam are installed in
unused areas to provide support for the fuel
4. Supplemental Fuel System Fuel Vent
tank on the sides and bottom.
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Rotorcraft Maintenance Manual
9G28-064-1
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Rotorcraft Maintenance Manual
EXISTING MAIN
FUEL CELL
GRAVITY FILL PORT
LEVEL CONTROL CHECK VALVE
VALVE SUPPORT GRAVITY FILL PORT
9G28-064-2
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Rotorcraft Maintenance Manual
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CSP900RMM2 MD Helicopters, Inc.
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A612
INSTRUMENT PANEL
FWD INTERCON PANEL
DS2 SP1 P118 J118 TB3-1 TB2-9
DS2
- +
40 D CB A HG FE
NOTE 1
AUX FUEL QTY
IND LT
NOTE: WIRE BETWEEN TB3-1A AND TB2-9H MAY BE DIFFERENT, DEPENDING ON OTHER INSTALLATIONS 9G28-069A
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Rotorcraft Maintenance Manual
LBL
(7). Install quantity transmitter. 1 7.81
(14). Service fuel tank as required (Ref. Figure 401. Supplemental Fuel Transfer
Section 12-00-00). Pump
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Rotorcraft Maintenance Manual
2. Supplemental Fuel Tank Filler Neck B. Supplemental Fuel Tank Filler Neck
Adapter Adapter Installation
(Ref. Figure 402)
A. Supplemental Fuel Tank Filler Neck
Adapter Removal Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
(Ref. Figure 402 and Figure 403)
C113 Fuel, Aviation Turbine
C216 Sealant, Fuel Resistant
(1). Defuel supplemental fuel tank (Ref.
Section 12-00-00).
Special Tools
(Ref. CSPSPM)
(2). Remove baggage compartment floor Item Nomenclature
(Ref. Section 53-20-00).
T1002 MilliOhm Meter
(3). Remove bolts (63 and 65) and washers Aviation Turbine Fuel
(64 and 66) attaching supplemental fuel
filler neck cover (61) (Ref. Figure 403).
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(5). Install screw, washers, nut, and (2). Pull gravity fill check valve (19) from
bonding jumpers to filler neck. fuel tank through keel beam and
remove.
(6). Using milli-ohm meter (T1002), test
filler adapter for a class S electrical (3). Remove packing (20) and discard.
bond (Ref. CSP-SPM). Environmental
seal is not required. B. Supplemental Fuel System Gravity Fill
Check Valve Installation
(7). Install center baggage floor panel (Ref.
(Ref. Figure 402)
Section 53-20-00).
(8). Perform supplemental fuel tank Consumable Materials
leak/pressure test. (Ref. CSPSPM)
Item Nomenclature
(9). Install right side baggage floor panel
(Ref. Section 53-20-00). C113 Fuel, Aviation Turbine
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4. Supplemental Fuel System Filler Neck B. Supplemental Fuel System Filler Neck
Installation
A. Supplemental Fuel System Filler Neck
Removal (Ref. Figure 402)
(Ref. Figure 402)
Special Tools
(1). Defuel supplemental fuel tank (Ref. (Ref. CSPSPM)
Section 12-00-00). Item Nomenclature
(2). Remove baggage compartment floor T1002 MilliOhm Meter
(Ref. Section 53-20-00).
(3). Remove bolts (63 and 65) and washers (1). Align filler neck mounting flange with
(64 and 66) attaching supplemental fuel hole in fuselage and install screws and
filler neck cover (61) (Ref. Figure 403). washers. Torque screws (Ref. CSP-
SPM).
(4). Remove sealant from around periphery
of filler neck cover. Remove cover. (2). Slide filler hose centered over gap
between filler adapter and filler neck.
(5). Remove right side baggage floor panel Torque hose clamps (Ref. CSP-SPM).
(Ref. Section 53-20-00).
(3). Install screw, washers, nut, clamp, and
(6). Remove bolt (5), washers (6), nut (7), bonding jumpers to filler neck.
bonding jumpers (8), and clamp (12)
from filler neck (2). (4). Using milli-ohm meter (T1002), test
gravity fill check valve for a class S
Aviation Turbine Fuel electrical bond (Ref. CSP-SPM).
Environmental seal is not required.
(5). Install center baggage floor panel (Ref.
Section 53-20-00).
(7). Loosen hose clamps (16) and slide hose (6). Perform supplemental fuel tank
(13) up on filler neck (2) to expose tank leak/pressure test.
adapter (14).
(7). Install right side baggage floor panel
(8). Remove bolts (3) and washers (4) from (Ref. Section 53-20-00).
filler neck mounting flange.
(8). Position supplemental fuel tank filler
(9). Remove nut ring assembly (18) and neck cover and install bolts and
filler neck (2). washers. Torque bolts (Ref. CSP-SPM).
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1
2 3 (8PL)
18
4 (8PL)
2
5
2X 6
7
21
8 (2PL)
12 16 (2PL)
20
13
19
14
9
2X 10 WL
11 101.110
14
15
17
1.
CAP, FUEL, GRAVITY FILL PORT 11. NUT, SELF LOCKING
2.
NECK, FUEL GRAVITY FILL PORT 12. CLAMP, LOOP TYPE, BONDING
3.
BOLT, PAN HEAD, CLOSE TOLERANCE 13. HOSE, FUEL, GRAVITY FILL PORT
4.
WASHER, FLAT 14. TANK ADAPTER, FUEL, GRAVITY FILL PORT
5.
BOLT, PAN HEAD, CLOSE TOLERANCE 15. BOLT, HEX HEAD, CLOSE TOLERANCE
6.
WASHER, FLAT 16. CLAMP, HOSE
7.
NUT, SELF LOCKING 17. WASHER, FLAT
8.
JUMPER ASSEMBLY, BONDING AND CURRENT 18. NUT RING ASSEMBLY
RETURN 19. CHECK VALVE, FUEL, GRAVITY FILL PORT
9. BOLT, HEX HEAD, CLOSE TOLERANCE 20. PACKING, PREFORMED
10. WASHER, FLAT 21. PACKING, PREFORMED
Figure 402. Supplemental Fuel System Filler Neck
5. Supplemental Fuel System Quantity (3). Remove nut (40) and washer (68)
Transmitter disconnect electrical lead from top of
quantity transmitter (28).
A. Supplemental Fuel System Quantity
Transmitter Removal NOTE:
It is necessary to angle the transmitter
(Ref. Figure 403) during removal to allow the float arm to
be retracted through the opening in the
(1). Defuel supplemental fuel tank (Ref.
fuel tank.
Section 12-00-00).
Quantity transmitter mounting holes are
(2). Remove baggage compartment floor non-symmetrical and arm is clocked at
(Ref. Section 53-20-00). the 9:30 position at installation.
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Ensure float or float arm does (6). Remove lockwire (32) and slide hose
CAUTION not become entangled in inter (31) to expose end of vent tube (35).
nal wiring or damaged by contact with in
ternal components during installation. (7). Remove bolts (23), washers (24), and
remove bonding jumper (30) from fuel
(1). Install gasket onto transmitter and vent fitting (22).
align with mounting holes.
(8). Remove fuel vent fitting (22) and
(2). Insert float and float arm through packing (75). Discard packing.
opening in fuel tank.
NOTE: Use care when removing fuel tank cov
(3). Install screws and washers. Torque er, transfer pump wire harness has approxi
screws (Ref. CSP-SPM). mately 10 in. (25.4 cm) of excess length.
(4). Install electrical lead onto quantity (9). Remove bolts (25) and washers (26) and
transmitter and install nut. Torque nut remove fuel tank cover(20). Remove
(Ref. CSP-SPM). and discard packing (21).
(5). Install baggage floor (Ref. Section (10). Straighten tab on lockwasher (6) and
53-20-00). remove jam nut (5) and lockwasher (6).
Discard lockwasher (Ref. Figure 401).
(6). Perform supplemental fuel tank
leak/pressure test. (11). Remove connector (8) from cover (7)
(Ref. Figure 401).
(7). Perform supplemental fuel quantity
operational test. (12). Remove retaining ring (76) and wave
washer (9) and remove vent/rollover
(8). Service fuel tank as required (Ref. valve (2) from cover. Remove packing
Section 12-00-00). (3) and discard.
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NOTE: Lubricate new packings with aviation (2). Remove foam support (10) (Ref.
turbine fuel (C113). Figure 404).
(2). Install new packing onto vent/rollover (3). Disconnect fuel transfer hose (49) from
valve and install valve into cover. supplemental fuel tank (4) (Ref.
Figure 403). Cap and plug open
(3). Install wave washer and retaining ring. connections.
(4). Install new packing into top of vent/rol (4). Remove bolts (18), washers (19), bolts
lover valve and install vent fitting. (33), and washers (34) and remove hat
support channel (17).
(5). Install bolts, washers,and bonding
jumper. Torque bolts (Ref. CSP-SPM). (5). Disconnect electrical connector (27) and
nut (40) washer (68) and wire from top
(6). Using milli-ohm meter (T1002), test of fuel tank cover (20).
vent/rollover valve for a class S electri
cal bond (Ref. CSP-SPM). Environmen (6). Remove lockwire from vent hose (31)
tal seal is not required. and separate vent tube (35) from vent
hose (31).
(7). Install new packing into groove on top
of fuel tank and install cover. Install (7). From underside of boattail tub, push up
and torque bolts (Ref. CSP-SPM). on fuel tank adjacent to plug (50) to
loosen the hook and loop attachment
(8). Using milli-ohm meter (T1002), test (72).
fuel tank cover for a class C electrical
bond (Ref. CSP-SPM). Environmental (8). Carefully lift fuel tank vertically from
seal is not required. fuel tank cavity.
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(7). Apply a fillet of sealant (C216) to the (5). Remove lockwire (32) and slide hose
inner and outer periphery of the (31) to expose end of vent tube (35).
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NOTE: Use care when removing fuel tank cov (1). Install new check valve with new
er, transfer pump wire harness has approxi packing on bulkhead tube fitting.
mately 10 in. (25.4 cm) of excess length. Torque check valve (Ref. CSP-SPM).
(6). Remove bolts (25) and washers (26).
Remove fuel tank cover (20). Remove (2). Using milli-ohm meter (T1002), test
and discard packing (21). check valve for a class S electrical bond
(Ref. CSP-SPM).
(7). Disconnect pump to auxiliary cell outlet
hose (77) from check valve (80).
(3). Attach pump to auxiliary cell outlet
(8). Remove check valve from bulkhead hose to check valve. Torque hose (Ref.
tube fitting (48) and discard packing CSP-SPM).
(79).
B. Supplemental Fuel Check Valve (4). Install new packing into groove on top
Installation of fuel tank and install cover. Install
and torque bolts (Ref. CSP-SPM).
(Ref. Figure 403)
Consumable Materials
(5). Slide vent hose to equally cover gap
(Ref. CSPSPM)
between vent tubes and install lockwire
Item Nomenclature
(C702)
C702 Lockwire
C113 Fuel, Aviation Turbine (6). Connect wire harness to transfer pump
connector.
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12
11
18
19 10
17
16
15 4
6
37 14
38 X 2 FS 30
235.532 7
39
73
13 8 (3PL)
23 (2PL)
36 24 (2PL)
31 (2PL) 22 42 (2PL)
43 2X (2PL)
20
RBL 44 (2PL)
21 35
35 24.000
25 (20PL)
26 (20PL) 32 (2PL)
BL
0.000 10-12 in-lb
40
1.13-1.36 Nm
68
32 (4PL) 31
41
33 (4PL) 28
34 (4PL) 74 WL 45
94.157
27
29 (5PL) 46
67 (5PL) 32 (4PL)
32 (4PL)
9G28-065-1
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FS
235.50
54
53 55
SUPPLEMENTAL 72
FUEL TANK 47
69 LOOKING DOWN
FS
230.50
48
49 70
53
LBL
12.000
EARLY CONFIGURATION
LOOKING DOWN
52 51
14
77
LBL
79 9.160
80
47
SUPPLEMENTAL 69
FUEL TANK FS
FS 243.632
230.500 50
70 78 71
48 LOOKING UP
49
LBL
12.000
CURRENT CONFIGURATION
LOOKING DOWN
9G28-065-2A
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FS
230.50
56 (2PL)
57
61
58 REF
57
58 (6PL)
59 (6PL)
63 60 (6PL)
64
RBL
75 24.00
76
9
WL
65
104.21
66
3
62
RBL
24.00
9G28-065-3
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9. Supplemental Fuel Tank Foam Support B. Supplemental Fuel Tank Foam Support
Installation
A. Supplemental Fuel Tank Foam Support
Removal Consumable Materials
(Ref. CSPSPM)
(Ref. Figure 404) Item Nomenclature
(1). Remove fuel tank. C216 Sealant, Fuel Resistant
C721 Tape, Foam
NOTE: Foam support components are installed
with sealant or hook and loop tape. (Ref. Figure 404)
(2). Remove foam support as required by (1). If foam was installed with sealant,
pulling foam support loose from clean loose foam from attachment area
adjacent structure. to ensure a good bond.
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Sealant, Fuel Resistant (C216) (3). Install foam support as required using
hand pressure to ensure good attach
ment to adjacent structure.
(4). Use foam tape (C721) to hold in place
until sealant cures.
(2). If installing support foam with sealant (5). Remove tape.
(C216), apply sealant to foam in area of
attachment. (6). Install fuel tank.
10
8
9
9G28-072
(1). Defuel supplemental and main fuel (4). Remove fuel transfer hose (3).
tanks (Ref. Section 12-00-00).
(5). Remove fuel transfer elbow (4).
(2). Remove center baggage floor panel (6). Remove main fuel tank aft LH access
(Ref. Section 53-20-00). cover (Ref. Section 28-00-00).
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NOTE: Prior to removing all bolts (17) reach (2). Install new packing onto check valve.
under access cover and support the fuel level
Ensure flow arrow on check
control valve (13). CAUTION valve is facing down after instal
(7). Remove bolts (17) washers (18) and lation.
packings (19). (3). Install check valve into aft LH main
(8). Disconnect fuel transfer hose (10) from fuel tank vent/rollover valve mounting
elbow (9) and remove fuel level support plate. Torque check valve (Ref. CSP-
valve and attached parts. SPM).
(4). Lubricate new packing with aviation
(9). Remove check valve (6) from aft LH turbine fuel (C113).
main fuel tank vent/rollover valve
mounting plate. Remove packing (7) (5). Install nut onto bulkhead elbow and
and discard. install new packing onto elbow.
(10). Remove loosen jam nut (8) and remove (6). Install bulkhead elbow into check
bulkhead elbow(9) from check valve. valve. Torque jam nut (Ref. CSP-SPM).
Remove packing (7) and discard. (7). Attach fuel level control valve to
Remove jam nut. support bracket. Torque bolts (Ref.
(11). Disconnect fuel transfer hose (10) from CSP-SPM).
reducer (11). (8). Lubricate new packing with aviation
turbine fuel (C113).
(12). Remove reducer (11) from fuel level
control valve (13). Remove and discard (9). Install new packing onto reducer and
packing (12). install reducer into fuel level control
valve. Torque reducer (Ref. CSP-SPM).
(13). Remove bolts (14) and washers (15)
from fuel level control valve and remove (10). Using milli-ohm meter (T1002), test
valve from support bracket assembly. between reducer, level control valve,
and control valve support for a class S
B. Supplemental Fuel Transfer System electrical bond (Ref. CSP-SPM).
Installation Environmental seal is not required.
(Ref. Figure 405) (11). Attach fuel transfer hose to reducer.
Torque hose (Ref. CSP-SPM).
Consumable Materials (12). Place fuel level control valve support
(Ref. CSPSPM) and attached parts into main fuel tank.
Item Nomenclature (13). Attach fuel transfer hose to elbow at
C113 Fuel, Aviation Turbine check valve. Torque hose (Ref. CSP-
SPM).
(14). Support fuel level valve and position
Special Tools main fuel tank access cover over valve
(Ref. CSPSPM) support bracket. Install bolts, washers,
Item Nomenclature and packings. Torque bolts (Ref.
T1002 MilliOhm Meter CSP-SPM).
(15). Using milli-ohm meter (T1002), test
Aviation Turbine Fuel between access panel and control valve
support for a class S electrical bond
(Ref. CSP-SPM). Environmental seal is
not required.
(16). Align access cover attachment holes
(1). Lubricate new packing with aviation and install bolts and washers. Torque
turbine fuel (C113). bolts (Ref. CSP-SPM).
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(17). Install fuel transfer elbow into vent/rol (20). Attach transfer hose to supplemental
lover mounting plate. Torque elbow fuel tank fitting. Torque hose (Ref.
(Ref. CSP-SPM). CSP-SPM).
(18). Using milli-ohm meter (T1002), test (21). Install center and aft cabin floor panels
hose and elbow for a class S electrical (Ref. Section 53-20-00).
bond (Ref. CSP-SPM). Environmental (22). Install center baggage floor panel (Ref.
seal is not required. Section 53-20-00).
(19). Install fuel transfer hose onto elbow. (23). Perform main and supplemental fuel
Torque hose (Ref. CSP-SPM). tank leak check/pressure test.
4 (REF)
17 (4PL) 7 (REF)
18 (4PL) FS
19 (4PL) 230.500
6 (REF) 5 4
1 3
20
WL
104.400
16 11
12 6
14 (4PL) 7 (2PL)
15 (4PL)
10 8
2
13
9
9G28-066
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(15). Inspect fuel quantity transmitter for D. Supplemental Fuel Cavity Inspection
condition and security. Repair or
replace as required. Aviation Turbine Fuel
(16). Install fuel tank access cover.
(17). Perform supplemental fuel tank leak
check/pressure test.
(18). Fuel helicopter as required (Ref. (1). Remove supplemental fuel tank.
Section 12-00-00).
(2). Remove supplemental fuel tank support
C. Supplemental Fuel Transfer Inspection foam.
NOTE: (3). Inspect supplemental fuel tank and
Perform Supplemental Fuel Tank Transfer filler neck installation cavity for:
Operational Test to determine if transfer
components are operating correctly. If the (a). Ensure openings through boattail tub
transfer test does not indicate improper op skin are clear and open.
eration, a visual inspection is not required.
(b). Ensure all openings to adjacent areas
Perform fuel transfer inspection when floor
are sealed with tape and sealant to
panels are removed for other maintenance.
provide a fuel and fuel vapor tight
(1). Defuel main fuel tank (Ref. Section barrier. No openings allowed to
12-00-00). adjacent areas. Repair or replace as
required.
Aviation Turbine Fuel
(c). Inspect support foam for condition
and security. Repair or replace as
required.
(2). Perform Supplemental Fuel Tank 1). Support foam maximum allowable
Inspection - Fuselage Internal. irregularities of 0.060 in. (1.52
mm) in depth, within 0.50 in.
(3). Remove cabin floor panels A170 and (12.7 mm) of part edges.
A217 (Ref. Section 53-20-00).
2). Other surfaces maximum allow
System Contamination able irregularities of 0.125 in (3.18
CAUTION
mm) in depth.
(4). Remove aft LH main fuel tank access
cover (Ref. Section 28-00-00). 3). Inspect condition of fuel tank
attaching hook or loop tape. Repair
(5). Inspect fuel transfer components for or replace as required.
condition and security. Repair and
replace as required. (d). Inspect fuel tank sump support for
condition and security.
(6). Install aft LH main fuel tank access
cover (Ref. Section 28-00-00). (e). Ensure drain hole in fuel filler neck
compartment is clear and open.
(7). Install cabin floor panels A170 and
A217 (Ref. Section 53-20-00). (4). Install fuel tank support foam.
(8). Perform Fuel Cell Leak Check/Pressure
Test (Ref. Section 28-00-00). (5). Install supplemental fuel tank.
(9). Fuel helicopter as required (Ref. (6). Perform Supplemental Fuel Tank Leak
Section 12-00-00). Check/Pressure Test.
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2. Supplemental Fuel Tank Leak (8). Connect the air supply and U-tube
Check/Pressure Test manometer (T2014-4) hose to the fuel
transfer hose (2).
A. Supplemental Fuel Tank Leak
Check/Pressure Test Method 1 (Requires (9). Use clean, regulated, low pressure,
Floor Panel Removal) filtered, compressed air source, an
accurate pressure gage and a shut-off
(Ref. Figure 601) valve.
Ensure baggage floor is
CAUTION installed with a minimum of ev
Consumable Materials
(Ref. CSPSPM) ery other screw.
Item Nomenclature (10). Ensure supplemental fuel filler cap is
C702 Lockwire tightly secured.
C809 Leak Detector, Liquid (11). If new fuel cell is installed, slowly apply
2.0 psig (13.8 kPa) using air pressure
regulator (T2014-6), 56 inches of
Special Tools water as measured on the manometer
(Ref. CSPSPM) (T2014-4) to the hose and hold for 10
Item Nomenclature minutes as a precautionary measure.
This will allow air trapped between the
T20144 Manometer cell and the helicopter structure to
T20146 Regulator, Air Pressure escape and also allow the cell to adjust
to the contour of the cell cavity. Release
the air pressure slowly and repeat if
(1). Defuel supplemental fuel tank (Ref. necessary.
Section 12-00-00).
(12). Slowly apply 2.0 psig (13.8 kPa) of
(2). Remove baggage compartment floor regulated air pressure to obtain 56
(Ref. Section 53-20-00). inches of water to the fuel cell as
measured on the manometer
Aviation Turbine Fuel (T2014-4).
(13). After the air supply pressure is shut off,
verify that the air pressure inside does
not drop more than 0.125 psig (0.86
kPa) or 3.5 inches of water after 15
(3). Remove lockwire (2) and slide hose (1) minutes as measured on the manomet
to expose end of vent tube (3). er (T2014-4).
Do not attempt to remove
NOTE: Cap must be capable of retaining 2.0 WARNING access panels with air pres
psig (13.8 kPa). sure applied. This could result in seri
ous injury and damage to fuselage
(4). Cap end of vent tube (3). structure.
(5). Install baggage compartment floor with (14). If leakage exceeds the amount allow
a minimum of every other fastener (Ref. able, apply liquid leak detector (C809)
Section 53-20-00). to areas suspected of leaking.
(6). Remove aft left main fuel tank vent/rol (15). Test fuel drain plug.
lover valve access panel AL230 (Ref. (16). Slowly release air pressure from fuel
Section 53-20-00). cell.
(7). Disconnect fuel transfer hose (2) from (17). Remove baggage area floor panels and
elbow fitting (1). check all connections.
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(18). Reinstall panels and retest. (21). Reconnect fuel transfer hose to elbow
fitting. Torque fitting (Ref. CSP-SPM).
(19). If test is successful, slowly release air
pressure from fuel cell, disconnect the
(22). Reinstall aft left main fuel tank
air supply and U-tube manometer
vent/rollover valve access panel AL230
(T2014-4) hose from the fuel transfer
(Ref. Section 53-20-00).
hose.
(20). Reconnect vent hose to vent tube and (23). Reinstall baggage floor panels (Ref.
secure with lockwire (C702). Section 53-20-00).
FS
235.532
2 (2PL) 3
1
BL
0.00
9G28-075
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FS
230.50
1 2
9G28-076
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3. Supplemental Fuel Quantity Operational (2). Fill the supplemental fuel tank full
Test (Ref. Section 12-00-00)
(Ref. Figure 602) (3). Verify the IIDS and FUEL PROBE
circuit breakers on the A601 essential
(1). Defuel supplemental fuel tank (Ref circuit breaker panel are in (Ref.
Section 12-00-00). Section 96-00-00).
(2). Place helicopter in normal ground (4). Verify the AUX FUEL XMIT and AUX
attitude of 3 degrees nose up (Ref. FUEL circuit breaker on the A620
Section 08-20-00). electrical load center is in (Ref. Section
96-00-00).
(3). Verify the AUX FUEL XMIT circuit
(5). Apply electrical power to the aircraft
breaker on the A620 electrical load (Ref. Section 96-00-00).
center is in (Ref. Section 96-00-00).
(6). Place supplemental fuel transfer switch
(4). Apply electrical power to the aircraft (2) in the ON position.
(Ref. Section 96-00-00).
(7). Verify pump indicator light (1) illumi
(5). Verify supplemental fuel quantity nates and transfer pump is operating
indicator (3) indicates EMPTY. audibly.
(6). Verify supplemental fuel quantity (8). Transfer of fuel shall stop once 34 lb
indicates from EMPTY to FULL as (15 kg)(5 U.S. gal (18.9 L)) to 170 lb
supplemental fuel tank is filled (Ref. (77 kg)(25 U.S. gal (94.6 L)) of fuel
Section 12-00-00). has been transferred.
(7). Remove power from aircraft (Ref. NOTE: Fuel transfer has stopped when the
Section 96-00-00). main and supplemental fuel quantity indi
cators have stabilized and possibly an audi
ble change in transfer pump sound.
4. Supplemental Fuel Transfer Operational
Test (9). Continue to run transfer pump for 10
minutes and verify no change in fuel
(Ref. Figure 602) quantity indication for main or supple
mental fuel tank.
(1). Service main fuel tank to approximate
ly 564 lb (256 kg) (83 U.S. gal (314 (10). Remove power from aircraft (Ref.
L)) (Ref. Section 12-00-00). Section 96-00-00).
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1
2
3 (NOTE)
5.25 IN
1.50 IN (13.34 cm)
(3.81 cm)
1.40 IN
(3.56 cm)
5.19 IN
(13.18 cm)
9G28-068
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2
(1). Mark panel using old panel or new
doublers. 3
1
(5). Drill doubler and nutplate rivet holes
and deburr. 9G28-077
1. MODIFIED RIGHT OUTBOARD BAGGAGE FLOOR
PANEL
(6). Touch up bare aluminum (Ref. CSP- 2. UPPER OUTBOARD DOUBLER
3. UPPER INBOARD DOUBLER
SPM). 4. LOWER PANEL DOUBLER
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4. Supplemental Fuel Tank Support Foam component protrusion with foam tape
Repair (C718).
(6). Build up thickness of tape to allow
Consumable Materials approximately 30 percent compression
(Ref. CSPSPM) after fuel tank installation.
Item Nomenclature
C216 Sealant, Fuel Resistant 5. Supplemental Fuel Tank Cavity Vapor
C310 Primer
Barrier Repair
C411 Adhesive, Epoxy
C505 Foam, Rigid, Structural, Closed Cell Consumable Materials
(Ref. CSPSPM)
C720 Tape, Fastener, Hook & Loop
Item Nomenclature
C718 Tape, Foam
C216 Sealant, Fuel Resistant
C719 Tape, Aluminum
Sealant, Fuel Resistant (C216)
Sealant, Fuel Resistant (C216)
(3). Surface seal all foam repairs with (3). Clean surface with solvent cleaner
primer (C310). (C429) and allow to air dry a minimum
of 15 minutes.
(4). Rebond loose hook & loop tape (C720)
with sealant (C216). (4). Install new foam tape (C718) along
outboard flange of fuel neck cover.
(5). Fill all areas where foam supports are
unsupported due to structural and (5). Install fuel neck cover.
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Rotorcraft Maintenance Manual
7. Supplemental Fuel Check Valve (6). Remove bolts (12) and washers (13).
Modification Remove fuel tank cover (7). Remove
and discard packing (8).
A check valve may be installed inside the
supplemental fuel tank to prevent fuel from (7). Disconnect and remove existing pump
flowing from the supplemental fuel tank to the to auxiliary cell outlet hose.
main fuel tank when the transfer pump is not
on. (8). Remove nut (16) and washer (15) from
bulkhead tube fitting.
Consumable Materials (9). Install washer (14), four washers (15)
(Ref. CSPSPM) and nut (16) on bulkhead tube fitting.
Item Nomenclature Torque nut (Ref. CSP-SPM).
C702 Lockwire Upon installation of check
C113 Fuel, Aviation Turbine CAUTION valve, insure arrow on valve
points in direction of fuel flow in system.
NOTE: Lubricate new packing with aviation
Special Tools
turbine fuel (C113).
(Ref. CSPSPM)
Item Nomenclature (10). Install check valve (17) on bulkhead
T1002 MilliOhm Meter tube fitting with new packings (19).
Torque check valve (Ref. CSP-SPM).
(Ref. Figure 804) (11). Using milli-ohm meter (T1002), test
check valve for a class S electrical bond
(1). Defuel supplemental fuel tank (Ref. (Ref. CSP-SPM).
Section 12-00-00).
(12). Attach new pump to auxiliary cell
(2). Remove baggage compartment floor outlet hose (18) to check valve and
(Ref. Section 53-20-00). pump fitting. Torque hose (Ref. CSP-
(3). Remove bolts (1), washers (2), bolts (3), SPM).
and washers (4) and remove hat (13). Install new packing (8) into groove on
support channel (5). top of fuel tank and install cover with
(4). Disconnect electrical connector (6) from bolts (12) and washers (13). Torque
top of fuel tank cover (7). bolts (Ref. CSP-SPM).
Aviation Turbine Fuel (14). Slide vent hose (10) to equally cover
gap between vent tubes (11) and install
lockwire (C702) (Ref. CSP-SPM).
(15). Connect electrical connector (6) to
transfer pump connector on top of fuel
(5). Remove lockwire (9) and slide hose (10) tank cover (7).
to expose end of vent tube (11).
(16). Install support hat channel (5) with
NOTE: Use care when removing fuel tank cov bolts (3), washers (4), bolts (1), and
er, transfer pump wire harness has approxi washers (2). Torque bolts (Ref. CSP-
mately 10 in. (25.4 cm) of excess length. SPM).
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Rotorcraft Maintenance Manual
1
2
10 (2PL)
7 18
8
11
17
12 19
13
BL
0.000
16
9 (4PL) SUPPLEMENTAL 15
FUEL TANK
3 (4PL) FS
4 (4PL) 230.500
6 BULKHEAD 14
TUBE
FITTING REF
9G28-079
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Rotorcraft Maintenance Manual
(17). Install baggage floor (Ref. Section (19). Perform supplemental fuel quantity
53-20-00). operational test.
(18). Perform supplemental fuel tank (20). Service fuel tank as required (Ref.
leak/pressure test. Section 12-00-00).
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
Chapter
HYDRAULIC SYSTEM
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
29 Contents Revision 25
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page ii
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
290000
Hydraulic System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
HYDRAULIC SYSTEM
DESCRIPTION AND OPERATION
1. Hydraulic System ing system's pressure decreases to between
200 psig and 400 psig.
(Ref. Figure 1)
Fluid is carried through drilled passages to the
The hydraulic control system is a dual circuit contact face of each piston shoe for lubrication,
system. The system supplies pressure to three cooling, and hydrostatic balance. This hydro
dual circuit servoactuators to assist main rotor static balance reduces bearing contact
flight controls operation. System 2 also pressures, minimizing friction and wear. Other
supplies pressure to a single circuit servoac parts are lubricated and cooled with this fluid
tuator to assist anti-torque/directional flight as it circulates at 0.02 to 0.08 gpm through the
controls operation. The hydraulic system uses pump and returns to the manifold/reservoir.
hydraulic fluid (C112) that is approved for B. Manifold/Reservoir Assemblies
operations in temperatures between -40 F to
+275 F. Servicing is accomplished by using The manifold/reservoir assembly distributes
ground support equipment, or the optional the pressurized hydraulic fluid to the servoac
hand pump. tuators. The manifold/reservoir assembly is
the collection point for the fluid returns, and
Systems 1 and 2 operate nominally at 500 contains the system operating fluid. The
psig. If pressure is lost in one of the hydraulic manifold/reservoir assembly components are
systems, the remaining system pump output mounted in an aluminum alloy housing. All
pressure increases to 1000 psig. Each circuit fluid connection fittings on the manifold/reser
consists of the following components: voir are of the ring-lock type.
The bootstrap reservoir prevents cavitation
2. Hydraulic Components during high system flow demands. It main
tains a 2.4 psig minimum static pressure to
(Ref. Figure 2) the pump when the system is shut down and
27 psig during normal system operation.
A. Variable Delivery Pumps
The reservoir bleed valve provides for removal
The two hydraulic pumps are piston type of entrapped air and prevents the reservoir
variable displacement pumps capable of from being over pressurized above 150 psig.
providing flow rates up to 2.2 gpm. Each pump The valve is a spring-loaded valve used to
is driven by an accessory drive on the main bleed the system during servicing. The valve is
transmission. The pump drive shaft is coupled mounted in the housing assembly at the
to the transmission accessory drive by a spline highest point. CURRENT CONFIG - The
which will shear in the event of a physical bleed valve is also used for obtaining fluid
overload. samples.
A system relief valve prevents damage to the
Each pump contains nine pistons arranged hydraulic system in the event the pressure
axially in a floating cylinder block. A compen compensator in the pump malfunctions. The
sator circuit varies pump displacement to valve actuates at 1350 psig and resets at a
maintain a constant 500 psig during varying minimum pressure of 1150 psig.
system flow requirements, providing rapid
pump response. Mechanical stops at full flow The pressure and return filters are standard
and full cut off positions prevent system five micron filter elements contained in
damage. threaded filter bowls. When the filter bowl
assembly is removed a shutoff valve closes,
If pressure is lost in one of the hydraulic isolating the system fluid to prevent leakage.
systems, the functioning system's pump A set of spring-loaded levers prevent the filter
compensator circuit is reset to 1000 psig. The bowl from being installed without the filter
compensator is reset when the mis-function element.
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Rotorcraft Maintenance Manual
The Delta P indicator indicates when the filter EARLY CONFIG - The fluid sampling valve
is to be replaced. A pressure drop across the provides for fluid samples to be taken while
dirty filter displaces a piston inside the the system is fully pressurized. The valve
indicator releasing the center pop-up. A nozzle is fitted with a protective cap attached
thermal lockout prevents a false indication to a security chain.
during low fluid temperature conditions. The
indicator can only be reset after removing the The quantity indicator provides visual
dirty filter. indication of reservoir fluid quantity. The
indicator has individual FULL and REFILL
marks for fluid level at hot and cold fluid
The return filter bypass valve provides a temperatures.
bypass around the filter if the pressure drop
across the filter becomes excessive. It is a The GSE isolation valve in the GSE return
spring-loaded poppet type relief valve. port of the manifold separates the GSE return
lines from the hydraulic system. It is a
spring-loaded poppet valve which opens when
The pressure transducer is a strain gauge, 200 psig is applied to the GSE pressure port
bridge type transducer which converts psig to and resets at a minimum pressure of 80 psig.
an electrical signal for cockpit indications.
During a system pressure loss the HYD 1/2 C. Distribution System
light illuminates on the IIDS and the system
pressures are displayed on the fault line. Stainless steel tubing is used for hydraulic
fluid distribution to reduce corrosion and
damage. Permaswedge fittings help to
The high temperature switch is installed in minimize the possibility of leakage by reducing
the return line to the reservoir. The switch the number of threaded connectors. Clamp
comes on at approximately 235 F, and off at blocks provide spacing of 0.25 in (6.35 mm) for
approximately 205 F. An overheat condition is the tubing to prevent chafing.
displayed on the IIDS.
Hydraulic hoses are installed at the actuators
to allow freedom of movement during opera
The system pressure check valve prevents tion. The hoses are sleeved for fire protection
reverse flow of hydraulic fluid within the and all threaded fittings are safety wired.
manifold. The check valve is a removable
cartridge type check valve and is integrated D. GSE Panels
into a fitting within the manifold.
The GSE panel is located on the left side of the
main transmission deck. The panel provides
The system solenoid valve simulates loss of quick disconnect for ground servicing equip
system pressure for pump compensator ment. The panel has a pressure and return
functional checks. When open, the valve short line connected to the manifold/reservoir. The
circuits supply pressure to return, reducing GSE panel is isolated from the hydraulic
system pressure to approximately 200 psig. system when not in use.
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VARIABLE VARIABLE
DELIVERY DELIVERY
PUMP PUMP
9G29-005A
Page 3
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
GSE PANELS
SAMPLING
PRESSURE VALVE
TRANSDUCER
FLUID TEMP
-40C 95C
F
F U
U L
L L
L
FLUID LEVEL R
SIGHT GAUGE R E
E F
SYSTEM SELECT F I
EARLY CONFIG I L
SOLENOID
L L
L EMPTY
LOOKING INBOARD
CURRENT CONFIG
RETURN FILTER
BY-PASS VALVE
HIGH PRESSURE
RELIEF VALVE
BLEED VALVE
ISOLATION FLUID TEMP
VALVE -40C 95C
FULL
TEMPERATURE
SWITCH FULL
REFILL
REFILL
EMPTY
FILTER BOWL
(PRESSURE) VIEW ROTATED
FILTER BOWL LOOKING DOWN
(RETURN) 9G29-003B
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HANDLE IN
STOWED POSITION
FLUID LEVEL
INDICATOR
SYS #1
OUTLET PORT
SYS #2
OUTLET PORT
HANDLE IN
SELECTOR VALVE OPERATING POSITION
LEVER
9G29-008
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
HYDRAULIC SYSTEM
FAULT ISOLATION
1. Hydraulic System Troubleshooting Troubleshooting tables should be used with
system schematics, electrical wiring diagrams,
serviceability checks and other detailed
(Ref. Figure 101 and Figure 102) procedures in this and other chapters of the
manual.
The following troubleshooting procedures are a Comprehensive wiring diagrams are available
brief summary of hydraulic system faults, in the Rotorcraft Maintenance Manual
which may be encountered (Ref. Table 101). CSP-900RMM-3 (Ref. Section 98-40-00).
1 HYD and HYD 2 not Faulty K17/8 AOG relay. Replace relay K17/8. 963000
present on IIDS during
System 1 and System 2 self 28 vdc not present at Test and repair wiring. 980000
test. K17/8B2.
CB 48 inoperative. Replace circuit breaker. 963000
Faulty switch S5 A606 Utility Replace switch. 963000
Control Panel.
1 HYD not present on IIDS Open ground between Test and repair wiring. 980000
during System 1 self test. GS107J and P429B.
Faulty test solenoid. Replace solenoid.
28 vdc not present at Test and repair wiring. 980000
K17/8B2.
CB 48 inoperative. Replace circuit breaker. 963000
Faulty switch S5 A606 Utility Replace switch. 963000
Control Panel.
1 HYD present on IIDS and Faulty pump. Internally Test pump output pressure with 290000
low pressure reading present worn. mechanical gauge and repair or
on alpha numeric display. replace pump as necessary.
Loose / broken fitting or Repair/replace fitting/line. 290000
cracked/broken line.
Leaking actuator. Repair/replace actuator. 671000
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Rotorcraft Maintenance Manual
HYD 2 present on IIDS and Faulty pump. Internally Test pump output pressure with 290000
low pressure reading present worn. mechanical gauge and repair or
on alpha numeric display. replace pump as necessary.
Loose / broken fitting or Repair/replace fitting/line. 290000
cracked/broken line.
Leaking actuator. Repair/replace actuator. 671000
Hydraulic System 1 or 2 filter Filter is dirty. Replace hydaulic filter and 290000
impending bypass delta reset bypass (delta P) indicator.
pressure indicator will not
reset. Bypass (delta P) indicator Remove and clean bypass 290000
(NOTE: dirty. (delta P) indicator.
Filter bowl must be removed Faulty bypass (delta P) Replace bypass (delta P) 290000
to allow button to be reset) indicator. indicator.
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A606
UTILITY CONTROL PANEL
J2 P102 W123
Q
HYD OIL PRESS 1 EXCIT HI 15
HYD OIL PRESS 1 EXCIT LO 16
HYD OIL PRESS HI 17
HYD OIL PRESS LO 18
9G29-004-1B
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Rotorcraft Maintenance Manual
A606
UTILITY CONTROL PANEL
A612
S5 W124 FWD INTERCONNECT PANEL W123 W129
HYD TEST SWITCH J1 P171
J1 P117 P172 J6
3 SYS 1 J155 P155
83
2 L 84
OFF
M 85 86 R
1 SYS 2 GS107-B E S
N 86
AOG RELAY
K1-7/8
B3
B1 B2
A620
ELECTRICAL LOAD CENTER A3
CB48 W124 A2
A1
CFU 7
J2 P374
5A 37 6 6
X1 X2
HYD TEST
8
RIGHT
A401
GENERATOR MANIFOLD/
BUS 87 RESERVOIR 2
P425 J3
A SYS SELECT
A2 A612 W123
B SOLENOID
IIDS W122 FWD INTERCONNECT PANEL
J155 P155
P421 J1
P170 J9 J1 P171
J5 P105 E T B
TEMP SWITCH
GS107-E A
HYD OIL TEMP 2 HI R 83 84 U
P423 J2
J3 P103 Q
Q Q Q Q Q Q Q
HYD OIL PRESS 2 EXCIT HI 15 84 85 V A
HYD OIL PRESS 2 EXCIT LO 16 85 87 X B PRESS XDCR
HYD OIL PRESS 2 HI 17 86 88 Y C
HYD OIL PRESS 2 LO 18 87 89 W D
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HYDRAULIC SYSTEM
MAINTENANCE PRACTICES
1. Hydraulic System Inspection/Test (3). Inspect for chafed, deteriorated, cut,
frayed and/or cracked hoses. None
A. Hydraulic System Inspection allowed.
(Ref. Figure 201) (4). Inspect for loose, broken and/or cracked
clamps. None allowed.
(1). Inspect exterior surfaces of hydraulic
components for nicks, gouges, (5). Inspect manifold/reservoir fluid level;
scratches, cracks and corrosion. Service as required. Replace contami
nated filters.
(a). Minor scratches, without burrs or
raised material, that do not pene (6). Inspect electrical components.
trate through protective finish are (a). Foreign objects and corroded, bent
acceptable without rework. broken, loose or missing pins. None
(b). Nicks, gouges, corrosion pits or other allowed.
minor surface damage that does not (b). Dirt, contamination with fluid or
exceed a depth of 0.040-inch (0.102 rough locking action. None allowed.
cm) or 10 percent of material thick
ness, whichever is less after rework, (c). Wire harness for chafing and loose
are permissible. installation. None allowed.
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(e). Operate flight controls through a (2). Perform hydraulic system check per
minimum of 25 full-stroke cycles current Rotorcraft Flight Manual
with the hydraulic system pressur (Ref. Section 01-00-00, Table 201).
ized.
(3). Shut down helicopter per current
(f). Leakage at the gland seals or at Rotorcraft Flight Manual (Ref. Section
weep holes shall not exceed 1 drop 01-00-00, Table 201).
per 25 cycles.
E. Hydraulic System Functional Test (with
(g). Depressurize system and remove GSE Pressure).
GSE cart (Ref. Figure 201). (1). Apply power to dc buses and close IIDS
circuit breaker (Ref. Section 96-00-00).
(2). Operate pumps by ground running
helicopter on one engine at idle (65%) (2). Verify 1 HYD 2 caution segments
RPM per current Rotorcraft Flight illuminate on IIDS panel.
Manual (Ref. Section 01-00-00,
Table 201) and inspect the pumps seal (3). Select HYD PRESS on IIDS alphanu
drain for a maximum seepage of 5 meric display (Ref. Section 95-00-00).
drops in 3 minutes. (4). Apply 1000 psig external hydraulic
pressure to system 1 (Ref. Section
C. Hydraulic System Static Leak Test
29-00-00).
NOTE: Leakages are based on a static leakage (5). Slowly decrease pressure to 200 psig
rate of 10 drops per dynamic seal. and then slowly increase pressure to
1000 psig.
(1). When main rotor control actuator
leakage is observed on aircraft standing NOTE: Hydraulic system 2 caution segment
idle, the following procedure shall be should remain illuminated throughout this
used to determine if leakage is unac portion of test.
ceptable:
(a). Verify pressure indication on IIDS
(2). Wipe actuator and clean up any fluid panel alphanumeric display.
spillage.
(b). Verify that hydraulic system 1
(3). Re-inspect in 24 hours. Accumulated caution segment illuminates before
leakage from any of the three servoac 250 psig and that segment goes out
tuators shall not exceed the equivalent at or before 510 psig.
of one teaspoon or roughly a fluid spot (6). Remove external hydraulic pressure
not exceeding eight inches in diameter. and disconnect GSE cart from system 1
GSE ports (Ref. Section 29-00-00).
D. Hydraulic System Operational Test
(Aircraft Ground Run) (7). Turn off dc power (Ref. Section
96-00-00).
(1). Ground run helicopter per current
Rotorcraft Flight Manual (Ref. Section (8). Repeat Steps E-1 through E-8 for
01-00-00, Table 201). system 2.
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2 3
SYSTEM NO. 2
2
1
SYSTEM NO. 1
9G29-012
1. GSE PANEL 3. VARIABLE DELIVERY PUMPS
2. MANIFOLD/RESERVOIR 4. DIRECTIONAL ACTUATOR
Figure 201. Hydraulic Systems 1 and 2
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Rotorcraft Maintenance Manual
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3
5 1
2
7
9G29-002
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Rotorcraft Maintenance Manual
(g). Connect pump control hose (5) to (7). Safety all hose fittings with lockwire
pump control port fitting. Torque (C702).
hose fitting.
(8). If necessary, service both hydraulic
(4). Service both hydraulic systems (Ref. systems (Ref. Section 12-00-00).
Section 12-00-00).
(9). Pressure leak test both hydraulic
(5). Slowly loosen pump control hose (5) systems (Ref. Section 29-00-00).
fitting until fluid begins to seep from
fitting. Allow fluid to drain until air is (10). Install swashplate forward fairing
bled from line. assembly T155. Install and close
forward access door L155 or R155 (Ref
(6). Torque pump control hose (5) fitting. Section 06-00-00).
2 5
4
8 7 (4 PL)
6 (4 PL)
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Rotorcraft Maintenance Manual
(2). Place rags on transmission deck (d). Disconnect hose from manifold CS
beneath manifold/reservoir to catch DR port fitting (10).
hydraulic fluid spills. (e). Disconnect tube from manifold
PRESS port fitting (11).
Hydraulic Fluid (C112)
(f). Disconnect tube from manifold RTN
port fitting (12).
(g). Disconnect tube from manifold GSE
PRESS port fitting (13).
(3). Drain all hydraulic fluid, as practical,
from manifold/reservoir through bleed (h). Disconnect tube from manifold GSE
valve. RTN port fitting (14).
(8). Install protective caps on all tubes,
(4). For removal of manifold/reservoir
hoses and manifold fluid port fittings.
No. 1, detach the following electrical
connectors. (9). Remove manifold/reservoir.
(a). Detach connector P427 from temper (a). Remove bolts (15) and washers (16)
ature switch (1). from base of support bracket and lift
manifold/reservoir assembly from the
(b). Detach connector P428 from pressure deck.
transducer (2).
(b). Remove rags and clean any spilled
(c). Detach connector P429 from system fluid from transmission deck.
select solenoid (3). (c). Clean dried sealant from edges of
manifold support bracket and
(5). For removal of manifold/reservoir mounting surface of deck.
No. 2, detach the following electrical
connectors. B. Hydraulic Manifold/Reservoir Inspection
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(8). Service hydraulic system (Ref. Section (6). Remove and discard packing.
12-00-00). (7). Remove filter element and compression
spring from bowl.
(9). Pressure leak test hydraulic system
(Ref. Section 29-00-00). (8). Deposit residual hydraulic fluid from
bowl into hazardous waste disposal
(10). Install swashplate forward fairing container.
assembly T155. Install and close B. Hydraulic Manifold/Reservoir Filter and
forward access door assembly L155 or Bowl Assembly Installation
R155. (Ref. Section 53-30-00).
(Ref. Figure 204)
6. Hydraulic Manifold/Reservoir Filter and NOTE: This task is typical for System 1 left
Bowl Assembly side and System 2 right side, except where
noted.
A. Hydraulic Manifold/Reservoir Filter and
Bowl Assembly Removal
Consumable Materials
(Ref. CSPSPM)
(Ref. Figure 204) Item Nomenclature
C112 Hydraulic Fluid
NOTE:
This task is typical for System 1 left side
and System 2 right side, except where Hydraulic Fluid (C112)
noted.
Each hydraulic manifold/reservoir has
two filter and bowl assemblies, one on ei
ther side of the manifold fluid level sight (1). Reset Delta P indicator, if applicable
glass. Removal procedures are typical for (Ref Section 29-00-00).
either assembly.
(2). Install compression spring into filter
(1). Open transmission forward access door bowl.
assembly L155 or R155. (Ref. Section
(3). Install new filter element, open end up,
53-30-00).
into filter bowl.
(2). Depress and hold spring-loaded lock (4). Lubricate new packing with hydraulic
lever located on the manifold above fluid (C112) and install atop flange of
filter bowl assembly. bowl.
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(5). Slide filter bowl beneath hydraulic (b). P423 on manifold/reservoir No. 2.
manifold filter port.
Residual Fluids
CAUTION
(6). Raise bowl and engage threads of bowl
with threads of manifold filter port.
(6). Remove transducer (2) and perform
(7). Depress and hold lock lever while Hydraulic Pressure Transducer
threading filter bowl into manifold. Inspection (Ref. Section 29-00-00).
Tighten hand tight and release lock
B. Hydraulic Pressure Transducer
lever.
Inspection
(8). Service hydraulic system (Ref. Section (1). Inspect electrical connector for damage.
12-00-00). None allowed.
(9). Verify no leaks are present in flam (2). Inspect electrical receptacle for damage.
mable fluid systems, where mainte None allowed.
nance or replacement of components,
lines, or fittings has occurred, by (3). Inspect transducer and manifold/reser
application of system pressure and voir for stripped or damaged threads.
visual inspection prior to helicopter None allowed.
being returned to service.
C. Hydraulic Pressure Transducer
(10). Close forward access door L155 or R155 Installation
(Ref Section 06-00-00).
(Ref. Figure 204)
7. Hydraulic Pressure Transducer NOTE: This task is typical for left or right hand
transducers except where noted.
A. Hydraulic Pressure Transducer Removal
(Ref. Figure 204) Consumable Materials
(Ref. CSPSPM)
NOTE: This task is typical for System 1 left Item Nomenclature
side and System 2 right side, except where
noted. C112 Hydraulic Fluid
C702 Lockwire
(1). Open forward access door L155 or R155
(Ref. Section 53-30-00).
Hydraulic Fluid (C112)
(2). Place rags on transmission deck
beneath manifold/reservoir to catch
hydraulic fluid spills.
Hydraulic Fluid (C112) (1). Lubricate new packing and pressure
transducer (2) with hydraulic fluid
(C112). Install packing on transducer.
(2). Install and torque transducer (2).
(3). Drain all hydraulic fluid, as practical, Safety transducer with lockwire (C702).
from manifold/reservoir through bleed (3). Apply torque stripe to transducer (2),
valve. (Ref. CSP-SPM, Section 20-10-00,
Identification Stripe).
(4). Cut and discard lockwire from pressure
transducer (2). (4). Attach electrical connector.
(5). Detach electrical connector. (a). P428 on manifold/reservoir No. 1.
(a). P428 on manifold/reservoir No. 1. (b). P423 on manifold/reservoir No. 2.
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(3). Cut and discard safety wire. (4). Remove rags and clean any spilled fluid
from transmission deck.
Residual Fluids
CAUTION (5). Attach electrical connector.
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4
3
5
9 1
55 -65 in-lb
6.2 - 7.3 Nm 2
11
12
10
8
13
14
6
15 (3 PL)
16 (3 PL) 9G29-010A
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(3). Remove dirt from indicator, use air gun (2). Install indicator.
with low pressure dry air 20-30 psig (3). Install washers and screws.
(138-207 kPa).
(a). Torque screws 35 to 45 in-lb (3.95
(4). Install indicator. to 5.08 Nm).
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(4). Safety screws with lockwire (C702). (11). Close Access Door L155 or R155 (ref.
Section 06-00-00).
(5). Make sure bypass (delta P) indicator is
in. If necessary, reset bypass (delta P)
indicator.
11. System Select Solenoid
(6). Remove rags and if necessary, clean
transmission deck.
A. System Select Solenoid Removal
(7). Service hydraulic system (ref. Section
12-00-00).
(Ref. Figure 205)
(8). Do the Hydraulic System Pressure
Leak Test, look at the bypass (delta P)
indicator for leaks. NOTE: This task is typical for system 1 and
system 2, unless noted.
(9). Close Access Door L155 or R155 (ref.
Section 06-00-00).
(1). Open Access Door L155 or R155 (ref.
10. Bleed Valve Section 06-00-00).
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3
2
5 4
8
1
9
7
10
11
14
13
16
15 12
16
9g29-014B
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12. Hydraulic Hand Pump (Optional) (3). Inspect hand pump reservoir for leaks
and evidence of possible fluid contami
A. Hydraulic Hand Pump Removal nation. None allowed.
(Ref. Figure 206)
(4). Inspect reservoir sight glass for cracks,
(1). Open transmission forward access door crazing and discoloration. Replace hand
assembly L155 (Ref. Section 06-00-00). pump if sight glass is leaking or visual
reference is impaired.
Hydraulic Fluid (C112)
C. Hydraulic Hand Pump Installation
(b). Disconnect system No. 1 fill tube (3) Hydraulic Fluid (C112)
from upper port fitting of pump (1)
and install protective caps on open
fittings of tube and upper outlet port
of pump.
(c). Set hand pump system select lever (2). Install hydraulic hand pump.
(2) to system No. 1.
(a). Align pump (1) with nutplate holes
(d). Disconnect system No. 2 fill tube (4) on left-hand edge of transmission
from lower port fitting of pump (1) deck, just aft of hydraulic system
and install protective caps on open GSE panel.
fittings of tube and lower outlet port
of pump. (b). Install bolts (5) and washers (6).
Torque bolts.
(e). Remove bolts (5) and washers (6) to
remove pump from transmission (c). Lubricate threads of pump port
deck. fittings with clean hydraulic fluid
(C112).
(4). Install protective caps on open tube
fittings (3 and 4). (d). Connect system No. 2 pump fill tube
(4) to lower port fitting of pump (1).
(5). Remove container and clean any spilled
Torque tube fitting.
hydraulic fluid from transmission deck.
B. Hydraulic Hand Pump Inspection (e). Connect system No. 1 pump fill tube
(3) to upper port fitting of pump
(1). Inspect tube end fitting(s) and pump (1).Torque tube fitting.
port fitting(s) for nicks, dents, cracks,
rounded flats and stripped or damaged (3). Service hydraulic system (Ref. Section
threads. None allowed. 12-00-00).
(2). Inspect hand pump and attaching (4). Close transmission forward access door
surfaces for corrosion. None allowed. assembly L155 (Ref. Section 06-00-00).
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5 (4 PL)
6 (4 PL) 3
VIEW ROTATED
2 9G29-009
1. HAND PUMP 4. SYSTEM NO.2 FILL TUBE
2. SYSTEM SELECT LEVER 5. BOLT
3. SYSTEM NO. 1 FILL TUBE 6. WASHER
Figure 206. Hydraulic Hand Pump (Optional)
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Chapter
LANDING GEAR
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
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ROTORCRAFT MAINTENANCE MANUAL
Page ii
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ROTORCRAFT MAINTENANCE MANUAL
Page iii
32 Contents Revision 34
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ROTORCRAFT MAINTENANCE MANUAL
Page iv
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
320000
Landing Gear
Assembly
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
LANDING GEAR
DESCRIPTION AND OPERATION
1. Standard Landing Gear Assembly The aft crosstube is attached to the fuselage at
FS 233.0 and BL 23.25 by the aft saddle
A. Introduction assembly. The forward and aft crosstubes
provide elastic deformation during normal
The standard landing gear assembly (landing landings. The crosstubes provide energy
gear) supports the helicopter when it is in attenuation and permanent deformation
contact with the ground. The landing gear can during severe landings.
withstand loads made during landing, ground
handling, and provides a stable platform to C. Forward and Aft Saddle Assemblies
prevent ground resonance.
The forward and aft saddle assemblies are
The landing gear primarily absorbs normal 7050 T7451 aluminum alloy clamps that
landing forces, with the capabilities to absorb attach to the fuselage fittings. The clamp
severe landing forces during overload condi assemblies secure the forward and aft cross
tions. The landing gear dimensions are based tube assemblies to the exterior of the helicop
on the required minimum roll-over and ter.
minimum pitch-over angles. A minimum
angle of 27 degrees is maintained from the The saddle assemblies have elastomeric
center of gravity (CG) location to the skid-to- rubber pads installed between the clamp and
ground contact point. The landing gear has crosstube to decrease landing gear-to-ground
these components: resonance oscillations.
B. Forward and Aft Crosstubes The forward spacer fittings are 7075 T6
aluminum alloy spacers that attach to the
The forward and aft crosstubes are energy forward crosstube assembly and skid tubes.
absorbing tubes constructed from 7075 T6 The spacer fittings secure the skid tubes to the
aluminum alloy. The forward crosstube crosstube assembly. The spacer fittings
attaches to the fuselage at FS 154.0 and BL transfer landing loads from the skid tubes to
9.275 by the forward saddle assembly. the crosstube assemblies.
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F. Landing Gear Damper Assemblies The reservoir fluid level indicator (1) is a
rotating shaft which shows through a 120 pie
shaped window. When the reservoir is filled,
The landing gear damper assemblies are the window shows green with a very thin
bidirectional hydraulic units that attach to the wedge of red showing to the first notch (2) on
aft crosstube assembly and skid tubes. The the housing. The thin wedge of red shows the
damper assemblies secure the skid tubes to reservoir is not completely full, to allow for
the crosstube assembly while transferring fluid expansion.
landing loads from the skid tubes to the
crosstube assembly. The dampers also dissi G. Skid Tubes
pate landing gear-to-ground resonance
oscillations and absorb vertical shock loads The skid tubes are 7075 T6 aluminum alloy
during landings. tubes that are attached to the forward and aft
crosstube assemblies by the forward spacer
fittings and damper assemblies. The skid
Each damper is an aluminum alloy housing tubes provide a ground contact point for the
with an internal bidirectional hydraulic landing gear. Each skid tube has a forward,
metering circuit. The damping rate of the unit middle and aft steel abrasion strip that
is controlled by forcing fluid from one side of protects the skid tubes during landing.
the internal damper piston to the other side of
the internal piston head. An internal bidirec The middle of the skid provides a fixed
tional fixed orifice is housed in the piston head bushing/pin location for use of the ground
to meter the damping rate. The damper handling wheels during ground operations. A
incorporates an integral reservoir to supply crew station access step is located on the top of
compensation for thermal expansion and fluid each skid tube. The access step provides a 4 by
leakage. 8 inch (10 by 20 cm) non-slip step area.
SIDE STOP
CLAMP ASSEMBLY
AFT
CROSSTUBE
PLUG
AFT AFT
ABRASION STRIP SADDLE ASSEMBLY
FORWARD DAMPER
CROSSTUBE ASSEMBLY
FORWARD FORWARD
FORWARD SADDLE ASSEMBLY SPACER FITTING
ABRASION STRIP
GROUND HANDLING
STEP ATTACH POINTS
MID ABRASION
STRIP
SKID TUBE
9G32-001
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LANDING GEAR
FAULT ISOLATION
1. Standard Landing Gear Assembly
Troubleshooting
The troubleshooting procedures of Table 101
are a brief summary of landing gear system
faults that can occur.
Table 101. Standard Landing Gear Assembly Troubleshooting
Fault Probable Cause Corrective Action Ref. Section
Unusual or too much Damper damage Examine saddle pads, side 320000
vibration Saddle assembly pad stop clamp pads, and/or
damage landing gear damper
assemblies
Side stop clamp pad
damage
Incorrect ground attitude Crosstube damage Examine forward and aft 320000
crosstubes
Landing gear damper Fluid level low Examine fluid level and fill 320000 &
assembly low Damper damage damper with fluid, if necessary 120000
Examine dampers 320000
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LANDING GEAR
REMOVAL / INSTALLATION
1. Forward LH and RH Side StopClamp contact surface of forward crosstube (3)
Assemblies (ref. CSP-SPM, Section 20-20-00).
(3). Remove nut (12), washers (9, 11), the (e). Torque nut (12) 70 to 90 in-lb (7.91
end of jumper (2), and bolt (10) from to 10.17 Nm) more than the run-on
forward stop-clamp (1). torque (ref. CSP-SPM, Section
20-10-10)..
(4). Open forward stop-clamp (1) to remove
from forward crosstube (3). Sealing Compound (C211)
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REF.
ENVIRONMENTAL
SEALING COMPOUND
8
7 8
5
4
6
9 10
11
12
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2
1
RIGHT SIDE SHOWN
LEFT SIDE TYPICAL 2
REF.
ENVIRONMENTAL
SEALING
COMPOUND
14
14
AFT, 7 TO 13
9 (REF) CLEARANCE
2 (REF)
13 6 2 (REF)
9
8 (REF)
11
12
4
7 10
4
6
LEFT SIDE SHOWN,
5 RIGHT SIDE TYPICAL.
9G32-030
1. AFT CROSSTUBE (REF. IPL, 320000, FIG. 1) 8. AFT STOPCLAMP
2. FUSELAGE FITTING (NO IPL REF.) 9. PAD (REF. IPL, 320000, FIG. 6)
3. BRACKET 10. BOLT (REF. IPL, 320000, FIG. 1)
4. JUMPER (REF. IPL, 320000, FIG. 1) 11. COUNTERSUNK WASHER
5. BOLT 12. FLAT WASHER
6. WASHER 13. NUT
7. NUT 14. SKID TUBE ASSEMBLY
Figure 402. Removal and Installation of the Aft StopClamps
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2. Landing Gear (Aft) LH and RH Side (1). Prepare the mating surfaces of aft
StopClamp Assemblies stop-clamp (8), end of jumper (4), and
aft crosstube (1) for an electrical bond
A. Removal of the Aft StopClamps (ref. CSP-SPM, Section 20-50-00).
(Ref. Figure 402)
Make sure countersunk washer
CAUTION
NOTE: This task is typical for the LH or RH aft (11) is next to head of bolt (10)
stop-clamp assemblies. before you install jumper (4). Incorrect as
sembly can cause electrical problems.
Sealing Compound (C211)
(2). Install aft stop-clamp (8) on aft
crosstube (1) with bolt (10), counter
sunk washer (11), the end of jumper (4),
flat washer (12), and nut (13).
(1). Remove sealing compound (C211) from
head of bolt (10). (3). Turn aft stop-clamp (8) 7 to 13 de
grees aft from the 12 o'clock position.
(2). Remove bolt (10), countersunk washer
(11), the end of jumper (4), flat washer (4). Make sure there is a 0.06 inch (1.5
(12), and nut (13). mm) clearance between fuselage
fitting (2) and pad (9) of aft stop-clamp
(3). Let jumper (4) hang loose until installa (8).
tion.
(5). Torque nut (13) 70 to 90 in-lb (7.91 to
(4). Open aft stop-clamp (8) to remove from 10.17 Nm) more than the run-on
aft crosstube (1). torque (ref. CSP-SPM, Section
B. Installation of the Aft StopClamps 20-10-10).
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2
4
3
1
10 8
9 6 (REF)
7 21
4 (REF)
5 (REF)
21
16
14
14
2 (REF) 20
12
13
12
15
18
18
17
20 (REF)
16 (REF) 17 19
19
REF. ENVIRONMENTAL
REF. ENVIRONMENTAL SEALING COMPOUND
SEALING COMPOUND
LEFT SIDE SHOWN.
LEFT SIDE SHOWN. RIGHT SIDE TYPICAL.
RIGHT SIDE TYPICAL.
9G32-007-1D
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(1). Hoist the rotorcraft until damper (1). Prepare the mating surfaces of aft and
assemblies (3) are extended (ref. forward saddle assemblies (4, 6), ends
Section 07-10-00). of jumpers (13), and aft and forward
crosstubes (2, 5) for an electrical bond
Make sure you support the land (ref. CSP-SPM, Section 20-50-00).
CAUTION ing gear assembly with jacks
during removal. Damage to components can (2). Put landing gear assembly (1) under
occur. rotorcraft.
NOTE: Use jacks and/or blocks to help center
(2). Carefully loosen jam nut (8) and the landing gear assembly and to keep the
round-end bolt (10) sufficiently to saddles parallel to the fittings.
disengage from and not touch compres
sion pad (11) of fuselage fitting (6). (a). Align saddle pads (21) on aft saddles
(20) and forward saddles (16) with aft
NOTE: If necessary, remove forward side- fuselage fittings (4) and forward
clamps (ref. Procedure 1.A.). fuselage fittings (6).
(3). Remove bolts (15), flat washers (14), (3). Lower the rotorcraft until aft and
ends of jumpers (13), countersunk forward fuselage fittings (4, 6) meet aft
washers (12), and forward saddles (16) and forward saddles (16, 20).
from forward fuselage fittings (6). (4). Install countersunk washers (17), flat
washers (18), bolts (19), and aft saddles
(4). Remove bolts (19), flat washers (18), (20) on aft fuselage fittings (4).
countersunk washers (17), and aft
saddles (20) from aft fuselage fittings (a). Torque bolts (19) 300 to 430 in-lb
(4). (33.90 to 48.58 Nm) more than the
run-on torque (ref. CSP-SPM,
(5). Remove landing gear assembly (1). Section 20-10-10).
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(a). Torque bolts (15) 130 to 180 in-lb (1). Scuff sand mating surfaces of saddle
(14.69 to 20.34 Nm) more than the pad (21) and fuselage fitting (4, 6) or
run-on torque (ref. CSP-SPM, saddle (16, 20) with a scouring pad
Section 20-10-10). (C817).
Chemical Coating (C233)
Sealing Compound (C211)
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(7). Trim pad flush +0.060 inch (1.52 mm) assembly (ref. Procedure 3.B.), aft
/ -0.000 inch (0.00 mm). saddle (ref. Procedure 4.B.), or forward
(8). As necessary, install landing gear saddle (ref. Procedure 5.B.).
1
2
6 2
5
5 (REF)
8 6 (REF)
7 9
10
11 12 1 (REF)
14
2 (REF)
13
3 (REF)
15 18
17
16 DRAIN PORTS (BOTH SIDES)
LEFT SIDE SHOWN,
RIGHT SIDE TYPICAL.
3 (REF)
19 20
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7. Assembly and Disassembly of the (3). Attach forward spacer fitting (6) to
Standard Landing Gear Assembly forward crosstube (5) with countersunk
washers (7), bolts (8), flat washers (9),
A. Removal of the Forward Spacer Fittings and nuts (10).
(Ref. Figure 404) (4). Attach forward spacer fitting (6) to skid
tubes (3, 4) with washers (11) and bolts
NOTE: This task is typical for the left or right (12).
forward spacer fittings.
Sealing Compound (C211)
Jacking
(2). Remove sealant from heads of bolts (8, (6). Lower the rotorcraft (ref. Section
12). 07-10-00).
C. Removal of the Damper Assemblies
(3). Remove nuts (10), flat washers (9),
countersunk washers (7), and bolts (8). (Ref. Figure 404)
(4). Remove bolts (12) and washers (11). NOTE: This task is typical for the left or right
damper assembly.
(5). Remove forward spacer fitting (6).
Jacking
B. Installation of the Forward Spacer
Fittings
NOTE: This task is typical for the left or right (1). If necessary, jack the rotorcraft until
forward spacer fittings. skid tubes (3, 4) clear the ground (ref.
Section 07-10-00).
(1). If necessary, jack the rotorcraft until (7). Remove damper assembly (2).
skid tubes (3, 4) clear the ground (ref. D. Installation of the Damper Assemblies
Section 07-10-00).
(Ref. Figure 404)
(2). Align the bolt holes of forward spacer
fitting (6), skid tubes (3, 4), and forward NOTE: This task is typical for the left or right
crosstube (5). damper assembly.
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Jacking
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C211 Sealing Compound, Corrosion Inhibitive
C702 Lockwire (1). Jack the rotorcraft until damper
assemblies (2) are fully extended (ref.
Section 07-10-00).
(1). Align the bolt holes of damper assembly
(2) and aft crosstube (1). (2). Remove sealing compound (C211) from
heads of bolts (12, 20).
(2). Install countersunk washers (13), bolts
(14), flat washers (15), and nuts (16). (3). Remove bolts (12) and washers (11)
from forward fitting spacer (6) and skid
(3). Install countersunk washers (17) and tube (3 or 4).
bolts (18). (4). Remove bolts (20) and washers (19)
(a). Torque bolts (18) 100 to 140 in-lb from dampers (2) and skid tube (3 or 4).
(11.30 to 15.82 Nm). F. Installation of the Skid Tube Assemblies
(b). Safety bolts (18) with lockwire (Ref. Figure 404)
(C702).
NOTE: This task is typical for the LH or RH
(4). Attach damper assembly (2) to skid skid tube assemblies.
tube assembly (3 or 4) with washers
(19) and bolts (20). Consumable Materials
(5). Apply masking tape to drain ports of (Ref. CSPSPM)
damper assembly (2). Item Nomenclature
C211 Sealing Compound, Corrosion Inhibitive
Sealing Compound (C211)
(1). Put skid tube (3 or 4) in position.
(a). Align skid tube (3 or 4) with forward
spacer fitting (6) and damper assem
Do not put sealing compound bly (2).
CAUTION (C211) in the drain ports of
damper assemblies (2). Blocked drain ports (2). Attach skid tube (3 or 4) to damper
can cause internal corrosion in damper as assembly (2) with washers (19) and
semblies (2). bolts (20).
(3). Attach skid tube (3 or 4) to forward
(6). Environmentally seal all external spacer fitting (6) with washers (11) and
mating parts with sealing compound bolts (12).
(C211) (ref. CSP-SPM, Section
20-50-00). Sealing Compound (C211)
(7). Remove masking tape.
(8). Lower the rotorcraft (ref. Section
07-10-00).
(4). Environmentally seal all external
E. Removal of the Skid Tube Assemblies mating parts with sealing compound
(C211) (ref. CSP-SPM, Section
(Ref. Figure 404) 20-50-00).
NOTE: This task is typical for the LH or RH (5). Lower the rotorcraft (ref. Section
skid tube assemblies. 07-10-00).
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(3). Remove bolts (14, 18), washers (13, 15, (2). Remove bolts (8), countersunk washers
17), and nuts (16) from damper assem (7), flat washers (9), and nuts (10) from
blies (2) and aft crosstube (1). forward spacer fittings (6) and forward
(4). Remove aft crosstube (1). crosstube (5).
H. Installation of the Aft Crosstube (3). Remove forward crosstube (5) from
(Ref. Figure 404) forward spacer fittings (6).
(4). Environmentally seal all external (3). Environmentally seal all external
mating parts with sealing compound mating parts with sealing compound
(C211) (ref. CSP-SPM, Section (C211) (ref. CSP-SPM, Section
20-50-00). 20-50-00).
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13 12 11
4 PL
10
8 9
8
8 9
4 3 8
7
2
6 PL
10
8 9
10 9 8
8
7
8
6
10 5
8
9
98
7
9G32-007-3B
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8. Assembly and Disassembly of the LH and (3). If necessary, lower the rotorcraft (ref.
RH Skid Tube Assemblies Section 07-10-00).
A. Removal of the Forward Abrasion Strips C. Removal of the Mid Abrasion Strips
NOTE: This task is typical for the left or right NOTE: This task is typical for the mid abrasion
forward abrasion strips. strips on either the LH or RH skid tube as
semblies.
Jacking
Jacking
(a). Torque screws (4) (ref. CSP-SPM, (1). Install mid abrasion strips (5) with
20-10-00). bolts (6, 7), washers (8), spacers (9),
and nuts (10).
Sealing Compound (C213)
(a). Torque bolts (6, 7) and nuts (10) (ref.
CSP-SPM, Section 20-10-00).
(2). Install mid abrasion strips (5) with
bolts (7), washers (8), spacers (9), and
(2). Install a fillet seal around all external nuts (10).
mating parts and fasteners with sealing
compound (C213) (ref. CSP-SPM, (a). Torque bolts (7) and nuts (10) (ref.
Section 20-50-00). CSP-SPM, 20-10-00).
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(Ref. Figure 405) NOTE: This task is typical for each ground
handling attach point on either the LH or
RH skid tube assemblies.
NOTE: This task is typical for the aft abrasion
strips on either the LH or RH skid tube as (1). Remove sealant from the head of bolt
semblies. (7).
(2). Remove nut (10), bolt (7), washers (8),
Jacking
and spacers (9).
H. Installation of a Ground Handling Attach
Point
(Ref. Figure 405)
(1). If necessary, jack the rotorcraft until NOTE: This task is typical for each ground
skid tubes (3, 4) clear the ground (ref. handling attach point on either the LH or
Section 07-10-00). RH skid tube assemblies.
F. Installation of the Aft Abrasion Strips (1). Install bolt (7), washers (8), spacers (9),
and nut (10).
(Ref. Figure 405) (a). Torque bolt (7) and nut (10) (ref.
CSP-SPM, Section 20-10-00).
NOTE: This task is typical for the aft abrasion Sealing Compound (C213)
strips on either the LH or RH skid tube as
semblies.
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LANDING GEAR
INSPECTION / TEST
1. Aft and Forward Saddle Assemblies (a). No damage, deformation, or corrosion
permitted.
NOTE: If the optional cargo hook is used, there
is an additional inspection for the aft saddle (5). Examine forward and aft saddle
assemblies (ref. Section 25-55-00, Inspec bushing holes for damage, deformation,
tion / Check, Aft Saddle Clamp Inspection). and corrosion.
A. Inspections (a). No damage, deformation, or corrosion
(Ref. Figure 601) permitted.
(1). Examine saddle clamps (3, 10) for (6). Examine saddle pads (7, 15) for
missing bolts (4, 11) and washers (5, 6, deterioration, protrusions, and tears.
12, 14). (a). No deterioration, protrusions, or
(a). Replace missing bolts (4, 11) and tears permitted.
washers (5, 6, 12, 14).
(7). Examine saddle pads (7, 15) bonded to
(2). Remove saddle (3, 10) (ref. 32-00-00, saddle assemblies (3, 10) for wear.
Landing Gear Assembly Removal).
NOTE: Bonded saddle pads (7, 15) are trimmed
(3). Examine saddle (3, 10) for cracks, flush, or 0.06 inch (1.5 mm) maximum to
dents, gouges, and corrosion. flat surface on fuselage fittings (2, 9) and
saddle assemblies (3, 10).
(a). No cracks, dents, gouges, or corrosion
permitted. (a). No wear permitted.
(4). Examine forward and aft saddle (8). Examine saddle pad bonds for cracks.
fastener holes for damage, deformation,
and corrosion. (a). No cracks permitted.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
9
7
REF. 3 1
15
3
15 REF. ENVIRONMENTAL
SEALING COMPOUND 6
13 10 5
14 14
4
12
11 8
12
11
REF. ENVIRONMENTAL
SEALING COMPOUND 9G32-022C
1. AFT CROSSTUBE 9. FORWARD FUSELAGE FITTING
2. AFT FUSELAGE FITTING 10. FORWARD SADDLE
3. AFT SADDLE 11. BOLT
4. BOLT 12. COUNTERSUNK WASHER
5. COUNTERSUNK WASHER 13. JUMPER
6. FLAT WASHER 14. FLAT WASHER
7. SADDLE PAD 15. SADDLE PAD
8. FORWARD CROSSTUBE
Figure 601. Saddle Inspections
Page 602
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Rotorcraft Maintenance Manual
13
REF.
ENVIRONMENTAL
SEALING 4
COMPOUND
1 12
8 14
5 6
2
11
9
3
9
10
9G32-029
1. SIDESTOP CLAMP 8. NUT
2. JUMPER 9. FLAT WASHER
3. BRACKET 10. SCREW
4. AFT CROSSTUBE 11. NUT
5. COUNTERSUNK WASHER 12. PAD
6. BOLT 13. FUSELAGE FITTING
7. FLAT WASHER 14. AFT SADDLE
Figure 602. Aft SideStop Clamp Inspections
2. Aft LH and RH SideStop Clamp (4). Examine environmental sealing
Assemblies compound of jumper (2) terminals for
cracks.
A. Inspection of the Aft Clamp Assemblies
(a). No cracks permitted.
(Ref. Figure 602)
(5). Examine jumper (2) bolt holes for
(1). Examine side-stop clamps (1) for damage, deformation, and corrosion.
cracks, dents, gouges, and corrosion.
(a). No damage, deformation, or corrosion
(a). No cracks, dents, gouges, or corrosion permitted.
permitted. (6). Remove side stop clamps (1) (ref.
Section 32-00-00, Removal/Installa
(2). Examine side-stop clamps (1) for
tion).
missing bolts (6), washers (5, 7), and
nuts (8). (7). Examine dowel pin hole for damage,
deformation, and corrosion.
(a). Replace missing bolts (6), washers (5,
7), and nuts (8). (a). No damage, deformation, or corrosion
permitted.
(3). Examine jumpers (2) for corrosion.
(8). Examine clamp pad (12) for cuts,
(a). No corrosion permitted. deterioration, or protrusion.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(a). No cuts, deterioration, or protrusion (3). Examine jumpers (2) for corrosion.
permitted.
(a). No corrosion permitted.
3. Forward LH and RH SideStop Clamp (4). Examine environmental sealing
Assemblies compound of jumper (2) terminals for
cracks.
A. Inspection of the Forward Clamp
Assemblies (a). No cracks permitted.
(Ref. Figure 603) (5). Examine jumper (2) bolt holes for
damage, deformation, and corrosion.
(1). Examine side-stop clamps (1) for
corrosion, cracks, dents, and gouges. (a). No damage, deformation, or corrosion
permitted.
(a). No corrosion, cracks, dents, or gouges (6). Remove side-stop clamps (2) (ref.
permitted. Section 32-00-00, Removal/Installa
tion).
(2). Examine side-stop clamps (1) for
missing nuts (4, 12), washers (5, 9, 11), (7). Examine dowel pin (7) hole for damage,
and bolts (6, 10). deformation, and corrosion.
(a). Replace missing nuts (4, 12), washers (a). No damage, deformation, or corrosion
(5, 9, 11), and bolts (6, 10). permitted.
REF.
ENVIRONMENTAL
SEALING COMPOUND
8
8 (REF)
5
4
6
7
9 10
11
12
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Rotorcraft Maintenance Manual
2.2495
2.2390
Page 605
32-00-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(1). Examine the forward crosstube for (a). Nominal unloaded measurement is
cracks, dents, gouges, and corrosion. 88.30 inch (224.28 cm).
(a). No cracks, dents, gouges, or corrosion (b). If the measurement is more than the
permitted. maximum spread (ref. Table 602),
replace the forward crosstube.
(2). Examine the forward crosstube for
indications of contact with the fuselage Table 602. Maximum Forward Crosstube Spread
fittings or the front saddle assemblies.
Gross Weight
(a). If there are indications of contact, During Operation Maximum Spread
replace the forward crosstube. 6000 lb (2721.6 kg) 89.60 inch (227.58 cm)
(3). Examine the forward crosstube bolt 6250 lb (2835.0 kg) 89.25 inch (226.69 cm)
holes for damage, deformation, and
corrosion. 6500 lb (2948.4 kg) 88.91 inch (225.83 cm)
9G32-019C
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Rotorcraft Maintenance Manual
6 7
9G32-021A
Page 607
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
D. Fluid Level Check of the Landing Gear (b). The reservoir is near empty when the
Damper Assemblies window shows red.
(Ref. Figure 607) (2). If the red has reached or is below the
(1). Make sure the fluid level indicator (1) is second notch (3), fill the reservoir (ref.
between the first notch (2) and second Section 12-00-00, Landing Gear).
notch (3) of the window.
NOTE: This lets the fluid contract.
(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.
2 3
RED 1
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Rotorcraft Maintenance Manual
E. Landing Gear Damper Assembly (4). Make sure there is a clearance between
Inspection damper cover and inner cover.
(3). Examine dampers (1) for missing nuts (a). No damage deformation, or corrosion
(5, 11), bolts (3, 7, 9), and washers (2, 4, permitted.
6, 8, 10). (7). Examine 4 drain ports of damper (1) for
blockage.
(a). Replace missing nuts (5, 11), bolts (3,
7, 9), and washers (2, 4, 6, 8, 10). (a). No blockage permitted.
13 3
2
1
9
8
10
4 11
5
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32-00-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
18.5 INCH 7
(46.99 CM)
10 INCH
(25.40 CM)
13 INCH
(33.02 CM)
11
5 6
7
9G32-018D
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Rotorcraft Maintenance Manual
F. Skid Tube Assembly Inspection (9). Examine skid tube plugs (2) for cracks.
(Ref. Figure 609) (a). No cracks permitted.
(1). Jack helicopter (ref. Section 07-10-00). (10). Examine steps (3) or large steps (4) for
corrosion, cracks, loose rivets, and wear.
(2). Examine skid tubes (1) for cracks and
dents. (a). No corrosion, loose rivets, or wear
permitted.
(a). No cracks or dents permitted.
(11). Examine skid tube abrasion strips (5, 8,
(3). Examine skid tubes (1) for corrosion, 13) to skid tube (1) bolt holes for
nicks, and scratches in the nonrepair damage, deformation, and corrosion.
able area between sections B and C.
(a). No damage, deformation, or corrosion
(a). No corrosion, nicks, or scratches permitted.
permitted.
(12). Examine abrasion strips (5, 8, 13) for
(4). Examine Section A for corrosion, corrosion, cracks, looseness, and wear.
nicks, and scratches. (a). No corrosion, cracks, looseness, or
(a). Damage deeper than 0.010 inch wear permitted.
(0.25 mm) not permitted. (13). Examine abrasion strips (5, 8, 13) for
(5). Examine Section B for corrosion, missing nuts (12), spacers (11), washers
nicks, and scratches. (6, 10), screws (7, 15), and bolts (9).
(a). Replace missing nuts (12), spacers
(a). Damage deeper than 0.010 inch
(11), washers (6, 10), screws (7, 15),
(0.25 mm) not permitted.
and bolts (9).
(6). Examine Section C for corrosion, (14). Examine skid tube ground handling for
nicks, and scratches. missing nuts (12), spacers (11), washers
(a). Damage deeper than 0.025 inch (10), and bolts (9).
(0.64 mm) not permitted. (a). Replace missing nuts (12), spacers
(7). Examine Section D for corrosion, (11), washers (10), and bolts (9).
nicks, and scratches. (15). Examine nuts (12), spacers (11),
washers (10), and bolts (9) for corrosion.
(a). Damage deeper than 0.040 inch
(1.02 mm) not permitted. (a). No corrosion permitted.
(8). Examine skid tubes (1) for missing skid (16). Examine skid tube ground handling
tube plugs (2). bolt holes for corrosion.
(a). Replace missing skid tube plugs (2). (a). No corrosion permitted.
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Rotorcraft Maintenance Manual
Page 612
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Rotorcraft Maintenance Manual
LANDING GEAR
REPAIRS
1. Landing Gear Damper Assemblies compound (C211) from drain ports with
A. Drain Port Repair a brush, scribe, or other instrument.
(Ref. Figure 801) (2). Make sure drain ports are open after
Do not damage adjacent repair.
CAUTION material when you remove
unwanted material or sealing compound
(C211).
(1). Remove unwanted material or sealing
9G32026
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32-00-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
18.5 INCH
(46.99 CM)
10 INCH
(25.40 CM)
13 INCH
(33.02 CM)
OPTIONAL SKID TUBE STEP
12 INCH
(30.48 CM)
9G32-025B
2. LeftHand and RightHand Skid Tube (1). Blend out nicks, scratches, or corrosion
Assemblies in repairable sections A, B, C, and D
A. Blend Repair (ref. CSP-SPM, Section 20-40-00,
Mechanical Defects).
(Ref. Figure 802)
(2). Refinish the blended area (ref. CSP-
CAUTION SPM, Section 20-30-00).
Do not remove material and do the blend NOTE: Material removal and repair procedure
repair more than once on a surface. can be done one time only on a surface.
Material removed from the surface of
Section A cannot be deeper than 0.010 3. Nonslip Surfaces
inch (0.25 mm).
(Ref. CSP-SPM, Section 20-30-00, Landing
Material removed from the surface of Gear Nonslip Surface)
Section B cannot be deeper than 0.010
inch (0.25 mm).
Material removed from the surface of
Section C cannot be deeper than 0.025
inch (0.64 mm).
Material removed from the surface of
Section D cannot be deeper than 0.040
inch (1.02 mm).
Do not remove material adjacent to the
bolt holes for the landing gear damper as
sembly in Section D.
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Rotorcraft Maintenance Manual
Section
324000
Ground Handling
Wheels
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
The requirement to ground transport the MD The steel rims rotate on a spindle by means of
Explorer on prepared surfaces is met be means an inner and outer tapered roller bearing with
of skid mounted ground handling wheels. an external grease fitting on the hub for
periodic servicing.
A. Description and Function
(1). Inspect wheels for cracks and defects,
(Ref. Figure 201) none allowed.
(2). At regular intervals (yearly) repack
Special Tools wheel bearings.
(Ref. CSPSPM) D. Main Frame Body
Item Nomenclature
T101 Ground Handling Wheel Set The main body is a rectangular box frame
weldment constructed from 1/4 1020 steel
plate.
The ground handling wheel set (T101) consists
E. Hydraulic Jack
of two each dual wheel assemblies, which
support a fully equipped MD Explorer approxi A six ton jack is held in place on the main
mately three inches above the ground. frame by a support plate.
The Wheel Assembly consists of two pneumat The jack retains a vertical position, during
ic tires, rims, spindles, a main frame body, raising and lowering of the wheels.
hydraulic jack, and attach cradle.
The ram of the hydraulic jack is in constant
B. Tires contact with the upper cross frame of the main
body, providing vertical pumping leverage
The Wheel Assembly has two 14 inch diame forcing the spindle and wheels down.
ter, 500 x 5 Cleveland with 10 ply, 65 psi
(1). At regular intervals (yearly) inspect
Goodyear tires mounted on steel rims, with a
hydraulic jacks for proper fluid levels.
load rating of at least 1120 lb at 35 mph.
F. Attach Cradle
(1). At regular intervals examine tire
pressure and inflate to 65 psi. Permanently fixed to the bottom of the main
body is a slotted lock down cradle. The cradle
(2). Inspect tires for wear and cuts, none is constructed from 3/16 steel plate and is
allowed. contoured to conform to the MD Explorer skid.
Page 201
32-40-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
VIEW ROTATED
9G32017A
1. GROUND HANDLING WHEEL SET (T101)
Figure 201. Ground Handling Wheel Set
Page 202
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Rotorcraft Maintenance Manual
Chapter
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
52 Contents Revision 32
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page ii
Revision 32 52 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page iii
52 Contents Revision 32
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page iv
Revision 32 52 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page v
52 Contents Revision 32
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page vi
Revision 32 52 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
520000
Doors and Windows
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
52-00-00 Revision 20
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
COCKPIT
SIDE DOOR
COCKPIT DOOR
RELEASE MECHANISM
C
DOOR HINGE
B
A-A
B
GAS STRUT
B-B
COCKPIT DOOR
C-C RELEASE MECHANISM
9G52003
Page 2
Original 52-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
COCKPIT SIDE
(DOOR) WINDOW
9G52002
Page 3
52-00-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
DOOR UPPER
TRACK
& FITTING
B-B E
C
LINK ASSY
LOWER , AFT
CABIN SIDE DOOR CABIN DOOR
CABIN DOOR
CARRIAGE
C
E
TRACK ROLLER
D D
C-C
PIVOT-LUG ASSY
LOWER, FWD
CABIN DOOR
TRACK ROLLER
D-D
DOOR TRACK
E-E CARRIAGE ROLLER
9G52004A
Page 4
Original 52-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
CABIN SIDE
WINDOW
9G52001
Page 5
52-00-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
9G52006
Page 6
Original 52-00-00
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Rotorcraft Maintenance Manual
Page 101
52-00-00 Revision 22
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Rotorcraft Maintenance Manual
Page 102
Revision 22 52-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
NOTE: Left and right side door assemblies are (2). Apply aircraft grease (C107) to bush
typical. ings (7) and bolts (6).
(3). Install bushings (7), bolts (6), washers
(1). Disengage door latching mechanism (1) (5) and nuts (4) securing door assembly
to open cockpit door assembly (2). (2) to fork assembly (13).
(2). With cockpit door (2) swung in open (4). Tighten nuts and install new cotter
position, pull lower end of gas strut (9) pins.
up away from pivot post ball fitting (33)
to remove. (5). Activate door release handle (16) to
permit attachment of door restraint end
When activating cockpit door re fitting (31) and strap to lower fork
CAUTION lease mechanism, spacer (29) or assembly (13).
washer (30) may fall loose as retaining
bosses (12) are removed. (6). Safety door release handle (16) to
airframe using lockwire (C715).
(3). Activate cockpit door release handle (7). Apply aircraft grease (C107) to ball
(16) to release door restraint end fitting fitting (33).
(31) and strap.
(8). Push down end of gas strut (9) onto
(4). Re-engage release handle (16) to secure pivot post ball fitting (33) to attach.
door fork assemblies (13).
(9). Close door (2) and re-engage door
(5). Remove and discard cotter pins (3). latching mechanism (1).
Remove nuts (4), washers (5), bolts (6)
and bushings (7) that attach hinge 2. Cockpit Door Assembly Quick Removal
mechanism (8) of cockpit door assembly A. Cockpit Door Assembly Quick Removal
(2) to door fork assembly (13).
(Ref. Figure 401)
(6). Remove door (2).
(1). Disengage door latching mechanism (1)
B. Cockpit Door Assembly Installation to open cockpit door assembly (2).
(Ref. Figure 401) (2). With cockpit door (2) swung in open
position, pull lower end of gas strut (9)
up away from pivot post ball fitting (33)
Consumable Materials to remove.
(Ref. CSPSPM)
Item Nomenclature When activating cockpit door re
CAUTION lease mechanism, spacer (29) or
C107 Grease, Aircraft washer (30) may fall loose as retaining
C715 Lockwire bosses (12) are removed.
(3). Activate cockpit door release handle
(1). Align hinge mechanism (8) of cockpit (16) to disengage pull rod assemblies
door assembly (2) with door fork (11) and release cockpit door retaining
assembly (13). boss (12).
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(4). Remove complete door assembly (2) A. Cockpit Door Assembly Removal (With
with retainers (27) and fork assemblies Outside Quick Release Pins)
(13) attached.
(Ref. Figure 401)
B. Cockpit Door Assembly Quick
Outside - Removal from outside the helicop
Installation
ter.
(Ref. Figure 401) (1). Open cockpit door assembly.
(2). Disengage and remove snap pin (82)
Consumable Materials
from removable restraint assembly
(Ref. CSPSPM)
(83).
Item Nomenclature
C107 Grease, Aircraft (3). Move door restraint aside.
C715 Lockwire (4). Replace door snap pin into removable
restraint assembly.
(1). Install cockpit door assembly (2) with (5). Remove lower and upper door quick
retainers (27) and fork assemblies (13) release pins (84) while supporting door
attached. with hand.
(2). Attach door restraint end fitting (31) (6). Pull door away from aircraft.
and strap to lower fork assembly (13).
Inside - Removal from inside the helicopter.
Grease, Aircraft (C107)
(7). Open cockpit door assembly.
When activating cockpit door re
CAUTION lease mechanism, spacer (29) or
washer (30) may fall loose as retaining
(3). Apply aircraft grease (C107) to end of bosses (12) are removed.
pull rod assemblies (11).
(8). Activate cockpit door release handle
(4). Align pull rods (11) with retaining boss (16) to disengage pull rod assemblies
(12). (11) and release cockpit door retaining
boss (12).
(5). Engage cockpit door release handle (16)
and verify insertion of pull rods (11) (9). Remove complete door assembly (2)
into retaining boss (12). with retainers (27) and fork assemblies
(13) attached.
(6). Safety door release handle (16) to
B. Cockpit Door Assembly Installation (With
airframe using lockwire (C715).
Outside Quick Release Pins)
(7). Ensure that lower pivot post ball fitting (Ref. Figure 401)
(33) is lubricated with aircraft grease
(C107) prior to installation of gas strut
(9). Consumable Materials
(Ref. CSPSPM)
(8). Push down lower end of gas strut (9) Item Nomenclature
onto lower pivot post ball fitting (33) to C107 Grease, Aircraft
attach.
C715 Lockwire
3. Cockpit Door Assembly (With Outside
Quick Release Pins) Outside - Installation from outside the
helicopter.
NOTE: Helicopters equipped with outside
quick release pins do not have a gas strut (1). Align door hinges with airframe hinge
installed. halves.
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Rotorcraft Maintenance Manual
(2). Insert lower and upper door quick B. Gas Strut Installation
release pins (84).
(Ref. Figure 401)
(3). Remove snap pin (82) from removable
restraint assembly (83). Consumable Materials
(Ref. CSPSPM)
(4). Align restraint assembly halves and
Item Nomenclature
insert snap pin.
C107 Grease, Aircraft
(5). Close cockpit door assembly.
Inside - Installation from inside the Grease, Aircraft (C107)
helicopter.
(6). Install cockpit door assembly (2) with
retainers (27) and fork assemblies (13)
attached. (1). Ensure that pivot post ball fittings (33)
(7). Attach door removable restraint (83) are lubricated with aircraft grease
and strap to lower fork assembly (13). (C107) prior to installation of gas strut
(9).
Grease, Aircraft (C107)
(2). Push down upper end of gas strut (9)
onto pivot post ball fitting (33) to
attach.
(3). Push down lower end of gas strut (9)
(8). Apply aircraft grease (C107) to end of onto lower pivot post ball fitting (33) to
pull rod assemblies (11). attach.
(9). Align pull rods (11) with retaining boss (4). Install retaining spring clip (34)
(12). securing upper end of gas strut (9) to
pivot post ball fitting (33).
(10). Engage cockpit door release handle (16)
and verify insertion of pull rods (11) 5. Hinge Flanged Housing Cockpit Door
into retaining boss (12). A. Flanged Housing Removal
(11). Safety door release handle (16) to (Ref. Figure 401)
airframe using lockwire (C715).
NOTE: Left and Right side are typical.
4. Gas Strut Cockpit Door (1). Remove cockpit door assembly (2) (Ref.
A. Gas Strut Removal Section 52-00-00).
(2). Activate cockpit door release handle
(Ref. Figure 401)
(16) to disengage pull rod assembly
NOTE: Left and Right side are typical. (11).
(1). Remove retaining spring clip (34) that (3). Remove door fork assemblies (13).
secures upper end of gas strut (9) to Caution should be taken when
pivot post ball fitting (33). CAUTION removing sealing compound
from around housings and other bonded
(2). With cockpit door (2) swung in open
components so as not to damage surround
position, pull lower end of gas strut (9)
ing fuselage surfaces.
up away from pivot post ball fitting (33)
to remove. (4). Remove bond from upper retaining boss
(12) and spacers (28 and 29).
(3). Pull upper end of gas strut (9) up away
from pivot post ball fitting (33) to (5). Remove rivets (14) that attach flanged
remove. housings (15) to airframe.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(6). Remove sealant from around housing (7). Activate cockpit door release handle
(15) and remove housing. (16) and verify insertion of pull rods
(11) into retaining boss (12).
B. Flanged Housing Installation
(8). Install cockpit door assembly (2) (Ref.
(Ref. Figure 401) Section 52-00-00).
6. Fork Assembly, Cockpit Door
Consumable Materials A. Fork Assembly Removal
(Ref. CSPSPM)
Item Nomenclature (Ref. Figure 401)
C107 Grease, Aircraft NOTE: Left and Right side are typical.
C206 Sealing Compound (1). Remove cockpit door assembly (2) (Ref.
C310 Primer Section 52-00-00).
(2). Activate cockpit door release handle
Primer (C310) (16) to disengage pull rod assemblies
(11).
(3). Remove fork assemblies (13) and
retainers (27).
B. Fork Assembly Installation
(1). Wet install rivets (14) into flanged
housing (15) with primer (C310). (Ref. Figure 401)
(4). Bond upper retaining boss (12) to (3). Apply aircraft grease (C107) to ends of
spacer (29) with sealing compound pull rod assemblies (11).
(C206).
(4). Activate cockpit door release handle
(5). Install cockpit door fork assemblies (13) (16) and verify insertion of pull rods
(Ref. Section 52-00-00). (11) into retaining boss (12).
(5). Install cockpit door assembly (2) (Ref.
Grease, Aircraft (C107) Section 52-00-00).
7. Pull Rod Assembly
A. Pull Rod Assembly Removal
(Ref. Figure 401)
(6). Apply aircraft grease (C107) to ends of
pull rod assemblies. NOTE: Left and Right side are typical.
Page 404
Revision 20 52-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
(1). Wet install rivets (21) with primer
C107 Grease, Aircraft
(C310) attaching cockpit door release
stop bracket (19) to fuselage door
frame.
(1). Insert end of pull rod (11) into door
release handle (16). (2). Install washer (18) and nut (17)
securing stop bracket (19) to cockpit
Grease, Aircraft (C107) door release shaft (20).
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Sealing Compound (C206) (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).
(1). Bond upper retaining boss (12) to
spacer (29) using sealing compound Primer (C310)
(C206).
(2). Bond lower retaining boss (12) to door
restraint end fitting (31) using sealing
compound (C206).
(3). Wet install rivets (21) with primer
Grease, Aircraft (C107) (C310) attaching cockpit door release
stop bracket (19) to fuselage door
frame.
(4). Install washer (18) and nut (17)
attaching stop bracket (19) and door
(3). Apply aircraft aircraft grease (C107) to release handle (16) to shaft (20).
ends of pull rod assemblies (11).
(5). Safety door release handle (16) to
(4). Activate cockpit door release handle airframe using lockwire (C715).
(16) and verify insertion of pull rods
(11) into retaining boss (12). 11. Flanged Fitting, Cockpit Door Release
A. Flanged Fitting Removal
10. Shaft, Cockpit Door Release
(Ref. Figure 401)
A. Shaft Removal
NOTE: Left and Right side are typical.
(Ref. Figure 401)
Caution should be taken when
NOTE: Left and Right side are typical. CAUTION removing sealing compound
from around bonded components so as not to
(1). Remove nut (17) and washer (18) that
damage surrounding fuselage surfaces.
attach cockpit door release stop bracket
(19) to cockpit door release shaft (20) . (1). Remove cockpit door release stop
bracket (19) and cockpit door release
(2). Remove rivets (21) that attach stop handle (16) Ref. Section 52-00-00).
bracket (19) to fuselage door frame.
(2). Remove rivets (24) that attach cockpit
(3). Remove cockpit door release handle (16) door release flanged fitting (23) to
(4). Remove tubular spring pin (22) from fuselage door frame.
cockpit door release flanged fitting (23) (3). Remove sealant from around flanged
and remove shaft (20). fitting (23) and remove fitting.
B. Shaft Installation B. Flanged Fitting Installation
(Ref. Figure 401) (Ref. Figure 401)
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(1). Wet install rivets (24) with primer (1). Install cockpit door release handle (16)
(C310) attaching cockpit door release using aircraft grease (C107).
flanged fitting (23) to fuselage door Primer (C310)
frame.
Sealing Compound (C206)
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(7). Rotate clevis (56) down away from cable (6). Tighten hex fittings (48) at each
(49) without twisting cable (49). position.
(8). Remove and discard cotter pin (55). (7). Install screws (39) and washers (38)
Remove clevis pin (53) and washer (54) attaching support plate assemblies (41)
that attaches clevis assembly (56) to link and cable assembly (49) to door frame.
(52). (8). Install clevis pin (50) and cotter pin (51)
(9). Remove and discard cotter pin (51). attaching link (52) to housing assembly
Remove clevis pin (50) attaching link (42) bellcrank. Ensure that notch in
(52) to housing assembly (42) bellcrank. link faces in towards housing assembly.
(9). Install clevis pin (53), washer (54) and
(10). Remove screws (39) and washers (38) cotter pin (55) attaching clevis assem
that attach support plate assemblies (41) bly (56) to link (52).
and cable assembly (49) to door frame.
(10). Rotate clevis (56) up into cable (49) as
(11). Remove screws (37) and washers (38) far as it will go without twisting cable
that attach both upper and lower latch (49).
block assemblies (40).
(11). Rotate handle (47) to the fully closed
(12). Remove screws (44 and 45) that attach (SAFELOCK, horizontal) position.
interior door handle assembly (47). Ensure that hex nut (57) does not
bottom out against the support plate
(13). Remove screws (35 and 36) that attach (41).
exterior door handle (46), housing
assembly (42) and spacers (43) in door (12). Loosen hex nut (57) and adjust clevis
frame. (58) so that bolt in upper latch block
assembly (40) protrudes fully (full
B. Door Latch Mechanism Installation LOCK position).
(Original Configuration)
NOTE:
(Ref. Figure 401) This can be verified by pushing the bolt in
and confirming that there is no more than
0.010 in. (0.254 mm) of play.
Consumable Materials
(Ref. CSPSPM) Do not pull assembly down or rotate han
Item Nomenclature dle to accomplish the alignment. Align
ment should only be accomplished with
C239 Sealant
everything in full LOCK position.
(13). Install clevis pin (53), washer (54) and
(1). Install screws (35 and 36) attaching cotter pin (55) attaching clevis (58) to
exterior door handle (46), housing upper latch block (40).
assembly (42) and spacers (43) in door
frame. Sealant (C239)
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(17). Install clevis pin (53), washer (54) and sion spring (71) and connecting tube
cotter pin (55) attaching clevis (58) to (76).
lower latch block assembly (40).
(4). Remove and discard cotter pin (70).
(18). Loosen hex nut (57) and adjust turn Remove clevis pin (68) and washer (69)
buckle rod (60) so that bolt in lower that attaches clevis (75) to upper latch
latch block assembly (40) protrudes block assembly (40).
fully (full LOCK position).
(5). Remove screw (72), washer (73) and
NOTE: This can be verified by pushing the bolt spacer (74) that attaches extension
in and confirming that there is no more than spring (71) to door.
0.010 in. (0.254 mm) of play. (6). Remove and discard cotter pin (70).
Sealant (C239) Remove clevis pin (68) and washer (69)
that attaches clevis (58) to lower latch
block assembly (40).
(7). Remove turnbuckle rod (60) from clevis
(67).
(19). Apply sealant (C239) and tighten hex
nut (57). (8). Remove and discard cotter pin (66).
Remove clevis pin (64) and washer (65)
(20). Install clevis pin (61), spacer (62) and that attaches clevis (67) to housing
return spring (63) through clevis (56) assembly (42) bellcrank.
and attach to lower support plate
(9). Remove screws (37) and washers (38)
assembly (41).
that attach both upper and lower latch
(21). Install (interior) cockpit door panel block assemblies (40) to door.
(Ref. Section 25-10-00). (10). Remove screws (44 and 45) that attach
(22). Install cockpit door assembly (2) on interior door handle assembly (47).
aircraft (Ref. Section 52-00-00). (11). Remove screws (35 and 36) that attach
exterior door handle (46), spacers (43)
(23). Ensure proper alignment and operation
and housing assembly (42) to door
of latch mechanism when reinstalled on
aircraft (Ref. Section 52-00-00, Cockpit frame.
Door Rigging Verification - Original B. Door Latch Mechanism Installation (New
Configuration). Configuration
14. Door Latch Mechanism, Cockpit (New (Ref. Figure 401)
Configuration)
Consumable Materials
A. Door Latch Mechanism Removal (New
(Ref. CSPSPM)
Configuration)
Item Nomenclature
(Ref. Figure 401) C239 Sealant
NOTE: Left and Right side latch mechanisms
are typical. NOTE: Left and Right side latch mechanisms
are typical.
(1). Remove cockpit door assembly (2) (Ref.
Section 52-00-00). (1). Install screws (35 and 36) attaching
exterior door handle (46), housing
(2). Remove (interior) cockpit door panel assembly (42) and spacers (43) in door
(Ref. Section 25-10-00). frame.
(3). Remove and discard cotter pin (80). NOTE: Ensure handle will be in horizontal
Remove clevis pin (77) and washers (78 position with respect to aircraft when door is
and 79) that attach clevis (67), exten installed on aircraft.
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(2). Install screws (44 and 45) attaching NOTE: Verify protrusion by pushing the bolt in
interior door handle assembly (47). and confirming that there is no more than
0.010 in. (0.254 mm) of play.
(3). Install screws (37) and washers (38)
attaching both upper and lower latch (15). Adjust connecting tube (76) so that
block assemblies (40) to door. bottom attachment hole lines up with
hole on clevis (67).
(4). Install clevis pin (64), washer (65) and
(16). Install clevis pin (77), washers (78 and
cotter pin (66) attaching clevis (67) to
79) and cotter pin (80) connecting clevis
housing assembly (42) bellcrank.
(67), extension spring (71) and connect
(5). Assemble turnbuckle rod (60), hex nut ing tube (76).
(57) and clevis (58). (17). Ensure all cotter pins are installed and
bent.
(6). Rotate handle (47) to the fully closed
SAFELOCK (horizontal) position. (18). Install (interior) cockpit door panel
(Ref. Section 25-10-00).
(7). Attach clevis (67) to turnbuckle rod
(60). (19). Verify condition and security of strikes
(81) to fuselage door frame.
(8). Install clevis pin (68), washer (69) and
(20). Install cockpit door assembly (2) on
cotter pin (70) attaching clevis (58) to
aircraft (Ref. Section 52-00-00).
lower latch block (40).
(21). Ensure proper alignment and operation
(9). Loosen hex nut (57) and adjust turn of latch mechanism when reinstalled on
buckle rod (60) so that bolt in lower aircraft (Ref. Section 52-00-00, Cockpit
latch block (40) protrudes fully (full Door Rigging Verification - New
LOCK position). Configuration).
NOTE: This can be verified by pushing the bolt 15. Cockpit Door Window
in and confirming that there is no more than
0.010 in. (0.254 mm) of play. A. Window Removal
(11). Install extension spring (71) onto door (Ref. Figure 401)
using spacer (74), screw (72) and NOTE: If old window seal is soft and workable,
washer (73). install window with loop of string method. If
seal is hardened or dry from age, remove old
(12). Assemble clevis (75) and connecting
seal and replace (Ref. Section 52-00-00).
tube (76) together.
(1). Install string around inside periphery
(13). Install clevis pin (68), washer (69) and of window seal (32).
cotter pin (70) attaching clevis (75) to
upper latch block (40). (2). With window pressed against seal (32),
slowly pull string out of seal allowing
(14). Push connecting tube (76) up so that window (26) to slip under lip of seal.
bolt of upper latch block (40) protrudes Continue process until entire window
fully (full LOCK position). edge slips under lip of seal.
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16. Window Seal, Cockpit Door (2). Install new window seal (32) around
edge of window (26) transparency.
A. Seal Removal
(Ref. Figure 401) (3). Mask off window (26) transparency to
(1). Peel seal (32) from around inside edge minimize contact from squeeze out of
of door frame while removing window silicone compound (C221).
(26).
B. Seal Installation Silicone Compound (C221)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature (4). Apply silicone compound (C221) around
C221 Silicone Compound door frame that mates to surface of
C420 Solvent, Cleaning seal. Spread evenly using small brush.
Solvent, Cleaning (C420) (5). Install window (26) with seal (32) into
door frame and press down edges to
ensure even contact of surfaces.
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26
2
25
25
35
36 1 32
81
25
81 14
15
12
29
6
8 27 28
13
16
24
11
7
16
5
4
3
14
15
30 11
23
6 12
27
20 13
22
31
24
33
21 7
17 5 10
18 4
33 3
19 9
34
9G52-007-1
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38 (4 PL)
37 (4 PL)
48
40
53
48 54
57 58 55 47
52
49
41 44
38 (2 PL) 39 (2 PL)
41 53
54
38 (4 PL) 55
48 50 45
51
39 (4 PL)
35
48 42
57
63 56
53
61 54
55 36
62 43 59 (REF)
52
46 VIEW LOOKING DOWN
59
60
53
LOCK POSITION
54
55
57 SLAM POSITION
57 OPEN POSITION
58
ORIGINAL CONFIGURATION
53
54
55
38 (4 PL)
37 (4 PL)
40
9G52-007-2
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70
69 REF 75
NOTE
40
NOTE
UPPER AND LOWER LATCH
BLOCKS ARE TYPICAL
76
72 67
73 60 57
REF 71
74 71
58
A
REF 76 77 40
78
A
68
69
70
79
80
47
REF 67 44
35
42 45
65
66
46 43 (2 PL)
36
VIEW A-A
64
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85
12
83
82
84
86
9G52-007-4
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(2). Remove pin rivet or bolt (39), washers B. Lower Aft Cabin Door Link Installation
(12 and 32), and post (34). Remove
track roller (35). (Ref. Figure 402)
(1). Remove nut (6), washers (7), bolt (8), (1). Install bushing, use aircraft grease
and bushing (9). (C107).
(2). Put carrage in its installed position.
(2). Remove nut (11), washers (12 and 13),
bolt (14), and bushing (15). Remove link (3). Install bolt, washers, and nut. Torque
(10). nut.
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(2). Remove door stops (4 and 41) and Grease, Aircraft (C107)
bushings (28 and 27).
(2). Install door stops. (2). Put pivot lug in its installed position.
(3). Install quick release pins. (3). Install bushing, pin rivet, washers, and
nut. Torque nut.
25. Cabin Door Stop Pad (4). Install cabin door.
A. Stop Pad Removal 27. Pivot Lug Vertical Track Roller
(Ref. Figure 402) A. Pivot Lug Vertical Track Roller Removal
(1). Remove lower aft cabin door link. (Ref. Figure 402)
(2). Remove nut (20), washer (19), and bolt (1). Remove cabin door.
(18). Remove stop pad (21).
(2). Remove nut (11), washer (32) if
B. Stop Pad Installation installed, washer (33), post (34), and
pin rivet or screw or bolt (31). Remove
(Ref. Figure 402) track roller (35).
(1). Install bolt, stop pad, washer, and nut. B. Pivot Lug Track Vertical Roller
Torque nut. Installation
(2). Install lower aft cabin door link. (Ref. Figure 402)
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28. Pivot Lug Horizontal Track Roller (4). Remove screws (55 and 56), washers
(54), bolts (48 and 69), and support
A. Pivot Lug Horizontal Track Roller plates (57 and 70).
Removal
(5). Remove and discard cotter pins (49).
(Ref. Figure 402) Remove washers (44) and clevis pins
(50). Disconnect tubes (46 and 47).
(1). Remove cabin door.
(6). Remove tubes (46 and 47).
(2). Remove pin rivet or screw (31), washer
(32) if installed, post (34), and spacer (7). Remove screws (58 and 59) and
(38). Remove track roller (35). washers (54). Remove inner door
handle (60).
B. Pivot Lug Horizontal Track Roller
(8). Remove and discard cotter pin (43).
Installation
Remove clevis pin (52). Disconnect tube
(Ref. Figure 402) (53).
(9). Remove clevis (66) and nut (67).
Consumable Materials (10). Remove and discard cotter pin (49).
(Ref. CSPSPM) Remove washer (44) and clevis pin (50).
Item Nomenclature Disconnect tube (53).
C310 Primer
(11). Remove tube (53).
(12). Remove screws (63 and 64), outer door
(1). Install post in track roller. handle (61), and handle housing (62).
Primer (C310) (13). Remove screws (65), washers (54), and
bellcrank (51).
(14). Remove screws (59), washers (54), and
strike plates (71 and 72).
(2). Apply primer (C310) to mating surfaces B. Door Latch Mechanism Installation and
of spacer and pivot lug. Rigging
(3). While primer is wet, install pin rivet or (Ref. Figure 402)
screw, washer if installed, post with
track roller, and spacer. Torque pin Consumable Materials
rivet or screw. (Ref. CSPSPM)
Item Nomenclature
(4). Install cabin door.
C239 Sealant
29. Cabin Door Latch Mechanism (EARLY
CONFIG) (1). Put bellcrank in its installed position.
Install screws and washers. Torque
A. Door Latch Mechanism Removal
screws.
(Ref. Figure 402) (2). Put outer door handle and handle
NOTE: Left and right latch mechanisms are housing in their installed position,
typical. install screws. Torque screws.
(3). Install clevis and nut in tube (53) with
(1). Remove cabin door. approximately one half of clevis in tube.
(2). Remove cabin door trim panel (Ref. Do not tighten nut at this time.
Section 25-20-00). (4). Put tube (53) in its installed position.
(3). Remove and discard cotter pins (43). (5). Connect tube (53) to handle housing
Remove washers (44) and clevis pins assembly and install clevis pin, washer,
(45). and cotter pin.
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(6). Adjust clevis on tube (53) until bell (22). Put inner door handle in its installed
crank is at approximately a 30 degree position and install screws and wash
angle. Do not tighten nut at this time. ers. Torque screws.
(7). Install clevis pin and cotter pin. (23). Turn inner handle clockwise to SAFE
LOCK position.
(8). Put tube (46) in its installed position.
(24). Make a measurement of the distance
(9). Install clevis in tube (46) with approxi top bolt extends above door frame.
mately one half of clevis in tube. Dimensions must be 1.15 in (38 mm).
(25). Make a measurement of the distance
(10). Connect tube (46) to bellcrank and
bottom bolt extends below door frame.
install clevis pin, washer, and cotter
Dimensions must be 1.28 in. (32.5 mm).
pin. Do not bend ends of cotter pin at
this time. (26). If necessary, adjust tube (53) to get the
correct dimensions.
(11). Put top bolt and support plate in their
installed positions. Install screws and Sealant (C239)
washers. Torque screws.
(17). Connect tube (47) to bellcrank and (31). Install cabin door.
install clevis pin, washer, and cotter (32). Do the Cabin Door Rigging Verification
pin. Do not bend ends of cotter pin at procedure.
this time.
(33). Do the Cabin Door Operational Test
(18). Put bottom bolt and support plate in procedure.
their installed position. Install screws
and washers. Torque screws. 30. Cabin Door Bolting System (CURRENT
CONFIG)
(19). Connect tube (47) to bottom bolt.
Install clevis pin, washer, and cotter (Ref. Figure 403)
pin.
NOTE: Left and right latch mechanisms are
(20). Adjust clevis in tube (47) until bottom typical.
bolt extends 1.28 in. (32.5 mm) below
A. Bolting System Removal
door frame.
(1). Remove cabin door.
(21). When adjustment is correct, connect
tube (47) and install clevis pin, washer, (2). Remove cabin door trim panel (Ref.
and cotter pin. Section 25-20-00).
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(13). Remove screws (16 and 17), washers (13). Connect tube (18) to top bolt and install
(3), top bolt (14), and support plate (15). clevis pin, washer, and cotter pin.
(14). Adjust rod end in tube (18) until top
(14). Remove tube (18). bolt extends 1.28 in. (32.5 mm) above
(15). Remove and discard cotter pin (12). door frame. Torque nut.
Remove washer (11) and clevis pin (13). (15). When adjustment is correct, connect
Disconnect tube (9) from bellcrank (1). tube (18) and install clevis pin, washer,
and cotter pin.
(16). Remove and discard cotter pin (12).
Remove washer (11) and clevis pin (10). (16). Put tube (21) in door.
Disconnect tube (9) from handle (17). Install rod end and nut in tube (21)
housing (4). with approximately one half of rod end
(17). Remove tube (9). in tube.
(18). Install lower bolt, support plate,
(18). Remove screws (6 and 7), handle (5), screws, and washers. Torque screws.
and handle housing (4).
(19). Connect tube (21) to lower bolt and
(19). Remove screws (2), washers (3), and install clevis pin, washer, and cotter
bellcrank (1). pin.
B. Bolting System Installation and Rigging (20). Adjust rod end in tube (21) lower bolt
extends 1.36 in. (34.5 mm) below door
(1). Install bellcrank, screws, and washers. frame.
Torque screws.
(21). When adjustment is correct, connect
(2). Install handle housing, handle, and tube (21) and install clevis pin, washer,
screws. Torque screws. and cotter pin.
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5
2
22
23 1
22
5
23
17
3 5 16
4 17
28
25
31
32
39 12
35 35
40 32 34 34
5
12 12 38
34
42 26 31
12
33
41 24 11
29 35 32
27
9G52-008-1C
Figure 402. Cabin Door/Window With EARLY CONFIG Latch Mechanism (Sheet 1 of 2)
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14
73 (4 PL)
12
15 31 LEFT SIDE SHOWN
10 74
6 13
7 32
8
9 35
20 34
19 33
11
37
11 35
33 32
21 18 12
30 11
36
71
59 59
54 56
54
48 57 59
58 60
55 4 PL
54
54
45
43
44
46 63 61
44 64
53 49
62
47
44
68 50
45
43
46 65
69 55 68 54
54 50 50
51
70 44 44
49 49
59 56 52
54 54 43 53
72 68
66 67 47
9G52-008-2D
Figure 402. Cabin Door/Window With EARLY CONFIG Latch Mechanism (Sheet 2 of 2)
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17 ( 2 PL)
3 ( 2 PL)
16 ( 4 PL ) 5
3 ( 4 PL )
6
12
7
14 12 11
15
19
18 ( REF ) 18 ( REF )
11
9
8 10 4
18
23 1 26
13
20
12 28 ( 2 PL )
13 11
12
2 (3 PL)
3 (3 PL) 11 9 ( REF )
12 13
11 9 ( REF )
22
23
21
21 ( REF )
11 19
12
25 29
27 ( 4 PL )
3 ( 4 PL )
16 ( 4 PL )
3 ( 4 PL )
24
17 ( 2 PL)
3 ( 2 PL)
9G52-015A
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(2). Support door weight and remove nut B. Door Strut Assembly Installation
(5), washers (2, 3 and 4) and bolt (1) (Ref. Figure 404)
that join upper fuselage hinge (28) and
upper door hinge (29). (1). Install bolt (8), washer (3) and nut (5)
attaching door strut assembly (16) to
(3). Remove nut (5), washers (2, 3 and 7) strut bracket hinge half (31).
and bolt (6) that join lower spoiler
35. Strut Bracket Hinge Half
hinge (34) and lower door hinge (35).
A. Strut Bracket Hinge Half Removal
(4). Remove baggage door assembly (30). (Ref. Figure 404)
B. Baggage Door Assembly Installation (1). Remove door strut assembly (16) (Ref.
Section 52-00-00).
(Ref. Figure 404) (2). Remove hinge pin (32) that attaches
strut bracket hinge half (31) to struc
tural hinge butt (33).
(1). Align baggage door assembly (30) with
upper and lower door hinge halves. (3). Remove hinge (31).
B. Strut Bracket Hinge Half Installation
(2). Install bolt (1), washers (2, 3 and 4) and
nut (5) joining upper door hinge (29) (Ref. Figure 404)
and upper fuselage hinge (28).
(1). Cut hinge pin (32) 0.22 - 0.28 in. (5.58
- 7.11 mm) shorter than hinge (31).
(3). Install bolt (6), washers (2, 3 and 7) and
nut (5) joining lower spoiler hinge (34) (2). Align hinge halves and install hinge pin
and lower door hinge (35). (32) and center within body of hinge.
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(3). Install door strut assembly (16) (Ref. (7). Remove nut (51) and washers (49 and
Section 52-00-00). 50) that attach bellcrank (47) to crank
spindle.
36. Strut Bracket
(8). Remove nuts (68), washers (67) and
A. Strut Bracket Removal bolts (66) that attach exterior handle
assembly (48).
(Ref. Figure 404)
(9). Remove nuts (22), washers (20) and
(1). Remove nut (11), washers (10) and bolts (21) that attach mounting bracket
screws (9) that attach strut bracket (12) assembly (42) to door assembly (30).
to door assembly (30). B. Door Latch Mechanism Installation
(2). Remove bracket (12). (Ref. Figure 404)
B. Strut Bracket Installation
Consumable Materials
(Ref. Figure 404) (Ref. CSPSPM)
Item Nomenclature
(1). Align strut bracket (12) with mounting C239 Sealant
holes in baggage door assembly (30).
(2). Install screws (9), washers (10) and nut (1). Install washers (44) and nuts (45)
(11) attaching bracket (12) to door attaching stop studs (43) to mounting
assembly (30). bracket assembly (42).
37. Door Latch Mechanism, Baggage (2). Install bolt (69), washer (44) and nut
(45) attaching pawl (46) to bellcrank
A. Door Latch Mechanism Removal (47).
(Ref. Figure 404) (3). Install bolts (21), washers (20) and nuts
(22) attaching mounting bracket
(1). Remove baggage door assembly (Ref. assembly (42) to door assembly (30).
Section 52-00-00).
(4). Install bolts (66), washers (67) and nuts
(2). Remove door trim panel (Ref. Section (68) attaching exterior handle assembly
25-50-00). (48).
(3). Remove and discard cotter pins (62). (5). Install washers (49 and 50) and nut
Remove washers (61) and clevis pins (51) attaching bellcrank (47) to crank
(60) that attach upper and lower spindle.
connecting tubes (52) to bellcrank (47). NOTE:
(4). Remove upper and lower bolt rod Position upper support block (23) with
assemblies (53 and 54) from bolt guide thin edge up and lower support block (24)
assemblies (19). with thin edge down.
Use washers (18) if required such that top
(5). Remove and discard cotter pins (57). and bottom bolt rods will be in contact
Remove washers (56) and clevis pins with aft face of striker plates, and door
(55) that attach rod ends (63) to upper outer mold line is flush with shell within
and lower bolt rod assemblies (53 and 0.030 in. (0.762 mm). Also ensure that
54). bolt rods are in contact with inboard face
of striker plates by adjusting striker
(6). Remove nuts (14), washers (2 and 18) plates.
and bolts (17 and 36) that attach upper
and lower support blocks (23 and 24) (6). Install bolts (17 and 36), washers (2
and guide assemblies (19) to door and 18) and nuts (14) attaching upper
assembly (30). and lower support blocks (23 and 24)
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and bolt guide assemblies (19) to door (17). Insert bolt rod assembly (54) into lower
(30). guide assembly (19).
(7). Thread rod end (63) and hex nut (64) (18). Install clevis pin (60), washer (61) and
into upper end of connecting tube cotter pin (62) attaching upper end of
assembly (52). Do not tighten hex nut connecting tube (52) to bellcrank (47).
at this time. (19). Rotate rod end (63) in connecting tube
(52) until 19.60 0.50 in. (49.78 1.27
(8). Install clevis pin (55), washers (56) and
cm) dimension, measured from center
cotter pin (57) attaching rod end (63) to
of handle (48) to end of bolt rod (54),
upper bolt rod assembly (53).
will be obtained while connecting tube
(9). Install washer (58) and compression (52) is connected to bellcrank (47).
spring (59) on bolt rod assembly (53). Ensure that flat end of rod end
CAUTION (63) is parallel with flat end of
(10). Insert bolt rod assembly (53) into upper connecting tube (52) before tightening hex
guide assembly (19). nut (64). Failure to do so will result in inter
ference with door bolting system operation.
(11). Install clevis pin (60), washer (61) and
cotter pin (62) attaching lower end of Sealant (C239)
connecting tube (52) to bellcrank (47).
Sealant (C239)
(22). Install door trim panel (Ref. Section
25-50-00).
(23). Install baggage door assembly (Ref.
Section 52-00-00).
(24). Ensure proper alignment and operation
(13). Apply sealant (C239) to threads of rod of latch mechanism when reinstalled on
end (63) and tighten hex nut (64). aircraft (Ref. Section 52-00-00,
Baggage Door Rigging Verification).
(14). Thread rod end (63) and hex nut (64)
into end of lower connecting tube 38. Lower Hinges, Door and Spoiler
assembly (52). Do not tighten hex nut
at this time. A. Lower Hinge Removal
(15). Install clevis pin (55), washers (56) and (Ref. Figure 404)
cotter pin (57) attaching rod end (63) to (1). Remove door assembly (30) (Ref.
lower bolt rod assembly (54). Section 52-00-00).
(16). Install washer (58) and compression (2). Remove bolts (38) and washers (37)
spring (65) on lower bolt rod assembly that attach lower door hinge (35), lower
(54). spoiler hinge (34) and shims (27).
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(3). Remove hinges (34 and 35) and shims (2). Remove nuts (14), washers (2) and bolts
(27). (39 and 40) that attach upper fuselage
hinge (28) and shims (25).
B. Lower Hinge Installation
(Ref. Figure 404) (3). Remove hinge (28) and shims (25).
(1). Align hinges (34 and 35) and shims (27) B. Upper Fuselage Hinge Installation
and install washers (37) and bolts (38)
attaching lower door hinge (35) and (Ref. Figure 404)
lower spoiler hinge (34).
(2). Install door assembly (30) (Ref. Section (1). Align hinge (28) and shims (25) and
52-00-00) install bolts (39 and 40), washers (2)
and nuts (14).
39. Upper Hinge, Door
(2). Install door assembly (30) (Ref. Section
A. Upper Door Hinge Removal 52-00-00).
(Ref. Figure 404)
41. Hinge Stop
(1). Remove door assembly (30) (Ref.
Section 52-00-00). A. Hinge Stop Removal
(2). Remove nuts (14), washers (2) and bolts
(38) that attach upper door hinge (29) (Ref. Figure 404)
and shims (26).
(1). Remove upper fuselage hinge (28).
(3). Remove hinge (29) and shims (26).
(2). Remove rivets (71) that attach hinge
B. Upper Door Hinge Installation
stop (70) to hinge (28).
(Ref. Figure 404)
B. Hinge Stop Installation
(1). Align hinge (29) and shims (26) and
install bolts (38), washers (2) and nuts (Ref. Figure 404)
(14).
(2). Install door assembly (30) (Ref. Section NOTE: Locate hinge stop such that a minimum
52-00-00). clearance of 0.10 inch (2.54 mm) is main
tained between the baggage door and the aft
40. Upper Hinge, Fuselage fuselage when the door is in the open posi
tion.
A. Upper Fuselage Hinge Removal
(Ref. Figure 404) (1). Install rivets (71) attaching hinge stop
(70) to upper fuselage hinge (28)
(1). Remove door assembly (30) (Ref.
Section 52-00-00). (2). Install fuselage hinge (28).
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60 46 69 60
61 44 61
62 68 (2 PL) 45 62
67 (2 PL) 43 (2 PL)
66 (2 PL)
42 52
52 47
44 (2 PL)
45 (2 PL)
48
3 14
5
33 2
30
17 41 2
36 9 16 15
32
19
31
8
53
59 23
65
57 2 14
18
58
21 51 9
56 10
55 50
49 12
56
10
20 42
63 11
52
64
20 22
52 REF
47
17
18
24 14
2
54
9G52-009-1A
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14
2
13
25
28
2 14
40 2
14
39 70
71
1
2
4 2
38
2 25
29 3 5
26
26
27
6
2
2
14
3
34 37 38
5
27 35 38
37
9G52-009-2B
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Rotorcraft Maintenance Manual
D. Baggage Door Switch Bracket (EARLY H. Baggage Door Switch Bracket (CURRENT
CONFIG) Installation CONFIG) Installation
(1). Put bracket in its installed position and (1). Put bracket in its installed position and
install screws, washers, and if neces install screws, washers, if necessary
sary spacer washers. Torque screws. spacer washers, and nuts. Torque nuts.
(2). Install baggage door switch. (2). Install baggage door switch.
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10 (3 PL)
9 (2 PL)
8 (2 PL)
19 (2 PL)
2 (2 PL)
18 (2 PL) 11 (2 PL)
20
7 1
21
2 (2 PL
17 (6 PL)
22
16 (2 PL)
3 (2 PL)
14 (2 PL)
11 (2 PL)
4 (2 PL)
12 (2 PL) (NOTE)
15 (4 PL)
(NOTE) EARLY CONFIG
5 (2 PL)
6 (2 PL)
14 (2 PL)
9G52-017
NOTE:
IF NECESSARY TO GET THE CORRECT ADJUSTMENT, ADD WASHERS BETWEEN BRACKET AND HELICOPTER STRUCTURE.
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(14). Visually inspect window retainer for (b). Apply a force of 25 lbs. centrally to
cuts, cracks, or signs of deterioration. the outside of door window. There
No damage allowed. Replace if dam shall be no visual sign of seal break
aged (Ref Section 52-00-00). ing away from window all around on
(a). Apply a force of 50 lbs. centrally to both sides.
the inside of door window. There
shall be no visual sign of seal break
ing away from window all around on
both sides.
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(4). Rotate handle from SAFELOCK to (15). CURRENT CONFIG - Open door to
OPEN position using a torque wrench. 52 in. (132 cm) position. Ensure
Torque shall not exceed 75 in-lb (8.47 forward edge of door is aft of aft door
Nm). pillar.
(5). Rotate handle from OPEN to SAFE C. Baggage Door Operational Test
LOCK position using a torque wrench.
(1). Verify door handle at all positions for
Torque shall not exceed 75 in-lb (8.47
functional operation.
Nm).
(2). Close and latch door from outside and
(6). Rotate handle to KEYLOCK position. observe closure and positive locking as
Lock latching mechanism. handle is turned to SAFELOCK
(7). On outside door handle, apply a torque position.
of 50 in-lb (5.65 Nm) towards the (3). Verify that key locks and unlocks door
OPEN position. Handle shall remain in handle.
KEYLOCK position.
(4). Verify that door releases and opens
(a). EARLY CONFIG - Handle remains without restriction when handle is
downward approximately 80 DEG turned to open position.
from horizontal.
3. Door Latch Mechanism Rigging
(b). CURRENT CONFIG - Handle Verification
remains horizontal.
A. Cockpit Door Latch Mechanism Rigging
(8). On inside door handle, apply a torque of Verification Original Configuration
75 in-lb (8.47 Nm) towards the
OPEN position. Door shall unlatch. (Ref. Figure 602)
(1). With door open, rotate handle to fully
(9). Unlock latching mechanism. closed SAFELOCK position and check
(10). EARLY CONFIG - Unlatch door using position of bolts (no free play allowed).
outside handle. Pull door outward, but (2). Rotate handle to OPEN position to
do not slide aft. ensure that bolts are fully retracted (no
(a). Rotate handle to SLAM position. free play allowed) and release handle.
(3). Mechanism must move and stop at
(b). At inside door handle, pull door SLAM position (if not, adjust detent
closed using a 50 lb (22.68 kg) force. setscrews).
Door shall close shut.
NOTE: At this position, bolts should be able to
(11). Move door stops to aft positions. push in.
(a). EARLY CONFIG - 50 in. (127 cm). (4). Move handle to OPEN position and
clamp upper bolt to prevent it from
(b). CURRENT CONFIG - 52 in. protruding.
(132 cm).
(5). Rotate handle towards SAFELOCK
(12). Unlatch door, open and close door using position until it stops.
a force of 10 lb (4.54 kg). Door shall
move smoothly along full length of (6). Apply force to handle and observe if
track. there is any side load at link (1) and
clevis (2).
(13). Open door and engage hold open
mechanism. (7). If side load exists, and results in
sideways movement of clevis (2),
(14). Close door using a force of 30 lb eliminate it by loosening screws (3) on
(13.61 kg). Mechanism shall prevent cable support plate assembly (4) and
door from closing. move it to line up link (1) and clevis (2).
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SAFE LOCK
(FLIGHT POSITION)
OPEN
4
SLAM 3
KEYLOCK
2
MAINTAIN A STRAIGHT
ALIGNMENT OF THESE TWO
ITEMS AT THE LOADING
POSITION WHEN THE BOLT
1 IS CLAMPED DOWN.
DETENT ADJUSTMENT
ORIGINAL CONFIGURATION
SETSCREW
9G52-014
1. LINK 3. SCREW
2. CLEVIS 4. CABLE SUPPORT PLATE
Figure 602. Cockpit Door Latch Mechanism Rigging Verification
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LATCH
PIN
UPPER
1.28 IN.
(3.25 CM)
(NOTE 1)
COVER
PLATE
COVER PLATE
1.36 IN.
LATCH PIN (3.45 CM)
BOTTOM (NOTE 1) SAFE LOCK
( FLIGHT POSITION )
LATCHING
POSITION 10 o 30
OPENED
POSITION
80 o TYP
TO CLOSE
80 o
SLAM
CURRENT CONFIGURATION
80 o TYP
TO OPEN
OPENED
POSITION
NOTES:
1. CURRENT CONFIG SHOWN. 9G52-013A
Figure 603. Cabin and Baggage Door Latch Mechanism Rigging Verification (Sheet 1 of 2)
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BOLT ROD
ASSEMBLY
BOLT ROD
ASSEMBLY
9G52-016
Figure 603. Cabin and Baggage Door Latch Mechanism Rigging Verification (Sheet 2 of 2)
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Chapter
FUSELAGE
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
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ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
Page xii
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
531000
Windscreens and
Nose Area
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
53-10-00 Revision 13
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Rotorcraft Maintenance Manual
COCKPIT
INSTALLATION
RH COCKPIT
WINDSCREEN
RH CHIN
WINDSCREEN
LH COCKPIT
WINDSCREEN
COCKPIT
WINDSCREENS
INSTALLATION
LH CHIN
WINDSCREEN
9G53-026
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The cockpit roof structure attaches the upper structure and to the tub shell of the general
portion of the cockpit assembly to the center tub assembly. Fastening is by rivets.
section of the fuselage. The cockpit roof
structure is fastened to the center pillar and The chin bow assembly is made up of an outer
the left and right door pillars, the FS 155.50 skin panel and left and right inner skin panels
frame assembly, and side skin assemblies of that are secondarily bonded together.
the general tub assembly. Fastening is by The outer skin panel is fabricated of graphite/
rivets. epoxy with barrier plies of fiberglass/epoxy. In
The cockpit roof structure is a composite the center of the panel above the opening for
sandwich panel. The panel incorporates the aircraft battery, the panel incorporates a
multiple plies of graphite/epoxy and a syntac section of Nomex honeycomb core cocured with
tic epoxy foam core. Around the periphery the the panel skin.
core terminates and the panel transitions to a Both the left and right inner skin panels are
monolithic laminate. fabricated using multiple plies of graphite/
Center Pillar The center pillar is a primary epoxy and fiberglass/epoxy cocured as mono
structural component that provides the lithic laminates.
attachment and structural support for the Door Pillars The left and right door pillar
inboard edges of the left and right cockpit assemblies are primary structural components
windscreens. The upper end of the pillar is that support the outboard edges of the cockpit
mechanically fastened to the cockpit roof and chin windscreens. These components
structure, and to the FS 155.50 frame assem attach, and are the door frames, for the left
bly of the general tub assembly. The lower end and right cockpit doors. Each door pillar is
of the pillar is secondarily bonded to the chin attached to the roof structure, chin bow
bow assembly. assembly, and forward tub skin by rivets.
The center pillar is ``I shaped in cross section Each pillar assembly consists of an outer skin
and is fabricated as a composite sandwich and an upper and lower inner door pillar. All
panel with monolithic laminate flanges. The components are fabricated as monolithic
center section of pillar incorporates multiple laminates utilizing multiple plies of graphite/
plies of graphite/epoxy and fiberglass/epoxy epoxy and barrier plies of fiberglass/epoxy.
cocured with Nomex honeycomb and syntactic
epoxy foam cores. The cap flanges are mono Battery Box Panels The battery box panels
lithic and incorporate additional plies of are secondary structural components. One
graphite/epoxy. upper and two side battery box panels, are
fastened to each other and the interior surface
Chin Bow Assembly The chin bow assembly of the chin bow assembly using secondary
is a primary structural component. The angles and rivets. The panels are located
assembly provides support and provisions for adjacent at the cutout in the chin bow assem
attachment of the lower edges of the left and bly. Along the lower edges of the side panels,
right cockpit windscreeens, and the upper secondary angles are riveted to the panels
edges of the left and right chin windscreens. which in turn bolt to the battery floor assem
The assembly also attaches the nose access bly of the cockpit floor installation.
door assembly, the landing light window, and
battery box panels. The upper ends of the chin Each of the battery box panels is fabricated of
bow assembly are mechanically fastened to the multiple ply graphite/epoxy cocured with a
left and right door pillar assemblies. The lower Nomex honeycomb core. Around the periphery
portion of the assembly is mechanically of the panel, the core is tapered and the panel
fastened to the cockpit subfloor support transitions to monolithic laminate flanges.
Page 3
53-10-00 Original
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Rotorcraft Maintenance Manual
CHIN BOW
ASSEMBLY
NOSE ACCESS
DOOR ASSEMBLY BATTERY
BOX
LANDING LIGHT PANELS TUB FORWARD SKIN
WINDOW (LH SHOWN, RH OPPOSITE) 9G53-041
Nose Access Door Assembly The battery The mounting bracket and shim are fabricated
access door assembly is a secondary structural from aluminum alloy sheet. The hinges and
component that allows access to the battery turnlock fasteners and retaining rings are
box. The access door is hinge mounted at the standard hardware.
top to the chin bow assembly. In the closed
position, the access door is retained by two Attachment Angles, Brackets, Plates, and
quarter turn fasteners. Retention of the door Straps The attachment angles, brackets,
in the opened position is by a strut mounted on plates and straps are secondary structural
the chin bow assembly and a bracket mounted components that are used for attachment of
on the nose access door panel. components within the assembly. These
components are formed and fabricated from
The components included in the battery access aluminum alloy sheet and attached by rivets
door assembly are the battery access door, or pins and collars.
strut mounting bracket, hinges, a shim, and
quarter turn turnlock studs and retaining B. Cockpit Roof Skin
rings. The hinges and the strut mounting
The cockpit roof skin is a primary structural
bracket are fastened by rivets.
shear panel that supports the upper portion of
the cockpit assembly. This panel attaches to
A battery access door seal is bonded to the chin the roof structure of the cockpit assembly and
bow assembly. This provides an environmental to a flange on the FS 155.50 frame assembly of
seal for the battery compartment. the general tub assembly by rivets.
The access door is fabricated of multiple plies The cockpit roof skin is fabricated of multiple
of graphite/epoxy and barrier plies of fiber plies of graphite/epoxy and a barrier ply of
glass/epoxy cocured with a syntactic epoxy fiberglass/epoxy cocured with a syntactic epoxy
foam core. Around the periphery of the door, foam core. Around the periphery the panel
the panel transitions to a monolithic laminate. transitions to a monolithic laminate.
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Rotorcraft Maintenance Manual
Left or right wiper does not Faulty wiring Test and repair wiring 206000
operate in any switch position
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Page 201
53-10-00 Original
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1
4
5
9G53-088
1. RIGHT CHIN WINDSCREEN 4. LEFT COCKPIT WINDSCREEN
2. RIGHT COCKPIT WINDSCREEN 5. LEFT CHIN WINDSCREEN
3. COCKPIT INSTALLATION
Figure 201. Cockpit Windscreens
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Page 203
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Rotorcraft Maintenance Manual
(1). Remove nut (7) and washer (8) F. Wiper Link Installation (EARLY CONFIG)
Figure 205 from wiper blade. (Ref. Figure 203 and Figure 205)
(2). Remove nut (33) and washer (34) (1). Install link onto bracket and clamp
Figure 203, attaching wiper arm to assembly and install bolt and washer.
motor shaft. Torque bolt to allow free rotation of
link, minimizing freeplay.
(3). Loosen hub bolt (37).
(2). Install link onto wiper blade and install
(4). Straighten arm and remove arm from nut and washer. Torque nut (Ref.
motor shaft and wiper blade. CSP-SPM).
D. Wiper Arm Installation G. Wiper Link Removal (CURRENT CONFIG)
(Ref. Figure 203 and Figure 205) (Ref. Figure 203 and Figure 205)
Ensure wiper motor is in the (1). Remove bolt (9), washer (10) and nut
CAUTION PARK position prior to instal (11) Figure 205 and remove wiper link
ling arm. from upper link (14).
(1). Apply electrical power to the helicopter (2). Remove cotter pin (10), nut (9), washers
and verify that the motor is in the (8 and 7) and bolt (6) Figure 203 and
PARK position. Remove power (Ref. remove link from bracket (38 or 39).
Section 96-00-00). H. Wiper Link Installation (CURRENT
(2). Position wiper arm over wiper motor CONFIG)
shaft and wiper blade. Ensure wiper (Ref. Figure 203 and Figure 205)
arm is positioned correctly (Ref.
Figure 205). (1). Install link onto bracket and install
bolt, washer and nut. Torque bolt to
(3). Install wiper arm onto motor shaft and allow free rotation of link, minimizing
wiper blade. freeplay. Intall new cotter pin.
(4). Install nut and washer onto motor (2). Install link onto upper link and install
shaft. Torque nut maximum of 60 in lb bolt, washer and nut. Torque nut (Ref.
(6.78 Nm). CSP-SPM).
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I. Wiper Arm Clamp Removal (EARLY (1). Position wiper motor and install bolts
CONFIG) and washers. Torque bolts (Ref.
CSP-SPM).
(Ref. Figure 203)
Verify proper P535/P536 con
(1). Remove wiper arm assembly. CAUTION nection.
(2). Remove link assembly. (2). Prepare surface for electrical bond (Ref.
(3). Remove screws (40), washers (41 and CSP-SPM).
42), nuts (43) and remove bracket (38 (3). Attach bonding jumper and electrical
or 39). connection.
(4). Remove bolt (20), washers (21), and nut (4). Perform electrical bond check Class L
(22) from clamp (14) and remove clamp. (Ref. CSP-SPM).
J. Wiper Arm Clamp Installation (EARLY Sealing Compound (C205)
CONFIG)
(Ref. Figure 203)
(1). Install clamp onto wiper motor shaft
and install bolt, washer, and nut. (5). Seal bonding jumper attaching hard
ware with sealing compound (C205)
(2). Install bracket washers, screws, and (Ref. CSP-SPM).
nuts. Torque nuts 8-10 in lbs
(0.90-1.13 Nm). (6). Install wiper arm clamp (EARLY
CONFIG).
(3). Install link assembly.
M. Wiper Motor Mounting Bracket Removal
(4). Install wiper arm assembly.
(Ref. Figure 203)
Ensure clamp is located axially
CAUTION flush with shoulder below (1). Remove wiper motor.
splined motor output shaft.
(2). Remove sufficient sealant to remove
(5). Torque nut on clamp (Ref. CSP-SPM). screws (16).
K. Wiper Motor Removal (3). Remove screws (16), washers (17),
washers (18), and nuts (19).
(Ref. Figure 203)
(4). Remove bracket (2 or 5).
(1). Remove wiper arm clamp (EARLY
CONFIG). N. Wiper Motor Mounting Bracket
Installation
(2). Disconnect electrical connector and
bonding jumper. (Ref. Figure 203)
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Rotorcraft Maintenance Manual
(Ref. Figure 204) (4). Install access panels PL120 and PR120
(Ref. Section 06-00-00).
Power Off (5). Restore power to helicopter (Ref.
Section 96-00-00).
Q. Windscreen Wiper Inspection
(Ref. Figure 203 and Figure 205)
(1). Verify all power is removed from
helicopter (Ref. Section 96-00-00). (1). Inspect all hardware for condition and
security. Tighten/replace any loose/un
(2). Remove access panels PL120 and serviceable hardware.
PR120 (Ref. Section 06-00-00).
(2). Inspect wiper blade for deterioration.
(3). Detach connector P539 from connector None allowed.
J1. (3). Inspect electrical components for
condition and security. Repair/replace
(4). Remove screws (1) and washers (2) any unserviceable components.
attaching relay panel (3). Remove relay
panel. (4). Check rigging of wiper installation.
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31
25 (2 PL)
32
25 (4 PL)
23 (4 PL)
27
24 (4 PL)
9 REF
1
3 (2 PL)
ROTATED 180 33 (2 PL) 2
LH SHOWN RH OPP 37 34 (2 PL)
4
35 (2 PL)
20 (2 PL) 36 (2 PL)
21 2X (2 PL)
22 (2 PL) 5
39 6 (2 PL)
7 2X (2 PL)
8 2X (2 PL)
9 (2 PL)
10 (2 PL)
11 (2 PL)
12
16 (4 PL)
17 (4 PL)
18 (4 PL) 15
19 (4 PL)
40 (4PL) 38
41 (4PL)
42 (4PL) 14 (2 PL) 13 (2 PL)
43 (4PL) 29 (8 PL)
30 (16 PL)
9G53-126-1
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Rotorcraft Maintenance Manual
28
46
(EARLY CONFIGURATION)
46
WIPERS
HI
LO
OFF
46
44
(CURRENT CONFIGURATION)
(CURRENT CONFIGURATION)
(OPTIONAL LOCATIONS)
WINDSCREEN
WIPER CONTROL 9G53-126-2
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
1
2
( 3 PLCS )
LOOKING INBOARD
9g53-130
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
2 (REF)
7 (4 PL)
8 (4 PL)
1 (REF)
EARLY CONFIGURATION
4 (REF)
2.0-4.5 IN
( 5.1-11.4 cm )
2.0-4.5 IN
3 (REF) ( 5.1-11.4 cm )
7 (2 PL)
8 (2 PL)
2
6 (REF) 5 (REF)
12 (2 PL)
13 (2 PL)
9 (2 PL)
10 (4 PL)
11 (2 PL)
14
CURRENT CONFIGURATION 3
5
9G53-127
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3. Landing Light Window Panel (N82) C. Landing Light Window Panel Installation
(Ref. Figure 206)
A. Landing Light Window Panel Inspection
(1). Position landing light window panel in
(Ref. Table 202) frame and align screw holes.
(2). Secure window to airframe with screws,
(1). Inspect window panel for pits, cracks, packing washers and flat washers.
scratches and general condition. Repair
or replace as required. 4. Nose Access Door (N80)
A. Nose Access Door Inspection
(2). Inspect for loose or missing fasteners.
Repair or replace as required. (1). Inspect door for general condition and
security. No damage allowed.
B. Landing Light Window Panel Removal
(2). Inspect door lock (if applicable) and
quarter-turn fasteners for security and
(Ref. Figure 206) verify proper operation. No damage
allowed.
(1). Remove screws, packing washers and
flat washers which secure landing light (3). Inspect hinges for proper operation,
window panel into airframe. loose or missing fasteners. Repair or
replace as required.
(2). Remove window from airframe, using (4). Inspect door frame seal for security and
care to prevent damage to seal bond serviceable condition. No damage
surfaces. allowed.
Table 202. Landing Light Window Allowable Repairs
Part Number Name Zone Maximum Depth Maximum Length Minimum Spacing
900F2305048 Window, Landing Light All 0.03 in (0.76 mm) 6.0 in (15.2 cm) 0.5 in (12.7 mm)
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1
2 9G53-086
1. NOSE ACCESS DOOR (N80)
2. LANDING LIGHT WINDOW (N82)
Figure 206. Landing Light Window Panel / Nose Access Door
B. Nose Access Door Removal (1). Prepare surface for electrical bond (Ref.
CSP-SPM).
(Ref. Figure 206)
(1). Unlock nose access door (if applicable). (2). Secure door and bonding leads to
hinges with screws, washers and nuts.
(2). Disengage quarter-turn fasteners at
Torque nuts.
bottom of door. Open door.
(3). Remove sealant from hinge attach Sealing Compound (C203)
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
(3). Apply sealing compound (C203) to
(Ref. Figure 206) bonding lead terminals and attaching
hardware.
Consumable Materials
(Ref. CSPSPM) (4). Close door and engage quarter-turn
Item Nomenclature fasteners.
C203 Sealing Compound
(5). Lock nose access door (as required).
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Rotorcraft Maintenance Manual
Section
532000
Lower and Center
Fuselage
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
UPPER WORK
PLATFORM
INSTALLATION
BAGGAGE FLOOR
INSTALLATION
DOOR TRACKS
INSTALLATION
CABIN FLOOR
INSTALLATION
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
B. Fuel Cell Liner Assemblies resin impregnated carbon fiber fabric are
inlaid.
The fuel cell liner assemblies, installed as a
Support Rib Channels The support rib
forward and aft assembly, are secondary channels are secondary structural components
structural components that distribute the that capture the upper edge of each respective
vertical load produced by the fuel in the fuel fuel cell rib when the fuel cell liner assemblies
cell to the fuel cell ribs and keel beams of the are installed.
tub assembly, and the FS 155.50 and the FS
230.50 bulkheads. Each assembly is installed Each support rib channel is fabricated using
with seals, and together forms the lower one ply of aramid/epoxy and one ply of
closure panel for the fuel cell cavity. carbon/epoxy cocured as a monolithic lami
nate. The channels are installed on the
Each liner assembly is fabricated from underside of each fuel cell liner panel using
multiple details. The primary components rivets and secondary bonding. The forward
within each assembly are the fuel cell liner fuel cell liner assembly utilizes nine support
panel, support rib channels, insulators, and rib channels and the aft fuel cell liner utilizes
beads. one support rib channel.
Insulators The insulators are fiberglass
Fuel Cell Liner The fuel cell liner panel is barriers that are bonded over the heads of the
fabricated as a composite sandwich panel that rivets (on the fuel cell side) that secure the
utilizes multiple ply epoxy resin impregnated support rib channels.
carbon fiber fabric and epoxy resin impreg
nated fiberglass fabric skins cocured with a Beads The beads are rubber strips that are
Nomex honeycomb core. In areas in which bonded to the upper surface of the fuel cell
secondary attachment of the support rib liner panels. The beads provide for the
channels occurs the honeycomb core is tapered drainage of fuel from the fuel cell cavity in the
and additional reinforcement plies of epoxy event of fuel leakage from the fuel cell.
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Rotorcraft Maintenance Manual
FUEL CELL
LINER SEALS
RH FS 218.50 DOOR
FS 155.50 FRAME FRAME ASSEMBLY
LH FS 230.50 LOWER
FS 230.50 TUB FRAME ASSEMBLY
BULKHEAD
ASSEMBLY
BOAT TAIL
FUEL DRAIN ACCESS ASSEMBLY
PANEL ASSEMBLY
RH AVIONICS ACCESS
PANEL ASSEMBLY
TUB
SHELL ASSEMBLY
LH FS 166.50 DOOR
FRAME ASSEMBLY
(RH OPPOSITE)
CENTER ACCESS
PANEL ASSEMBLY SUMP ACCESS
LH AVIONICS ACCESS PANEL ASSEMBLY
NOTE: FWD SKID ATTACHMENT FITTING AND AFT PANEL ASSEMBLY
SKID ATTACHMENT ASSEMBLY ARE NOT SHOWN.
9G53-028A
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Rotorcraft Maintenance Manual
C. Tub Shell Assembly that support the loads in the vertical direction
produced by the fuel in the fuel cell. Six fuel
(Ref. Figure 3) cell support ribs are positioned laterally
The tub shell assembly is fabricated from between the keel beams, and are located at FS
multiple composite detail parts joined together 166.50, FS 176.60, FS 190.25, FS 199.20, FS
by bonding or rivets.The primary components 209.90, and FS 220.20. The ribs are mechani
included in this assembly are the tub shell, the cally fastened to the keel beams by means of
left and right keel beams, and the fuel cell auxiliary cleats or angles.
support ribs. Secondary components include Early Configuration - The ribs are secondarily
the cockpit and cabin sills, tub shell longerons, bonded to the tub shell.
fuel cell liner attachment angles, lower door Current Configuration - Fuel cell support ribs
track pockets, and miscellaneous support are riveted to the tub shell.
angles.
All fuel cell ribs are fabricated as composite
Tub Shell The tub shell is a primary sandwich panels, that utilize multiple ply
structural component and is the load bearing graphite/epoxy skins cocured with Nomex
skin of the lower section of the fuselage. honeycomb cores. The honeycomb core
terminates at the integral attachment flanges
The sides of the tub shell are fabricated as a which are monolithic laminates.
composite sandwich panel that is typically two
ply outer and one ply inner graphite/epoxy Auxiliary Components The auxiliary
skins cocured with a Nomex honeycomb core. components, such as the cockpit and cabin
In areas in which secondary attachment of sills, tub shell longerons, fuel cell liner
additional components will occur, the honey attachment angles, and the lower door track
comb core is tapered and additional reinforce pockets are secondary structural components.
ment plies of graphite/epoxy are inlaid. The
center section between LBL 24 and RBL 24 is These auxiliary components are all composite
typically three ply graphite/epoxy solid monolithic laminates utilizing multiple plies of
laminate. In areas in which secondary graphite/epoxy.
attachment of additional components occur,
additional reinforcement plies of graphite/ The primary function of the cockpit and cabin
epoxy are inlaid. In areas in which secondary sills are to provide for attachment of the
attachment of metallic components occurs, a cockpit and cabin compartment floor panels.
barrier ply of fiberglass/epoxy is cocured to the The function of the tub shell longerons is to
surface of the respective skin. On the exterior provide stiffening of the tub shell. The function
surface of the tub shell a barrier ply of of the fuel liner attachment angles is to
fiberglass/epoxy and a ply of Astrostrik
is provide provisions for attachment of the fuel
cocured to the panel. cell liner. The primary function of the door
track pockets is to provide attachment of the
Fuel Cell Support Ribs The fuel cell support forward ends of the lower door tracks for the
ribs are the primary structural components cabin doors.
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Rotorcraft Maintenance Manual
RH KEEL BEAM
ASSEMBLY
FUEL CELL
SUPPORT RIBS LH KEEL BEAM
ASSEMBLY
FUEL CELL LINER
ATTACHMENT ANGLE
(LH AND RH TYPICAL)
COCKPIT SILL
(LH AND RH TYPICAL)
CABIN SILL
(LH AND RH TYPICAL)
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Rotorcraft Maintenance Manual
D. Cockpit Subfloor Support Structure Each assembly combines a vertical web, with
Assembly an integral upper flange, a lower flange cap,
and several vertical stiffening channels and
(Ref. Figure 4 and Figure 5) angles. All components within each assembly,
The cockpit subfloor support structure with the exception of the secondary attach
assembly provides the support for the cockpit ment angle along the aft edge and hardware,
floor panels, the structural interface and are fabricated from aluminum alloy sheet. The
mounting provisions for the cockpit console, secondary attachment angles are machined
the crew seats, and the cockpit mounted flight from aluminum alloy extrusions. All compo
control components. In addition, this assembly, nents within these assemblies are joined using
forms the left, center, and right avionics bays. rivets.
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Rotorcraft Maintenance Manual
RH PLOUGH
BEAM ASSEMBLY
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
FS 155.50 FRAME
ASSEMBLY
TUB ASSEMBLY
(REFERENCE)
FS 155.50 TUB
BULKHEAD ASSEMBLY
RH FWD SKID
ATTACHMENT
FITTING
LH FWD SKID
ATTACHMENT FITTING 9G53-031A
Figure 5. FS 155.50 Tub Bulkhead and Frame Assemblies, Forward Skid Attachment Fittings
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Rotorcraft Maintenance Manual
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
K. Cabin Door Frames Assemblies The components included in this assembly are
the boat tail tub, the boat tail sills, attachment
(Ref. Figure 2) cleats, spoiler attachment inserts, and bonded
nutplates.
The cabin door frame assemblies are second
ary structural components. These components Boat Tail Tub The boat tail tub is a primary
support loads in the vertical and lateral structural component and is the load bearing
directions. These assemblies attach to the tub skin in the aft lower section of the fuselage.
shell and keel beams of the tub assembly, the
edge of the panel that forms the cabin door The boat tail tub is a composite sandwich
opening, and adjacent structure of the roof panel that utilizes multiple ply graphite/epoxy
assembly. Secondary attachment of these skins cocured with a Nomex honeycomb core.
assemblies is by rivets. Each assembly also In areas in which secondary attachment of
provides for attachment of the cabin floor additional components will occur, the honey
panels. comb core is tapered and additional reinforce
ment plies of graphite/epoxy are inlaid. In
FS 166.50 Door Frame Assemblies The left areas in which secondary attachment of
and right FS 166.50 door frame assemblies are metallic components will occur, a barrier ply of
located along the forward lower edge of the fiberglass/epoxy is cocured to the surface of the
cabin door openings. respective skin. On the exterior surface of the
boat tail tub a ply of Astrostrik
is cocured to
the panel.
Each assembly consists of an upper frame, a
lower riblet, and secondary attachment angles.
All components within these assemblies, Boat Tail Sills The boat tail sills are second
excluding the hardware, are fabricated from ary structural components and are the
aluminum alloy sheet. Secondary fastening of provisions for attachment of the lower edges of
the detail components is by rivets. the rear fuselage shell assemblies. The sills
also provide the provisions for attachment of
FS 218.50 Door Frame Assemblies The left the baggage floor panels.
and right FS 218.50 door frame assemblies are
located along the aft edge of the cabin door The sills are composite on aircraft serial
openings. numbers 900-00010 through 900-00028
and are fabricated using multiple plies of
Each assembly consists of a frame, a floor graphite/epoxy cocured as a monolithic
support channel, a reinforcing angle, and an laminates. On aircraft serial numbers
attachment cleat. All components within these 900-00029 through 900-99999 the sills are
assemblies, excluding the hardware, are fabricated of aluminum alloy. The sills are
fabricated from aluminum alloy sheet. fastened to the boat tail tub by rivets.
Secondary fastening of the detail components
is by rivets. Attachment cleats The attachment cleats
are secondary structural components and
L. Boat Tail Assembly function as auxiliary attachment provisions for
the boat tail assembly.
(Ref. Figure 2)
The cleats are fabricated from aluminum alloy
The boat tail assembly, combined with the tub sheet. The cleats are fastened to the upper
assembly, forms the bottom of the fuselage flange of the boat tail sills by rivets.
structure. This assembly attaches mechanical
ly using rivets to the aft skid attachment Spoiler Attachment Inserts The spoiler
assembly, to the left and right FS 230.50 lower attachment inserts are nylon inserts that are
frame assemblies, and to the lower edge of the secondarily bonded into cored area of the boat
left and right rear fuselage shell assemblies. tail tub panel.
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Rotorcraft Maintenance Manual
RH AFT SKID
ATTACHMENT FITTING
LH AFT SKID
ATTACHMENT FITTING
KEEL BEAM
ATTACHMENT
FITTINGS
CROSSTUBE
BOX PANELS
VIEW ROTATED
CROSSTUBE BOX
ATTACHMENT ANGLE 9G53-032
Page 13
53-20-00 Original
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Rotorcraft Maintenance Manual
3. Side Skin Installation Side Skin Panel The left and right side skin
panels are composite sandwich panels that
utilizes skins and reinforcement plies of
(Ref. Figure 1) graphite/epoxy and fiberglass/epoxy cocured
with a syntactic epoxy foam core 0.020 inch
The side skin installation installs the left and (0.51 mm). Around the periphery of each
right side skin panel assemblies, the (aft) door panel, and in the areas of secondary attach
posts for the cockpit doors, and fillets at the ment of additional components, the core is
corner joints of the cockpit and cabin door tapered and the panel transitions to form
openings. Sub-components within this monolithic laminate attachment flanges. In
installation are attachment cleats, stiffeners, addition, a ply of Astrostrik
is cocured to the
and packers or shims. exterior surface of each panel.
Footsteps and Hand Grips The left and right
The side skin panel assemblies attach to the foot steps and hand grips are composite
FS 155.50 frame assembly, the A-Frame monolithic laminates. These laminates utilize
assembly, adjacent structure of the roof cocured skins and reinforcement plies of
assembly, and the left and right FS 166.50 graphite/epoxy and fiberglass/epoxy.
door frame assemblies . The door posts attach
Step Tread Plates and Grips The step plates
along the forward edge of the panel assemblies
and grips are installed within the cavity of the
and join to the cockpit door pillars of the
footsteps and hand grips respectively. These
cockpit assembly at the top, and the cockpit
components are fabricated from aluminum
sills of the tub assembly. Installation of all
alloy sheet.
components within this installation is by
rivets. Stiffeners and Support Angles The cabin
side skin stiffeners and support angles are
A. Side Skin Panel Assemblies secondary structural components. These
components are composite monolithic lami
nates utilizing cocured skins and reinforce
The left and right side skin panel assemblies ment plies of graphite/epoxy and fiberglass/
are primary structural components. These epoxy.
panel assemblies are load bearing skins that
support shear loads in the longitudinal and B. Door Posts
vertical directions. The door posts are secondary structural
components and are fabricated from aluminum
Each side skin panel assembly includes a skin alloy sheet.
panel, footstep and step tread plate, handgrip C. Fillets
and grip, stiffeners, and support angles. All
components, with the exception of the step The fillets are secondary structural compo
tread plate and grip, are secondarily bonded to nents that are fabricated using aluminum
the precured skin panel. alloy sheet.
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Rotorcraft Maintenance Manual
BATTERY FLOOR
ASSEMBLY (RIVETED)
LH CYCLIC FLOOR PANEL
ASSEMBLY (RIVETED)
9G53-034
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53-20-00 Revision 13
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
5. Cabin Floor Panels right forward fuel vent valve access covers,
and the left and right aft fuel vent valve access
(Ref. Figure 8) covers. These panels are fabricated from
The cabin floor panel installation installs a aluminum alloy sheet.
combination of composite and metallic panels
that form the cabin floor. All panels are C. Seat Tracks
secondary structural components and are
stressed panels. (Ref. Figure 8)
Page 16
Original 53-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
SEAL
CENTER FLOOR
PANEL ASSEMBLY
A170*
SEAL
(4 PL)
SEAT TRACK
SEAT TRACK
(4 PL)
(4 PL)
AFT FLOOR
PANEL ASSEMBLY
A217*
FORWARD FLOOR
PANEL ASSEMBLY
AR160* SEAL
(3 PL)
SEAL
(3 PL)
9G53-035
Page 17
53-20-00 Original
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Rotorcraft Maintenance Manual
Page 18
Original 53-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
AFT BAGGAGE
TIEDOWN PLATE
CENTER TIEDOWN
RH OUTBOARD FITTING
FLOOR PANEL
LH OUTBOARD
CARGO TIEDOWN FLOOR PANEL
STUD AND RING
(2 PL)
9G53-036
Page 19
53-20-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(Ref. Figure 1 and Figure 10) Quarter Turn Fastener Hardware The
quarter turn fastener hardware consists of
The platform assemblies are attached by grommets, studs, and retaining rings. These
riveted hinges, and cable assemblies. All components are standard hardware.
Page 20
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Rotorcraft Maintenance Manual
HINGE (2 PL)
PLATFORM SUPPORT
BRACKET (2 PL)
QUARTER TURN
FASTENER (2 PL)
UPPER PLATFORM
CABLE ASSEMBLY
(2 PL)
QUARTER TURN FASTENER
RECEPTACLE (2 PL) PLATFORM SUPPORT
BRACKET (2 PL)
HINGE (2 PL)
QUARTER TURN
FASTENER (2 PL)
LOWER PLATFORM
Page 21
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
C. Fuselage Exterior Panel Inspection age, and mechanical fasteners that are
loose. None permitted.
(1). Inspect the surface of exterior aircraft
panels for dents, gouges, holes, corro (2). Inspect the A-frame assembly for
sion and apparent damage. None cracks, mechanical damage, and
permitted. mechanical fasteners that are loose.
None permitted.
(2). Inspect the exterior panels for loose or
missing screws. None permitted. (3). Inspect the outboard side of keel beams
for cracks, delamination, and impact
D. Fuselage Cockpit Area Inspection damage. None permitted.
(1). Inspect the cockpit structure for cracks,
(4). Inspect the keel beam to tub joint.
mechanical damage or loose mechanical
fasteners. None permitted. (a). Early Config - Perform a coin tap
(2). Inspect the subfloor structure and test on the bondline between the keel
exterior of tub shell for cracks, mechan beam and fuselage tub assembly (ref.
ical damage, and mechanical fasteners CSP-SPM, Section 20-90-00). Tap
that are loose. None permitted. along the bottom of the fuselage. No
voids permitted.
(3). Inspect FS 155.50 frame assembly in
the cockpit area for cracks, mechanical (b). Current Config - Look for rivets
damage, and mechanical fasteners that that are loose or show signs of
are loose. None permitted. movement. None permitted
1 9G53-058
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Rotorcraft Maintenance Manual
Page 203
53-20-00 Revision 23
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
3. Cockpit Outboard Right Floor Panel 4. Cockpit Floor Access Panels (AL138 and
(AR129) AR138)
A. Cockpit Floor Access Panels Removal
A. Cockpit Outboard Right Floor Panel (Ref. Figure 202)
Removal
CAUTION
(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
CAUTION cause loss of screws and possible FOD
contamination. During panel removal,
keep track of screw locations by pressing
Screw lengths vary at different locations
screws into a sheet of cardboard in a pat
around each floor panel. Failure to install
tern following the original hardware
the correct length screws may damage installation.
nutplates in the floor substructure or
cause loss of screws and possible FOD Use of power tools during removal or
installation of panels and attaching hard
contamination. During panel removal,
ware may damage nutplates or deform
keep track of screw locations by pressing
holes in composite panels and covers.
screws into a sheet of cardboard in a pat
tern following the original hardware NOTE: This task is typical for the removal of
installation. the left or right cockpit floor access panel,
AL138 or AR138.
Use of power tools during removal or (1). Remove the cockpit seats and carpet
installation of panels and attaching hard (Ref. Section 25-10-00).
ware may damage nutplates or deform
holes in composite panels and covers. (2). Remove the cabin floor forward panel
assembly A160 (Ref. Section 53-20-00).
(3). Remove the screws and washers from
(1). Remove the pilot seat and cockpit cockpit floor access panel AL138 and
carpet (Ref. Section 25-10-00). AR138 (3 or 4).
(4). Remove the cockpit floor access panel
(2). Remove screws and washers from the AL138.
cockpit outboard-right floor panel B. Cockpit Floor Access Panels Installation
AR129 (2) (Ref. 06-00-00).
(Ref. Figure 202)
NOTE: This task is typical for the installation
B. Cockpit Outboard Right Floor Panel of the left or right cockpit floor access panel,
Installation AL138 or AR138.
(1). Install the cockpit floor access panels
(Ref. Figure 202) AL138 or AR138 (3 or 4).
(2). Install the screws and washers.
Torque the screws.
(1). Install the cockpit outboard-right floor
panel AR129 (2) (Ref. 06-00-00). (3). Install the cabin floor forward panel
assembly, A160 (Ref. Section
53-20-00).
(2). Install the cockpit carpet and pilot seat (4). Install the cockpit carpet and seats
(Ref. Section 25-10-00). (Ref. Section 25-10-00).
Page 204
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Rotorcraft Maintenance Manual
9G53-102
1. COCKPIT OUTBOARD LEFT FLOOR PANEL (AL129) 3. COCKPIT FLOOR LEFT ACCESS PANEL (AL138)
2. COCKPIT OUTBOARD RIGHT FLOOR PANEL (AR129) 4. COCKPIT FLOOR RIGHT ACCESS PANEL (AR138)
Figure 202. Cockpit Floor Panels
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Rotorcraft Maintenance Manual
5. Cabin Floor Forward And Aft Access 6. Cabin Floor Outboard Panels (AL165 and
Covers (AL155, AR155, AL230 and AR165)
AR230)
A. Cabin Floor Outboard Panel Removal
A. Cabin Floor Access Cover Removal
(Ref. Figure 203)
(Ref. Figure 203)
Defuel the helicopter before you CAUTION
CAUTION remove floor panels AL155,
AR155, AL230, or AR230. Damage to the Defuel the helicopter before you remove
structure can occur if you remove these pan both floor panels AL165 and AR165.
els with fuel in the helicopter. Damage to the structure can occur if
you remove both of these panels with fuel
NOTE: This task is typical for the removal of in the helicopter.
the cabin floor access covers AL155, AR155, Screw lengths vary at different locations
AL230 or AR230. around each floor panel. Failure to install
(1). Defuel helicopter (Ref. Section the correct length screws may damage
12-00-00). nutplates in the floor substructure or
cause loss of screws and possible FOD
(2). If necessary, remove the cabin seats contamination. During panel removal,
and carpet (Ref. Section 25-20-00). keep track of screw locations by pressing
screws into a sheet of cardboard in a pat
(3). Remove the cabin floor access covers tern following the original hardware
AL155, AR155, AL230 and AR230 installation.
(1, 2, 3 or 4).
Use of power tools during removal or
(a). Remove the screws and washers that installation of panels and attaching hard
attach the covers to the floor panel ware may damage nutplates or deform
and top of the fuel cell. holes in composite panels and covers.
B. Cabin Floor Access Covers Installation NOTE:
(Ref. Figure 203) This task is typical for the removal of the
left or right cabin floor outboard panel,
NOTE: This task is typical for the installation AL165 or AR165.
of the cabin floor access covers AL155,
AR155, AL230 or AR230. You may remove only one of the two out
board floor panels AL165 or AR165 with
(1). Position the cabin floor access covers out defueling the helicopter.
AL155, AR155, AL230 and AR230
(1, 2, 3 or 4) on opening. (1). Defuel helicopter (Ref. Section
12-00-00).
(2). Align the holes of the cover with the
nutplate holes. (2). If necessary, remove cabin seats and
carpet (Ref. Section 25-20-00).
(3). Install the screws that attach the
access cover to the fuel cell. Make sure (3). Remove the screws and washers from
they are flush with the top of the cover. cabin kick strip.
(4). Install the screws and washers that (4). Remove the screws and washers from
attach the access cover to the floor cabin floor outboard panels AL165 or
panel. Torque all screws. AR165 (5 or 6).
(5). If necessary, install the cabin carpet (5). Slide the panel inboard, away from the
and seats (Ref. Section 25-20-00). kick strip too remove.
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B. Cabin Floor Outboard Panel Installation (2). If necessary, remove the cabin seats
and carpet (Ref. Section 25-20-00).
(Ref. Figure 203)
NOTE: This task is typical for installation of
left or right cabin floor outboard panels, (3). Remove the screws and washers along
AL165 or AR165. the leading edge of the cabin floor
center panel assembly A170 (8).
(1). Position the outboard edge of the cabin
floor outboard panels AL165 or AR165
(5 or 6) under the kick strip and align (4). Remove the left and right cabin floor
the holes. forward access covers AL155 and
AR155 (Ref Section 53-20-00).
(2). Install the screws and washers along
the edge of the panel and kick strip.
Torque screws. (5). Remove the remaining screws and
washers along the edges of the cabin
(3). If necessary, install cabin carpet and floor forward panel assembly A160 (7).
seats (Ref. Section 25-20-00).
7. Cabin Floor Forward Panel Assembly B. Cabin Floor Forward Panel Installation
(A160)
A. Cabin Floor Forward Panel Assembly
Removal (Ref. Figure 203)
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8. Cabin Floor Center Panel (A170) (7). Thread the jam nuts down against
backing plates.
A. Cabin Floor Center Panel Removal
(8). Remove the screws that attach the fuel
(Ref. Figure 203) cell to the floor panel.
(9). Loosen the jam nuts until there is no
Special Tools torque pressure from fuel cell rod
(Ref. CSPSPM) (T801). Remove rods with jam nuts and
Item Nomenclature backing plates.
T801 Fuel Cell Rod
(10). Remove the cabin floor center panel
assembly A170 (8) from cabin. Use care
to prevent damage to panel seals.
CAUTION
B. Cabin Floor Center Panel Installation
Defuel the helicopter before you remove
floor panels AL165 and AR165. Damage (Ref. Figure 203)
to the structure can occur if you remove
both of these panels with fuel in the heli Special Tools
copter. (Ref. CSPSPM)
Screw lengths vary at different locations Item Nomenclature
around each floor panel. Failure to install T801 Fuel Cell Rod
the correct length screws may damage
nutplates in the floor substructure or
cause loss of screws and possible FOD (1). Install the cabin floor forward panel
contamination. During panel removal, assembly A160 (7).
keep track of screw locations by pressing (2). Install the cabin floor aft panel
screws into a sheet of cardboard in a pat assembly A217 (9).
tern following the original hardware
installation. (3). Place the cabin floor center panel
assembly A170 (8) over fuel cell and
Use of power tools during removal or
align holes in panel with holes in
installation of panels and attaching hard
substructure. Do not install the screws.
ware may damage nutplates or deform
holes in composite panels and covers. (4). Thread four fuel cell rod (T801) (with
jam nuts and backing plates) through
(1). Defuel the helicopter (Ref. Section holes in cabin floor center panel A170
12-00-00). (8) and into the access covers on top of
(2). If necessary, remove the cabin seats fuel cell.
and carpet (Ref. Section 25-20-00). (5). Thread the fuel cell rod jam nuts down
(3). Remove the left and right cabin floor against backing plates too pull the fuel
outboard panels AL165 and AR165 cell up against the floor panel.
(5 and 6). (6). Install the screws through the floor
panel and into the fuel cell access
(4). Remove the screws and washers along
covers.
the edges of the cabin floor center panel
assembly A170 (8). (7). Remove the fuel cell rods.
(5). Remove the vapor plugs (10) from the (8). Install vapor plugs (10).
holes in the cabin floor center panel
(9). Install screws and washers around
assembly A170 (8).
edges of panel A170 (8).
(6). Thread fuel cell rod (T801) with jam (10). Torque screws.
nuts and backing plates into four holes
in panel (8). Engage threads into the (11). If necessary, install cabin carpet and
fuel cell access covers. seats (Ref. Section 25-20-00).
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9. Cabin Floor Aft Panel Assembly (A217) (3). Remove the screws and washers along
trailing edge of cabin floor center panel
A. Cabin Floor Aft Panel Assembly Removal assembly A170 (8).
(4). Remove the left and right cabin floor
(Ref. Figure 203) aft access covers AL230 and AR230
(Ref. Section 53-20-00).
CAUTION (5). Remove the baggage floor center panel
A235 (Ref. Section 53-20-00).
Defuel the helicopter before you remove
floor panels AL230 or AR230. Damage to B. Cabin Floor Aft Panel Installation
the structure can occur if you remove
these panels with fuel in the helicopter. (Ref. Figure 203)
Screw lengths vary at different locations (1). Position the cabin floor aft panel A217
around each floor panel. Failure to install (9) with left and right cabin floor aft
the correct length screws may damage access cover (AL230 and AR230)
nutplates in the floor substructure or openings aft.
cause loss of screws and possible FOD
(2). Install the screws and washers along
contamination. During panel removal,
forward edge of panel A217 (9).
keep track of screw locations by pressing
screws into a sheet of cardboard in a pat (3). Install the left and right aft access
tern following the original hardware covers AL230 and AR230
installation. (Ref. Section 53-20-00).
Use of power tools during removal or (4). Install the baggage floor center panel
installation of panels and attaching hard A235 (Ref. Section 53-20-00).
ware may damage nutplates or deform
holes in composite panels and covers. (5). Install the screws and washers along
the trailing edge of cabin floor center
(1). Defuel the helicopter (Ref. Section panel A170 (8).
12-00-00).
(6). Torque the screws.
(2). If necessary, remove the cabin seats (7). If necessary, install the cabin carpet
and carpet (Ref. Section 25-20-00). and seats (Ref. Section 25-20-00).
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4
3
8
6 9
10
9G53-103
1. CABIN FLOOR LEFT FORWARD ACCESS COVER 5. CABIN FLOOR LEFT OUTBOARD PANEL (AL165)
(AL155) 6. CABIN FLOOR RIGHT OUTBOARD PANEL (AR165)
2. CABIN FLOOR RIGHT FORWARD ACCESS COVER 7. CABIN FLOOR FORWARD PANEL ASSEMBLY (A160)
(AR155) 8. CABIN FLOOR CENTER PANEL ASSEMBLY (A170)
3. CABIN FLOOR LEFT AFT ACCESS COVER (AL230) 9. CABIN FLOOR AFT PANEL ASSEMBLY (A217)
4. CABIN FLOOR RIGHT AFT ACCESS COVER (AR230) 10. VAPOR PLUG
Figure 203. Cabin Floor Panels
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B. Baggage Floor Center Panel Installation NOTE: This task is typical for the removal of
the left and right baggage compartment
(Ref. Figure 204) floor panels AL250 and AR250.
(1). Install the baggage floor center panel
(1). Defuel helicopter (Ref. Section
A235 (1) to the substructure with
screws and washers. 12-00-00).
(2). If necessary, install the baggage (2). If necessary, remove the baggage
compartment carpet compartment carpet
(Ref. Section 25-50-00). (Ref. Section 25-50-00).
11. Baggage Floor Outboard Panels (AL250 (3). Remove the baggage floor center panel
and AR250) A235 (Ref. Section 53-20-00).
A. Baggage Floor Outboard Panels Removal (4). Remove the screws and washers that
attach the left and right baggage floor
(Ref. Figure 204) outboard panels AL250 and AR250
(2 or 3) to substructure.
CAUTION
B. Baggage Floor Outboard Panels
Screw lengths vary at different locations Installation
around each floor panel. Failure to install
the correct length screws may damage (Ref. Figure 204)
nutplates in the floor substructure or
cause loss of screws and possible FOD NOTE: This task is typical for installation of
contamination. During panel removal, left and right baggage compartment floor
keep track of screw locations by pressing panels AL250 and AR250.
screws into a sheet of cardboard in a pat
tern following the original hardware (1). Install the left and right baggage floor
installation. outboard panels AL250 and AR250
Use of power tools during removal or (2 or 3) to substructure with screws and
installation of panels and attaching hard washers.
ware may damage nutplates or deform (2). Install the baggage floor center panel
holes in composite panels and covers. A235 (Ref. Section 53-20-00).
Defuel the helicopter before you remove
floor panel A235. Damage to the struc (3). If necessary, install the baggage
ture can occur if you remove this panel compartment carpet
with fuel in the helicopter. (Ref. Section 25-50-00).
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3
2
9G53-101
1. BAGGAGE FLOOR CENTER PANEL (A235) 3. BAGGAGE FLOOR RH OUTBOARD PANEL (AR250)
2. BAGGAGE FLOOR LH OUTBOARD PANEL (AL250)
Figure 204. Baggage Compartment Floor Panels
12. Cabin Step (Optional) B. Cabin Step Installation
(Ref. Figure 205)
A. Cabin Step Removal
Consumable Materials
(Ref. Figure 205) (Ref. CSPSPM)
Item Nomenclature
C237 Sealant
NOTE: This task is typical for removal of the
left and right cabin steps.
NOTE: This task is typical for installation of
the left and right cabin steps.
(1). Remove the outboard floor panel AL165
or AR165 (Ref. Section 53-20-00). (1). Remove the cabin step plugs (5) if
installed.
(2). Remove the nuts (1), washers (2) and (2). Remove the outboard floor panel AL165
bolts (3) that attach the cabin step (4) or AR165 (Ref. Section 53-20-00).
to airframe. (3). Slide the boot (6) over each tube end of
step (4).
(3). Remove sealant from the step to (4). Insert the tube ends of cabin step
airframe interface. through holes in fuselage and align bolt
holes.
(4). Install the cabin step plugs (5) if the (5). Make sure both step support saddles (7)
cabin step is permanently removed. are looped below the cabin step.
(6). Install the step on the frame with bolts
(5). Install the outboard floor panel AL165 (3), washers (2) and nuts (1). Torque
or AR165 (Ref. Section 53-20-00). the nuts.
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Consumable Materials
(Ref. CSPSPM)
(7). Apply sealant (C237) to the faying
Item Nomenclature
surfaces of the boots and airframe.
C237 Sealant
13. Cabin Step Plug
Sealant (C237)
A. Cabin Step Plug Removal
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2 1
2
3
1
2
2
3
6
7
6 4
5 (2PL)
9G53-118
1. NUT 5. CABIN STEP PLUG
2. WASHER 6. BOOT
3. BOLT 7. SUPPORT SADDLE
4. CABIN STEP
Figure 205. Cabin Step (Optional)
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Rotorcraft Maintenance Manual
Section
533000
Fuselage Upper
Deck and Aft Area
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
NOTAR INLET
SCREEN ASSEMBLY
AFT COWLING
INSTALLATION
ENGINE DECK
THERMAL INSULATION
INSTALLATION (NOT VISIBLE
IN THIS VIEW)
ROOF
ASSEMBLY
FIREWALL BUILDUP
ASSEMBLY
900 CONFIG
FORWARD DUCT INSTALLATION AND NOTAR DIVERTER
STATOR AND DIVERTER PLATE INSTALLATION
(NOT VISIBLE IN THIS VIEW)
NACA CONFIG
9G53038A
Page 2
Original 53-30-00
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Rotorcraft Maintenance Manual
ROOF STRUCTURE
ASSEMBLY
LH AFT
FILLET FAIRING
(LH SHOWN,
RH OPPOSITE)
LH REAR FUSELAGE
SHELL ASSEMBLY
(LH SHOWN, RH OPPOSITE)
9G53045
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53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
A. Roof Structure Assembly B. Engine Deck, Aft Deck, and Aft Outer
Deck Skins
(Ref. Figure 3)
(Ref. Figure 3)
The roof structure assembly forms the load
The engine deck, aft deck, and aft outer deck
bearing structure that supports the main
skins complete the deck skin aft of the forward
rotor, transmission drive, and propulsion
roof deck skin for the roof assembly. These
subsystems.
components are primary structural compo
The major components contained within the nents and function as the shear panels for the
roof structure assembly are the A-Frame roof assembly.
assembly, FS 230.50 upper aft frame assembly, The left and right titanium deck skins are
the forward and mid roof installations, aft installed in the three deck areas contained
deck structure assembly, roof beam installa within the engine compartment firewalls. The
tions, engine deck, aft deck, aft deck outer left and right aluminum engine deck skins are
skins, cabin seat forward upper support installed immediately inboard and aft of the
assembly, support installations for the flight engine compartment firewalls. The titanium
controls, environmental control system (ECS), deck skins are fabricated from .016-inches
hydraulic subsystems, firewall and flight thick titanium alloy sheet. The aluminum deck
controls support channels, and forward cowl skins are fabricated from .020-inches thick
attachment angles. aluminum alloy sheet.
Secondary components include deck skin The left and right aft deck and aft outer deck
doublers and stiffeners, tension, shear and skins are located aft of the anti-torque fan
secondary attachment clips and cleats, support structure. The aft deck and aft outer
reinforcement gussets, and standard hard deck skins are fabricated from .020-inches
ware. thick aluminum alloy sheet.
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Rotorcraft Maintenance Manual
LH AFT
DECK SKIN
RH ENGINE RH AFT
DECK SKIN RH AFT DECK SKIN
RH TITANIUM OUTER SKIN
DECK SKIN
LH AFT
OUTER SKIN
LH ENGINE
DECK SKIN
9G53044
Page 5
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
LH FORWARD MAST
FITTING ASSEMBLY
CENTER BEAM
RH VERTICAL LEG
LH VERTICAL LEG
9G53046
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Original 53-30-00
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Rotorcraft Maintenance Manual
D. Forward Roof Structure Installation The longeron doublers, deck skin stiffeners,
reinforcing strap and doubler, and attachment
(Ref. Figure 5) cleats and clips are fabricated from aluminum
alloy sheet.
The major components within this installation
are the forward roof deck and FS 166.749 roof Forward Roof Intercostal The forward roof
deck doublers, forward longerons, forward roof intercostal is a primary structural component
intercostal, FS 155.50 roof angle, and RBL that supports the hydraulic system compo
8.50 reinforcing angle. nents mounted on the upper deck. This
component resembles a longeron and is
Secondary components include longeron installed inboard of the longeron at LBL 18.50.
doublers, deck skin stiffeners, a reinforcing Structural attachment of this component is
strap, and attachment cleats and clips. similar to the longerons.
Forward and FS 166.749 Roof Deck Doublers The forward roof intercostal is formed with
The forward and FS 166.749 roof deck integral flanges and flanged lightening holes.
doublers are installed as secondary structural This component is fabricated from aluminum
components alloy sheet.
These two doublers function as deck skin Flight Controls Support Roof Structure
reinforcements to support the upper deck Installation The primary structural compo
mounted flight controls. Both doublers are nents within this installation are the flight
fabricated from aluminum alloy sheet. controls support intercostals. The two longitu
dinal intercostals attach to the FS 155.50
Forward Longerons Five forward longerons frame assembly, and eight lateral intercostals.
are primary structural components that The eight lateral intercostals attach to the
support upper deck loads in the vertical and longerons of the forward structure installation.
longitudinal directions. The forward longerons In addition, the upper flanges of each of these
are fabricated from aluminum alloy sheet. intercostals are attached to the forward roof
deck skin. The intercostals are fabricated from
FS 155.50 Roof Angle and RBL 8.50 Reinforc- aluminum alloy sheet.
ing Angle The FS 155.50 roof angle and the
RBL 8.50 reinforcing angle are secondary Secondary structural components included
structural components that provide the within this installation are the tension and
forward attachment provisions for the forward attachment clips and cleats, reinforcement and
roof deck skin. stiffening angles, and A-frame radius blocks.
Both the FS 155.50 roof angle and the RBL
8.50 reinforcing angle are fabricated from The attachment, tension clips, cleats, and
aluminum alloy. reinforcement angles are fabricated from
aluminum alloy sheet. The radius blocks are
machined from aluminum alloy stock.
Longeron Doublers, Deck Skin Stiffeners,
Reinforcing Strap, Attachment Cleats and
Clips The longeron doublers, deck skin ECS Roof Support Installations All compo
stiffeners, reinforcing strap, and attachment nents installed within this support installation
cleats and clips are secondary structural are secondary structural components, and
components. The longeron doubler reinforce provide attachment for components of the
the webs of the longerons in the areas of the ventilation and optional air conditioning
cutouts for the ventilation ducting. The subsystems.
reinforcing strap, a doubler, and the attach
ment cleats and clips are installed to provide The intercostals, clips, and cleats are fabri
local area reinforcement for secondary cated from aluminum alloy sheet. The radius
attachment of additional deck mounted blocks are machined from aluminum alloy
hydraulic components. stock.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Hydraulics Roof Support Installation The longerons are primary structural components
hydraulics roof support installation installs that support upper deck loads in the vertical
additional secondary structural components and longitudinal directions.
and related standard hardware to the roof
structure. The additional components provide
the attachment for the left and right manifold The roof longerons, the shear cleats, and the
/ reservoirs and the optional hand pump of the attachment cleats are fabricated from alumi
hydraulic subsystem. num alloy sheet.
This installation installs two intercostals and
associated clips, between LBL and RBL 7.75 Longeron Reinforcing Angles The longeron
and 18.50. Intercostals, stiffeners, gussets, and reinforcing angles are primary structural
attachment cleats are installed immediately
installed at the the aft ends of the LBL and
aft of FS 155.50 between BL 0.00 and LBL
RBL 18.50 longerons. The longeron reinforcing
7.75 for support of the hydraulic hand pump.
angles are fabricated from aluminum alloy
The components within this installation are
sheet.
fabricated from aluminum alloy sheet.
Forward Cowl Attachment Angles The
forward cowl attachment angles are secondary Cabin Seat Forward Upper Support Assem-
structural components. The forward cowl bly Within the roof assembly, the cabin seat
attachment angles are fabricated from forward upper support assembly contains the
aluminum alloy sheet. secondary structural components that provide
the attachment for the passenger seats.
E. Mid Roof Installation
(Ref. Figure 5) This assembly includes bracket assemblies,
The major components within this installation cleat assemblies, bearing plates, and anchor
are the forward roof deck skin, roof longerons, plates. These components are installed on the
longeron reinforcing angles, left and right aft underside of the horizontal webs of the left and
engine attachment assemblies, engine right roof beams, and against the lower
mounting intercostals, mid roof straps, flanges of the longeron components of the
longeron and bridging doublers, FS 220.50 forward roof structure.
deck skin and inboard longeron deck skin
doublers, and fuel valve mount bracket
assemblies. The detail components within this assembly
are fabricated from aluminum alloy sheet. All
Secondary components include deck skin components are installed with rivets.
stiffeners, lower flange channels, and standard
hardware.
Aft Engine Attachment Assemblies The
Forward Roof Deck Skin The forward roof
left-hand and right-hand aft engine attach
deck skin is the upper deck skin located
ment assemblies installed within this installa
immediately aft of the FS 155.50 frame
tion are primary structural components that
assembly and forward of the engine inlet
plenums. The skin extends to the left and right provide the provisions for attachment of the
roof beams. This component is a primary forward leg of the bipod engine mounts.
structural component and functions as the
shear panel for the roof structure. The forward
roof skin is fabricated from .020-inches thick Each aft engine attachment assembly consists
aluminum alloy sheet. of a fitting and a flanged bushing machined
from titanium alloy stock. The flanged
Roof Longerons Five roof longerons are bushings are standard corrosion resistant
utilized within this assembly to join the FS steel. The bushings are press fit installed into
230.50 upper aft frame assembly, the A-frame each fitting, and then reamed to final hole
assembly, and the forward deck skin. These size.
Page 8
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Engine Mounting Intercostals The engine The deck skin doublers and inboard longeron
mounting intercostals are primary structural deck skin doublers are fabricated from
components. These components are fabricated aluminum alloy sheet.
from aluminum alloy sheet.
Deck Skin Stiffeners and Lower Flange
Valve Mount Bracket Assemblies The valve Channels The deck skin stiffeners and
mount bracket assemblies and intercostals are channels are installed on the underside of the
secondary structural components that provide forward roof deck skin.
the for mounting of a left and a right engine
Two lower flange channels function to support
fuel supply frangible self-sealing valve.
and stabilize the longerons. The deck stiffeners
The left bracket assembly is located immedi and lower flange channels are fabricated from
ately outboard of the LBL 18.50 longeron aluminum alloy sheet.
between FS 224.53 and FS 227.53. The right F. Aft Deck Structure Assembly
bracket assembly is located immediately
inboard of the RBL 7.75 longeron between FS (Ref. Figure 5)
216.50 and FS 219.50.
The major components contained within the
Each valve mount bracket assembly consists of aft deck structure assembly are the aft section
a valve mount bracket, two tension (mounting) longerons, aft deck sub-longerons, aft deck
clips, and standard hardware. The bracket, intercostals, aft deck subframe, aft deck insert
tension clips, and intercostals are fabricated frame assembly, and aft deck engine attach
from aluminum alloy sheet. ment assemblies.
Mid Roof Straps The mid roof straps are Secondary components include bearing and
secondary structural components that function doubler plates, radius blocks, attachment,
as doublers for the forward roof deck skin. The reinforcing, and stiffening angles, doubler and
straps are located on the forward deck skin attachment cleats, and hardware.
approximately at FS 200 and FS 206. The mid Aft Section Longerons The aft section
roof straps are fabricated from aluminum alloy longerons are primary structural components
sheet. that support upper deck loads in the vertical
and longitudinal directions.
Longeron and Bridging Doublers The
longeron and bridging doublers are secondary The four longerons contained within this
structural components that are installed at the assembly are located at LBL and RBL 18.50,
forward ends of each of the roof longerons. The and at LBL and RBL 7.75. The forward ends
longeron and bridging doublers are fabricated of these longerons terminate and are attached
from aluminum alloy sheet. to the FS 230.50 upper aft frame assembly.
The aft ends of the LBL and RBL 7.75
FS 220.50 Deck Skin and Inboard Longeron longerons terminate and attach to the aft deck
Deck Doublers The left and right FS 220.50 insert frame assembly.
deck skin doublers and the left and right
inboard longeron deck doublers are secondary The aft section longerons, and secondary
structural components that are installed near attachment cleats or angles are fabricated
the aft edge of the forward roof deck skin. from aluminum alloy sheet.
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53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Aft Deck SubLongerons The aft deck Aft Deck Engine Attachment Assemblies -
sub-longerons are primary structural compo The left and right aft engine attachment
nents that provide support for the engine assemblies are primary structural components
attachment assemblies and the directional that provide the provisions for attachment of
controls of the flight controls subsystem. the two aft legs of the bipod engine mounts.
The sub-longerons and secondary attachment Each aft engine attachment assembly consists
angles are fabricated from aluminum alloy of a fitting and a flanged bushing. The aft
sheet. engine attachment fittings are machined from
titanium alloy stock. The flanged bushings are
Aft Deck Intercostals The aft deck intercos corrosion resistant steel. The bushings are
tals are primary structural components and press fit installed into each fitting, and then
are located at FS 235.69 and FS 245.25. reamed to the final hole dimension.
The aft deck intercostals provide the attach Flight Controls Aft Support Channel The
ment and support for engine attachment flight controls aft support channel is a primary
assemblies. structural component of the roof structure
The intercostals, the bearing plates, and assembly that provides attachment and
attachment angles are fabricated from support for the directional controls of the flight
aluminum alloy sheet. controls subsystem. The flight controls aft
support channel is fabricated from aluminum
Aft Deck Subframe The aft deck subframe is alloy sheet.
a primary structural component that bridges
the left and right longerons and aft deck Firewall Channels The left and right firewall
structure. In addition, this member also channels are primary structural components
provides for attachment of the engine attach that support the firewall build-up assembly.
ment assemblies. The firewall channels are fabricated from
aluminum alloy sheet.
The subframe and attachment angles are
fabricated from aluminum alloy sheet. Cowl Attachment Angles The cowl attach
ment angle components of the roof assembly
Aft Deck Insert Frame Assembly The aft are secondary structural components that
deck insert frame assembly is a primary provide the lower attachment for the engine
structural component. To facilitate removal of air inlet screen assemblies (or optional inlet air
the anti-torque drive shaft, this frame particle separators), the engine cowl assem
assembly is retained by bolts. The frame insert blies, and the exhaust ejector cowl assemblies.
and doublers are fabricated from aluminum The cowl attachment angles are fabricated
alloy sheet. from titanium alloy sheet.
Page 10
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
G. Roof Beam Installations tive engine deck, aft outer, and aft deck skins,
and the rear fuselage shell assembly. The aft
(Ref. Figure 3 and Figure 5) deck angle is fabricated from aluminum alloy
sheet.
The major components contained within each
roof beam installation are the vertical and Track Pockets The track pockets are
horizontal webs, roof beam and handhold secondary structural components that form
support ribs, extrusion angle, aft deck angle, evironmental closeouts at the cutouts in the
track pockets, forward and aft outer roof beam forward outer skin for the upper cabin door
skins, and rear stay deck fitting assembly. track.
Secondary components include cowl support The track pockets are composite components
clips and doublers, door track brackets and that are fabricated as monolithic laminates.
cleats, and roof beam attachment cleats, Each track pocket is fabricated using multiple
doublers, splice components, and standard plies of graphite/epoxy and fiberglass/epoxy.
hardware. The doublers are fabricated from aluminum
alloy sheet.
Vertical and Horizontal Webs The vertical
and horizontal web components are primary Forward and Aft Outer Roof Beam Skins The
structural components that when combined roof beam forward and aft outer skins are
with the roof beam outer skins form the primary structural components that when
triangular shaped roof beam. The vertical and combined with the roof beam vertical and
horizontal webs are fabricated from aluminum horizontal web components form the triangu
alloy sheet. lar shaped beam.
Roof Beam and Handhold Support Ribs The The forward roof beam skin is installed from
roof beam and handhold support ribs are the 155.50 frame and terminates immediately
secondary structural components that provide forward of the FS 230.50 frame. The aft roof
attachment for the vertical and horizontal beam skin is installed from the aft end of the
webs, and the outer roof beam skins. forward skin to FS 268.00. The roof beam
forward and aft outer skins are fabricated
The roof beam and handhold support ribs are from aluminum alloy sheet.
installed internal to the triangular shaped
sub-structure formed by the vertical webs, Rear Stay Deck Fitting Assembly The rear
horizontal webs, and the outer skins. stay deck fitting assembly is a primary
structural component that provides for
The handhold support ribs are installed at FS attachment of the rear stay assembly for the
160.63, 167.60, 218.50, and 225.47. Roof beam left or right engine.
support ribs are installed at FS 188.00,
197.66, 207.36, 230.50, and 249.78. The roof The rear stay deck fitting assembly consists of
beam and handhold support ribs are fabri a fitting and a flanged bushing. The fitting is
cated from aluminum alloy sheet. machined from titanium alloy stock. The
flanged bushing is a standard corrosion
Extrusion Angle The extrusion angle is a resistant steel component. The bushing is
primary structural component that is installed press fit installed into the fitting, and then
between the vertical and horizontal web reamed to the final hole dimension.
components. The extrusion angle extends
from the FS 155.5 frame to FS 225,0. The Secondary Components The secondary
extrusion angle is machined from aluminum components include cowl support clips and
alloy extrusion. doublers, door track brackets and cleats, roof
beam attachment cleats, doublers, and web
Aft Deck Angle The aft deck angle is a splice components are secondary structural
primary structural component that functions components. These components are fabricated
as the attachment angle between the respec from aluminum alloy sheet.
Page 11
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
RH FIREWALL
SUPPORT CHANNEL
AFT DECK STRUCTURE
ASSEMBLY LH FIREWALL
RH ROOF BEAM SUPPORT CHANNEL
INSTALLATION
FS 230.50 UPPER
FRAME ASSEMBLY
AFRAME ASSEMBLY
Page 12
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
H. FS 230.50 Aft Frame Assembly The fittings are attached to the deck skin by
rivets.
(Ref. Figure 5 and Figure 6)
Each mast fitting assembly consists of a fitting
The FS 230.50 upper aft frame assembly is and a flanged bushing. The mast fittings are
joined to the left and right FS 230.50 lower machined from aluminum alloy stock. The
frame assemblies. This is a built-up assembly flanged bushings are machined from corrosion
that is primary structure and provides support resistant steel. The bushings are press fit
for the main rotor and drive system loads in all installed into each fitting, and then reamed to
three directions. Main rotor and drive system the final hole dimension.
loads are transferred by the left and right aft
mast fitting assemblies and the left and right Static Mast Channels The left and right
engine attachment assemblies. static mast channels provide support for the
left and right mast fitting assembly. Each
Frame Web The frame web is a primary channel attaches through the FS 230.50 frame
structural component. The web is the shear web to the aft side of the mast fitting assem
panel for the upper section of the FS 230.50 bly. The channels are also attached to the
frame, and is the platform onto which all vertical channels and roof beams. Attachment
components within this assembly are fastened. is by pins and collars or rivets. The channels
This web is fabricated from aluminum alloy are machined from aluminum alloy stock.
sheet.
Engine Attachment Assemblies The four
Horizontal Channel Frame The horizontal engine attachment assemblies are primary
frame is a secondary structural component structural components. The assemblies provide
that is the upper frame member for the for attachment of the forward leg of the tripod
through opening between the baggage engine mounts and the aft leg of the bipod
compartment and the passenger cabin. The engine mounts. Attachment is by pins and
horizontal frame is fabricated from aluminum collars.
alloy sheet.
Each engine attachment assembly consists of a
Aft Frame ZSection The aft frame Z-sec fitting and a flanged bushing. The engine
tion is a primary structural component that attachment fittings are machined from
functions as a longitudinal support member. In titanium alloy stock. The flanged bushings are
addition to providing support for the deck corrosion resistant steel. The bushings are
structure, this component provides attachment press fit installed into each fitting, and then
of the anchor plates used for upper attachment reamed to the final hole dimension.
of the aft row of passenger seats. The aft
frame Z-section is fabricated from aluminum Fuel Valve Support Bracket Assemblies
alloy sheet. The fuel valve support bracket assembly is a
secondary structural component that provides
Vertical Channels The left and right vertical for mounting of the left and right fuel shutoff
channels are primary structural components valve assembly. The bracket is attached by
that support vertical and longitudinal loads. rivets. The valve support bracket assembly is
These components form the vertical edges of fabricated from aluminum alloy sheet.
the through opening between the baggage
compartment and cabin. The left and right Doublers, Gussets, Angles, Channel Frames
vertical channels are fabricated from alumi and Brackets The doublers, gussets,
num alloy sheet. stiffening angles, channel frames and brackets
are secondary structural components. These
Mast Fitting Assemblies The left and right components are fabricated from aluminum
mast fitting assemblies are primary structural alloy sheet.
components that provide for attachment of the
static mast assembly and aft support trusses. Tie-down Rings and Studs - A tie-down
ring and stud is installed into the left and
The mast fitting assemblies are attached to right side of the FS 230.50 upper frame
the FS 230.50 frame web at LBL and RBL assembly. The tie-down rings are steel and are
18.50 and roof longerons by pins and collars. standard load ring hardware.
Page 13
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
RH ENGINE ATTACHMENT
ASSEMBLIES
LH ENGINE ATTACHMENT
ASSEMBLIES
LH AFT MAST
FITTING ASSEMBLY
RH OUTBOARD
(ATTACHMENT) CHANNEL
RH VERTICAL CHANNEL
LH OUTBOARD (ATTACHMENT)
CHANNEL
RH VERTICAL CHANNEL
9G53047
Page 14
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 15
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
UPPER PORTION
INLET ASSEMBLY*
FORWARD INLET
PANEL*
MIDDLE NOTAR
INLET DUCT ASSEMBLY
Page 16
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
A. AntiTorque Fan Forward Duct mounting provisions for the upper half of the
Installation fan stator vane assembly, center diffuser, and
the anti-torque fan aft diffuser.
(Ref. Figure 8)
The upper duct is a composite component that
The forward duct installation for the anti- is fabricated with multiple plies of graphite/
torque fan includes the inlet lower duct epoxy. In areas in which attachment of
assembly, drive shaft cover, fan fairing/cent metallic components will occur, barrier plies of
erbody assembly, and wire harness. fiberglass/epoxy are cocured to the faying
Fan Inlet Lower Duct Assembly - The inlet surfaces. The secondary attachment angles
lower duct assembly, combines with the inlet and clips are fabricated from aluminum alloy
and middle duct assemblies to form the air sheet.
passage to the inlet of the anti-torque fan.
Lower Duct Assembly The lower duct
The forward and aft duct components are both assembly is a non-structural removable
fabricated as monolithic laminates. Each component. The lower duct assembly forms the
component utilizes multiple plies of graphite/ lower aft portion of the aft duct assembly. The
epoxy. In addition the aft duct, in areas of lower duct assembly contains the through
secondary attachment of, or to, metallic panel provisions for the electrical harness that
components, barrier plies of fiberglass/epoxy extends through the tailboom to the empen
are cocured to applicable surfaces. nage. The sides of the lower duct assembly are
retained to the sides of the upper duct assem
Fan Drive Shaft Cover - The drive shaft cover bly by means of bolts and secondary attach
covers the underside of the fan drive shaft in ment angles and clips. The aft edge of the
the area beneath the upper deck, and aft to lower duct assembly is retained to the lower
the lower duct assembly. The cover is fabri portion of the interior flange of the tailboom
cated with multiple plies of graphite/epoxy. attach ring assembly by machine screws.
Fan Fairing/Centerbody Assembly The fan The lower duct assembly is fabricated with
fairing/centerbody assembly covers the fan multiple plies of graphite/epoxy. In areas
drive shaft and fairs the center hub of the fan where attachment of metallic components will
assembly on the air inlet side. occur, barrier plies of fiberglass/epoxy are
cocured to the faying surfaces. The secondary
The fan fairing/centerbody assembly consists attachment angles are fabricated from
of a left and right component. Both compo aluminum alloy sheet.
nents are fabricated with multiple plies of
graphite/epoxy. Lower Access Panel Assembly The lower
access panel assembly is a non-structural
B. AntiTorque Fan Aft Duct Assembly and removable component. The lower access panel
Installation assembly combines with the lower duct
(Ref. Figure 8) assembly and forms the lower half of the aft
duct assembly. The lower access panel
The anti-torque fan aft duct assembly directs assembly provides the support of the anti-
the discharge air from the anti-torque fan into torque fan lower stator vanes and lower half of
the tailboom. The aft duct assembly includes the center diffuser. Retention of the panel
the upper duct assembly, lower duct assembly, assembly is by four adjustable latches.
diverter plate assembly, fan stator vane
assemblies, fan center body diffuser assem The lower access panel assembly is fabricated
blies, and the lower access panel assembly. with multiple plies of graphite/epoxy. In areas
where attachment of metallic components will
Upper Duct Assembly The upper duct occur, barrier plies of fiberglass/epoxy are
assembly is a fixed duct that is a secondary cocured to the faying surfaces. Both the upper
structural component that attaches to and and lower components of the aft diffuser are
supports the anti-torque fan support struc fabricated with multiple plies of graphite/
ture. The upper duct assembly contains the epoxy.
Page 17
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
C. AntiTorque Fan DiffuserStator and Both the upper and lower components of the
Diverter Plate Installation center diffuser are are fabricated as monolithic
laminates. Each composite laminate utilizes
(Ref. Figure 8) multiple plies of graphite/epoxy.
Upper and Lower Aft Diffuser - The
The diffuser-stator and diverter plate
combined components of the aft diffuser
installation includes the installation of the
function to diffuse the air flow exiting the
stator vanes, the upper and lower components
anti-torque fan. The process of diffusion,
of the center diffuser , the upper and lower
involves the gradual increase in flow area and
components of the aft diffuser, the diverter
the conversion of air velocity pressure (dynam
plate assembly, and an electrical access cover.
ic pressure) to static pressure.
Stator Vane Assemblies - The stator vane The upper component of the aft diffuser, is
assemblies function to straighten the air flow attached at the forward end to the center
exiting the anti-torque fan. Nineteen vane diffuser. At the aft end, the upper component
assemblies that are supported by the upper is attached to the diverter plate assembly. The
duct and lower access panel. lower component of the aft diffuser is sup
ported by the upper component and is retained
The stator vane assemblies consist of a vane by bolts and turn lock type fasteners.
with threaded inserts. The vanes are fabri
cated using glass fiber reinforced polypropy Both the upper and lower components of the
lene material that is injection molded. aft diffuser are fabricated as monolithic
laminates. Each laminate utilizes multiple
Upper and Lower Center Diffuser -The plies of graphite/epoxy.
center diffuser consists of an upper and lower Diverter Plate Assembly - The diverter plate
diffuser component that supports the inner assembly is a non-structural component. The
ends of the stator vane assemblies. The upper diverter plate assembly turns the air exiting
center diffuser is attached to the forward end the fan for alignment with the tailboom. The
of the aft diffuser. Attachment of the upper diverter plate also supports and fairs the fan
center diffuser is by the (upper) stator vane control components that are in the fan airflow
assemblies, screws, and the upper duct of the path.
aft duct assembly. Attachment of the lower
center diffuser is by the (lower) stator vane Electrical Access Cover - This access cover
assemblies, screws, and the lower fan access assembly covers the installed electrical
panel. The upper and lower components of the harness, that extends through the tailboom to
center diffuser are aligned by pins that are the empennage. The electrical access cover is
retained in the lower. fabricated from polycarbonate sheet.
Page 18
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
RH NOTAR FAN
FAIRING/CENTER BODY
LH NOTAR FAN
FAIRING/CENTER BODY
LOWER AFT
NOTAR INLET DUCT
NOTAR DRIVE LOWER FORWARD
SHAFT COVER NOTAR INLET DUCT
STATOR
VANES
ASSEMBLY UPPER AFT
UPPER CENTER DIFFUSER ASSEMBLY
DIFFUSER ASSEMBLY
DIVERTER PLATE
ASSEMBLY
9G53107
Figure 8. Forward Duct, Aft Duct, AntiTorque DiffuserStator, and Diverter Plate Installation
Page 19
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
D. AntiTorque Fan Support Structure Aft Frame - The aft frame is a primary
structural component that provides the aft
structural interface and support for the fan
(Ref. Figure 9) installation. The aft frame also attaches the
forward end of the fan aft duct assembly. The
aft frame assembly is fabricated from alumi
The major components included in this num alloy sheet.
support structure are the fan support ring,
forward frame assembly, aft frame, left and Duct Inner Skins The left and right duct
inner skins are primary structural components
right duct inner skins, upper and lower
that provide the attachment and support for
intercostals, and left and right WL 159.00
the felt-metal tip seal for the fan assembly.
intercostals, and lower skin web.
The left and right inner skins form a circular
ring that is attached to both the forward frame
Secondary components installed within this assembly and the aft frame. The duct inner
structure include doubler plates and angles, skins are fabricated from aluminum alloy
stiffeners, channels, and standard hardware. sheet.
Intercostals The upper, lower, and left and
Fan Support Ring - The fan support ring is right WL 159.00 intercostals are secondary
machined from aluminum alloy stock. The fan structural components. The are fabricated
support ring contains a peripheral flange that from aluminum alloy sheet.
attaches onto the forward frame assembly. E. Tailboom Attachment Ring Assembly
Three arms provide the attachment for the fan
fairing/centerbody, the support for the fan (Ref. Figure 9)
bearing housing, and the fan support bearing
The tailboom attachment ring assembly is a
housing.
primary structural component that attaches
the tailboom to the aft section of the fuselage.
The inner flange of the ring assembly provides
Forward Frame Assembly - The forward
for attachment of the aft flanges of the upper
frame assembly is a primary structural
and lower anti-torque fan duct assemblies.
component that provides for installation and
attachment of the fan support ring. This The tailboom attachment ring assembly
component also provides the forward structur consists of the tailboom attachment ring,
al interface and support for the anti-torque nutplates, two close tolerance bolts and bolt
fan installation. The forward frame assembly retainers. The tailboom attachment ring is
is fabricated from aluminum alloy sheet. machined from aluminum alloy stock.
Page 20
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
WL 159.00 INTERCOSTALS
FWD FRAME UPPER
SUPPORT RING ASSEMBLY INTERCOSTAL
UPPER DUCT ASSEMBLY
RH INNER SKIN DUCT
LOWER DUCT
ASSEMBLY
LOWER ACCESS
PANEL ASSEMBLY
LH INNER SKIN
LOWER INTERCOSTAL DUCT
AFT FRAME
TAILBOOM ATTACHMENT
RING ASSEMBLY
9G53033
Figure 9. AntiTorque Fan Support Structure, Aft Duct Assembly, and Tailboom Attachment
Ring Assembly
Page 21
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
RH REAR FUSELAGE
SHELL ASSEMBLY
LH REAR FUSELAGE
SHELL ASSEMBLY
CUTOUT FOR UPPER WORK PLATFORM
(LH SHOWN, RH OPPOSITE)
9G53049
Page 22
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
SPLICE PLATE
REAR FUSELAGE
SHELL
(REF)
UPPER BAG
GAGE
DOOR FRAME
UPPER STRIKER
PLATE
SIDE STRIKER
RH KICK STRIP
LOWER STRIKER
PLATE
CENTER KICK STRIP
LH KICK STRIP
LOWER BAGGAGE
DOOR FRAME
9G53037
Page 23
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
The forward fairings and doors installation (NACA CONFIG) On aircraft with NACA
includes the forward and aft swashplate engine inlets installed, the forward fairing
fairing assemblies, the left and right forward support assemblies also support the forward
access door assemblies, the left and right end of the NACA inlet duct.
transmission access door assemblies, hinge
and door latch hardware, and the left and Each forward fairing support assembly
right forward fairing support assemblies. consists of metallic supports, frames, doublers,
Components within this installation, although intercostals, angles, a 4-mesh wire oil cooler
not considered structural, do transfer and inlet screen, and a composite oil cooler inlet
support aerodynamic air loads generated by duct frame. All metallic components are
flight or by main rotor down wash. fabricated from aluminum alloy sheet. The
4-mesh wire cloth oil cooler inlet screen is
A. Swashplate Fairing Assemblies fabricated from 0.032-0.035 in. (0.81-0.89
mm) diameter corrosion resistant steel wire.
The forward and aft swashplate fairing The oil cooler inlet duct frame is fabricated as
assemblies join to each other on each side. The a cocured multiple ply monolithic laminate
forward end of the combined assembly is incorporating graphite/epoxy and fiberglass/
attached to the FS 155.50 fuselage bulkhead. epoxy.
The aft end of the combined assembly is
attached to the forward firewall assembly and C. Fixed Panel Assemblies
the left and right inlet panels. The center of
the combined assembly is attached to the The left and right fixed panel assemblies are
forward fairing support assemblies. All removable filler panels that are installed
attachments to supporting structure or between the lower aft edge of the transmission
components, as well as at the joint to each access door and the lower edge of the forward
other, is by screws and bolts. inlet panel. The fixed panel assemblies
complete the seal land and incorporate the aft
The forward and aft swashplate fairing mounting provisions for the transmission
assemblies are constructed of multiple plies of access doors. Attachment of the panel assem
graphite/epoxy cocured with Nomex honey blies is by screws and bolts.
comb core. Around the periphery of each panel
assembly, and in the areas of secondary The fixed panel assemblies are built-up
attachment, the core tapers and the sandwich assemblies. Each assembly consists of a panel,
panel transitions to form monolithic laminate frame, and spacer, as well as standard
flanges that incorporate additional reinforce hardware. All components are fabricated from
ment plies of graphite/epoxy. aluminum alloy sheet.
Page 24
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
D. Forward Access Door Assemblies (EARLY CONFIG) - Each access door assem
bly is hinge mounted to the outboard edges of
The left and right forward access doors provide the aft swashplate fairing assembly and is
access to the forward area of the upper deck. retained in the closed position by means of
Each access door assembly is hinge mounted to latches and or quarter turn fasteners.
outboard edges of the forward swashplate
fairing assembly and is retained in the closed The transmission access door assemblies are
position by means of latches and or quarter fabricated of graphite/epoxy skins cocured with
turn fasteners. In the opened position, each a Nomex honeycomb core. Around the periph
door assembly is supported by a locking strut ery of the panel assembly, and in the areas of
assembly. hinge and latch attachment, the core is
tapered and the panel transitions to form
The forward and transmission access door monolithic laminate flanges which incorporate
assemblies are fabricated of graphite/epoxy additional plies of graphite/epoxy. In the areas
cocured with a Nomex honeycomb core. of secondary attachment of metallic compo
Around the periphery of the panel assembly, nents, barrier plies of fiberglass/epoxy are
and in the areas of hinge attachment, the core cocured to the faying surfaces. In the opened
is tapered and the panel transitions to form position, each door assembly is supported by a
monolithic laminate flanges which incorporate locking strut assembly.
additional reinforcement plies of graphite/
epoxy. In the areas of secondary attachment of (NACA CONFIG) The left and right transmis
metallic components, barrier plies of fiber sion access doors are separated into two door
glass/epoxy are cocured to the faying surfaces. assemblies, one above the NACA inlet and one
panel below the NACA inlet. The upper door
The door seals installed around the periphery assembly is hinge mounted to the outboard
of each door assembly are closed cell silicone edges of the aft swashplate fairing assembly
material with a self-adhering backing. and is retained in the closed position by
E. Transmission Access Door Assemblies quarter turn fasteners. The lower door
assembly is retained by quarter turn fasteners
The left and right transmission access doors only.
provide access to the aft area of the upper
deck. The transmission access door and panel
assemblies are fabricated of graphite/epoxy. In
The door seals installed around the periphery the areas of secondary attachment of metallic
of each door assembly are closed cell silicone components, barrier plies of fiberglass/epoxy
material with a self-adhering backing. are cocured to the faying surfaces.
Page 25
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
900 CONFIG
*LH SHOWN, RH OPPOSITE
NACA CONFIG
9G53104A
Page 26
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
8. Aft Cowling and Fairing Installation The insulation blanket provides fire and heat
protection for the composite panel. The
(Ref. Figure 13) insulation blanket is a molded assembly that
The aft cowling installation includes the is fabricated with special fire proof fabric inner
installation of the left and right engine cowl and outer skins separated by heat insulating
assemblies, the left and right exhaust ejector filler material. Installation of the blanket onto
cowls, the left and right deck angle seals, and the panel is by a silicone type adhesive.
the tailboom upper fairing assembly. Compo B. Exhaust Ejector Cowl Assemblies
nents installed within this installation,
although not considered structural, do transfer The left and right exhaust ejector cowl
and support aerodynamic air loads generated assemblies cover the secondary exhaust
by flight or by main rotor down wash. ejector. Attachment of each cowl assembly is
by means of screws and nutplates. Each
A. Engine Cowl Assemblies exhaust ejector cowl assembly includes upper
Each engine cowl assembly includes an engine and lower cowl panels, a closeout panel, and
cowl panel, upper edge stiffeners, (air vent) standard hardware. The upper, lower, and
screens and screen frames, insulation blanket, closeout panels are secondarily bonded and
and standard hardware. The left and right rivet together to form the completed cowl
engine cowl assemblies combine with the inlet assembly.
panel, inboard and aft firewall components,
The upper and lower panels of each assembly
deck skin components, and engine deck
is fabricated of graphite/epoxy that incorpo
thermal insulation, to form the fire proof
rates stiffening ribs of cocured syntactic foam
enclosure that contains the engine and the core, with local barrier plies of fiberglass/epoxy
primary exhaust nozzle. Each cowl assembly is
in areas of metallic component interface.
attached by screws and nutplates.
The closeout panel, located at the aft, outboard
The engine cowl panel is composite and is
corner of each cowl assembly, is fabricated as a
fabricated as a monolithic laminate, that
monolithic laminate that utilizes multiple plies
incorporates stiffening ribs of cocured syntactic
of graphite/epoxy.
foam core material. The panel is fabrication of
graphite/epoxy with local barrier plies of C. Tailboom Upper Fairing Assembly
fiberglass/epoxy in areas of metallic compo
nent interface. A forward and an aft edge The tailboom upper fairing assembly closes out
stiffener are fabricated from aluminum alloy the aft end of the upper deck fairings installa
sheet. tion between the exhaust ejector cowl assem
blies. The fairing assembly is attached by
Two screens are contained within each cowl screws and mating nutplates.
assembly. The screens are fabricated from 4
mesh 0.032-0.035 in. (0.81-0.89 mm) The tailboom upper fairing assembly consists
diameter corrosion resistant steel wire. The of a fairing panel and edge seals. The fairing
screen frames are fabricated from titanium panel is fabricated using multiple plies of
alloy sheet. The screens and screen frames are graphite/epoxy. The edge seals are closed cell
retained by rivets. silicone material with a self-adhering backing.
Page 27
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
9G53105
Page 28
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 401
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
2
4
1
900 CONFIG
NACA CONFIG
9G53-091A
Page 402
Original 53-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(1). Extend access door strut (2) to the fully (3). Remove screws (4) and washers (5), and
locked position. remove strut bracket.
(2). Secure end fittings of strut to bracket (4). Remove nut (7), washers (6), and ball
on swashplate fairing support assembly screw (8) from bracket.
and bracket (3) on inner surface of
access door. D. Access Door Strut Bracket Installation
(Ref. Figure 402)
(a). Ensure strut is positioned with
extended rod end fitting at bracket of NOTE: Installation of access door strut brack
swashplate fairing support. ets is typical.
(b). Slide case (9) of quick-disconnect ball (1). Install ball screw (8) on strut bracket
joint end fitting along axis of strut. (3) using washers (6) and nut (7).
Torque nut.
(c). Position end fitting socket over ball
end of ball screw (8) and release case. (2). Position strut bracket over molded-in
Ensure case is completely seated over inserts on inner surface of access door
ball end of ball screw. panel (1).
C. Access Door Strut Bracket Removal (a). On forward access doors, L155 and
R155, ensure ball end of ball screw is
(Ref. Figure 402) positioned aft.
NOTE: Removal of access door strut brackets is (b). On transmission access doors, L210
typical. and R210, ensure ball end of ball
screw is positioned forward.
(1). Gain access to door strut (2) and strut
bracket (3). (3). Install screws (4) and washers (5).
Torque screws.
(2). Disconnect door strut attachment to
strut bracket (Ref. Section 53-30-00). (4). Connect door strut (2) to ball screw (8).
Page 403
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
1 2
10
9
3 LOOKING INBOARD
LEFT SIDE
VIEW ROTATED
4 (2 PL) 2
5 (2 PL)
8
6 VIEW ROTATED
7 9G53-087A
1. DOOR PANEL 6. WASHER
2. DOOR STRUT 7. NUT
3. STRUT BRACKET 8. BALL SCREW
4. SCREW 9. CASE
5. WASHER 10. LOCK RELEASE COLLAR
Figure 402. Access Door Strut and Strut Bracket
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
10
3 8 (2 PL) 6
9 (2 PL)
4 (2 PL) 7
5 (2 PL)
LOOKING AFT
LOOKING FWD LOOKING AFT 9G53-064
1. FORWARD ACCESS DOOR (L155, R155) 8. BOLT
2. STRIKER PLATE 9. WASHER
3. STRIKER ADJUSTMENT PLATE 10. STRIKER PLATE
4. BOLT 11. STRIKER ADJUSTMENT PLATE
5. WASHER 12. BOLT
6. STRIKER PLATE 13. WASHER
7. STRIKER ADJUSTMENT PLATE
Figure 403. Access Door Strikers (EARLY CONFIG)
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Rotorcraft Maintenance Manual
NOTE: Removal of the left and right forward (1). Position forward fairing support
fairing support assemblies is typical. assembly (1) on upper deck outboard of
oil cooler blower air inlet duct.
(1). Remove forward access doors, L155 and (2). Slide support assembly inboard ensur
R155, and transmission access doors, ing oil cooler blower air inlet duct
L210 and R210 as applicable (Ref. engages duct frame of support assem
Section 53-30-00). bly. Ensure seal (6) is properly seated
between air inlet duct and duct frame
(2). Remove access door struts (Ref. Section around entire periphery.
53-30-00).
(3). Install bolts (2) and washers (3) in
(3). (NACA CONFIG) Remove NACA inlet support assembly (1). Torque bolts.
duct (Ref. Section 71-60-00). (4). Install bolts (4) and washers (5) in
support assembly to upper deck. Torque
(4). Remove bolts (2) and washers (3) from bolts.
support assembly (1) to forward
swashplate fairing assembly. (5). (NACA CONFIG) Install NACA inlet
duct (Ref. Section 71-60-00).
(5). Remove bolts (4) and washers (5) from (6). Install forward access doors, L155 and
support assembly to upper deck. R155, and transmission access doors,
L210 and R210 as applicable (Ref.
(6). Remove support assembly by sliding Section 53-30-00).
assembly outboard insuring duct frame
of support assembly is clear of oil cooler (7). Install access door struts (Ref. Section
air inlet duct and remove. 53-30-00).
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2 (2 PL)
3 (2 PL)
4 4
5 5
EARLY CONFIG
(2). Remove screws (2) and washers (3) (b). Ensure the lower edge of the panel
which secure panel (4) to fixed panel (4) nests against the outboard
bracket (5), deck angle (6) and engine surface of the deck angle (6).
air inlet assembly (7). Ensure upper aft
corner of panel assembly frame (8) (2). Install screws (2) and washers (3).
clears flange of inlet assembly as panel Torque screws.
assembly is removed.
(3). Close transmission access door, L210 or
B. Fixed Panel Assembly Installation R210 as applicable, and check for
proper operation of access door (Ref.
(Ref. Figure 405) Section 53-30-00).
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9 (4 PL)
10 (4 PL) 5
6 3 (4 PL)
2 (4 PL)
8
9G53-066
(2). (NACA CONFIG) Open transmission (3). Install screw (2) and washer (3) at the
access door, L210 or R210 as applicable lower, forward corner of fixed panel
(Ref. Section 06-00-00). assembly (4). Torque screw.
(4). (EARLY CONFIG) Install striker (1)
(3). (EARLY CONFIG) Remove striker (1)
for aft latch of transmission access door
for aft latch of transmission access door
(Ref. Section 53-30-00).
(Ref. Section 53-30-00).
(5). Close transmission access door, L210 or
(4). Remove screw (2) and washer (3) from R210 as applicable (Ref Section
lower, forward corner or fixed panel 06-00-00).
assembly (4).
(6). (EARLY CONFIG) Check for proper
(5). Remove bolts (9) and washers (10) operation of aft latch. Adjust access
securing fixed panel bracket (5) to door latch and/or striker if necessary
upper deck. (Ref. Section 53-30-00).
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
7. Oil Cooler Air Outlet Screen Assembly (b). Install screws with wet sealing
compound (C211), (C212), (C213), or
A. Oil Cooler Air Outlet Screen Assembly (C214) or primer (C309) and torque
Removal screws.
(Ref. Figure 406) 8. Swashplate Forward Fairing Assembly
(T155)
NOTE: Removal of left and right oil cooler air
outlet screen assemblies is typical. A. Swashplate Forward Fairing Assembly
Removal
(1). Remove screws and washers securing
oil cooler screen (1) to swashplate aft (Ref. Figure 406)
fairing (3).
(1). Remove forward access doors, L155 and
(2). Remove oil cooler air outlet screen R155, and transmission access doors,
assembly. L210 and R210 assemblies (Ref. Section
53-30-00).
B. Oil Cooler Air Outlet Screen Assembly
Installation (2). Disconnect vent system inlet to separa
tor flexible duct (8) by removing band
(Ref. Figure 406) clamp at bottom of duct (Ref. Section
21-20-00).
Consumable Materials (3). Fairing Assembly with Generator
(Ref. CSPSPM) Cooling Modification - Detach
Item Nomenclature cooling ducts from swashplate fairing
C211 Sealing Compound, Corrosion Inhibitive (Ref. Section 71-60-00, Cooling Duct
Removal).
C212 Sealing Compound, Corrosion Inhibitive
C213 Sealing Compound, Corrosion Inhibitive (4). Remove screws and washers securing
C214 Sealing Compound, Corrosion Inhibitive forward edge of swashplate forward
fairing assembly (2).
C309 Primer
(5). Remove screws, washers, and nuts at
joint to swashplate aft fairing assembly.
NOTE: Installation of left and right oil cooler
air outlet screen assemblies is typical. (6). Remove torq-set bolts (4), washers (5),
and nuts (6) securing splice angle (7) to
(1). Position oil cooler air outlet screen outboard flanges of fairing assembly.
assembly (1) over outlet on swashplate
aft fairing assembly (3). (7). Remove screws and washers securing
upper end of forward fairing support
Sealing Compound (C211) assembly to outboard flanges of fairing
assembly.
Ensure forward end of aft
CAUTION swashplate fairing assembly is
supported prior to complete removal of
Primer (C309) hardware.
(8). Remove fairing assembly by moving
assembly forward and up.
(a). Ensure flanges at joints to swash
(2). Install screws and washers. plate aft fairing assembly are com
pletely disengaged.
(a). Ensure screws properly engage
nutplates on flange of cooling ex (b). Ensure outboard flanges are clear of
haust duct. upper ends of support assemblies.
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Rotorcraft Maintenance Manual
(9). Remove hinges if applicable (Ref assembly. Install screws with wet
Section 53-30-00). sealing compound (C211), (C212),
(C213), or (C214) or primer (C309) and
B. Swashplate Forward Fairing Assembly
torque screws.
Installation
(Ref. Figure 406)
(4). Install torq-set bolts (4), washers (5)
and nuts (6) to secure flanges of fairing
Consumable Materials
(Ref. CSPSPM) assembly to splice angle (7). Install
Item Nomenclature bolts with wet sealing compound
(C211), (C212), (C213), or (C214) or
C211 Sealing Compound, Corrosion Inhibitive
primer (C309) and torque nuts.
C212 Sealing Compound, Corrosion Inhibitive
C213 Sealing Compound, Corrosion Inhibitive
C214 Sealing Compound, Corrosion Inhibitive (5). Install screws, washers, and nuts at
C309 Primer joint to aft swashplate fairing assembly.
Install screws with wet sealing com
pound (C211), (C212), (C213), or (C214)
(1). Install or replace hinges if applicable
or primer (C309) and torque nuts.
(Ref. Section 53-30-00).
(2). Position swashplate forward fairing
assembly (2) over swashplate and mast (6). Install screws and washers at forward
support assemblies with front edge on edge of fairing assembly. Install screws
flange of FS 155 frame. with wet sealing compound (C211),
(C212), (C213), or (C214) or primer
(a). Ensure aft flanges of fairing assem
(C309) and torque screws.
bly nest over mating flanges of
swashplate aft assembly.
(b). Ensure outboard flanges of fairing (7). Fairing Assembly with Generator
assembly are inboard of upper ends Cooling Modification - Attach
of support assemblies and that cooling ducts to swashplate fairing (Ref.
flanges of splice angles are inboard of Section 71-60-00, Cooling Duct
flanges. Installation).
Sealing Compound (C211)
(8). Connect vent system inlet to separator
flexible duct (8) (Ref. Section
21-20-00).
Primer (C309)
(9). Install forward access doors, L155 and
R155, and transmission access doors,
L210 and R210 assemblies (Ref. Section
53-30-00).
(3). Install screws and washers to secure
support assemblies to flanges of fairing
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4 (4 PL)
5 (4 PL)
6 (4 PL)
7 1
2
3
8
9. Swashplate Aft Fairing Assembly (T220) (4). Remove screws, washers, and nuts at
joint to swashplate forward fairing
A. Swashplate Aft Fairing Assembly assembly.
Removal
(5). Remove torq-set bolts (4), washers (5)
and nuts (6) securing flanges of fairing
(Ref. Figure 406) assembly to splice angle (7).
(1). Remove forward access doors, L155 and (6). Remove fairing assembly by lifting aft
R155, and transmission access doors, edge up and moving assembly aft and
L210 and R210 assemblies (Ref. Section up.
53-30-00).
(a). Ensure flanges at joints to swash
(2). Remove screws and washer from left plate forward fairing assembly are
and right oil cooler air outlet screens completely disengaged.
(1).
(b). Ensure fairing assembly is clear of oil
(3). Remove screws and washers securing cooler blower exhaust ducts.
aft edge of swashplate aft fairing
assembly (3) to firewall and engine air (7). Remove hinges if applicable (Ref
inlet assemblies. Section 53-30-00).
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Rotorcraft Maintenance Manual
(8). Remove oil dipstick handhold assem Install bolts with wet sealing compound
blies if applicable (Ref. Section (C211), (C212), (C213), or (C214) or
53-30-00). primer (C309). Torque nuts.
B. Swashplate Aft Fairing Assembly (5). Install screws, washers, and nuts at
Installation joint to forward swashplate fairing
assembly. Install screws with wet
(Ref. Figure 406) sealing compound (C211), (C212),
(C213), or (C214) or primer (C309).
Torque screws.
Consumable Materials
(Ref. CSPSPM) (6). Install screws, and washers on aft edge
Item Nomenclature of assembly. Install screws with wet
C211 Sealing Compound, Corrosion Inhibitive sealing compound (C211), (C212),
C212 Sealing Compound, Corrosion Inhibitive (C213), or (C214) or primer (C309).
Torque screws.
C213 Sealing Compound, Corrosion Inhibitive
C214 Sealing Compound, Corrosion Inhibitive (7). Install left and right oil cooler air outlet
C309 Primer screen assemblies (1) with screws and
washers. Torque screws.
(1). Install or replace hinges if applicable (8). Install forward access doors, L155 and
(Ref. Section 53-30-00). R155, and transmission access doors,
L210 and R210 assemblies (Ref. Section
(2). Install or replace oil dipstick handholds 53-30-00).
if applicable (Ref. Section 53-30-00).
10. Engine Cowl Assembly (L260, R260)
(3). Position swashplate aft fairing assem
bly (3) over swashplate and mast A. Engine Cowl Assembly Removal
support with aft edge on flanges of
firewall and engine air inlet assemblies. (Ref. Figure 407)
(a). Ensure forward flanges of fairing NOTE: Removal of engine cowl L260 and R260
assembly nest under mating flanges assemblies is typical.
of swashplate forward fairing assem
bly. (1). Remove screws (1) and washers (2)
which secure engine cowl assembly to
(b). Ensure outboard flanges nest over airframe.
splice angles (7).
(2). Remove engine cowl assembly (3).
Sealing Compound (C211)
B. Engine Cowl Assembly Installation
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Rotorcraft Maintenance Manual
1
2
9G53-093A
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Rotorcraft Maintenance Manual
1
2
3
4
5
9G53-092A
1. SCREW 4. SCREW
2. WASHER 5. WASHER
3. TAILBOOM UPPER FAIRING ASSEMBLY (T292) 6. EXHAUST EJECTOR COWL ASSEMBLY (L270)
Figure 408. Exhaust Ejector Cowl Assembly
12. Engine Upper Inlet Assembly firewall assembly (4). Remove inlet
assembly.
A. Engine Upper Inlet Assembly Removal
B. Engine Upper Inlet Assembly Installation
(Ref. Figure 409)
(Ref. Figure 409)
NOTE: Removal of left and right engine upper NOTE: Installation of left and right engine up
inlet assemblies is typical. per inlet assemblies is typical.
(1). Remove fixed panel assembly (Ref (1). Secure upper inlet assembly (3) to
Section 53-30-00). firewall assembly (4) with bolts (1) and
washers (2). Torque bolts.
(2). Remove engine cowl assembly L260 or
R260 (Ref. Section 53-30-00). (2). Install engine firewall to plenum seals
(Ref. Section 71-00-00).
(3). (NACA CONFIG) - Remove NACA
inlet duct (Ref. Section 71-60-00). (3). Install engine wash system (Ref.
Section 71-60-00).
(4). Remove inlet screen or inlet particle
separator (Ref. Section 71-60-00). (4). (NACA CONFIG) - Install NACA inlet
duct (Ref. Section 71-60-00).
(5). Remove engine wash system (Ref. (5). Install inlet screen or inlet particle
Section 71-60-00). separator (Ref. Section 71-60-00).
(6). Remove engine firewall to plenum seals (6). Install engine cowl assembly L260 or
(Ref. Section 71-00-00). R260 (Ref. Section 53-30-00).
(7). Remove bolts (1) and washers (2) which (7). Install fixed panel assembly (Ref
secure upper inlet assembly (3) to Section 53-30-00).
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Rotorcraft Maintenance Manual
1 (15 PL)
2 (15 PL)
9G53-116
1. BOLT 3. ENGINE UPPER INLET ASSEMBLY
2. WASHER 4. FIREWALL ASSEMBLY
Figure 409. Engine Upper Inlet Assembly
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Rotorcraft Maintenance Manual
13. AntiTorque Inlet Screen Assembly (4). Remove bolts (4) and washers (5) which
secure duct assembly (3) to upper deck.
A. Inlet Screen Assembly Removal
(5). Lift and remove inlet duct assembly (3)
(Ref. Figure 410) from middle inlet duct (8) and firewall.
B. Inlet Assembly Installation
CAUTION
(Ref. Figure 410)
FOD
FOD
Screws utilized to secure inlet screen as CAUTION
sembly are captive-type fasteners and
should only be removed from assembly for (1). Position and align mounting holes of
replacement. inlet assembly (3) to upper deck and
install bolts (4) and washers (5). Torque
(1). Disengage captive screws (1). screws.
(2). Remove inlet screen assembly (2). (2). Install swashplate aft fairing assembly
(Ref. Section 53-30-00).
B. Inlet Screen Assembly Installation
(3). Install left and right engine cowl
(Ref. Figure 410) assemblies (Ref. Section 53-30-00).
FOD (4). Install left and right exhaust ejector
CAUTION
cowls (Ref. Section 53-30-00).
(1). Position inlet screen assembly (2) over 15. Middle Inlet Duct Assembly (F4)
inlet cavity of upper inlet duct assembly
and align mounting holes. A. Middle Inlet Duct Assembly Removal
(2). Engage captive screws (1) with nut (Ref. Figure 410)
plates on inlet assembly (3) and torque (1). Remove forward duct assembly F1, F2
screws. and F3 (Ref. Section 53-30-00).
14. Upper Inlet Duct Assembly (T240) (2). Remove upper inlet duct assembly
T240 (Ref. Section 53-30-00).
A. Inlet Assembly Removal
(3). Remove bolts (6) and washers (7) which
(Ref. Figure 410) secure middle inlet duct assembly (8) to
fan support structure (9).
FOD
CAUTION NOTE: Sealing compound used between duct
assembly and upper deck is actually a self-
(1). Remove left and right exhaust ejector forming gasket. Care should be taken not to
cowls L270, R270 (Ref. Section damage this gasket when removing duct as
53-30-00). sembly.
(2). Remove left and right engine cowl (4). Using a putty knife (or equivalent), if
assemblies L260, R260 (Ref. Section necessary, carefully break seal between
53-30-00). faying surfaces of duct assembly, upper
deck and fan support structure.
(3). Remove swashplate aft fairing assem
bly T220 (Ref. Section 53-30-00). (5). Remove duct assembly.
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Consumable Materials
(Ref. CSPSPM)
Item Nomenclature (d). Apply release agent (C417) to contact
surfaces of duct, upper deck and fan
C417 Release Agent support structure. Allow releasing
C419 Alcohol, Isopropyl agent to dry before applying sealant.
C209 Sealing Compound, Dichromate Cured
Sealing Compound (C209)
Alcohol, Isopropyl (C419)
(c). Allow to air dry for a minimum of ten (5). Install upper inlet duct assembly T240
minutes. (Ref. Section 53-30-00).
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2
1
5 (4 PL)
3 4 (4 PL)
10
6 (5 PL)
7 (5 PL)
ENGINE AND FIREWALL
NOT SHOWN
9G53-115
1. CAPTIVE SCREW 6. BOLT
2. INLET SCREEN ASSEMBLY 7. WASHER
3. UPPER INLET DUCT ASSEMBLY (T240) 8. MIDDLE INLET DUCT ASSEMBLY (F4)
4. BOLT 9. FAN SUPPORT STRUCTURE
5. WASHER 10. UPPER DECK
Figure 410. Upper and Middle Inlet Duct Assemblies
Page 419
53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
16. Forward Duct Assembly, AntiTorque Fan (5). Remove wire harness W130.
(F1, F2 and F3)
A. Forward Duct Removal (a). Remove bolts (13), nuts (14) and
washers (16) securing clamps (17)
(Ref. Figure 411) and harness (18) to inside of right
(1). Remove baggage compartment soft fairing half (10).
insulation roof panels (Ref. Section
25-50-00).
(b). Remove lockwire and detach electri
NOTE: Sealing compound used between duct cal connector P434 from azimuth
assembly and upper deck is actually a self- sensor.
forming gasket. Care should be taken not to
damage this gasket when removing duct as
sembly. (c). Remove lockwire and detach electri
cal connector P433 from vibration
(2). Using a putty knife (or equivalent), if sensor.
necessary, carefully break seal between
faying surfaces of duct assembly and
upper deck. (6). Remove right half of fairing/centerbody.
(3). Remove aft section of forward duct
assembly. (a). Remove bolts (13), nuts (14) and
washers (6) which secure fairing half
(a). Remove bolts (1) and washers (2)
(10) to inside contour of duct assem
which fasten duct assembly (3) to
bly (7).
forward edge of fan support structure
(4).
(b). Remove bolts (5) and washers (6) (b). Remove bolt (15) securing fairing half
which fasten aft section of duct to right-hand strut of fan support
assembly (3) to forward section (7). frame.
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(d). Apply release agent (C417) to contact (c). Attach connector P390 to receptacle
surfaces of cover (19) and fore and aft J390. Safety with lockwire (C701).
sections of duct assembly (3 and 7).
(d). Seal wire harness and grommet to
Allow releasing agent to dry before
duct assembly using sealing com
applying sealant.
pound (C209).
(2). Set aft section of duct assembly (3) (6). Install right half of fan fairing/center
aside for later installation. body assembly.
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Rotorcraft Maintenance Manual
(a). Position fairing (10) around right (d). Secure centerbody fairing assembly
side of fan drive shaft. to upper inlet duct cover (11) with
screw (8) and washer (6).
(b). Attach wide radius of fairing (10) to
clip on right-hand fan support strut (10). Torque all hardware installed in the
with bolt (15). preceding steps.
(c). Attach forward end of fairing half to Sealing Compound (C209)
inside contour of forward duct (7)
with bolts (13), nuts (14) and wash
ers (6).
(7). Install wire harness W130 inside right
centerbody fairing half. NOTE:
Do not apply sealant in nutplate regions
(a). Secure wire harness to fairing (10) of duct assembly.
with clamps (17), using bolts (13),
washers (16) and nuts (14). Torque Apply sealing compound only if forming a
nuts. new seal. If the original seal is not dam
aged, proceed with final installation of
(b). Attach electrical connector P433 to duct assembly.
vibration sensor. Safety with lock
wire (C701). (11). Install aft section of duct assembly.
(c). Attach electrical connector P434 to (a). Apply sealing compound (C209) to
azimuth sensor. Safety with lockwire surfaces of aft duct section (3) where
(C701). it contacts the upper deck, forward
duct section (7) and forward edge of
(8). Inspect to ensure that no portion of fan support structure (4).
wire harness or fairing is chafing
against fan drive shaft or coupling. (b). Align aft duct (3) with nutplates
between forward section of duct and
(9). Assemble left half of fairing /centerbody forward edge of fan support struc
to right half. ture.
(a). Attach left fairing half (9) to clips on (c). Install bolts (5) and washers (6)
bottom and left-hand struts of fan along forward and top edges of duct.
support frame with one bolt (15)
each. (d). Install bolts (1) and washers (2)
along aft edge of duct.
(b). Attach forward end of fairing half to
inside contour of forward duct (7) (e). Torque bolts. Wipe off excess sealant
with bolts (13), washers (6) and nuts as required.
(14).
(12). Install baggage compartment roof
(c). Fasten centerbody fairing halves insulation panel (Ref. Section
together with screws (12). 25-50-00).
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5 5
6 6
6
8 5
6
5 18
6
12
13 (2 PL)
14 (2 PL)
15 16 (2 PL)
18 4 17 (2 PL)
13 (4 PL) LOOKING INBOARD
14 (4 PL) LEFT SIDE
6 (4 PL) 10
1 (10 PL)
2 (10 PL)
11 3
19 9G53-023A
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Rotorcraft Maintenance Manual
17. Aft Duct Assembly, AntiTorque Fan (F6, (1). Put upper center diffuser in its
F7, and F8) installed position.
A. Lower Center Diffuser and Access Panel (2). Install screws (6) and washers (2).
Removal
(Ref. Figure 412) (3). Install screws (7) and washers (8).
(1). Remove baggage compartment roof Do not torque stator vane
insulation panel (Ref. Section CAUTION screws too much, damage to sta
25-50-00). tor vanes can occur.
(2). Release adjustable tension latches (1).
(4). Install screws (9) and washers (10).
(3). Lower lower center diffuser and access Torque screws 3-6 in-lb (0.339-0.678
panel (5) until locating pins (4) disen Nwm) plus drag torque.
gage from holes in upper center diffuser
(3) and remove panel. (5). Torque screws (6 and 7).
B. Upper Center Diffuser Removal
D. Lower Center Diffuser and Access Panel
(Ref. Figure 412) Installation.
(1). Remove lower diffuser and access (Ref. Figure 412)
panel.
(2). Remove screws (6) and washers (2). Make sure pilot directional ped
CAUTION als are approximately in their
(3). Remove screws (7) and washers (8). center position, damage to fan blades and
stators can occur.
NOTE: If fan pitch control rod is installed, turn
upper center diffuser to go around rod.
(1). Put lower diffuser and access panel in
(4). Remove screws (9) and washers (10). its installed position and engage
Remove upper center diffuser (3). locating pins.
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Rotorcraft Maintenance Manual
9 (6 PL)
10 (6 PL)
9
10 9
10
2
6
8 (7 PL) 2 (4 PL)
7 (7 PL)
6 (4 PL) 4 (4 PL)
LOOKING AFT
9G53-024A
1. ADJUSTABLE TENSION LATCHES 6. SCREW
2. WASHER 7. SCREW
3. UPPER CENTER DIFFUSER (F6) 8. WASHER
4. LOCATING PINS 9. SCREW
5. LOWER CENTER DIFFUSER AND ACCESS PANEL (F7, 10. WASHER
F8)
Figure 412. Aft Duct Assembly, AntiTorque Fan
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Rotorcraft Maintenance Manual
18. Diverter Plate and Aft Diffuser Assembly B. Diverter Plate and Aft Diffuser
Installation
A. Diverter Plate and Aft Diffuser Removal
(Ref. Figure 413)
(Ref. Figure 413)
Consumable Materials
(1). Remove lower center diffuser and (Ref. CSPSPM)
access panel F7 and F8 (Ref. Section Item Nomenclature
53-30-00). C417 Release Agent
C419 Alcohol, Isopropyl
(2). Remove upper center diffuser F6 (Ref.
C205 Sealing Compound
Section 53-30-00).
(3). Disconnect control rod from anti-torque (1). Install anti-torque controls in diverter
fan (Ref. Section 67-20-00). plate assembly (Ref. Section 67-20-00).
(4). Disconnect force limiting control rod (2). Prepare contact surfaces of diverter
from outer bellcrank (Ref. Section plate (18), aft diffuser halves (21 and
67-20-00). 22), duct assembly halves (5 and 15)
and tailboom attachment ring (16) for
(5). Remove screws (1 and 2) and washers installation.
(3) which secure electrical access cover Alcohol, Isopropyl (C419)
(4) to lower duct assembly (5).
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Rotorcraft Maintenance Manual
Sealing Compound (C205) (6). Route wire harness (10) and coax cable
(11) through opening in left side of
lower duct and secure to airframe with
clamps (8 and 9), screw (6) and washer
(7). Torque screw. Attach electrical
(4). Apply a fillet bead of sealing compound connectors.
(C205) along contact surfaces of
diverter plate (18) and aft diffuser (7). Install electrical access cover (4) with
halves (21 and 22). screws (1 and 2) and washers (3).
(5). Install diverter plate (18) and lower Sealing Compound (C205)
duct assembly (5).
(a). Align holes in outboard edges of
diverter plate (18) with nutplates in
outboard edges of upper duct assem
bly (15). (8). Apply a fillet bead of sealing compound
(b). Install nylon fasteners (17) in (C205) along contact surfaces of aft
outboard edges of diverter plate (18). duct, electrical access panel and
diverter plate.
(c). Attach lower duct assembly to under
side of diverter plate and upper duct (9). Connect force limiting control rod to
assembly with screws (19) and outer bellcrank (Ref. Section
washers (20). 67-20-00).
(d). Attach lower duct to tailboom (10). Connect control rod to anti-torque fan
attachment ring (16) with screws (2) (Ref. Section 67-20-00).
and washers (3).
(e). Attach lower duct to brackets (14) (11). Install upper center diffuser (Ref.
with screws (12) and washers (13). Section 53-30-00).
(f). Torque all attaching hardware (12). Install lower center diffuser and access
installed in the preceding steps. panel (Ref. Section 53-30-00).
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Rotorcraft Maintenance Manual
21
11 15
6 18
7
8
9 17 22
14
2 (12 PL)
16 3 (12 PL)
10 1 (2 PL)
23 (4 PL)
5
4
20 (6 PL)
19 (6 PL)
12 (2 PL)
13 (2 PL)
9G53-108
1. SCREW 13. WASHER
2. SCREW 14. BRACKET
3. WASHER 15. FAN UPPER DUCT ASSEMBLY (F5)
4. ELECTRICAL ACCESS COVER 16. TAILBOOM ATTACHMENT RING
5. FAN LOWER DUCT ASSEMBLY (F9) 17. NYLON FASTENERS
6. SCREW 18. DIVERTER PLATE ASSEMBLY
7. WASHER 19. SCREW
8. CLAMP 20. WASHER
9. CLAMP 21. AFT DIFFUSER, UPPER
10. WIRE HARNESS 22. AFT DIFFUSER, LOWER
11. COAX CABLE 23. QUARTER TURN FASTENER
12. SCREW
Figure 413. Diverter Plate and Aft Diffuser Assembly
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Rotorcraft Maintenance Manual
Page 601
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Rotorcraft Maintenance Manual
LH SHOWN, RH OPPOSITE
90007610100-101-c-f
9G53-074
B. Access Door Striker Adjustment (2). Loosen bolts (1) securing striker plate
(2) sufficiently to allow movement of
striker plate over serrations of striker
(Ref. Figure 602)
adjustment plate (3).
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Rotorcraft Maintenance Manual
2 1 (2 PL)
1 (2 PL) 2
LOOKING AFT
LOOKING AFT
9G53-075
1. BOLT 3. STRIKER ADJUSTMENT PLATE
2. STRIKER PLATE 4. ACCESS DOOR
Figure 602. Access Door Striker Adjustment (EARLY CONFIG)
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Rotorcraft Maintenance Manual
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53-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
4 (4 PL)
5 (4 PL)
6 (4 PL)
LH SHOWN, RH OPPOSITE
9G53076
1. ACCESS DOOR PANEL 4. SCREW
2. COWLING LATCH 5. WASHER
3. LATCH SHIM 6. NUT
Figure 801. Cowling Latch Replacement (EARLY CONFIG)
B. Forward Access Door Seal Replacement
CAUTION
(Ref. Figure 802) During seal replacement place door as
sembly on appropriate pads to avoid dam
age to composite door skin.
Consumable Materials During seal removal use appropriate non
(Ref. CSPSPM) metallic scraper, if required, to avoid
Item Nomenclature damage to composite seal lands.
C425 Solvent, Cleaning
(1). Remove access door assembly (Ref.
Section 53-30-00).
NOTE: Seal replacement for forward access (2). Remove seals (2) and (3) from access
doors, L155 and R155 is typical. door panel (4).
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
3
3
2 2 2 2
Page 804
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
900 CONFIG
1. SUPPORT ASSEMBLY
2. SEAL
Figure 803. Support Assembly Duct Frame Seal
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
3. Swashplate Aft Fairing Assembly (T220) (6). Remove handhold and drill transferred
hole patterns. Drill rivet and turnlock
A. Oil Dipstick Handhold Replacement fastener holes.
(Ref. Figure 804) (7). Position seal (6), prior to removal of
protective film on surface with adhe
sive, around perimeter of handhold
Consumable Materials
adjacent to edges on inboard surface of
(Ref. CSPSPM)
flanges.
Item Nomenclature
C425 Solvent, Cleaning (a). Cut ends to form a butt joint.
C211 Sealing Compound, Corrosion Inhibitive (b). Cut 0.374-0.381 in (9.5-9.68 mm)
C212 Sealing Compound, Corrosion Inhibitive diameter holes in seal at turnlock
C213 Sealing Compound, Corrosion Inhibitive fastener locations to clear outside
C214 Sealing Compound, Corrosion Inhibitive diameter of retaining washers.
C309 Primer (8). Prepare flanges on inboard surface of
handhold for application of seal (Ref.
CSP-SPM, Section 20-50-00).
NOTE: Replacement of the left and right oil
dipstick handholds is typical. (9). Remove protective film from seal and
apply seal to inboard surfaces of
(1). Remove rivets (2) securing hinge (5) to handhold flanges. Use moderate hand
oil dipstick handhold (1) and remove pressure to ensure proper adhesion.
handhold.
(10). Install turnlock fastener studs (3) and
(2). Remove turnlock fastener studs (3) and retaining washers (4).
retaining washers (4).
Sealing Compound (C211)
(3). Position replacement handhold (1) on
swashplate aft fairing assembly.
(a). Ensure handhold overlaps forward
edge of opening in fairing assembly Primer (C309)
0.53 in (13.46 mm).
(b). Ensure handhold overlaps outboard
edge of opening in fairing assembly
1.17 in (2.97 cm). (11). Attach handhold to hinge (5) on fairing
assembly using rivets (2).
(4). Fold hinge (5) over flange of handhold
and transfer existing rivet hole pattern (a). Install rivets with wet sealing
in hinge to flange of handhold. compound (C211), (C2120, (C213), or
(C214) or primer (C309).
(5). Transfer existing turnlock receptacle
locations on fairing assembly to (b). Install rivets with bulb ends out
outboard flange of handhold. board.
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Rotorcraft Maintenance Manual
2 (5 PL)
5
1
3 (2 PL)
4 (2 PL)
9G53084
1. HANDHOLD 4. RETAINING WASHER
2. RIVET 5. HINGE
3. STUD 6. SEAL
Figure 804. Oil Dipstick Handhold
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Rotorcraft Maintenance Manual
Page 808
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Rotorcraft Maintenance Manual
Section
534000
Tailboom
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
TAILBOOM
DESCRIPTION AND OPERATION
1. Tailboom General On helicopters with the thruster extension, the
tailboom/thruster left and right upper fairing
(Ref. Figure 1) assemblies cover and fair the empennage to
The major components contained in this area tailboom, and the upper half of the tailboom to
of the fuselage are the tailboom assembly, thruster extension attach points. The tail
tailboom bumper, tailboom/thruster, left and boom/thruster lower fairing assembly covers
right upper fairing assemblies, and tailboom/ and fairs the lower portion of the empennage
thruster lower fairing assembly. attachment frames and the lower half of the
tailboom to thruster extension attach point.
2. Tailboom Bumper Attachment of the fairing assemblies is by
screws.
(Ref. Figure 1)
On helicopters with the thruster extension, the
The tail bumper provides protection for the left and right thruster extension fairing
tailboom assembly and thruster. The tail assemblies cover and fair the tailboom to
bumper is attached to both empennage thruster extension attach point and thruster
attachment frames by mating bosses and extension to thruster attach point. Attachment
clevis type pins. The tailboom bumper is of the fairing assemblies is by screws.
fabricated from aluminum alloy tubing.
Each fairing assembly consists of a composite
3. Tailboom/Thruster Fairing Assemblies fairing panel, self-adhering silicone rubber
seals, and standard hardware. Each fairing
(Ref. Figure 1) panel is fabricated as a monolithic laminate
using multiple plies of aramid/epoxy. Portions
The tailboom/thruster left and right upper of the upper edges of the left and right upper
fairing assemblies cover and fair the empen fairing panels cocured syntactic foam.
nage to tailboom, and the upper half of the
tailboom to thruster attach points. The On helicopters with the thruster extension, the
tailboom/thruster lower fairing assembly tailboom/thruster right upper fairing has one
covers and fairs the lower portion of the vortex generator bonded to it. The tailboom/
empennage attachment frames and the lower thruster right lower fairing has seven vortex
half of the tailboom to thruster attach point. generators bonded to it. The right thruster
Attachment of the fairing assemblies is by extension fairing has ten vortex generators
screws. bonded to it.
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Rotorcraft Maintenance Manual
RH TAILBOOM/THRUSTER
UPPER FAIRING ASSEMBLY LH TAILBOOM/THRUSTER
UPPER FAIRING ASSEMBLY
TAILBOOM ASSEMBLY
TAILBOOM BUMPER
LOWER TAILBOOM/THRUSTER
FAIRING ASSEMBLY
VORTEX
GENERATOR
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Rotorcraft Maintenance Manual
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
detail components are composite and are the interior surfaces of the tailboom, mating
secondarily bonded to form the assembly using surfaces of the airfoils, and slat assembly. The
a high temperature epoxy adhesive. upper and lower inlet ramps are both nonme
tallic components fabricated from polycarbo
E. Upper and Lower Airfoils nate plastic sheet.
The upper and lower airfoils are air entrance H. Forward Coaxial Cover, Aft Coaxial
control devices on the interior surface of the Cover, and Aft Wiring Cover
tailboom assembly for the air circulation
control slots. The upper airfoil is installed The coaxial and wiring covers allow coaxial
parallel to and immediately above the leading cable and wiring to enter and exit the tailboom
edge of the slat assembly. The lower airfoil is assembly without allowing air to escape. The
installed parallel to and immediately below forward coaxial cover is installed below the
the trailing edge of the slat assembly. Each forward end of the lower air circulation control
airfoil is secondarily bonded and faired to the slot and attached to the forward end or the
interior surface of the tailboom. lower airfoil. The lower inlet ramp overlaps
the upper part of the forward coaxial cover.
The upper and lower airfoils are composite The aft coaxial cover and aft wiring cover are
assemblies consisting of an airfoil skin and installed at the aft end of the slat assembly
several integral support ribs. All components and lower airfoil assembly. Each cover is
within each assembly are fabricated as secondarily bonded and faired to the interior
monolithic laminates using multiple plies of surfaces of the tailboom, mating surfaces of
graphite/epoxy. the airfoils, and slat assembly. The forward
F. Slot Vanes coaxial cover, aft coaxial cover, and aft wiring
cover are both nonmetallic components
The slot vanes function as airflow straighten fabricated from polycarbonate plastic sheet.
ers for the anti-torque fan air exiting the air
circulation control slots on the tailboom I. Fuselage Attachment, Empennage
assembly. In the upper air circulation control Attachment Frames, and Intercostals
slot, sixteen slot vanes are installed equally
spaced between the trailing edge of the upper The fuselage attachment frame is located at
airfoil and the leading edge of the slat assem the forward end of the tailboom assembly, and
bly. In the lower air circulation control slot, provides for attachment of the tailboom
sixteen slot vanes are installed equally spaced assembly to the tailboom attachment ring
between the trailing edge of the slat assembly assembly. The forward and aft empennage
and the leading edge of the lower airfoil. Each attachment frames are located at the aft end
slot vane is secondarily bonded. The slot vanes of the tailboom assembly, and contain the
are nonmetallic components fabricated from provisions for attachment of the horizontal
polycarbonate plastic sheet. stabilizer and thruster assemblies. The left
and right intercostal assemblies are installed
G. Upper and Lower Inlet Ramps between the forward and aft empennage
attachment frames adjacent to the provisions
The upper and lower inlet ramps function as for attachment of the horizontal stabilizer.
air entrance control devices at the forward
ends of the air circulation slots on the interior The fuselage, and forward and aft empennage
surface of the tailboom assembly. The upper attachment frames, are machined from
inlet ramp is installed at the forward end of aluminum alloy stock. The left and right
the upper air circulation control slot and intercostals are fabricated from aluminum
overlaps the upper airfoil and leading edge of alloy sheet. The fuselage attachment frame is
the slat assembly. The lower inlet ramp is installed using titanium pins and aluminum
installed at the forward end of the lower air collars. The forward and aft empennage
circulation control slot and overlaps the frames are installed using titanium blind
trailing edge of the slat assembly, the lower fasteners. The intercostals are installed using
airfoil, and the forward coaxial cover. Each a combination of titanium pins and aluminum
inlet ramp is secondarily bonded and faired to collars, and titanium blind fasteners.
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Rotorcraft Maintenance Manual
TAILBOOM
UPPER AIRFOIL
SLOT VANE
RH DIVERTER
ATTACH FLANGE
UPPER
INLET RAMP AFT
WIRING COVER
AFT
COAXIAL COVER
SLOT VANE
LOWER TAILBOOM
INLET RAMP LOWER AIRFOIL
DIVERTER
FORWARD
PLATE
COAXIAL COVER
VORTEX
LH DIVERTER GENERATORS
FUSELAGE ATTACH FLANGE
ATTACH FRAME
THRUSTER EXTENSION VIEW ROTATED
9G53-111A
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Rotorcraft Maintenance Manual
Page 6
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
TAILBOOM
MAINTENANCE PRACTICES
1. Tailboom Inspections (Area 7) (g). If installed, examine thruster exten
sion fairing support for cracks, voids,
A. Tailboom Inspection dents, holes, scratches, delamina
(Ref. Figure 201) tions, and correct installation. No
defects permitted.
(1). If installed, examine vortex generators
for damage (ref. Figure 205). No (h). Examine tailboom/thruster fairings
damage permitted. S2, SL1, and SR1 for condition. No
defects permitted.
(2). Remove access panels S2, SL1, and SR1
(ref. Figure 201).
(i). If installed, examine thruster exten
(3). If installed, remove access panels SL8 sion fairings SL8 and SR8 for condi
and SR8. tion. No defects permitted.
(4). Do an external tailboom inspection as (j). Examine anti-collision light and
follows: navigation light for serviceable
NOTE: Do not remove tailboom unless you find condition. Repair or replace as
an indication of cracks, corrosion, or incor necessary (ref. CSP-900RMM-3,
Section 96-40-00).
rect installation.
(a). Examine tailboom attach frame and (k). Examine light lenses for moisture
attach holes for cracks, corrosion, and condensation. If moisture is found,
correct installation. No defects remove lens and clean (ref.
permitted. CSP-900RMM-3, Section 96-40-00).
(b). Examine tailboom surface and (5). Do an internal tailboom inspection as
tailboom circulation control slots for follows:
cracks, voids, dents, holes, scratches,
delamination, and correct installa (a). Examine diverter plate for cracks,
tion. No defects permitted. delaminations, and separation. None
NOTE: Damage to slots can decrease the rotor permitted.
craft performance during a hover.
(b). Examine slot vanes for condition and
(c). Examine empennage attach brackets correct installation. No defects
for cracks, corrosion, and correct permitted.
installation. No defects permitted.
(c). Examine tailboom for missing slot
(d). Examine thruster attach frame and vanes. None permitted.
attach holes for cracks, corrosion, and
correct installation. No defects (d). Examine control cable attach brack
permitted. ets for cracks, corrosion, corrosion,
(e). If installed, examine thruster exten and condition. No defects permitted.
sion attach frame and attach holes
for cracks and corrosion. No defects (e). Examine control cable conduit for
permitted. cracks, separation, and delamination.
None permitted.
(f). If installed, examine thruster exten
sion barrel for cracks, voids, dents, (f). Make sure air circulation area is
holes, scratches, delaminations, and clean and has no unwanted material.
correct installation. No defects If necessary, clean with mild soap
permitted. and water.
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Rotorcraft Maintenance Manual
4
3
1 14
11
19 (16 PL)
13
15
12
19 (16 PL) 2
6
10 8
16
7
18
17
9G53-110A
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(6). Install access panels S2, SL1, and SR1. 1). The measurement must be 20.12 to
20.62 inch (51.10 to 52.37 cm).
(7). (Post-SB900-099) Install access
panels SL8 and SR8. (c). Remove Access Panel S2.
(8). Make sure there is clearance of 0.12 to
0.25 inch (3.0 to 6.4 mm) between (d). Examine forward and aft empennage
access panels and rotating cone. attach frames for damage and correct
installation.
B. Tailboom Bumper Inspection
1). No damage or incorrect installa
(Ref. Figure 204) tion permitted.
(1). Examine bumper for correct installa
(e). If installed, examine forward and aft
tion.
thruster extension frames for dam
(a). No defects permitted. age and correct installation.
(2). Examine bumper (5 or 6) for deforma 1). No damage or incorrect installa
tion: tion permitted.
(a). Bumper (5) Measure outer
(f). Examine rotating cone for damage
dimension of tube in the bend radius
(ref. Section 67-20-00).
at upper end of bumper (5) in two
positions 90 degrees from each other. 1). No damage permitted.
1). If the difference of the two measure
ments is more than 5 percent, the (g). Examine left and right empennage
bumper must be replaced. lower endplates for damage (ref.
Section 53-55-00).
(b). Bumper Assembly (6) Measure
Dimension A from the bottom of the 1). No damage permitted.
tailboom/thruster to the bottom of
the bumper assembly (6). (h). Install Access Panel S2.
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Rotorcraft Maintenance Manual
48
26
27
28 31
29
25
30
50 50
2 23
4 21
6
19
8
17
10
12 15
49 ( 24 PL ) 13
14
16 11
18 9
35 20
7
22
5
36 24 3 TAILBOOM END FITTING
1
43 ( TORQUE SEQUENCE )
33
32 LOOKING FORWARD
38 39
41
47
42
36
37
34 40 44
46 45 47 45 9G53-048A
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(4). Remove screw (26), washer (27) and (9). Remove tailboom (48) from fuselage.
clamps (28 and 29) which secure wire NOTE: Four persons are necessary to remove
harness (30) and coax cable (31) to the tailboom. Two to support the tailboom
airframe. beneath the empennage, one to support the
(5). Disconnect wire harness (30) and coax tailboom at the forward end, and one to re
(31). move the attach hardware and swivel.
(6). Disconnect control cable rod end (32) (a). Remove bolts (1, 3 through 24) and
from directional bellcrank (33). washers (49) securing tailboom (48)
to fuselage.
(a). Remove and discard cotter pin (34).
(b). Remove nuts (2, 23) and washers (49)
(b). Remove bolt (35), washers (36) and from captive bolts (50).
nut (37).
(c). Slowly remove tailboom from captive
(7). Remove rod end (32), tab washer (38), bolts (50) while removing the swivel
jam nut (39) and sleeve (40) from cable and remaining jam nut (47) from the
(41). control cable.
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Rotorcraft Maintenance Manual
(d). Guide wire harness, coax cable and (b). Align captive bolts in fuselage fitting
control cable through their access with bolt holes in tailboom end
holes while removing tailboom. fitting.
(10). Place tailboom in a suitable cradle. (c). Route control cable through access
Prevent damage to the vertical stabiliz hole and install jam nut and swivel
ers and tailboom bumper. on cable before routing cable through
control bracket.
B. Tailboom Installation
(d). Install tailboom onto captive bolts
(Ref. Figure 202) while routing control cable, wire
harness, and coax cable through
their respective holes.
Consumable Materials
(Ref. CSPSPM) (e). Install washers and nuts on captive
Item Nomenclature bolts.
C101 Lubricant, Solid Film (f). Install bolts and washers through
C702 Lockwire tailboom end fitting and torque bolts
C229 Sealant, Conductive
and nuts following the sequence
shown in Figure 202, starting at bolt
number 1. Torque to 60 in-lb (6.78
NOTE: Four persons are necessary to install the Nm). Repeat torque sequence at 120
tailboom Two to support the tailboom be in-lb (13.56 Nm).
neath the empennage, one to support the tail (5). Clean up any sealant squeeze out at
boom at the forward end, and one to install attach bolts.
the attach hardware and swivel.
(6). Test tailboom for Class R electrical
Lubricant, Solid Film (C101) bond (ref. CSP-SPM).
(7). Attach swivel to control bracket with
bolts, washers, and nuts. Torque nuts.
(8). Thread jam nut onto cable forward of
(1). Spray coat threads of captive bolts (50) swivel. Tighten finger tight.
and bolts (1, 3 through 24) with solid
(9). Install sleeve over end of cable.
film lubricant (C101).
(10). Attach rod end with tab washer and
(2). Clean mating bond prepared areas at jam nut to cable. Torque jam nut and
attach bolts (4, 21) on fuselage and safety with lockwire (C702).
tailboom.
(11). Attach rod end to directional bellcrank
Sealant, Conductive (C229) with bolt, washers, and nut. Torque nut
and install cotter pin.
(12). Rig directional flight controls and
torque and safety swivel jam nuts (ref.
Section 67-10-00).
(3). Apply sealant (C229) to tailboom attach
bolts (4, 21). Install tailboom while (13). Connect wire harness and coax cable.
sealant is wet.
(14). Secure harness and coax to airframe
(4). Attach tailboom to fuselage. with clamps, screw, and washer.
(15). Install electrical access cover.
(a). Align tailboom end fitting with
fuselage end fitting, keep their attach (16). Install access panels F7 and F8 (ref.
surfaces parallel. Section 53-30-00).
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
1 (20 PL)
3 (20 PL)
5
6
9 (32 PL)
10 (32 PL)
11
11 8
1 (8 PL)
3 (8 PL)
4 2 (18 PL)
3 (18 PL) 5
WITHOUT THRUSTER EXTENSION
12
7
4
WITH THRUSTER EXTENSION
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Rotorcraft Maintenance Manual
(2). Disconnect electrical connector from (2). Install screws and washers. Torque
tailboom. Remove fairing (4). screws.
(3). Install lower thruster/tailboom fairing.
B. Lower Tailboom/Thruster Fairing
Assembly Installation (4). If tailboom extension is not installed,
make sure there is clearance of 0.12 to
(Ref. Figure 203) 0.25 inch (3.1 to 6.4 mm) between
fairings and rotating cone.
(1). Connect electrical connector to tail
boom. 5. Thruster Extension Fairing Assembly
(SL8, SR8)
(2). Align lower thruster/tailboom fairing
S2 with upper tailboom/thruster fairing A. Thruster Extension Fairing Assembly
SL1 and SR1 FWD and AFT tailboom Removal
frames, and thruster extension fairing
support. (Ref. Figure 203)
(3). Install screws and washers. Torque (1). Remove upper tailboom/thruster
screws. fairing.
(2). Remove screws (9) and washers (10).
(4). If tailboom extension is not installed, Remove fairings SL8 (7) and SR8 (8).
make sure there is clearance of 0.12 to
0.25 inch (3.1 to 6.4 mm) between B. Thruster Extension Fairing Assembly
fairings and rotating cone. Installation
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1
1
3, 4
9G53-085B
1. COTTER PIN 4. TAILBOOM BUMPER ASSEMBLY
2. TAILBUMPER PIN 5. FWD AND AFT TAILBOOM/THRUSTER FRAMES
3. TAILBOOM BUMPER
Figure 204. Tailboom Bumper
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Rotorcraft Maintenance Manual
(2). Remove cotter pins (1) from tailbumper Sealing Compound (C205)
pins (2).
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2
12.15-13.15 IN.
(30.86-33.40 cm)
1
REF. 5
5
REF. 5 REF. 4
3
11.50-12.50 IN.
(29.21-31.75 cm)
VIEW LOOKING
FORWARD
17.69-18.69 IN.
(44.93-47.47 cm)
2X 1.00 IN.
(2.54 cm)
5.25-5.75 IN.
(13.34-14.61 cm)
19X 3.40 IN. ALONG TAILBOOM SURFACE
(8.64 cm)
9.23-9.73 IN.
(23.44-24.71 cm)
ALONG TAILBOOM SURFACE
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7. Vortex Generator
CAUTION
A. Vortex Generator Removal Do not sand into or expose composite fi
bers.
(Ref. Figure 205) Do not use aluminum oxide abrasives on
graphite/epoxy materials.
(1). Apply masking tape around vortex
generator to be removed. (2). Remove surface gloss with scouring pad
(C817) or 180 grit or finer sandpaper.
(2). Remove paint at edge of vortex genera
tor (ref. CSP-SPM, Section 20-40-00, Solvent Cleaner (C429)
Paint Removal Mechanical)
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1 (10 PL) 3
2 (10 PL)
9G53-132
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(5). Remove bolts (1) and washers (2). (5). Install access panels SL8 and SR8.
(6). Install access panels SL1 and SR1.
(6). Remove thruster extension (3) from
tailboom (7). Install Access Panel S2.
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11
1
2 (16 PL)
10
REF. 1
3
2 (16 PL)
9
8 REF. 2
6 REF. 2
5 4
VIEW LOOKING
FORWARD
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9. Tailboom Slot Vane NOTE: This task is typical for upper and lower
slot vane installation.
A. Tailboom Slot Vane Removal
(Ref. Figure 207) Alcohol, Isopropyl (C419)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C419 Alcohol, Isopropyl
(1). Clean surface of slot vane and attach
surfaces with isopropyl alcohol (C419).
NOTE: This task is typical for upper and lower
slot vane removal. Do not use cotton or wool
WARNING cloth with cyanoacrylate
(1). Remove thruster extension.
adhesive. Cotton or wool can cause a
Do not use sharp tools when re strong reaction with cyanoacrylate
CAUTION moving slot vane. adhesive, which can cause a fire.
(2). Remove sealing compound (6) from
edges of slot vane (2). Remove slot Adhesive, Cyanoacrylate (C442)
vane.
Alcohol, Isopropyl (C419)
Consumable Materials
(Ref. CSPSPM) (4). Seal accessible edges of slot vane with
Item Nomenclature sealing compound (C234). Maximum
C419 Alcohol, Isopropyl sealing compound width 0.12 inch (3.0
C234 Sealing Compound mm).
C442 Adhesive, Cyanoacrylate
(5). Install thruster extension.
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10. Tailboom Inlet Ramp NOTE: This task is typical for upper and lower
inlet ramp installation.
A. Tailboom Inlet Ramp Removal
(Ref. Figure 207) Alcohol, Isopropyl (C419)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C419 Alcohol, Isopropyl (1). Wipe inlet ramp and tailboom with
isopropyl alcohol (C419).
NOTE: This task is typical for upper and lower
inlet ramp removal.
NOTE: Align inlet ramp to match contour of
tailboom surface. Maximum incorrect align
(1). Remove tailboom. ment 0.10 inch (2.5 mm).
Do not damage inner surface of Adhesive (C426)
CAUTION tailboom.
(2). Cut inlet ramp (9) or (10) from tailboom
(1).
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Consumable Materials
(1). Wipe aft coaxial cover and tailboom
(Ref. CSPSPM)
with isopropyl alcohol (C419).
Item Nomenclature
C419 Alcohol, Isopropyl Adhesive (C426)
Do not damage inner surface of (2). Mix adhesive (C426), refer to manufac
CAUTION tailboom. turer's instructions.
(2). Cut aft coaxial cover (7) from tailboom NOTE: The thickness of the adhesive must be
(1). 0.002 to 0.040 inch (0.05 to 1.02 mm).
(3). Bond aft coaxial cover to inner surface
CAUTION of tailboom with adhesive (C426).
(4). Allow adhesive (C426) to cure, refer to
Do not sand into or expose composite fi manufacturer's instructions.
bers.
Adhesive, Epoxy (C405)
Do not use aluminum oxide abrasives on
graphite/epoxy materials.
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F. Tailboom Aft Wiring Cover Installation (4). Allow adhesive (C426) to cure, refer to
manufacturer's instructions.
(Ref. Figure 207) Adhesive, Epoxy (C405)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature (5). Mix epoxy adhesive (C405), refer to
C419 Alcohol, Isopropyl manufacturer's instructions.
C426 Adhesive (6). Fill and fair aft wiring cover with epoxy
C405 Adhesive, Epoxy adhesive (C405).
(7). Allow epoxy adhesive (C405) to cure,
refer to manufacturer' instructions.
NOTE: Align aft wiring cover forward end to
match contour of mating airfoils. (8). Install thruster extension.
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Section
535500
Empennage
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
EMPENNAGE
DESCRIPTION AND OPERATION
1. Empennage General between the empennage attach frames. The
panel gives access to the inner side of the spar
(Ref. Figure 1) during the installation of the inboard ribs and
The empennage has the components that empennage attach fittings. The empennage
follow: horizontal stabilizer, elastomeric wire harnesses come out through this panel.
damper, left and right, upper and lower The panel is made from aluminum alloy sheet.
endplates, and fairings. The panel is installed with blind titanium
fasteners.
2. Horizontal Stabilizer
C. Inboard and Outboard Rib
(Ref. Figure 1)
The inboard and outboard ribs are installed
The horizontal stabilizer is a control surface longitudinally against the inner surfaces of the
that does not move. It gives pitch stability to horizontal stabilizer spar. The left and right
the helicopter in forward flight. inboard ribs give support to the empennage
The horizontal stabilizer is attached to two attach frames. The left and right outboard ribs
frames on the aft end of the tailboom. On the give support to the upper and lower journal
right side, the horizontal stabilizer is attached (bearing) housings.
to the frames by bolts that permit the stabiliz The left and right inboard ribs are machined
er to pivot. On the left side, the horizontal from aluminum alloy plate. The ribs are
stabilizer is attached to an elastomeric damper installed with blind titanium fasteners.
that decreases vibration into the empennage
attach frames. The left and right outboard ribs are made of
monolithic laminates with multiple plies of
The horizontal stabilizer has the components graphite/epoxy. The ribs are installed with
that follow: horizontal stabilizer bonded blind titanium fasteners.
assembly, lower structural skin panel, inboard
and outboard ribs, empennage attach fittings D. Empennage Attach Fitting and Intercostal
and intercostals, journal (bearing) housings,
journal bearings, attach brackets, and access The empennage attach fittings and intercos
tals attach the horizontal stabilizer to the
covers.
attach frames on the aft end or the tailboom.
A. Horizontal Stabilizer Bonded Assembly The left and right empennage attach fittings
are installed against the external side of the
The horizontal stabilizer bonded assembly has horizontal stabilizer spar. The forward and aft
the components that follow: spar, trailing edge intercostals are installed between the forward
core, and trailing edge skin. and aft empennage attach frames, and to the
horizontal stabilizer spar. The attach fittings
The spar and trailing edge skin are made as and intercostals are installed with blind
monolithic laminates of graphite/epoxy. The titanium fasteners and/or rivets.
spar has an external surface ply of Astro
strike
aluminum mesh on the lower surface The left and right empennage attach frames
and Astrostrike
and aluminum foil on the are machined from aluminum alloy plate. The
upper surface. The Astrostrike
and alumi forward and aft intercostals are made from
num foil give lightning strike protection and a aluminum alloy sheet.
ground for antenna installations. The trailing
edge core is machined nomex honeycomb. E. Journal Housings and Journal Bearings
B. Lower Structural Skin Panel The journal housings and journal bearings
give support for the left and right endplate
The lower structural skin panel is installed on spar tubes. The left and right upper and lower
the bottom of the horizontal stabilizer spar journal housings are installed at the outboard
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ends of the horizontal stabilizer spar. Each and lower endplates are installed on a spar
journal housing has an integral attach flange tube that is controlled by the Vertical Stabiliz
and is installed with blind titanium fasteners. er Control System (VSCS), for more data about
The journal bearings are installed into the the VSCS system, refer to Section 67-00-00.
journal housings with an interference fit.
The left and right upper and lower endplates
The left and right upper and lower journal
are installed on the spar tubes and are
housings are machined from aluminum alloy
different at each location. The upper endplates
plate. The journal bearings have an aluminum
have different trailing edge tabs. Only the
alloy outer housing and a flanged Karon
The attach brackets are installed to the inner The endplates are installed on the spar tubes
side of the horizontal stabilizer spar and give with internal blocks, bolts with lock device,
support for the Vertical Stabilization Control and special nut assemblies. Each endplate has
System (VSCS) actuators, refer to Section an endplate body, upper and lower blocks,
67-20-00 for more date about the VSCS closeouts, and tip cap.
system. The attach brackets are installed with
blind titanium fasteners.
A. Endplate Body
The attach brackets are made from aluminum
alloy sheet, and standard hardware. The endplate body is a monolithic laminate
with thicker areas at the leading edge and
3. Elastomeric Damper center sections. The skins are applied on a ply
of syntactic foam at the leading edge and are a
(Ref. Figure 1)
monolithic laminate at the aft section. All
The elastomeric damper attaches the horizon sections and skins are cocured as one assem
tal stabilizer to the left side of the attach bly. All plies in the reinforced sections and the
frames on the aft end of the tailboom. The skins are made of graphite/epoxy. Astrostrike
elastomeric damper inboard side is attached to is installed around the leading edge and ends
the flanges of the attach frames. On the at the spar.
outboard side the elastomeric damper is
attached to the left side attach fitting on the B. Endplate Block
horizontal stabilizer. The elastomeric damper
is attached with bolts and nutplates. The endplate blocks are monolithic laminate
fittings made of multiple plies of fiberglass/
The elastomeric damper has an inboard and
epoxy. The blocks are bonded into the endplate
outboard attach plate connected to a elasto
body with an epoxy adhesive.
meric pad. The damper also has a pin on each
end of the inboard attach plate that engages a
related slot on the outboard attach plate. The C. Closeout
pins and slots keep the damper together if the
elastomeric material comes loose from one of The closeouts are monolithic laminate compo
the two plates. And it is an indication of nents made of multiple plies of graphite/epoxy.
elastomeric pad condition. The attach plates The closeouts are bonded into the endplate
are machined from aluminum alloy stock. The bodies with an epoxy adhesive.
pins are heat treated corrosion resistant steel.
D. Tip Cap
4. Endplate
(Ref. Figure 1) The tip caps are monolithic laminate compo
nents made of multiple plies of resin impreg
The upper and lower endplates are movable nated carbon fiber fabric. The tip caps are
control surfaces that help control yaw of the bonded onto the endplate body with an epoxy
helicopter in forward flight. Each side upper adhesive.
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E. Trailing Edge Tab board ends of the horizontal stabilizer and fair
the endplates to the horizontal stabilizer. The
The trailing edge tabs installed on the two position lights are also installed on the
upper and on the left lower endplates, are fairings, refer to Section 96-40-00 for more
monolithic laminate components made of data about the position lights. The fairings are
multiple plies of resin impregnated carbon installed with screws and nutplates on the
fiber fabric. The trailing edge tabs are bonded horizontal stabilizer.
onto the trailing edge of the endplate bodies
with an epoxy adhesive.
5. Fairing The fairings are made with multiple plies of
graphite/epoxy and barrier plies of fiberglass/
The forward and aft fairings close the out epoxy.
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RIGHT SIDE
UPPER ENDPLATE
LEFT SIDE
UPPER ENDPLATE
RIGHT SIDE
RH AFT FAIRING ENDPLATE SPAR TUBE
ELASTOMERIC
DAMPER
LH FORWARD FAIRING
LEFT SIDE
LOWER ENDPLATE
RIGHT SIDE
ATTACH FITTING
FORWARD ATTACH
INTERCOSTAL (AFT NOT IN VIEW)
LOWER SKIN PANEL
LH INBOARD
RIB (RH OPPOSITE)
LEFT SIDE
ATTACH FITTING 9G53-040-1
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LH UPPER JOURNAL
(BEARING) HOUSING
(RH OPPOSITE)
LH OUTBOARD
RIB (RH OPPOSITE)
JOURNAL BEARING (4 PL)
LH LOWER JOURNAL
(BEARING) HOUSING
(RH OPPOSITE)
CLOSEOUT
TIP CAP
ENDPLATE BODY
AFT CLOSEOUT
ENDPLATE
FORWARD BLOCK (2 PL)
CLOSEOUT
LEFT UPPER ENDPLATE SHOWN
(TYPICAL)
9G53-040-2
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EMPENNAGE
REMOVAL / INSTALLATION
1. Empennage (2). Connect electrical connectors P310,
P317, and antenna coaxial connector (if
A. Empennage Removal installed.
(Ref. Figure 401) (3). Align empennage left mount with
(1). Remove tailboom/thruster fairings SL1, damper safety pins and right mount
SR1, and S2 (Ref. Section 53-40-00). trunnions with bushings in right side of
attach frames.
(2). Remove nuts (3) and washers (4) and
disconnect bond jumpers (1). (4). Install bolts, shims, washers, and
plastic washers. Use shims to get a
(3). Remove safety wire from bolts (5) and clearance of 0.00-0.002 in. (0.00-0.051
discard. Remove bolts (5), washers (8), mm) between attach frames and
and washers (18). empennage.
(4). Measure and record thickness of (5). Align empennage and damper bolt
washers (18). holes, install bolts and washers. Install
washers between empennage and
(5). Remove safety wire from jam nuts (9) damper to get 0.00-0.010 in
and discard. Remove jam nuts (9) and (0.00-0.254 mm) compression on
washers (11). damper. Torque bolts and safety with
lockwire (C702).
(6). Record location of shims (12) and
plastic washers (13). (6). Install two jam nuts on each bolt.
(7). Put a support below the empennage. Torque inner jam nuts 20-30 in-lb
(2.26-3.39 Nwm). Torque outer jam
(8). Remove bolts (10), washers (11), shims nuts to standard torque. Safety with
(12), and plastic washers (13). lockwire (C702).
(9). Lift empennage up and to the left away (7). Prepare mating surfaces of empennage
from damper safety pins, do not pull on and bond jumper for electrical bond
wire harnesses below empennage. (Ref. CSP-SPM, Section 20-50-00).
(10). Disconnect electrical connectors P310 (8). Install bond jumpers, washers, and
(15), P317 (16), and antenna coaxial nuts. Torque nuts.
connector (if installed) and remove
empennage. (9). Test bond jumpers for Class L
electrical bond (Ref. CSP-SPM, Section
B. Empennage Installation 20-50-00).
(Ref. Figure 401) Sealant, Fuel Resistant (C216)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire (10). Environmentally seal bond jumpers,
C216 Sealant, Fuel Resistant use sealant (C216) (Ref. CSP-SPM,
Section 20-50-00).
(1). Put empennage above attach frames (11). Install tailboom/thruster fairings SL1,
and put a support below it. SR1, and S2 (Ref. Section 53-40-00).
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17 6
2
16
7
15
7 REF
18 (4 PL)
11 10
LOOKING AFT
1 (2 PL)
11
9 (2 PL)
4 (2 PL)
3 (2 PL)
12
11
13
14 (4 PL)
12 13
8 (4 PL)
5 (4 PL)
FWD MOUNT SHOWN 7
AFT MOUNT OPPOSITE
8 (4 PL)
2
9G53-001B
1. BOND JUMPER 10. BOLT
2. FORWARD ATTACH FRAME 11. WASHER
3. NUT 12. SHIM
4. WASHER 13. PLASTIC WASHER
5. BOLT 14. BOLT
6. EMPENNAGE 15. ELECTRICAL CONNECTOR (P310)
7. ELASTOMERIC DAMPER 16. ELECTRICAL CONNECTOR (P317)
8. WASHER 17. AFT ATTACH FRAME
9. JAM NUT 18. WASHER
Figure 401. Empennage
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(4). Remove screw (5), washers (6), nut (7), (4). Install forward fairing, screws, and
clamp (8), and bond jumper (4). washers. Torque screws.
10 (11 PL )
11 ( 11 PL )
RH SIDE
5
2
6 (2 PL)
8
7
4 9
LH SIDE
3
11 (13 PL)
1
10 (13 PL )
9G53-006
1. FORWARD FAIRING 7. NUT
2. HORIZONTAL STABILIZER 8. CLAMP
3. POSITION LIGHT 9. AFT FAIRING
4. BOND JUMPER 10. SCREW
5. SCREW 11. WASHER
6. WASHER
Figure 402. Stabilizer Outboard Fairing
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4. Upper and Lower Horizontal Endplates (3). Make sure the bolt holes of the end
(Vertical Stabilizer) plates are out-of-round.
B. Endplate Installation
A. Endplate Removal
(Ref. Figure 403)
(Ref. Figure 403)
NOTE: This task is typical for the left and
right, upper and lower, endplate installa
NOTE: This task is typical for the left and tion.
right, upper and lower, endplate removal.
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C216 Sealant, Fuel Resistant
3
C228 Sealant Primer
C226 Sealing and Locking Compound
1 (2 PL) C429 Solvent Cleaner
2 (2 PL)
9G53-055A
1. BOLT
2. WASHER
3. UPPER HORIZONTAL ENDPLATE (VERTICAL (3). Apply sealant primer (C228) to threads
STABILIZER)
4. LOWER HORIZONTAL ENDPLATE (VERTICAL
of bolts (refer to manufacturer instruc
STABILIZER) tions).
5. ENDPLATE SPAR TUBE
Sealing and Locking Compound (C226)
Figure 403. Horizontal Endplates (Vertical
Stabilizer)
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Be careful when you install (5). Make sure lock devices in endplate
WARNING endplates. It is possible to attach bolts (1) are serviceable (ref.
install endplates in an incorrect posi CSP-SPM, Section 20-10-00)
tion. This can cause the helicopter to
be less stable in the directional control (6). Put endplates (3, 4) in their installed
azimuth. positions with washers (2) and bolts (1).
Bolts that attach lower end (a). Torque bolts 9 to 17 in-lb (1.02 to
CAUTION plates are longer than bolts that 1.92 Nm) (ref. CSP-SPM, Section
attach upper endplates. 20-10-00).
(7). Test washers (2) for Class L electrical
NOTE:
bond (ref. CSP-SPM, Section
When you install upper right or upper left 20-50-00).
endplate, make sure tab on trailing edge
of endplate is pointed outboard. Sealant, Fuel Resistant (C216)
When 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 (8). Environmentally seal washers (2) and
ing edge tab. bolt (1) heads to endplates (3, 4) with
Bolts (1) that attach endplates have a sealant (C216) (ref. CSP-SPM, Section
lock device. 20-50-00).
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EMPENNAGE
INSPECTION / TEST
1. Empennage (a). Remove remaining sealant.
A. Empennage Inspection (Area 7) (b). Remove bolt, make sure lock device is
serviceable (ref. CSP-SPM, Section
(Ref. Figure 401) 20-10-00).
(1). Examine skin for cracks, bond separa (c). Install bolt and environmentally seal
tion, and damage. None permitted. (ref. Endplate Installation).
(2). Examine attach fitting for damage and C. Endplate Spar Tube Inspection (Area 7)
loose or missing attach hardware. None (Ref. Section 67-20-00)
permitted.
D. Elastomeric Damper Condition Test
(3). Examine access panels, nutplate (Ref. Figure 602)
fasteners, and position lights for
damage. None permitted. NOTE: Do test at 55 to 91F (12.78 to
32.78C).
(4). Examine access panel gaskets for
condition and correct installation. No (1). Pull left side of the horizontal down as
damage permitted. far as possible. Check for a minimum
clearance of 0.050 inch (1.27 mm)
(5). Examine endplate torque tubes for between upper left tailboom/thruster
axial end play. Maximum permitted extension fairing edge and horizontal.
0.040 inch (1.016 mm).
(2). Remove upper left tailboom/thruster
(Ref. Figure 601) extension fairing (ref. Section
53-40-00).
NOTE: Measure radial play with a dial indica
(3). Examine forward and aft slots and pins
tor. Make measurement no more than 0.125
for an indication they have touched. If
inch (3.18 mm) from end of journal bear
they have touched, replace damper.
ing, perpendicular to the torque tube. Mea
Record new damper serial number in
sure total play, aft to forward or left to right.
the rotorcraft log book.
(6). Examine endplate torque tubes for NOTE: Do not permanently mark, position can
radial play. Maximum permitted, 0.013 change between inspections.
inch (0.33 mm).
(4). With no load applied to horizontal,
B. Endplate Inspection (Area 7) make a mark aligned with top of
forward pin.
(Ref. Figure 403)
(5). Make another mark 0.22 inch (5.59
(1). Examine skin for cracks, bond separa mm) above the first mark.
tion, and damage. None permitted.
(6). Make another mark 0.34 inch (8.64
(2). Examine for a clearance between mm) above the first mark.
endplate and horizontal stabilizer. NOTE: Put protection on top side of horizontal
(3). Examine endplate attach bolts for stabilizer while you do the steps that follow.
condition of environmental seal and (7). In 5 seconds or less, put 50 lb (22.68
correct installatin. No defects per kg) on top of horizontal stabilizer.
mitted.
(a). Put weight at left outboard end,
(4). If attach bolt is loose or environmental against endplate, and 4 to 6 inch
seal is loose or missing, do the proce (101.6 to 152.4 mm) aft of horizontal
dure that follows: leading edge.
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(8). After 60 seconds, look at forward pin. (9). Remove the 50 lb (22.68 kg) and
protection from horizontal.
(a). If top of pin is between the 0.22 inch
(5.6 mm) and 0.34 inch (8.6 mm) (10). Install upper left tailboom/thruster
marks, damper is serviceable. fairing (ref. Section 53-40-00).
9G53-119B
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EMPENNAGE
REPAIRS
1. Journal Bearing Replacement mately 0.20 inch (5.08 mm) with a
hacksaw blade.
(Ref. Figure 801)
(6). Collapse journal bearing.
Consumable Materials (7). Remove journal bearing from journal
(Ref. CSPSPM) housing, push bearing in.
Item Nomenclature
(8). Clean inner side of journal housing
C205 Sealing Compound with acetone (C436).
C436 Acetone
(9). Examine journal housing for damage
and corrosion.
A. Journal Bearing Removal
(a). No damage or corrosion permitted.
(1). Remove upper and lower endplates (ref.
B. Journal Bearing Installation
Endplate Removal).
NOTE: Journal bearing has an interference fit.
(2). Remove outboard fairing (ref. Stabilizer
Outboard Fairing (SR3, SL3) Removal). (1). Put journal bearing in dry ice, or a
freezer, to become cold at -321_F
(3). Remove spar tube (ref. Section (-1965C) minimum.
67-20-00, Spar Tube Removal).
(2). Heat journal housing with a heat gun
(4). Remove sealing compound from journal below 2505F (1215C) maximum.
bearing.
NOTE: Journal bearing flange must be fully
against journal housing.
CAUTION
(3). Push journal bearing into journal
Do not cut through journal bearing into housing with your hand.
journal housing.
(4). Make sure journal bearing is installed
Journal bearing is approximately 0.250 with flange fully against journal
inch (6.35 mm) thick. housing.
If journal housing is damaged, horizontal
stabilizer must be sent to MDHI for re Sealing Compound (C205)
pair.
NOTE:
Cut through upper journal bearing on for
ward side, to make it easier to collapse (5). Apply sealing compound (C205) all
journal bearing. around journal bearing.
Cut through lower journal bearing on aft (6). Install spar tube (ref. Section
side, to make it easier to collapse journal 67-20-00, Spar Tube Installation).
bearing.
(7). Install outboard fairing (ref. Stabilizer
When you cut journal bearing, stop and Outboard Fairing (SR3, SL3) Installa
measure depth of cut frequently. tion).
(5). Carefully cut a groove the full length of (8). Install upper and lower endplates (ref.
journal bearing to a depth of approxi Endplate Installation).
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Rotorcraft Maintenance Manual
JOURNAL BEARING
INSTALLED FULLY AGAINST (3). Clean horizontal stabilizer surface in
JOURNAL HOUSING
area where sealing compound gasket
CUT LOWER JOURNAL will be installed with solvent cleaner
BEARING ON INNER AFT SIDE (C429).
(4). Clean access cover inner and outer
surface with solvent cleaner (C429).
(5). Put spacers on access door where
JOURNAL HOUSING
sealing compound gasket will touch and
keep in place with tape.
Release Agent (C417)
Consumable Materials
(9). Dry release agent (C417) in air for 30
(Ref. CSPSPM)
minutes minimum.
Item Nomenclature Sealing Compound (C234)
C429 Solvent Cleaner
C417 Release Agent
C234 Sealing Compound
(10). Apply a thin layer of sealing compound
NOTE: This repair is typical for all horizontal (C234) adhesion promoter to surface of
stabilizer access panel sealing compound horizontal stabilizer where sealing
gaskets formed at installation. compound gasket will be installed.
(11). Dry sealing compound (C234) adhesion
(1). Remove loose sealing compound from
promoter in air for 30 minutes mini
horizontal stabilizer.
mum.
(2). If necessary, make spacers to keep the (12). Apply sealing compound (C234) to
correct gap between the horizontal surface of horizontal stabilizer.
stabilizer and access panel as follows:
NOTE: Apply sufficient sealing compound to
(a). Make spacers from aluminum sheet more than fill gap between access panel and
or plastic sheet. horizontal stabilizer.
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
Chapter
MAIN ROTOR
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
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ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
Page iii
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ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
Page v
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ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
Page vii
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ROTORCRAFT MAINTENANCE MANUAL
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ROTORCRAFT MAINTENANCE MANUAL
Page ix
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ROTORCRAFT MAINTENANCE MANUAL
Page x
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
620000
Main Rotor System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
4. Main Rotor Hub Assembly the upper hub half and the non-rotating
components of the main rotor installation.
The main rotor hub assembly mounts the main
rotor system to the static support mast and is F. Hub Liner
driven by the main rotor drive shaft.
The hub liner is a stainless steel tube in the
The main rotor hub assembly consists of: center of the upper hub half that fits snugly
over the stationary support mast. During main
A. Upper and Lower Hub Halves rotor hub installation a hub retaining nut is
threaded to the top of the stationary support
The rotor hub halves are machined, hardened mast. The retaining nut presses the upper
aluminum alloy. Rotor hub halves mount and bearing inner race against the bearing
transmit drive force to the rest of the main rotor pre-load shim, which presses the hub liner
system rotating components. Moisture contami against a machined shoulder on the stationary
nation and corrosion are prevented by neo mast. The lower bearing inner race is an
prene and stainless steel spring seals. interference fit on the hub liner. The hub liner
B. Flexbeam also provides the inner contact surface for the
lower and center upper hub seals.
The flexbeam is attached between the rotor
blade and the main rotor hub. Flexing of the G. Drive Ring
beam allows rotor blades to move about the
The drive ring is a machined, hardened, and
feathering, flapping, and lead/lag axes without
anodized aluminum alloy two piece component.
the need for hinges. Flexbeams transfer driving
The drive ring is attached to the upper hub half
force from the hub to the rotor blades. The
by clamp up and to the lower hub half through
flexbeams are a composite structure made of
the striker plate brackets. The drive ring
laminated fiberglass. Flexbeam attachment
provides drive through the scissors to the
points are hardened stainless steel bushings
rotating swashplate.
embedded in the laminate. An elastomeric
flexbeam bumper is bonded around the H. Grounding Brushes and Straps
flexbeam to reduce flexbeam deflections during
rotor starts and stops. The grounding brushes and straps are the
grounding path from the pitchcases to the
C. Hub Plate stationary support mast. The brushes are
A hardened steel hub plate is sandwiched located on the drive ring at the upper scissors
between the hub halves to absorb centrifugal attachment point. The carbon brushes ground
loads. The hub plate also separates the the rotating hub assembly to the stationary
lead/lag legs of the flexbeams into the upper support mast through a groove at the bottom of
and lower hub halves. the hub liner. The straps (bonding jumpers)
provide positive bonding between the rotor
D. Fretting Buffer blade, pitchcases, and hub assembly.
The fretting buffer has been removed from the I. Droop Stop
helicopter. It is not necessary and made it
more difficult to get a good seal around the The droop stop limits the rotor blade droop
drive plate to main rotor hub joint. angle at low rotor speed. As the rotor blades
loose lift with reduced rotor speed, the droop
E. Tapered Roller Bearing Set stop roller contacts the striker plate on the main
rotor hub. The droop stop roller is mounted to
The tapered roller bearing sets transfer flight the pitchcase by the axle and lower damper cap.
and static loads between the rotating and The striker plate is fixed to the rotor hub drive
non-rotating sections of the main rotor hub. The ring by the droop stop striker support. The
upper bearing carries most of the load, and the droop stop striker plate and roller are made of
lower bearing acts as a follower, centering the stainless steel. The inner diameter of the droop
hub on the static mast of the helicopter. The stop roller is coated with molybdenum disulfide
tapered roller bearing sets are located between and needs no lubrication.
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Rotorcraft Maintenance Manual
5. Data Plates data. The data plates provide part number and
serial number identification for the main rotor
Data plates shall be bonded to the top of the hub assembly as a complete unit and the
rotor hub assembly in plain sight. Areas that upper hub assembly specifically. Exceptions
require specific processes, such as eddy current are the upper and lower bearings which have
inspections and web surfaces, should be avoided electrolytic etch marking.
(Ref. Main Rotor Upper Hub Inspection).
A. Data Plate Marking C. Overhaul Data Plates
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Rotorcraft Maintenance Manual
ROTOR BLADE
ROTOR BLADE
RETENTION BOLTS
FLEXBEAM
BUMPER
PITCHCASE
UPPER
DRIVE DAMPER CAP DAMPER
GROUNDING
PLATE
STRAPS
FLEXBEAM
UPPER
CENTERING
HUB
BEARING
PITCH INBOARD
CHANGE ABRASION STRIP
HORN
LOWER
HUB
DRIVE
RING OUTBOARD
ABRASION STRIP
SCISSORS
TRIM TAB
ASSEMBLY
9G62-001A
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Rotorcraft Maintenance Manual
6. Upper Flight Controls Subsystem longitudinal and lateral flight control. The
stationary swashplate also transmits the
(Ref. Figure 2) control inputs to the rotating swashplate
The upper flight controls subsystem uniformly through the swashplate bearing.
transmits cyclic and collective inputs to the
C. Rotating Swashplate
main rotor blades. The outcome is lift about
the vertical, lateral and longitudinal control The rotating swashplate is located directly
axes of the helicopter. above and assembled to the stationary
The upper flight control subsystem consists of: swashplate by the swashplate bearing. The
rotating swashplate transfers control inputs to
A. Mixer Assembly the pitch links. The rotating swashplate is a
five star figure and is made of forged 7050
The mixer assembly transmits main rotor aluminum alloy.
hydraulic actuator inputs to the stationary
swashplate. The mixer assembly is mounted to D. Scissors Assembly
and pivots on two rod end bearings attached to
the static mast base. The scissors assembly transfers rotational
drive from the main rotor hub to the rotating
The mixer assembly utilizes three horizontal swashplate. The scissors assembly also
beams which are constructed of forged 7050 maintains the alignment of the rotating
aluminum alloy. The mixer also includes; an swashplate and main rotor positioning the
adjustable collective link, a non-adjustable arms of the swashplate directly below the
collective link, a longitudinal link, and a pitch change horns. The scissors are made of
lateral/anti-rotation link. anodized, machined, cast aluminum.
B. Stationary Swashplate
E. Pitch Links
The stationary swashplate is located directly
above the mixer and below the rotating The pitch links link the pitchcases to the
swashplate. The stationary swashplate is rotating swashplate and are constructed of
constructed of forged 7050 aluminum alloy. titanium. The pitch links twist the flexbeams
through the pitchcases which changes the
The stationary swashplate receives collective rotor blade angle in reference to the rotating
and cyclic control inputs and coordinates swashplate.
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Rotorcraft Maintenance Manual
SCISSORS DRIVE
LINK ASSEMBLY
PITCH LINK
ASSEMBLY
NON-ADJUSTABLE COLLECTIVE
LINK ASSEMBLY
LONGITUDINAL
LINK ASSEMBLY
ADJUSTABLE COLLECTIVE
LINK ASSEMBLY
HYDRAULIC ACTUATOR
MOUNTING BRACKET
SUPPORT ROD ATTACHMENT
9G62016A
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Rotorcraft Maintenance Manual
Vertical or lateral vibration. Main rotor components Install main rotor components 620000
reinstalled in other than in original position, or do the 180000
original position. track and balance of main rotor.
Main rotor hub or hub Inspect main rotor hub 622000
components damaged. assembly.
Crossover rotor instability Cyclic control not centered Do the flexbeam inspection. 622000
High vertical, roll or pitch at low rotor speed.
vibration felt by the pilot Flexbeam damaged. Do the flexbeam inspection. 622000
which occurs between 35%
to 40% Nr on startup and
shutdown.
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Section
621000
Main Rotor Blade
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
4
6 (NOTE)
7 7
5 5
2
8 14
8
3 13
EARLY CONFIGURATION 10
9
11
11
15
12
1
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Rotorcraft Maintenance Manual
NOTE: Make small movements with the main Support the main rotor
rotor blade as you remove the blade reten WARNING blade during installation.
tion bolts. Make sure the bolts freely come Have one person on a maintenance
out of the blades. stand.
Do not use or spring clip (13) as
CAUTION a lever to remove blade reten Use care when installing the
tion bolts. This is an incorrect use of the CAUTION main rotor blade.
spring clip. The spring clip can loose shape
and tension if bent too much. Move the tab
Damage can easily occur to the thin plies
of the spring clip until there is sufficient
space to disengage from the nut. Use a sock in the forward area of the root fitting (ref.
et to hold and loosen nut (16), as necessary. Figure 401).
(a). Disengage spring clip (13). Do not move the rotor blade tip up more
than 4.0 ft. (1.22 m) when the rotor is not
Leave cam handles (14) and in operation. And do not move the
CAUTION spring clips (13) on removed flexbeam up more than 1.0 in. (2.54 cm)
blade retention bolts (11) in the OPEN posi at the blade attach point. Damage to the
tion. Bushings can become damaged when flexbeam can occur..
the bolt is not installed and cam handle is
closed.
Limit the pitchcase movement with pad
(b). Open cam handles (14). ding (cloth, foam, packing material, etc.)
around the flexbeam with the main rotor
Do not tap the bottom of the blade removed. This prevents damage to
CAUTION blade retention bolts. This will the flexbeam and pitchcase.
expand the bushings of the bolt and lock the
bolt in the blade.
NOTE: Install the main rotor blades and blade
(c). Lightly tap the top of blade retention
retention bolts at their original locations.
bolts (11) with a mallet to loosen the
bushings.
(d). Remove blade retention bolts (11) NOTE: Make sure the trim tab pitch is set at
and O-rings (15). zero degrees (ref. 18-00-00) if you install a
new blade or do not reinstall a blade in its
(8). Carefully remove main rotor blade (2) original location.
from pitchcase (9).
B. Main Rotor Blade Installation
(1). Align pitchcase (9) for the blade
(Ref. Figure 402) installation with the maintenance
stand.
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature (2). Remove padding from pitchcase (9).
C216 Sealant, Fuel Resistant
C702 Lockwire (3). Position the blade in pitchcase (9) with
flexbeam (10) between the top and
Special Tools bottom blade root bushings.
(Ref. CSPSPM)
Item Nomenclature
NA Push/Pull Spring Scale (50 to 150 lbf / (4). Align the holes in the blade root of
22.68 to 68.04 kgf) main rotor blade (2), pitchcase (9), and
flexbeam (10).
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Rotorcraft Maintenance Manual
4
3
0.005 INCH.
(0.127 MM)
9 (5 PL)
0.005 INCH.
(0.127 MM) 1 (10 PL)
6
SECTION A-A (TYPICAL)
7 (5 PL)
9G62096
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Rotorcraft Maintenance Manual
(Ref. Figure 403) (d). Install bolt (1) until thrust washer (3)
Blade Retention Bolts. is 0.010 to 0.040 inch (0.25 to 1.02
WARNING The expansion bushings of mm) from the top surface of
the blade retention bolts can lose pitchcase (7).
tension after installation. This can
(e). Make sure lock ring (5) is fully
cause a loss of the initial torque. Do the
outside of the bottom surface of
Special Inspection retorque
pitchcase (7).
procedures until there is no loss of
torque (ref. Section 05-20-10, Table 203, (f). With a 5/16-inch hex wrench, push
and Section 62-10-00, Inspection/ in and hold plunger (2) at top of the
Check, Torque Check of the (-101) bolt until hex nut (4) moves freely.
Blade Retention Bolts). Failure to do
this can cause the loss of a main rotor (g). Torque hex nut (4) to 800 in-lb
blade from the helicopter during (90.39 Nm).
operation.
(h). Remove the hex wrench.
Do not apply lubricant or
WARNING preservative on the blade
(i). Increase torque until plunger (2)
retention bolts. moves up.
Do not install -103 or -105 bolts
CAUTION with -101 bolts. 1). Do not torque more than 1100
in-lb (124.28 Nm).
(5). BLADE RETENTION BOLT (PN
900R3100001-101) - Install blade 2). If plunger (2) does not move up
retention bolt (1). before 1100 in-lb (124.28 Nm) of
torque, loosen hex nut (4) and
(a). Push in and hold plunger (2) with a repeat the torque sequence.
5/16-inch hex wrench.
(j). Make sure lock ring (5) expands
(b). Tighten hex nut (4) to remove all outside of the bottom surface of
play in the expandable bushings. pitchcase (7) after plunger (2) is in the
(c). Remove the hex wrench. UP position.
Do not align the slots of the (k). Check for a minimum gap of 0.005
CAUTION expandable bushings of blade inch (0.13 mm) between thrust
retention bolt (1). Make sure the slots are washer (3) and the top surface of
random and that adjacent slots are not pitchcase (7).
aligned.
(l). Check for a minimum gap of 0.005
NOTE: Make small movements with the main inch (0.13 mm) between lock ring
rotor blade as you install the blade (5) and the bottom surface of
retention bolts. Make sure the bolts freely pitchcase (7).
go into the blades. The bolts can be installed
by hand with minimum force. (m). Make sure pawl (6) is extended.
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Rotorcraft Maintenance Manual
2
8 3
10
FORCE F
6
4
BOTTOM SURFACE
5 1 (10 PL)
7 (10 PL)
SLOT
A
8 (5 PL) 11 (5 PL)
9 (5 PL)
9G62097
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
NOTE: Listen for a click or snap when the (j). Make sure lock ring (6) is expanded
spring clip moves over the adjustment nut. outside the bottom surface of
pitchcase (9).
(k). Make sure the hex hole of spring clip
(i). Make sure cam handle (3) is centered (4) engages and is centered over
in the slot of retainer (8). adjustment nut (5).
2
3
4
9 8
11
1 (10 PL)
6 5 8 (10 PL)
BOTTOM SURFACE
SLOT
A A
SECTION A-A (TYPICAL)
9 (5 PL)
12 (5 PL)
10 (5 PL)
9g62-098
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Rotorcraft Maintenance Manual
(l). Make sure the gap between thrust Do not install -101 bolts with
washer (2) and retainer (8) is not CAUTION -103 or -105 bolts. If -103 and
more than 0.100 inch (2.54 mm). -105 bolts are installed on the same rotor
head, equally space the bolts around the
rotor head to prevent a rotor imbalance.
(m). Record the final installation force of
each blade retention bolt (1) in (7). BLADE RETENTION BOLT (PN
Rotorcraft Log Book for future special 900R3100001-105) - Install blade
inspections (ref. Section 05-20-10, retention bolt (1).
Table 203, Special Inspection - After
Component Installation, Main Rotor: (a). Install O-ring (8) under thrust
Blade Retention Bolt Torque Check) washer (4).
and force checks (ref. Section
62-10-00, Inspection/Check, Force (b). Put retainer (9) on top of pitchcase
Check of the (-103) Blade Retention (10).
Bolts).
(c). Align the holes for the blade
retention bolts of retainer (9),
(Ref. Figure 405) pitchcase (10), flexbeam (11), and
main rotor blade (12).
Blade Retention Bolts.
WARNING The expansion bushings of
Do not align the slots of the
the blade retention bolts can lose CAUTION expandable bushings of blade
tension after installation. This can retention bolt (1). Make sure the slots are
cause a loss of the initial torque. Do the random and that adjacent slots are not
Special Inspection retorque aligned.
procedures (ref. Section 05-20-10,
Table 203, and Section 62-10-00, NOTE: Make small movements with the main
Inspection/Check, Torque Check of the rotor blade as you install the blade retention
(-105) Blade Retention Bolts). Failure bolts. Make sure the bolts freely go into the
to do this can cause the loss of a main blades. The bolts can be installed by hand
rotor blade from the helicopter during with minimum force.
operation.
(d). Install blade retention bolt (1) in
Do not apply lubricant or retainer (9), pitchcase (10), flexbeam
WARNING preservative on blade (11), and main rotor blade (12).
retention bolts.
1). Make sure spring clip (5) is aligned
in the center of the slot of retainer
Use care when handling the (9).
CAUTION main rotor blade.
2). Make sure lock ring (7) is fully
Do not move the rotor blade tip up more outside the bottom surface of
than 4.0 ft. (1.22 m) when the rotor is not pitchcase (10).
in operation. And do not move the
flexbeam up more than 1.0 in. (2.54 cm) (e). Turn torque nut (2) with a torque
at the blade attach point. Damage to the wrench to make sure that the torque
flexbeam can occur.. necessary to turn cam handle (3)
before the bushings expand is not
Limit the pitchcase movement with more than 21 in-lb (2.37 Nm).
padding (cloth, foam, packing material,
etc.) around the flexbeam with the main 1). If the required torque is more than
rotor blade removed. This prevents the specified limit, replace blade
damage to the flexbeam and pitchcase. retention bolt (1).
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Keep the bolt holes of retainer (m). Record the final installation torque of
CAUTION (9), pitchcase (10), flexbeam each blade retention bolt (1) in the
(11), and main rotor blade (12) in alignment Rotorcraft Log Book for future special
as you torque the nut. A misalignment inspections (ref. Section 05-20-10,
during installation can damage a blade Table 203, Special Inspection - After
retention bolt. Component Installation, Main Rotor:
Blade Retention Bolt Torque Check)
and torque checks (ref. Section
NOTE: Torque is when spring clip (5) has 62-10-00, Inspection/Check, Torque
pushed across the bolt end, just before full Check of the (-105) Blade Retention
engagement with adjustment nut (6). Bolts).
(Ref. Figure 402)
(f). Torque torque nut (2) 350 to 450
Make sure the electrical bond
in-lb (39.54 to 50.84 Nm) as you CAUTION between the main rotor blades
keep the bolt holes aligned until cam
handle (3) closes. and pitchcases is correctly done. Damage to
the metal components of the main rotor
mast can occur.
(g). If necessary, turn adjustment nut (6), (8). Prepare bonding jumpers (3) and main
in the tightening direction only, to rotor blade (2) for electrical bonding
align the nut with the hex hole of (ref. CSP-SPM, Section 20-50-00,
spring clip (5). Electrical Bonding).
(9). Attach bonding jumpers (3) to main
(h). Move and center spring clip (5) over rotor blade (2) with bolts (4).
adjustment nut (6).
(a). Torque bolts (4) 15 to 20 in-lb (1.69
to 2.26 Nm).
NOTE: Listen for a click or snap when the
spring clip moves over the adjustment nut. (10). Test bonding jumper (3) attachments of
main rotor blade (2) and pitchcase (9)
for electrical bond, Class H (ref.
(i). Make sure spring clip (5) is centered CSP-SPM, Section 20-50-00,
in the slot of retainer (9). Electrical Bonding).
(11). Safety bolts (4) with lockwire (C702).
(j). Make sure lock ring (7) expanded Sealant, Fuel Resistant (C216)
outside the bottom surface of
pitchcase (10).
(k). Make sure the hex hole of spring clip (12). Seal the heads of bolts (4) with sealant
(5) engages and is centered on (C216) (ref. CSP-SPM).
adjustment nut (6).
(13). Do a main rotor track and balance as
necessary (ref. Section 18-00-00,
(l). Make sure the gap between thrust Vibration And Noise Analysis,
washer (4) and retainer (9) is not Maintenance Practices, Main Rotor
more than 0.100 inch (2.54 mm). Track And Balance).
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(1). Examine blade (1) for scratches, nicks, NOTE: For areas that cannot be blended out,
gouges, depressions and cracks. tell the MDHI Field Service Department to
get more information.
(a). Repairable damage is limited to
outboard trailing corner, maximum (2). Examine abrasion strips (2, 3) for
after removal of damage 0.50 inch corrosion.
(12.7 mm) radius from outboard
trailing corner. (a). If there is corrosion, remove it (ref.
CSP-SPM, Section 20-40-00,
(2). Do the inspection of main rotor blade Corrosion Removal).
(1) abrasion strip (ref. Procedure 1.B.).
(3). Do the inspection of main rotor blade (3). Inspect abrasion strips (2, 3) for pits.
(1) trim tab (ref. Procedure 1.C.).
(a). If the depth of a pit is more than
(4). Examine the root fairing for cracks, 0.030 inch (0.76 mm), tell the
depressions, or holes. MDHI Field Service Department.
(a). The maximum allowable repairable (b). If the depth is less than the specified
damage: limit, do a blend repair of the pits
Cracks cannot be more than 6.0 inch (ref. CSP-SPM, Section 20-40-00,
Mechanical Defects).
(15.24 cm) in length.
Depressions or holes with combined (4). Examine main rotor blade (1) for voids
areas no more than 0.30 inch2 (1.94 open to edge between inboard (2) and
cm2) (ref. Root Fairing Repair, Main outboard (3) abrasion strips.
Rotor Blade).
(a). If there is a void, tell the MDHI Field
(5). Examine blade (1) for loose retention Service Department for more infor
bolts (ref. Procedure 2.A., Procedure mation.
2.B., or Procedure 2.C., as applicable).
(5). Examine outboard abrasion strip (3)
B. Main Rotor Blade Abrasion Strip adjacent to weight pocket for cracks.
Inspection
(a). No cracks are permitted.
Consumable Materials
(Ref. CSPSPM) (b). If there are cracks, tell the MDHI
Item Nomenclature Field Service Department to get more
information.
C216 Sealant, Fuel Resistant
(6). Examine area where outboard abrasion
Do not do a fluorescent pene strip (3) is overlapped by the edge of
CAUTION trant inspection (FPI). Once the inboard abrasion (2) strip for cracks.
surface of the blade is contaminated, that
area cannot be bonded. (a). Repair cracks that are within the
limits (ref. Repair, Outboard Abra
(1). Examine abrasion strips (2, 3) for sion Strip Crack Repair, Main Rotor
erosion. Blade).
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Sta. 203
WEIGHT POCKET
AREAS WHERE CRACK IN THE
OUTBOARD ABRASION STRIP FILLER MATERIAL MIGHT OCCUR.
BLADE
TAB
SEGMENT
9G62085
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Rotorcraft Maintenance Manual
2
0.50 INCH
(12.7 MM)
NOTE 1
NOTE 2
LE LE
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Rotorcraft Maintenance Manual
(b). Anomalies must be less than or equal (1). Examine the trim tabs (5) for cracks.
to 2.0 inch2 (12.9 cm2) with a (a). If there are cracks, tell the MDHI
maximum chordwise width of 0.50 Field Service Department to get more
inch (12.7 mm). information and instruction.
(c). Accumulated anomalies from Sta. 70 NOTE:
to Sta. 123 must be less than or Some indications can appear on the sur
equal to 8.0 inch2 (51.6 cm2) of total face parallel to the chord-wise direction.
area. These are usually the bondlines between
adjacent segments of the tab, not cracks.
(d). Accumulated anomalies from Sta.
123 to Sta. 171 and Sta. 171 to Sta. Cracks in the filler material or paint
188 must be less than or equal to 5.0 around trim tab (5) do not represent
inch 2 (32.26 cm2) of total area. structural damage and are permitted.
(2). Do a coin tap inspection for anomalies
(e). Accumulated anomalies from Sta. of trim tab (5) to blade skin bond (ref.
188 to Sta. 203 must be less than or CSP-SPM, Section 20-90-00, Coin Tap
equal to 1.75 inch2 (11.29 cm2) of Inspection).
total area.
NOTE: Tell the MDHI Field Service Depart
(f). Acceptable anomalies no closer than ment if anomalies are more than the speci
1.00 inch (25.4 mm) to the spanwise fied limits that follow.
ends and no closer than 0.15 inch
(3.8 mm) to aft edges of abrasion (a). Anomalies less than or equal to 0.30
strips (2, 3). inch (7.6 mm) aft to trailing edge of
blade are acceptable for length of
trim tab (5).
(9). Inspect inboard tip of inboard abrasion
strip (2) for disbond. If disbond is (b). Anomalies less than or equal to 0.50
discovered, do these steps: inch (12.7 mm) chordwise is per
mitted.
(a). Examine blade (1) after every flight.
(c). Accumulated anomalies less than or
(b). Record length of disbond, number of equal to 0.25 inch2 (1.61 cm2) of
flights, and flight hours from discov total area per segment are permitted.
ery until disbond limit is reached. (3). Do a coin tap inspection for anomalies
over trim tab (5) aft of the blade
(c). Once disbond limit is reached, trailing edge (ref. CSP-SPM, Section
contact field service representative 20-90-00, Coin Tap Inspection).
for further instruction.
NOTE: Tell the MDHI Field Service Depart
C. Main Rotor Blade Trim Tab Inspection ment if anomalies are more than the speci
fied limits that follow.
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
1 (NOTE)
4
3
0.005 INCH
(0.127 MM)
8
0.005 INCH.
(0.127 MM)
6
NOTE: THERE IS A SPECIAL TORQUE PROCEDURE FOR BLADE RETENTION BOLT.
MAKE SURE YOU FOLLOW THE PROCEDURE.
9G62093
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1 (NOTE)
11
7
GAP 2
8
10
FORCE F
6
5
4
NOTE: THERE IS A SPECIAL TORQUE PROCEDURE FOR BLADE RETENTION BOLT.
MAKE SURE YOU FOLLOW THE PROCEDURE. BOTTOM SURFACE
9G62
Figure 603. Torque Check for the (103) Blade Retention Bolts
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Rotorcraft Maintenance Manual
B. Force Check of the Blade Retention Bolts NOTE: If necessary, make small movements of
(PN 900R3100001103) the main rotor blade to help loosen the
bushings.
(Ref. Figure 603)
(5). Do a check of Force F with a push/pull
NOTE: Blade retention bolt (1) can be adjusted spring scale.
by turning hex nut (5) located at the end of
bolt. NOTE: Force F is when spring clip (4) has
pushed across the bolt end, just before hex
(1). Release the collective friction to remove nut (5) is engaged.
the preload of the flexbeams (ref. (a). Force F must be 65 to 115 lbf (29.48
Section 67-10-00, Rotor Flight to 52.16 kgf).
Controls Removal/Installation).
1). The force cannot be less than 90
(a). Apply electrical power with ground percent of the recorded final
power unit (T2002) (ref. installation force or 65 lbf (29.48
CSP-900RMM-3, Electrical Power kgf) which ever is greater. (ref.
Maintenance Practices, Helicopter Section 62-10-00, Main Rotor
Electrical Power). Blade Removal/Installation).
(b). Push the collective friction release (b). If Force F is equal to or more than 90
switch forward to release the percent of the recorded final
collective friction. installation force and greater than 65
lbf (29.48 kgf) go to Step (6).
(c). Raise the pilot collective stick
sufficiently to unload the collective (c). If Force F is less than 90 percent of
controls (approximately 15 to 30 the recorded final installation force or
percent indication on the IIDS). less than 65 lbf (29.48 kgf) which
ever is greater retorque blade
(d). Remove electrical power (ref. retention bolt (ref. Section 62-10-00,
CSP-900RMM-3, Electrical Power Main Rotor Blade Removal/-
Maintenance Practices, Helicopter Installation).
Electrical Power).
(d). If necessary, turn hex nut (5), in the
(2). Support main rotor blade (11) in line tightening direction only, to align and
with the angle of pitchcase (9). center the hex nut (5) with the
hex-shaped hole of spring clip (4)
Do not use the spring clip as a without a recheck of Force F.
CAUTION lever to remove blade retention (6). Move and center spring clip (4) over hex
bolts. The spring clip can loose shape and nut (5).
tension if bent too much. This is an incorrect
use of the spring clip. Move the tab of the NOTE: Listen for a click or snap when the
spring clip until there is sufficient space to spring clip moves over the hex nut.
disengage from the hex nut. Use a socket to
hold and loosen hex nut, as necessary. (7). Make sure lock ring (6) is expanded
outside the bottom surface of pitchcase
(3). Disengage spring clip (4) from hex nut (9).
(5). (8). Make sure the hex-shaped hole of
Do not tap the bottom of the spring clip (4) is centered over hex nut
CAUTION blade retention bolts. This will (5).
expand the bushings of the bolt and lock the (9). Make sure cam handle (3) is centered in
bolt in position. the slot of retainer (8).
(4). Lightly tap the top of blade retention (10). Make sure the gap between thrust
bolt (1) with a mallet to loosen the washer (2) and retainer (8) is not more
bushings. than 0.100 inch (2.54 mm).
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(11). Record the locations of blade retention (12). Repeat this procedure for the remaining
bolts (1) that lost force in the Rotorcraft 9 blade retention bolts (1).
Log Book.
1 (NOTE)
12
2 3
4
10 9 8
11
7
NOTE: THERE IS A SPECIAL TORQUE PROCEDURE FOR BLADE RETENTION BOLT. 6
MAKE SURE YOU FOLLOW THE PROCEDURE. 5
BOTTOM SURFACE
9G62095
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C. Torque Check of the Blade Retention NOTE: If necessary, make small movements of
Bolts (PN 900R3100001105) the main rotor blade to help loosen the
bushings.
(Ref. Figure 604)
(5). Do a torque check on torque nut (2).
NOTE: Blade retention bolt (1) can be adjusted
by turning adjustment nut (6) located at the (a). The torque must be 350 to 450 in-lb
end of bolt. (39.54 to 50.84 Nm).
1). The loss of torque cannot be more
(1). Release the collective friction to remove than 10 percent of the recorded
the preload of the flexbeams (ref. final installation torque (ref.
67-10-00, Rotor Flight Controls 62-10-00, Main Rotor Blade
Removal/Installation). Removal/Installation).
(a). Apply electrical power with ground 2). The torque cannot be less than 350
power unit (T2002) (ref. in-lb (39.54 Nm).
CSP-900RMM-3, Electrical Power
Maintenance Practices, Helicopter (b). If the torque is equal to or more than
Electrical Power). 90 percent of the recorded final
installation torque and greater than
(b). Push the collective friction release 350 in-lb (39.54 Nm) go to Step (6).
switch forward to release the
collective friction. (c). If the torque is less than 90 percent
of the recorded final installation
(c). Raise the pilot collective stick torque or less than 350 in-lb (39.54
sufficiently to unload the collective Nm) retorque blade retention bolt
controls (approximately 15 to 30 (ref. 62-10-00, Main Rotor Blade
percent indication on the IIDS). Removal/Installation).
(d). Remove electrical power (ref. (d). If necessary, turn adjustment nut (6),
CSP-900RMM-3, Electrical Power in the tightening direction only, to
Maintenance Practices, Helicopter align the nut with the hex-shaped
Electrical Power). hole of spring clip (5) without a
recheck of the torque.
(2). Support main rotor blade (12) in line
(6). Move and center spring clip (5) over
with the angle of pitchcase (10).
adjustment nut (6).
Do not use the spring clip as a NOTE: Listen for a click or snap when the
CAUTION lever to remove blade retention spring clip moves over the adjustment nut.
bolts. The spring clip can loose shape and
tension if bent too much. This is an incorrect (7). Make sure lock ring (7) expanded
use of the spring clip. Move the tab of the outside the bottom surface of pitchcase
spring clip until there is sufficient space to (10).
disengage from the hex nut. Use a socket to
hold and loosen hex nut, as necessary. (8). Make sure the hex-shaped hole in
spring clip (5) is centered over
(3). Disengage spring clip (4) from adjustment nut (6).
adjustment nut (6). (9). Make sure spring clip (5) is centered in
Do not tap the bottom of the the slot of retainer (9).
CAUTION blade retention bolts. This will (10). Make sure the gap between thrust
expand the bushings of the bolt and lock the washer (4) and retainer (9) is 0.100
bolt in position. inch (2.54 mm).
(4). Lightly tap the top of blade retention (11). Record the locations of blade retention
bolt (1) with a mallet to loosen the bolts (1) that lost torque in the Rotor
bushings. craft Log Book.
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Rotorcraft Maintenance Manual
(12). Repeat this procedure for the remaining 1). Visually examine the assembled
9 blade retention bolts (1). bolt for damage.
D. Gap Check of the Blade Retention Bolts 2). Re-install an undamaged bolt (ref.
NOTE: Do this check for the -103 and -105 Section 62-10-00, Main Rotor
blade retention bolts only. Blade Removal/Installation).
(Ref. Figure 603 and Figure 604) (2). Measure the gap at two locations, 180
degrees apart, with a feeler gage.
(1). Visually examine blade retention bolts
for a gap between washer and retainer.
(a). The gap is more than 0.100 inch
(a). Make sure O-rings are installed. (2.54 mm) remove blade retention
bolt (ref. Section 62-10-00, Main
1). Install missing O-rings (ref. Rotor Blade Removal/Installation).
Section 62-10-00, Main Rotor
Blade Removal/Installation). 1). Visually examine the assembled
(b). If there is a gap, go to Step (2). bolt for damage.
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Rotorcraft Maintenance Manual
(a). Wipe with a clean dry cloth. (a). Vacuum to remove sanding residue.
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Rotorcraft Maintenance Manual
B. Main Rotor Blade Root Fairing Doubler (5). Brush a thin coat of epoxy resin, the size
Installation of the doubler ply, onto the nonporous
release film on the opposite side from the
(Ref. Figure 801) dimensional mark of the plies.
Consumable Materials (6). Place the doubler plies onto the epoxy
(Ref. CSPSPM) resin, apply another thin coat of resin,
Item Nomenclature and cover with additional pieces of
C429 Solvent Cleaner nonporous release film.
C814 Abrasive Paper
C501 Fiber Cloth, EGlass (7). Using a plastic squeegee, carefully
C504 Resin, Epoxy work the resin into the fabric. Work
excess resin outboard of the fabric.
Solvent Cleaner (C429)
(8). Cut the doubler plies and nonporous
release film to the finished dimension
marked on the nonporous release film.
(1). Wipe fairing surface with solvent NOTE: Fiberglass orientation is optional.
cleaner (C429) or equivalent, and air
dry for a minimum of 15 minutes.
(9). Place the first (smaller) ply onto the
NOTE: The first doubler ply overlaps the faired repair, ensuring not to entrap air.
filler by 0.5 - 0.75 inches (12.7 - 19.05 mm).
The second doubler ply overlaps the first ply (10). Place the second ply onto the first ply.
by 0.5 - 0.75 inches (12.7 - 19.05 mm)
(2). Mark pieces of nonporous release film, (11). Cover repair with nonporous release film
approximately 3.00 inches (7.62 cm.) and work out any trapped air or
larger than the doubler ply with the wrinkles.
finished dimension of the doubler ply.
Resin, Epoxy (C504) NOTE: If using elevated temperature cure, cure
temperature must be monitored with cali
brated equipment.
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Rotorcraft Maintenance Manual
9G62049A
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Rotorcraft Maintenance Manual
and cover with additional piece of NOTE: If using elevated temperature cure, cure
nonporous release film. temperature must be monitored with cali
brated equipment.
(9). Using a plastic squeegee, carefully
work the resin into the fabric. Work (15). Cure repair 24 hours @ Room Temperature
excess resin outboard of the fabric. or 90 Minutes @160F "10 (71 " 6C).
Protective Equipment
(10). Cut the doubler plies and nonporous
release film to the finished dimension
marked on the nonporous release film.
(13). Cover repair with nonporous release film (18). Touch up Main Rotor Blade Paint (Ref.
and work out any trapped air or CSP-SPM).
wrinkles.
(19). Perform blade balance at an approved
(14). Vacuum bag top and bottom repair area MDHI approved facility. Contact your
together and apply vacuum pressure, MDHI Field Service Representative for
20-29 Inches of mercury. more information.
VACUUM PORT
VACUUM SOURCE VACUUM BAG FILM
BREATHER
RELEASE FILM
REPAIR
PART
9G62-087
SHEET 1 NOTES:
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Rotorcraft Maintenance Manual
BLADE 4.80 IN
TRAILING 1.70 IN (12.19 cm)
EDGE 1ST PLY (4.32 cm)
2.20 IN 3.80 IN
0.75 IN R 2ND PLY (5.59 cm) (9.65 cm)
(19.05 mm) 0.93 IN R 1.20 IN
(23.62 mm) COVER PLY
0.93 IN R COVER PLY (3.05 cm)
(23.62 mm) 2.80 IN
(7.1 cm)
1.20 IN
(3.05 cm) 2ND PLY 2.20 IN
1.12 IN R (5.59 cm)
(2.84 cm) TOP VIEW 1ST PLY
1.70 IN
BLADE TIP (4.32 cm)
NOTCH OPPOSITE
BLADE 1.0 IN
0.75 IN R (2.54 cm)
TRAILING 3.80 IN (19.05 mm) 0.5 IN MAXIMUM
EDGE (9.65 cm) DAMAGE BLADE
(12.7 mm)
2.80 IN MAXIMUM AREA TRAILING
1.40 IN
(7.1 cm) 3.56 cm) EDGE
BOTTOM VIEW
TRAILING EDGE
DAMAGE
AREA 1.70 IN
0.75 IN R 1ST PLY (4.32 cm)
(19.05 mm) 2.20 IN
2ND PLY (5.59 cm)
0.93 IN R
(23.62 mm) COVER PLY
4.80 IN 1.20 IN
1.12 IN R (12.19 cm) (3.05 cm)
(2.84 cm)
TOP VIEW TRAILING
EDGE
9G62051C
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Rotorcraft Maintenance Manual
3. Abrasion Strip Edge Sealing, Main Rotor strip edges with sealing compound
Blade (C212), sealing compound (C213), or
(Ref. Figure 803). sealing compound (C234).
(a). Use a plastic spatula or flat edged
Consumable Materials tool to smooth sealing compound
(Ref. CSPSPM) down into groove behind abrasion
Item Nomenclature strip.
C212 Sealing Compound, Corrosion Inhibitive
C213 Sealing Compound, Corrosion Inhibitive (3). Remove masking tape.
C234 Sealing Compound Do not heat more than 170 5F
CAUTION (77 5C).
(1). Apply masking tape to blade on two
(4). Cure for a minimum of 8 hours at
sides of area to be sealed.
room temperature or at 150 5F (66 5C)
NOTE: You can be use sealing compound for 2 hours.
(C234) when sealing compound is applied in
colder temperatures.
Sealing Compound (C212)
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4. Outboard Abrasion Strip Crack Repair, (3). Clean surface with solvent cleaner
Main Rotor Blade (C429) or equivalent, and wipe dry
immediately.
(Ref. Figure 804)
(4). Allow the surface to air dry for a
Consumable Materials
minimum of 15 minutes.
(Ref. CSPSPM) Bonding, General (C403)
Item Nomenclature
C202 Sealing Compound
C403 Bonding, General
C429 Solvent Cleaner
C717 Tape, Polyethylene Sealing Compound (C202)
C817 Pad, Scouring, Cellulose/Nylon
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
OUTBOARD
ABRASION
INBOARD STRIP
ABRASION ABRASION STRIP
STRIP OVERLAY 1.75 IN (4.445 CM)
REPAIRABLE
AREA
TAPE OVERLAP
9G62077
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Section
622000
Main Rotor Hub
Assembly
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
Make sure main rotor hub (14). Install bolts in retention nut. Torque
WARNING seats fully on static mast. bolts in sequence 1 through 12. Refer to
numbers on safety ring. Torque to 45-55
in-lbs (5.0-6.2 Nm).
CAUTION
(15). Torque in sequence again to95-105
Make sure hub upper seal and seal spring in-lbs (10.7-11.8 Nm).
are not damaged by upper bearing cone
during hub assembly installation. (16). Loosen bolts in reverse order of torque
If hub assembly does not seat correctly on sequence and remove.
mast, do not force into position. Remove
hub assembly, determine cause, correct the (17). Remove safety ring.
problem, and reinstall. (18). Install two bolts into retention nut. Do
not fully tighten bolts
(3). Make sure static mast is clean. Install
main rotor hub on static mast. (19). Hand tighten retention nut until nut is
against nut retainer.
(4). Inspect hub upper seal and seal spring
(Ref. Main Rotor Hub Upper Bearing (20). Remove bolts from retention nut.
Inspection).
NOTE:
(5). Remove helicopter sling. If necessary, loosen retention nut to align
bolt holes with holes in safety ring.
(6). Install nut retainer open side up.
Retention nut must be on static mast far
Retention nut has Left handed enough for safety ring to engage static
CAUTION threads. mast tabs of ring with notches in top of
static mast and not slip off mast when
NOTE: Make sure threads of retention nut and bolts are fully torqued.
bolts have no oil or grease contamination. Bolts must not clamp safety ring to reten
tion nut after last torque sequence.
(7). Install main rotor hub retention nut
counterclockwise on static mast. (21). Install safety ring, align tabs of ring
with notches in top of static mast.
(8). Apply antiseize compound (C220) to
threads of two bolts. (22). Apply anti-seize compound (C220) to
bolts.
(9). Install two bolts into retention nut. Do
not fully tighten bolts NOTE: Do not loosen bolts between each torque
sequence.
(10). Hand tighten retention nut until nut is
(23). Install bolts and torque in sequence 1
against nut retainer. thru 12 to 35-45 in-lbs (3.9-5.0 Nm)..
Refer to sequence numbers on safety
(11). Remove bolts from retention nut. ring.
NOTE: If necessary, loosen retention nut to (24). Torque in sequence again to80-90
align bolt holes with holes in safety ring. in-lbs (9.0-10.1 Nm) three times.
Turn the main rotor hub 360 degrees
(12). Install safety ring over retention nut, before each torque sequence.
align tabs of ring with notches in top of
static mast. (25). Torque in sequence again and again
until torque becomes stable. Turn main
(13). Apply antiseize compound (C220) to rotor hub 360 degrees before each
threads of bolts. torque sequence.
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5
4 (12 PL)
11
3 (NOTE)
12
10
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2. Main Rotor Hub Damper (8). Remove sealant from cap (6) and
pitchcase (2).
(Ref. Figure 402)
NOTE:
Consumable Materials Dampers must be installed or replaced as
(Ref. CSPSPM) a set. A set is one upper and one lower
Item Nomenclature damper of the same pitch case.
C702 Lockwire Before you remove dampers, identify each
C211 Sealing Compound, Corrosion Inhibitive damper location, position, and alignment
C229 Sealant, Conductive (e.g., blue blade, top, and an arrow that
C418 Release Agent
shows inboard direction).
Damper sets must be installed at same
location, position, and alignment as re
A. Main Rotor Hub Damper Removal moved.
Do not move the rotor blade tip
CAUTION up more than 4.0 ft. (1.22 m)
(9). Remove nut (12) and washer (13) from
upper damper (10). Remove damper.
when the rotor is not in operation. And do
not move the flexbeam up more than 1.0 in. (10). Remove nut (12) and washer (13) from
(2.54 cm) at the blade attach point. Dam lower damper (14). Remove damper.
age to the flexbeam can occur.
B. Main Rotor Hub Damper Installation
NOTE: This task is for the removal of one damp
er set at a time with the main rotor hub NOTE:
installed on the helicopter, and is typical.
This task is for the installation of one
(1). Lift main rotor blade approximately level damper set with the main rotor hub
and put a support below it. Or remove it installed on the helicopter, and is typical.
(Ref. Section 62-10-00). Removed dampers must be installed in
same location, position, and alignment as
(2). Release collective friction unit and move removed (e.g., blue blade, top, and an ar
collective up until outboard end of row that shows inboard direction).
pitchcase is approximately 90 to the
static mast (Ref. Section 67-10-00). Dampers must be replaced as a set.
Damper caps and shims must be installed
CAUTION at same location as removed.
Damper shims are free and not attached (1). If dampers are new, do the procedure
to damper or damper cap. that follows:
Upper and lower damper must have same (a). Temporarily install upper and lower
quantity of shims installed. damper cap on pitchcase using bolts
(3). Remove and discard lockwire from bolts and washers. Torque bolts.
(3). Remove bolts and washers (4).
(b). Measure and record dimension from
(4). Remove lower damper cap (1) and outside center of upper damper cap to
shim(s) (5). outside center of lower damper cap.
(5). Remove adhesive from bolts (7). (c). Remove damper caps from pitchcase.
(6). Remove and discard lockwire from bolts NOTE: Do not use nuts again if nut can be
(7). Remove bolts (7), washers (8), and installed by hand.
bonding jumpers (9).
(d). Install lower damper on centering
(7). Remove upper damper cap (6) and bearing with washer and nut. Torque
shim(s) (5). nut.
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(e). Install upper damper on centering NOTE: The same quantity of shims must be
bearing with washer and nut. Torque installed in upper and lower damper instal
nut. lations.
NOTE: Do not install damper shims at this time. Table 1. Main Rotor Damper Shim Quantity
(f). Install lower damper cap on pitchcase Dimension Qty.
with bolts and washers. Torque bolts. 0.1080.142 in. (2.7433.606 mm) None
Release Agent (C418) 0.0970.107 in. (2.4632.717 mm) 2 (1 ea.)
0.0850.096 in. (2.1592.438 mm) 4 (2 ea.)
0.0770.084 in. (1.9552.133 mm) 6 (3 ea.)
0.0690.076 in. (1.7521.930 mm) 8 (4 ea.)
(g). Apply release agent (C418) to upper
surface of pitchcase. (q). If necessary, remove damper caps
Sealant, Conductive (C229) and add shims.
(2). If dampers were removed, do the
procedure that follows:
NOTE: Do not use nuts again if nut can be
installed by hand.
(h). Apply sealant (C229) on two semicir
cular electrical bond areas on bottom (a). Install lower damper on centering
side of the upper damper cap. bearing with washer and nut. Torque
nut.
(i). Install upper damper cap, bolts (3),
and washers (4). (b). Install upper damper on centering
bearing with washer and nut. Torque
(j). At center bolt holes, prepare surface nut.
for electrical bond (Ref. CSP-SPM).
(c). Install lower damper cap on pitchcase
Loose bonding jumpers rub on with bolts and washers. Torque bolts.
CAUTION the pitch case and cause wear.
Release Agent (C418)
Make sure bonding jumpers are aligned in
an X and tie-wrapped in the center.
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Loose bonding jumpers rub on (2). Remove and discard cotter pin (17).
CAUTION the pitch case and cause wear. Remove nut (18), and washer (19).
Make sure bonding jumpers are aligned in Remove centering bearing (11).
an X and tie-wrapped in the center.
B. Centering Bearing Installation
(h). Install bonding jumpers, bolts (7),
and washers (8). NOTE: This task is typical for main rotor hub
centering bearing installation.
(i). Connect bonding jumpers together
where they are across each other. Put Lubricant, Solid Film (C101)
tie-wraps 2 in. apart.
(j). Torque all upper damper cap bolts.
(3). Safety bolts, use lockwire (C702).
(1). Spray threads of snubber bolt (20) with
Sealing Compound (C211) solid film lubricant (C101).
(2). Install centering bearing, nut, and
washer. Torque nut 300-360 in-lb
(33.90-40.67 Nwm) and install new
cotter pin.
(4). Environmentally seal bolts (3 and 7),
use sealing compound (C211) (Ref. (3). Install main rotor hub dampers.
CSP-SPM).
4. Main Rotor Pitchcase
Do not move the rotor blade tip
CAUTION up more than 4.0 ft. (1.22 m) (Ref. Figure 402)
when the rotor is not in operation. And do A. Pitchcase Removal
not move the flexbeam up more than 1.0 in.
(2.54 cm) at the blade attach point. Dam NOTE: If more than one pitchcase is removed,
age to the flexbeam can occur. identify all removed components to make
sure they are installed in their initial posi
(5). Lower or install main rotor blade (Ref. tion.
Section 62-10-00).
Do not move the rotor blade tip
(6). Do the main rotor hub droop angle test. CAUTION up more than 4.0 ft. (1.22 m)
when the rotor is not in operation. And do
(7). Do the main rotor track and balance
not move the flexbeam up more than 1.0 in.
(Ref. Section 18-00-00).
(2.54 cm) at the blade attach point. Dam
age to the flexbeam can occur.
3. Main Rotor Centering Bearing
(1). Remove main rotor blade (Ref. Section
(Ref. Figure 402) 62-10-00).
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Do not move the rotor blade tip (2). Install main rotor hub dampers.
CAUTION up more than 4.0 ft. (1.22 m)
when the rotor is not in operation. And do (3). Connect pitch link to pitch case (Ref.
not move the flexbeam up more than 1.0 in. Section 62-30-00).
(2.54 cm) at the blade attach point. Dam
age to the flexbeam can occur.
(4). Install main rotor blade (Ref. Section
(1). Install pitchcase on main rotor hub. 62-10-00).
7
2 PL
8
3 9 (2 PL)
4 PL
4
6 15
11
19
5
12
13
18
10
17
2
20
16
14
13
12
5
1
9G620064A
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5 1
(Ref. Figure 403)
5
Consumable Materials 8
(Ref. CSPSPM)
Item Nomenclature
C309 Primer 7
(4). Remove droop stop axle from roller. Figure 403. Main Rotor Droop Stop Roller
B. Droop Stop Roller Installation 6. Main Rotor Droop Stop Striker Plate
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(2). Remove and discard cotter pins (1). bonding jumpers(16), and bolts (15).
Remove nuts (2), washers (3), bolts (4), Remove droop stop support (7).
striker plate (5) and shim (6).
NOTE: If you will install a new droop stop sup
B. Striker Plate Installation port, do the step that follows.
NOTE: This task is typical for main rotor droop (5). Remove and discard cotter pins (1).
stop striker plate installation. Remove nuts (2), washers (3), bolts (4),
striker plate (5), and shims (6).
Compound, Anti-Seize (C220)
B. Droop Stop Support Installation
NOTE: This task is typical for main rotor droop
stop support installation.
(1). Apply anti-seize compound (C220) to (1). If droop stop support is new, do the
bolts (4). steps that follow.
(2). Install bolts, striker plate, shim, (a). Install shims, striker plate, bolts,
washers, and nuts. Torque nuts and washers, and nuts. Torque nuts
install new cotter pins. 20-25 in-lbs (2.26-2.82 Nwm).
(3). Do the main rotor hub droop angle test. (b). Install new cotter pins.
7. Main Rotor Droop Stop Support (2). Prepare surface for electrical bond (Ref.
CSP-SPM).
(Ref. Figure 404)
(3). Install bolts, washers, bonding jump
ers, droop stop support, washers, and
Consumable Materials nuts. Torque nuts 36-46 in-lbs
(Ref. CSPSPM) (4.07-5.20 Nwm).
Item Nomenclature
C211 Sealing Compound, Corrosion Inhibitive (4). Install new cotter pins.
(5). Test for Class S electrical bond (Ref.
A. Droop Stop Support Removal CSP-SPM).
NOTE: This task is typical for main rotor droop If you install more than one
CAUTION droop stop support, you must
stop support removal.
torque nuts you removed to the procedure
Do not move the rotor blade tip shown in Flexbeam Installation. If you do
CAUTION up more than 4.0 ft. (1.22 m) not do the procedure, damage to main rotor
when the rotor is not in operation. And do hub can occur.
not move the flexbeam up more than 1.0 in.
(6). Record locking (run-on) torque for nut
(2.54 cm) at the blade attach point. Dam
and add to torque value.
age to the flexbeam can occur.
(7). Install bolt, washers, and nut. Torque
(1). Lift main rotor blade approximately level
nut 370-420 in-lbs (41.8-47.45 Nwm)
and put a support below it. This will lift
plus (+) locking torque.
droop stop roller off striker plate, or
remove blade. Sealing Compound (C211)
(2). Remove nut (8), washers (9 and 10),
and bolt (11).
(3). Remove sealing compound from bolts
(15). (8). Cover bolt heads (15) with sealing
compound (C211) (Ref. CSP-SPM.
(4). Remove and discard cotter pins (12).
Remove nuts (13), washers (14), (9). Do the main rotor hub droop angle test.
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11
10
18
17
24
19 23 15
2 PL 27 (2 PL)
21 14
22
16 (2 PL) 26 (2 PL)
1 (2 PL)
2 (2 PL)
3 (2 PL)
7
6
5
4 (2 PL)
28
28
9 25 (2 PL)
8
24 (2 PL)
14 (2 PL)
12 (2 PL) 13 (2 PL)
9G62065A
Figure 404. Main Rotor Hub Droop Stop and Grounding Brush Installation
11. Hub Plate, Main Rotor 12. Lower Hub, Main Rotor
(Ref. Flexbeam Removal and Installation) (Ref. Flexbeam Removal and Installation)
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4 6
14 (5 PL)
3 1.034-1.035 IN
5 (2.626-2.629 cm)
7
11
13
16
14
1
8 12
10
3
B 10
8
D
5 E
15 (5 PL) 2 1 9
6
11 A
C 15
7
4
9 2
13
TORQUE SEQUENCE
VIEW LOOKING DOWN
TOP VIEW
9G62020C
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(3). Remove drive ring assembly. (2). Put upper hub half top down on a work
bench.
(4). Remove nuts (1), washers (2), counter Move flexbeam legs as necessary while
sunk washers (3), and bolts (4). you install hub plate.
(5). Remove and discard cotter pins (5). (3). Install upper leg of flexbeams in
flexbeam pockets and install hub plate.
NOTE: Aid of 1 or 2 persons is recommended.
(4). Install lower hub half and install bolts,
CAUTION countersunk washers, washers, and
nuts. Do not tighten nuts at this time.
When you remove bolts (9) and separate
hub halves, flexbeams will not be kept in (5). Install flexbeam bolts, countersunk
hub. Flexbeams can fall and damage to washers, washers, and nuts. Do not
flexbeam can occur. tighten nuts at this time.
Do not use force to remove flexbeam bolt (6). Turn main rotor hub top up.
(9). Damage to lead/lag shims (14 and 15)
can occur. (7). Record locking (run-on) torque for each
nut and add to torque values.
(6). Remove nuts (6), washers (7), counter
(8). Do these steps for flexbeams installed
sunk washers (8), and flexbeam bolts
on 900R1101000-111 hub assemblies:
(9).
(a). Torque nuts (6) in sequence A, B, C,
(7). Separate lower hub half (10) from D, and E 800 in-lb (90.39 Nm).
upper hub half (11).
(b). Torque bolts (9) in sequence A, B, C,
(8). Remove hub plate (12) and flexbeams D, and E 1600 to 1650 in-lb (180.78
(13). to 186.42 Nm).
B. Flexbeam Installation Do not torque more than 1800
CAUTION in-lb (203.37 Nm) plus (+)
(Ref. Figure 405)
locking torque during alignment. Damage
to the hub assembly can occur.
Consumable Materials
(Ref. CSPSPM) (c). Align the pin holes in bolt (9) with
Item Nomenclature the castellations of nut (6).
C101 Lubricant, Solid Film (d). Install new cotter pins (5).
(e). Torque nuts (1) in sequence 1 thru 10
Lubricant, Solid Film (C101) 110 to 210 in-lb (12.43 to 23.73
Nm).
(f). Torque nuts (1) again in sequence 1
thru 10 320 to 420 in-lb (36.16 to
47.45 Nm).
(1). Apply solid film lubricant (C101) to
threads of bolts (4) and flexbeam bolts (g). Torque nuts (1) at locations 11, 12,
(9). Dry in air a minimum of 6 hours. 13, 14, and 15:
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1). Find the run-on torque for bolts 14. Lead/Lag Leg Wear Shim, Main Rotor Hub
(4).
(Ref. Figure 405)
2). Torque nuts (1) to the run-on
torque for bolts (4). Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
a). Stop when the torque of nuts (1)
begins to be more than the C814 Abrasive Paper
run-on torque of bolt (4). C412 Adhesive Promoter, Epoxy
C419 Alcohol, Isopropyl
NOTE: Bolts (4) must be snug, but not tight. C426 Adhesive
C309 Primer
(9). Do these steps for flexbeams installed C418 Release Agent
on 900R1101000-113 thru -125 hub
assemblies: Special Tools
(Ref. CSPSPM)
(a). Torque nuts (6) in sequence A, B, C, Item Nomenclature
D, and E 800 to 850 in-lb (90.39 to T908 Flex Beam Wear Shim Installation Tool
96.04 Nm) plus (+) locking torque.
(d). Install new cotter pins (5). B. Lead/Lag Leg Wear Shim Installation
(11). Install pitchcase assemblies (ref. (2). Wipe surface, use isopropyl alcohol
Procedure 4.B.). (C419). Dry 15 minutes in air.
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Adhesive Promoter, Epoxy (C412) (6). Install shim in hub and align hole in
shim with bolt hole in hub.
(4). Apply release agent (C418) or equiva (9). Cure at ambient temperature a
lent to flex beam wear shim installation minimum of 24 hours or at 150 to
tool (T908). 1705F (65.5 to 76.65C) for 2 hours
minimum.
Adhesive (C426)
Primer (C309)
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15
6
1
2
4 GREASE
5
7
13
8
8 12
14
GREASE
10
5
GREASE
11
9
9G62047
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15. Upper Hub Assembly (4). Install nut retainer and hub retention
nut (ref. Main Rotor Hub Installation).
A. Upper Hub Buildup
17. Upper Bearing, Upper Hub Assembly
(Ref. Figure 406)
(Ref. Figure 406)
Upper hub assembly records, to include part
number, serial number, and necessary
dimensions, are to be kept with the hub. Consumable Materials
(Ref. CSPSPM)
Assembly records are to be put in the Rotor Item Nomenclature
craft Log Book at hub installation. C104 Grease
Grease (C104)
(1). Remove hub retention nut and nut
retainer (ref. Main Rotor Hub Remov
al).
(2). Make sure upper seal stop is installed. (4). Put two upper bearing removal tool
(T907) (15) below lip of bearing cone (2)
(3). Install new upper seal and press into between bearing rollers (3) and lift
position, use hub upper seal tool (T909). bearing (1).
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(3). Install bearing. Make sure bearing (1). Make sure space between bearing and
rollers fully touch bearing cup. seal is full of grease to the top edge of
bearing cone, use grease (C104).
(4). Fill space above bearing to top of Primer (C310)
bearing cone with grease (C104).
(6). Install new upper seal. (2). Apply primer (C310) to mating surface
of lower seal.
18. Shim, Upper Hub Assembly (3). Install lower seal in hub, use hub lower
bearing seal and outer race installation
(Ref. Lower Bearing Removal and Installation) tool (T911). Install while primer is wet.
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NOTE:
(1). Fill lower bearing with grease (C104).
Bearing cones, rollers, and cups must be
replaced as a set. (2). Install lower bearing on hub liner, use
hub lower bearing liner tool (T910).
Always wear rubber or clean fabric gloves
Make sure all hub spaces are
when you touch bearing to prevent con CAUTION filled with grease to prevent
tamination of bearing with oil from your
skin. condensation.
(3). Fill space between center seal and
(1). Remove lower seal. lower bearing cup with grease (C104).
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(4). Install lower bearing with liner into B. Upper Bearing Cup Installation
hub.
NOTE:
(5). Install lower seal. Bearing cones, rollers, and cups must be
replaced as a set. It can be necessary to
install a different bearing spacer (shim)
22. Upper Bearing Cup (Outer Race), Upper when you replace upper bearing.
Hub Assembly
If you replace bearing, record serial num
ber of new bearing in rotorcraft log book.
(Ref. Figure 406)
Always wear rubber or clean fabric gloves
when you touch bearing to prevent con
Consumable Materials tamination of bearing with oil from your
(Ref. CSPSPM) skin.
Item Nomenclature
(1). Measure and record outer diameter of
C104 Grease bearing cup, use 6 - 7 in. outside
micrometer (T2020).
Special Tools (2). Measure and record inner diameter of
(Ref. CSPSPM) upper hub where cup will be installed,
Item Nomenclature use 2 - 6 in. dial bore gage (T2021).
T912 Upper Bearing Outer Race Installation
Tool, Hub Bearing cup outer diameter
CAUTION must be between 0.006 and
T917 Race Removal Tool
0.009 inch (0.15 and 0.23 mm) larger than
T2018 Press, Hydraulic upper hub inner diameter.
T2020 Micrometer, Outside, 6 7 In.
(3). Record the difference between the two
T2021 Dial Bore Gage, 2 6 In. measurements.
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26. Identification Plate,Upper Hub Assembly NOTE: Do not install identification plate over
serial number or part number.
(1). Make faying surface of hub rough with
400 grit abrasive paper (C814) or
1 equivalent.
Solvent, Cleaning (C423)
2
(2). Wipe clean with cleaning solvent (C423)
then dry in air for a minimum of 10
minutes.
(3). Apply adhesive in less than 2 hours
after solvent is dry.
Adhesive, Epoxy (C407)
TOP VIEW
9G62-066A
1. IDENTIFICATION PLATE
2. APPLY FORCE TO TURN HUB HERE (4). Bond identification plate (16) to hub
Figure 407. Upper Hub Bearing Preload Pull with epoxy adhesive (C407) and edge
Direction and Hub Identification seal.
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5
4
1
3 9G62081B
1. NUT 4. WASHER
2. WASHER 5. BOLT
3. PITCH HORN
Figure 408. Pitch Horn Replacement
28. Pitch Horn (6). If necessary, remove bolts (5) and
washers (4).
Be careful, do not damage pitch
CAUTION case or inside doubler. Do not use chemicals to remove
CAUTION sealant.
NOTE: This task is typical for all pitch horns.
(7). Remove sealant from the mating
A. Pitch Horn Removal surface of the pitchcase and pitch horn.
(Ref. Figure 408) B. Pitch Horn Installation
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(a). Make sure the bolt holes of pitch (b). Safety nuts (1) with lockwire (C702).
horn (3) and the pitchcase align at all
4 places. Sealing Compound (C211)
(3). Install bolts (5) wet with sealing (6). If necessary, touch up paint with
compound (C211). Dupont Imron 5000, or 6000 polyure
thane color number, 17925 (FED-
(4). Install washers (2) and nuts (1). STD-595) (ref. CSP-SPM).
(a). Torque nuts (1) 30 to 40 in-lb (3.39 (7). Connect pitch link to pitchcase (ref.
to 4.52 Nm). Section 62-30-00).
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Do not move the rotor blade tip (4). Examine main rotor hub (1) for nicks
CAUTION up more than 4.0 ft. (1.22 m) and scratches. None permitted (ref.
when the rotor is not in operation. And do Repair, Hub Small Nick and Scratch).
not move the flexbeam up more than 1.0 in. (5). Examine main rotor hub (1) for loose or
(2.54 cm) at the blade attach point. Dam missing lockwire and cotter pins.
age to the flexbeam can occur. Replace if loose or missing.
NOTE: Examine all components for condition (6). Examine nuts (2) for loss of torque
and/or unusual wear. If a component has an (broken torque stripe). Torque loose
indication of unusual wear or you are not flexbeam nuts.
sure of its condition, replace the component.
(7). Examine upper and lower damper caps
(1). Disassemble main rotor hub assembly (3, 4) for cracks and correct installation.
(1) for inspection. No cracks or incorrect installation
permitted.
(2). Examine main rotor hub (1) for cracks.
(8). Examine lower damper caps (4) for a
NOTE: Make sure the areas adjacent to the maximum wear of 0.020 inch (0.51
bolts of the upper and lower hubs are fully mm) where droop stop roller (13)
examined for cracks. contacts damper cap (4).
NOTE: Particles of rubber are an indication of
(a). No cracks permitted.
damper separation.
(3). Examine main rotor hub (1) for corro (9). Examine upper and lower dampers (5)
sion as follows: for separation. None permitted.
(a). Examine flexbeam pockets (2, (a). Torque or replace loose or missing
Figure 802) for corrosion. hardware.
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(a). Torque or replace loose or missing 1). The radial play cannot be more
hardware. than 0.050 inch (1.27 mm)
maximum.
(11). Examine centering bearing housing for
cracks. None permitted. (d). Replace rollers (13) with damage,
unwanted movement, or radial play
(12). Examine pitchcase (7) for cracks. None
more than permitted.
permitted.
(13). Examine inner surfaces of pitchcase (7) (e). Examine rollers (13) for correct
for unwanted material. None per installation. Torque or replace loose
mitted. or missing hardware.
(14). Examine droop stop striker plate (11) (18). Examine drive ring (14) for cracks and
for cracks and correct installation. No correct installation. No cracks or
cracks or incorrect installation per incorrect installation permitted.
mitted.
(a). Torque or replace loose or missing
(a). Torque or replace loose or missing hardware.
hardware.
(19). Examine grounding jumpers (15 and
(15). Examine droop stop striker plate for 16) for broken wires and correct
wear where roller touches plate. installation. No broken wires or
Maximum wear 0.100 inch (2.54 mm). incorrect installation permitted.
(16). Examine droop stop supports (12): (a). Torque or replace loose or missing
(a). Examine supports (12) for condition. hardware.
(b). Examine supports (12) for cracks in (20). Examine ground brush holder (17) for
the upper bend area. correct installation. Torque or replace
loose or missing hardware.
(c). Replace supports (12) with damage
or cracks in the upper bend area. (21). Examine ground brush (18) for wear.
Minimum length 0.375 inch (9.52 mm).
(d). Make sure that components are
correctly attached. B. Identification/Data Plate Inspection
(e). Torque or replace loose or missing NOTE:
hardware.
The plate location is on top of the main ro
(17). Examine droop stop rollers (13) of lower tor hub assembly.
damper cap assemblies (4): Plates show current configuration of hub
(a). Examine rollers (13) for damage. assembly must agree with data recorded
in the rotorcraft log book.
(b). Make sure rollers (13) move freely.
(1). Make sure plates are tightly attached.
(c). Measure the radial play of rollers
(13). (2). Make sure you can read plates.
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10
7
3 15
9
1
5 17 18
2 (NOTE 2) 5
14 VIEW ROTATED
NOTE 1 6
16
5
NOTE 3
NOTE 3
12 REF 6
4
5
13 5
11
12 NOTE 3
REF. 14
NOTES:
1. UPPER BEND AREA.
2. REFER TO FLEXBEAM INSTALLATION FOR TORQUE PROCEDURE.
3. EXAMINE ELASTROMERIC MATERIAL FOR DETERIORATION.
9G62013D
1. MAIN ROTOR HUB 10. FLEXBEAM BUMPER
2. FLEXBEAM NUT 11. STRIKER PLATE, DROOP STOP
3. UPPER DAMPER CAP 12. DROOP STOP SUPPORT
4. LOWER DAMPER CAP 13. DROOP STOP ROLLER
5. DAMPER 14. DRIVE RING
6. CENTERING BEARING 15. GROUNDING JUMPER
7. PITCHCASE 16. GROUNDING JUMPER
8. ROTOR BLADE 17. GROUNDING BRUSH HOLDER
9. FLEXBEAM 18. GROUND BRUSH
Figure 601. Main Rotor Hub Assembly
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C. Flexbeam Inspection (Area 4) (2). Inspect the areas of the flexbeam that
you can access for delamination (fiber
(Ref. Figure 602) fuzz, separation, breakage).
(3). EARLY CONFIG - Inspect the top and
Consumable Materials bottom of the flexbeam where lead and
(Ref. CSPSPM) lag legs join. Maximum crack length 2.0
Item Nomenclature in. (5.08 cm).
C432 Cleaner
NOTE: Ref. Service Bulletin SB900-001 (most
current revision), for ferry flight permitted
limits.
Special Tools
(4). Inspect the top and bottom of the shear
(Ref. CSPSPM)
web surface for surface cracks. None
Item Nomenclature
permitted.
T906 Borescope
(5). EARLY CONFIG - Inspect the leading
and trailing edges of the flexbeam and
Cleaner (C432) flexbeam legs for a visible separation
between the flexbeam laminates and
shear web. Maximum separation 1.0 in.
(2.54 cm) in specified areas only.
(6). CURRENT CONFIG - Inspect the
Do not move the rotor blade tip wrapped part of the flexbeam and
CAUTION up more than 4.0 ft. (1.22 m) flexbeam legs for a visible separation
when the rotor is not in operation. And do between the flexbeam and wrap.
not move the flexbeam up more than 1.0 in.
Visible cracks of the resin along the
(2.54 cm) at the blade attach point. Dam
edges of the wrap is permitted.
age to the flexbeam can occur.
Maximum crack in the legs 1.00 in.
NOTE: (25.4 mm).
Flexbeam inspection intervals are differ No loose wrap permitted.
ent for different flexbeams. Ref. Section
05-20-10 for inspection interval by part (7). Inspect the flexbeam bumper for
number. deterioration and cracks. No damage
permitted.
If a borescope is not available, you must
remove the main rotor pitchcase to in (8). Inspect edges of flexbeam between 1.0
spect the flexbeam. in. and 2.0 in. inboard of blade attach
If you are not sure of the borescope or hole center for nicks. Maximum depth
visual indications, remove the pitchcase. 0.020 in. (0.508 mm) with no fiber
damage permitted. Break sharp edges
Support the main rotor blade during the and fill with a resin wash.
inspection. Have one person on a mainte
nance stand. (9). Inspect shear web between 1.0 in. and
2.0 in. inboard of blade attach hole
(1). Use cleaner (C432) to clean the flex center for nicks. Break sharp edges and
beam before inspection. fill with a resin wash.
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BUMPER ASSEMBLY
NOTE 8
NOTE 4
SHEAR WEB
LEAD LEG
SHEAR WEB
NOTE 3 NOTE 5
LEAD LEG
FIBERGLASS WRAP NOTE 1 NOTE 12 SHEAR WEB
NOTE 1
ATTACH
POINT SHEAR WEB SURFACE
NOTE 7
LAG LEG
NOTE 1
NOTE 2
NOTE 6 WRAPPED CONFIG
NOTE 2 ATTACH
POINT 9G62-048G
NOTES:
1. VISIBLE SEPARATION OF THE WRAPS ALONG EACH SIDE OF THE LEGS OR ALONG EACH SIDE OF THE MAIN BODY OF THE FLEXBEAM IS
PERMITTED. NO SINGLE OR COMBINED SEPARATION LONGER THAN 1.0 IN. (2.54 cm) IS PERMITTED ON EACH SIDE.
2. DISREGARD INDICATIONS OF SEPERATION IN THIS AREA UNDER THE INBOARD END OF THE SHOES.
3. 1 IN (2.54 cm) MAXIMUM SEPERATION.
4. 2 IN (5.08 cm) MAXIMUM CRACK (TOP OR BOTTOM).
5. VISIBLE FISSURES IN THE RESIN/SEALANT ALONG OR UNDER THE FLEXBEAM BRIDGE ARE PERMITTED. THEY CAN BE FILLED WITH A RESIN WASH
6. CRACKING OF SEALANT ALONG INSIDE EDGE OF UNWRAPPED AREA IS PERMITTED.
7. NO SHEAR WEB SURFACE CRACKS PERMITTED. BREAK SHARP EDGES OF NICKS IN SHEAR WEB AND FILL WITH A RESIN WASH.
8. NO BUMPER ASSEMBLY DETERIORATION, SUCH AS PERMANENT COMPRESSION, DEFORMATION, TEARS, OR CRACKS PERMITTED.
9. NICKS 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 WRINCKLES IN THE WRAP CAN APPEAR TO BE FIBER SEPARATION OR BREAK. CLOSE EXAMINATION IS NECESSARY
TO DETERMINE WHETHER THE INDICATION IS A FIBER SERARATION OF A FOLD. A FOLD CAN APPEAR AS AN ACCUMULATION OF RESIN. A FOLD OR
WRINKLE IS PERMITTED, BUT A FIBER SEPARATION OR BREAK IS NOT.
12. DARK LINES THAT INDICATE GAPS BETWEEN THE EDGE OF ONE WRAP AND THE EDGE OF THE NEXT WRAP ARE NORMAL AND PERMITTED.
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LEAD LEG
NOTE 1 SHEAR WEB
FIBERGLASS WRAP
NOTE 1
NOTE 1
FIBERGLASS WRAP
BUMPER ASSEMBLY
NOTE 7
ATTACH
POINT
ATTACH
POINT FULLY WRAPPED (CURRENT) CONFIG
NOTE 5
OUTBOARD
NOTE 6
LATERAL
NOTE 2
APEX
NOTE 4
NOTES:
1. VISIBLE SEPARATION OF THE WRAPS ALONG EACH SIDE OF THE LEGS OR ALONG EACH SIDE OF THE MAIN BODY OF THE FLEXBEAM IS
PERMITTED. NO SINGLE OR COMBINED SEPARATION LONGER THAN 1.0 INCH.(2.54 CM) IS PERMITTED ON EACH SIDE.
2. VISIBLE FISSURES IN THE RESIN ARE PERMITTED IN THE WRAPS BETWEEN THE APEX AND THE FLEXBEAM BRIDGE. THEY CAN BE FILLED WITH A
RESIN WASH TO PREVENT COLLECTION OF MOISTURE.
3. VISIBLE FISSURES IN THE RESIN/SEALANT ALONG OR UNDER THE FLEXEAM BRIDGE ARE PERMITTED. THEY CAN BE FILLED WITH A RESIN WASH.
4. A SEPARATION (SPLIT) EXTENDING OUTBOARD FROM THE APEX IS NOT PERMITTED IF IT IS VISIBLE BEYOND THE FLEXBEAM BRIDGE.
5. DISREGARD INDICATIONS OF SEPARATION IN THIS AREA UNDER THE INBOARD END OF SHOES.
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 DETORIORATION, SUCH AS PERMAMENT COMPRESSION, DEFORMATION, TEARS OR CRACKS PERMITTED.
8. A LOOSE OR BROKEN WRAP THAT CAN BE LIFTED UP ALONG AN EDGE IS CAUSE FOR REJECTION.
9. MANUFACTURING FOLDS OR WRINKLES IN THE WRAPS CAN APPEAR TO BE FIBER SEPARATION OR BREAK. CLOSE EXAMINATION IS NECESSARY TO
DETERMINE WHETHER THE INDICATION IS A FIBER SEPARATION OR A FOLD. A FOLD CAN APPEAR AS AN ACCUMULATION OF RESIN. A FOLD OR
WRINKLE IS PERMITTED, BUT A FIBER SEPARATION OR BREAK IS NOT.
10. NICKS 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. 9G62-090A
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(12). Examine bearing rollers and bearing (2). Make sure shims did not move up or
cup for true brinelling. Maximum overlap on sides of hub.
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2
6 1 18 (5 PL)
7
VIEW ROTATED
LOOKING UP
5
8
11
14
16 19 (5 PL)
9
15
17
13
12
21
22
10
20 VIEW ROTATED
LOOKING DOWN
9G62025D
1. UPPER BEARING 12. LOWER BEARING
2. UPPER BEARING CONE 13. LOWER BEARING CUP
3. UPPER BEARING ROLLER 14. HUB (CENTER) PLATE
4. UPPER BEARING CAGE 15. FLEXBEAM POCKET
5. UPPER BEARING CUP 16. LOWER HUB HALF
6. UPPER BEARING SEAL 17. HUB LINER
7. UPPER BEARING SEAL SPRING 18. LEAD SHIM (UPPER)
8. UPPER BEARING SEAL STOP 19. LAG SHIM (LOWER)
9. CENTER SEAL 20. LOWER BEARING CONE
10. LOWER BEARING SEAL 21. LOWER BEARING ROLLER
11. UPPER HUB HALF 22. LOWER BEARING CAGE
Figure 603. Main Rotor Hub Inspection
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Rotorcraft Maintenance Manual
2. Main Rotor Hub Special Inspections (2). Examine upper surface of main rotor
upper hub surface for corrosion. None
A. Main Rotor Upper Hub Web Inspection permitted.
(Ref. Figure 604)
Make sure paint stripper and
(1). Examine main rotor upper hub (1) web CAUTION solvent does not go into upper
areas (2) for cracks. No cracks per bearing and grease seal area.
mitted.
(2). Remove paint from web areas (2). Use (3). If necessary, remove paint from bolt
paint removal chemical procedure (ref. holes (3) and bolt hole upper chamfer.
CSP-SPM). Use paint removal chemical procedure
(ref. CSP-SPM).
(3). If you are not sure of the results of a
visual inspection, do the Main Rotor (4). Examine bolt holes (3) for cracks, use a
Hub Eddy Current Inspection. 10X magnifying glass. No cracks
permitted.
(4). Apply primer (C308) and white finish
enamel (C302). Use Paint Repair
procedure (ref. CSP-SPM). (5). Examine chamfer at top of bolt holes (3)
for cracks with a 10X magnifying glass.
B. Main Rotor Upper Hub Flange Inspection No cracks permitted.
(Ref. Figure 604)
(6). If you are not sure of the results of a
(1). Remove main rotor drive plate (ref. visual inspection, do the Main Rotor
Section 63-10-00). Hub Eddy Current Inspection.
3 (10 PL)
2
(5 PL)
VIEW LOOKING DOWN AT TOP OF UPPER HUB
(DRIVE PLATE REMOVED)
9G62014C
1. MAIN ROTOR UPPER HUB 3. BOLT HOLES
2. MAIN ROTOR UPPER HUB WEB AREA
Figure 604. Main Rotor Upper Hub Inspection
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Rotorcraft Maintenance Manual
1 (5 PL)
2 (5 PL)
9 (10 PL) 3
8
5
REF. 4
6
REF. 7
9G62026G
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C. 100Hour Inspection of the Main Rotor (b). Examine flexbeams (5) for delamina
Hub Assembly tion. None permitted.
(Ref. Figure 605) (4). Examine main rotor upper hub (8) for
cracks at the joint between the five ribs
(1) and upper drive flange, use a 10X
Consumable Materials
magnifying glass. No cracks permitted.
(Ref. CSPSPM)
Item Nomenclature (5). If you are not sure of the results of a
C432 Cleaner visual inspection, do the Main Rotor
Hub Eddy Current Inspection.
(6). Examine main rotor upper hub between
Special Tools the ribs in the fillet area (2) for cracks
(Ref. CSPSPM) with a 10X magnifying glass. No cracks
Item Nomenclature permitted.
T906 Borescope
(7). If you are not sure of the results of a
visual inspection, do the Main Rotor
(1). Examine main rotor hub assembly with Hub Eddy Current Inspection.
borescope (T906).
(8). Examine area around bolt holes (9) for
(2). Examine pitchcases (3): cracks or wear. None permitted.
(a). Examine inboard and outboard (9). Examine main rotor hub for loose or
machined edges on pitchcases (3) for missing lockwire and cotter pins.
delamination or cracks. Replace if loose or missing.
1). If there is delamination or cracks, (10). Examine nuts (10, 12) for loss of torque
replace pitchcase (3). (broken torque stripe). Torque loose
flexbeam nuts.
(b). Examine inboard edge of pitchcases
(3) immediately above pitch horns (6) (11). Do the Main Rotor Drive Plate Nut
for cracks or separations. Torque Verification (ref. Section
63-10-00).
1). If there are cracks or separation,
replace pitchcase (3). NOTE: Particles of rubber are an indication of
damper separation.
(3). Examine flexbeams (5):
(12). Examine dampers (4) for separation of
Cleaner (C432) the elastomeric material. None per
mitted.
(a). Torque or replace loose or missing
hardware.
(a). If necessary, clean flexbeams (5) with (13). Do Procedure 2.D., 50-Hour Inspec
cleaner (C432). tion for the Center Bearing Assembly.
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D. 50Hour Inspection for the Center (a). Replace center bearings () with a
Bearing Assemblies separation between the elastomeric
material and housing.
(Ref. Figure 605)
(3). Examine center bearings (7) for
Special Tools separation between the elastomeric
(Ref. CSPSPM) material and center bushing.
Item Nomenclature NOTE:
T906 Borescope
Rubber particles are indication of separa
tion.
(1). Examine center bearings () with If the housing is not aligned with the cen
borescope (T906). ter bushing, it is an indication of center
ing bearing separation.
NOTE: Black powder is an indication of a light
deterioration of the elastomeric material (a). Replace center bearings () with a
and is permitted. separation between the elastomeric
material and center bushing.
(2). Examine center bearings (7) for
separation between the elastomeric (4). Examine center bearings () for cracks.
material and housing.
(a). Replace center bearings () with a
NOTE: crack in the housing.
Rubber particles are indication of separa
tion. (b). Surface cracks in the elastomeric
material are permitted.
If the housing is not aligned with the cen
ter bushing, it is an indication of center (5). Torque or replace loose or missing
ing bearing separation. hardware.
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Rotorcraft Maintenance Manual
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
10 PL
5 PL
5 PL
NOTE 2 (5 PL)
NOTE 1 (5 PL)
CRACK INDICATIONS
2 INCREMENT
SET NORTEC 19 OR EQUIVALENT AS FOLLOWS:
NOTES:
1. NUT, WASHER, AND BOLT REMOVED TO CLEARLY SHOW AREA OF INSPECTION.
2. EXAMINE THE TWO SIDES OF RIB. 9G62028B
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Rotorcraft Maintenance Manual
E. Main Rotor Upper Hub Eddy Current NOTE: The upper hub material is forged alumi
Inspection num alloy 7149-T7352.
NOTE: Unit and probe must be calibrated be (11). If the upper hub is good, apply primer
fore inspection, each half hour during in (C308) and white finish enamel (C302)
spection, at the end of inspection, and if a (ref. CSP-SPM, 20-30-00, Main Rotor
cable or probe is changed. Hub).
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3. Main Rotor Hub Test (1). Move main rotor controls until the top
of upper damper cap (2) is approximate
A. Main Rotor Hub Droop Angle Test ly level with the top of upper hub (1).
(Ref. Figure 607) (2). Measure the droop angle for each rotor
blade.
Special Tools
(a). Put inclinometer (T203) on a flat and
(Ref. CSPSPM)
level surface of upper hub (1) parallel
Item Nomenclature
to pitchcase (2).
T203 Inclinometer
1). Record the angle measurement.
Upper Damper
Hub Cap Droop
Blade Angle Angle Angle
1. =
2. =
3. =
4. =
5. =
3
(4). Add or subtract shims (6) as necessary
to get the correct droop angle (ref.
Removal/Installation procedures for the
droop stop striker plate).
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Rotorcraft Maintenance Manual
Consumable Materials
(Ref. CSPSPM) Consumable Materials
Item Nomenclature (Ref. CSPSPM)
Item Nomenclature
C804 Abrasive Cloth
C804 Abrasive Cloth
C807 Sandpaper
(5). Apply alodine (C241) to repair area (ref. (7). Make a record in the Rotorcraft Log
CSP-SPM). Book of repair area.
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9G62046B
2
1 VIEW LOOKING UP
(WEAR SHIM
REMOVED)
WEAR SHIM
9G62-061A
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Rotorcraft Maintenance Manual
SIDE VIEW
9G62-076B
Page 804
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Rotorcraft Maintenance Manual
2. Repairs for the FlexbeamBumper (5). Do Step (4). until cloth stays clean.
Assemblies
Sealing Compound (C201)
A. Flexbeam Bumper Repair
(Ref. Figure 803)
Be careful when you remove (10). Use a clamp or weight to apply pres
CAUTION adhesive. Do not damage glass sure until sealing compound cures.
fibers.
(11). Apply a thin layer of sealing compound
(2). Remove remaining adhesive with your (C201) to edge of bumper. Fully cure
hand. You can use a plastic or wood sealant.
scraper.
Adhesive (C426)
(3). Lightly rub surface with abrasive cloth
(C810) until surface primer not glossy.
Solvent, Cleaning (C425)
(12). Apply a thin layer of adhesive (C426) to
bumper where tape will be installed.
Cure adhesive for 24 hours.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
SHEAR WEB
FLEXBEAM BRIDGE
1
APEX
1. AREA BETWEEN FLEXBEAM APEX AND FLEXBEAM 3. AREA WHERE NICKS CAN BE REPAIRED
BRIDGE WHERE FISSURES CAN BE FILLED
2. AREA ALONG OR UNDER FLEXBEAM BRIDGE
WHERE FISSURES CAN BE FILLED
Figure 804. Flexbeam Fissure Fill and Nick Repair
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Rotorcraft Maintenance Manual
Consumable Materials
(Ref. CSPSPM)
NOTE: Surface of the flexbeam must be clean, Item Nomenclature
dry, and have no contamination. C425 Solvent, Cleaning
C504 Resin, Epoxy
(1). Clean surface of flexbeam in area of
fissure (1, 2). C802 Cloth, NonLint
C807 Sandpaper
NOTE: Wipe surface before solvent dries.
(1). Break sharp edges of nick with sandpa
(a). Wipe surface with a non-lint cloth per (C807).
(C802) moist with cleaning solvent
(C425). Solvent, Cleaning (C425)
Sealant, Fuel Resistant (C216) (a). Wipe surface with a non-lint cloth
(C802) moist with cleaning solvent
(C425).
NOTE: Wipe surface before solvent dries.
Resin, Epoxy (C504)
(2). Mix epoxy resin (C504) or sealant
(C216) (ref. manufacturers instruc
tions).
NOTE: You must mix epoxy resin or sealant in NOTE: You must mix epoxy resin in a clean
a clean wax free container. Apply epoxy res wax free container. Apply epoxy resin before
in or sealant before expiration of material expiration of material pot life.
pot life.
(3). Mix epoxy resin (C504) (Ref. manufac
(3). Apply a thin coat of epoxy resin (C504) turers instructions).
or sealant (C216) to seal fissure (1, 2). (4). Apply a thin coat of epoxy resin (C504)
to seal nick (3).
(4). Cure epoxy resin (C504) or sealant
(C216) (ref. manufacturers instruc (5). Cure epoxy resin (C504) (ref. manufac
tions). turers instructions).
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4 (5 PL)
10
6 (5 PL)
2
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
Section
623000
Swashplate and
Mixer
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
NOTE: Laminated washers (17) to be equal and 18), and nut (14). Torque the nut
within 0.002 inch (0.050 mm) of each other 30-40 inch pounds (3.39-4.52 Nm)
after adjustment for axial play. and install a new cotter pin (13).
(2). Adjust thickness of laminated washers (4). Install the washer (1) and nut (3) on
(17) to allow axial play between upper the lower drive link assembly (4).
and lowers scissors of 0.001-0.003 inch (5). Torque nut (3) and install a new cotter
(0.025-0.076 mm). pin (2).
(3). Attach the lower and upper link (6). Perform swashplate drive link
assemblies with bolt (19), washers (15 inspection.
5 REF
9
8
DIRECTION OF
15 ROTATION
12 14 18
11
10
7 5
13 19
16 16
2 PLACES 6 12 REF 20 17
4
4 REF
VIEW ROTATED
1
3
2
9G62-071C
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
4. Lateral AntiTorque Drive Link Assembly (4). Torque the nut and install a new cotter
pin.
(Ref. Figure 403)
A. Lateral AntiTorque Drive Link Assembly 5. Longitudinal Drive Link Assembly
Removal
(Ref. Figure 403)
(1). Remove and discard cotter pin (2).
A. Longitudinal Drive Link Assembly
(2). Remove the nut (3), washer (4), Removal
bushing (5), washer (6), and upper
bolt (7). (1). Remove and discard cotter pin (21).
(3). Remove and discard cotter pins (8 and (2). Remove the nut (22), washer (23),
14). bushing (24), washer (25), and upper
bolt (26).
(4). Remove the nuts (9 and 15), washers
(10 and 16), bushings (11 and 17), (3). Remove and discard cotter pin (27).
washers (12 and 18) and lower bolts (13
and 19). (4). Remove the nut (28), washer (29),
bushing (30), washer (31), and lower
(5). Remove torque link (20). bolt (32).
B. Lateral AntiTorque Drive Link Assembly
(5). Remove drive link (33).
Installation
(1). Install the torque link, lower bolts, B. Longitudinal Drive Link Assembly
washers, bushings, and nuts. Installation
(2). Torque the nuts and install new cotter (1). Install drive link, bolts, washers,
pins. bushings, and nuts.
(3). Install the upper bolt, washers, bush (2). Torque the nuts and install new cotter
ing, and nut. pins.
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24 23 22
21 7
26 25
1
6
4
33
2
20
32
31
10 8
11
30 12
13
9
15
34
29
28 14
17 16
27 19
35 18 9G62-074
1. SWASHPLATE 19. BOLT
2. COTTER PIN 20. LATERAL DRIVE LINK
3. NUT 21. COTTER PIN
4. WASHER 22. NUT
5. BUSHING 23. WASHER
6. WASHER 24. BUSHING
7. BOLT 25. WASHER
8. COTTER PIN
26. BOLT
9. NUT
27. COTTER PIN
10. WASHER
28. NUT
11. BUSHING
12. WASHER 29. WASHER
13. BOLT 30. BUSHING
14. COTTER PIN 31. WASHER
15. NUT 32. BOLT
16. WASHER 33. LONGITUDINAL DRIVE LINK
17. BUSHING 34. LONGITUDINAL MIXER BELLCRANK ASSEMBLY
18. WASHER 35. LATERAL MIXER BELLCRANK ASSEMBLY
Figure 403. Lateral and Longitudinal Link Assembly
6. NonAdjustable Collective Drive Link (3). Release collective friction (Ref. Section
Assembly 67-10-00) and raise collective stick
slightly to unload flight controls.
(Ref. Figure 404)
(4). Disconnect upper end of lateral and
A. NonAdjustable Collective Drive Link longitudinal drive links to enable
Assembly Removal movement of swashplate.
(1). Remove forward access door assemblies (5). Remove and discard cotter pin (9).
L155 and R155 (Ref. Section
53-30-00). (6). Remove nut (8), washers (6 and 7) and
upper bolt (5).
(2). Remove forward swashplate fairing
assembly T155 (Ref. Section 53-30-00). (7). Remove and discard cotter pin (25).
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CSP900RMM2 MD Helicopters, Inc.
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(8). Remove nut (24), washer (23) shims (5). Remove and discard cotter pin (15).
(10), bushing (22), washer (21) and
lower bolt (20). (6). Remove nut (16), washer (14), shims
(13), washer (12), and upper bolt (11).
(9). Raise swashplate to allow removal of
drive link (1). (7). Remove and discard cotter pin (27).
B. NonAdjustable Collective Drive Link
(8). Remove nut (28), washer (26), bushing
Assembly Installation
(19), washer (18), and lower bolt (17).
NOTE: Install peel shims to both sides of clevis
to obtain 0.002-0.006 inch (0.050-0.152 (9). Raise swashplate to allow removal of
mm) play prior to torque. drive link (2).
(1). Install drive link, lower bolt, washer, B. Adjustable Collective Drive Link
bushing, shims, washer, and nut. Assembly Installation
Torque nut and install new cotter pin.
NOTE:
(2). Install upper bolt, washers, and nut.
Torque nut and install new cotter pin. If installing new adjustable collective
drive link, ensure there is a nominal
(3). Connect lateral and longitudinal drive length of 3.750 inches (9.525 cm) from
links. center of bearing to center of clevis end. If
adjustment is required to allow installa
(4). Install forward swashplate fairing tion, cut safety wire, loosen both jamnuts
assembly T155 (Ref. Section 53-30-00). and rotate barrel. Torque jamnuts
(5). Install forward access door assemblies 660-780 in-lbs. (74.55 - 88.11 N.m) and
L155 and R155 (Ref. Section safety wire.
53-30-00). Install peel shims to both sides of clevis to
obtain 0.002-0.006 inch (0.050-0.152
7. Adjustable Collective Drive Link mm) play prior to torque.
Assembly
(Ref. Figure 404) (1). Install drive link, lower bolt, washers,
bushing, washer, and nut. Torque nut
A. Adjustable Collective Drive Link and install new cotter pin.
Assembly Removal
(2). Install upper bolt, washer, shims,
(1). Remove forward access door assemblies washer, and nut. Torque nut and install
L155 and R155 (Ref. Section new cotter pin.
53-30-00).
(3). Connect lateral and longitudinal drive
(2). Remove forward swashplate fairing
links.
assembly T155 (Ref. Section 53-30-00).
(3). Release collective friction (Ref. Section (4). Install forward swashplate fairing
67-10-00) and raise collective stick assemblies T155 (Ref. Section
slightly to unload flight controls. 53-30-00).
(4). Disconnect one end of lateral and (5). Install forward access door assemblies
longitudinal drive links to enable L155 and R155 (Ref. Section
movement of swashplate. 53-30-00).
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SHIM
CLEVIS 13
12 11
5
14 6
15
7
16 8
1
2
10
4 REF 9
26 27
SHIM INSTALLATION TYP
25 4
17
23 18
19
28
24 3
22
3 REF 21
20
9G62-073
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(1). Disconnect upper end of lateral, (4). Remove nut (23), washer (22), lateral
longitudinal, and collective hydraulic pivot cap (21), bolt (17), retaining ring
actuators (Ref. Section 67-10-00). (19), lateral pivot support (18), and
(2). Remove lateral anti-torque drive link. lateral pivot thrust washer (20).
Remove lateral mixer bellcrank (4).
(3). Remove longitudinal drive link.
B. Lateral Mixer Bellcrank Installation
(4). Remove adjustable and non-adjustable
collective drive links.
Consumable Materials
(5). Remove and discard cotter pins (10).
(Ref. CSPSPM)
(6). Remove nut (9), washer (8), bushing Item Nomenclature
(7), washer (6), and left bolt (5). C308 Primer
(7). Remove nut (16), washer (15), bushing
(14),bushing (13), washer (12), and
right bolt (11). Remove mixer (1). (1). Install lateral mixer bellcrank.
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10. Longitudinal Mixer Bellcrank (5). Connect lower end of longitudinal drive
link.
(Ref. Figure 405)
(6). Connect upper end of longitudinal
A. Longitudinal Mixer Bellcrank Removal hydraulic actuator (Ref. Section
67-10-00).
(1). Disconnect upper end of longitudinal
hydraulic actuator (Ref. Section 11. Collective Mixer Bellcrank
67-10-00).
(Ref. Figure 405)
(2). Disconnect lower end of longitudinal
drive link. A. Collective Mixer Bellcrank Removal
(3). Remove and discard cotter pin (32). (1). Disconnect upper end of collective
hydraulic actuator (Ref. Section
(4). Remove nut (31), washer (30), longitu 67-10-00).
dinal pivot cap (29), bolt (25), retaining
ring (27), longitudinal pivot support (2). Remove lateral mixer bellcrank.
(26), and longitudinal pivot thrust (3). Remove longitudinal mixer bellcrank.
washer (28). Remove longitudinal mixer
bellcrank (3). (4). Disconnect lower ends of non-adjust
able and adjustable collective drive
B. Longitudinal Mixer Bellcrank Installation links.
(5). Remove and discard cotter pins (10).
Consumable Materials
(Ref. CSPSPM) (6). Remove nut (9), washer (8), bushing
Item Nomenclature (7), washer (6), and left bolt (5).
C308 Primer
(7). Remove nut (16), washer (15), bushing
(14), bushing (13), washer (12), and
(1). Install longitudinal mixer bellcrank. right bolt (11). Remove collective mixer
bellcrank (2).
(2). Install longitudinal pivot thrust
washer, longitudinal pivot support, and B. Collective Mixer Bellcrank Installation
retaining ring. (1). Install collective mixer bellcrank, left
NOTE: If you use waterborne primer, do not bolt, washer, bushing, washer, and nut.
thin with water. Use acetone (C436). Torque nut and install new cotter pin.
(2). Install right bolt, washers, bushings
Primer (C308)
and nut. Torque nut and install new
cotter pin.
(3). Connect lower ends of non-adjustable
and adjustable collective drive links.
(3). Install bolt, install wet with primer (4). Install longitudinal mixer bellcrank.
(C308).
(5). Install lateral mixer bellcrank.
(4). Install longitudinal pivot cap, washer,
and nut. Torque nut and install new (6). Connect upper end of collective hydrau
cotter pin. lic actuator (Ref. Section 67-10-00).
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Rotorcraft Maintenance Manual
29
30
31
25
26
27 23
28 22 21
24
3 32
13
12
11
5
6 20 19
18
17
2
4
16
10
15
14
10
33
34
9G62009C
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Rotorcraft Maintenance Manual
12. Swashplate Azimuth Sensor (4). Torque nuts. Safety with lockwire
(C702).
(Ref. Figure 406)
(5). Connect electrical connector P430.
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire
ROTATING
B. Swashplate Azimuth Sensor Installation SWASHPLATE
MS3456W10SL-4S, electrical connector
backshell to a MHS5842WR1002L, and get 4
two NAS1423C10 nuts. Discard nut that
comes on azimuth sensor.
(1). On rotating swashplate, turn setscrew
in until flush. 3 STATIONARY
SWASHPLATE
(2). Measure gap between rotating and
stationary swashplates. Turn setscrew 1 2
out half the distance between swash
plates minus 0.025 in. (0.64 mm). 9G62-072
1. AZIMUTH SENSOR
(3). Install azimuth sensor into stationary 2. NUT
swashplate until distance between 3. NUT
azimuth sensor and setscrew is 4. SETSCREW
5. CONNECTOR (P430)
0.025-0.035 in. (0.635-0.889 mm).
Tighten nut. Figure 406. Swashplate Azimuth Sensor
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Rotorcraft Maintenance Manual
Page 412
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Rotorcraft Maintenance Manual
B. EARLY CONFIG Retainer Rings and (a). Mask the angular and spherical
Seals Installation (One Piece Retainer swashplate bearings and plug bolt
Ring) holes.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
SPHERICAL SLIDER
BEARING
OUTER RACE
NON-ROTATING
ROTATING SWASHPLATE
SWASHPLATE
9G62045A
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Rotorcraft Maintenance Manual
RETAINING RING,
INNER (NOTE)
BEARING, ANNULAR CONTACT NOTE: UP MARKING ON TOP OF RINGS
ROTATING RETAINING RING,
SWASHPLATE OUTER (NOTE)
RETAINER INSTALLATION
TOP VIEW
9G62044A
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(6). Place swashplate press plate (T505) (5) (4). Partially install outer labyrinth seal
on bolt heads. Ensure swashplate and bearing retainer with all but three
assembly and tooling are centered bolts and washers.
beneath piston of press. Press non-ro
tating swashplate assembly from (5). Thread three NAS6604-60 bolts into
rotating swashplate. rotating swashplate assembly.
B. NonRotating Swashplate Installation (6). Center rotating swashplate assembly
over non-rotating swashplate.
(1). Place non-rotating swashplate support
tool (T507) (6) on base of press.
(7). Place swashplate press plate (T505) on
(2). Support non-rotating swashplate on bolt heads. Ensure swashplate assem
support tool. bly and tooling are centered beneath
piston of press. Press rotating swash
Compound, Anti-Seize (C220) plate onto non-rotating swashplate
assembly.
5
5
3 (3 PL)
3 (3 PL)
8
4 7 4
1
6
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
16. Swashplate Spherical Slider Bearing (6). Place swashplate press plate (T505) (7)
on bolt heads. Ensure swashplate
(Ref. Figure 411) assembly and tooling are centered
beneath piston of press. Press swash
Consumable Materials plate assembly from spherical slider
(Ref. CSPSPM) bearing.
Item Nomenclature
B. Swashplate Spherical Slider Bearing
C220 Compound, AntiSeize Installation
C702 Lockwire
(1). Place non-rotating swashplate support
tool (T507) (1) on base of bearing press.
Special Tools
(Ref. CSPSPM) (2). Support swashplate assembly on
Item Nomenclature non-rotating swashplate support tool
T504 Support Tool, Spherical Slider Bearing (T507).
T505 Press Plate, Swashplate Compound, Anti-Seize (C220)
T507 Support Tool, NonRotating Swashplate
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
12 (4 PL) 8
11 (4 PL) 3
7 10 (4 PL)
5
6 (3 PL)
3
3
4 2
ROTATED 180 DEGREES
2
5 1
BEARING INSTALLATION
BEARING REMOVAL
9G62-068
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Rotorcraft Maintenance Manual
(2). Place a wooden board on base of press. (4). Place swashplate on wooden board.
Compound, Anti-Seize (C220)
(5). Place bearing on top of swashplate.
3
5
1
4
2 (3 PL)
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Rotorcraft Maintenance Manual
Page 420
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Rotorcraft Maintenance Manual
(4). Inspect spherical slider bearing (3) for (10). Inspect the drive link attach spherical
maximum play in non-rotating swash bearing (11) for a maximum play of
plate (1) of 0.011 inch (0.279 mm) 0.008 inch (0.203 mm) radial and
radial and 0.035 inch (0.889 mm) 0.040 inch (1.016 mm) axial.
axial. B. Swashplate Assembly Upper Bearing
(5). Inspect spherical slider bearing (3) for a Inspection
maximum radial play on static mast of (1). Remove bolts (8), washers (9), retainer
0.020 inch (0.508 mm). rings (4 and 5), and labyrinth seals (6
(6). Inspect spherical bearings where the and 7).
collective, lateral and longitudinal links (2). Inspect for corrosion. None permitted.
attach (12, 13, and 14) to non-rotating
swashplate (1) . Check for a maximum (3). Inspect for grease leakage. Minor
play of 0.008 inch (0.203 mm) radial grease leakage allowed if bearing
and 0.040 inch (1.016 mm) axial. operates smoothly.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
12 (2 PL)
A
13 11
11 2
4 13
7 REF 6 10
8 (20 PL) 3
9 (20 PL)
6 REF
7
5
14
2
A
Section A-A 9G62029A
1. NONROTATING SWASHPLATE ASSEMBLY 8. BOLT
2. ROTATING SWASHPLATE ASSEMBLY 9. WASHER
3. SELFALIGNING SPHERICAL/SLIDER BEARING 10. ANGULAR CONTACT BALL BEARING
4. BEARING RETAINER RING, OUTER 11. SPHERICAL BEARING, DRIVE LINK ATTACH
5. BEARING RETAINER RING, INNER 12. SPHERICAL BEARING, COLLECTIVE LINK ATTACH
6. LABYRINTH SEAL RING, ROTATING 13. SPHERICAL BEARING, LATERAL ATTACH
7. LABYRINTH SEAL RING, NONROTATING 14. SPHERICAL BEARING, LONGITUDINAL ATTACH
Figure 601. Swashplate Assembly
Page 602
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Rotorcraft Maintenance Manual
C. Swashplate Drive Link Inspection (d). Prevent the rotor from turning, use
rotor brake (if installed).
(Ref. Figure 602)
(1). Inspect to determine the rotational play (e). Manually rotate swashplate forward
between the rotating swashplate and and backward without moving the
the lower drive link.
main rotor. Maximum allowable play
(a). Ensure collective control is in down of 0.140 inch (3.556 mm).
position and cyclic control is in
neutral position .
(f). If allowable play is exceeded, repair
(b). Ensure laminated washers (3) are or replace drive scissors assembly (ref
around outside diameter of sleeve (2) Scissors Drive Link Assembly
and not offset (trapped). If washers Repair).
are offset, replace the lower drive
link and attaching hardware.
(2). Inspect for gouges, dents and scratches.
(c). Attach a dial indicator so the plunger Repair or replace drive scissors assem
is compressed against the head of one bly (ref Scissors Drive Link Assembly
of the lower pitch link attach bolts. Repair).
2 4
5 (2 PL)
3 6
7
1
VIEW ROTATED 9G62043A
1. LOWER DRIVE LINK 5. WASHER
2. DRIVE LINK PIVOT SLEEVE 6. NUT
3. LAMINATED WASHER 7. COTTER PIN
4. BOLT
Figure 602. Swashplate Drive Link Assembly
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
2
1
INSPECTION AREA
FOR CRACKS
VIEW ROTATED
9g62-079
1. LATERAL MIXER BELLCRANK 2. LATERAL ANTITORQUE DRIVE LINK
Figure 603. Lateral Mixer Bellcrank And Lateral Antitorque Drive Link
Page 604
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Rotorcraft Maintenance Manual
CERAMIC
MATERIAL
LATER CONFIG
EARLY CONFIG
9g62-078A
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 606
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(1). Remove bearing, use applicable tools (2). Install bearing. Install bearing wet
and hydraulic press. with epoxy primer (C317). Use applica
ble tools and hydraulic press.
Solvent Cleaner (C429) (3). Make sure bearing stays flush to pitch
link housing.
(4). Let parts cool to ambient temperature.
NOTE: Make sure bearing can not be pushed
from housing with your fingers.
(5). Remove primer from bearing surfaces.
(2). Remove red dot, sealant and/or primer, (6). Apply primer (C308) to make a fillet
use solvent cleaner (C429) and a plastic between outer edge of bearing and
or wooden scraper. housing.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
STAKED FLANGE
PRESS TOOL
HOUSING
HOUSING
SUPPORT
MAXIMUM PERMITTED
DIMENSION
BEARING
REMOVAL 9G62058B
Page 802
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Rotorcraft Maintenance Manual
STAKING TOOL
BEARING OUTER RACE
ROLLED OUTBOARD
ON HOUSING
HOUSING
STAKING TOOL
HOUSING
PILOT
BEARING OUTER RACE
PLATEN
RETAINER SWAGING
ROLLER
BEARING MUST BE 0.010 IN. (0.254 mm) 0.002 IN (0.051 mm)
MAXIMUM ABOVE OR BELOW MAXIMUM
SURFACE OF HOUSING
PILOT
HOUSING BEARING
NECESSARY DIMENSIONS BEFORE STAKING
ARBOR
PLATEN
9G62056B
ROLLER SWEGE STAKING
Page 803
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
If bearing moves, maximum move pitch link with a red dot, use gloss red
ment in opposite direction must not acrylic lacquer (C319).
be more than 0.004 in. (0.102 mm).
Lacquer, Acrylic, Gloss Red (C319) (3). Put number of times bearing has been
replaced on end of housing, use perma
nent ink. No maximum number of
times bearing can be replaced, if
housing is within serviceable limits.
(2). After proof load is complete, identify
DIAL INDICATOR
OR
TRANSDUCER
LOAD HERE
LOAD APPLIED TO
BEARING OUTER RACE
HOUSING
PLATEN
9G62-057
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(5). Examine upper scissors drive link (2) (2). Remove upper scissors drive link (2).
for condition and damage. Maximum
permitted depth 0.005 in. (0.127 mm). (3). Examine hole of flanged bearings (6).
Maximum inner dimension 0.3760 in.
Chemical Coating (C233) (9.55 mm). Replace bearings as a set.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
2
1
6
2 REF
3 REF LUG
3 5
4 (4 PL)
9G62059B
1. SCISSORS DRIVE LINK ASSEMBLY 4. BEARING, FLANGED
2. UPPER SCISSORS DRIVE LINK 5. WASHER, LAMINATED
3. LOWER SCISSORS DRIVE LINK 6. BUSHING, FLANGED
Figure 804. Scissors Drive Link Repair
C. Upper Drive Link Flanged Bearing scratch depth permitted 0.0005 inch
Removal (0.0127 mm).
(Ref. Figure 805) Chemical Coating (C233)
(1). Outboard upper drive link flanged
bearing removal.
(a). Put upper drive link (1) in a soft
jawed vise. (a). Make damaged area smooth and
apply chemical coating (C233).
(b). Cut threads in flanged bearing (2),
use 7/16 x 20 NF tapered tap. Do not D. Upper Drive Link Flanged Bearing
cut into inboard bearing. Installation
(Ref. Figure 805)
(c). Cut threads to bottom of bearing (2),
use 7/16 x 20 NF bottom tap. Do not
cut into inboard bearing. CAUTION
(d). Install scissors assembly bushing tool Flanged bearings (6) are longer than the
set (T508). Hold bolt (T508-1) and thickness of the drive link. Put a support
turn nut (T508-2) to remove bearing under drive link so bearing can go fully
(2). through drive link.
If you use waterborne primer to install
(2). Inboard upper drive link flanged bearings, do no thin primer with water.
bearing removal. Use acetone (C436).
(a). Remove inboard bearings (3). Use Primer (C308)
arbor press and support (T508-6).
(b). Remove lower end bearings (6). Use
arbor press and support (T508-6).
(3). Examine holes in upper scissor. Maxi (1). Install bearings. Install wet with
mum inner dimension 0.5001-0.5006 primer (C308). Use arbor press, punch,
in. (12.7025-12.7152 mm). Maximum plate, and support.
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Rotorcraft Maintenance Manual
(2). Remove primer from bearing surfaces. between outer edge of bearing flange
(3). Apply primer (C308) to make a fillet and drive link.
NOTE 1
2 NOTE 2
1 2
T508-1
1
T508-2
T508-3 3
T508-4
3
T508-5
NOTE 3
1 4
2
3 1
5
NOTE 4
6
NOTES:
1. START THREADS IN FLANGED BEARING WITH TAPERED TAP. 7
2. COMPLETE THREADS IN 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. 9G62084A
SUPPORT FOR DRIVE LINK MUST HAVE A HOLE LARGER THAN OUTER DIMENSION OF BEARING
SO BEARING CAN GO FULLY THROUGH DRIVE LINK.
Page 807
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
E. Lower Drive Link Flanged Bearing to end of bearing. Add the two measure
Removal ments and make a record of them as
dimension A.
(Ref. Figure 806)
(2). Measure width of lower drive link
(1). Put lower drive link (1) in a soft jawed across where bearings are installed.
vice, point scissors stop lug (4) up. Make a record of measurement as
(2). Carefully remove bearing (2) inner dimension B.
shoulder, use a 0.375 in. (9.525 mm)
(3). Subtract dimension B from dimension
cobalt drill bit.
A to find thickness of laminated
(3). Put lower drive link on flanged bearing washer.
removal tool (T508-6) and remove
bearing with inner shoulder and (4). Remove laminates from new laminated
laminated washer (3). washer to get the necessary thickness.
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Rotorcraft Maintenance Manual
4
1
2
5 5
NOTE 1
1 T508-6
MEASUREMENT
3 LOWER DRIVE LINK
1
2
MEASUREMENT
BEARING (2 PL)
4
T508-6
NOTE 4
NOTES:
1. REMOVE SHOULDER FROM ONE FLANGED BEARING.
2. REMOVE BEARING, USE A 0.482 IN. (12.123 mm) PUNCH. 9G62083A
3. REMOVE OTHER BEARING, USE A 0.495 IN. (12.573 mm) PUNCH.
4. USE T508-6 BEARING SUPPORT UNDER LOWER DRIVE LINK.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
3. Drive Link Attach Bearing Replacement drill motor. Maximum depth of cut
0.125 in. (3.17 mm).
(Ref. Figure 807)
(4). Remove bearing flange cutting tool
(T918).
Special Tools
(Ref. CSPSPM) (5). Remove drive link bearing from
Item Nomenclature swashplate (Ref. Pitch Link Bearing
T918 Bearing Flange Cutting Tool Removal procedure).
(6). Examine drive link attach hole in
A. Drive Link Attach Bearing Removal swashplate for scratches, gouges, or
tool marks. None permitted.
(1). Remove swashplate.
(7). Examine hole dimension. Maximum
0.905 in. (22.987 mm).
CAUTION
B. Drive Link Attach Bearing Installation
Bearing swaged flange must be cut off be
fore bearing removal (1). Install drive link bearing in swashplate
(Ref. Pitch Link Bearing Installation
Dimension of bearing cutter must not be
procedure).
more than 0.900000 in. (22.86000 mm).
(2). Stake drive link bearing in swashplate
(2). Install bearing flange cutting tool (Ref. Pitch Link Bearing Staking
(T918) on swashplate, put pilot of procedure).
cutter through bearing to align cutter
back up block and clamp block. (3). Proof load drive link bearing (Ref. Pitch
Link Bearing Proof Load procedure.
(3). Cut into staked flange of bearing, use
bearing flange cutting tool (T918) and a (4). Install swashplate.
Page 810
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
2 REF
3 5
1
4
2
9G62075A
1. DRIVE LINK ATTACH BEARING 4. BEARING FLANGE CUTTING TOOL (T918), BACK UP
2. SWASHPLATE BLOCK
3. BEARING FLANGE CUTTING TOOL (T918), CUTTER 5. CLAMP OF APPLICABLE SIZE
Figure 807. Drive Link Attach Bearing Flange Removal
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Rotorcraft Maintenance Manual
Page 812
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Rotorcraft Maintenance Manual
Chapter
TRANSMISSION AND
DRIVE SYSTEM
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
63 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page ii
Revision 34 63 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page iii
63 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page iv
Revision 34 63 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page v
63 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page vi
Revision 34 63 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page vii
63 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page viii
Revision 34 63 Contents
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
Page ix
63 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Page x
Revision 34 63 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
630000
Rotor Drive System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 1
63-00-00 Revision 25
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 2
Original 63-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
MAIN ROTOR
DRIVE SHAFT
STATIC MAST
SUPPORT ASSEMBLY
PRESSURE
TRANSDUCER
STRUT INPUT
ASSEMBLY DRIVE SHAFTS
BLOWER HOUSING
ASSEMBLY
LUBRICATION
PUMP
DECK FITTING
TRANSMISSION
ASSEMBLY HYDRAULIC ASSEMBLY
PUMP DRIVE NOTAR FAN
DRIVE SHAFT
TEMPERATURE
PROBE AND
SWITCH
9G63-022-1
Page 3
63-00-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
EXHAUST DUCT
INTERCONNECT DUCT
OIL COOLER
AIRFRAME
DECK
INLET DUCT
PRESSURE SWITCH
(LOW)
OIL LEVEL
INDICATOR
MAGNETIC
CHIP DETECTOR
VIEW ROTATED
9G63-022-2
Page 4
Original 63-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Page 5
63-00-00 Revision 19
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Page 6
Revision 25 63-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
PRESSURE
RELIEF VALVE
OIL COOLER
PRESSURE
TRANSDUCER
PRESSURE
SWITCH
OIL IN
PRESSURE
RELIEF VALVE
9G63-023
Page 7
63-00-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
The disk is mounted on the Anti-Torque fan The hydraulic control valve is located on the
drive flange of the Anti-Torque Fan drive main transmission deck. The control valve is a
quill. The disk is of one piece steel construc reservoir for hydraulic fluid (C112) used to
tion, with four equally spaced mounting holes operate the rotor brake subsystem. A remov
and is factory balanced. able filler cap is located on top of the control
valve, for servicing.
B. Brake Head Assembly When the rotor brake handle in the crew
station is pulled, the control valve internal
The brake head assembly is mounted on the metering circuit pressurizes fluid to the brake
main transmission housing. The brake head head assembly.
assembly consists of a housing, calipers, steel
carriers, and linings. The housing is made of D. Control Linkage
cast aluminum and anodized to prevent The control linkage is located in the cockpit
corrosion. Two caliper pistons are mounted in ceiling above the pilot seat. The handle has a
the housing. The steel carriers, and linings are lockout feature that prevents the handle from
seated in the housing and is moved by the being inadvertently operated. To apply the
opposed caliper pistons. rotor brake, the control handle is rotated and
pulled down. The control handle moves the
The brake head assembly receives hydraulic hydraulic control valve metering circuit control
pressure and fluid flow from the hydraulic rod to pressurize the system. The control valve
control valve. When fluid pressure is in pressurizes the brake head assembly to a
creased, the opposed caliper pistons in the maximum pressure of 500 psig.
brake head housing extend outward toward
each other. Each piston contacts a steel carrier When the control handle is pushed upward,
and lining that presses against the disk. This the control valve internal metering circuit
engagement causes friction between the disk decreases pressure, while maintaining a back
and linings, resulting in a braking action. pressure of 10 psig.
E. Hydraulic Tubing
The braking action causes the disk, Anti-
Torque fan drive quill, Anti-Torque fan drive The hydraulic tubing is stainless steel high
shaft, Anti-Torque fan, main transmission, pressure tubing. The tubing routes hydraulic
main rotor drive shaft, and main rotor to stop fluid from the hydraulic control valve to the
rotating. When fluid pressure is decreased, the break head assembly.
pistons retract into the brake head housing by
a return spring. The linings disengage the disk F. Proximity Switches
and returns to the disk clearance dimension
Two proximity switches are installed in the
maintained by a self adjusting mechanism.
brake head assembly. The switches indepen
dently monitor the position of each brake
Each lining has a wear indicator. When the assembly piston.
wear indicator on a lining becomes exposed,
that is a visual indication to replace the lining. The switches complete an electrical circuit to
the IIDS display. The electrical circuit illumi
Bleeder assemblies are located on the brake nates the Rotor Brake light on the IIDS
head housing. The bleeder assemblies provide display during rotor brake subsystem applica
a means to bleed air from the hydraulic lines tion. The Rotor Brake light is extinguished
and brake head housing internal ports. when the rotor brake subsystem is released.
Page 8
Revision 20 63-00-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
HYDRAULIC
TUBE
CONTROL LINKAGE
HYDRAULIC
CONTROL VALVE
DISK
BRAKE HEAD
ASSEMBLY
PROXIMITY
SWITCH
PROXIMITY
SWITCH VIEW ROTATED
9G63-024
FAULT ISOLATION
Excessive oil leak from input Damaged seal. Replace pinion Assy or perform 632000
pinion assembly. Input Pinion Assembly Seal
Replacement.
Poor fit between seal and Replace pinion Assy or perform 632000
shaft. Input Pinion Assembly Seal
Replacement.
Excessive axial displace- Perform Engine to Transmis- 710000
ment at input flanges. sion Alignment.
Impending bypass indicator Faulty bypass indicator. Replace impending bypass 632100
popped in less than 100 indicator.
hours since filter change.
Lubrication pump impending Clogged oil filter. Reset indicator. On second 632100
bypass indicator popped. popup, replace 3 micron
transmission filter.
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XMSN HI OIL TEMP Open wire between: P412D Test and repair wiring. 980000
WARNING illuminated, but and P104M, P412E and
XMSN HI OIL TEMP ground.
WARNING not displayed on
IIDS A/N display. Faulty temp probe & switch Replace temp probe & switch 632000
transducer. transducer.
Loss of XMSN OIL TEMP Faulty temp probe & switch Replace faulty temp probe & 632000
reading. transducer. switch transducer.
Open wire between: P412A Test and repair wiring. 980000
and P10329, P412B and
P10330 or P412C and
P10331.
XMSN LOW OIL TEMP Faulty thermal bypass valve. Replace thermal bypass valve. 632100
CAUTION illuminated and/or
XMSN OIL TEMP C DD
indicates low.
No XMSN OIL PRESS Loss of 7.5 Vdc excitation to Test P411 pins A and B for 7.5 980000
%PSI DD with engines pressure switch. Vdc. If no voltage, test and
running. repair wiring.
Open wire between: P411C Test and repair wiring. 980000
and P10221 or P411D and
P10222.
Faulty oil pressure Replace oil pressure 632000
transducer. transducer.
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
TQ SPLIT EXCEED High rate of torque change Pilot clears IIDS AN display. NA
displayed on IIDS A/N with one engine slightly No maintenance action
display resulting in lagging behind the other, required.
Exceedance Log parameter or When Exceedance Data is
XSMN TQ SPLIT operating in Manual Mode downloaded, XSMN TQ SPLIT
with a large torque split and recording is not required.
switching to Auto Mode
without matching torques
first.
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Rotorcraft Maintenance Manual
5
6
7
8
10
9
9G63-030
1. PRESSURE TRANSDUCER 6. CONNECTOR (P412)
2. CONNECTOR (P411) 7. PRESSURE SWITCH (LOW)
3. SPEED PICKUP (TRANSMISSION ) 8. CONNECTOR (P413)
4. CONNECTOR (P417) 9. CHIP DETECTOR
5. TEMP PROBE & SWITCH 10. CONNECTOR (P415)
Figure 101. Transmission Sensors Location
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Rotorcraft Maintenance Manual
Transmission Oil Pressure to % Oil Pressure Nr @ or Below 85% 0-200 PSI and 0-120 %PSI
120
HIGH PRESSURE CAUTION @
100 PSI AND 100% PSI
110 NOTE 2 AND 3
80
LOW PRESSURE CAUTION @
70 NR 50% AND BELOW 24 PSI AND 75% PSI
NOTE 2 AND 3
60
50
LOW PRESSURE WARNING @
NR 51%-85% 16 PSI AND 50% PSI
40 NOTE 3 AND 4
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Rotorcraft Maintenance Manual
Transmission Oil Pressure to % Oil Pressure Nr @ or Above 86% 0-200 PSI and 0-120 %PSI
120
HIGH PRESSURE CAUTION @
110 100 PSI AND 100% PSI
NOTE 2 AND 3
80
LOW PRESSURE CAUTION @
34 PSI AND 75% PSI
70 NOTE 2 AND 3
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Rotorcraft Maintenance Manual
A403 A2
MAIN TRANSMISSION IIDS
J5 P411 W129 P157 J157 P102 J2
Q Q Q W123 Q
A 1 19 HI XMSN OIL
PRESS EXCIT
B 2 20 LO
OIL PRESSURE
C 3 21 HI XMSN OIL
D 22 LO PRESS
4
A612
FWD INTERCONNECT PANEL
W123 W122
P171 J1 J3 P170 P103 J3
J3 P417 P P P P
P P P P
A 5 21 22 36 NR HI
NR SPEED SENSOR
B 6 22 23 37 NR LO
J4 P412 T T T T T T
T T
C 11 25 69 29 LO 2
OIL TEMP SENSOR 30 LO 1 XMSN OIL TEMP
B 12 26 70
A 13 27 71 31 HI
D 14
OIL TEMP HI
E E
W122 P105 J5
J1 P413
9G63-021B
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PRESSURE
RELIEF VALVE
OIL COOLER
PRESSURE
TRANSDUCER
PRESSURE
SWITCH
OIL IN
PRESSURE
RELIEF VALVE
9G63-023
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Rotorcraft Maintenance Manual
Section
631000
Drive Shafts /
Clutches / Couplings
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
DRIVE SHAFTS/CLUTCHES/COUPLINGS
REMOVAL/INSTALLATION
1. Main Rotor Drive Shaft Make sure the correct lubricat
CAUTION ing oil specification for trans
A. Main Rotor Drive Shaft Removal
mission before starting work. Do not mix
(Ref. Figure 401) different lubricating oils, damage will re
The main rotor drive shaft cover sult. (ref. Section 12-00-00, Table 1.)
CAUTION retains a spring-loaded drive
shaft. Exercise care during removal of the NOTE: Make sure bevel on wear sleeve (17)
cover. Injury to personnel can occur. points down after installation.
(1). Remove sealing compound from bolts
(2) and nuts (5). (1). If removed, install wear sleeve (17) and
spacer (18). (Wear sleeve has a small
(2). Remove bolts (2), countersunk washers bevel on the inside for ease of installa
(3), washers (4), and nuts (5). tion.)
(3). Remove main rotor drive shaft cover (1)
and discard O-ring (6). Grease, Synthetic (C110)
The spring and the carrier sup
CAUTION port lockwasher (ref. Section
63-20-00, Figure 402) at the bottom of the
drive shaft may become adhered to the drive
shaft with grease, causing them to be re
moved with the drive shaft. When removing (2). Pack upper and lower spines of drive
the drive shaft, while preventing the trans shaft with synthetic grease (C110).
mission from rotating, rotate the drive shaft
to brake the grease seal to the spring. (3). Apply a film of synthetic grease (C110)
over spacer (18) and lower seal sleeve
(4). Carefully lift drive shaft (10) from surface (17).
static mast (11).
NOTE: In replacing drive shaft with like new NOTE: Carefully lower drive shaft (10). The
item, perform following step. drive shaft lower spline must pass through a
(5). Remove damper assembly retaining lower seal (6, Figure 403) before engaging
ring (8). Remove damper (7) and transmission spline.
discard o-ring (9).
(4). Carefully lift drive shaft (10, ref.
(6). Remove wear sleeve (17) and spacer Figure 401) and install in static mast
(18). (11).
B. Main Rotor Drive Shaft Installation
(Ref. Figure 401) Oil, Lubricating (C122)
Oil, Lubricating (C106)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C110 Grease, Synthetic
C101 Lubricant, Solid Film (5). Lubricate new O-ring (9) with proper
C211 Sealing Compound, Corrosion Inhibitive lubricating oil and install on damper
C106 Oil, Lubricating assembly (7).
or
C122 Oil, Lubricating (6). Install damper (7) and retaining ring
(8).
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1
2 (6 PL)
(NOTES)
3 (6 PL)
6
18
8
8
1 3
9
6
10
7
9
5 17
4 2
7 10
12
13 (10 PL)
5 (6 PL)
20 (DO NOT INSTALL)
16
19
14 (10 PL)
15 (10 PL)
NOTES:
1. MAIN ROTOR DRIVE PLATE ATTACH
NUT TORQUE SEQUENCE. 11
2. START NUMBERS AT ONE OF THE 10 HOLES.
9G63-001G
1. MAIN ROTOR DRIVE SHAFT COVER (REF. IPL, 11. STATIC MAST
620000, FIG. 2) 12. MAIN ROTOR DRIVE PLATE
2. BOLT 13. BOLT
3. COUNTERSUNK WASHER 14. WASHER
4. WASHER 15. NUT
5. NUT 16. ORING (POST SL900066)
6. ORING 17. WEAR SLEEVE
7. DAMPER 18. SPACER
8. RETAINING RING 19. MAIN ROTOR HUB
9. ORING 20. FRETTING BUFFER DO NOT INSTALL
10. MAIN ROTOR DRIVE SHAFT
Figure 401. Main Rotor Drive Shaft and Drive Plate
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Rotorcraft Maintenance Manual
(7). Lubricate new O-ring (6) with lubricat B. Main Rotor Drive Plate Installation
ing oil (C106) and install on drive shaft
cover (1). (Ref. Figure 401)
Consumable Materials
Lubricant, Solid Film (C101)
(Ref. CSPSPM)
Item Nomenclature
C101 Lubricant, Solid Film
C122 Oil, Lubricating
C211 Sealing Compound, Corrosion Inhibitive
(8). Lubricate bolts (2) with solid film
lubricant (C101). (1). Number torque sequence on drive plate
(12) with a permanent marker.
NOTE: If minimum torque does not meet re NOTE: Do not install fretting buffer (20). Fret
quirements, both nuts (5) and bolts (2) must ting buffer is not necessary and its removal
be replaced. will make it easier to apply the environmen
tal seal around main rotor hub and drive
(9). Install bolts (2), countersunk washers plate.
(3), washers (4) and nuts (5). Torque Oil, Lubricating (C122)
nuts (5) plus locking (run-on) torque
(ref. CSP-SPM).
2. Main Rotor Drive Plate (5). Lubricate bolts (13) with solid film
lubricant (C101).
A. Main Rotor Drive Plate Removal NOTE:
Record locking (run-on) torque of each
(Ref. Figure 401) nut (15) in Rotorcraft Log Book.
If a nut has less than 6.5 in-lb (0.73 Nm)
(1). Remove main rotor drive shaft (ref. locking torque, that nut (15) and related
Section 63-10-00). bolt (13) must be replaced.
Record location of nuts (15) that have less
(2). Remove adhesive from bolts (13) and than 6.5 in-lb (0.73 Nm) locking torque
nuts (15). in Rotorcraft Log Book.
(6). Install bolts (13), washers (14), and
(3). Remove bolts (13), washers (14), nuts nuts (15).
(15). and drive plate (12).
(a). Find locking (run-on) torque of each
nut (15) (ref. CSP-SPM, Section
(4). Discard O-ring (16). 20-10-00, Torque Values).
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(b). Torque nuts (15) in sequence, 1 thru 3. Main Rotor Drive Shaft Upper Seal
10, to 80 to 90 in-lb (9.04 to 10.17
A. Main Rotor Drive Shaft Upper Seal
Nm) plus (+) locking torque. Removal
(Ref. Figure 402)
(c). Torque nuts (15) again in sequence, 1
(1). Remove main rotor drive plate (ref.
thru 10, to 160 to 180 in-lb (18.08
Section 63-10-00).
to 20.34 Nm) plus (+) locking
torque. (2). Remove spiral retaining ring (3) from
drive plate (2). Remove and discard
upper seal (1).
(d). Torque nuts (15) again in sequence, 1
B. Main Rotor Drive Shaft Upper Seal
thru 10, to 230 to 250 in-lb (25.99 Installation
to 28.25 Nm) plus (+) locking
torque. (Ref. Figure 402)
(1). Install upper seal (1) in main rotor
drive plate (2). Install spiral ring (3).
Sealing Compound (C211)
NOTE: Make sure the lip of the upper seal is
facing drive plate splines.
(2). Install main rotor drive plate (ref.
Procedure 2.B.).
9G63-003
1. UPPER SEAL, MAIN ROTOR HEAD (REF. IPL,
(11). Refer to Section 05-20-10, Table 203, 620000, FIG. 2)
Special Inspection - After Component 2. MAIN ROTOR DRIVE PLATE
Installation, Main Rotor Drive Plate 3. SPIRAL RETAINING RING
Nut Torque Verification, for more Figure 402. Main Rotor Drive Shaft Upper
maintenance. Seal
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Rotorcraft Maintenance Manual
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4
(4 PL)
3
(4 PL)
9G63-004A
1. TRANSMISSION SEAL (REF. IPL, 620000, FIG. 2) 4. WASHER
2. STATIC MAST BASE 5. ORING
3. BOLT 6. LOWER SEAL
Figure 403. Main Rotor Drive Shaft Lower Seal
4. Main Rotor Drive Shaft Lower Seal (a). Discard lower seal (6).
A. Main Rotor Drive Shaft Lower Seal B. Main Rotor Drive Shaft Lower Seal
Removal Installation
(Ref. Figure 403)
(Ref. Figure 403)
(1). Remove main transmission (ref. Section Consumable Materials
63-20-00). (Ref. CSPSPM)
Item Nomenclature
(2). Remove sealant from bolts (3).
C106 Oil, Lubricating
(3). Remove bolts (3) and washers (4) from C205 Sealing Compound
transmission seal (1). C211 Sealing Compound, Corrosion Inhibitive
(4). Remove transmission seal (1) from
static mast base (2). (1). Install lower seal (6) in transmission
seal (1).
(5). Remove O-ring (5).
Oil, Lubricating (C106)
(a). Discard O-ring (5).
If serviceable, the transmission
CAUTION seal can be reused. Use care
during removal of the lower seal to prevent (2). Lubricate new O-ring (5) with lubricat
damage to the transmission seal. ing oil (C106).
(6). Remove lower seal (6) from transmis (3). Install O-ring (5) on transmission seal
sion seal (1). (1).
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Rotorcraft Maintenance Manual
(4). Install transmission seal (1) on static (a). Torque bolts (3) 36 to 46 in-lb (4.07
mast base (2). to 5.20 Nm).
Sealing Compound (C205) Sealing Compound (C211)
(5). Apply sealing compound (C205) to bolts (7). Seal bolts (3) with sealing compound
(3). (C211) (ref. CSP-SPM, 20-50-00,
Mechanical Fastener Sealing).
(6). With sealing compound (C205) still wet,
install transmission seal (1) with bolts (8). Install main transmission (ref. Section
(3) and washers (4). 63-20-00).
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5
3
1
2
(4 PL)
2
(4 PL)
9G63-002A
Figure 404. Removal and Installation of the Input Drive Shaft Assemblies
5. Input Drive Shaft Assemblies B. Drive Shaft Installation
(Ref. Figure 404)
A. Drive Shaft Removal
CAUTION
(Ref. Figure 404)
The drive shaft has a very thin wall thick
NOTE: This task is typical for left or right drive ness. Try to not touch other parts during
shaft removal. installation of the drive shaft. Damage
can cause an unbalanced drive shaft.
(1). Open Access Panel L210 and/or Access Axial displacement can cause too much oil
Panel R210 (ref. Section 06-00-00). leakage from the input pinion assembly.
If you think there is a misalignment dur
The drive shaft has a very thin ing the installation procedure, do the En
CAUTION wall thickness. Try to not touch gine to Transmission Alignment proce
other parts during removal of the drive dure (ref. Section 71-00-00,
shaft. Damage can cause an unbalanced Inspection/Test).
drive shaft.
NOTE: This task is typical for left or right drive
shaft installation.
(2). Remove bolts (2) from transmission
flange (3). (1). If a new drive shaft or new input pinion
assembly components are to be
(3). Remove bolts (2) from engine flange (4). installed, do the Engine to Transmis
sion Alignment procedure (ref. Section
71-00-00, Inspection/Test).
(4). Carefully remove drive shaft (1) from
transmission flange (3) and engine (2). Close Access Panel L210 and/or Access
flange (4). Panel R210 (ref. Section 06-00-00).
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(3). Carefully install drive shaft (1) between (4). Install bolts (2) in transmission flange
transmission flange (3) and engine (3).
flange (4).
(5). Install bolts (2) in engine flange (4).
NOTE: Correct alignment provides zero to posi (6). Torque bolts (2) 70 to 90 in-lb (7.91 to
tive clearance between the flanges to install 10.17 Nm) more than the locking
the drive shaft in tension. torque.
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2 (4 PL)
4
3 1
2 (4 PL) 1
9G63-027
1. FAN DRIVE SHAFT (REF. IPL, 631000, FIG. 2) 3. TRANSMISSION FLANGE
2. BOLT 4. ANTITORQUE COUPLING
Figure 405. Removal and Installation of NOTARr Fan Drive Shaft Assembly
6. NOTARr Fan Drive Shaft Assembly
CAUTION
A. Fan Drive Shaft Removal The fan drive shaft has very thin wall
thickness. Avoid contact with other parts
during removal of the fan drive shaft.
(Ref. Figure 405) Damage can cause an unbalanced fan
drive shaft.
Do not remove couplings from fan drive
(1). Remove access panels L210 and R210
shaft. Removal of couplings can cause an
(ref. Section 53-30-00).
unbalanced fan drive shaft (this does not
refer to the anti-torque fan shaft cou
(2). Remove Access Panel T220 (ref. Section pling).
53-30-00). (6). Remove bolts (2) from both ends of fan
drive shaft (1).
(3). Remove the electrical load center (7). Carefully remove fan drive shaft (1).
assembly (ref. Section 96-00-00).
B. Fan Drive Shaft Installation
(4). Remove the anti-torque fan forward (Ref. Figure 405)
duct assembly F1, F2, and F3 (ref.
Section 53-30-00). Consumable Materials
(Ref. CSPSPM)
(5). Remove the upper inlet duct cover from Item Nomenclature
the forward duct assembly (ref. Section C231 Releasing Agent
53-30-00).
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Rotorcraft Maintenance Manual
(a). Measure the gap between fan drive (b). Torque bolts (2) 70 to 90 in-lb (7.91
shaft (1) and anti-torque fan cou to 10.17 Nm) more than the locking
pling (4). torque.
(3). Install the upper inlet duct cover on the
forward duct assembly (ref. Section
1). The gap must be 0.001 to 0.010 53-30-00).
inch (0.03 to 0.25 mm).
(4). Install the anti-torque fan forward
duct assembly F1, F2, and F3 (ref.
2). If the gap is more than 0.010 inch Section 53-30-00).
(0.25 mm), refer to the anti-
torque fan support installation (ref. (5). Install the electrical load center
Section 64-30-00). assembly (ref. Section 96-00-00).
(6). Install Access Panel T220 (ref. Section
53-30-00).
3). Make sure the minimum running
torque of the nutplates is 3.5 in-lb (7). Install access panels L210 and R210
(0.40 Nm) before bolt installation. (ref. Section 53-30-00).
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9g63-042-3
NO NICKS, DENTS
OR SCRATCHES
PERMITTED IN
BASE METAL IN
THIS AREA PROFILE AREA
NICKS AND
SCRATCHES
PERMITTED
IN BASE
METAL IN
THIS AREA 9g63-042-1
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(2). Externally inspect diaphragms for 3. Main Rotor Drive Shaft Inspection
dents. None permitted.
A. Drive Shaft
(a). Dents found in the profile area
(Figure 602) shall require anti- (1). Wipe off all grease.
torque drive shaft replacement.
(2). Inspect all surfaces of drive shaft for
(3). Externally inspect diaphragm profile dents, nicks, scratches and evidence of
paint for crazed lines. Ref. Figure 602. deformation.
(a). If crazed lines are found, input drive (a). No damage of any kind is permitted
shaft is to be rejected and replaced in the area within 2.000 inch (50.80
(ref. Section 63-10-00). This is an mm) of the spline. No cracks are
indication that the input drive shaft allowed.
has seen over angle or torque condi
(b). Nicks, scratches and dents not
tion.
exceeding 0.004 inch (0.10 mm) in
(4). Externally inspect outer rim for nicks depth and 1.000 inch (25.40 mm) in
and scratches. Refer to Figure 603. length are permitted if polished out.
(a). Nicks and scratches on the outer rim (3). Inspect all external surfaces of shaft for
up to 0.010 inch (0.25 mm) in depth corrosion.
and 1.000 inch (25.40 mm) in
length which can be polished out are
NOTE: Spline surfaces will normally display a
permitted. wear pattern (discoloration or removal of sil
ver plating), however, pitting, spalling, or
(b). Nicks and scratches on the outer rim heavy grooved wear marks over more than
deeper than 0.0100 inch (0.25 mm) 50 percent of the wear area is not permitted.
and longer than 1.000 inch (25.40
mm) in length are not permitted. (4). Inspect splines on both ends of drive
Replace input drive shaft. shaft for excessive wear by measuring
distance across two 0.142 inch (3.61
(5). Inspect diaphragm surface for corro mm) diameter pins placed in opposite
sion. Shafts with traces of corrosion on spline grooves.
this area must be discarded.
NOTE: Measurements are to be taken over the
C. Flanges two pins, at a four places (minimum),
approximately 45 degrees apart, and aver
(1). Inspect flange faces of shaft for cracks, aged. When taking these measurements,
corrosion and fretting. No cracks
the pins must be carefully placed at the face
allowed.
width mid-point of the spline. The resulting
(a). Corrosion up to 0.006 in. (0.152 mm) value must be greater than or equal to the
in depth which can be polished out minimum value specified.
are permitted. Ref. Figure 603.
(a). For the upper spline, the dimension
(b). Corrosion deeper than 0.006 inch must be 4.4811 inch (113.820 mm)
(0.15 mm) is not permitted. Replace minimum.
input drive shaft.
(b). For the lower spline, the dimension
(c). If fretting marks are deeper than must be 3.6588 inch (92.934 mm)
0.006 inch (0.15 mm) replace input minimum.
drive shaft.
(5). If you are not sure of the shaft condi
D. Mounting Bolts tion, do a magnetic particle inspection
(ref. CSP-SPM, Section 20-90-00, Part
Inspect mounting bolts for torque. E.).
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SURFACE X DIMENSION 1
SURFACE Y
SURFACE Z
CORROSION PIT DEPTH DIMENSION 3
DIMENSION 2
9G63-057
DIM. 1 DIM. 3
DIM. 2 DIM. 2
= DIM. 4 = DIM. 5
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(a). Measure the distance from Surface (3). After completion of a Drive Plate
X to Surface Z and record value as Pitting Repair, do these steps:
Dimension 1.
(a). Measure the distance from Surface
(b). Measure the depth of corrosion/fret X to Surface Z.
ting pits and record the value as
Dimension 2. 1). The dimension must be more than
or equal to 2.107 inch (53.52
(c). Measure distance from Surface Y to mm).
Surface Z, and record the value as
Dimension 3. (b). Measure the distance from Surface
Y to Surface Z.
(d). If Dimension 1 is more than or
equal to 2.109 inch (53.66 mm), do 1). The dimension must be more than
these steps: or equal to 0.190 inch (4.83 mm).
1). Subtract Dimension 2 from (c). If the dimensions do not satisfy the
Dimension 1, and record the result requirements, contact a MDHI Field
as Dimension 4. Representative.
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(NOTE 1)
6
10
9
5
4 2
7
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. 9G63-036
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(2). Remove sealant from bolts and nuts (if Sealing Compound (C211)
applicable).
(4). Torque nuts in sequence, 1 thru 10, to NOTE: Ref. CSP-900RMM-2, Section
230 to 250 in-lb (25.98 to 28.25 Nm) 05-20-10, Table 203, Special Inspection -
plus (+) the locking (run-on) torque After Component Installation, Main Rotor
(ref. CSP-SPM, Section 20-10-00, Drive Plate Nut Torque Check, for addition
Torque Wrenches). al inspection requirements.
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A. Blend Repair
Consumable Materials
(1). Blend damaged area no deeper than
(Ref. CSPSPM)
0.015 inch (0.38 mm) with abrasive
Item Nomenclature
cloth (C804) to completely remove
damage. C311 Primer, Heresite
C312 Primer, Heresite
(a). Maintain a smooth transition into C423 Solvent, Cleaning
surrounding undamaged surface. C804 Abrasive Cloth
(b). Total rework area cannot have more (1). Blend damaged area no deeper than
than 4 reworks on center of tube. 0.010 inch (0.25 mm) with abrasive
cloth (C804) to completely remove
Solvent, Cleaning (C423) damage.
(a). Maintain a smooth transition into
surrounding undamaged surface.
(b). Total rework area cannot have more
than 4 reworks on center of tube.
(2). Clean shaft with cleaning solvent Solvent, Cleaning (C423)
(C423).
(a). Let heresite primer (C311) dry for 1 (3). Apply heresite primer (C311) to
hour minimum at 203F (95C). abraded area of shaft.
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Rotorcraft Maintenance Manual
(a). Let heresite primer (C311) dry for 1 (1). Blend damaged area no deeper than
hour minimum at 203F (95C). 0.004 inch (0.10 mm) with abrasive
cloth (C804) to completely remove
Primer, Heresite (C312) damage.
.005 A
MATING SURFACE
FILLET
-A- RADIUS
9G63-056
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4. Main Rotor Drive Plate Repairs (a). Machine the surface 0.001 inch
(0.03 mm) past depth required to
A. Pitting Repair remove all corrosion and fretting pits.
(b). The surface finish must be 32 RMS.
(Ref. Figure 801)
(c). The fillet radius must be 0.005 to
0.015 inch (0.13 to 0.38 mm).
Consumable Materials
(Ref. CSPSPM) (d). The mating surface must be perpen
Item Nomenclature dicular to the centerline of Base A
Commercial Plating, Cadmium (BrushOn) within 0.005 inch (0.13 mm).
QQP416, Type II, CL 2 (2). Do a magnetic particle inspection (ref.
CSP-SPM, Section 20-90-00, Part E.).
(1). Machine mating surface of drive plate (3). Brush cadmium plate with a certified
to upper hub assembly to satisfy the low embrittlement solution to machined
following requirements: surface of drive plate.
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Section
632000
Gearboxes
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
GEARBOXES
REMOVAL/INSTALLATION
1. Main Transmission Assembly (g). Detach lateral vibration sensor
connector P431 (21).
A. Transmission Removal
NOTE: Residual oil could remain in oil lines
(Ref. Figure 402) and heat exchanger assemblies. When re
moving oil lines or components, take precau
Special Tools tions to catch oil with rags or a suitable con
(Ref. CSPSPM) tainer.
Item Nomenclature
System Contamination
T301 Transmission Removal Kit CAUTION
T3011 Dolly Assembly
T3012 Tray Assembly (8). Remove lockwire from left and right
hand oil out hoses (1). Remove left and
T3013 Pin
right hand oil out hoses (1). Drain
residual oil.
(1). Remove forward access door assembly
(9). Remove lockwire from left and right
L155 and R155 (Ref. Section hand oil in hoses (4). Remove left and
53-30-00). right hand oil in hoses (4). Drain
(2). Remove swashplate forward fairing residual oil.
assembly T155 (Ref. Section 53-30-00).
(10). Remove right hand heat exchanger
(3). Remove transmission access door assembly (Ref. Section 63-21-00).
assembly L210 and R210 (Ref. Section Drain residual oil.
53-30-00).
(11). Drain residual oil from left hand heat
(4). Remove swashplate aft fairing assem exchanger (Ref. Section 63-21-00).
bly T220 (Ref. Section 53-30-00). (12). Remove left hand cooling interconnect
(5). Drain transmission oil (Ref. Section duct (4, Figure 404, Ref. Section
12-00-00). 63-21-00).
(6). Remove main rotor drive shaft (Ref. (13). Remove hydraulic pumps (Ref. Section
Section 63-10-00). 29-00-00). Leave hydraulic lines
connected.
(7). Detach connectors.
(14). Remove No.2 hydraulic manifold/reser
(a). Detach pressure transducer connec voir (Ref. Section 29-00-00).
tor P411 (3, Ref. Figure 408).
(15). Remove oil filler assembly (Ref. Section
(b). Detach temperature probe and 63-21-00).
switch connector P412 (11).
(16). Remove left and right hand input drive
(c). Detach pressure switch connector shaft (Ref. Section 63-10-00).
P413 (14).
(17). Remove NOTAR anti-torque drive
(d). Detach chip detector connector P415 shaft (Ref. Section 63-10-00).
(17).
(18). Disconnect and remove rotor brake
(e). Detach speed pickup connector P417 hydraulic line if applicable (Ref. Section
(6). 63-22-00). Leave clamps and brackets
attached to line.
(f). Detach vertical vibration sensor
connector P432 (10, Ref. Figure 402). (19). Remove drain pans.
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(20). Install transmission removal kit (T301) (22). Cut and discard lockwire and remove
(Ref. Figure 401). tension bolts (17), countersunk washers
(16) and bolt isolators (15) from mast
(a). Position tray assembly (T301-2) (1) base.
under main transmission assembly.
(23). Raise ball caster jackscrews (4, Ref.
(b). Remove quick release pins (T301-3) Figure 401) until clearance is obtained
(2) and separate dolly assembly between transmission and mast base.
(T301-1) (3) sections. (24). Remove right hand mid-forward truss
and mid-aft truss mast base support
(c). Place dolly assembly (T301-1)
strut assemblies (Ref. Section
sections under transmission and
63-30-00).
connect sections with quick release
pins (T301-3). (25). Rotate transmission as necessary to
clear blockages and slide transmission
(d). Lower ball caster jackscrews (4) at to end of tray.
each corner of dolly assembly
(T301-1) until dolly meets bottom of NOTE: If replacing main transmission with
transmission assembly. like new item, perform the following steps.
(21). Remove bolt (18, Ref. Figure 402) and (26). Remove segmented isolators (11, Ref.
washer (19) and disconnect bonding Figure 402) from transmission.
jumper (20) from transmission. (27). Remove unions (2) and discard O-rings
(3).
(28). Remove unions (5) and discard O-rings
(6).
(29). Remove rotor brake head assembly and
disk if applicable (Ref. Section
63-22-00).
(30). Remove drain tubes.
1 (31). Remove left and right hand blower
impeller and blower housing assembly
3 (Ref. Section 63-21-00).
(32). Cut and discard lockwire and remove
vibration sensor (9) from velocimeter
bracket (8).
2 (33). Remove velocimeter bracket (8).
(a). Remove sealing compound from bolts
(7).
(b). Remove bolts and velocimeter
bracket.
(34). Remove carrier seal cover (12).
4
9G63-033
(a). Remove sealing compound from
1. TRAY ASSEMBLY (T3012) screws (14).
2. PIN (T3013)
3. DOLLY ASSEMBLY (T3011) (b). Cut and discard lockwire.
4. BALL CASTER JACKSCREW
(c). Remove screws (14), washers (13)
Figure 401. Transmission Tool and carrier seal cover (12).
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Rotorcraft Maintenance Manual
(35). Do the main rotor driveshaft inspection. Lubricant, Solid Film (C101)
B. Transmission Installation
Special Tools
(Ref. CSPSPM)
Item Nomenclature (e). Using mechanical fastener sealing
T301 Transmission Removal Kit method (Ref. CSP-SPM), apply
sealing compound (C211) to heads of
T3011 Dolly Assembly bolts.
T3012 Tray Assembly
(3). Install vibration sensor (9).
T3013 Pin
(a). Install vibration sensor on velocime
ter bracket. Torque vibration sensor
NOTE: If replacing main transmission with (9).
like new item, perform following steps.
(b). Safety vibration sensor with lockwire
(C702).
(1). Install carrier seal cover.
(4). Install left and right hand blower
(a). Install carrier seal cover (12) with housing assemblies and blower impeller
screws (14) and washers (13). Torque (Ref. Section 63-21-00).
screws (14).
(5). Install drain tubes if removed.
(b). Safety screws with lockwire (C702). (6). Install rotor brake disk and head
assembly if removed (Ref. Section
Sealing Compound (C211) 63-22-00).
Grease, Synthetic (C110)
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25
15
18
20
19
14
21 23 4 PL
13
12
11 (TYP) 22
24
25 -30 in-lb
2.8 - 3.8 Nm
8 7 (2 PL)
10
4 (2 PL)
6 5
2 PL
3
2 1 (2 PL)
2 PL
9G63-018B
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(11). Ensure spring (22) and lockwasher (24) (a). Spray threads of bolt (18) with solid
are installed. film lubricant (C101).
(b). Connect bonding jumper (20) to
(12). Install transmission on dolly assembly transmission with washer (19) and
(T301-1) (1, Ref. Figure 401). bolt (18). Torque bolt (18).
(18). Remove main transmission removal kit
(13). Slide transmission on tray assembly (T301) (Ref. Figure 401).
(T301-2) (3) under mast base assembly (a). Raise ball caster jackscrews (4)
and orient correctly. completely at each corner of dolly
assembly (T301-1) (1).
(14). Lower ball caster jackscrews (4) at each (b). Remove quick release pins (T301-3)
corner of dolly assembly (T301-1) (1) (2) and separate dolly assembly
until transmission mates with mast (T301-1) sections.
base.
(c). Remove dolly assembly (T301-1) (1)
and tray assembly (3) from transmis
(15). Install bolt isolators. sion deck.
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(19). Install right hand mid-forward truss (b). Attach temperature probe and switch
and mid-aft truss mast base support connector P412 (11).
strut assemblies (Ref. Section
63-30-00). (c). Attach pressure switch connector
P413 (14).
(20). Install drip pans.
(d). Attach chip detector connector P415
(21). Install rotor brake hydraulic line if (17).
applicable (Ref. Section 63-22-00).
(e). Attach speed pickup connector P417
(22). Install anti-torque drive shaft (Ref.
(6).
Section 63-10-00).
(23). Check engine to transmission align (f). Attach vertical vibration sensor
ment and realign if necessary (Ref. connector P432 (10, Ref. Figure 402).
Section 71-00-00). (g). Attach lateral vibration sensor
(24). Install left and right hand input drive connector P431 (21) to vibration
shafts (Ref. Section 63-10-00). sensor (23).
(25). Install oil filler assembly (Ref. Section (35). Install main rotor drive shaft (Ref.
63-21-00). Section 63-10-00).
(26). Install hydraulic pumps (Ref. Section (36). Service transmission (Ref. Section
29-00-00). 12-00-00).
(27). Install No.2 hydraulic manifold/reser (37). Verify no leaks are present in flam
voir (Ref. Section 29-00-00). mable fluid systems, where mainten
(28). Install left hand cooling interconnect ance or replacement of components,
duct (4, Figure 404, Ref. Section lines, or fittings has occurred, by
63-21-00). application of system pressure and
visual inspection prior to helicopter
(29). Install right hand heat exchanger being returned to service.
assembly (Ref. Section 63-20-20).
(38). Install swashplate aft fairing assembly
(30). Connect oil out hoses (1). Torque hoses T220 (Ref. Section 53-30-00).
(1).
(39). Install swashplate forward fairing
(31). Safety oil out hoses (1) with lockwire assembly T155 (Ref. Section 53-30-00).
(C702).
(40). Install transmission access door
(32). Connect oil in hoses (4). Torque hoses assembly L210 and R210 (Ref. Section
(4). 53-30-00).
(33). Safety oil in hoses (4) with lockwire
(41). Install forward access door assembly
(C702).
L155 and R155 (Ref. Section
(34). Attach connectors. 53-30-00).
(a). Attach pressure transducer connector (42). Perform transmission operation test -
P411 (3, Ref. Figure 408). run-up (Ref. Section 63-20-00).
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Special Tools
Special Tools
(Ref. CSPSPM)
(Ref. CSPSPM)
Item Nomenclature
Item Nomenclature
T304 Guide Pins
T304 Guide Pins T2004 Heat Gun
T306 Jackscrews
NOTE: This task is typical for left or right input
pinion installation.
NOTE: This task is typical for left or right input Oil, Lubricating (C122)
pinion removal. Oil, Lubricating (C106)
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(7). Perform transmission operation test - (10). Using fillet surface sealing method (Ref.
manual rotation (Ref. Section CSP-SPM), apply sealing compound
63-20-00). (C205) to parting line of input pinion
assembly (1) and main transmission
(8). Connect flexible drain tubing to input assembly (2).
pinion assembly. Safety connection with (11). Install input drive shaft assembly (Ref.
lockwire (C702). Section 63-10-00).
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REMOVAL
7
4
(8 PL)
2
62 -82 in-lb
3 7 - 9.2 Nm
(8 PL)
9G63-006A
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(8). Install rotor brake disk (Ref. Section 4. Lubrication Pump Drive Assembly
63-22-00).
(9). Service transmission (Ref. Section NOTE: If helicopter is equipped with a
12-00-00). 900D1400006-101 transmission, ensure
original input pinion is retained with trans
(10). Install anti-torque drive shaft mission. (Ref. Section 05-10-00, Table 201).
assembly (Ref. Section 63-10-00).
(11). Verify no leaks are present in flam A. Lubrication Pump Drive Assembly
mable fluid systems, where mainten Removal
ance or replacement of components,
lines, or fittings has occurred, by (Ref. Figure 405)
application of system pressure and
visual inspection prior to helicopter
being returned to service. Special Tools
(Ref. CSPSPM)
Item Nomenclature
T306 Jackscrews
5
(1). Remove lubrication pump (Ref. Section
63-21-00).
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Rotorcraft Maintenance Manual
B. Lubrication Pump Drive Assembly pump drive assembly (1) and main
Installation transmission (2).
(Ref. Figure 405) (4). Install lubrication pump (Ref. Section
63-21-00).
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C106 Oil, Lubricating
or
C122 Oil, Lubricating
C205 Sealing Compound
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Rotorcraft Maintenance Manual
Special Tools
(Ref. CSPSPM) NOTE: This task is typical for left or right hy
Item Nomenclature draulic pump accessory drive assembly
installation.
T344 Puller Assembly
Oil, Lubricating (C122)
Oil, Lubricating (C106)
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Rotorcraft Maintenance Manual
6
(6). Using mechanical fastener sealing
method (Ref. CSP-SPM), apply sealing
compound (C205) to heads of bolts (4).
(7). Using fillet surface sealing method (Ref.
CSP-SPM), apply sealing compound
(C205) to parting line of hydraulic 9
2
pump accessory drive assembly (1) and 8
1
main transmission (2). 7
9G63-011A
1. HYDRAULIC PUMP ACCESSORY DRIVE
2. MAIN TRANSMISSION
3. DRAIN TUBING
4. BOLT
5. WASHER
6. ORING
7. ACCESSORY SEAL HOUSING ASSEMBLY
8. ORING
9. ACCESSORY BEARING RETAINER ASSEMBLY
Figure 406. Hydraulic Pump Accessory Drive
Assembly
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6. Blower Drive Assembly (5). Remove blower drive assembly (1) from
main transmission (2) and discard
NOTE: If helicopter is equipped with a O-ring (5).
900D1400006-101 transmission, ensure
original input pinion is retained with trans B. Blower Drive Assembly Installation
mission. (Ref. Section 05-10-00, Table 201).
(Ref. Figure 407)
A. Blower Drive Assembly Removal
(4). Remove sealing compound from (4). Using mechanical fastener sealing
surfaces of blower drive assembly (1) method (Ref. CSP-SPM), apply sealing
and main transmission (2). compound (C205) to nuts (3).
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Rotorcraft Maintenance Manual
(5). Using fillet surface sealing method (Ref. Oil, Lubricating (C122)
CSP-SPM), apply sealing compound Oil, Lubricating (C106)
(C205) to parting line of blower drive
assembly (1) and main transmission
(2).
(6). Service transmission (Ref. Section
12-00-00).
Verify proper lubricating oil for
(7). Install blower housing assembly (Ref. CAUTION transmission before starting
Section 63-21-00). work. Do not mix different specification lu
(8). Verify no leaks are present in bricating oil, damage will result. (Ref. Sec
flammable fluid systems, where tion 12-00-00, Table 1)
maintenance or replacement of
components, lines, or fittings has (1). Lubricate new O-ring (4) and pressure
occurred, by application of system transducer (1) threads with proper
pressure and visual inspection prior to lubricating oil. Install O-ring on
helicopter being returned to service. pressure transducer.
7. Pressure Transducer
(2). Install and torque pressure transducer
A. Pressure Transducer Removal
(1). Safety transducer with lockwire
(Ref. Figure 408) (C712).
(1). Open transmission access door assem
bly L210 and R210 (Ref. Section Sealing Compound (C205)
06-00-00).
(2). Detach connector P411 (3) from
pressure transducer (1).
(3). Remove sealing compound from
surfaces of pressure transducer (1) and (3). Using fillet surface sealing method (Ref.
main transmission (2). CSP-SPM), apply sealing compound
(C205) to parting line of pressure
(4). Cut and discard lockwire from trans transducer (1) and main transmission
ducer. Remove transducer from main (2).
transmission (2) and discard O-ring (4).
B. Pressure Transducer Installation (4). Verify no leaks are present in flam
mable fluid systems, where mainten
(Ref. Figure 408) ance or replacement of components,
lines, or fittings has occurred, by
Consumable Materials application of system pressure and
(Ref. CSPSPM) visual inspection prior to helicopter
Item Nomenclature being returned to service.
C106 Oil, Lubricating
or (5). Attach connector P411 (3).
C122 Oil, Lubricating
C712 Lockwire (6). Close transmission access door assem
C205 Sealing Compound bly L210 and R210 (Ref. Section
06-00-00).
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(1). Open transmission access door assem Verify proper lubricating oil for
bly L210 and R210 (Ref. Section CAUTION transmission before starting
06-00-00). work. Do not mix different specification lu
bricating oil, damage will result. (Ref. Sec
(2). Detach connector P417 (6) from tion 12-00-00, Table 1)
transmission speed pickup (5).
(2). Lubricate new O-ring (9) with proper
(3). Remove sealing compound from bolts lubricating oil and install on transmis
(7). Remove bolts (7) and washers (8). sion speed pickup (5).
(4). Remove sealing compound from (3). Install speed pickup with bolts (7) and
surfaces of speed pickup (5) and main washers (8). Torque bolts (7).
transmission (2). Sealing Compound (C205)
(5). Remove speed pickup (5) and discard
O-ring (9).
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(1). Open forward access door assembly Verify proper lubricating oil for
R155 (Ref. Section 06-00-00). CAUTION transmission before starting
work. Do not mix different specification lu
(2). Open transmission access door assem bricating oil, damage will result. (Ref. Sec
bly R210 (Ref. Section 06-00-00). tion 12-00-00, Table 1)
(3). Drain oil from transmission (Ref. (1). Lubricate new O-ring (12) and temper
Section 12-00-00). ature probe and switch (10) threads
with proper lubricating oil. Install
NOTE: Residual oil could remain in oil lines. O-ring on temperature probe and
When removing oil lines or components, switch.
take precautions to catch oil in rags or a
suitable container. (2). Install and torque temperature probe
and switch (10). Safety temperature
(4). Detach connector P412 (11) from probe and switch with lockwire (C712).
temperature probe and switch (10). Sealing Compound (C205)
(5). Remove sealing compound from
transmission housing (2), temperature
probe and switch (10).
(6). Cut and discard lockwire from tempera (3). Using fillet surface sealing method (Ref.
ture probe and switch (10). Remove CSP-SPM), apply sealing compound
temperature probe and switch (10) from (C205) to parting line of temperature
main transmission (2) and discard probe and switch (10) and main
O-ring (12). transmission (2).
(4). Attach connector P412 (11).
B. Temperature Probe and Switch
Installation (5). Service transmission (Ref. Section
12-00-00).
(Ref. Figure 408)
(6). Verify no leaks are present in flam
mable fluid systems, where mainten
Consumable Materials ance or replacement of components,
(Ref. CSPSPM) lines, or fittings has occurred, by
Item Nomenclature application of system pressure and
C106 Oil, Lubricating visual inspection prior to helicopter
being returned to service.
or
C122 Oil, Lubricating (7). Close forward access door assembly
C712 Lockwire R155 (Ref. Section 06-00-00).
C205 Sealing Compound (8). Close transmission access door assem
bly R210 (Ref. Section 06-00-00).
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70 -85 in-lb
7.9 - 9.6 Nm 4
1
3
5
6
2
12
8 (2 PL)
7
(2 PL)
32 -37 in-lb 11
3.6 - 9.1 Nm
VIEW ROTATED 10
70 -85 in-lb 70 -85 in-lb
15
7.9 - 9.6 Nm 7.9 - 9.6 Nm
13
14 20
70 -85 in-lb
19 7.9 - 9.6 Nm
18
16
17
9G63-013
Figure 408. Transmission Pressure Transducer, Speed Pickup, Chip Detector, Temperature
Probe & Switch and Pressure Switch
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12. Chip Detector Screen and Valve (Housing) Oil, Lubricating (C122)
Assembly Oil, Lubricating (C106)
A. Screen and Valve (Housing) Assembly
Removal
(Ref. Figure 408)
(1). Remove chip detector (Ref Section
Verify proper lubricating oil for
63-20-00). CAUTION transmission before starting
(2). Remove sealing compound from work. Do not mix different specification lu
transmission housing (2), chip detector bricating oil, damage will result. (Ref. Sec
screen and valve assembly (19). tion 12-00-00, Table 1)
(3). Cut and discard lockwire from chip
detector screen and valve assembly (1). Lubricate new O-ring (20) and chip
(19). detector screen and valve assembly (19)
threads with proper lubricating oil and
(4). Remove valve assembly from main install O-ring on valve assembly.
transmission (2) and discard O-ring
(20).
(2). Install and torque screen and valve
B. Screen and Valve (Housing) Assembly assembly (19). Safety valve assembly
Installation with lockwire (C712).
(Ref. Figure 408)
Sealing Compound (C205)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C106 Oil, Lubricating
or
(3). Using fillet surface sealing method (Ref.
C122 Oil, Lubricating CSP-SPM), apply sealing compound
C712 Lockwire (C205) to parting line of screen and
C205 Sealing Compound valve assembly (19) and main transmis
sion (2).
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GEARBOXES
INSPECTION/TEST
1. Transmission Inspections (Area 3) must be less than 2cc in one hour or
one drop in one minute.
(Ref. Figure 601)
(4). Examine external surface of transmis
A. Transmission Inspection sion for damage and corrosion. None
permitted.
(1). Examine transmission for loose,
(5). Examine transmission for loose or
missing, and damaged bolts and nuts.
missing environmental seal at all
None permitted.
mating lines and on all bolts and nuts.
(2). Examine transmission shaft seals for (6). Examine all electrical connectors for
indication of oil leakage. Leakage rate correct installation and condition. No
at shaft seals must be less than 2cc in incorrect installation or unserviceable
one hour or one drop in one minute. condition permitted.
(3). Examine input pinions for indication of (7). Make sure transmission oil level is
leakage. Leakage rate at input pinions correct (Ref. Section 12-00-00).
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MATING LINE
ENVIRONMENTAL SEAL
9g63-065-1
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9g63_065_2
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9g63_065_3
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B. Acoustic Isolator Inspection Bearings operators can not remove are made
of M50 or CBS-600 (Japanese equivalents).
(1). Examine acoustic isolator for too much M50 metal particles are from Planetary
elastomeric material out from between bearings and CBS-600 metal particles are
static mast support and transmission. from tapered roller bearings. If you get these
No damage permitted. metal particles, it is necessary to overhaul
transmission.
(2). Examine external surfaces of acoustic
isolator for cracks or delamination. No Other metals in transmission are 4340
damage permitted. clutches and 4130 lock nuts.
NOTE: Loose bolts can be an indication of wear
or deterioration of acoustic isolator. Metal particles can be found on chip detector
when transmission CHIPS caution message is
(3). Examine bolts that attach transmission shown on Integrated Instrument Display
to mast base for correct installation. No System (IIDS) or during usual maintenance. If
incorrect installation permitted. there are metal particles, it is not necessarily
an indication transmission is unserviceable.
C. Chip Detector Inspection But, the type and quantity of metal particles
found can be an indication there is a defective
NOTE: For more aid, speak to your local MDHI transmission component.
Field Service Representative.
(1). Remove chip detector and screen/valve
The components of the transmission are made (housing) assembly.
of different materials. You can find which
component(s) made the metal particles when (2). Examine chip detector and housing for
you have an Energy Dispersive X-ray Spec metal particles (Ref. Table 601).
troscopy, or equivalent test, done.
Operator removable bearings are made of (3). Make sure chip detector and housing
52100. These are the hydraulic pump, cooling are clean of all particles.
blower, notar, input, lube pump, and clutch
bearings. Some of these can be replaced (4). Install screen/valve (housing) assembly
without removal of the transmission. and chip detector.
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(e). Low yellow C caution segment is not (3). Manually rotate one transmission input
illuminated. pinion in the ``drive direction and
observe:
(f). High yellow oil C caution segment is
not illuminated. (a). Rotation is smooth and requires
constant input torque.
(g). High red C warning segment is not (b). Ensure pinion is rotated a minimum
illuminated. of 6 complete revolutions.
(h). CHIPS is not illuminated. (4). Subsequent to the rotational test in the
``drive direction, manually rotate the
(i). ROTOR BRAKE is not illuminated pinion in the reverse direction or
in caution/warning cluster. ``clutch overrunning direction and
(4). Shutdown engine (left or right) per observe:
current Rotorcraft Flight Manual (Ref. (a). Rotation is smooth and requires
Section 01-00-00, Table 201) and constant torque.
observe following conditions on IIDS
secondary panel: (b). Ensure pinion is rotated a minimum
of 6 complete revolutions.
(a). With rotor rpm 70% or less, apply (c). Observe during rotation the other
rotor brake and check for ROTOR input pinion or any output drive
BRAKE illumination in caution/ pinions rotate.
warning cluster.
(5). Repeat steps (3). and (4). for the
(b). On ELECTRICAL MASTER panel opposite transmission input pinion.
set POWER switch to OFF.
(6). Manually rotate the anti-torque fan
(5). With rotor stopped, check transmission pinion in the ``driven direction and
area and components for oil leakage. observe:
None allowed. (a). Rotation is smooth and requires
constant torque.
(6). Inspect for servicing of oil (Ref. Section
12-00-00). (b). Ensure pinion is rotated a minimum
of 6 complete revolutions.
(7). Inspect lubrication pump filter impend
ing bypass indicator for indication of (7). Subsequent to the rotational test of the
impending bypass. Replace lubrication anti-torque fan pinion in the ``driven
pump filter assembly (Ref. Section direction, manually rotate the pinion in
63-21-00) if impending bypass indica the reverse direction and observe:
tor is popped and push in impending (a). Rotation is smooth and requires
bypass indicator. constant torque.
B. Transmission Operational Test Manual (b). Ensure pinion is rotated a minimum
Rotation of 6 complete revolutions.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(5). On ELECTRICAL MASTER panel, (10). If the amount of metal particle deposits
set POWER switch to OFF. have decreased and only small amounts
are found, continue transmission in
(6). Remove short from chip detector. service.
(7). Detach connector from chip detector. E. Transmission Flush Procedure
(8). Install chip detector (Ref. Section
63-20-00). Consumable Materials
(Ref. CSPSPM)
D. Transmission Serviceability Test Item Nomenclature
(1). Flush main transmission (Ref. Section C106 Oil, Lubricating
12-00-00)
(2). Perform chip detector test. (1). Ground run helicopter per current
Rotorcraft Flight Manual (Ref. Section
NOTE: If test is being performed within 50 01-00-00, Table 201), until transmis
hours of last serviceability test, and filter sion temperature has stabilized.
pop-up indicator is acceptable (Ref. Section
(2). Shutdown helicopter.
12-00-00, Main Transmission Flush), lu
brication pump filter assembly replacement NOTE: Removing chip detector housing pro
is not required. vides a larger drain opening and may en
sure a better flush.
(3). Replace 3 micron transmission filter
and clean or replace 75 micron filter in Oil, Lubricating (C106)
the lubrication pump filter assembly
(Ref. Sections 63-21-00 and
05-20-10).
(4). Service transmission oil (Ref. Section
12-00-00). (3). Remove chip detector and drain
transmission oil immediately while oil
(5). Hover helicopter per current Rotorcraft remains warm.
Flight Manual (Ref. Section 01-00-00,
Table 201), for 20 minutes and (4). Remove chip detector screen/valve
monitor CHIP indicator. (housing) assembly.
(5). Drain transmission oil from heat
(6). Shutdown helicopter and perform chip
exchanger drain valve (Ref. Section
detector inspection.
63-21-00).
(7). If the amount of metal particle deposits
NOTE: Add oil to flush transmission if required
is larger than before transmission oil
for additional cleaning.
change, or contain magnetic chips
larger than 0.14 inch (3.56 mm) in (6). Remove lubrication pump filter assem
any direction, replace transmission. bly (3 and 75 micron filters) (Ref.
Section 63-21-00).
(8). If the amount of metal particle deposits
have decreased and only small amounts NOTE: Ensure lubrication pump filter impend
are found, continue transmission in ing bypass (pop-up) indicator has not popped.
service.
(7). Inspect lubrication pump cavity for
(9). After 5 hours of normal operation, chips or sediment (Ref. Section
perform chip detector inspection. 63-21-00).
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Rotorcraft Maintenance Manual
NOTE: If no particles are found, bypass indicator F. Main Transmission Lubrication Pump
is acceptable. If filters have less than 50 Filter Assembly Cleaning
hours of operational time, there is no need for
filter replacement. Replace only if question Consumable Materials
able. (Ref. CSPSPM)
Item Nomenclature
(8). Ensure chip detector and housing are C106 Oil, Lubricating
clean of any chips or sediment. Install
components but do not safety wire Oil, Lubricating (C106)
housing at this time.
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
GEARBOXES
REPAIRS
1. Main Transmission Assembly Seal (6). Loosen locknut (6) using wrench (T311)
Replacement and remove from input pinion assem
bly.
A. Input Pinion Assembly Seal Replacement
(7). Remove clutch outer race (7) from input
(Ref. Figure 801 and Figure 802) pinion assembly using puller assembly
(T313). (Ref. Figure 802, View B)
Consumable Materials
(8). Remove the spacer (12) between input
(Ref. CSPSPM) pinion assembly (1) and clutch outer
Item Nomenclature race (7).
C106 Oil, Lubricating
or NOTE: Current Configuration clutch outer race
(7, Figure 801) has plasma coating at seal
C122 Oil, Lubricating
land area and replaces Early Configuration
C119 Grease, Lubricating clutch outer race (7) and wear sleeve (14).
C322 Marking Ink, Black
(9). Inspect seal lip contact area on clutch
outer race (7).
Special Tools
(Ref. CSPSPM) (a). Current Configuration - No visible
Item Nomenclature depth in the seal lip contact area, nor
T309 Mount Assembly any visible damage to wear surface is
T310 Pusher Assembly allowed. If damaged, replace clutch
T311 Wrench
outer race (7).
T312 Guide (b). Early Configuration - Inspect wear
T313 Puller Assembly sleeve (14) for damage; no visible
T314 Pusher depth in the seal lip contact area, nor
any visible damage to wear surface
T315 Puller Assembly
or flange. Any damage requires
T332 Mount replacement of clutch outer race (7).
T333 Pusher
T345 Pusher NOTE: Replacement of early configuration
clutch outer race (7) and wear sleeve (14)
with current configuration is an upgrade
(1). Remove input pinion assembly (1) (Ref. and re-identification of input pinion assem
Input Pinion Assembly Removal). bly is required.
Cover opening in transmission (10). Disassembly of clutch assembly is not
CAUTION to prevent entry of foreign ob required, unless clutch outer race
jects. replacement or additional inspection is
needed.
(2). Remove retaining ring (2, Figure 801).
(a). Remove clutch (13), bearing (8) from
(3). Remove sleeve (3); discard O-ring (4). clutch outer race (7).
(4). Set mount assembly (T309) on a vise 1). Replace clutch outer race (7) with
and secure input pinion assembly (1) new current configuration.
with bolt. (Ref. Figure 802, View A)
2). Line through existing part number
(5). Remove lockwasher (5, Figure 801) on outer diameter of input pinion
from input pinion assembly using puller assembly (1) with marking ink
assembly (T315). (C322).
Page 801
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
3). Mark new part number (18). Place spacer (12) in input pinion
900D1400534-101 with marking assembly (1).
ink (C322) next to lined through
marking. (19). Assemble clutch assembly, if disas
Example: sembled for inspection.
900D1400534-101 (new P/N) (a). Install clutch (13) into clutch outer
ASSY 900D1400532-101 (old P/N) race (7), using guide (T312). (Ref.
Figure 802, View E)
(11). Remove seal housing (9); discard
O-ring (10). NOTE: In the next step, clutch outer race must
be rotated counter clockwise while inserting
(12). Remove oil seal (11) from seal housing onto input pinion assembly to allow clutch
(9) using mount (T332) and pusher sprags to disengage from the inner race.
(T333). (Ref. Figure 802, View C)
(20). Install clutch outer race onto input
Grease, Lubricating (C119) pinion assembly
(21). Using pusher assembly (T310), install
bearing (8) onto input assembly (1)
using a hand press. (Ref. Figure 802,
View F)
(13). Apply lubricating grease (C119) to
inner surface of seal housing (9). (22). Set mount assembly (T309) on a vise
and secure input pinion assembly with
(14). Liberally apply lubricating grease a bolt.
(C119) between two lips of oil seal (11,
Figure 801). Wipe off excess grease (23). Apply proper lubricating oil to locknut
spilled over. threads and end surface which contact
with bearing inner race.
(15). Insert oil seal into seal housing using
(24). Install locknut (6, Figure 801) and
pusher (T314). (Ref. Figure 802, View
torque to 1910 - 2120 inch-pounds
D)
(216 - 240 Nm) using wrench (T311).
Oil, Lubricating (C122) NOTE: Ensure two locking tangs of lockwasher
Oil, Lubricating (C106) secure locknut. Use pusher tool (T345) for
lockwasher installation, if required.
(25). Install lockwasher (5) over locknut.
(26). Install new O-ring (4), coated with
Verify proper lubricating oil for proper lubricating oil in groove of sleeve
CAUTION transmission before starting (3).
work. Do not mix different specification lu
bricating oil, damage will result. (Ref. Sec (27). Install sleeve onto outer race.
tion 12-00-00, Table 1) (28). Install retaining ring (2).
(16). Apply proper lubricating oil to O-ring (29). Check that the clutch positively
(10, Figure 801) and install on seal engages when outer race is rotated
housing. clockwise.
(17). Insert seal housing into input pinion (30). Install input pinion assembly (Ref.
assembly. Input Pinion Assembly Installation).
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Rotorcraft Maintenance Manual
1 9
10
4
5
6 2
EARLY CONFIGURATION
8
12 13 7
11
14 7
12 13
11 10 9
1
8 6 5 4 2
3
9G63045A
Page 803
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
PULLER ( T315 )
LOCKWASHER
INPUT PINION
ASSEMBLY ROTATE
PULLER ASSEMBLY ( T313 )
MOUNT
( T309 ) BEARING
VISE CLUTCH
SPACER
VIEW A
INPUT PINION
LOCKWASHER REMOVAL
VIEW B
REMOVAL OF THE CLUTCH OUTER RACE
9G63-058
Figure 802. Input Pinion Assembly Seal Replacement Special Tools (Sheet 1 of 2 )
Page 804
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Rotorcraft Maintenance Manual
PUSH
PUSHER PUSH
(T333) PUSHER
(T314)
OIL SEAL
SEAL HOUSING
SEAL HOUSING
OIL SEAL
VIEW D
MOUNT OIL SEAL INSTALLATION
(T332)
BEARING
CLUTCH
OUTER RACE
E E
PUSH GUIDE
VIEW E - E
MARKING IS VISIBLE AS INPUT PINION
VIEWED FROM ABOVE ASSEMBLY
CLUTCH
INPUT PINION
CLUTCH OUTER RACE
VIEW E
CLUTCH INSTALLATION
VIEW F
BALL BEARING INSTALLATION
9G63059
Figure 802. Input Pinion Assembly Seal Replacement Special Tools (Sheet 2 of 2 )
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
B. Fan Drive Assembly Seal and Wear (7). Remove flange assembly (4) using
Sleeve Replacement puller assembly (T320) (Ref.
Figure 804).
(Ref. Figure 803, Figure 804, Figure 805 and
Figure 806) (8). Inspect wear sleeve (6, Figure 803) for
damage; no visible depth in the seal lip
contact area, nor any visible damage to
Consumable Materials wear surface or flange. Any damage
(Ref. CSPSPM) requires replacement of wear sleeve (6).
Item Nomenclature
(9). Replace damaged wear sleeve (6). Refer
C106 Oil, Lubricating
to Figure 805 for tool set-up.
or
C122 Oil, Lubricating
NOTE: Wear sleeve flange may have to be cut
prior to attaching remover assembly (T324).
C119 Grease, Lubricating
(a). If installed, mark location of wear
Special Tools sleeve inner end on flange assembly.
(Ref. CSPSPM) (b). If installed, remove wear sleeve
Item Nomenclature flange by cutting edge of flange to
T318 Mount Assembly tear-off groove.
T319 Wrench Assembly (c). Twist and pull wear sleeve flange to
T320 Puller Assembly remove along tear-off groove.
T321 Pusher (d). Remove and discard wear sleeve
T322 Puller Assembly using remover assembly (T324).
T323 Pusher (e). To prevent leaks, remove residual
T324 Remover Assembly wear sleeve adhesive compound from
T325 Pusher flange assembly (4, Figure 803) using
T334 Pusher cloth dampened with solvent (Ref.
CSP-SPM, Section 20-20-00,
General Cleaning).
(1). Drain transmission oil until oil level is
below the sight gauge (Ref. Section NOTE: Until removed, wear sleeve flange will
12-00-00). hold retaining ring and dust seal on flange
assembly (4, Figure 803).
(2). Remove fan drive assembly (Ref. Fan (f). Remove retaining ring (7) and dust
Drive Assembly Removal). seal (8). Clean dust seal.
Cover opening in transmission (g). Install retaining ring (7) on flange
CAUTION to prevent entry of foreign ob assembly (4).
jects.
(h). Install dust seal (8) on flange assem
(3). Set mount assembly (T318) on a vise bly (4). Ensure dust seal protrusion
and secure fan drive assembly (1, around inner diameter faces outside
Figure 803) with bolt. (Ref. Figure 805).
(i). Install new wear sleeve on flange
(4). Remove lockwasher (2, Figure 803)
assembly, use pusher (T323). Align
from fan drive assembly with puller
end of wear sleeve with mark made
assembly (T322) (Ref. Figure 804).
in step (9).(a).
(5). Loosen locknut (3, Figure 803) with NOTE: To prevent wear sleeve deformation and
wrench assembly (T319) and remove it leakage, wear sleeve flange is not removed
from fan drive assembly. after installation.
(6). Remove retaining ring (7) from groove (10). Remove seal housing (10, Figure 803)
of seal housing (10). from fan drive assembly (1).
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Rotorcraft Maintenance Manual
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1
9 6 8 4
3
2
11 7
5
1 11
5
10 9
6
8
7
3 2
4
P63-047A
Page 807
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
ROTATE
PULLER
(T322)
ROTATE
PULLER
(T320)
FLANGE
ASSEMBLY
LOCKWASHER
FAN DRIVE
ASSEMBLY
FAN DRIVE
MOUNT
(T318)
MOUNT
(T318)
LOCKWASHER REMOVAL
FLANGE ASSEMBLY REMOVAL
9G63060
Figure 804. Fan Drive Assembly Lockwasher and Flange Assembly Removal
Page 808
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(12). Replace oil seal (9) in seal housing (10). (14). Apply proper oil to new O-ring (5) and
Refer to Figure 806 for tool set-up. install on fan drive assembly (1).
(a). Remove oil seal (9, Figure 803) from (15). Install seal housing (10) into fan drive
seal housing using pusher (T334). assembly (1).
Oil, Lubricating (C122) (19). Install locknut into fan drive assembly
Oil, Lubricating (C106) using wrench assembly (T319). Torque
nut to 433 - 520 inch-pounds (48.9 -
58.7 Nm).
NOTE: Ensure two locking tangs of lockwasher
secure locknut. Use pusher tool (T325) for
Verify proper lubricating oil for lockwasher installation, if required.
CAUTION transmission before starting
(20). Install lockwasher (2) onto locknut.
work. Do not mix different specification lu
bricating oil, damage will result. (Ref. Sec (21). Install fan drive assembly (Ref. Fan
tion 12-00-00, Table 1) Drive Assembly Installation).
(13). Apply proper oil to new O-ring (11) and (22). Service transmission (Ref. Section
install on seal housing (10). 12-00-00).
Page 809
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
IF IT EXISTS
WEAR SLEEVE FLANGE
MAY HAVE TO BE CUT
REMOVER PRIOR TO ATTACHING
(T324) PUSH
ROTATE PULLER ASSEMBLY.
PUSHER
(T323)
REMOVAL OF FLANGE
WEAR SLEEVE
FLANGE ASSEMBLY
RETAINING RING
RETAINING RING
FLANGE ASSEMBLY
PUSHER
PUSHER (T321)
(T334)
OIL SEAL
OIL SEAL
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
C. Blower Drive Pinion Assembly Seal surface or flange. Any damage to wear
Replacement (On Transmission) sleeve requires removal and replace
ment per Blower Drive Pinion Assem
(Ref. Figure 807, Figure 809) bly Seal and Wear Sleeve Replacement.
(5). Replace oil seal (6) in seal housing (4).
Consumable Materials
Refer to Figure 809 for tool set-up.
(Ref. CSPSPM)
Item Nomenclature (a). Remove oil seal from seal housing
C106 Oil, Lubricating using pusher assembly (T337).
or Grease, Lubricating (C119)
C122 Oil, Lubricating
C119 Grease, Lubricating
Special Tools
(Ref. CSPSPM) (b). Apply lubricating grease (C119) to
Item Nomenclature inner surface of seal housing.
T329 Pusher
(c). Insert new oil seal into seal housing
T330 Pusher using pusher (T329).
T331 Remover Assembly
T337 Pusher Assembly
(d). Liberally apply lubricating grease
(C119) between two lips of new oil
seal (6, Figure 807). Wipe off excess
Oil, Lubricating (C122) grease.
Oil, Lubricating (C106)
(6). Apply proper lubricating oil to O-ring
(7) and install on seal housing.
(7). Install seal housing (4) into blower
drive pinion assembly (1).
Verify proper lubricating oil for
CAUTION transmission before starting (8). Install laminated shim (3). If new shim
work. Do not mix different specification lu installed, measure and adjust thickness
bricating oil, damage will result. (Ref. Sec of laminated shim (3) as indicated.
tion 12-00-00, Table 1) (a). Install seal housing and retaining
ring into drive pinion assembly.
(1). Remove oil cooler blower (Ref. Section
63-21-00, Blower Housing Assembly (b). Measure clearance between seal
Removal). housing (4) and retaining ring (2)
with thickness gage. Dial gage may
(2). Remove retaining ring (2, Figure 807) also be used to measure axial end
and laminated shim (3) from blower
play.
drive pinion assembly (1).
(c). Peel laminated shim (3) to obtain
(3). Remove seal housing (4) from blower thickness equal to measured clear
drive pinion assembly. Discard O-ring ance +0.0 / -0.004 inch (+0.0 / -0.1
(7). mm).
Blower drive pinion wear sleeve
CAUTION can not be replaced on the
(d). Remove retaining ring and install
new adjusted shim.
transmission. Blower Drive Pinion Assem
bly must be removed from transmission. (9). Install retaining ring (2).
(4). Inspect wear sleeve (5) for damage; no (10). Install oil cooler blower assembly (Ref.
visible depth in the seal lip contact Section 63-21-00, Blower Housing
area, nor any visible damage to wear Assembly Installation).
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
D. Blower Drive Pinion Assembly Seal and (4). Set mount assembly (T341) on a vise
Wear Sleeve Replacement and secure blower drive pinion assem
bly (1) (Ref. Figure 808 for tool set-up).
(Ref. Figure 807, Figure 808 and Figure 809)
(5). Inspect wear sleeve (5) for damage; no
visible depth in the seal lip contact
Consumable Materials
area, nor any visible damage to wear
(Ref. CSPSPM)
surface or flange. Any damage requires
Item Nomenclature
replacement of wear sleeve (5).
C106 Oil, Lubricating
or (6). Replace damaged wear sleeve (5). Refer
to Figure 808 for tool setup.
C122 Oil, Lubricating
C119 Grease, Lubricating Use care not to cut or damage
CAUTION gearshaft or housing bore when
Special Tools removing wear sleeve. Damaged gearshaft
(Ref. CSPSPM) or housing requires replacement of Blower
Item Nomenclature Drive Pinion Assembly.
T329 Pusher (a). Mark location of wear sleeve inner
T330 Pusher end on pinion.
T337 Pusher Assembly (b). Cut wear sleeve with X-ACTO blade
T341 Mount Assembly or flat edged knife.
(c). Grasp cut edge of wear sleeve with
Oil, Lubricating (C122) small-nose pliers, twist and pull to
Oil, Lubricating (C106) remove wear sleeve from pinion.
(d). Remove blower drive pinion assembly
(1) from mount assembly (T341).
(e). To prevent leaks, remove residual
Verify proper lubricating oil for wear sleeve adhesive compound from
CAUTION transmission before starting blower pinion (10, Figure 807) using
work. Do not mix different specification lu cloth dampened with solvent (Ref.
bricating oil, damage will result. (Ref. Sec CSP-SPM, Section 20-20-00,
tion 12-00-00, Table 1) General Cleaning).
(1). Remove blower drive assembly (Ref. (f). Inspect and ensure blower pinion
Blower Drive Assembly Removal). shaft has not been damaged during
wear sleeve removal. Damaged
Cover opening in transmission gearshaft requires replacement of
CAUTION to prevent entry of foreign ob Blower Drive Pinion Assembly.
jects.
(g). Install new wear sleeve (5) on blower
(2). Remove retaining ring (2, Figure 807) drive pinion (1), use pusher (T330).
and laminated shim (3) from blower Align end of wear sleeve with mark
drive pinion assembly (1). made in step (6).(a).
(3). Remove seal housing (4) from blower NOTE: To prevent wear sleeve deformation and
drive pinion assembly. Discard O-ring leakage, wear sleeve flange is not removed
(7). after installation.
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(7). Replace oil seal (6) in seal housing (4). (10). Install laminated shim (3). If new shim
Refer to Figure 809 for tool set-up. installed, measure and adjust thickness
of laminated shim (3) as indicated.
(a). Remove oil seal from seal housing
using pusher assembly (T337). (a). Install seal housing and retaining
Grease, Lubricating (C119) ring into drive pinion assembly.
(9). Install seal housing (4) into blower (12). Install blower drive assembly (Ref.
drive pinion assembly (1). Blower Drive Assembly Installation).
Page 813
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Rotorcraft Maintenance Manual
9 6
10 8
3
7
2
1
10 1
9
8
3 2
9G63052
Page 814
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
FLANGE OF
WEAR SLEEVE
PUSH
PUSHER
(T330)
WEAR SLEEVE
WEAR SLEEVE
BLOWER PINION
MOUNT ASSEMBLY
(T341)
9G63055A
Page 815
63-20-00 Revision 25
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
PUSH PUSH
PUSHER
(T329)
PUSHER
(T337)
OIL SEAL
SEAL HOUSING
Page 816
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
E. Hydraulic Pump Accessory Drive (3). Inspect wear sleeve (2) for damage; no
Assembly Seal and Wear Sleeve visible depth in the seal lip contact
Replacement area, nor any visible damage to wear
surface or flange. Any damage requires
(Ref. Figure 810, Figure 811, and Figure 812) replacement of wear sleeve (2).
Page 817
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(5). Replace oil seal (9) in seal housing (11). (c). Insert new oil seal into seal housing
Refer to Figure 812 for tool set-up. using pusher (T326) and mount
(T336).
(a). Remove oil seal from seal housing (d). Liberally apply lubricating grease
using pusher (T335) and mount (C119) between two lips of new oil
(T348). Discard oil seal. seal (9, Figure 810). Wipe off excess
grease.
Grease, Lubricating (C119) (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 accessory drive assembly (Ref.
(b). Apply lubricating grease (C119) to Hydraulic Pump Accessory Drive
inner surface of seal housing. Assembly Installation).
Page 818
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Rotorcraft Maintenance Manual
5
2
6
10
11
9G63-061
1. PINION 7. LOCKNUT
2. WEAR SLEEVE 8. LOCKWASHER
3. RETAINER 9. OIL SEAL
4. BEARING 10. ORING
5. WASHER 11. HOUSING
6. BOLT
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Rotorcraft Maintenance Manual
FLANGE OF SLEEVE
DETAIL A
PUSH PUSHER
P63-063
Figure 811. Hydraulic Pump Accessory Drive Assembly Wear Sleeve Replacement
PUSH
PUSH
PUSHER
PUSHER
OIL SEAL
SEAL HOUSING
OIL SEAL
SEAL HOUSING
MOUNT
MOUNT
P63-062
Figure 812. Hydraulic Pump Accessory Drive Assembly Oil Seal Replacement
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Section
632100
Transmission
Lubrication and
Cooling System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
6
(2). Spray threads of bolts (7) with solid
9
film lubricant (C101).
2 (3). Install oil filler assembly (1) with bolts
9G63-019 (7) and washers (8). Torque bolts (7).
1. OIL FILLER ASSEMBLY
2. FLEXIBLE DRAIN TUBING Sealing Compound (C211)
3. BOLT
4. WASHER
5. NUT
6. HALF CLAMP
7. BOLT
8. WASHER (4). Using mechanical fastener sealing
9. ORING
method (Ref. CSP-SPM), apply sealing
Figure 401. Oil Filler Assembly compound (C211) to heads of bolts (7).
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Rotorcraft Maintenance Manual
(5). Install half clamp (6) around transmis B. Lubrication Pump Assembly Installation
sion mast base strut with bolts (3),
washers (4) and nuts (5). Torque bolts (Ref. Figure 402)
(3).
Consumable Materials
(6). Connect flexible drain tubing (2) to oil (Ref. CSPSPM)
filler assembly and safety with lockwire Item Nomenclature
(C702). C106 Oil, Lubricating
or
(7). Close transmission access door assem
bly R210 (Ref. Section 06-00-00). C122 Oil, Lubricating
C702 Lockwire
2. Lubrication Pump Assembly C205 Sealing Compound
(3). Remove lockwire from oil hoses (3). NOTE: Ensure oil transfer tube (12) is installed
Disconnect oil hoses (3) from pump (1). in transmission (2).
(2). Lubricate new O-ring (11) with proper
(4). Remove fittings (4) from pump (1) and lubricating oil and install on transfer
discard O-rings (5). tube (12).
(5). Remove sealing compound from pump (3). Align pump (1) with main transmission
(1) and bolts (6). (2).
(4). Install bolts (6) and washers (8). Torque
(6). Cut and discard lockwire between
bolts (6).
mounting bolts (6) and transmission
chip detector (7). Remove bolts (6) and (5). Lubricate new O-rings (5) with proper
washers (8). lubricating oil and install on fittings (4).
(7). Install bolts (6) in jacking holes, or (6). Install fittings (4) in pump (1). Torque
removal screws (13) with 1/4-28 UNF fittings (4).
thread, and alternately tighten to
provide an even pull to remove pump (7). Connect oil hoses (3) to pump. Torque
(1) from transmission (2) and discard hoses (3).
O-rings (9, 10 and 11). (8). Safety hoses (3) with lockwire (C702).
NOTE: Ensure oil transfer tube (12) stays in (9). Safety chip detector (7) to mounting
position in transmission (2). bolt (6) with lockwire (C702).
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
13
62 -82 in-lb 10
7.0 - 9.2 Nm
9
6
3 (4 PL)
8
(4-PL)
12
11
2
4
5
1
7
5
4 VIEW ROTATED
3
REMOVAL
9G63-014A
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Rotorcraft Maintenance Manual
Consumable Materials
Verify proper lubricating oil for
CAUTION transmission before starting
(Ref. CSPSPM)
Item Nomenclature
work. Do not mix different specification lu
bricating oil, damage will result. (Ref. Sec C106 Oil, Lubricating
tion 12-00-00, Table 1) or
C122 Oil, Lubricating
(1). Lubricate new O-ring (3) and threads C702 Lockwire
of relief valve with proper lubricating
oil and install O-ring on relief valve.
Oil, Lubricating (C122)
Oil, Lubricating (C106)
(2). Install pressure relief valve (1) in
lubrication pump (2) and torque relief
valve (1).
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Rotorcraft Maintenance Manual
(2). Remove bolts (10) and washers (11). (2). Install new filters (4 and 5) in lubrica
tion pump (2).
(3). Remove lubrication pump housing cover
plate (12). If necessary, install bolts (10) (3). Lubricate new O-ring (9) with proper
in jacking holes and alternately tighten lubricating oil and install on transfer
to provide an even pull to remove cover. tube (8).
Discard O-rings (9 and 13).
(4). Lubricate new O-ring (13) with proper
lubricating oil and install on lubrication
(4). Remove and discard filters (4 and 5) pump housing cover plate (12).
and O-rings (6 and 7).
(5). Install cover plate (12) with bolts (10)
H. Lubrication Pump Filter Assembly and washers (11). Torque bolts (10).
Installation
(6). Replenish transmission with oil as
required (Ref. Section 12-00-00).
(Ref. Figure 403)
(7). Install forward access door assembly
L155 (Ref. Section 53-30-00).
Consumable Materials
(Ref. CSPSPM)
(8). Verify no leaks are present in flam
Item Nomenclature
mable fluid systems, where mainten
C106 Oil, Lubricating ance or replacement of components,
or
lines, or fittings has occurred, by
application of system pressure and
C122 Oil, Lubricating visual inspection prior to helicopter
being returned to service.
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7 8
9
4 PL 3
11 1
20 -25 in-lb 12
2.2 - 2.8 Nm 16
15 220 -240 in-lb
24.8 - 27.1 Nm
9G63-005A
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Rotorcraft Maintenance Manual
1
8 (4 PL)
7 (4 PL) 43
(NOTE 1)
4
5 (14 PL) 42 (NOTE 3)
(NOTE 1)
6 (14 PL
2
21
22
33
41 (NOTE 3) 3
35
43
10 30 (14 PL)
40
34 26
38 29 (14 PL)
36 (NOTE 1)
23 (2 PL)
(NOTE 1)
39 37 24 (2 PL) 25
(NOTE 1) (2 PL)
44 (NOTE 4) 45 (NOTE 4)
32
20 (6 PL)
19 9
18 16 25
(NOTE 2) (2 PL)
14
17 28 31 (6 PL)
(NOTE 1)
15 27
13
12 (2 PL)
11 (2 PL)
(NOTE 1)
NOTES:
1. TORQUE 36-46 in-lb (4.0-5.1 Nm)
2. TORQUE 160-180 in-lb (18.0-20.3 Nm)
3. TORQUE 50-60 ft-lb (67.8-81.3 Nm)
4. TORQUE 129-179 in-lb (14.6-20.2 Nm)
9G63-007B
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(3). Install blower impeller (9), washer (17) (6). Verify tip clearance between impeller
and bearing retaining locknut (16). (9) and shroud (13) is 0.020-0.024 in.
Using transmission blower shaft socket (0.508-0.609 mm) (Ref. Figure 405).
(T303) torque locknut (16).
(a). If required, remove shroud (13, Ref.
(4). Install blower shroud (13) and shim Figure 404) and adjust shim (14)
(14). thickness to get proper clearance.
13
NOTE:
Peel shim thickness is 0.002-0.003 in.
(0.050-0.076 mm).
Remove peel shim to decrease tip clear
ance. 9G63-009
Add peel shim to increase tip clearance. Figure 405. Impeller Tip Clearance
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Rotorcraft Maintenance Manual
NOTE: If the aircraft has the CURRENT (11). Install oil out hose (2) to heat exchang
CONFIG Air Conditioning System, refer to er (3). Torque hose nut.
Condenser Assembly Installation (CUR
RENT CONFIG) (Ref. Section 21-50-00). (12). Safety oil in hose (1) and oil out hose (2)
with lockwire (C702).
(7). If necessary, install the Air Condition
ing Condenser (Ref. Section 21-50-00). (13). Install swashplate aft fairing assembly
T220 (Ref. Section 53-30-00).
(8). Install cooling interconnect duct (4)
with bolts (5) and washers (6). Torque
(14). Install transmission access door
bolts (5).
assembly L210 and R210
(9). Install bolts (7) and washers (8). Torque (Ref. Section 53-30-00).
bolts (7).
(15). Install forward access door assembly
(10). Install oil in hose (1) to heat exchanger L155 and R155
(3). Torque hose nut. (Ref. Section 53-30-00).
36 -46 in-lb
4.0 - 5.1 Nm
2
(4 PL)
1
6 (4 PL)
3 (4 PL)
4
5
5(4 PL) 9G63-008
1. COOLING EXHAUST DUCT 4. BLOWER HOUSING ASSEMBLY
2. BOLT 5. BOLT
3. WASHER 6. WASHER
Figure 406. Blower Housing Assembly
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(8). Remove transmission oil out hose (2) B. Heat Exchanger Assembly Installation
from heat exchanger (3).
(Ref. Figure 404)
(9). Remove lockwire from oil in hose (21)
and oil out hose (22). Consumable Materials
(Ref. CSPSPM)
(10). Remove engine oil in hose (21) from Item Nomenclature
heat exchanger (3). C106 Oil, Lubricating
or
(11). Remove engine oil out hose (22) from C122 Oil, Lubricating
heat exchanger (3).
C211 Sealing Compound, Corrosion Inhibitive
C702 Lockwire
NOTE: If the aircraft has the CURRENT
CONFIG Air Conditioning System, refer to
Condenser Assembly Removal (CURRENT Oil, Lubricating (C122)
CONFIG) (Ref. Section 21-50-00). Oil, Lubricating (C106)
(13). Remove cooling interconnect duct (4) by Verify proper lubricating oil for
removing bolts (5 and 7) and washers (6 CAUTION transmission before starting
and 8). work. Do not mix different specification lu
bricating oil, damage will result. (Ref. Sec
(14). Remove sealing compound from heat tion 12-00-00, Table 1)
exchanger mount bolts (23 and 24).
NOTE:
(15). Remove mount bolts (23 and 24) and This task is typical for left or right heat
countersunk washers (25). exchanger installation.
If the aircraft has the CURRENT CON
(16). Remove heat exchanger, cooling inlet FIG Air Conditioning System, refer to
duct (26) and heat exchanger mounts Condenser Assembly Installation (CUR
(27 and 28) as a unit. RENT CONFIG) (Ref. Section 21-50-00).
(19). Cut and discard lockwire and remove (4). Install heat exchanger (3) cooling inlet
heat exchanger plug and bleeder duct (26) and mounts (27 and 28) with
fittings (37 and 38) and discard O-rings bolts (23 and 24) and countersunk
(39 and 40). washers (25). Torque bolts (23 and 24).
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B. Thermal Bypass Valve Installation (2). Install new valve gasket (43) onto
thermal bypass valve (41 or 42).
(Ref. Figure 404)
(3). Install thermal bypass valve (41 or 42)
into heat exchanger (3) and torque
Consumable Materials
bypass valve (41 or 42).
(Ref. CSPSPM)
Item Nomenclature (4). Safety thermal bypass valve (41 or 42)
C106 Oil, Lubricating with lockwire (C702).
or
(5). Install forward fairing support assem
C122 Oil, Lubricating bly (Ref. Section 53-30-00).
C702 Lockwire
(6). Service transmission (Ref. Section
12-00-00).
Oil, Lubricating (C122)
Oil, Lubricating (C106) (7). Service engine (Ref. Section 12-00-00).
(8). Verify no leaks are present in flam
mable fluid systems, where mainten
ance or replacement of components,
lines, or fittings has occurred, by
Verify proper lubricating oil for application of system pressure and
CAUTION transmission before starting visual inspection prior to helicopter
work. Do not mix different specification lu being returned to service.
bricating oil, damage will result. (Ref. Sec
tion 12-00-00, Table 1) (9). Install swashplate forward fairing
assembly T155 (Ref. Section 53-30-00).
NOTE:
This task is typical for left or right hand (10). Install swashplate aft fairing assembly
(transmission oil and/or engine oil) ther T220 (Ref. Section 53-30-00).
mal bypass valve installation. (11). Install forward access door assembly
If thermal bypass valve is reinstalled, L155 and R155 (Ref. Section
valve gasket must be replaced with new 53-30-00).
one.
(12). Install transmission access door
(1). Apply a thin coat of proper lubricating assembly L210 and R210 (Ref. Section
oil to new valve gasket (43). 53-30-00).
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(1). Open transmission access door assem (5). Inspect for security of bearing retaining
bly L210 and R210 (Ref. Section lockwasher. Replace if loose.
06-00-00). (6). Inspect housing for cracks, nicks and
debris. No damage allowed.
(2). Inspect hoses, fittings and lubrication
pump for leaks and security. No leaks (7). Install cooling interconnect duct.
allowed. Torque or replace loose or (8). Close transmission access door assem
missing hardware. bly L210 and R210 (Ref. Section
(3). Inspect heat exchanger, fittings and 06-00-00).
hoses for leaks and security. No leaks B. Cooling Ducts Inspection
allowed. Torque or replace loose or
missing hardware. (1). Open transmission access door assem
bly L210 and R210 (Ref. Section
(4). Inspect electrical connections at oil 06-00-00).
temperature switch, pressure switch, (2). Inspect for cracks, deterioration and
speed pickup and chip detector for security. No damage allowed. Torque or
corrosion and security of connectors replace loose or missing hardware.
(Ref. Section 63-20-00). No corrosion
allowed. (3). Inspect for debris. None allowed.
(5). Inspect oil temperature switch, pres (4). Close transmission access door assem
sure switch, speed pickup and chip bly L210 and R210 (Ref. Section
detector for leaks and security. No leaks 06-00-00).
allowed. C. Heat Exchanger Inspection
(6). Inspect lubrication filter impending (1). Open transmission access door assem
bypass indicator for indication of bly L210 and R210 (Ref. Section
impending bypass. Replace filter if 06-00-00).
impending bypass indicator is popped. (2). Inspect for dents. If dents are greater
(7). Close transmission access door assem than 0.125 inch (3.2 mm) deep,
bly L210 and R210 (Ref. Section replace heat exchanger.
06-00-00). (3). Inspect for nicks and scratches. Repair
nicks and scratches that are less than
2. Cooling System 0.0312 inch (0.88 mm) deep.
A. Cooling Blower Impeller and Housing (4). Inspect for loose, damaged, or missing
Inspection nut plates and rivets. None allowed.
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Rotorcraft Maintenance Manual
(8). Inspect each aft heat exchanger mount (9). Inspect the flange area that surrounds
web for cracks near the lower outboard the third nutplate from the bottom on
bolt hole. Use a 3X power magnifying the forward side of the heat exchanger.
glass. No cracks permitted. Use a 3X power magnifying glass.
Reference Figure 601. No cracks permitted.
Reference Figure 601.
NOTE 1
NOTE 2
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Rotorcraft Maintenance Manual
Cleaner (C432)
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
Section
632200
Rotor Brake
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
ROTOR BRAKE
FAULT ISOLATION
The following troubleshooting procedures are a Comprehensive wiring diagrams are available
brief summary of rotor brake system faults, in the Rotorcraft Maintenance Manual
which may be encountered (Ref. Table 101). CSP-900RMM-3 (Ref. Section 98-40-00).
Rotor Brake will not apply System low on fluid. Service reservoir. 120000
sufficient pressure to slow
rotor. Air in rotor brake system. Bleed rotor brake system. 120000
Brake head assembly Repair brake head assembly. 010000
leaking. (Ref. Related Manufacturers
Publications)
Lining worn excessively. Replace lining. (Ref. Related 010000
Manufacturers Publications)
binding of caliper (head) Lightly lubricate guide bolts, 632200
hardware springs and slide bore of lining
using spray lubricant (C120)
loose or worn bolts or Replace bolts, springs and 632200
bushings that attach caliper bushings (as a set).
(head) assembly.
Rotor Brake handle has rotor brake head is not Lightly lubricate guide bolts, 632200
abnormal vibration or moving smoothly due to springs and slide bore of lining
ratcheting or irregular feel binding hardware using spray lubricant (C120)
when applied.
loose or worn bolts or Replace bolts, springs and 632200
bushings that attach caliper bushings (as a set).
(head) assembly.
Rotor Brake chatters when Rotor RPM too high. Allow rotor speed to decrease
applied. and reapply.
Brake disk worn unevenly. Remove and replace brake 632200
disk.
ROTOR BRAKE CAUTION Faulty wiring. Test and repair wiring. 980000
light does not illuminate when
brake is applied. Faulty proximity switch. Replace proximity switches. 010000
(Ref. Related Manufacturers
Publications)
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A2 PROXIMITY SWITCH
IIDS W129 (ROTOR BRAKE)
W123 J155 P155 P522 J1
J4 P104
ROTOR BRAKE 1 ENGAGED
(BRAKE ON = OPEN) N G C OUTPUT
GS107-C
A620 H B
E COMMON
ELECTRICAL LOAD CENTER
CB33 A 16-32VDC
RTR BRK
J3 P377
PROXIMITY SWITCH
5A X J (ROTOR BRAKE)
P523 J1
Y K A 16-32VDC
BAT
BUS
GS105-C
E L B COMMON
W122 A612 M C OUTPUT
FWD INTERCONNECT PANEL
J5 P105 P170 J3 J1 P171
ROTOR BRAKE 2 ENGAGED
(BRAKE ON = GND) D 52 11
J3 P103 TB2-1
ROTOR BRAKE INSTALLED 41 94 M J
S R N
GS102-K
E 92 D C A
9G630281
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A2 ROTOR BRAKE
IIDS W129 1 SENSOR
W123 J155 P155 P522 J1
J4 P104
ROTOR BRAKE 1 ENGAGED
(BRAKE ON = OPEN) N G C OUTPUT
A601 GS107-C
CIRCUIT BREAKER PANEL E H B COMMON
BAT
BUS
A612
FWD INTERCONNECT PANEL
P174 J9 TB2-7 ROTOR BRAKE
J1 P171 2 SENSOR
G A
P523 J1
114 J
E 115 K A 16-32VDC
W122
F
GS105-C
J5 P105 P170 J3 E L B COMMON
ROTOR BRAKE 2 ENGAGED
(BRAKE ON = GND) D 52 C OUTPUT
11 M
J3 P103 TB2-1
ROTOR BRAKE INSTALLED 41 94 M J
S R N
GS102-K
E 92 D C A
9G630282
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Rotorcraft Maintenance Manual
ROTOR BRAKE
MAINTENANCE PRACTICES
1. Rotor Brake System Hydraulic Fluid (C112)
(1). Open transmission access door assem (10). Repeat steps (8). and (9). until fluid
bly R210 (Ref. Section 06-00-00). output from bleed port is free from all
air bubbles.
(2). Remove screw (1). (11). Remove drain line (T2017) and tighten
bleeder valve (2).
(12). Install screw (1).
(3). Attach drain line (T2017) to bleeder
valve (2). Place free end of drain line in (13). Close transmission access door assem
a suitable clean container. bly R210 (Ref. Section 06-00-00).
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1
9G63034
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ROTOR BRAKE
REMOVAL/INSTALLATION
1. Rotor Brake Head Assembly B. Rotor Brake Head Assembly Installation
(Ref. Figure 401)
A. Rotor Brake Head Assembly Removal
Consumable Materials
(Ref. CSPSPM)
(Ref. Figure 401) Item Nomenclature
C702 Lockwire
(1). Open transmission access door assem
bly L210 and R210 (Ref. Section NOTE: Ensure there is adequate clearance be
06-00-00). tween brake linings to fit over rotor brake
disc. Running clearance to be 0.060-in.
(1.524 mm) between disk and linings.
(2). Detach connectors P522 (3) and P523
(4). (1). Install rotor brake head assembly (1)
on main transmission (2). Install bolts
(9) and washers (10). Torque bolts (9).
NOTE: Take precautions to catch hydraulic
fluid with container and/or rags. (2). Safety bolts (9) with lockwire (C702).
Hydraulic Fluid (C112)
System Contamination
CAUTION
Hydraulic Fluid (C112) (3). Remove cap and plug and connect
hydraulic line (5) and torque tube nut
(Ref. CSP-SPM).
(4). Install screw (7) and washer (8) in
clamp (6). Torque screw (7).
(5). Attach connectors P522 (3) and P523
(3). Disconnect hydraulic line (5) from rotor (4).
brake head assembly (1). Install cap
and plug. (6). Bleed rotor brake (Ref. Section
63-22-00).
(7). Verify no leaks are present in flam
(4). Remove screw (7), washer (8) and mable fluid systems, where mainten
clamp (6) from hydraulic tube (5). ance or replacement of components,
lines, or fittings has occurred, by
application of system pressure and
(5). Cut and discard lockwire from bolts (9). visual inspection prior to helicopter
being returned to service.
(6). Remove bolts (9) and washers (10). (8). Close transmission access door assem
Remove rotor brake head assembly (1) bly L210 and R210 (Ref. Section
from main transmission (2). 06-00-00).
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(1). Install rotor brake linings (21) with (1). Install proximity switch (22). Torque
abrasive surface toward disk. proximity switch (22).
(2). Secure proximity switch (22) with
NOTE: If bolts (19) are being replaced with new lockwire (C702).
hardware, replace bolts (19), bushings (23)
and springs (20) as a set. (3). Attach connector P522 (3) or P523 (4).
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11
4 PL
15 4 PL 13
14 12
16
5
18
21
6
12 -15 in-lb 3 2
1.3 - 1.6 Nm 7
20
17
23 REF. 3
1
(2 PL)
19 (2 PL)
37 - 42 in-lb
4.2 - 4.7 Nm 9 10
4 PL
150 - 160 in-lb 4
16.9 - 18.1 Nm 22
9G63-015B
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(2). Remove rotor brake head assembly (2). Remove and discard cotter pin (4).
(Ref. Section 63-22-00). (3). Remove washer (5) and pin (6).
(3). Remove nuts (13), washers (15 and 16) (4). Remove bolts (7 and 8) and washers (9).
and bolts (14) from disk (11). Remove B. Rotor Brake Control Linkage Installation
rotor brake disk (11) from flange (12).
(Ref. Figure 402)
B. Rotor Brake Disk Installation (1). Install control linkage (1), bolts (11),
washers (12) and nuts (10). Torque nuts
(Ref. Figure 401) (10).
(2). Install bolts (7 and 8) and washers (9).
(1). Install rotor brake disk (11) on flange
Torque bolts (7 and 8).
(12). Install bolts (14), washers (15 and
16) and nuts (13). Torque nuts (13). (3). Install pin (6), washer (5) and new
cotter pin (4).
(2). Install rotor brake head assembly (Ref.
Section 63-22-00). (4). Stow rotor brake handle by pushing up
into stow bracket (2).
(3). Install anti-torque drive shaft (Ref. (5). Check rotor brake rigging (Ref. Section
Section 63-10-00). 63-22-00).
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6. Rotor Brake Stow Lock Bracket 7. Rotor Brake Hydraulic Control Valve
A. Rotor Brake Hydraulic Control Valve
A. Rotor Brake Stow Lock Bracket Removal Removal
(Ref. Figure 402)
(Ref. Figure 402) (1). Open forward access door assembly
R155 (Ref. Section 06-00-00).
(1). Release rotor brake handle by raising (2). Remove and discard cotter pin (4).
up 0.5 inch (12.7 mm) and rotating
handle 15 degrees clockwise, then (3). Remove washer (5) and pin (6).
lower handle down. (4). Remove hose clamp assembly (18).
(5). Remove screws (19), washers (20) and
(2). Remove nuts (10), bolts (11) and closeout assembly (21).
washers (12). Remove stow (2).
(6). Remove tiedown strap (13) and flexible
tubing (14).
B. Rotor Brake Stow Lock Bracket NOTE: Take precautions to catch hydraulic
Installation fluid with container and/or rags.
System Contamination
(Ref. Figure 402) CAUTION
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Rotorcraft Maintenance Manual
24
27
26
25
30
29
32
REF. 15 28
33
32 31
14
33
13 REF. 15
9 9 34
8 7
15
3
8 16
17
23
1
9 20 18
(4 PL)
19
(4 PL)
2
REF. 1
10 5
4 22
12
6 21
11
12
5
3 PLACES
9G63-031
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Rotorcraft Maintenance Manual
B. Rotor Brake Hydraulic Control Valve (7). Install flexible tubing (14) with split
Installation facing forward and push down against
(Ref. Figure 402) rotor brake control valve (3). Install
new tiedown strap (13) approximately
(1). Prepare surface for electrical bond (Ref. at middle of tube nut.
CSP-SPM).
(2). Install plate assembly (22) on rotor
brake control valve (3). Install bolts (8). Check rotor brake rigging (Ref. Section
(16) and washers (17). Torque bolts 63-22-00).
(16).
(3). Install closeout assembly (21), screws
(19) and washers (20). Torque screws (9). Bleed rotor brake (Ref. Section
(19). 63-22-00).
(4). Install hose clamp assembly (18).
(5). Install pin (6) and washer (5). Install (10). Verify no leaks are present in flam
new cotter pin (4). mable fluid systems, where mainten
ance or replacement of components,
Hydraulic Fluid (C112)
lines, or fittings has occurred, by
application of system pressure and
visual inspection prior to helicopter
being returned to service.
(6). Remove cap and plug and connect
hydraulic line (15) on rotor brake
control valve (3) and torque tube nut (11). Close forward access door assembly
(Ref. CSP-SPM). R155 (Ref. Section 06-00-00).
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Rotorcraft Maintenance Manual
8. Rotor Brake Hydraulic Tube Assembly B. Rotor Brake Hydraulic Tube Assembly
Installation
A. Rotor Brake Hydraulic Tube Assembly (Ref. Figure 402)
Removal
Hydraulic Fluid (C112)
(Ref. Figure 402)
(2). Open transmission access door assem (2). Remove cap and plug and connect
bly L210 (Ref. Section 06-00-00). hydraulic line (15) on rotor brake
control valve (3).
(3). Remove tiedown strap (13) and flexible (3). Remove cap and plug and connect
tubing (14). hydraulic line (5, Ref. Figure 401) on
rotor brake head assembly (1).
NOTE: Take precautions to catch hydraulic (4). Install screw (7) and washer (8) in
fluid with container and/or rags. clamp (6). Torque screw (7).
(5). Install clamps (27, Ref. Figure 402),
System Contamination
CAUTION screws (25), washers (26) and nuts (24).
Torque nuts (24).
Hydraulic Fluid (C112) (6). Install clamp (31), screw (29), washer
(30) and nut (28). Torque nut (28).
(7). Torque tube nut on line (15) (Ref.
CSP-SPM).
(8). Install flexible tubing (14) with split
(4). Disconnect hydraulic line (15) from facing forward and push down against
rotor brake control valve (3). Install cap rotor brake control valve (3). Install
and plug. new tiedown strap (13) approximately
at middle of tube nut.
(5). Disconnect hydraulic line (5, Ref. (9). Torque tube nut on line (5, Ref.
Figure 401) from rotor brake head Figure 401), (Ref. CSP-SPM).
assembly (1). Install cap and plug.
(10). Bleed rotor brake (Ref. Section
63-22-00).
(6). Remove screw (7), washer (8) and
clamp (6) from hydraulic tube (5). (11). Verify no leaks are present in flam
mable fluid systems, where mainten
ance or replacement of components,
(7). Remove nuts (24, Ref. Figure 402),
lines, or fittings has occurred, by
screws (25), washers (26) and clamps
application of system pressure and
(27).
visual inspection prior to helicopter
being returned to service.
(8). Remove nut (28), screw (29), washer
(30) and clamp (31). (12). Close forward access door assembly
R155 and L155 (Ref. Section
06-00-00).
(9). Remove bolts (32), washers (33) and
clamp block (34). Remove hydraulic line (13). Close transmission access door assem
(15). bly L210 (Ref. Section 06-00-00).
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ROTOR BRAKE
INSPECTION / TEST / RIGGING
1. Rotor Brake B. Rotor Brake Rigging
A. Rotor Brake Inspection (Ref. Figure 601)
(1). Inspect rotor brake disc for wear, (1). Release rotor brake handle (1) from
grooves and security. Minimum disk stowed position by raising the lever
thickness 0.478 inch (12.14 mm). arm up 0.5 inch (12.7 mm). Rotate
Torque or replace loose or missing handle approximately 15 degrees
hardware. clockwise, then lower handle down
approximately 5 to 10 degrees.
(2). Inspect disk for cracks. None allowed.
(2). Remove safety wire and loosen nuts (2)
(3). Inspect rotor brake head for cracks. on lower link (3). Allow approximately
None allowed. 0.13 inch (3.3 mm) clearance between
adjusting nuts and rotor brake handle
(4). Inspect rotor brake head for fluid linkage (4). (Enough so that lower link
leakage, corrosion and security. No can slide forward and backward.)
leakage or corrosion allowed. Torque or
replace loose or missing hardware. (3). Stow rotor brake handle (1). Inspect to
ensure lower link (3) is still loose.
(5). Inspect rotor brake lining for wear, and
deterioration. Carrier & Lining Min. (4). Adjust lower link (3) by tightening
Thickness 0.233 inch. (5.92 mm). forward or aft nuts (2) until rotor brake
(Ref. Related Manufactures Publica handle (1) just touches bottom of piston
tions 01-00-00). (5), so that there is no compression on
piston.
Alcohol, Isopropyl (C419)
(5). Torque nuts (2) and secure with
lockwire (C702).
C. Rotor Brake Operational Check
(1). Run-up aircraft rotor to 100% operat
(6). Clean bolts, springs, bushings and
ing speed per current Rotorcraft Flight
lining carrier using isopropyl alcohol
Manual (Ref. 900RFM-1 900 CONFIG
(C419) or equivalent cleaner. Inspect
or CSP-902RFM-1 902 CONFIG).
for corrosion, cracks, nicks, gouges or
distortion. If damage is found, replace (2). Perform normal aircraft shutdown.
affected components (bolts, bushings Apply rotor brake below 70% Nr.
and springs are to be replaced as a set).
(3). Release rotor brake pressure during
(7). Inspect lining to disk clearances. last revolution of rotor.
Minimum clearance not less than 0.060
inch (1.52 mm). (4). Rotor must come to a complete stop
between (15 - 45 seconds) from the
(8). Inspect rotor brake connectors for time brake pressure is applied until the
security. Tighten connectors. blades stop rotating.
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Rotorcraft Maintenance Manual
3
2
(NOTE)
2
(NOTE)
5
1
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
ROTOR BRAKE
REPAIRS
1. Rotor Brake Assembly B. Rotor Brake Disk Repairs
A. Rotor Brake Head Repairs
For repairs to rotor brake head refer to For repairs to rotor brake disk refer to Related
Related Manufacturers Publications (Ref. Manufacturers Publications (Ref. Section
Section 01-00-00). 01-00-00).
Section
633000
Main Rotor Static
Mast
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
42
22 21
48
49
10
1400 -1700 in-lb
20 130 -180 in-lb 11 158.14 - 192.03 Nm
47 19 14.68 - 20.33 Nm 12
46
2 PL
18 13
41 14
70-90 in-lb
7.9 - 10.16 Nm 1
45 44 7
43
39 4 PLACES
40 2 PL
6
600-900 in-lb 5
9
67.77 - 101.66 Nm
8 4
38 37
2 3
36
35
17
(2 PL)
34 16 23
(2 PL)
28
15 27
(2 PL) 26
33 24
550 - 650 in-lb
62.12 - 73.42 Nm
29
30 RIGHT FORWARD 25
STRUT ONLY
31
70.90 in-lb
7.9-10.16 Nm
32
4 PLACES
9G63-026
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Rotorcraft Maintenance Manual
2. Truss Strut Assembly NOTE: After torquing nuts (15), check for a
minimum gap of 0.05 inch (1.27 mm) un
A. Left Hand Forward Truss Strut Removal der washer at bolt head and a minimum gap
of 0.05 inch (1.27 mm) at nut side.
(Ref. Figure 402)
(4). Install new cotter pin (10).
(1). Remove swashplate forward fairing (5). Install clamps.
assembly T155 (Ref. Section 53-30-00). (6). Install swashplate forward fairing
assembly T155 (Ref. Section 53-30-00).
(2). Remove clamps.
C. Left Hand Middle Forward Truss Strut
(3). Remove and discard cotter pin (10). Removal
(Ref. Figure 402)
(4). Remove nut (11), washer (12), counter
sunk washer (13) and bolt (14). (1). Remove swashplate forward fairing
assembly T155 and L210 fairing (Ref.
(5). Remove nuts (15), washers (16) and Section 53-30-00).
bolts (17). Remove strut (2). (2). Remove clamps.
B. Left Hand Forward Truss Strut (3). Remove and discard cotter pin (10).
Installation (4). Remove nut (11), washer (12), counter
sunk washer (13) and bolt (14).
(Ref. Figure 402)
(5). Remove nuts (15), washers (16) and
(1). Install strut (2), bolts (17), washers (16) bolts (17). Remove strut (3).
and nuts (15). D. Left Hand Middle Forward Truss Strut
Installation
(2). Install bolt (14), countersunk washer
(Ref. Figure 402)
(13), washer (12) and nut (11).
(1). Install strut (3), bolts (17), washers (16)
(3). Torque nuts (11 and 15). and nuts (15).
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Rotorcraft Maintenance Manual
(2). Install bolt (14), countersunk washer G. Left Hand Aft Truss Strut Removal
(13), washer (12) and nut (11).
(Ref. Figure 402)
(3). Torque nuts (11 and 15).
(1). Remove swashplate forward fairing
NOTE: After torquing nuts (15), check for a assembly T155, L210 and T220 fairings
minimum gap of 0.05 inch (1.27 mm) un (Ref. Section 53-30-00).
der washer at bolt head and a minimum gap
of 0.05 inch (1.27 mm) at nut side. (2). Remove and discard cotter pin (10).
(4). Install new cotter pin (10). (3). Remove nut (11), washer (12), counter
sunk washer (13) and bolt (14).
(5). Install clamps.
(4). Remove nuts (15), washers (16) and
(6). Install swashplate forward fairing
bolts (17). Remove strut (5).
assembly T155 and L210 fairing (Ref.
Section 53-30-00). H. Left Hand Aft Truss Strut Installation
E. Left Hand Middle Aft Truss Strut Removal (Ref. Figure 402)
(Ref. Figure 402)
(1). Install strut (5), bolts (17), washers (16)
(1). Remove swashplate forward fairing and nuts (15).
assembly T155, L210 and T220 fairings
(Ref. Section 53-30-00). (2). Install bolt (14), countersunk washer
(13), washer (12) and nut (11).
(2). Remove clamps.
(3). Torque nuts (11 and 15).
(3). Remove and discard cotter pin (10).
NOTE: After torquing nuts (15), check for a
(4). Remove nut (11), washer (12), counter minimum gap of 0.025 inch (0.635 mm)
sunk washer (13) and bolt (14). under washer at bolt head and a minimum
gap of 0.025 inch (0.635 mm) at nut side.
(5). Remove nuts (15), washers (16) and
bolts (17). Remove strut (4). (4). Install new cotter pin (10).
F. Left Hand Middle Aft Truss Strut (5). Install swashplate forward fairing
Installation assembly T155, L210 and T220 fairings
(Ref. Section 53-30-00).
(Ref. Figure 402)
(1). Install strut (4), bolts (17), washers (16) I. Right Hand Forward Truss Strut Removal
and nuts (15). (Ref. Figure 402)
(2). Install bolt (14), countersunk washer
(1). Remove swashplate forward fairing
(13), washer (12) and nut (11).
assembly T155 and R210 fairing (Ref.
(3). Torque nuts (11 and 15). Section 53-30-00).
NOTE: After torquing nuts (15), check for a (2). Remove clamps.
minimum gap of 0.05 inch (1.27 mm) un
der washer at bolt head and a minimum gap (3). Remove sealing compound, nut (29),
of 0.05 inch (1.27 mm) at nut side. washer (30) and bonding jumper (31).
(4). Install new cotter pin (10). (4). Remove and discard cotter pin (10).
(5). Install clamps. (5). Remove nut (11), washer (12), counter
sunk washer (13) and bolt (14).
(6). Install swashplate forward fairing
assembly T155, L210 and T220 fairings (6). Remove nuts (15), washers (16) and
(Ref. Section 53-30-00). bolts (17). Remove strut (9).
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Rotorcraft Maintenance Manual
J. Right Hand Forward Truss Strut (4). Remove nut (11), washer (12), counter
Installation sunk washer (13) and bolt (14).
(Ref. Figure 402) (5). Remove nuts (15), washers (16) and
bolts (17). Remove strut (8).
Consumable Materials L. Right Hand Middle Forward Truss Strut
(Ref. CSPSPM) Installation
Item Nomenclature
(Ref. Figure 402)
C205 Sealing Compound
(1). Install strut (8), bolts (17), washers (16)
and nuts (15).
(1). Install strut (9), bolts (17), washers (16)
and nuts (15). (2). Install bolt (14), countersunk washer
(13), washer (12) and nut (11).
(2). Install bolt (14), countersunk washer
(13), washer (12) and nut (11). (3). Torque nuts (11 and 15).
(3). Torque nuts (11 and 15). NOTE: After torquing nuts (15), check for a
minimum gap of 0.05 inch (1.27 mm) un
NOTE: After torquing nuts (15), check for a der washer at bolt head and a minimum gap
minimum gap of 0.05 inch (1.27 mm) un of 0.05 inch (1.27 mm) at nut side.
der washer at bolt head and a minimum gap
of 0.05 inch (1.27 mm) at nut side. (4). Install new cotter pin (10).
(5). Install clamps.
(4). Install new cotter pin (10).
(6). Install swashplate forward fairing
(5). Install clamps. assembly T155, R210 and T220 fairings
(6). Prepare surface for electrical bond (Ref. (Ref. Section 53-30-00).
CSP-SPM). M. Right Hand Middle Aft Truss Strut
(7). Install bonding jumper (31), washer Removal
(30) and nut (29). Torque nut (29). (Ref. Figure 402)
Sealing Compound (C205) (1). Remove swashplate forward fairing
assembly T155, R210 and T220 fairings
(Ref. Section 53-30-00).
(2). Remove half clamp from oil filler.
(8). Using sealing compound (C205), seal (3). Remove and discard cotter pin (10).
nut (29) (Ref. CSP-SPM).
(4). Remove nut (11), washer (12), counter
(9). Install swashplate forward fairing sunk washer (13) and bolt (14).
assembly T155 and R210 fairing (Ref.
(5). Remove nuts (15), washers (16) and
Section 53-30-00).
bolts (17). Remove strut (7).
K. Right Hand Middle Forward Truss Strut N. Right Hand Middle Aft Truss Strut
Removal Installation
(Ref. Figure 402) (Ref. Figure 402)
(1). Remove swashplate forward fairing (1). Install strut (7), bolts (17), washers (16)
assembly T155, R210 and T220 fairings and nuts (15).
(Ref. Section 53-30-00).
(2). Install bolt (14), countersunk washer
(2). Remove clamps. (13), washer (12) and nut (11).
(3). Remove and discard cotter pin (10). (3). Torque nuts (11 and 15).
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
NOTE: After torquing nuts (15), check for a 3. Truss Deck Fitting Assembly
minimum gap of 0.05 inch (1.27 mm) un
der washer at bolt head and a minimum gap A. Left Hand Forward Truss Deck Fitting
of 0.05 inch (1.27 mm) at nut side. Removal
(5). Install half clamp from oil filler. (1). Remove left hand forward truss and left
hand middle forward truss (Ref. Section
(6). Install swashplate forward fairing 63-30-00).
assembly T155, R210 and T220 fairings
(Ref. Section 53-30-00). (2). Remove forward roof/insulation panel
(Ref. Section 25-20-00).
O. Right Hand Aft Truss Strut Removal
(3). Remove sealing compound from bolt
(Ref. Figure 402) (34) and truss fitting (35).
(1). Remove swashplate forward fairing (4). Remove nut (32), bolt (34), and PLI
assembly T155, R210 and T220 fairings washer (33). Discard PLI washer (33).
(Ref. Section 53-30-00). Remove truss fitting (35).
(2). Remove clamps. B. Left Hand Forward Truss Deck Fitting
Installation
(3). Remove and discard cotter pin (10).
(Ref. Figure 402)
(4). Remove nut (11), washer (12), counter
sunk washer (13) and bolt (14).
Consumable Materials
(5). Remove nuts (15), washers (16) and (Ref. CSPSPM)
bolts (17). Remove strut (6). Item Nomenclature
C211 Sealing Compound, Corrosion Inhibitive
P. Right Hand Aft Truss Strut Installation
(Ref. Figure 402)
(1). Install truss fitting (35), bolt (34), new
(1). Install strut (6), bolts (17), washers (16) PLI washer (33) and nut (32).
and nuts (15). (2). Torque bolt (34) in the following
(2). Install bolt (14), countersunk washer method.
(13), washer (12) and nut (11). (a). Hold bolt (34), insert scribe (or
(3). Torque nuts (11 and 15). equivalent), into hole of new PLI
washer (33).
NOTE: After torquing nuts (15), check for a
minimum gap of 0.025 inch (0.635 mm) NOTE: Torque is correct when washer (33) no
under washer at bolt head and a minimum longer turns.
gap of 0.025 inch (0.635 mm) at nut side. Do not continue to tighten bolt
CAUTION after washer no longer turns.
(4). Install new cotter pin (10).
Damage to washer, bolt, and nut will occur.
(5). Install clamps. Washer, bolt and nut must be replaced if
over-torque occurs.
(6). Install swashplate forward fairing
assembly T155, R210 and T220 fairings (b). Tighten bolt (34) 1/8 turn at a time
(Ref. Section 53-30-00). while turning washer (33).
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Rotorcraft Maintenance Manual
Sealing Compound (C211) (a). Hold bolt (34), insert scribe (or
equivalent), into hole of new PLI
washer (33).
C. Left Hand Aft Truss Deck Fitting Removal (3). Using sealing compound (C211), seal
bolt (34) using mechanical fastener
(Ref. Figure 402)
sealing method (Ref. CSP-SPM).
(1). Remove left hand middle aft truss and
(4). Using sealing compound (C211), seal
left hand aft truss (Ref. Section
around truss fitting (36) using fillet
63-30-00).
surface sealing method (Ref. CSP-
(2). Remove aft roof/insulation panel (Ref. SPM).
Section 25-20-00).
(5). Install aft roof/insulation panel (Ref.
(3). Remove sealing compound from bolt Section 25-20-00).
(34) and truss fitting (36).
(6). Install left hand middle aft truss and
(4). Remove nut (32), bolt (34), and PLI left hand aft truss (Ref. Section
washer (33). Discard PLI washer (33). 63-30-00).
Remove truss fitting (36).
E. Right Hand Forward Truss Deck Fitting
D. Left Hand Aft Truss Deck Fitting Removal
Installation
(Ref. Figure 402)
(Ref. Figure 402)
(1). Remove right hand forward truss and
right hand middle forward truss (Ref.
Consumable Materials Section 63-30-00).
(Ref. CSPSPM)
Item Nomenclature (2). Remove forward roof/insulation panel
C211 Sealing Compound, Corrosion Inhibitive (Ref. Section 25-20-00).
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
F. Right Hand Forward Truss Deck Fitting G. Right Hand Aft Truss Fitting Deck
Installation Removal
(6). Install right hand forward truss and (3). Using sealing compound (C211), seal
right hand middle truss (Ref. Section bolt (34) using mechanical fastener
63-30-00). sealing method (Ref. CSP-SPM).
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Rotorcraft Maintenance Manual
(4). Using sealing compound (C211), seal (2). Remove nut (25), washer (26), counter
around truss fitting (37) using fillet sunk washer (27) and bolt (28).
surface sealing method (Ref. CSP-
SPM). (3). Remove and discard cotter pin (18).
(5). Install aft roof/insulation panel (Ref. (4). Remove nut (19), washer (20), counter
Section 25-20-00). sunk washer (21), bolt (22) and actua
tor support tie strap (23).
(6). Install right hand middle aft truss and
right hand aft truss (Ref. Section B. Actuator Support Tie Strap Installation
63-30-00). (Ref. Figure 402)
4. Mixer Pivot Support Assembly NOTE: This task is typical for left or right hand
actuator support tie strap installation.
A. Mixer Pivot Support Removal
(Ref. Figure 402) (1). Install actuator support tie strap (23),
bolt (22), countersunk washer (21),
NOTE: This task is typical for left or right hand washer (20) and nut (19).
mixer pivot support removal.
(2). Install bolt (28), countersunk washer
(1). Remove mixer assembly (Ref. Section (27), washer (26) and nut (25).
62-30-00).
(3). Torque nuts (19 and 25).
(2). Remove and discard cotter pin (39).
(4). Install new cotter pins (18 and 24).
(3). Remove nut (40), washers (41) and
mixer pivot support (42). 6. Actuator Support Assembly
NOTE: This task is typical for left or right hand (1). Remove actuator support tie straps
mixer pivot support installation. (Ref. Section 63-30-00).
(1). Install mixer pivot support (42), (2). Remove and discard cotter pin (43).
washers (41) and nut (40). Torque nut
(3). Remove nut (44), washer (45), counter
(40).
sunk washer (46), bolt (47) and actua
(2). Install new cotter pin (39). tor supports (48 and 49).
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
Primer (C308)
CAUTION
The lower bearing boss is a critical area.
No repair is permitted on the lower bear
ing boss.
(8). Apply primer (C309)to repair area of The area 0.125 in. (3.175 mm) immedi
static mast. Dry film thickness of ately below lower bearing boss is a critical
0.0006-0.0010 in. (0.015-0.025 mm) area. No repair is permitted in this area.
(Ref. CSP-SPM, Section 20-30-00). Repair is permitted on lower angled area
(9). Dry in air for a minimum of one hour between mast base and nickel plated sur
before you apply finish enamel. face.
Repair is permitted in open area that is
Finish Enamel, White (C302) more than 0.125 in. (3.175 mm) below
lower bearing boss and above nickel
plated surface.
Solvent Cleaner (C429)
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Rotorcraft Maintenance Manual
(7). Dry main rotor static mast in air for a Figure 801. Static Mast
minimum of 15 minutes before you
apply primer. C. Main Rotor Static Mast Inner
surfacePitting Corrosion Repair
Primer (C308) (Ref. Figure 802)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
(8). Apply primer (C308)to repair area of C308 Primer
static mast. Dry film thickness of C313 Paint Stripper
0.0006-0.0010 in. (0.015-0.025 mm)
C432 Cleaner
(Ref. CSP-SPM, Section 20-30-00).
C802 Cloth, NonLint
(9). Dry in air for a minimum of one hour C807 Sandpaper
before you apply finish enamel.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(1). Remove main rotor drive shaft. (a). Remove pitting, use sandpaper
(C807) or finer. Move sandpaper
parallel to mast center line and not
CAUTION radially.
Do not permit paint stripper or unwanted (b). Solvent wipe with cleaner (C432)and
material to go down inner or outer sur a non-lint cloth (C802).
faces of mast below repair.
(c). Visually examine repair area to make
Do not permit paint stripper or unwanted sure pit(s) are removed, use a bright
material to go into transmission. Damage light and minimum of10x magnifica
to transmission can occur. tion.
Speak to an MDHI Field Service Repre
(d). Inner dimension of static mast can
sentative if unwanted materials go into
not be than 3.769 in. (95.733 mm).
transmission.
If inner dimension is more than
permitted, speak to an MDHI Field
Paint Stripper (C313)
Service Representative.
NOTE:
Cadmium plating must be done as speci
fied in QQ-P-416 Type II Class 2, mini
(2). Remove primer from inner surface of mum thickness 0.0003 in. (0.3 mil).
main rotor static mast where there is Cadmium plating must be applied by an
pitting corrosion, use paint stripper individual or service center that is ap
(C313) (Ref. CSP-SPM). Remove paint proved by the equipment manufacturer
stripper with moist cloth, do not scrub for the brush plating procedure.
area and do not flush. You must use an approved low embrittle
ment solution for all brush plating proce
Cleaner (C432)
dures.
(6). Touch up cadmium plating, use a brush
on procedure.
(7). Clean area with cleaner (C432) and a
(3). Clean main rotor static mast repair non-lint cloth (C802). Clean surface
area with cleaner (C432) and a non-lint with another clean cloth before solvent
cloth (C802). evaporates.
Do not use a mechanical grinder (8). Clean again and again until cloth stays
CAUTION to remove corrosion. It can clean.
cause too much heat in repair areas. (9). Dry main rotor static mast in air for a
minimum of 15 minutes before you
NOTE: Make measurement before and after apply primer.
material removal.
Primer (C308)
(4). Measure mast inner dimension.
Dimension permitted is 3.749-3.769 in.
(95.225-95.733 mm).
(5). If after pitting removed, dimension will (10). Apply primer (C308) to repair area of
not be more than 3.769 in. (95.733 static mast. Dry film thickness of
mm), do the steps that follow: 0.0006-0.0010 in. (0.015-0.025 mm)
(Ref. CSP-SPM, Section 20-30-00).
NOTE: Make pits smooth on an area 10 times
the dimension of the depth dimension. (11). Dry in air for a minimum of one hour.
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(12). Install main rotor hub (Ref. Section (14). Do the Main Rotor Drive Plate Nut
62-20-00) Torque Verification (Ref. Special
Inspection - After Component Installa
tion Section 05-20-10 and Section
(13). Install main rotor drive shaft. 63-10-00).
ID REPAIR
AREA.
9G63-044
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63-30-00 Revision 32
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
C308 Primer
C302 Finish Enamel, White
(4). Apply primer (C308) to mast base. Dry
film thickness of 0.0006-0.0010 in.
Consumable Materials (0.015-0.025 mm) (Ref. CSP-SPM,
(Ref. CSPSPM) Section 20-30-00).
Item Nomenclature
(5). Dry in air for a minimum of one hour
before you apply finish enamel.
(1). Recommended Method - Remove
mast support base. Finish Enamel, White (C302)
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Revision 32 63-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Chapter
ANTI-TORQUE ASSEMBLY
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
Page i
64 Contents Revision 34
CSP900RMM2 MD Helicopters, Inc.
ROTORCRAFT MAINTENANCE MANUAL
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Anti-Torque Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Anti-Torque Fan System Inspection (Area 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Anti-Torque Fan Component Inspection (Area 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Table 601.Fan Pitch Plate Damage Limits (Ref. Figure 402) . . . . . . . . . . . . . . . . 602
Table 602.Fan Blade Damage Limits (Ref. Figure 601) . . . . . . . . . . . . . . . . . . . . . 602
Figure 601.Fan Blade Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Table 603.Fan Hub Damage Limits (Ref. Figure 602) . . . . . . . . . . . . . . . . . . . . . . 605
Figure 602.Fan Hub Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
C. Pitch Control Inspection (Area 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
D. Anti-Torque Fan Support Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
E. Anti-Torque Fan Liner (Felt Metal Seal) Inspection . . . . . . . . . . . . . . . . . . . . . . . . 607
F. Tension-Torsion Strap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
Figure 603.Tension-Torsion Strap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
Repair/Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Anti-Torque Fan Balance Weight Rivet Stud Replacement . . . . . . . . . . . . . . . . . . 801
Figure 801.Rivet Stud Replacement (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
2. Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
A. Anti-Torque Fan Assembly Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Table 801.Anti-Torque Fan Assembly Configuration Conversions . . . . . . . . . . . 803
Table 802.Anti-Torque Fan Modification Criteria . . . . . . . . . . . . . . . . . . . . . . . . . 803
Page ii
Revision 34 64 Contents
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Section
643000
NOTAR
AntiTorque Fan
System
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
2. AntiTorque Fan Assembly Components Pitch Plate - A sliding pitch plate uniformly
changes the angle of the blades through the
pitch horns which are part of the blade spar.
Fan Hub - The fan hub is an aluminum alloy The pitch plate is aluminum alloy and
forging centered on an angular contact mounted to a stainless steel shaft which slides
double-row ball bearing that reacts to changes inside the hub support shaft. As the pitch plate
to thrust in both directions. slides with the shaft, it actuates each blade
pitch horn to control the blades. Replaceable
Center Spline Assembly - The center spline cuff bushings are at each pitch horn/pitch
assembly attaches to the fan hub with thirteen plate interface to minimize the effects of wear.
bolts and nuts. These bolts also attach the The pitch plate rotates with the blades about a
inboard end of the tension-torsion straps to double row ball pitch bearing.
the spline/hub assembly. The spline assembly
also provides the spline drive surfaces to mate Pitch Control - Pitch control is applied to the
with the fan support driveshaft. pitch plate by a stationary control rod end
through a double row ball bearing. This allows
Tension-Torsion Straps - Tension-torsion the transition from stationary to rotating pitch
straps attach the blades to the hub. The straps control.
react to blade centrifugal forces while provid
ing a torsional spring counteracting blade Interrupter - A steel pin is installed at one
pitch forces. The tension-torsion strap is location on the forward face of the fan hub.
comprised of a continuous Kevlar filament This pin acts as a magnetic field interrupter
wound around a Corrosion Resistance Steel for the azimuth sensor used by the aircraft
Alloy (CRES) spool type bushing at each end. installed balancing equipment.
Page 1
64-30-00 Original
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
FAN PITCH
CONTROL ASSY
FAN LINER
FAN HUB
TENSIONTORSION
STRAPS
BLADE ASSY
9G64001
Page 2
Original 64-30-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(4). Remove pitch assembly (ref. Section (12). If necessary, disengage rotor brake.
64-30-03).
B. Installation of the AntiTorque Fan
(5). Measure and record clearance between System
fan blade tips to felt seal.
(Ref. Figure 401)
(a). Clearance must be 0.030 to 0.065
inch (0.76 to 1.65 mm).
Consumable Materials
(6). Measure and record clearance between (Ref. CSPSPM)
each fan blade and hub. Item Nomenclature
(a). If clearance of a blade is more than C702 Lockwire
the average clearance of other blades
by more than 0.10 inch (2.5 mm),
remove and inspect the torsion-ten Special Tools
sion strap for that blade (ref. Section (Ref. CSPSPM)
65-30-00, Inspection Test). Item Nomenclature
(7). Remove upper center diffuser assembly T603 AntiTorque Shaft Socket
F6 (ref. Section 53-30-00).
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64-30-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
10
8
5
4
3
6 5
2
1
12 7
11
13
9G64-003B
1. FAN CONTROL SHAFT ASSY 8. BOLT
2. PITCH ASSY 9. FAN
3. COTTER PIN 10. WASHER
4. NUT 11. FAN SUPPORT SHAFT
5. WASHER 12. LOCKWASHER
6. BOLT 13. LOCKNUT
7. ROD END BEARING
Figure 401. AntiTorque Fan System
Do not leave fan on support (1). Apply rotor brake (if installed) (ref.
CAUTION shaft without locknut. Fan can applicable Rotorcraft Flight Manual
slip off support shaft and cause damage to refer to Section 01-00-00, Table 201).
helicopter or injury to personnel.
(2). Put fan on fan support shaft with pitch
plate aft.
NOTE: If helicopter does not have a rotor (3). Align fan splines with fan support shaft
brake, you must have the aid of one more splines and push forward.
person. Manually hold main rotor hub so fan
does not turn while lock nut is being remo (4). Install locknut on fan support shaft,
ved. with anti-torque shaft socket (T603).
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Rotorcraft Maintenance Manual
(a). Torque locknut 70 to 80 ft-lb (94.9 (14). Align clevis of pitch control rod with
to 108.5 Nm). pitch control assembly rod end bearing.
(5). Align tabs of new lockwasher with (15). Install bolt, washers, and nut. Torque
notches of locknut and install on fan nut and install cotter pin.
support shaft. (16). Turn rotor system and listen for
unusual noises. None permitted.
(6). Push lockwasher forward over locknut.
(17). Make sure there is clearance of 0.020
(7). Make sure two tabs of lockwasher go to 0.040 inch (0.51 to 1.02 mm)
through notches of lock nut and engage between fan interrupter and azimuth
forward side of lock nut. sensor. If necessary adjust azimuth
sensor.
(8). If necessary, disengage rotor brake.
(18). Remove WARNING from cockpit that
(9). Make sure fan blade tips to fan liner flight controls are disconnected.
clearance is 0.030 to 0.065 inch (0.76
to 1.65 mm). (19). Do the Anti-Torque/Directional
Controls Travel/Rigging Verification
(10). Install upper center diffuser F6 (ref. procedure (ref. Section 67-20-00).
Section 53-30-00). (20). Install access panels F7 and F8 (ref.
Section 53-30-00).
(11). Put pitch control assembly in fan
support shaft, align bolt holes. (21). Do the Fan Balance Procedure (ref.
Section 18-00-00).
(12). Install bolts and washers. Torque bolts.
(22). Install baggage compartment soft
(13). Safety bolts in pairs, use lockwire insulation roof panels (ref. Section
(C702). 25-50-00).
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
10
25
6 REF
12
13
7 REF 24 11
26 15
16
VIEW ROTATED
22
1
6 5
13 17
4
21 14
9 7
20
3
23
2 18
19
9G64-002-1A
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Rotorcraft Maintenance Manual
1 REF
5 REF
APPLY SEALANT TO
THIS EDGE ONLY
15 REF
DO NOT PERMIT SEALANT
ON THIS SURFACE
14 REF
16 REF
FILLET SEAL
VIEW ROTATED
CURE DATE
LORD R
SHELTON CT.USA 11/04
Page 405
64-30-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
C. AntiTorque Fan Disassembly (c). Install nut and washer. Torque nut.
If stud locking collar is loose, replace
(Ref. Figure 402) collar and stud (ref. Anti-Torque Fan
Balance Weight Rivet Stud Replace
(1). Remove anti-torque fan assembly. ment.
NOTE: If you will assemble fan with same D. AntiTorque Fan Assembly
blades and tension-torsion straps, mark (Ref. Figure 402)
their locations in hub before disassembly.
Use a soft tip felt pen.
Consumable Materials
(2). Remove nuts (12), washers (13), and (Ref. CSPSPM)
bolts (14). Item Nomenclature
C213 Sealing Compound, Corrosion Inhibitive
(3). Pull blades (9) out to disconnect C226 Sealing and Locking Compound
tension-torsion straps (5) from center C228 Sealant Primer
spline (16) and disengage pitch horns
C308 Primer
from pitch plate (10).
C310 Primer
NOTE: Center spline is installed with wet seal C827 Desiccant
ant.
(4). Remove pitch plate (10) and center NOTE: If hub is not replaced, and interrupter
spline (16). pin or balance studs are not defective, go to
Step (4).
(5). Turn each blade sufficiently to remove (1). Install fan balance interrupter pin (23).
cotter pin (2) and washer (3).
(a). Point fan hub (1) inner rim down.
(6). Remove pins (8) and tension-torsion
straps (5).
NOTE: Rivet hole where pin is installed is lo
cated 4.125 inch (104.78 mm) from center
(7). Carefully remove blades (9), move of hub.
counterweight arms through openings (b). Remove all burrs and clean rivet hole
in outer rim of hub (1). in hub.
(8). Remove bushings (17). NOTE: If you use a waterborne primer, do not
thin with water Use acetone (C436).
(9). Remove sleeve (24).
Primer (C308)
NOTE:
Do not change balance stud and washers
unless they are defective, or a fan compo
nent is replacement. (c). Apply a thin layer of primer (C308)
There is one installation washer on each to rivet hole.
balance stud. All other washers are for NOTE: Install pin while primer is still wet.
fan balance.
(d). Install pin (23).
(10). If a fan blade is replaced and more than
one washer is installed on its related (e). Tap head of pin with a non-metallic
balance stud (18), do the procedure that hammer until pin is fully installed.
follows: (f). Install collar (22).
(a). Remove nut (21) and washer (20). (2). If removed, install balance stud(s) (ref.
Anti-Torque Fan Balance Weight Rivet
(b). Remove balance washer(s). Stud Replacement).
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Rotorcraft Maintenance Manual
Do not tighten nuts on studs too NOTE: If you can not seal package; put, ten
CAUTION much. If you tighten nut too sion-torsion strap, package, and desiccant
much, balance stud locking collar can be (C827) in new plastic bag.
come loose during subsequent nut removal.
(b). Put tension-torsion strap in package
(3). Install one washer (20) and nut (21) on and seal package openings with tape.
each balance stud. Torque nuts. (c). Put package in box and seal box with
tape.
(4). Point fan hub (1) open side up.
(11). If tension-torsion strap(s) is new, do
(5). Push bushings (17) in each of thirteen the steps that follow:
1.370 in. (34.80 mm) diameter holes in (a). Remove tension-torsion strap from
inner rim of hub (1). Make sure bushing package and write the word EX
flanges are on inner side of rim. PIRATION DATE on the strap face
and date five years after the package
(6). Install sleeves (24) in outer rim of hub is opened, use permanent ink.
(1).
(b). Make an item component record card
NOTE: If a fan blade is replaced, transfer coun for each tension-torsion strap.
terweights from old blade to new blade.
NOTE: Install tension-torsion straps so that
the cure date is in view when fan is as
(7). If necessary, install counterweights (ref.
sembled.
counterweight removal/installation).
(12). Put large bushing end of tension-tor
Center spline bolts have the sion strap in blade spar.
WARNING same life limit as the fan
hub. Because these bolts do not have (13). Align holes in blade spar and tension-
serial numbers, their lives must be the torsion strap. Install pin.
same as the fan hub they were first (14). Turn blade sufficiently to install washer
installed in, and must be replaced and cotter pin.
when the hub is replaced.
(15). Turn blade to 20 mark on fan hub. Pull
(8). Carefully install blades, move counter blade out until counterweight arms are
weight arms through sleeves in outer against outer rim of hub.
rim of hub and blade spars through
NOTE: Replace center spline bushings if loose,
inner rim bushings.
damaged, or missing.
(9). Align blade index mark with 20 mark (16). If installation of center spline bushing
on fan hub. is necessary, do the procedure that
follows:
NOTE:
Primer (C310)
Tension-torsion straps have a life limit
that starts when their package is opened.
Tension-torsion straps can be put back in
their package, and life limit not started, if
not out of the package more than five (a). Apply primer (C310) to outside
days. diameter of center spline bushing.
(b). While primer is still wet, press
(10). If tension-torsion strap is removed bushing into 0.375 inch (9.53 mm)
from package for no more than five diameter hole of center spline.
days, do the steps that follow:
NOTE: If you install a new 900R2441007-101
(a). Replace desiccant in package, use center spline, you must also replace support
desiccant (C827). shaft and fan shaft coupling.
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64-30-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(18). Put center spline, with bushing side up, (Ref. Figure 402)
in center of hub. Align center spline and
hub bolt holes. Consumable Materials
(Ref. CSPSPM)
(19). Hold pitch plate above fan and align Item Nomenclature
pitch plate bushings with blade pitch
C226 Sealing and Locking Compound
horns.
C228 Sealant Primer
(20). Move blades in to engage blade pitch
horns with pitch plate bushings align
tension-torsion strap bolt holes with Sealant Primer (C228)
holes in center spline.
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Rotorcraft Maintenance Manual
Page 409
64-30-00 Revision 34
CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
If you use a water-based prim (6). Apply primer (C308) to bolts (2).
CAUTION er, do not thin it with water. Use
acetone (C436) to thin the primer. (a). Install bolts (2) and washers (3)
while primer (C308) is still wet.
(4). Apply primer (C308) to the mating
surfaces of housing (7) and slider (10).
(b). Torque bolts (2) (ref. CSP-SPM,
(a). Install slider (10) in housing (7) while Section 20-10-00).
primer (C308) is still wet.
(c). Safety bolts (2) to outer retainer (4)
(5). Apply primer (C308) to mating surface
with lockwire (C702).
of housing (7) and outer retainer (4).
(a). Install outer retainer (4) in housing (7). Install pitch control (ref. Procedure
(7) while primer (C308) is still wet. 1.D.).
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Rotorcraft Maintenance Manual
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
20
3
2
18
21
19 20
15
16
14 19
17
5 6 7
4
6
12
8
13 12
9
11
10
9G64-005A
1. FAN SUPPORT ASSEMBLY 12. LABYRINTH SEAL
2. BRACKET WITH AZIMUTH SENSOR 13. SUPPORT HOUSING
3. BRACKET WITH VIBRATION SENSOR 14. FAN SHAFT COUPLING
4. COTTER PIN 15. NUT
5. NUT 16. LOCK WASHER
6. WASHER 17. SHIM
7. BOLT 18. AZIMUTH SENSOR
8. BEARING RETAINER 19. NUT
9. SUPPORT SHAFT 20. WASHER
10. BEARING 21. VIBRATION SENSOR
11. BEARING REMOVAL RING
Figure 404. AntiTorque Fan Assembly
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Rotorcraft Maintenance Manual
(9). EARLY CONFIG - Remove washer (6) (2). Lubricate bearing as necessary (ref.
and bolt (7). Section 12-00-00).
Oil (C111)
(10). CURRENT CONFIG - Remove cotter
pin (4), nut (5), and washer (6) at
azimuth sensor bracket (2).
(11). CURRENT CONFIG - Remove
bracket (2), washer (6), and bolt (7). (3). Apply a thin layer of oil (C111) to
support shaft.
(12). Remove cotter pin (4), nut (5), washer
(6), and vibration sensor bracket (3). (4). Install bearing removal ring and
bearing on support shaft.
(13). Remove washer (6) and bolt (7).
(5). Push support bearing on shaft so
NOTE: Bolt at top location is shorter than other bearing is tight against ring.
two bolts.
NOTE: If you install a new 900R2441007-101
Fan support can fall out of sup center spline (ref. 64-30-01), you must also
CAUTION port frame when you remove replace 900R2441002-101 support shaft
bolts. Hold fan support when you remove (ref. 64-30-02) and 900R2444002-101 fan
last bolt. shaft coupling.
(14). Remove cotter pin (4), nut (5), washers (6). Install support shaft, bearing removal
(6), and bolt (7) from top location. ring, and bearing into support housing.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(7). Install bearing retainer on shaft and NOTE: If you install a new 900R2441007-101
align retainer and housing bolt holes. center spline (ref. Section 64-30-01), you
must also replace 900R2441002-101 sup
(8). Install anti-torque fan support. port shaft (ref. Section 64-30-02) and
900R2444002-101 fan shaft coupling.
D. AntiTorque Fan Support Installation
(11). Install fan shaft coupling and lock nut
(1). Install fan support in support frame with anti-torque shaft socket (T603).
and align bolt holes. Torque lock nut 70 to 80 ft-lb (94.92
to 108.48 Nm).
NOTE: (12). Connect anti-torque drive shaft to
Do not torque nuts until all nuts are transmission (Ref. Section 63-10-00).
installed.
(13). Install two bolts in fan shaft coupling,
Bolt at top location is shorter than other do not tighten bolts.
two bolts.
(14). Measure clearance between coupling
(2). Install top bolt, washers, and nut. and anti-torque drive shaft. Clearance
must be 0.001 to 0.010 inch (0.03 to
NOTE: 0.25 mm).
EARLY CONFIG - 900R2445005-101 NOTE: Shim laminates are 0.003 inch (0.08
azimuth sensor bracket is installed on aft mm) thick.
side of fan support frame.
(15). Remove layers from shim to get
CURRENT CONFIG - necessary thickness.
900R2445005-103 azimuth sensor brack
et is installed on forward side of bearing (16). Remove two bolts from anti-torque
retainer. drive shaft at coupling.
(17). Remove anti-torque drive shaft (ref.
(3). Install bolt, washer, azimuth sensor Section 63-10-00).
and bracket, washer, and nut at lower
right hole of support frame. (18). Remove lock nut, use anti-torque shaft
socket (T603).
(4). Install bolt, washer, vibration sensor
and bracket, washer, and nut at lower (19). Remove coupling.
left hole of support frame. (20). Install shim, coupling, and lock nut
with anti-torque shaft socket (T603).
(5). Torque nuts and install cotter pins. Torque lock nut 70 to 80 ft-lb (94.92
to 108.48 Nm).
(6). Connect electrical connector P434 to
vibration sensor. (21). Install new lock washer.
(7). Connect electrical connector P433 to (22). Install fan driveshaft (ref. Section
azimuth sensor. 63-10-00).
4. Magnetic Motional Pickup Transducer
(8). Safety azimuth sensor and vibration
sensor electrical connectors with A. Removal of Pickup Transducer
lockwire (C702).
(1). Remove right half of anti-torque fan
(9). Install anti-torque fan. center body (ref. Section 53-30-00).
(2). Remove and discard lockwire from
(10). Make sure clearance between fan electrical connector P433, transducer
balance interrupter pin and azimuth (18), bracket (2), and nuts (19).
sensor is 0.020 to 0.040 inch (0.51 to
1.02 mm). (3). Disconnect electrical connector P433.
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Rotorcraft Maintenance Manual
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11
2 21 (3 PL) 20 (3 PL)
20 (3 PL)
3 19 (3 PL)
4
1 REF
10 15 REF
7
16 REF
1
15 6
18
16 12
7
FAN LINER
AFTER MACHINING
FAN LINER
BEFORE MACHINING
22
17
13 (2 PL)
14 (2 PL)
CROSS SECTION VIEW
23 (2 PL)
9G64-008A
1. FAN TIP SEAL TOOL (PART 1) 13. CAP SCREW
2. CALIBRATION ARM 14. WASHER
3. CUTTER 15. POSITION LOCK KNOB
4. MOTOR COLLET 16. ADJUSTMENT KNOB
5. PIN 17. SPEED HANDLE
6. FAN SUPPORT 18. AIR PRESSURE VALVE
7. THRUST BEARING 19. BOLT
8. SPACER 20. WASHER
9. NYLON WASHER 21. NUT
10. THRUST BEARING RETAINER 22. BALL LOCK PIN
11. THREADED KNOB 23. SPACER
12. FAN TIP SEAL TOOL (PART 2)
Figure 405. Felt Seal Machining
C. Felt Seal Machining (2). Remove anti-torque fan support
assembly.
(Ref. Figure 405)
NOTE: Felt metal material can cause FOD con
tamination.
Special Tools
(Ref. CSPSPM) (3). Apply masking tape and plastic sheet to
Item Nomenclature baggage compartment, fan duct, and
T602 Fan Tip Seal Tool fan diffuser areas.
(1). Remove anti-torque fan driveshaft (ref. NOTE: Make sure fan tip seal tool (T602) is
Section 63-10-00). clean before you install it.
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Rotorcraft Maintenance Manual
(4). Install pin (5) in fan support (6). (22). Make sure there is no radial or axial
movement in tool (1).
(5). Install bolts (19), washers (20), and
nuts (21). (23). Lubricate tool motor with pneumatic
tool oil.
(a). Torque nuts.
Eye protection, a respirator,
(6). Put cutter (3) in motor collet (4). Do not WARNING gloves, and protective cloth
tighten collet. ing must be worn during felt seal ma
chining.
(7). Apply a thin film of oil to inner side of
pin (5) and outer side of tool (1) shaft. (24). Loosen position lock knob (15) and turn
adjustment knob (16) to position cutter
(8). Put tool (1) in pin (5) and push forward. (3) for a cut of not more than one fourth
width of cutter (3).
(9). Turn tool (1) by hand and adjust cutter
(3) to highest point on felt seal. (a). Tighten position lock knob (15).
(a). Tighten collet (4). (25). Connect speed handle (17) to tool (12).
(a). Tighten threaded knob (11). (37). Remove thrust bearing from tool shaft.
(20). Put tool (12) on tool (1) and install ball (38). In Step (15)., did cutter (3) touch the
stop on calibration arm (2)?
lock pin (22).
(a). No, go to Step (12).
(21). Install cap screws (13), washers (14),
and spacers (23). Torque cap screws. (b). Yes, go to Step (39).
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Rotorcraft Maintenance Manual
(39). Remove nuts, washers, and bolts. (42). Install support assembly.
Remove pin.
(43). Install diaphragm NOTAR shaft
(40). Clean baggage compartment, fan duct assembly (ref. Section 63-10-00).
and diffuser areas.
(44). Install fan assembly.
(41). Remove masking tape and plastic
sheet. (45). Install pitch assembly.
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(2). Make sure blade tips to felt metal tip (6). Hub inner rim bushings for cracks and
seal clearance is a minimum of 0.030 wear. None permitted.
in. (0.762 mm). Maximum clearance
0.065 in. (1.651 mm). (7). Center spline for cracks. No cracks
permitted.
(3). Turn main rotor. Listen for unusual
noises. (8). Center spline for wear and corrosion.
No wear or corrosion permitted in
(4). Measure clearance between fan blades female splines or twenty-six attach
and hub. If clearance for a blade is holes. All other areas, make damage
more than the average clearance of smooth, maximum depth 0.005 in.
other blades by more than 0.10 in. (0.127mm) maximum area 0.010 sq in.
(2.54 mm), replace that torsion-tension (12.9 sq mm). No limit on quantity of
strap and blade. separate areas of damage.
(5). Make sure there is a clearance of
0.020-0.040 in. (0.50-1.02 mm) (9). Center spline hub for loose, cracked, or
between fan interrupter and azimuth worn bushings. None permitted.
sensor. If necessary, adjust azimuth
(10). Blades for cracks, nicks, scratches,
sensor.
erosion, impact damage, bulges, or
(6). Install lower center diffuser F7 and blisters.
lower access panel F8 (Ref. Section
53-30-00). (11). Pitch horns for loose counterweights. If
loose, do the Pitch Horn Counterweight
B. AntiTorque Fan Component Inspection Set Screw Replacement.
(Area 6)
(12). Pitch horn for too much wear (not
(Ref. Figure 402 and Figure 601)
round). None permitted.
(Ref. Table 601, Table 602, and Table 603)
(13). Fan hub for cracks. None permitted.
NOTE: If you think a part is unserviceable,
speak to MDHI Field Service Department (14). Fan hub for scratches, nicks, and
for more instructions. gouges.
Examine anti-torque fan components as (15). Fan hub for loose or damaged balance
follows: studs. None permitted.
(1). Pitch plate for cracks, wear, and
(16). Fan hub for loose or damaged magnetic
corrosion.
interrupter. None permitted.
(2). Pitch plate bushings for wear, grooves
or cracks. None permitted. (17). Hub sleeves for missing segment. None
permitted.
(3). Tension-torsion straps for nicks or cuts
where kevlar fibers show. None per (a). If sleeve is replaced, examine hole in
mitted. hub for wear. No wear permitted.
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Rotorcraft Maintenance Manual
Table 601. Fan Pitch Plate Damage Limits (Ref. Figure 402)
Maximum Maximum
Examine Serviceable Limits Repairable Limits Repair Procedure
Pitch plate for scratches, Maximum damage Maximum material Make damage smooth,
nicks, and missing permitted, 0.020 in. (0.51 removal, 0.020 in. (0.51 use 240 grit abrasive cloth
material. mm) in depth or 0.020 sq. mm). (C810) (or finer). Remove
in. (12.9 sq. mm) in area. surface defects or sharp
Minimum distance edges. Touch up surface
between damage, 0.25 in. finish with alodine (C241)
(6.35 mm). No more than and primer (C308).
three locations of damage
permitted in each sq. in.
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Table 602. Fan Blade Damage Limits (Ref. Figure 601) (Cont.)
Maximum Maximum
Examine Serviceable Limits Repairable Limits Repair Procedure
Area E Maximum damage Maximum material Make damage smooth,
fan blade spar cylinder for permitted, 0.015 in. (0.38 removal, 0.015 in. (0.38 use 240 grit abrasive cloth
scratches, nicks, and mm) in depth or 0.020 sq. mm). (C810) (or finer). Remove
missing material. in. (12.9 sq. mm) in area. surface defects or sharp
Minimum distance edges. Touch up surface
between damage, 0.25 in. finish with alodine (C241)
(6.35 mm). No more than and primer (C308).
three locations of damage
permitted in each sq. in.
Area H Damage permitted within Material can not be Make damage smooth,
fan blade outer tip surface specified limits in location removed from area B. use a file and then 240 grit
for scratches, nicks, shown. Remove other damage at abrasive cloth (C810) (or
missing material, and a 45 degree angle. finer). Remove sharp
damage. Minimum blade thichness edges and surface
at outer tip, 0.050 in. defects.
(1.27 mm). A smooth
groove less than 0.040 in.
(1.016 mm) in depth and
0.250 in. (6.35 mm) wide
is permitted. The groove
must not go to edge of fan
blade.
Area J Damage permitted within Maximum surface defect, Lightly clean crack with
fan blade forward and aft specified limits in location 1.0 in. (25.4 mm) in scouring pad (C817) and
surfaces for defects and shown. length or 0.03 in. (0.76 seal cyanoacrylate
cracks. mm) in height. Maximum adhesive (C442).
crack length, 0.75 in.
(19.1 mm).
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Rotorcraft Maintenance Manual
0.5 IN.
2.5 IN
(12.7 mm)
(6.35 cm)
0.06 IN.
(1.52 mm)
B 0.125 IN.
(3.18 mm)
3.0 IN. A
(7.62 cm) 0.30 IN.
(7.62 mm)
0.06 IN. C
(1.52 mm) G
0.050 (1.27mm)
J D
0.30 IN.
MINIMUM (7.62 mm)
E
REPAIR SURFACE
-45 ANGLE
VIEW LOOKING UP
VIEW LOOKING DOWN
NOTE:
IGNORE TOOL MARKS AND PLASTIC FLOW INDICATIONS THAT ARE IN THE MOLDED PART OF THE FAN BLADE. THESE
ARE NOT AN INDICATION OF DEFECTS OR DAMAGE. 9G64-009D
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B C
B
C
9G64-011
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(3). Examine for cracks in felt metal seal (4). X-ray inspection must be done at an
material. None permitted. x-ray laboratory.
(3). Examine tension-torsion straps for the (5). Examine all areas of strap on x-ray
defects that follow: film for progressive fiber fractures.
Carefully examine very important
(a). Nicks or cuts where kevlar fibers areas. None permitted.
show. None permitted. (6). Replace unserviceable straps, and
reassemble anti-torque fan.
(b). Strap bushings for cracks and wear.
None permitted. (7). Install anti-torque fan.
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KV 80
MA 8
TIME 25 SECONDS
FFD 48 INCHES
FILM D2 OR EQUIVALENT
SCREENS NONE
DENSITY IN VERY
IMPORTANT AREAS 1.80 to 2.25 H & D
RADIATION SOURCE
0 DEGREES
XX - XX
PROGRESSIVE
FIBER
FRACTURE
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A. AntiTorque Fan Balance Weight Rivet (b). Gently tap head of rivet stud with a
Stud Replacement non-metallic hammer to fully seat
rivet stud.
(Ref. Figure 801) NOTE: Collars shall not be reused. Collars
shall be replaced with the same part num
ber as the original installation.
Consumable Materials
(Ref. CSPSPM) (5). Install new collar.
Item Nomenclature
(a). Thread collar (4) onto pin rivet stud.
C310 Primer
(b). Place box-end wrench over wrench
C402 Adhesive, Epoxy
ing device of collar.
(c). Insert hex wrench into hex cavity at
(1). Remove nut (1) and washer (2) from pin top of rivet stud.
rivet stud (3).
(d). Hold rivet stud stationary and
tighten collar onto rivet stud until
(2). Remove stud (3) and collar (4) from hub
wrenching device shears from collar.
(5) with hex wrench and locking pliers.
Primer (C310)
(3). Prepare hub for balance rivet stud
installation.
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Rotorcraft Maintenance Manual
9G64004
1. NUT
2. BALANCE WASHER
3. PIN RIVET STUD
4. LOCKING COLLAR
5. FAN HUB
Page 802
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Rotorcraft Maintenance Manual
NOTE: 900R3442009-103 and 900R6442009-103 Tension Torsion Straps are two-way inter
changeable with each other and can be used in any combination with each other.
Chapter
FLIGHT CONTROLS
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
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MD Helicopters, Inc. CSP-900RMM-2
Rotorcraft Maintenance Manual
Section
670000
Flight Controls
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
FLIGHT CONTROLS
DESCRIPTION AND OPERATION
1. Flight Controls Cyclic Stick Base - Separates longitudinal
and lateral inputs and contains the secondary
The flight controls consist of the cyclic controls, cyclic control stops.
collective controls, upper flight controls,
anti-torque/directional controls, and vertical Longitudinal Trim Actuator - Allows the
stabilizer control subsystems. pilot to alleviate longitudinal cyclic stick flight
loads for trim flight conditions.
The MD900 helicopter is right command. The
helicopter may be equipped with either single Longitudinal Controls Balance Spring -
or dual pilot control installations. In a dual Balances longitudinal control load resulting
control helicopter the left main rotor controls from control component weight.
may be removed, the directional pedals
de-coupled and stowed, and covers placed over Longitudinal Linkages - Transmit longitu
the openings. dinal cyclic stick input to the upper flight
controls.
The main rotor flight controls combine pilot
inputs, from the cyclic and collective control Longitudinal Servoactuator - Hydraulical
stick assemblies, to control main rotor blade ly assists longitudinal linkage inputs to the
pitch. The cyclic and collective control stick upper flight controls.
inputs provide for longitudinal, lateral, and
vertical control. Lateral Trim Actuator - Allows the pilot to
alleviate lateral cyclic stick flight loads for
The anti-torque/directional pedal inputs are trim flight conditions.
transmitted to the anti-torque fan and direct
jet thruster for directional control, and Lateral Linkages - Transmit lateral cyclic
anti-torque. stick input to the upper flight controls.
Lateral Servoactuator - Hydraulically
2. Cyclic Controls Subsystem
assists lateral linkage inputs to the upper
(Ref. Figure 1) flight controls.
The cyclic controls subsystem provides A. Cyclic Stick Assembly
helicopter longitudinal and lateral control. The
cyclic controls move the upper controls to The cyclic stick assembly is located in front of
increase or decrease the main rotor blades the pilots seat. The cyclic stick is a curved
angle of attack in a cyclical manner around the aluminum tube with a control head and
main rotor azimuth. The result is a change in provides the pilot longitudinal and lateral
the helicopter pitch and/or roll attitude. The control of the helicopter. The cyclic stick is
cyclic control subsystem consists of the attached to the cyclic base. The cyclic base
following components: limits the range of travel at the cyclic grip to
11 inches longitudinally and 10 inches
Cyclic Stick Assembly - Provides pilot laterally.
control of helicopter pitch and/or roll attitude.
Cyclic stick inputs are transferred through
Cyclic Stick Centering Device - Assists the control linkages and push-pull tubes to the
pilot in centering the cyclic stick assembly, longitudinal and lateral hydraulic servoactua
both longitudinally and laterally, during tors. The servoactuators transmit cyclic inputs
engine start-up and shut-down. into the upper flight controls.
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A two way transmit switch, four way trim cyclic stick inputs. The pivoting bracket
switch, cargo hook release switch (if equipped), outputs the lateral cyclic stick inputs.
emergency float deploy switch (if equipped),
and auto pilot disconnect switch (if equipped) Incorporated into the pivoting bellcrank
are located on the cyclic stick assembly control bracket are secondary cyclic control stops.
grip. The transmit switch transmits on either Secondary cyclic control stops are machined as
the radio or intercommunications system. The part of the pivoting bracket and are not
trim switch controls the longitudinal and adjustable.
lateral trim actuators. Optional equipment E. Longitudinal and Lateral Trim Actuators
switches perform functions as indicated.
The longitudinal and lateral trim actuators
B. Copilot (Quick Release) Cyclic Stick are located below the pilot's seat under the
cockpit floor panel. The trim actuators
The quick release cyclic stick allows for the compensate for control loads from the main
removal and installation of the cyclic stick rotor system during flight. The actuators act
assembly without tools. The quick release through spring cartridges to provide gradient
cyclic stick is held in place by two spring clips force from the centered position the pilot
(expandable bolts). selects.
Single pilot operation using the quick release The cyclic trim switch, located on top of the
cyclic stick is prohibited. cyclic stick grip, has five positions: OFF at the
center, FORWARD, AFT, LEFT and RIGHT.
C. Cyclic Stick Centering Device When the trim button is moved from the
spring loaded OFF position to any of the four
The cyclic stick centering device, or centering trim directions, the trim actuators are
strap, is located on the front of the pilots cyclic energized, and the force gradient springs are
stick assembly. The strap is bolted to the cyclic repositioned to a new trim center.
stick at the top, and secured at the bottom, in
the stowed position, with a hook and loop Each trim actuator is an electrically energized
fastener. The strap is extended and aligned rotary actuator assembly installed in parallel
with the centering placard on the instrument to the longitudinal or lateral control path. The
panel directly in front of the cyclic stick. The actuators are secured to a bracket that is
centering device is used to aid the pilot in mounted to the forward fuselage substructure.
locating neutral cyclic stick position. Centering The cyclic trim gradient springs are linked to
the cyclic stick during engine start-up and the longitudinal and lateral linkages by dual
shut-down minimizes oscillatory loading of the attachment bellcranks.
main rotor flexbeams.
F. Longitudinal and Lateral Linkages
D. Cyclic Stick Base
The longitudinal and lateral linkages are
The cyclic stick base is attached to the located below the pilot's seat under the cockpit
underside of the cockpit floor directly aft of the floor, in the controls closet behind the pilot's
cyclic stick opening. The cyclic base splits the seat, in the cabin roof structure, and on the
longitudinal and lateral cyclic stick inputs into upper deck. The longitudinal and lateral
separate control paths. linkages move with cyclic input from the cyclic
stick assembly to control rods, located in the
The cyclic stick is attached to the longitudinal controls closet. The control rods in the controls
bellcrank which is mounted in the lateral closet move linkages in the cabin roof struc
bracket which pivots in the cyclic base. The ture to the longitudinal and lateral hydraulic
longitudinal bellcrank outputs longitudinal servoactuators.
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CYCLIC
CARGO HOOK TRIM
SWITCH REF.
RELEASE SWITCH UPPER DECK
AUTO PILOT CONTROLS
DISCONNECT
SWITCH
FLOAT
DEPLOY
SWITCH
LONGITUDINAL CLOSET
TRANSMIT CONTROL ROD
SWITCH LATERAL
VIEW ROTATED VIEW ROTATED CLOSET
CONTROL
SPRING CLIPS ROD
CYCLIC STICK
CENTERING STRAP LONGITUDINAL
BALANCE SPRING
ATTACH CLIP
LONGITUDINAL
CYCLIC STICK BRACKET
COPILOT LONGITUDINAL
QUICK DUAL CONTROLS BELLCRANK
RELEASE LONGITUDINAL
CYCLIC CONTROL CONTROL ROD LATERAL
STICK BOOT BRACKET
CYCLIC LONGITUDINAL
BASE CONTROL ROD
EXPANDABLE
DIAMETER BOLT
LONGITUDINAL LATERAL
CONTROL ROD BELLCRANK
LATERAL
CONTROL
STOP
LONGITUDINAL LATERAL
CONTROL STOP CONTROL ROD
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Rotorcraft Maintenance Manual
UPPER CONTROLS
LONGITUDINAL MIXER ARM
LONGITUDINAL HYDRAULIC
SERVOACTUATOR
UPPER CONTROLS
LATERAL MIXER ARM
LONGITUDINAL
CONTROL ROD BOOT
LONGITUDINAL/COLLECTIVE
FOD COVER LATERAL HYDRAULIC
FOD COVER SERVOACTUATOR
LATERAL
FOD COVER
UPPER DECK
CONTROL BRACKET
UPPER DECK LONGITUDINAL ACTUATOR
LONGITUDINAL ACTUATOR ATTACH CLEVIS
CONTROL ROD
LONGITUDINAL
UPPER DECK CONTROL BELLCRANK
BRACKET LONGITUDINAL
BRACKET
LONGITUDINAL
CONTROL ROD
LATERAL ACTUATOR
ATTACH CLEVIS
LATERAL
LATERAL CONTROL ROD BELLCRANK
UPPER DECK
LATERAL BELLCRANK
9G67-002-2B
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The collective friction unit is linked to the F. Collective Controls Balance Spring
collective stick assembly by the collective
friction link.
The collective controls balance spring balances
D. Collective Friction Release Switch
collective control loads caused be control
The collective friction release switch is located component weight. The balance spring
on the under side of the collective stick control attaches to a bracket which is attached to
module. The collective friction release switch cockpit sub-structure, and to a clip attached to
allows the pilot to turn off friction by moving the bottom connecting bolt of the collective
the switch forward or momentarily release the closet control rod. An electrical tie down strap
friction by moving the switch aft. The momen
is installed loosely through the balance spring
tary release position is spring loaded to return
to the center or on position. The co-pilot's to retain the spring in position in the event of
collective control module has the momentary spring failure.
release function only.
E. Collective Linkages G. Collective Servoactuator
The collective linkages are located below the
pilots seat under the cockpit floor, in the
controls closet behind the pilot's seat, in the The collective servoactuator is located on the
cabin roof structure, and on the upper deck. upper deck in front of the transmission. The
The collective stick assembly inputs are hydraulic servoactuator assists control linkage
transmitted through the linkages and push- inputs to position main rotor upper flight
pull tubes to the collective servoactuator. controls.
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UPPER CONTROLS
COLLECTIVE MIXER
ARM
COLLECTIVE HYDRAULIC
SERVOACTUATOR
COLLECTIVE SERVOACTUATOR
CONTROL ROD
LONGITUDINAL/COLLECTIVE
FOD COVER
COLLECTIVE
BELLCRANK
COLLECTIVE
COLLECTIVE CLOSET BRACKET
CONTROL ROD COLLECTIVE
BELLCRANK
COLLECTIVE
DETENT MODULE CONTROL CONTROL ROD
BRACKET
POSITION
SENSOR LINK
DETENT MODULE
MOUNTING BRACKET
COLLECTIVE POSITION
ENGINE BALANCE SPRING SENSOR CRANK
MANUAL CONTROL ATTACH CLIP
TWIST GRIPS
POSITION TRANSDUCER
COLLECTIVE
POSITION SENSOR SENSOR BELLCRANK
PILOT BRACKET
COLLECTIVE STICK CLAMP BRACKET
COLLECTIVE FRICTION
RELEASE SWITCH COLLECTIVE POSITION
SENSOR INSTALLATION
COLLECTIVE INTERCONNECT
CONTROL ROD 9G67-011-1b
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COLLECTIVE FRICTION
UNIT
COLLECTIVE FRICTION
ARM
COLLECTIVE FRICTION
COLLECTIVE LINK LINK
COLLECTIVE STICK
DOWN STOP
DUAL BEARING
ROD END
YAW SYNC
CURRENT
900 C0NFIG CONFIG 9G67-011-2A
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UPPER DECK
DIRECTIONAL
CLOSET DIRECTIONAL BELLCRANK
CONTROL ROD
AFT DIRECTIONAL
CONTROL ROD
PEDAL
ADJUSTMENT DUAL CONTROL
STOP DIRECTIONAL PEDAL
PEDAL CRANK
CONTROL ROD
ATTACH BOLT
HEEL REST
PEDAL
CRANK
PEDAL
PILOT RIGHT FRICTION
DIRECTIONAL ASSEMBLY
PEDAL RIGHT
HEEL REST
902 CONFIG SUPPORT
PEDAL ANTICIPATOR LEFT
HOOK AND LOOP FASTENER
FOR STOWING PEDALS HEEL REST
DIRECTIONAL
SUPPORT
INTERCONNECT
CONTROL ROD
DIRECTIONAL
CRANK
PEDAL CRANK
PILOT RIGHT CONTROL ROD
PEDAL CRANK
9G67-012-1A
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Rotorcraft Maintenance Manual
DIRECTIONAL
CONTROL ROD
DIRECTIONAL DIRECTIONAL
DIRECTIONAL BELLCRANK
CONTROL ROD BRACKET
DIRECTIONAL
CONTROL ROD
UPPER DECK
DIRECTIONAL
CONTROL BRACKET
PUSH PULL
CABLE HOUSING
ATTACH BRACKET
DIRECTIONAL
BELLCRANK
DIRECTIONAL
BRACKET
TO THRUSTER
DIRECTIONAL
CONTROL CABLE
DIRECTIONAL
CONTROL ROD
OUTER BELLCRANK
DIVERTER PLATE FAN
CONTROL ROD
9G67-012-2A
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ROTATING CONE
ASSEMBLY
THRUSTER BUILDUP
ASSEMBLY
THRUSTER EXTENSION
ASSEMBLY
TAILBOOM
ASSEMBLY
THRUSTER
CONTROL ROD
THRUSTER
STATIONARY
CONE ASSEMBLY
DIRECTIONAL CONTROL
PUSH PULL CABLE
FORWARD
THRUSTER CONTROL CABLE
AFT
THRUSTER CONTROL CABLE
THRUSTER
STATIONARY
CONE ASSEMBLY
LIGHTNING
STRIKE SHIELD
THRUSTER CONTROL
CABLE DRUM
VIEW ROTATED
9G67-012-3C
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Rotorcraft Maintenance Manual
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G. Upper and Lower Horizontal Endplates control the horizontal endplates through
control rods and cranks.
COLLECTIVE
POSITION
YAW RATE
TRANSDUCER
GYRO
LATERAL
ACCELEROMETER
RIGHT VSCS YAW RATE
CONTROL UNIT GYRO
UPPER RIGHT
HORIZONTAL RIGHT VSCS
ENDPLATE LINKAGE LEFT VSCS
CONTROL
UNIT
UPPER LEFT
HORIZONTAL
ENDPLATE
RIGHT LINEAR
ACTUATOR
VSCS POSITION
INDICATORS
LEFT
LINEAR
ACTUATOR
LEFT VSCS
LINKAGE
9G67-013B
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Rotorcraft Maintenance Manual
FLIGHT CONTROLS
FAULT ISOLATION
1. Rotor Flight Controls System Troubleshooting tables should be used with the
Troubleshooting simplified system schematics, electrical wiring
diagrams, serviceability checks and other
(Ref. Table 101) detailed procedures referred to in this and
other chapters of the manual.
The following troubleshooting procedures are a Comprehensive wiring diagrams are available
brief summary of Rotor Flight Controls system in the Rotorcraft Maintenance Manual
faults, which may be encountered. CSP-900RMM-3 (Ref. Section 98-40-00).
Cyclic control pressure Faulty wiring. Test and repair wiring. 980000
cannot be reduced by
operating trim switch. Faulty connection. Troubleshoot trim actuator 671000
connection.
Trim switch inoperative. Troubleshoot actuator trim 671020
switch on cyclic grip.
Trim resistor failed. Test and/or replace trim 671000
resistor.
Trim actuator inoperative. Replace actuator. 671000
Trim change is too slow. Trim resistor failed. Test and/or replace trim 671000
resistor.
Defective trim actuator. Replace actuator. 671000
Trim change is too fast. Trim resistor failed. Test and/or replace trim 671000
resistor.
Binding, locking up or Control rod restrictions or Inspect control rod 671000
erratic action of cyclic misalignment. connections, rod end condition
control stick. and bearing movement, replace
or repair as required.
Control linkage restriction or Isolate restriction or damage 671000
damage. and remove, repair, or replace.
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Inadequate collective Aircraft may be above or Verify weight, reduce load if CSP900RFM1
control movement or near maximum take off required. or
response during normal weight. CSP900RFM1
operation.
Incorrect collective rigging. Correct collective rigging. 671000
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Noticeable dutch roll of Faulty wiring. Test and repair wiring. 980000
aircraft.
Malfunction of right yaw rate Perform VSCS Test Box and 672000
gyro. System Diagnostics
Procedures. Replace yaw rate
gyro.
Malfunction of left yaw rate Perform VSCS Test Box and 672000
gyro. System Diagnostics
Procedures. Replace yaw rate
gyro.
Vertical stabilizer endplates Faulty wiring. Test and repair wiring. 980000
will not hardover in a hover or
difficulty making a Malfunction of lateral Perform VSCS Test Box and 672000
coordinated turn. accelerometer. System Diagnostics
Procedures. Replace lateral
accelerometer.
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Rotorcraft Maintenance Manual
LEFT STAB FAIL, RIGHT Faulty wiring. Test and repair wiring. 980000
STAB FAIL or TOTAL STAB
FAIL message present on Faulty VSCS component. Perform VSCS Test Box and 672000
alpha numeric display of System Diagnostics
IIDS. Procedures. Replace faulty
component.
No deflection in lightning Liquid shim in this area too Sand liquid shim minimum 672000
strike contact; no measurable thick. required while maintaining an
gap between contact and even surface for mating part
cone surface. (See Notes).
Measurable gap between Lightning strike contact Replace lightning strike 672000
contact and cone surface, no warped or bent. contact.
contact with guide pin.
Deflection verified, Pin surface and/or contact Reprepare surfaces for 900CSPSPM
measurable gap exists, surface contaminated or electrical bonding.
contact fails bond check. corroded.
Guide pin not properly Test and repair. 900CSPSPM
grounded. 672000
NCFUR 1=2 on IIDS Faulty wiring. Test and repair wiring. 980000
alphanumeric display.
Pedal Potentiometer. Replace potentiometer. 672000
EEC. Ref. P&WC Fault Isolation 010000
Charts (Ref. Related
Manufacturers Publications).
NCFUR 1=13 on IIDS Faulty wiring. Test and repair wiring. 980000
alphanumeric display.
Pedal Potentiometer. Replace potentiometer. 672000
EEC. Ref. P&WC Fault Isolation 010000
Charts (Ref. Related
Manufacturers Publications).
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Section
671000
Rotor Flight
Controls
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(1). Disconnect electrical connector P1 (3). (3). Remove access panel AR138, AR145,
and B142 (Ref. Section 06-00-00).
Do not remove or loosen the hex
CAUTION head screws in the throttle twist (4). Disconnect electrical connector P2 (25).
grips. This could cause a disengagement of Be careful when you disconnect
the manual throttle mechanism. CAUTION mechanical engine control ca
bles. If you are not careful, damage to con
(2). Align holes in mechanical engine
trol cables can occur.
controls twist grip (23) as necessary
and remove screw (24). NOTE: Mark left and right mechanical engine
control cables (5).
(3). Remove control module (4).
(5). Remove and discard lockwire. Discon
B. Collective Control Module Installation nect mechanical engine control cables
(5).
(1). Install control module on end of
collective stick. NOTE: DUAL CONTROLS - Mark the left
and right mechanical engine control inter
(2). Align holes in mechanical engine connect cables (27).
controls twist grip as necessary and
install screw. Torque screw. (6). DUAL CONTROLS - Remove and
discard lockwire, disconnect mechanical
(3). Connect electrical connector P1. engine control interconnect cables (27).
(4). Do the mechanical engine controls (7). Apply external electrical power, use
operational check (Ref. Section ground power unit (T2002) (Ref.
76-00-00). CSP-900RMM-3).
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(8). Pull collective friction release switch (4). Environmentally seal bonding jumper
and lift pilot collective stick (2) to with sealant (C216) (Ref. CSP-SPM).
approximately 15 to 30 percent shown
on IIDS to unload collective controls. (5). Connect collective link and install bolt,
washers, and nut. Torque nut and
(9). Remove external electrical power (Ref. install new cotter pin.
CSP-900RMM-3).
(6). Connect collective friction unit link and
(10). Remove cotter pin (6) from bolt (9). install bolt, washers, and nut. Torque
nut and install new cotter pin.
(11). Remove nut (7), washers (8, 11 and 29),
and bolt (9) and disconnect collective Compound, Anti-Seize (C220)
link (12).
(3). Do a test on collective stick for Class (14). Install pilot crew seat (Ref. Section
L electrical bond (Ref. CSP-SPM). 25-10-00).
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4. Collective Friction Unit Link Assembly (4). Install collective stick boot.
(Ref. Figure 401) (5). Do steps (9). through (12). of collective
controls system rigging (lower).
Special Tools 5. Collective Friction Unit Arm Assembly
(Ref. CSPSPM)
Item Nomenclature (Ref. Figure 401)
T2002 Ground Power Unit
Special Tools
(Ref. CSPSPM)
A. Collective Friction Unit Link Assembly Item Nomenclature
Removal
T2002 Ground Power Unit
(1). Remove collective stick boot (1).
(2). Remove access panel B142 (Ref. Section A. Collective Friction Unit Arm Assembly
06-00-00). Removal
(3). Apply external electrical power, use (1). Remove center access panel B142 (Ref.
ground power unit (T2002) (Ref. Section 06-00-00).
CSP-900RMM-3). (2). Apply external electrical power, use
Moving Flight Controls ground power unit (T2002) (Ref.
CSP-900RMM-3).
Moving Flight Controls
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(2). Install bolt, washers, and nut. Torque (5). Disconnect electrical connector P153
nut and install new cotter pin. (20).
(3). Install center access panel B142 (Ref. (6). Remove cotter pin (6) from bolt (9).
Section 06-00-00).
(7). Remove nut (7), washers (8), and bolt
(4). Do steps (9). through (12). of Collective (9).
Controls System Rigging (Lower). (8). Remove environmental seal from
around collective friction unit (19).
6. Collective Friction Unit
(9). Remove bolts (21), washers (22), and
(Ref. Figure 401) collective friction unit (19).
B. Collective Friction Unit Installation
Consumable Materials
(Ref. CSPSPM) (1). Prepare collective friction unit to
Item Nomenclature structure mating surfaces for electrical
C216 Sealant, Fuel Resistant bond (Ref. CSP-SPM).
(2). Put collective friction unit in its
Special Tools installed position and installbolts and
(Ref. CSPSPM) washers. Torque bolts.
Item Nomenclature
(3). Do a test on collective friction unit for
T2002 Ground Power Unit Class L electrical bond (Ref. CSP-
SPM).
A. Collective Friction Unit Removal Sealant, Fuel Resistant (C216)
(1). Remove center access panel B142 (Ref.
Section 06-00-00).
(2). Apply external electrical power, use
ground power unit (T2002) (Ref. (4). Environmentally seal collective friction
CSP-900RMM-3). unit, use sealant (C216) (Ref. CSP-
SPM).
Flight Control Movement
CAUTION (5). Install bolt, washers, and nut. Torque
nut and install new cotter pin.
(3). Pull collective friction release switch
(6). Connect electrical connector P153.
and lift pilot collective stick (2) to
approximately 15 to 30 percent shown (7). Install center access panel B142 (Ref.
on IIDS to unload collective controls. Section 06-00-00).
(4). Remove external electrical power (Ref. (8). Do steps (9). through (12). of Collective
CSP-900RMM-3). Controls System Rigging (Lower).
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4
23
2
1
28 24
9 20
19
21
8 4 PL
22
26
25
27 TO COPILOT'S
COLLECTIVE
16 (DUAL CONTROLS)
7 11
8 8 17
6 9
7 6 15
18
10 8
29
7
29 TO MANUAL ENGINE CONTROLS
6 DETENT MODULE
13
11 8
9 5 (NOTE)
7
6
8 8
6
12 7
11
14 13
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7. Collective Stick Link Assembly (3). Install access panel AR145 and B142
(Ref. Section 06-00-00).
(Ref. Figure 402)
(4). Install collective stick boot.
Special Tools (5). Install pilot crew seat (Ref. Section
(Ref. CSPSPM) 25-10-00).
Item Nomenclature
8. Collective Cockpit Control Tube
T2002 Ground Power Unit
Assembly
(Ref. Figure 402)
A. Collective Stick Link Assembly Removal
A. Collective Cockpit Control Tube
(1). Remove pilot crew seat (Ref. Section Assembly Removal
25-10-00).
(1). Remove pilot crew seat (Ref. Section
(2). Remove collective stick boot (1). 25-10-00).
(3). Remove access panel AR145 and B142 (2). Remove floor access panel AR138 and
(Ref. Section 06-00-00). B142 (Ref. Section 06-00-00).
(4). Apply external electrical power, use (3). DUAL CONTROLS - Remove cotter
ground power unit (T2002) (Ref. pin (6) from bolt (50).
CSP-900RMM-3). (4). DUAL CONTROLS - Remove nut (7),
washers (11), and bolt (50) disconnect
Moving Flight Controls
interconnect control rod (21).
(5). Remove cotter pin (6) from bolt (45).
(6). Remove nut (7), washers (8), bushing
(22), and bolt (45).
(5). Pull collective friction release switch
and lift pilot collective stick (2) to (7). Remove cotter pin (6) from bolt (13).
approximately 15 to 30 percent shown
on IIDS to unload collective controls. (8). Remove nut (7), washers (11), and bolt
(13). Remove control tube (17).
(6). Remove external electrical power (Ref.
B. Collective Cockpit Control Tube
CSP-900RMM-3).
Assembly Installation
(7). Remove cotter pin (6) from bolt (9). (1). If a replacement control tube is
installed, make sure new control tube is
(8). Remove nut (7), washers (11, 51, and
set to the same length as removed
8), and bolt (9).
control tube.
(9). Remove cotter pin (6) from bolt (18). (2). Install control tube, bolt (45), bushing,
washers, and nut. Torque bolt and
(10). Remove nut (7), washers (8), and bolt
install new cotter pin.
(18). Remove collective link (12).
(3). Install bolt (13), washers, and nut.
B. Collective Stick Link Assembly Torque bolt and install new cotter pin.
Installation
(4). DUAL CONTROLS - Connect inter
(1). Install collective link, bolt (18), washers connect control rod and install bolt (50),
and nut. Torque nut and install new washers, and nut. Torque bolt and
cotter pin. install new cotter pin.
(2). Install bolt (9), washers, and nut. (5). Do the collective control system part of
Torque nut and install new cotter pin. the rotor flight controls rigging check.
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(6). Install floor access panel AR138 and (5). Remove nuts (27), washers (8), and
B142 (Ref. Section 06-00-00). bolts (28). Remove collective stick
bracket (14).
(7). Install pilot crew seat (Ref. Section
25-10-00). B. Collective Stick Bracket Assembly
Installation
9. Collective Stick Bellcrank Assembly (1). Prepare mating surfaces of collective
(Ref. Figure 402) stick bracket and structure for electri
cal bond (Ref. CSP-SPM).
(1). Remove pilot collective stick. (4). Remove cotter pin (6) from bolt (46).
(5). Remove nut (7), washers (8), bolt (46),
(2). Remove (6) from bolt (19). spacer (15), grommet (10), and spring
(3). Remove nut (7), washers (8 and 11) and attach clip (5).
bolt (19). (6). Remove cotter pin (6) from bolt (4).
(4). Remove fillet seal from around collec (7). Remove nut (7), washers (8), and bolt
tive stick bracket (14). (4). Remove closet control tube (43).
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(3). Install bolt (46), washers, spring clip, NOTE: Make a mark adjacent to the hole bal
grommet, spacer, and nut. Torque nut ance spring is installed in on lower collective
and install new cotter pin. balance spring bracket (39).
(6). Remove cotter pin (6) from bolt (46).
(4). Do the collective control system part of (7). Remove nut (7), washers (8), bolt (46),
the rotor flight controls rigging check. spacer (15), grommet (10) and spring
attach clip (5).
(5). Install controls closet and insulation
panels behind right crew seat (Ref. (8). Remove balance spring (36) from lower
Section 25-10-00). collective balance spring bracket (39).
(9). Remove spring attach clip (5) from
(6). Install floor access panel AR138 (Ref. balance spring (36).
Section 06-00-00). B. Collective Controls Balance Spring
Installation
(7). Install pilot crew seat (Ref. Section
25-10-00). (1). Install balance spring in hole in lower
attach bracket with mark.
12. Collective Controls Balance Spring (2). Install spring attach clip on upper end
of balance spring.
(Ref. Figure 402) (3). Install bolt, spring attach clip, washers,
grommet, spacer, and nut. Torque nut
and install new cotter pin.
Special Tools
(Ref. CSPSPM) (4). Apply external electrical power, use
Item Nomenclature ground power unit (T2002) (Ref.
CSP-900RMM-3).
T2001 Hydraulic Mule
Moving Flight Controls
T2002 Ground Power Unit
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full down position. Make sure tie down (7). Remove nut (7), four washers (8),
strap is loose on balance spring. If tie bushing (22) and bolt (45).
down strap is not loose, replace strap.
(8). Remove wires from module block (34)
(7). Remove hydraulic pressure (Ref. (Ref. CSP-SPM).
Section 29-00-00).
(9). Remove bolts (33), washers (11), and
(8). Remove external electrical power (Ref. collective position sensor assembly (35).
CSP-900RMM-3).
B. Collective Position Sensor Assembly
(9). Install floor access panel AR138 (Ref. Disassemble
Section 06-00-00).
(1). Remove cotter pin (6) from bolt (24).
(10). Install pilot crew seat (Ref. Section
25-10-10). (2). Remove nut (7), washers (20), and bolt
(24). Remove sensor link (25).
13. Collective Position Sensor Assembly (3). Remove cotter pin (6) from bolt (41).
(Ref. Figure 402) (4). Remove nut (7), washers (8), and bolt
(41). Remove sensor bellcrank (44).
Special Tools
(Ref. CSPSPM) (5). Remove screws (23), washers (8), and
Item Nomenclature potentiometer clamps (49). Remove
sensor transducer (47)
T2001 Hydraulic Mule
T2002 Ground Power Unit C. Collective Position Sensor Assembly
T1001 Analog Multimeter, Portable Reassemble
(1). If sensor transducer is new, do the
A. Collective Position Sensor Assembly procedure that follows:
Removal
(a). Do a test for resistance on each half
(1). Remove pilot crew seat (Ref. Section of the sensor transducer, use analog
25-10-00). multimeter (T1001)
(2). Remove floor access panel AR138 (Ref. (b). If the resistance is not the same,
Section 06-00-00). loosen screw on clamp between each
half and set both parts of transducer
(3). Apply external electrical power, use to the same resistance. Tighten screw
ground power unit (T2002) (Ref. on clamp sufficiently to prevent
CSP-900RMM-3). movement between the two parts.
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(10). Remove multimeter and stabilizer test (17). Remove external electrical power (Ref.
box (Ref. Section 67-20-00). CSP-900RMM-3).
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(2). Remove collective position sensor (3). Remove environmental seal from
assembly. around collective bellcrank bracket (48).
(3). Remove cotter pin (6) from bolt (30). (4). Remove bolts (4), washers (8), and
collective bracket (48).
(4). Remove nut (7), washers (8 and 11),
and bolt (30). Remove lower closet B. Collective Lower Closet Bellcrank
bellcrank (26). Bracket Assembly Installation
B. Collective Lower Closet Bellcrank (1). Prepare mating surfaces of collective
Assembly Installation bracket and structure for electrical
bond (Ref. CSP-SPM).
(1). Install collective bellcrank, bolt,
washers, and nut. Torque nut and (2). Do a test on bellcrank bracket for Class
install new cotter pin. L electrical bond (Ref. CSP-SPM).
(2). Install collective balance spring. (3). Install bracket, bolts, and washers.
Torque bolts.
(3). Install collective position sensor
assembly. Sealant, Fuel Resistant (C216)
15. Collective Lower Closet Bellcrank
Bracket Assembly
(Ref. Figure 402)
(4). Environmentally seal bracket, use
Consumable Materials sealant (C216) (Ref. CSP-SPM).
(Ref. CSPSPM)
Item Nomenclature
(5). Install collective position sensor
assembly.
C216 Sealant, Fuel Resistant
(6). Install collective lower closet bellcrank.
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6 3
7
8
2
48
1 8
43
7 11
6
43
51
9
28 8 17
3 PL 8
27
46
26 8 27
6 14 5 8 2 PL
15 29
19
8
7 11
8 8 REF. 43
7
12 7
10 6 20 24
6 20
8 25
16 6 REF. 33
18 11 REF. 11
6 13 31
11 (2 PL)
7 7
11 33 (2 PL)
TO COPILOT REF. 17
COLLECTIVE 21 11 (2 PL) 44
32 (2 PL) 30
8 5
6 47
50 7
6 11
11 REF. 17
7
REF. 43 34
38
22 35 REF. 31 VIEW ROTATED
REF. 25 8
8
8 7
45
36
6
8 42
REF. 44
7 37
6 REF. 26
8 8 8 40
41 23 49 (2 PL) 39 8
4 PL 9G67-021C
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(2). Remove access panel AL129 (Ref. (2). Push down and turn spring loaded
Section 06-00-00). collar, release spring loaded collar and
permit it to move up collective control
stick and engage lock mechanism.
(3). Disconnect electrical connector P2 (3).
(3). Install threaded collar on spring loaded
(4). Remove dust cap (26) from dust cap collar. Tighten threaded collar with
receptacle (35) and install on J141 (4). your hand.
(5). Remove threaded collar (22) from (4). Remove dust cap from J141 and install
spring loaded collar (23) and move up on dust cap receptacle (35).
collective control stick (31). (5). Connect electrical connector P2.
(6). Push down and turn spring loaded (6). Install access panel AL129 (Ref. Section
collar (23) to disengage lock mecha 06-00-00).
nism. (7). Install collective stick boot.
(7). Pull collective control stick (31) tube (8). Do the engine controls operational test
out of collective stick base (30). (Ref. Section 76-00-00).
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17. Copilot Collective Control Stick (2). Install collective control stick, bolts,
Assembly. washers, bonding jumper (inboard), and
nuts. Torque nuts and install new
(Ref. Figure 403) cotter pins.
Sealant, Fuel Resistant (C216)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C216 Sealant, Fuel Resistant
C220 Compound, AntiSeize (3). Environmentally seal bonding jumper,
C701 Lockwire use sealant (C216) (Ref. CSP-SPM).
(4). Install collective link, bolt, washers,
A. Copilot Collective Control Stick and nut. Torque nut and install new
Assembly Removal cotter pin.
(1). Remove copilot crew seat (Ref. Section Compound, Anti-Seize (C220)
25-10-00).
(2). Remove collective stick boot (1).
(3). Remove access panels AL129 and
AL138 (Ref. Section 06-00-00). (5). Apply anti-seize compound (C220) to
threads of mechanical engine control
(4). Disconnect electrical connector P2 (3). collective stick fittings.
(5). Remove dust cap (26) from dust cap Be careful when you connect
receptacle (35) and install on J141 (4) CAUTION mechanical engine control
or J532 (28). cables. If you are not careful damage can oc
NOTE: Tag left and right mechanical engine cur.
control interconnect cables (17). (6). Connect mechanical engine control
Be careful when you disconnect cables. Torque cable end nuts 60-80 in
CAUTION mechanical engine control lb (6.78-9.04 Nm) and safety with
cables. If you are not careful, damage can lockwire (C701).
occur. (7). Remove dust cap from receptacle J141
(6). Disconnect mechanical engine control or J532.
interconnect cables (17). (8). Install dust cap on dust cap receptacle.
(7). Remove cotter pin (6), nut (7), washers (9). Connect electrical connector P2.
(11), and bolt (8).
(10). Test collective control stick for Class L
(8). Remove environmental seal from bolt electrical bond (Ref. CSP-SPM).
(18) inboard location only.
(11). Do the engine controls operational test
(9). Remove cotter pins (6), nuts (7), (Ref. Section 76-00-00).
washers (11), and bolts (18). Remove
collective control stick (2). (12). Install access panels AL129 and AL138
(Ref. Section 06-00-00).
B. Copilot Collective Control Stick
Assembly Installation (13). Install collective stick boot.
(1). Prepare inner surface of inboard (14). Install copilot crew seat (Ref. Section
collective stick bracket to collective 25-10-00).
stick attach point and bonding jumper
for electrical bond (Ref. CSP-SPM). 18. Deleted
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(3). Install quick release pin through (1). Apply anti-seize compound (C220) to
collective stick. threads of mechanical engine control
collective stick fittings.
(4). Remove dust cap from receptacle J532.
NOTE:
(5). Connect electrical connector P2. If necessary, rotate collective stick grips
to engage interconnect cables.
(6). Install cap on cap receptacle.
Adjust micro adjust adapters (25) to make
sure cables are installed without tension
20. Interconnect Cable Assemblies load.
(Ref. Figure 403) Be careful when you connect
CAUTION mechanical engine control
Consumable Materials
cables, damage to cables can occur.
(Ref. CSPSPM) (2). Connect mechanical engine control
Item Nomenclature interconnect cable. Torque cable end
C701 Lockwire nuts and jam nuts 60-80 in lb
C220 Compound, AntiSeize (6.78-9.04 Nm) and safety with
lockwire (C701).
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20
7 11
3
11 6
4 18
26
6
7 5 (2 PL)
11 11
9 6
11 (2 PL)
16 11 7
14 10
11
11
21
7 11 7
6 25
20 11 6
17 13
17 24 8
11
24 1
11
15 14 30
(3 PL)
11 12
(3 PL)
MECHANICAL ENGINE CONTROL 22
CABLE COUPLING (TYPICAL)
31
23
19 16 EARLY 900 CONFIG
11 11 6
7 9G67-022-1
Figure 403. Copilot Collective Controls, Cockpit (Sheet 1 of 2)
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29
31
27
28 VIEW ROTATED
34
35
30
33
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25. FS 157.730 Collective Bellcrank 26. Collective (Cabin) Control Rod Assembly
Assembly
(Ref. Figure 404)
(Ref. Figure 404)
A. Collective (Cabin) Control Rod Assembly
A. Collective Bellcrank Assembly Removal Removal
(1). Remove cabin interior roof panels
(1). Remove access panels L155, R155 and (Ref. Section 25-20-00).
T155 (Ref. Section 06-00-00).
(2). Remove and discard cotter pins (2).
(2). Remove roof panels Remove nuts (3), washers (4), and bolts
(Ref. Section 25-20-00). (5) attaching both ends of collective
cabin control rod assembly (7) to
(3). Remove FS 155.500 FOD cover (1). collective upper closet bellcrank
assembly (8) and collective upper deck
(4). Remove and discard cotter pins (2). bellcrank assembly (11). Remove
Remove nuts (3), washers (4), and bolts control rod.
(5) attaching collective closet control
rod assembly (6) and collective control B. Collective (Cabin) Control Rod Assembly
rod assembly (7) to FS 157.730 collec Installation
tive bellcrank assembly (8).
(1). Install bolts, washers, and nuts
(5). Remove and discard cotter pin (2).Re attaching both ends of collective cabin
move nut (3), washers (4), and bolt (10) control rod assembly to collective upper
attaching collective bellcrank assembly closet bellcrank assembly and collective
(8) to control deck bracket assembly (9). upper deck bellcrank assembly. Torque
nuts and install new cotter pins.
(6). Remove bellcrank assembly (8).
(2). Verify collective control system rigging.
B. Collective Bellcrank Assembly
(3). Install cabin interior roof panels (Ref.
Installation
Section 25-20-00).
NOTE: Adjustment of control rods might be re 27. Collective Upper Deck Bellcrank
quired for installation. Assembly
(1). Install bolt, washers, and nut attaching (Ref. Figure 404)
FS 157.730 collective bellcrank assem
bly to control deck bracket assembly. A. Collective Upper Deck Bellcrank
Assembly Removal
(2). Install bolts, washers, and nuts
attaching collective closet control rod (1). Remove access panels L155, R155 and
assembly and collective control rod T155 (Ref. Section 06-00-00).
assembly to collective bellcrank (2). Remove roof panels (Ref. Section
assembly. 25-20-00).
(3). Verify collective control system rigging. (3). Remove collective/longitudinal FOD
(Ref. Section 67-10-00). cover (12).
(4). Torque nuts and install new cotter pins. (4). Remove and discard cotter pins (2).
Remove nuts (3), washers (4) and bolts
(5). Install FS 155.500 FOD cover. (5) attaching collective cabin control rod
assembly (7) and collective actuator
(6). Install roof panels control rod assembly (13) to collective
(Ref. Section 25-20-00). upper deck bellcrank assembly (11).
(7). Install access panels L155, R155 and (5). Remove and discard cotter pin (2).
T155 (Ref. Section 06-00-00). Remove nut (3), washers (4 and 14) and
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(2). Install bolt, washers, and nut attaching A. Collective To Actuator Control Rod
collective cabin control rod assembly to Assembly Removal
upper deck bellcrank bellcrank assem
bly. Torque nut and install new cotter (1). Remove collective/longitudinal FOD
pin. cover.
(3). Verify collective control system rigging. (2). Remove and discard cotter pin (2).
Remove nut (3), washers (4), and bolt
(5) attaching control rod assembly (13)
(4). Install collective/longitudinal FOD to collective upper deck bellcrank
cover. assembly (11).
(5). Install bolt, washer, and nut attaching (3). Remove and discard cotter pin (2).
collective actuator control rod assembly Remove nut (3), washers (4), and bolt
to upper deck bellcrank assembly. (17) attaching control rod assembly (13)
Torque nut and install new cotter pin. to collective servoactuator (18).
(6). Install roof panels (Ref. Section B. Collective To Actuator Control Rod
25-20-00). Assembly Installation
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2
3
18 REF. 18
4
17
11 13
1 12 2 2
3 REF. 13
8 3
7 4 4
16 REF. 11
14
6
15 4
10 REF. 8
5 5
4 2
4 9 19 (4 PL) 4 3
2 4
2 REF. 7 4
20 (4 PL)
5
3
3 4
4
2 REF. 16
REF. 6 4 REF. 7 3
5
9G67-024A
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(7). Slide cyclic stick (1) forward from (2). Pull cyclic stick boot (2) hook and loop
longitudinal crank assembly (7). fastener from floor.
(3). Remove boot from around cyclic stick
B. Cyclic Stick Assembly Installation assembly (1).
(4). Detach electrical connector P1 (5) from
(1). Slide cyclic stick assembly aft onto
receptacle J143.
longitudinal crank assembly
(a). If autopilot is installed, remove
(2). Install bolts, washers, and nuts. jumper plug from adjacent dummy
receptacle and install it on J143.
(3). Torque nuts maintaining gap under (b). If autopilot is not installed, remove
washer at bolt head and at nut. Gap at protective cover from adjacent
one side shall not exceed two times the dummy receptacle and install it on
gap at the other side. J143.
(4). Prepare bonding jumper attach point (5). Disconnect (two piece) electrical bond
for electrical bond (Ref. CSP-SPM). jumper (10).
(6). If necessary, remove screw (12) and
(5). Attach bonding jumper to airframe washer (11) attaching bonding jumper
with screw and washer. Torque screw. (10) to airframe.
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(7). Remove two spring clips (21) from (7). Install cyclic stick boot over cyclic stick
longitudinal crank assembly (7). assembly.
NOTE: Do not close the spring clips after re (8). Press hook and loop fasteners together
moval. The spring clips must be stored in to secure against floor and close around
the open position. cyclic stick.
(8). Slide cyclic stick assembly (1) forward (9). If necessary, close access panel L109
from longitudinal crank assembly (7) (Ref. Section 06-00-00).
and remove.
33. Pilot Cyclic Stick Centering Strap
(9). Install copilot (quick release) cyclic (Ref. Figure 405)
stick floor cover. Ensure velcro is firmly
engaged. (Ref CSP-900IPL-4
Sec. 91-10-00). Consumable Materials
(Ref. CSPSPM)
B. Copilot (Quick Release) Cyclic Stick Item Nomenclature
Assembly Installation C402 Adhesive, Epoxy
(1). Remove copilot (quick release) cyclic
stick floor cover. A. Pilot Cyclic Stick Centering Strap
Removal
(2). Slide cyclic stick assembly aft into
longitudinal crank assembly (7). (1). Remove nut (14), washers (15 and 18),
radius blocks (16), and bolt (19)
(3). Install two spring clips thru longitudi attaching cyclic stick centering strap
nal crank assembly (7) and cyclic stick (13) to pilot cyclic stick assembly (1)
assembly (1). Remove strap.
(4). Attach electrical connector P1 (5) to B. Pilot Cyclic Stick Centering Strap
receptacle J143 copilot. Installation
(a). If autopilot is installed, remove (1). Align cyclic stick centering strap on
jumper plug from J143 and install on pilot cyclic stick assembly.
adjacent dummy receptacle.
(2). Install bolt, radius blocks, washers, and
(b). If autopilot is not installed, remove nut. Torque nut.
protective cover from J143 and Adhesive, Epoxy (C402)
install it on adjacent dummy recep
tacle.
(5). If necessary, install screw (12) and
washer (11) attaching bonding jumper
(10) to airframe. (3). Bond hook tape strap attachment (17)
with epoxy adhesive (C402) to pilot
(6). Connect (two piece) electrical bond cyclic stick at point where centering
jumper (10). strap attaches in stowed position.
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19
13 18
REF 13
17 16
15 14
1
VIEW
ROTATED REF 1
3 20
2
4
6
6
9
7
8
5 22-24 IN LB
2.4-2.7 Nm
10
11
12
9G67-054
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23 22
5
24
10
11
12 21
OPEN CLOSED
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34. Cyclic Base Lateral Control Tube 35. Lateral Dual Control Interconnect Control
Assembly Rod Assembly
(Ref. Figure 406)
(Ref. Figure 406)
A. Lateral Interconnect Control Rod
Assembly Removal
A. Cyclic Base Lateral Control Tube
Assembly Removal (1). Remove FS 144.775 longitudinal
bracket assembly.
(1). Remove FS 144.775 longitudinal (2). Remove copilot crew seat (Ref. Section
bracket assembly. 25-10-00).
(3). remove access panels AL138 and B142
(2). Remove and discard cotter pin (9). (Ref. Section 06-00-00).
Remove nut (10), washers (11) and bolt
(12) attaching lateral control tube (4). Remove and discard cotter pins (9).
assembly (13) to lateral crank assembly Remove nuts (10), washers (11), and
(30). bolts (15) that attach both ends of
lateral interconnect control rod assem
bly (8).
(3). DUAL CONTROLS - Remove and
discard cotter pin (9). Remove nut (10), B. Lateral Interconnect Control Rod
washers (11), and bolt (15) attaching Assembly Installation
lateral interconnect control rod assem (1). Install bolts, washers, and nuts
bly (8) to dual bearing rod end (7). attaching both ends of lateral intercon
nect control rod. Torque nuts and
(4). Remove and discard cotter pin (9). install new cotter pins.
Remove nut (10), washers (11), and bolt
(16) attaching dual bearing rod end (7) (2). Install FS 144.774 longitudinal bracket
to lateral bellcrank assembly (14). assembly.
(3). Verify lateral cyclic control system
B. Cyclic Base Lateral Control Tube rigging.
Assembly Installation (4). Install access panels AL138 and B142
(Ref. Section 06-00-00).
(1). Install bolt, washers, and nut attaching
(5). Install copilot crew seat (Ref. Section
lateral control tube assembly to cyclic
25-10-00).
base assembly.
36. Pilot Cyclic Base Assembly
(2). Install bolt, washers, and nut attaching (Ref. Figure 406)
dual bearing rod end to lateral bell
crank assembly. A. Pilot Cyclic Base Assembly Removal
(1). Remove cyclic stick assembly.
(3). DUAL CONTROLS - Install bolt, (2). Remove FS 144.775 longitudinal
washers, and nut attaching lateral bracket assembly.
interconnect control rod assembly to
dual bearing rod end. (3). Remove and discard cotter pin (9).
Remove nut (10), washers (11), and bolt
(4). Verify lateral cyclic control system (12) attaching lateral control tube
rigging, if required. assembly (13) to lateral crank(30).
Support cyclic base assembly
CAUTION during attach nut removal.
(5). Torque nuts and install new cotter pins.
(4). Remove nuts (3), washers (4), and bolts
(6). Install FS 144.774 longitudinal bracket (5) attaching cyclic base assembly (1) to
assembly. cockpit floor section.
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NOTE: Washers (21) are not retained and will (4). Install washer and nut attaching aft
become adrift. end of crank assembly to base assem
bly. Torque nut and install lockwire
(C702).
(2). Remove and discard cotter pin (9).
Remove nut (10), washers (11 and 21) (5). Install bolt, washers, and nut attaching
and bolt (22) attaching longitudinal forward end of lateral crank assembly
crank assembly (6) to lateral crank to base assembly. Torque nut and
assembly (30). install new cotter pin.
(3). Remove screws (28), washers (27) and (6). Install screws and washers attaching
bearing retainer (24). bearing retainer to base assembly.
Torque screws.
(4). Remove and discard cotter pin (9). NOTE: Untorqued gap between the two crank
Remove nut (10), washers (11 and 29) assemblies is 0.004-0.014 in
and bolt (23) attaching forward end of (0.1016-0.3556 mm). Add washers (21) as
lateral crank assembly (30) to base required. Maximum two washers.
assembly (1).
(7). Install bolt, washers, and nut attaching
(5). Remove and discard safety wire. longitudinal crank assembly to lateral
Remove nut (20) and washer (19) crank assembly. Torque nut and install
attaching aft end of lateral crank (30) new cotter pin.
to base assembly (1).
(8). Install bolt, secondary stops, washers,
and nut attaching longitudinal control
(6). Separate base assembly (1) from crank rod assembly to longitudinal crank.
assembly (30). Torque nut and install new cotter pin.
(2). Install lateral crank assembly into (5). Verify lateral and longitudinal controls
cyclic base assembly. system rigging.
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4
6 3 18 15 16
11 10 14
9 9
11
10 11
11 11
11 23 12 11
26 13
28 (4 PL) 1 7 9
11 10 17
27 (4 PL)
29 10 9
10 11
9 11
REF 18 15
19 20
9
30 8 11 10
24 80-90 IN LB
11 9.03-10.16 Nm
26
22 11
25
9
11
10
6 21 (2 PL)
9G67-055
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37. Lateral Bellcrank Assembly (2). Install bolts and washers attaching
lateral bracket assembly. Torque bolts.
(Ref. Figure 407)
(3). Test lateral bracket assembly for class
A. Lateral Bellcrank Assembly Removal R electrical bond (CSP-SPM).
(1). Remove FS 144.775 longitudinal (4). Install lateral bellcrank assembly.
bracket assembly.
39. Lateral Gradient Spring Assembly
(2). Remove and discard cotter pin (12).
Remove nut (13), washers (14), and bolt (Ref. Figure 407)
(15) attaching dual bearing rod end (11)
and lateral controls tube assembly (2) A. Lateral Gradient Spring Assembly
to lateral bellcrank assembly (3). Removal
(3). Remove and discard cotter pin (12). (1). Remove FS 144.775 longitudinal
Remove nut (13), washers (14), and bolt bracket assembly.
(16) attaching control rod assembly (10)
(2). Remove and discard cotter pin (12).
to bellcrank assembly (3).
Remove nut (13), washers (14), and bolt
(4). Remove and discard cotter pin (12). (20) attaching lateral gradient spring
Remove nut (13), washers (14), and bolt assembly (6) to lateral trim actuator
(17) attaching bellcrank assembly (3) to crank (4).
lateral bracket assembly (5). (3). Remove and discard cotter pin (12).
B. Lateral Bellcrank Assembly Installation Remove nut (13), washers (14), and bolt
(33) attaching gradient spring (6) to
(1). Install bolt, washers, and nut attaching lateral bellcrank assembly (8).
lateral bellcrank assembly to lateral
bracket assembly. B. Lateral Gradient Spring Assembly
Installation
(2). Install bolt, washers, and nut attaching
control rod assembly to bellcrank. (1). Install bolt, washers, and nut attaching
lateral gradient spring assembly to
(3). Install bolt, washers, and nut attaching lateral bellcrank assembly. Torque nut
dual ball bearing rod end and tube and install new cotter pin.
assembly to bellcrank.
(2). Install bolt, washers, and nut attaching
(4). Torque nuts and install new cotter pins. gradient spring to lateral trim actuator
crank. Torque nut.
(5). Install FS 144.774 longitudinal bracket
assembly. (3). Install FS 144.775 longitudinal bracket
assembly.
38. Lateral Bracket Assembly
40. Lateral Trim Actuator Crank Assembly
(Ref. Figure 407)
(Ref. Figure 407)
A. Lateral Bracket Assembly Removal
A. Lateral Trim Actuator Crank Assembly
(1). Remove lateral bellcrank assembly. Removal
(2). Remove bolts (19) and washers (18) (1). Remove FS 144.775 longitudinal
attaching bracket assembly (5). bracket assembly.
B. Lateral Bracket Assembly Installation (2). Remove and discard cotter pin (12).
Remove nut (13), washers (14), and bolt
(1). Prepare bellcrank bracket and fuselage (20) attaching lateral gradient spring
structure mounting surfaces for (6) to lateral trim actuator crank
electrical bond (CSP-SPM). assembly (4).
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(3). Remove nut (21), washer (14), and bolt (3). Attach electrical connector P146 to the
(22) that attach crank assembly (4) to actuator assembly.
lateral trim actuator shaft (23).
(4). Install lateral trim actuator crank
B. Lateral Trim Actuator Crank Assembly assembly.
Installation
(5). Verify cyclic trim actuator operation
NOTE: Line up rigging holes in crank assembly (Ref. Rotor Flight Control System
and lateral trim actuator. Operational Test).
(1). Slide trim actuator crank onto actuator 42. Lateral Lower Closet Bellcrank Assembly
shaft and install bolt, washer, and nut.
Torque nut. (Ref. Figure 407)
(2). Install bolt, washers, and nut attaching A. Lateral Lower Closet Bellcrank Assembly
lateral gradient spring to lateral trim Removal
actuator crank. Torque nut and install (1). Remove pilot crew seat (Ref. Section
new cotter pin. 25-10-00).
(3). Install FS 144.775 longitudinal bracket (2). Remove access panel AR138 (Ref.
assembly. Section 06-00-00).
41. Lateral Trim Actuator Assembly (3). Remove insulation and controls closet
panels behind right crew seat (Ref.
(Ref. Figure 407) Section 25-10-00).
A. Trim Actuator Assembly Removal (4). Remove and discard cotter pin (12).
Remove nut (13), washers (14), and bolt
(1). Remove lateral trim actuator crank (33) attaching lateral gradient spring
assembly. (6) to lateral bellcrank assembly (8).
(2). Detach electrical connector P146 from (5). Remove and discard cotter pin (12).
lateral trim actuator assembly (25). Remove nut (13), washers (14), and bolt
(32) attaching control rod assembly (10)
NOTE: Washers (24) are not retained and will to bellcrank assembly (8).
become adrift.
(6). Remove and discard cotter pin (12).
(3). Remove bolts (27 and 28) and washers Remove nut (13), washers (14), and bolt
(26 and 24) attaching actuator assem (34) attaching closet control rod
bly (25). assembly (9) to bellcrank assembly (8).
B. Trim Actuator Assembly Installation (7). Remove and discard cotter pin (12).
Remove nut (13), washers (14), and bolt
NOTE: Trim resistors are required for -103 and (29) that attach bellcrank assembly (8)
-105 trim actuators. If actuators -107 or
to bellcrank bracket assembly (8).
later are installed, trim resistors are to be
removed from RH forward avionics bay. B. Lateral Lower Closet Bellcrank Assembly
Installation
(1). Prepare trim actuator and fuselage
structure mounting surfaces for (1). Install bolt, washers, and nut attaching
electrical bond (CSP-SPM). lateral bellcrank assembly to lateral
controls bracket assembly.
NOTE: Install washers (24) between lateral
trim actuator and mounting surface. (2). Install bolt, washers, and nut attaching
control rod assembly to bellcrank.
(2). Install bolts and washers attaching
lateral trim actuator assembly to (3). Install bolt, washers, and nut attaching
mounting surface. Torque bolts. closet control rod assembly to bellcrank.
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(4). Install bolt, washers, and nut attaching 44. Lateral Closet Control Rod Assembly
lateral gradient spring to bellcrank.
(Ref. Figure 407)
(5). Verify lateral cyclic control system
rigging. A. Lateral Control Rod Removal
(6). Torque nuts and install new cotter pins. (1). Remove pilot crew seat (Ref. Section
25-10-00).
(7). Install controls closet and insulation If
dual controls are installed, panels (2). Remove access panel AR138 (Ref.
behind right crew seat (Ref. Section Section 06-00-00).
25-10-00).
(3). Remove insulation and controls closet
(8). Install access panel AR138 (Ref. panels behind right crew seat (Ref.
Section 06-00-00). Section 25-10-00).
(9). Install pilot crew seat (Ref. Section (4). Remove and discard cotter pin (12).
25-10-00). Remove nut (13), washers (14), and bolt
(34) that attach lower end of lateral
43. Lateral Lower Closet Bellcrank Bracket
closet control rod assembly (9) to lateral
Assembly
lower closet bellcrank assembly (8).
(Ref. Figure 407)
(5). Remove and discard cotter pin (12).
A. Lateral Lower Closet Bracket Assembly Remove nut (13), washers (14), and bolt
Removal (35) attaching closet lateral control rod
assembly (9) to lateral closet upper
(1). Remove lateral lower closet bellcrank bellcrank assembly (36).
assembly.
B. Lateral Control Rod Installation
(2). Remove nuts (21), washers (14), and
bolts (30 and 31) attaching bracket (1). Install bolt, washers, and nut attaching
assembly (7). lateral closet control rod assembly to
lateral upper closet bellcrank. Torque
(3). Remove bolt (30) and washer (14)
nut and install new cotter pin.
attaching bracket assembly (7).
B. Lateral Lower Closet Bracket Assembly (2). Install bolt, washers, and nut attaching
Installation lateral closet control rod assembly to
lateral lower closet bellcrank assembly.
(1). Prepare lateral bracket and fuselage Torque nut and install new cotter pin.
structure mounting surfaces for
electrical bond (CSP-SPM). (3). Verify lateral cyclic control system
rigging.
(2). Install bolts, washers, and nuts
attaching bracket assembly to mount (4). Install controls closet and insulation
ing surface. Torque nuts. panels behind right crew seat (Ref.
Section 25-10-00).
(3). Install bolt and washer attaching
bracket assembly to mounting surface. (5). Install access panel AR138
Torque bolt. (Ref. Section 06-00-00).
(4). Install lateral lower closet bellcrank (6). Install pilot crew seat (Ref. Section
assembly. 25-10-00).
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1
10
8
7
6
17
5
16
2 14
4
3 14
25 15 REF 3 REF 10
19 (4 PL)
18 (4 PL)
14 REF 5
REF 2 14
11
13 14
14 12 13
13
12 12
28 (2 PL)
27 (2 PL)
26 (2 PL) 26 (2 PL)
12
REF 6
13
14
REF 4
14
20
14 21
REF 25 23
24 (4 PL) 22
9G67-003-1B
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36
14
FS 148.00 BULKHEAD
21 14
14
12
REF 7
31
13 12
14
13 REF 8
13
14 12
14
21 12 REF 9
14
14 29
13
14
REF 10
14 (3 PL) 30 (3 PL) 32
13
VIEW LOOKING FORWARD 14 14
12
33 14
14 34
REF 6 9G67-003-2D
1. CYCLIC STICK BASE ASSEMBLY 19. BOLT
2. CYCLIC BASE LATERAL CONTROL TUBE ASSEMBLY 20. BOLT
3. LATERAL BELLCRANK ASSEMBLY 21. NUT, SELF LOCKING
4. LATERAL TRIM ACTUATOR CRANK ASSEMBLY 22. BOLT
5. LATERAL BELLCRANK BRACKET ASSEMBLY 23. LATERAL TRIM ACTUATOR OUTPUT SHAFT
6. LATERAL FORCE GRADIENT SPRING ASSEMBLY 24. WASHER
7. LATERAL CLOSET BELLCRANK BRACKET ASSEMBLY 25. LATERAL TRIM ACTUATOR ASSEMBLY
8. LATERAL CLOSET LOWER BELLCRANK ASSEMBLY 26. WASHER
9. LATERAL CLOSET CONTROL TUBE ASSEMBLY 27. BOLT
10. LATERAL FORE AND AFT CONTROL TUBE ASSEMBLY 28. BOLT
11. LATERAL DUAL BEARING ROD END 29. BOLT
12. COTTER PIN 30. BOLT
13. NUT 31. BOLT
14. WASHER 32. BOLT
15. BOLT 33. BOLT
16. BOLT 34. BOLT
17. BOLT 35. BOLT
18. WASHER 36. LATERAL CLOSET UPPER BELLCRANK ASSEMBLY
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45. Upper Closet Lateral Bellcrank Assembly (5). Install FOD cover (FS 155.500).
(Ref. Figure 408) (6). Install roof panels (Ref. Section
25-20-00).
A. Upper Closet Lateral Bellcrank Assembly
Removal (7). Install controls closet and insulation
(1). Open access panels R155 and R210 panels behind right crew seat (Ref.
(Ref. Section 06-00-00). Section 25-10-00).
(2). Remove insulation and controls closet (8). Close access panels R155 and R210
panels behind right crew seat (Ref. (Ref. Section 06-00-00).
Section 25-10-00).
46. Lateral Deck Control Rod Assembly
(3). Remove roof panels (Ref. Section
25-20-00). (Ref. Figure 408)
(4). Remove FOD cover (FS 155.500). A. Lateral Deck Control Rod Assembly
Removal
(5). Remove and discard cotter pin (1).
Remove nut (2) washers (3), and bolt (4) (1). Remove roof panels (Ref. Section
that attach closet lateral control rod 25-20-00).
assembly (15) to upper closet lateral
bellcrank assembly (5). (2). Remove and discard cotter pin (1).
Remove nut (2), washers (3) and bolt (6)
(6). Remove and discard cotter pin (1). that attach lateral deck control rod
Remove nut (2), washers (3) and bolt (6) assembly (9) to upper closet lateral
that attach lateral deck control rod bellcrank assembly (5).
assembly (9) to bellcrank (5).
(3). Remove and discard cotter pin (1).
(7). Remove and discard cotter pin (1). Remove nut (2), washers (3) and bolt
Remove nut (2), washers (3) and bolt (7) (14) that attach control rod (9) to FS
that attach bellcrank (5) to bracket 165.588 bellcrank assembly (13).
assembly (8).
B. Lateral Deck Control Rod Assembly
B. Upper Closet Lateral Bellcrank Assembly
Installation
Installation
(1). Install bolt, washers, and nut attaching (1). Install bolt, washers, and nut attaching
upper closet lateral bellcrank assembly lateral deck control rod assembly to FS
to deck control bracket assembly. 165.588 bellcrank assembly. Torque nut
and install new cotter pin.
(2). Install bolt, washers, and nut attaching
lateral deck control rod assembly to (2). Install bolt, washers, and nut attaching
bellcrank. control rod to bellcrank. Torque nut and
install new cotter pin.
(3). Install bolt, washers, and nut attaching
lateral control rod assembly to bell (3). Verify lateral cyclic control system
crank. rigging.
(4). Torque all nuts and install new cotter (4). Install roof panels (Ref. Section
pins. 25-20-00).
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47. FS 165.588 Lateral Bellcrank Assembly (3). Install bolt, washers, and nut attaching
lateral controls link assembly to
(Ref. Figure 408) bellcrank.
A. Lateral Bellcrank Assembly Removal
(4). Verify lateral cyclic control system
(1). Open access panel L155 (Ref. Section rigging.
06-00-00).
(5). Torque nuts and install new cotter pins.
(2). Remove roof panels (Ref. Section
25-20-00). (6). Install roof panels (Ref. Section
25-20-00).
(3). Remove and discard cotter pin (1).
Remove nut (2), washers (3), and bolt
(7). Close access panel L155 (Ref. Section
(14) that attach lateral deck control rod
06-00-00).
assembly (9) to FS 165.588 bellcrank
assembly (12).
48. FS 165.588 Lateral Bracket Assembly
(4). Remove and discard cotter pin (1).
Remove nut (2), washers (3), and bolt (Ref. Figure 408)
(16) that attach lateral controls link
assembly (17) to bellcrank (13). A. Lateral Bracket Assembly Removal
(5). Remove and discard cotter pin (1). (1). Remove FS 165.588 lateral bellcrank
Remove nut (2), washers (3), and bolt assembly.
(10) that attach bellcrank (13) to lateral
bracket assembly (12). (2). Remove bolts (11) and washers (3) that
attach lateral bracket assembly (12).
B. Lateral Bellcrank Assembly Installation
(1). Install bolt, washers, and nut attaching B. Lateral Bracket Assembly Installation
FS 165.588 bellcrank assembly to
lateral bracket assembly. (1). Install bolts and washers attaching
lateral bracket assembly. Torque bolts.
(2). Install bolt, washers, and nut attaching
lateral deck control rod assembly to (2). Install FS 165.588 lateral bellcrank
bellcrank. assembly.
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(1). Remove roof panels (Ref. Section (1). Install bolt, washers, and nut attaching
25-20-00). lateral control link assembly to FS
170.536 lateral bellcrank assembly.
(2). Remove and discard cotter pin (2). (2). Install bolt, washers, and nut attaching
Remove nut (3), washers (4), and bolt link assembly to FS 165.588 lateral
(14) that attach lateral control link bellcrank assembly.
assembly (15) to FS 165.588 lateral
bellcrank assembly (16). (3). Torque nuts and install new cotter pins.
(3). Remove and discard cotter pin (2). (4). Install roof panels (Ref. Section
Remove nut (3), washers (4) and bolt 25-20-00).
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50. FS 170.536 Lateral Bellcrank Assembly 51. Lateral Actuator Control Rod Assembly
(Ref. Figure 409) (Ref. Figure 409)
A. Lateral Bellcrank Assembly Removal A. Lateral Actuator Control Rod Assembly
Removal
(1). Open access panels L155 and L210
(Ref. Section 06-00-00). (1). Open access panels L155 and L210
(Ref. Section 06-00-00).
(2). Remove roof panels (Ref. Section
25-20-00). (2). Remove roof panels (Ref. Section
25-20-00).
(3). Remove lateral FOD cover.
(3). Loosen hose clamp on lateral upper
(4). Remove and discard cotter pin (2). deck control rod boot.
Remove nut (3), washers (4), and bolt
(12) that attach lateral control link (4). Remove and discard cotter pin (2).
assembly (15) to FS 170.536 lateral Remove nut (3), washers (4) and bolt
bellcrank assembly (11). (12) that attach lateral to actuator
control rod assembly (6) to FS 170.536
(5). Remove and discard cotter pin (2). lateral bellcrank assembly (11).
Remove nut (3), washers (4), and bolt
(12) that attach lateral actuator control (5). Remove and discard cotter pin (2).
rod assembly (6) to bellcrank (11). Remove nut (3), washers (4) and bolt (5)
that attach control rod assembly (6) to
(6). Remove and discard cotter pin (2). lateral servoactuator unit (1).
Remove nut (3), washers (4), and bolt
(8) that attach bellcrank (11) to FS B. Lateral Actuator Control Rod Assembly
170.536 lateral bracket assembly (7). Installation
B. Lateral Bellcrank Assembly Installation CAUTION
Care should be taken to align
actuator bearing with mating
(1). Install bolt, washers, and nut attaching clevis of control rod to prevent damage to
FS 170.536 lateral bellcrank assembly bearing seal during control rod attachment.
to FS 170.536 lateral bracket assembly.
(1). Install bolt, washers, and nut attaching
(2). Install bolt, washers, and nut attaching lateral to actuator control rod assembly
lateral to actuator control rod assembly to lateral servoactuator unit.
to bellcrank.
(2). Install bolt, washers, and nut attaching
(3). Install bolt, washer, and nut attaching control rod assembly to FS 170.536
lateral control link assembly to bell lateral bellcrank assembly.
crank.
(3). Verify lateral cyclic control system
(4). Verify lateral cyclic control system rigging.
rigging.
(4). Torque nuts and install new cotter pins.
(5). Torque nuts and install new cotter pins.
(5). Install roof panels (Ref. Section
(6). Install lateral FOD cover. 25-20-00).
(7). Install roof panels (Ref. Section (6). Tighten hose clamp on lateral upper
25-20-00). deck control rod boot.
(8). Close access panels L155 and L210 (7). Close access panels L155 and L210
(Ref. Section 06-00-00). (Ref. Section 06-00-00).
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53. Longitudinal Trim Actuator Assembly (7). Torque nut and install new cotter pin.
(Ref. Figure 410) (8). Install access panel AR138 and close
access panel R128 (Ref. Section
A. Trim Actuator Assembly Removal 06-00-00).
(1). Remove pilot crew seat (Ref. Section (9). Install pilot crew seat (Ref. Section
25-10-00). 25-10-00).
(2). Remove access panel AR138 and open 54. Longitudinal Trim Actuator Crank
access panel R128 (Ref. Section Assembly
06-00-00).
(Ref. Figure 410)
(3). Remove and discard cotter pin (1).
Remove nut (2), washers (3), and bolt A. Longitudinal Trim Actuator Crank
(4) that attach longitudinal gradient Assembly Removal
spring assembly (5) to longitudinal trim
actuator crank assembly (7). (1). Remove pilot crew seat (Ref. Section
25-10-00).
(4). Detach electrical connector P144 from
(2). Remove access panel AR138 and open
longitudinal trim actuator assembly (8).
access panel R128 (Ref. Section
(5). Remove bolts (11 and 12) and washers 06-00-00).
(13, 14 and 56) that attach actuator (3). Remove and discard cotter pin (1).
assembly (8) to mounting surface.
Remove nut (2), washers (3), and bolt
B. Trim Actuator Assembly Installation (4) that attach longitudinal gradient
spring (5) to longitudinal trim actuator
NOTE: Trim resistors are required for -103 and crank assembly (7).
-105 trim actuators. If actuators -107 or
later are installed, trim resistors are to be (4). Remove nut (6), washer (14) and bolt
removed from RH forward avionics bay. (48) and slide crank assembly (7) off of
longitudinal trim actuator (8) shaft.
(1). Prepare surface for electrical bond (Ref.
CSP-SPM). B. Longitudinal Trim Actuator Crank
Assembly Installation
(2). Install bolts, washers attaching
longitudinal trim actuator assembly to
NOTE: Line up rigging holes while sliding
mounting surface. Torque bolts. crank onto trim actuator shaft.
(1). Slide longitudinal trim actuator crank
(3). Attach electrical connector P144 to
assembly onto longitudinal trim
actuator assembly.
actuator shaft. Torque nut.
(4). Verify cyclic trim actuator operation (2). Install bolt, washers, and nut attaching
(Ref. Rotor Flight Control System longitudinal gradient spring to crank.
Operational Test).
(3). Torque nut and install new cotter pin.
(5). Install bolt, washers, and nut attaching
longitudinal gradient spring assembly (4). Install access panel AR138 and close
to longitudinal trim actuator crank access panel R128 (Ref. Section
assembly. 06-00-00).
(6). Verify longitudinal cyclic control system (5). Install pilot crew seat (Ref. Section
rigging. 25-10-00).
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(2). Install bolt, washers, and nut attaching (2). Install bolts, washers, and nuts
gradient spring to FS 150.064 longitu attaching longitudinal interconnect
dinal bellcrank assembly. control rod assembly, FS 132.900
longitudinal control rod assembly and
(3). Torque nuts and install new cotter pins. longitudinal aft cockpit control rod
assembly to bellcrank assembly.
(4). Install controls closet and insulation
panels behind right crew seat (Ref. (3). Verify longitudinal cyclic control system
Section 25-10-00). rigging.
(4). Torque nuts and install new cotter pins.
(5). Install access panel AR138 and close
access panel R128 (Ref. Section (5). Install access panel AR138 (Ref.
06-00-00). Section 06-00-00).
(6). Install pilot crew seat (Ref. Section (6). Install pilot crew seat (Ref. Section
25-10-00). 25-10-00).
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(1). Remove pilot crew seat (Ref. Section (4). Install bolts, washers, and nuts
25-10-00). attaching longitudinal gradient spring
and longitudinal aft cockpit control rod
(2). Remove access panel AR138 (Ref. assembly to bellcrank assembly.
Section 06-00-00). (5). Verify longitudinal cyclic control system
rigging.
(3). Remove insulation and controls closet
panels behind right crew seat (Ref. (6). Torque nuts and install new cotter pins.
Section 25-10-00).
(7). Install controls closet and insulation
(4). Remove and discard cotter pins (1). panels behind right crew seat (Ref.
Remove nuts (2), washers (3) and bolts Section 25-10-00).
(9) that attach longitudinal gradient (8). Install access panel AR138 (Ref.
spring (5) and longitudinal aft cockpit Section 06-00-00).
control rod assembly (15) to FS 150.064
longitudinal bellcrank assembly (10). (9). Install pilot crew seat (Ref. Section
25-10-00).
(5). Remove and discard cotter pin (1).
Remove nut (17), washers (18, 19 and 58. FS 150.064 Longitudinal Bracket
45), spacer (20), bolt (21) and balance Assembly
spring clip (46) that attach balance (Ref. Figure 410)
spring cable assembly (22) to bellcrank
assembly (10). A. Longitudinal Bracket Assembly Removal
(1). Remove pilot crew seat (Ref. Section
(6). Remove and discard cotter pin (1). 25-10-00).
Remove nut (2), washers (3), bolt (32),
grommet (33) and spacer (34) that (2). Remove access panel AR138 (Ref.
attach the lower end of longitudinal Section 06-00-00).
closet control rod (35) to bellcrank
(3). Remove insulation and controls closet
assembly (10).
panels behind right crew seat (Ref.
(7). Remove and discard cotter pin (1). Section 25-10-00).
Remove nut (2), washers (14) and bolt (4). Remove lower closet directional
(9) that attach bellcrank assembly (10) bellcrank assembly (Ref. Section
to FS 150.064 longitudinal bracket 67-20-00).
assembly (16).
(5). Remove FS 150.064 longitudinal
(8). Remove bellcrank assembly (10). bellcrank assembly.
B. Longitudinal Bellcrank Assembly (6). Remove bolts (23) and bolt (47) and
Installation washers (3) and nuts (6) that attach FS
150.064 longitudinal bracket assembly
(1). Install bolt, washers, and nut attaching (16) to FS 144.775 longitudinal bracket
FS 150.064 longitudinal bellcrank assembly (24).
assembly to FS 150.064 longitudinal B. Longitudinal Bracket Assembly
bracket assembly. Installation
(2). Install bolt, spacer, grommet, washers, (1). Align FS 150.064 longitudinal bracket
and nut attaching lower end of longitu assembly with FS 144.775 longitudinal
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bracket assembly and install bolts, bolt, (9). Remove bolt (4), washers (3) and nuts
washers, and nuts. (6) that attach bracket assembly (24) to
mounting surface.
(2). Install FS 150.064 longitudinal bell
crank assembly. B. Longitudinal Bracket Assembly
Installation
(3). Install lower closet directional bell
crank assembly. (1). Prepare surface for electrical bond (Ref.
CSP-SPM).
(4). Torque nuts.
(2). Install bolt, washers, and nut attaching
(5). Install controls closet and insulation FS 144.775 longitudinal bracket
panels behind right crew seat (Ref. assembly.
Section 25-10-00). (3). Install bolt, washers, and nut attaching
(6). Install access panel AR138 (Ref. FS 144.775 longitudinal bellcrank
Section 06-00-00). assembly to bracket assembly.
(4). Install bolts, bolt, washers, and nuts
(7). Install pilot crew seat (Ref. Section attaching FS 150.064 longitudinal
25-10-00). bracket assembly to FS 144.775
59. FS 144.775 Longitudinal Bracket longitudinal bracket assembly.
Assembly (5). Torque nuts and install new cotter pins.
(Ref. Figure 410) (6). Install FS 150.064 longitudinal bell
crank assembly.
A. Longitudinal Bracket Assembly Removal
(7). Install FS 150.164 lateral controls
(1). Remove pilot crew seat (Ref. Section bracket assembly.
25-10-00).
(8). Install lower closet directional bell
(2). Remove access panel AR138 (Ref. crank assembly (Ref. Section
Section 06-00-00). 67-20-00).
(3). Remove insulation and controls closet (9). Install controls closet and insulation
panels behind right crew seat (Ref. panels behind right crew seat (Ref.
Section 25-10-00). Section 25-10-00).
(10). Install access panel AR138 (Ref.
(4). Remove FS 150.064 longitudinal
Section 06-00-00).
bellcrank assembly.
(11). Install pilot crew seat (Ref. Section
(5). Remove bolts (23) and bolt (47) and 25-10-00).
washers (3) and nuts (6) that attach FS
150.064 longitudinal bracket assembly 60. FS 132.900 Longitudinal Control Rod
(16) to FS 144.775 longitudinal bracket Assembly
assembly (24).
(Ref. Figure 410)
(6). Remove lower closet directional A. Longitudinal Control Rod Assembly
bellcrank assembly (Ref. Section Removal
67-20-00).
(1). Remove cyclic stick base assembly.
(7). Remove FS 150.164 lateral controls
bracket assembly. (2). Remove longitudinal control rod
assembly (Ref. Cyclic Stick Base
(8). Remove and discard cotter pin (1). Disassemble).
Remove bolt (27), washers (14 and 28)
B. Longitudinal Control Rod Assembly
and nut (26) that attach FS 144.775
Installation
longitudinal bellcrank assembly (29) to
FS 144.775 longitudinal bracket (1). Install longitudinal control rod assem
assembly (24). bly (Ref. Cyclic Stick Base Reassemble).
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(2). Install cyclic stick base assembly. (6). Install pilot crew seat (Ref. Section
25-10-00).
(3). Verify longitudinal cyclic control
rigging. 62. Longitudinal Closet Control Rod
Assembly
61. Longitudinal AftCockpit Control Rod
Assembly (Ref. Figure 410)
A. Longitudinal Closet Control Rod
(Ref. Figure 410)
Assembly Removal
A. Longitudinal AftCockpit Control Rod (1). Remove pilot crew seat (Ref. Section
Assembly Removal 25-10-00).
(1). Remove pilot crew seat (Ref. Section (2). Remove access panel AR138 (Ref.
25-10-00). Section 06-00-00).
(2). Remove access panel AR138 (Ref. (3). Remove insulation and controls closet
Section 06-00-00). panels behind right crew seat (Ref.
Section 25-10-00).
(3). Remove insulation and controls closet
panels behind right crew seat (Ref. (4). Remove and discard cotter pin (1).
Section 25-10-00). Remove nut (2), washers (3), bolt (32),
grommet (33), spacer (34) and balance
(4). Remove and discard cotter pins (1). spring clip (46) that attach lower end of
Remove nut (2), washers (3) and bolt longitudinal closet control rod assembly
(25) that attach forward end of longitu (35) to FS 150.064 longitudinal bell
dinal aft cockpit control rod assembly crank assembly (10).
(15) to FS 144.775 longitudinal bell
crank assembly (29). (5). Remove and discard cotter pin (1).
Remove nut (2), washers (3) and bolt
(5). Remove and discard cotter pins (1). (36) that attach upper end of control
Remove nut (2), washers (3) and bolt (9) rod (35) to FS 157.387 longitudinal
that attach aft end of control rod (15) to bellcrank assembly (37).
FS 150.064 longitudinal bellcrank
assembly (10). B. Longitudinal Closet Control Rod
Assembly Installation
B. Longitudinal AftCockpit Control Rod (1). Install bolt, washers, and nut attaching
Assembly Installation upper end of longitudinal closet control
(1). Install bolt, washers, and nut attaching rod assembly to FS 157.387 longitudi
forward end of longitudinal aft cockpit nal bellcrank assembly. Torque nut and
control rod to FS 144.775 longitudinal install new cotter pin.
bellcrank assembly. Torque nut and (2). Install bolt, washers, nut, grommet,
install new cotter pin. spacer, and balance spring clip attach
ing lower end of control rod to FS
(2). Install bolt, washers, and nut attaching
150.064 longitudinal bellcrank assem
aft end of control rod to FS150.064
bly. Torque nut and install new cotter
longitudinal bellcrank assembly. Torque
pin.
nut and install new cotter pin.
(3). Verify longitudinal cyclic control system
(3). Verify longitudinal cyclic rigging. rigging.
(4). Install controls closet and insulation (4). Install controls closet and insulation
panels behind right crew seat (Ref. panels behind right crew seat (Ref.
Section 25-10-00). Section 25-10-00).
(5). Install access panel AR138 (Ref. (5). Install access panel AR138 (Ref.
Section 06-00-00). Section 06-00-00).
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(6). Install pilot crew seats (Ref. Section 64. Balance Spring Clip
25-10-00).
(Ref. Figure 410)
63. Extension Spring
A. Balance Spring Clip Removal
(Ref. Figure 410) (1). Remove pilot crew seat (Ref. Section
A. Extension Spring Removal 25-10-00).
(1). Remove pilot crew seat (Ref. Section (2). Remove access panel AR138 (Ref.
25-10-00). Section 06-00-00.
(2). Remove access panel AR138 (Ref. (3). Remove insulation and controls closet
Section 06-00-00). panels behind right crew seat (Ref.
Section 25-10-00).
(3). Remove insulation and controls closet
panels behind right crew seat (Ref. (4). Remove and discard cotter pin (1).
Section 25-10-00). Remove nut (17), washers (18, 19 and
45), spacer (20), and bolt (21) that
(4). Remove and discard cotter pin (1). attach lower end of balance spring clip
Remove nut (17), washers (18, 19 and (46) to FS 150.064 longitudinal bell
45), spacer (20) and bolt (21) that crank assembly (10).
attach balance spring cable assembly
(22) to FS 150.064 longitudinal bell (5). Remove and discard cotter pin (1).
crank assembly (10). Remove nut (2), washers (3), bolt (32),
grommet (33) and spacer (34) that
(5). Remove and discard cotter pin (1). attach upper end of spring clip (46) to
Remove nut (38), washers (39, 40 and FS 150.064 longitudinal bellcrank
43), spacer (41) and bolt (44) that assembly (10).
attach lower end of extension spring
(42). B. Balance Spring Clip Installation
(1). Install bolt, washers, nut, grommet,
B. Extension Spring Installation
and spacer attaching upper end of
(1). Install bolt, spacer, washers, and nut balance spring clip to FS 150.064
attaching lower end of extension spring. longitudinal bellcrank assembly. Torque
nut and install new cotter pin.
(2). Install bolt, spacer, washers, and nut
attaching balance spring cable assem (2). Install bolt, spacer, washers, and nut
bly to FS 150.064 longitudinal bell attaching lower end of balance spring
crank assembly. clip to FS 150.064 longitudinal bell
crank assembly. Torque nut and install
(3). Torque nuts and install new cotter pins. new cotter pin.
(4). Install controls closet and insulation (3). Install controls closet and insulation
panels behind right crew seat (Ref. panels behind right crew seat (Ref.
Section 25-10-00). Section 25-10-00).
(5). Install access panel AR138 (Ref. (4). Install access panel AR138 (Ref.
Section 06-00-00. Section 06-00-00).
(6). Install pilot crew seats (Ref. Section (5). Install pilot crew seats (Ref. Section
25-10-00). 25-10-00).
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65. Longitudinal Interconnect Control Rod (49) that attach interconnect control
Assembly rod assembly (53) and copilots FS
132.900 longitudinal control rod
(Ref. Figure 410) assembly (31) to FS 143.785 longitudi
nal bellcrank assembly (54).
A. Longitudinal Interconnect Control Rod
Assembly Removal (4). Remove and discard cotter pin (1).
(1). Remove both pilot and copilot crew Remove nut (2), washers (3) and bolt
seats (Ref. Section 25-10-00). (50) that attach bellcrank assembly (54)
to FS 143.785 longitudinal bracket
(2). Remove access panels AR138 and assembly (55).
AL138 (Ref. Section 06-00-00).
B. Longitudinal Bellcrank Assembly
(3). Remove and discard cotter pins (1). Installation
Remove nuts (2), washers (3) and bolts
(25 and 49) that attach both ends of (1). Install bolt, washers, and nut attaching
longitudinal interconnect control rod FS 143.785 longitudinal bellcrank
assembly (53). assembly to FS 143.785 longitudinal
bracket assembly.
NOTE: Removal of FS 144.775 longitudinal
bellcrank (29) or interconnect control rod as (2). Install bolts, washers, and nuts
sembly (53) rod end may be necessary to re attaching FS 132.900 longitudinal
move control rod assembly (53). control rod assembly and interconnect
control rod assembly to bellcrank.
B. Longitudinal Interconnect Control Rod Torque nuts and install new cotter pins.
Assembly Installation
(3). Install access panel AL138 (Ref. Section
(1). Install bolts, washers, and nuts 06-00-00).
attaching both ends of longitudinal
interconnect control rod assembly. (4). Install copilot crew seat (Ref. Section
Torque nut and install new cotter pin. 25-10-00).
(2). Verify longitudinal cyclic control system
rigging. 67. FS 143.785 Longitudinal Bracket
Assembly
(3). Install access panels AR138 and AL138
(Ref. Section 06-00-00). (Ref. Figure 410)
(4). Install both pilot and copilot crew seats A. Longitudinal Bracket Assembly Removal
(Ref. Section 25-10-00).
(1). Remove FS 143.785 longitudinal
66. FS 143.785 Longitudinal Bellcrank bellcrank assembly (54).
Assembly
(2). Remove bolts (51 and 52) and washers
(Ref. Figure 410) (3) that attach FS 143.785 longitudinal
bracket assembly (55) to airframe.
A. Longitudinal Bellcrank Assembly
Removal
B. Longitudinal Bracket Assembly
(1). Remove copilot crew seat (Ref. Section Installation
25-10-00).
(1). Install bolts and washers attaching FS
(2). Remove access panel AL138 (Ref. 143.785 longitudinal bracket assembly.
Section 06-00-00). Torque bolts.
(3). Remove and discard cotter pins (1). (2). Install FS 143.785 longitudinal bell
Remove nuts (2), washers (3) and bolts crank assembly.
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VIEW ROTATED 1
37
23 3 2
3 6
24 3
16
1 3
2
14 36
REF. 35
33 34
REF. 35
3 32 3
3
14 46 1
9 REF. 10
47 35
REF. 5 REF. 10 9 2
14 15 3
4 3 12 (NOTE 1)
7 24 10
6
31 29
1 5 1 1
3 14
2 2
3
48 2 REF. 8 9
3 3
11 REF. 5
(NOTE 1)
13 56
(4 PL) 6
REF. 24 4 3
8
27
REF. 35 25
REF. 46 14
3
22 15
25
19 20
18
1 28
21 3
25
1 REF. 29 3 (2 PL)
17 2
2 REF. 31 1
3 30
VIEW ROTATED
45
TO DUAL
3 14 CONTROLS
3
3
1 26
REF. 10 41 40 30 2
43 39 2 (NOTE 2)
1
1
27 1
38
44 42
NOTES:
1. TORQUE 50 - 70 in-lb (5.64 - 7.90 Nm)
2. TORQUE 70 - 90 in-lb (7.90 - 10.16 Nm) 9G67-025-1B
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53
50
3 49 (2 PL)
51
3
3 (2 PL)
52
3
55
54
3 (2 PL)
3
31 (COPILOTS)
2 (2 PL) 1 (2 PL)
2
1 9G67-025-2
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68. FS 157.387 Longitudinal Bellcrank (5). Install FS 155.50 FOD cover (1)
Assembly (Ref. Section 67-10-00).
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(5). Install roof panels (Ref. Section (7). Close access panels R155 and R210
25-20-00). (Ref. Section 06-00-00).
70. FS 171.090 Longitudinal Bellcrank
Assembly 71. FS 171.090 Longitudinal Bracket
Assembly
(Ref. Figure 411)
A. Longitudinal Bellcrank Assembly (Ref. Figure 411)
Removal
(1). Open access panels R155 and R210 A. Longitudinal Bracket Assembly Removal
(Ref. Section 06-00-00).
(1). Open access panels R155 and R210
(2). Remove roof panels (Ref. Section (Ref. Section 06-00-00).
25-20-00).
(3). Remove collective/longitudinal FOD (2). Remove roof panels (Ref. Section
cover (14) (Ref. Section 67-10-00). 25-20-00).
(4). Remove and discard cotter pins (2).
Remove nuts (3), washers (4) and bolts (3). Remove collective/longitudinal FOD
(11) that attach FS 157.387 longitudi cover (14) (Ref. Section 67-10-00).
nal control rod assembly (7) and
longitudinal to actuator control rod (4). Remove FS 171.090 longitudinal
assembly (15) to FS 171.090 longitudi bellcrank assembly (13) (Ref. Section
nal bellcrank assembly (13). 67-10-00).
(5). Remove and discard cotter pin (2).
Remove nut (3), washers (4) and bolt (5). Remove bolts (18), washers (17) that
(12) that attach bellcrank assembly (13) attach FS 171.090 longitudinal bracket
to FS 171.090 longitudinal bracket assembly (16) to mounting surface.
assembly (16).
(6). Remove bracket assembly (16).
(6). Remove bellcrank assembly (13).
B. Longitudinal Bellcrank Assembly B. Longitudinal Bracket Assembly
Installation Installation
(1). Install bolt (12), washers (4) and nut (3)
attaching FS 171.090 longitudinal (1). Install bolts (18), washers (17) attach
bellcrank assembly (13) to FS 171.090 ing FS 171.090 longitudinal bracket
longitudinal bracket assembly (16). assembly (16) to mounting surface.
Torque bolts.
(2). Install bolts (11), washers (4) and nuts
(3) attaching FS 157.387 longitudinal
control rod assembly (7) and longitudi (2). Install FS 171.090 longitudinal bell
nal to actuator control rod assembly crank assembly (13) (Ref. Section
(15) to bellcrank assembly (13). 67-10-00).
(3). Verify longitudinal cyclic control system (3). Install collective/longitudinal FOD
rigging (Ref. Section 67-10-00). cover (14) (Ref. Section 67-10-00).
(4). Torque nuts and install new cotter pins.
(4). Install roof panels (Ref. Section
(5). Install collective/longitudinal FOD 25-20-00).
cover (14) (Ref. Section 67-10-00).
(6). Install roof panels (Ref. Section (5). Close access panels R155 and R210
25-20-00). (Ref. Section 06-00-00).
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20
15
14
1
10
13 REF. 15
8
16
4
7 3 4
19
2
6
REF. 20
REF. 13
2
3
REF. 8
4
11
2 4
3 2
REF. 7 4
4 4 REF. 15
5 3 3 18
4 4
2 2
REF. 6 REF. 16
3 4 11 17
4 2
4 5
3
9
12
REF. 10
4
REF. 7 9G67-026A
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(3). Remove FS 157.387 longitudinal (1). Open access panel R155 (Ref. Section
bellcrank assembly (Ref. Section 06-00-00).
67-10-00). (2). Remove screws (5) and washers (6) that
attach FS 155.500 FOD cover (1) to
(4). Remove FS 157.730 collective bellcrank mounting surfaces.
assembly (Ref. Section 67-10-00).
NOTE: Sealing compound used between FOD
(5). Remove upper closet lateral bellcrank cover and mounting surface is actually a
assembly (Ref. Section 67-10-00). self-forming gasket. Care should be taken
not to damage this gasket when removing
(6). Remove bolts (2) and washers (3) that FOD cover.
attach control deck bracket assembly
(4) to mounting deck surface. (3). Using a putty knife (or equivalent), if
necessary, carefully break seal between
(7). Remove bracket assembly (4). faying surfaces of FOD cover (1) and
mounting surfaces.
B. Control Deck Bracket Assembly (4). Remove FOD cover (1).
Installation
B. FOD Cover Installation
NOTE: Use washers (3) as required to compen
sate for variance in sealant thickness NOTE: Proceed with the following steps, only if
around FOD covers. forming a new FOD cover seal.
Release Agent, Fluorocarbon (C235)
(1). Install bolts (2) and washers (3)
attaching control deck bracket assem
bly (4) to deck. Torque bolts.
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NOTE: Screws are only to keep holes from clog NOTE: Sealing compound used between FOD
ging. cover and mounting surface is actually a
self-forming gasket. Care should be taken
(4). Install screws but do not tighten down. not to damage this gasket when removing
FOD cover.
(5). FOD cover may be removed leaving
formed seal to remain on deck surface (6). Using a putty knife, if necessary,
to cure, or leave cover in place and carefully break seal between faying
continue work. Allow compound to cure surfaces.
for 12 hours.
(7). Remove FOD cover (9).
NOTE: Proceed with the following steps if the
original FOD cover seal is not damaged. (8). Remove upper deck control rod boots
(10) (Ref. Section 67-10-00).
(6). Apply sealant (C205) to screws attach
ing vertical mounting surface of FOD B. FOD Cover Collective/Longitudinal
cover. Installation
(7). Install screws and washers attaching (1). Install upper deck control rod boots (10)
FOD cover to mounting surfaces . onto FOD cover (Ref. Section
Torque screws. 67-10-00).
(8). Close access panel R155 (Ref. Section Release Agent, Fluorocarbon (C235)
06-00-00).
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NOTE: Proceed with the following steps if the NOTE: Sealing compound used between FOD
original FOD cover seal is not damaged. cover and mounting surface is actually a
self-forming gasket. Care should be taken
(7). Install bolts (7) and washers (8) not to damage this gasket when removing
attaching FOD cover (9) to deck. FOD cover.
(8). Torque bolts. (6). Using a putty knife, (or equivalent) if
necessary, carefully break seal between
(9). Install screws (35) and washers (36) faying surfaces.
attaching drip pan drain (33) to drip
pan (31). (7). Remove FOD cover (11).
(10). Install dual hydraulic actuator units (8). Remove lateral upper deck control rod
(24 and 25) (Ref. Section 67-10-00). boot (14) (Ref. Section 67-10-00).
(11). Tighten hose clamps (23) on upper deck B. Lateral FOD Cover Installation
collective and longitudinal control rod
boots (10). (1). Install lateral upper deck control rod
boot (14) onto lateral FOD cover (11)
(12). Verify collective and longitudinal cyclic (Ref. Section 67-10-00).
rigging (Ref. Section 67-10-00).
Release Agent, Fluorocarbon (C235)
(13). Torque nuts and install new cotter pins.
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NOTE: Proceed with the following steps if the (Ref. Section 67-10-00) with drip pans
original FOD cover seal is not damaged. (31 and 32).
(7). Install screws (5) and washers (6) (5). Remove upper deck control rod boots
attaching FOD cover (11) to mounting (10 or 14) (Ref. Section 67-10-00).
surface.
(6). Separate bond between FOD covers (9
(8). Install screws (35) and washers (36) and 11) and drip pans (31 and 32) and
attaching drip pan drain (33) to drip remove.
pan (32).
B. Drip Pan Assembly Installation
(9). Install lateral dual hydraulic actuator Sealing Compound (C205)
unit (26) (Ref. Section 67-10-00).
(11). Verify lateral cyclic rigging (Ref. Section (1). Bond drip pan assemblies (31 and 32)
67-10-00). to FOD covers (9 and 11) using sealing
compound (C205).
(12). Torque nut and install new cotter pin.
(2). Install upper deck control rod boots (10
(13). Tighten hose clamp (23). or 14) (Ref. Section 67-10-00).
(14). Install access panels R155, T155 and (3). Install collective/longitudinal FOD
L155 (Ref. Section 53-30-00). cover (9) and lateral FOD cover (11)
(Ref. Section 67-10-00) with drip pans
77. Drip Pan Assembly, RH and LH (31 and 32).
(Ref. Figure 412) (4). Install screws (35) and washers (36)
attaching drip pan drains (33) to drip
pans (31 and 32).
Consumable Materials
(Ref. CSPSPM) (5). Install hydraulic actuator units (24, 25
Item Nomenclature and 26) (Ref. Section 67-10-00).
C205 Sealing Compound (6). Install access panels R155, T155 and
L155 (Ref. Section 53-30-00).
A. Drip Pan Assembly Removal 78. Control Rod Boot, Upper Deck
NOTE: Drip pan clip assembly (37) on RH Drip (Ref. Figure 412)
Pan Assembly is attached with screws (35)
and washers (36), clip assembly on LH Drip
Pan is riveted to pan. Consumable Materials
(Ref. CSPSPM)
(1). Remove access panels R155, T155 and Item Nomenclature
L155 (Ref. Section 53-30-00). C205 Sealing Compound
C235 Release Agent, Fluorocarbon
(2). Remove dual hydraulic actuator units
(24, 25 and 26) (Ref. Section 67-10-00).
A. Control Rod Boot Removal
(3). Remove screws (35) and washers (36)
that attach drip pan drains (33) to drip NOTE: This task is typical for all three upper
pans (31 and 32). deck control rod boots.
(4). Remove collective/longitudinal FOD (1). Remove access panels R155, T155 and
cover (9) and lateral FOD cover (11) L155 (Ref. Section 53-30-00).
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NOTE: Old configuration lateral FOD cover (3). Press boot (10 or 14) down on faying
(11) uses screws (5), washers (12) and nuts FOD cover surface with enough
(13) to attach control rod boot (14). FOD cov pressure to cause squeeze out of
er (11) will need to be removed to separate compound.
boot (14) from cover (11). New configuration
cover (11) utilizes nutplates on the under NOTE: Screws are only to keep holes from clog
side of FOD cover. ging.
(2). Remove and discard cotter pins (15).
Remove nuts (18), washers (17) and (4). Install screws (5) but do not tighten
bolts (16) that attach upper end of down.
actuator control rods to hydraulic
actuator units (24, 25 and 26).
(5). Remove boot leaving formed seal to
(3). Loosen hose clamps (23). remain on FOD cover surface to cure.
Allow compound to cure for 12 hours.
(4). Remove screws (5) and washers (12)
that attach boots (10 or 14) to FOD NOTE: Proceed with the following steps if the
covers (9 or 11). original FOD cover seal is not damaged.
(5). Using a putty knife, (or equivalent) if
necessary, carefully break seal between Sealing Compound (C205)
faying surfaces.
(6). Remove boots (10 or 14).
B. Control Rod Boot Installation
(Ref. Figure 412) (6). Apply sealing compound (C205) to
screws (5).
NOTE:
This task is typical for all three upper NOTE: Old configuration lateral FOD cover
deck control rod boots. (11) uses screws (5), washers (12) and nuts
If the original seal is not damaged, start (13) to attach control rod boot (14). New con
with step (6). figuration utilizes nutplates on the under
side of FOD cover.
Release Agent, Fluorocarbon (C235)
(7). Install screws (5) and washers (12)
attaching boots (10 or 14) to FOD cover.
NOTE: Proceed with the following steps, only if (10). Install bolts (16), washers (17) and nuts
forming a new FOD cover seal. (18) attaching upper end of actuator
Sealing Compound (C205) control rods to hydraulic actuator units
(24, 25 and 26).
(2). Apply sealing compound (C205) to (12). Install access panels R155, T155 and
faying surface of boot (10 or 14). L155 (Ref. Section 53-30-00).
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79. Tailstock Boot, Upper Deck (6). Remove and discard cotter pins (30).
Remove nuts (29), washers (28) and
(Ref. Figure 412 bolts (27) that attach both ends of dual
hydraulic actuator units (24, 25 and 26)
A. Tailstock Boot Removal to mixer assembly (19) and boosted
system bracket assembly (20).
(1). Remove access panels R155, T155 and
L155 (Ref. Section 53-30-00).
(7). Remove actuator unit (24, 25 and 26).
(2). Remove dual hydraulic actuator units
(24, 25 and 26) (Ref. Section 67-10-00).
B. Dual Hydraulic Actuator Unit Installation
(3). Remove upper deck tailstock boots (34).
B. Tailstock Boot Installation NOTE: This task is typical for all three actua
tor units.
(1). Install upper deck tailstock boots (34)
onto boosted system bracket assembly
(1). Install bolts (27), washers (28) and nuts
(20) and drip pans (31 and 32).
(29) attaching both ends of dual
(2). Install dual hydraulic actuator units hydraulic actuator units (24, 25 and 26)
(24, 25 and 26) (Ref. Section 67-10-00). to mixer assembly (19) and boosted
system bracket assembly (20).
(3). Install access panels R155, T155 and
L155 (Ref. Section 53-30-00). (2). Attach lateral to actuator, longitudinal
to actuator and collective to actuator
80. Dual Hydraulic Actuator Unit, Rotor control rods (Ref. Section 67-10-00).
Control
(Ref. Figure 412) (3). Verify collective and cyclic rigging (Ref.
Section 67-10-00).
Consumable Materials
(Ref. CSPSPM) (4). Torque all nuts and install new cotter
Item Nomenclature pins.
C702 Lockwire
(5). Attach hydraulic lines to actuators (Ref.
A. Dual Hydraulic Actuator Unit Removal Section 29-00-00).
NOTE: This task is typical for all three actua (6). Safety hydraulic line connections using
tor units. lockwire (C702).
(1). Remove access panels R155, T155 and
L155 (Ref. Section 53-30-00). (7). Restore pressure to hydraulic system
(Ref. Section 29-00-00).
(2). Remove pressure from hydraulic
system (Ref. Section 29-00-00).
Verify no leaks are present in
(3). Remove and discard lockwire from CAUTION flammable fluid systems, where
hydraulic line connections. maintenance or replacement of components,
lines, or fittings has occurred, by application
(4). Disconnect hydraulic lines from of system pressure and visual inspection
actuators (Ref. Section 29-00-00). prior to helicopter being returned to service.
(5). Detach lateral to actuator, longitudinal
to actuator and collective to actuator (8). Install access panels R155, T155 and
control rods (Ref. Section 67-10-00). L155 (Ref. Section 53-30-00).
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24
25
26 19
1
6 23
(3 PL)
10
5
(NOTE 1) 9 14
20
11
REF. 10
4 5
(NOTE 2)
REF. 23
28 28 12
29
REF. 10
27 34
30
18 17 35 (4 PL)
15 17 36 (4 PL)
REF. 19
16 33 2 PL
37
6 PLACES 36 35
31
7
REF. 23
3 PLACES
8 REF. 9
5
32 (NOTE 2)
21 12
5 PL
17
REF. 14
22
2 PL
17 12
REF. 11
13
REF. 20
5 (NOTE 1)
6 OLD
CONFIGURATION
NOTES: 8 PL
1. TORQUE 20 -25 in-lb (2.25 - 2.82 Nm)
2. TORQUE 12 -15 in-lb (1.35 - 1.69 Nm)
9G67-008B
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up position and make sure collective B. Rotor Flight Control System Inspection
position sensor link and collective (Area 2)
position sensor bellcrank do not go past Moving Flight Controls
center or become aligned.
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C. Rotor Flight Control System Inspection (a). Measure and make a record of the
(Area 3) torque necessary to turn the servoac
tuator input bearing. Maximum
Moving Flight Controls torque permitted 8.7 in-lb (0.983
Nwm).
(b). Measure and make a record of the
axial play of the servoactuator input
bearings. Maximum axial play
permitted 0.025 in. (0.635 mm).
CAUTION
(8). Examine FOD covers for cracks,
Do not move rotor flight controls through separation from their attach surface,
their full range unless hydraulic power is and defects. No defects permitted.
supplied to the helicopter. (9). Examine bellcranks and brackets for
Cyclic stick must be centered before you correct installation and damage. And
move collective control through its full bearings and/or bushings for rough
range of travel. operation or too much play. No defects
permitted.
Collective control must be set at approxi
mately 80% before you move cyclic control (10). Remove hydraulic pressure (Ref.
through its full range of travel. Section 29-00-00).
(1). Apply 1000 psig (6894.8 kPa) hydrau (11). Remove external electrical power (Ref.
lic pressure to hydraulic system CSP-900RMM-3).
number 1, use hydraulic mule (T2001) D. Rotor Flight Control System Operational
(Ref. Section 29-00-00). Test
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number 1 with hydraulic mule (T2001) (15). Move cyclic stick forward until it
(ref. Section 29-00-00). touches forward stop. Release stick and
let it go back to the center position.
(2). Apply external electrical power with
ground power unit (T2002) (ref. (16). Move cyclic stick aft until it touches aft
CSP-900RMM-3). stop. Release stick and let it go back to
the center position.
(3). Pull collective friction release switch,
(17). Move cyclic stick right until it touches
raise collective stick to approximately
the right stop. Release stick and let it
80% as shown on the IIDS, and release
go back to the center position.
switch.
(18). Move cyclic stick left until it touches
(4). Move cyclic stick full forward, aft, left the left stop. Release stick and let it go
and right. Cyclic stick should move back to the center position.
freely through full range of travel.
(19). On helicopters with copilot controls
(5). Trim cyclic stick full forward. Pull stick installed, do steps (4). thru (18). with
full aft and make sure it goes back to copilot cyclic controls.
full forward when released.
(20). Make sure cyclic stick is centered after
(6). Trim cyclic stick aft until the trim cyclic part of test is complete (ref. Part
motor stops. Push stick full forward and E., Cyclic Stick in Center Position
make sure it goes back to full aft when Procedure).
released. (21). Pull pilot collective friction release switch
(5 lb [2.27 kg]) and move the collective
(7). Make sure the time to trim from aft stick from full down to full up and back
trim motor stop to forward trim motor to full down.
stop is 15 to 23 seconds.
(a). Measure the force at the base of the
(8). Make sure the time to trim from grip, near the attachment screw.
forward trim motor stop to aft trim
motor stop is 15 to 23 seconds. (b). The force necessary to move the stick
must be equal to the force to move
(9). With cyclic stick trimmed approximately the stick down within 1 lb (0.45 kg).
center, the force to move the stick (c). Make sure collective controls operate
forward and aft should be equal to
smoothly, move easily, and move
within 1 lb (0.45 kg).
freely.
(10). Trim cyclic stick full left, pull the stick (22). Set the collective release switch to the
right and make sure it goes back to full high force setting (25 lb [11.34 kg]).
left when released.
(a). Measure the force at the base of the
(11). Trim cyclic stick right until the trim grip, near the attachment screw.
motor stops. push the stick full left and
(b). Up force plus down force divided by
make sure it goes back to full right
two must be 30 to 40 lb (13.61 to
when released.
18.14 kg).
(12). Make sure the time to trim from right (23). Pull collective friction release switch
trim motor stop to left trim motor stop and move collective stick to middle
is 15 to 23 seconds. position and set Collective Friction Unit
(CFU). Stick should stay in position. Do
(13). Make sure the time to trim from left again at other stick positions to make
trim motor stop to right trim motor stop sure of full CFU operation.
is 15 to 23 seconds.
(24). Pull collective friction release switch,
(14). Set cyclic trim actuators to the center lower collective stick to down stop, and
position. release switch.
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(25). Remove hydraulic pressure (ref. Section (2). Apply external electrical power with
29-00-00). ground power unit (T2002) (ref.
CSP-900RMM-3).
(26). Remove external electrical power (ref.
CSP-900RMM-3). NOTE:
Cyclic stick must be in center position
E. Cyclic Stick In Center Position Procedure
both laterally and longitudinally.
(Ref. Figure 601) Do this procedure while sitting in the pi
lot crew seat.
Special Tools (3). Detach bottom of cyclic stick center
(Ref. CSPSPM) position strap (1).
Item Nomenclature
T2001 Hydraulic Mule (4). Extend cyclic stick center position strap
T2002 Ground Power Unit (1) forward until it touches instrument
panel (3) cyclic stick center position
placard (2).
NOTE: Do this procedure when the helicopter
is serviced, in maintenance, or shutdown. (5). Strap (1) must be fully extended, in line
with placard (2), and touch placard (2).
Moving Flight Controls If necessary, move cyclic stick (4).
REF. 3 REF. 1
(EXTENDED POSITION)
2
REF. 1 1 (STOWED POSITION)
(EXTENDED
POSITION)
REF. 4
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(d). 5 micron filter applicable for 500 (f). Set shut off valve of test equipment
psig (3447.5 kPa). to ON position and apply hydraulic
pressure.
(e). 4 way valve applicable for 500 psig (g). Push input lever of servoactuator in
(3447.5 kPa). the extend direction until servoactua
tor is fully extended.
(f). Pressure gauge (0-500 psig
(0-3447.5 kPa). (h). Push on input lever of servoactuator
in the retract direction until servoac
(g). Check valve applicable for 500 psig tuator is fully retracted.
(3447.5 kPa) with 15 psid or less @
2.2 gpm (8.327 liters per minute)). (i). Extend and retract servoactuator
continuously until hoses and servoac
(h). Force measurement device, precision tuator are fully bled. Refill reservoir
of "0.1 lb (0.045 kg). as necessary.
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FLUID
CONTAINER
FILTER
CHECK
VALVE
SHUT OFF
VALVE
PRESSURE
GAUGE
INPUT LEVER
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G. Rotor Flight Controls Travel Check (5). Pull collective friction release switch
(12), lower collective stick (8) to down
(Ref. Figure 603) stop (13), and release switch.
(6). Make sure collective servoactuator
input lever (4) is overtraveled in the
Special Tools retracted direction.
(Ref. CSPSPM)
Item Nomenclature (7). Pull collective friction release switch
(12), raise collective stick (8) full up,
T2001 Hydraulic Mule and release switch.
T2002 Ground Power Unit
(8). Make sure collective servoactuator
input lever (4) is overtraveled in the
Moving Flight Controls extended direction.
(9). Pull collective friction release switch
(12), raise collective stick (8) to approxi
mately 80% as shown on the IIDS, and
release switch.
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H. Rotor Flight Controls Rigging Check (7). Apply external electrical power, use
ground power unit (T2002) (Ref.
(Ref. Figure 603) CSP-900RMM-3).
(8). Pull collective friction release switch
Special Tools (12), lower collective stick (8) to down
(Ref. CSPSPM) stop (13), and release switch.
Item Nomenclature
(9). Make sure 2.5 in. long rig pin (T501-2)
T2001 Hydraulic Mule
(40) can be put through bracket (39)
T2002 Ground Power Unit and bellcrank (42).
T5012 Rig Pin, 2.5 In. Long
(10). Make sure collective servoactuator
T5016 Rig Pin, 5.0 In. Long
input lever (4) is overtraveled in the
retracted direction.
Moving Flight Controls (11). Remove 2.5 in. long rig pin (T501-2)
(40).
(12). Pull collective friction release switch
(12), raise collective stick (8) full up,
and release switch.
CAUTION (13). Make sure collective servoactuator
If rig pins cannot be put into bellcranks input lever (4) is overtraveled in the
when doing this procedure, damage to extended direction.
flight controls or an out of rig condition (14). Pull collective friction release switch
can be the possible cause. Do a complete (12), lower collective stick (8) to down
inspection of bellcranks, brackets, control stop (13), and release switch.
rods, and structure where brackets are
attached. (15). Make sure 2.5 in. long rig pin (T501-2)
(15) can be put through pilot lateral
NOTE: An indication of overtravel is when crank (14) and longitudinal crank (28).
servoactuator input lever bushing in input
lever has moved from its center position (16). If copilot flight controls are installed,
with servoactuator against its travel stop. make sure 2.5 in. long rig pin (T501-2)
(15) can be put through copilot lateral
(1). Remove swashplate forward fairing crank (14) and longitudinal crank (28).
(T155) (Ref. Section 06-00-00). (17). Make sure 5.0 in. long rig pin (T501-6)
(46) can be put through longitudinal
(2). Remove FS155.50, collective/longitudi
nal, and lateral FOD covers. bellcrank (45) and bracket (43).
(18). Remove rig pins (T501-2 and T501-6).
(3). Remove roof panels (Ref. Section
25-20-00). (19). Move cyclic stick (31) full forward, use
trim switch (32).
(4). Remove access panels AR138 and
AR129 (Ref. Section 06-00-00). (20). Make sure longitudinal servoactuator
input lever (4) is overtraveled in the
(5). Disconnect bottom end of all pitch links, retracted position.
turn pitch links up, and temporarily
(21). Move cyclic stick (31) full aft, use trim
attach them to rotor head (Ref. section
switch.
62-30-00).
(22). Make sure longitudinal servoactuator
(6). Apply 1000 psig (6894.8 kPa) hydrau input lever (4) is overtraveled in the
lic pressure to hydraulic system extended direction.
number 1, use hydraulic mule (T2001)
(Ref. Section 29-00-00). (23). Put cyclic stick (31) in center position.
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(24). Make sure 2.5 in. long rig pin (T501-2) (2). Torque jam nuts on control rod ends
(29) can be put through pilot cyclic adjusted during this procedure to 95 -
bracket (30) and lateral crank (14). 110 in-lbs (10.73 - 11.29 Nwm) and
install safety devices.
(25). If copilot flight controls are installed,
make sure 2.5 in. long rig pin (T501-2)
Moving Flight Controls
(29) can be put through pilot cyclic
bracket (30) and lateral crank (14).
(26). Make sure 2.5 in. long rig pin (T501-2)
(33) can be put through bellcrank (34)
and bracket (36).
(3). Examine all areas where flight control
(27). Remove rig pins (T501-2). system components move for unwanted
(28). Move cyclic stick (31) full right, use materials.
trim switch (32).
(4). When rig pin holes are aligned after
(29). Make sure lateral servoactuator input control rods adjustment, there must be
lever (4) is overtraveled in the retracted no load in the system. You must be able
direction. to install and remove all rig pins at the
(30). Move cyclic stick (31) full left, use trim same time with a minimum of force.
switch (32).
B. Collective Controls System Rigging
(31). Make sure lateral servoactuator input (Lower)
lever (4) is overtraveled in the extended
direction. (Ref. Figure 603)
(32). Put cyclic stick (31) in center position.
(33). Remove hydraulic pressure (Ref. Special Tools
Section 29-00-00). (Ref. CSPSPM)
Item Nomenclature
(34). Remove external electrical power (Ref.
CSP-900RMM-3). T2001 Hydraulic Mule
T2002 Ground Power Unit
(35). Connect bottom end of all pitch links to
swashplate (Ref. section 62-30-00). T5012 Rig Pin, 2.5 In. Long
2. Rotor Flight Controls System Rigging (4). Remove roof panels (Ref. Section
25-20-00).
A. Prepare Rotor Flight Controls System For
Rigging (5). Remove access panels AR138 and
Control Rod Thread Engage AR129 (Ref. Section 06-00-00).
WARNING ment.
(6). Disconnect bottom end of all pitch links,
(1). You must only adjust control rod ends turn pitch links up, and temporarily
adjacent to rig pin locations during attach them to rotor head (Ref. section
initial rigging procedure. 62-30-00).
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(28). Install collective/longitudinal FOD (9). Put 2.5 in. long rig pin (T501-2) (29)
cover. through pilot lateral crank (14) and
bracket (30).
(29). Install swashplate forward fairing
(T155) (Ref. Section 06-00-00). (10). Apply external electrical power, use
ground power unit (T2002) (Ref.
(30). Install roof panels (Ref. Section CSP-900RMM-3).
25-20-00).
(11). Move cyclic stick (31) to align rig pin
(31). Install access panels AR138 and AR129 hole in longitudinal trim actuator arm
(Ref. Section 06-00-00). (26) with rig pin hole in trim actuator
(25), use trim switch (32).
(32). Remove hydraulic pressure (Ref.
Section 29-00-00). (12). Put 2.5 in. long rig pin (T501-2) (22)
through longitudinal trim actuator arm
(33). Remove external electrical power (Ref. (26) and trim actuator (25).
CSP-900RMM-3).
(13). Move cyclic stick (31) to align rig pin
C. Cyclic Trim Actuator Rigging hole in lateral trim actuator arm (21)
(Longitudinal And Lateral) with rig pin hole in trim actuator (23),
use trim switch (32).
(Ref. Figure 603)
(14). Put 2.5 in. long rig pin (T501-2) (27)
through lateral trim actuator arm (21)
Special Tools and trim actuator (23)
(Ref. CSPSPM)
Item Nomenclature (15). Remove external electrical power (Ref.
T5012 Rig Pin, 2.5 In. Long CSP-900RMM-3).
T2002 Ground Power Unit NOTE: Gradient spring must be connected
with no compression of the spring.
Moving Flight Controls (16). Adjust length of longitudinal gradient
spring (16) as necessary and connect it
to longitudinal bellcrank (17). Torque
jamnut on gradient spring 240 in-lb
(27.12 Nwm).
(1). Remove swashplate forward fairing (17). Adjust length of lateral gradient spring
(T155) (Ref. Section 06-00-00). (20) as necessary and connect it to
lateral bellcrank assembly (18). Torque
(2). Remove access panel AR138 (Ref. jamnut on gradient spring 240 in-lb
Section 06-00-00).
(27.12 Nwm).
(3). Open access panel R128 (Ref. Section (18). Remove rig pins (T501-2).
06-00-00).
(19). Make sure there is a minimum of 0.062
(4). Disconnect longitudinal control rod in. (1.5 7mm) between controls and
(47). adjacent structure. Adjust control rods
adjacent to bellcranks as necessary to
(5). Disconnect lateral control rod (37). get this clearance.
(6). Disconnect longitudinal gradient spring Be careful when you connect
(16) at longitudinal bellcrank (17). CAUTION control rod to servoactuator.
(7). Disconnect lateral gradient spring (20) Align servoactuator bearing with clevis of
at lateral bellcrank (18). control rod, damage to bearing seal can oc
cur.
(8). Put 2.5 in. long rig pin (T501-2) (15) (20). Connect longitudinal control rod (47).
through pilot lateral crank (14) and
longitudinal crank (28). (21). Connect lateral control rod (37).
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(22). Make sure there is no interference (7). If copilot flight controls are installed,
between rod ends and bellcrank clevis, remove access cover L109 (Ref. Section
rod ends not adjusted out past witness 06-00-00).
holes, and all jam nuts are tight.
(8). Disconnect bottom end of all pitch links,
(23). Make sure all nuts are tight and all turn pitch links up, and temporarily
safety devices (cotter pins, lock tabs, attach them to rotor head (Ref. section
and lockwire) are installed. 62-30-00).
Moving Flight Controls
(24). Install swashplate forward fairing
(T155) (Ref. Section 06-00-00).
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NOTE: An indication of overtravel is when (33). Remove external electrical power (Ref.
servoactuator input lever bushing in input CSP-900RMM-3).
lever has moved from its center position
with servoactuator against its travel stop. (34). Remove hydraulic pressure (Ref.
Section 29-00-00).
Be careful when you connect (35). Connect lower end of pitch links (Ref.
CAUTION control rod to servoactuator. Section 62-30-00).
Align servoactuator bearing with clevis of
control rod, damage to bearing seal can oc E. Lateral Cyclic Control System Rigging
cur. (Lower)
(23). Remove rig pins (T501-2) and NOTE: You must do the collective controls sys
(T501-6). tem rigging (lower) and cyclic trim actuator
rigging (longitudinal and lateral) before you
(24). Make sure there is a minimum of 0.062 do this procedure.
in. (1.5 7mm) between controls and
(1). Prepare rotor flight controls system for
adjacent structure. Adjust control rods
rigging.
adjacent to bellcranks as necessary to
get this clearance. (2). Remove swashplate forward fairing
(T155) (Ref. Section 06-00-00).
(25). Make sure there is no interference
between rod ends and bellcrank clevis, (3). Remove FS155.50, collective/longitudi
rod ends not adjusted out past witness nal, and lateral FOD covers.
holes, and all jam nuts are tight. (4). Remove roof panels (Ref. Section
25-20-00).
(26). Make sure all nuts are tight and all
safety devices (cotter pins, lock tabs, (5). Disconnect bottom end of all pitch links,
and lockwire) are installed. turn pitch links up, and temporarily
attach them to rotor head (Ref. section
(27). Put cyclic stick (31) in center position. 62-30-00).
(28). Install FS155.50, collective/longitudi (6). Remove access panels AR138 and
nal, and lateral FOD covers. AR129 (Ref. Section 06-00-00).
(29). Install swashplate forward fairing (7). If copilot flight controls are installed,
(T155) (Ref. Section 06-00-00). remove access cover L109 and R128
(Ref. Section 06-00-00).
(30). Install access panels AR138 and AR129
Moving Flight Controls
(Ref. Section 06-00-00).
(31). Close access panel R128 (Ref. Section
06-00-00).
(32). Install roof panels (Ref. Section (8). Apply 1000 psig (6894.8 kPa) hydrau
25-20-00) lic pressure to hydraulic system
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(16). If copilot flight controls are installed, (27). Make sure all nuts are tight and all
adjust lateral interconnect control rod safety devices (cotter pins, lock tabs,
(24) to put 2.5 in. long rig pin (T501-2) and lockwire) are installed.
(29) through copilot lateral crank (14) (28). Put cyclic stick (31) in center position.
and bracket (30).
(29). Install FS155.50, collective/longitudi
(17). Adjust lateral control rod (35) until 2.5 nal, and lateral FOD covers.
in. long rig pin (T501-2) (33) can be put
through bellcrank (34) and Bracket (30). Install swashplate forward fairing
(36). (T155) (Ref. Section 06-00-00).
(31). Install access panels AR138 and AR129
(18). Apply 1000 psig (6894.8 kPa) hydrau (Ref. Section 06-00-00).
lic pressure to hydraulic system
number 1, use hydraulic mule (T2001) (32). If removed, install access panel L109
(Ref. Section 29-00-00). and R128 (Ref. Section 06-00-00).
(33). Install roof panels (Ref. Section
(19). Remove rig pins from lateral controls. 25-20-00)
(20). Move cyclic stick (31) full right, use (34). Remove external electrical power (Ref.
trim switch (32). CSP-900RMM-3).
(35). Remove hydraulic pressure (Ref.
NOTE: An indication of overtravel is when Section 29-00-00).
servoactuator input lever bushing in input
lever has moved from its center position (36). Connect lower end of pitch links (Ref.
with servoactuator against its travel stop. Section 62-30-00).
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7 4 OVERTRAVEL IN EXTENDED 1
DIRECTION (UP)
6
5
OVERTRAVEL IN RETRACTED
DIRECTION (DOWN)
SERVOACTUATOR
TYPICAL
8
13
PILOT COLLECTIVE
32 COPILOT TYPICAL
12
REF. 9
11
(NOTE 1)
10
(NOTE 1)
31 9
PILOT CYCLIC
COPILOT TYPICAL 30
14
17
15
29
18
16 (NOTE 2)
19
26
20 (NOTE 2)
27 21 (NOTE 2)
26 (NOTE 2)
25 (NOTE 2) 24 22
NOTES: 23 (NOTE 2)
1. ONLY PILOT COLLECTIVE HAS A COLLECTIVE FRICTION UNIT.
2. ONLY PILOT CYCLIC HAS TRIM ACTUATORS AND GRADIENT SPRINGS. 9G67-035-1A
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46 47 42
45
38
44 37
43
39
LONGITUDINAL CYCLIC 36
40
41
COLLECTIVE
51 35
50
49 33
34
LATERAL CYCLIC
48
9G67-035-2A
1. LATERAL SERVOACTUATOR 27. RIG PIN
2. COLLECTIVE SERVOACTUATOR 28. LONGITUDINAL CRANK
3. LONGITUDINAL SERVOACTUATOR 29. RIG PIN
4. INPUT LEVER 30. BRACKET
5. INPUT BEARING 31. CYCLIC STICK
6. STOP BUSHING 32. CYCLIC STICK TRIM SWITCH
7. FEEDBACK LINK 33. RIG PIN
8. COLLECTIVE STICK 34. LATERAL BELLCRANK
9. COLLECTIVE STICK BRACKET 35. LATERAL CONTROL ROD
10. COLLECTIVE FRICTION UNIT 36. LATERAL BELLCRANK BRACKET
11. COLLECTIVE FRICTION UNIT LINK
37. LATERAL SERVOACTUATOR CONTROL ROD
12. COLLECTIVE FRICTION RELEASE SWITCH
38. COLLECTIVE SERVOACTUATOR CONTROL ROD
13. COLLECTIVE STICK DOWN STOP
39. COLLECTIVE BELLCRANK BRACKET
14. LATERAL CRANK
40. RIG PIN
15. RIG PIN
41. COLLECTIVE CONTROL ROD
16. LONGITUDINAL GRADIENT SPRING
17. LONGITUDINAL BELLCRANK 42. COLLECTIVE BELLCRANK
18. LATERAL BELLCRANK 43. LONGITUDINAL BELLCRANK BRACKET
19. LONGITUDINAL INTERCONNECT CONTROL ROD 44. LONGITUDINAL CONTROL ROD
20. LATERAL GRADIENT SPRING 45. LONGITUDINAL BELLCRANK
21. LATERAL TRIM ACTUATOR ARM 46. RIG PIN
22. RIG PIN 47. LONGITUDINAL SERVOACTUATOR CONTROL ROD
23. LATERAL TRIM ACTUATOR 48. COLLECTIVE POSITION SENSOR BELLCRANK
24. LATERAL INTERCONNECT CONTROL ROD 49. COCKPIT COLLECTIVE CONTROL TUBE
25. LONGITUDINAL TRIM ACTUATOR 50. COLLECTIVE POSITION SENSOR LINK
26. LONGITUDINAL TRIM ACTUATOR ARM 51. COLLECTIVE CLOSET CONTROL ROD
Figure 603.Rotor Flight Controls (Lower) (Sheet 2 of 2)
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F. Collective Controls Mixer Rigging (9). Put inclinometer (T203) against static
mast (1) at position (6). Make a record
(Ref. Figure 604) of the angle
(10). Put inclinometer (T203) on top of
Consumable Materials collective mixer bellcrank (4) at position
(Ref. CSPSPM) (5). Make a record of the angle
Item Nomenclature
(11). Angle between static mast (1) and top
C702 Lockwire of collective mixer bellcrank (4). Angle
must be 101.2-101.4 degrees.
(5). Apply external electrical power, use (f). If angle between the static mast (1)
ground power unit (T2002) (Ref. and top of collective mixer bellcrank
CSP-900RMM-3). (4) is not 101.2-101.4 degrees, do
steps (c). thru (e). again.
(6). Apply 1000 psig (6894.8 kPa) hydrau (g). Make sure servoactuator rod end (13)
lic pressure to hydraulic system is not more than 2.181 in. (55.397
number 1, use hydraulic mule (T2001) mm) above top of servoactuator
(Ref. Section 29-00-00). piston (14).
(7). Pull collective friction release switch (h). Tighten nut (12).
(16), lower collective stick (17) to down (i). Safety nut (12), use lockwire (C702).
stop (15), and release switch.
NOTE: An indication of overtravel is when
(8). Push down on servoactuator input lever servoactuator input lever bushing in input
(7) until servoactuator piston (14) is lever has moved from its center position
fully retracted. with servoactuator against its travel stop.
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12
11 9 6
14 8
1
NOTE 1
OVERTRAVEL IN RETRACTED
DIRECTION (DOWN)
OVERTRAVEL IN EXTENDED
DIRECTION (UP)
17
2
16
15
NOTES:
1. COLLECTIVE DOWN ANGLE 101.2-101.4 DEGREES.
COLLECTIVE UP ANGLE 90.3-92.1 DEGREES.
2. SERVOACTUATOR PISTON ROD END MUST NOT BE MORE THAN
2.181 IN (55.397 mm) ABOVE TOP OF SERVOACTUATOR PISTON. 9G67-014C
1. STATIC MAST 10. FEEDBACK LINK
2. COLLECTIVE SERVOACTUATOR CONTROL ROD 11. LOCK RING
3. COLLECTIVE SERVOACTUATOR 12. NUT
4. COLLECTIVE MIXER BELLCRANK 13. ROD END
5. COLLECTIVE INCLINOMETER POSITION 14. SERVOACTUATOR PISTON
6. STATIC MAST INCLINOMETER POSITION 15. COLLECTIVE DOWN STOP
7. INPUT LEVER 16. COLLECTIVE FRICTION RELEASE SWITCH
8. INPUT BEARING 17. COLLECTIVE STICK
9. STOP BUSHING
Figure 604. Collective Controls Mixer Rigging
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G. Longitudinal Cyclic Mixer Rigging (8). Install 2.5 in. long rig pin (T501-2) (21)
through bellcrank (19) and bracket (20).
(Ref. Figure 605)
(9). move cyclic stick (24) full forward, use
trim switch (25).
Consumable Materials
(Ref. CSPSPM) (10). Disconnect control rod (5).
Item Nomenclature
(11). Push down on servoactuator input lever
C702 Lockwire (11) until servoactuator piston (15) is
fully retracted.
(12). Put inclinometer (T203) against static
Special Tools mast (1) at position (10). Make a record
(Ref. CSPSPM) of the angle
Item Nomenclature
(13). Put inclinometer (T203) on top of
T2002 Ground Power Unit
longitudinal mixer bellcrank (8) at
T2001 Hydraulic Mule position (7). Make a record of the angle
T5012 Rig Pin, 2.5 In. Long
(14). Angle between static mast (1) and top
of longitudinal mixer bellcrank (8).
NOTE: You must do the collective controls sys Angle must be 112.1-112.3 degrees.
tem rigging (lower) and cyclic trim actuator
rigging (longitudinal and lateral) before you CAUTION
do this procedure.
All servoactuator piston rod end adjust
(1). Prepare rotor flight controls system for ments must be made with the piston
rigging. away from its internal travel stops.
Servoactuator piston rod end must not be
(2). Remove swashplate forward fairing
more than 2.181 in. (55.397 mm) above
(T155) (Ref. Section 06-00-00).
top of servoactuator piston.
(3). Remove collective/longitudinal FOD (15). If necessary, adjust longitudinal
cover. servoactuator piston rod end (18) as
follows:
(4). Disconnect bottom end of all pitch links,
turn pitch links up, and temporarily (a). Remove lockwire from nut (17).
attach them to rotor head (Ref. section
62-30-00). (b). Loosen nut (17).
Moving Flight Controls (c). Lift input lever (11) to move servoac
tuator piston (15) away from its
internal stop.
(d). Lift lock ring (16) and carefully turn
servoactuator piston (15), use flats at
(5). Apply external electrical power, use top of piston.
ground power unit (T2002) (Ref. NOTE: Turn piston left to lengthen (decrease
CSP-900RMM-3). angle) or right to shorten (increase angle).
(6). Apply 1000 psig (6894.8 kPa) hydrau (e). Push down on servoactuator input
lic pressure to hydraulic system lever (11) until servoactuator piston
number 1, use hydraulic mule (T2001) (15) is fully retracted.
(Ref. Section 29-00-00).
(f). If angle between the static mast (1)
(7). Pull collective friction release switch and top of longitudinal mixer bell
(23), lower collective stick (22) to full crank (8) is not 112.1-112.3 degrees,
down, and release switch. do steps (c). thru (e). again.
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(g). Make sure servoactuator rod end (18) (19). Make sure angle between static mast
is not more than 2.181 in. (55.397 (1) and top of longitudinal mixer
mm) above top of servoactuator bellcrank (8) is 99.97-100.07 degrees.
piston (15).
(20). Remove 2.5 in. long rig pin (T501-2)
(h). Tighten nut (17).
(21) from bellcrank (19) and bracket
(i). Safety nut (17), use lockwire (C702). (20).
NOTE: An indication of overtravel is when (21). Make sure there is no interference
servoactuator input lever bushing in input between rod ends and bellcrank clevis,
lever has moved from its center position rod ends not adjusted out past witness
with servoactuator against its travel stop. holes, and all rod end nuts are tight.
Be careful when you connect
CAUTION control rod to servoactuator. (22). Connect lower end of pitch links (Ref.
Align servoactuator bearing with clevis of Section 62-30-00)
control rod, damage to bearing seal can oc
cur. (23). Make sure all nuts are tight and all
safety devices (cotter pins, lock tabs,
(16). Adjust longitudinal control rod (5) until
and lockwire) are installed.
it can be connected to servoactuator (6)
with input lever (11) overtraveled in the
retracted direction. (24). Install collective/longitudinal FOD
cover.
(17). move cyclic stick (24) full aft, use trim
switch (25). (25). Install swashplate forward fairing
(T155) (Ref. Section 06-00-00).
Longitudinal servoactuator
CAUTION must overtravel in its full ex
tended and full retracted positions. (26). Remove hydraulic pressure (Ref.
Section 29-00-00).
(18). Make sure servoactuator input lever
(11) is overtraveled in the extended (27). Remove external electrical power (Ref.
direction. CSP-900RMM-3).
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H. Lateral Cyclic Mixer Rigging (8). Install 2.5 in. long rig pin (T501-2) (21)
through bellcrank (19) and bracket (20).
(Ref. Figure 605)
(9). move cyclic stick (24) full left, use trim
switch (25).
Consumable Materials
(Ref. CSPSPM) (10). Disconnect control rod (4).
Item Nomenclature
(11). Lift servoactuator input lever (11) until
C702 Lockwire servoactuator piston (15) is fully in the
extended direction.
(12). Put inclinometer (T203) against static
Special Tools
mast (1) at position (10). Make a record
(Ref. CSPSPM)
of the angle
Item Nomenclature
T2002 Ground Power Unit (13). Put inclinometer (T203) on top of
T2001 Hydraulic Mule lateral mixer bellcrank (2) at position
(9). Make a record of the angle
T5012 Rig Pin, 2.5 In. Long
(14). Angle between static mast (1) and top
of lateral mixer bellcrank (2). Angle
NOTE: You must do the collective controls sys must be 96.5 to 96.9 degrees.
tem rigging (lower) and cyclic trim actuator
rigging (longitudinal and lateral) before you
do this procedure. CAUTION
All servoactuator piston rod end adjust
(1). Prepare rotor flight controls system for
ments must be made with the piston
rigging.
away from its internal travel stops.
(2). Remove swashplate forward fairing Servoactuator piston rod end must not be
(T155) (ref. Section 06-00-00). more than 2.181 inch (55.40 mm) above
top of servoactuator piston.
(3). Remove collective/longitudinal FOD
cover. (15). If necessary, adjust lateral servoactua
tor piston rod end (18) as follows:
(4). Disconnect bottom end of all pitch links,
turn pitch links up, and temporarily (a). Remove lockwire from nut (17).
attach them to rotor head (ref. Section (b). Loosen nut (17).
62-30-00).
(c). Lower input lever (11) to move
Moving Flight Controls servoactuator piston (15) away from
its internal stop.
(d). Lift lock ring (16) and carefully turn
servoactuator piston (15), use flats at
top of piston.
(5). Apply external electrical power, use
ground power unit (T2002) (ref. NOTE: Turn piston left to lengthen (decrease
CSP-900RMM-3). angle) or right to shorten (increase angle).
(6). Apply 1000 psig (6894.8 kPa) hydrau (e). Lift servoactuator input lever (11)
lic pressure to hydraulic system until servoactuator piston (15) is
number 1, use hydraulic mule (T2001) fully in the extended direction.
(ref. Section 29-00-00).
(f). If angle between the static mast (1)
(7). Pull collective friction release switch and top of lateral mixer bellcrank (2)
(23), lower collective stick (22) to full is not 96.5 to 96.9 degrees, do steps
down, and release switch. (c). thru (e). again.
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(g). Make sure servoactuator rod end (18) (19). Make sure angle between static mast
is not more than 2.181 inch (55.40 (1) and top of lateral mixer bellcrank (2)
mm) above top of servoactuator is 101.6 to 102.0 degrees.
piston (15).
(20). Remove 2.5 in. long rig pin (T501-2)
(h). Tighten nut (17).
(21) from bellcrank (19) and bracket
(i). Safety nut (17) with lockwire (C702). (20).
NOTE: An indication of overtravel is when (21). Make sure there is no interference
servoactuator input lever bushing in input between rod ends and bellcrank clevis,
lever has moved from its center position rod ends not adjusted out past witness
with servoactuator against its travel stop. holes, and all rod end nuts are tight.
Be careful when you connect
CAUTION control rod to servoactuator. (22). Connect lower end of pitch links (ref.
Align servoactuator bearing with clevis of Section 62-30-00)
control rod, damage to bearing seal can oc
cur. (23). Make sure all nuts are tight and all
safety devices (cotter pins, lock tabs,
(16). Adjust lateral control rod (4) until it
and lockwire) are installed.
can be connected to servoactuator (3)
with input lever (11) overtraveled in the
extended direction. (24). Install collective/longitudinal FOD
cover.
(17). Move cyclic stick (24) full right with
trim switch (25). (25). Install swashplate forward fairing
(T155) (ref. Section 06-00-00).
Longitudinal servoactuator
CAUTION must overtravel in its full ex
tended and full retracted positions. (26). Remove hydraulic pressure (ref. Section
29-00-00).
(18). Make sure servoactuator input lever
(11) is overtraveled in the retracted (27). Remove external electrical power (ref.
direction. CSP-900RMM-3).
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17
16 10
13
15 12 1
OVERTRAVEL IN RETRACTED
DIRECTION (DOWN) 8
9
7
NOTE 2
NOTE 1
OVERTRAVEL IN EXTENDED
SERVOACTUATOR DIRECTION (UP)
TYPICAL 2
25 6
3
5
19
24
4
20
21 COLLECTIVE
23
22
NOTES:
1. LONGITUDINAL FORWARD ANGLE 112.1-112.3 DEGREES. LONGITUDINAL AFT ANGLE 99.97-100.07 DEGREES. 9G67-020
2. LATERAL RIGHT ANGLE 101.6-102.0 DEGREES. LATERAL LEFT ANGLE 96.5-96.9 DEGREES.
3. SERVOACTUATOR PISTON ROD END MUST NOT BE MORE THAN 2.181 IN (55.397 mm) ABOVE TOP OF SERVOACTUATOR PISTON.
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(1). Apply 1000 psig (6894.8 kPa) hydrau (j). If there are no short or open circuit
lic pressure to hydraulic system conditions, replace trim actuator and
number 1, use hydraulic mule (T2001) go to step (a).
(Ref. Section 29-00-00). (k). Make sure the time to trim from
forward trim motor stop to aft trim
(2). Apply external electrical power, use motor stop is 15-23 seconds.
ground power unit (T2002) (Ref.
CSP-900RMM-3). (l). Make sure the time to trim from aft
trim motor stop to forward trim
(3). Push in GCU L and GCU R circuit motor stop is 15-23 seconds.
breakers located on the essential bus
circuit breaker panel. (m). Put cyclic stick in center position.
(n). Pull collective friction release switch,
(4). Pull collective friction release switch, lower collective stick to full down,
raise collective stick to approximately and release switch.
80% as shown on the IIDS, and release
switch. (o). Remove hydraulic pressure (Ref.
Section 29-00-00).
(5). Find value for longitudinal trim
actuator as follows: (p). Remove external electrical power
(Ref. CSP-900RMM-3).
(a). Connect highest value resistor (2) to (q). Install resistor (2), washers (3), and
longitudinal trim resistor wires (1). screws (4). Torque screws.
(b). Push in TRIM circuit breaker on the (6). Find value for lateral trim actuator as
essential bus circuit breaker panel. follows:
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(a). Connect highest value resistor (2) to (j). If there are no short or open circuit
longitudinal trim resistor wires (1). conditions, replace trim actuator and
go to step (a).
(b). Push in TRIM circuit breaker on the
essential bus circuit breaker panel.
(k). Make sure the time to trim from
(c). move cyclic stick left, use trim right trim motor stop to left trim
switch. motor stop is 15-23 seconds.
(d). Make sure trim actuator moves cyclic
stick left. (l). Make sure the time to trim from left
trim motor stop to right trim motor
(e). move cyclic stick right, use trim stop is 15-23 seconds.
switch.
(f). Make sure trim actuator moves cyclic (m). Put cyclic stick in center position.
stick right.
(g). If trim actuator moves in the two (n). Pull collective friction release switch,
directions, go to step (k). lower collective stick to full down,
and release switch.
(h). If trim actuator does not move in one
of the two directions, install resistor
with lower resistance value and do (o). Remove hydraulic pressure (Ref.
steps (b). thru (f). again. Section 29-00-00).
(i). If trim actuator does not move after (p). Remove external electrical power
lowest resistance resistor is installed, (Ref. CSP-900RMM-3).
do a test for an open circuit condition
and a short circuit condition (Ref.
CSP-900RMM-3, Section 98-40-00 (q). Install resistor (2), washers (3), and
and CSP-SPM, Section 20-60-00). screws (4). Torque screws.
1 (4 PL)
3 (4 PL)
4 (4 PL)
2 (2 PL)
9G67-042A
1. RESISTOR WIRE 3. WASHER
2. RESISTOR 4. SCREW
Figure 606. Resistor Installation
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Rotorcraft Maintenance Manual
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Rotorcraft Maintenance Manual
(j). Remove external electrical power (k). Connect cut wire to splice (C820)
(Ref. CSP-900RMM-3). (Ref. CSP-SPM, Section 20-60-00
and Honeywell wire diagrams).
LOOKING INBOARD
RIGHT SIDE
9G67-060
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Rotorcraft Maintenance Manual
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MD Helicopters, Inc. CSP-900RMM-2
Rotorcraft Maintenance Manual
Section
671020
Collective Control
Module / Cyclic Grip
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
Float Deploy feature on cyclic Incorrect configuration cyclic Change to latest configuration 671020
grip does not operate grip 105 cyclic grip (Ref.
properly Figure 101)
Faulty switch Check switch and replace if 671020
required
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67-10-20 Original
CSP-900RMM-2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
S2
S3 S5
S1
S4
A218-167578-00
NC S5 A218-067680-00
L S5
H FLOAT
FLOAT H
DEPLOY DEPLOY
L
(D)
(D)
A218-067679-00 A218-067679-00
T AUTO S4 T AUTO S4
PILOT PILOT
S DISC S DISC
A218-067573-02 A218-067573-02
V S3 V S3
CARGO CARGO
U HOOK REL U HOOK REL
A218-101117-02 A218-101117-02
Z Z S2
DN FWD
PITCH/ PITCH/
ROLL ROLL
LT RT LT RT
(A) TRIM (A) TRIM
D D
UP AFT
E E
F S2 F
A218-167576-02
XMIT S1 XMIT S1
NO NO
A A
X X
B B
NC NC
(J) (J)
Y Y
NO NO
W ICS W ICS
900C3010064-103 900C3010064-105
STANDARD GRIP ALTERNATE GRIP WIRING
REQUIRED FOR FLOAT AND
AUTO PILOT INSTALLED OPTIONS
9G67043
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Rotorcraft Maintenance Manual
S1
COLLECTIVE FRICTION
RELEASE SWITCH
EEC RESET
S2
S7
GO AROUND
S8
RADIO
TUNING
S5
S6
S2
S7
S10
S3 S8
S10
AUTOPILOT YAW S9
S1
S6
SEARCH LIGHT EARLY CONFIG
S5
LIGHTS
HIGH S3
1
2 3 RPM
5 4
SWITCH
6
NORM
9G670271
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Rotorcraft Maintenance Manual
S5
S6
S2 S7
S8
S3
S9
900 CONFIG
(OFF GATE REMOVED)
9G670273
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Rotorcraft Maintenance Manual
S2
S5
S6
S7
S8
S3
S9
902 CONFIG-115
S5 S6
S7
S2
S9
S10
S8
S3
902 CONFIG-117
9G670272
(1). Verify all power is removed from (1). Install specific switch for replacement.
aircraft (Ref. Section 96-00-00).
(2). Secure with nuts (3) or other attaching
(2). Loosen connector P1 (1) collar and hardware to switchplate cover (1) or
remove electrical connector P1 (1) from collective control module (4) assembly.
bottom of collective control module (2).
(3). Install any set screws that may secure
(3). Align holes in throttle twist grip (3) as specific switches to switchplate.
required and remove attachment screw
(4). (4). Solder wires to new switch.
(4). Remove control module (2) from end of (5). Install screws (2) attaching switchplate
collective control stick assembly (5). cover (1) to control module (4).
B. Collective Control Module Disassemble Silicone Compound (C221)
(Ref. Figure 402)
NOTE: If control module warranty has expired,
switches may be replaced by owner/opera
tor. (6). Cover screw (2) heads with silicone
compound (C221).
(1). Remove collective control module
assembly (4) from collective control (7). Smooth compound flush with switch
stick. plate.
(2). Remove bonding compound (C221) from (8). Install control module (4) on collective
heads of switchplate screws (2). stick assembly.
(3). Remove screws (2) and remove switch D. Collective Control Module Installation
plate cover (1).
(Ref. Figure 402)
(4). Unsolder applicable wires if removing
any switches. Power Off
(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 (1). Verify all power is removed from
cover (1) or control module assembly aircraft (Ref. Section 96-00-00).
(4).
(2). Prepare surface for electrical bond (Ref.
(7). Remove specific switch for replacement. CSP-SPM).
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Rotorcraft Maintenance Manual
(3). Align and install collective control (5). Align and install electrical connector P1
module (2) onto end of collective control (1) on bottom of control module (2).
stick assembly (5). Tighten connector P1 (1) collar.
(6). Test electrical bond between points A
and B.
(4). Align holes in throttle twist grip (3) as
required and install attachment screw (7). Restore power to aircraft (Ref. Section
(4). Torque screw (4). 96-00-00).
3
4
5
2
POINT A
POINT B
9G67030
1. CONNECTOR P1 4. SCREW
2. COLLECTIVE CONTROL MODULE 5. COLLECTIVE CONTROL STICK ASSEMBLY
3. TWIST GRIP
4
3
1
2 (4 PL)
9G67045
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Rotorcraft Maintenance Manual
(1). Verify all power is removed from (5). Cover screws (2 and/or 6) heads with
aircraft (Ref. Section 96-00-00). silicone compound (C221).
(2). Loosen wire harness collar (1) at base (6). Smooth compound flush with switch
of cyclic grip assembly (2). plate and/or handle.
(3). Remove cyclic grip (2) straight out from D. Cyclic Grip Installation
end of cyclic stick assembly (3).
(Ref. Figure 403)
B. Cyclic Grip Disassemble
Power Off
(Ref. Figure 404)
NOTE: If cyclic grip warranty has expired,
switches may be replaced by owner/opera
tor. (1). Verify all power is removed from
(1). Remove cyclic grip assembly (1) from aircraft (Ref. Section 96-00-00).
cyclic stick. If Auto Pilot or Emergency
CAUTION Floats options are installed,
(2). Remove bonding compound (C221) from
heads of screws (2 and/or 6) of switch change to latest configuration grip (Ref. Fig
plate cover (3) and/or handle cover (4). ure 101, Section 67-10-20).
(3). Remove screws (2 and/or 6) and remove (2). Align connector portion of cyclic grip
switchplate (3) and/or handle (4). assembly (2) with upper end connection
on cyclic stick assembly (3) and plug
(4). Unsolder applicable wires if removing together.
any switches.
(3). Tighten wire harness collar (1).
(5). Remove set screws (5) that secure
specific switches. (4). Restore power to aircraft (Ref. Section
96-00-00).
(6). Remove switch for replacement.
3. Wire Harness W135, Cyclic Controls
C. Cyclic Grip Reassemble
A. Wire Harness W135, Cyclic Controls
(Ref. Figure 404) Removal
(Ref. Figure 403)
Consumable Materials
(Ref. CSPSPM) Power Off
Item Nomenclature
C221 Silicone Compound
(1). Install switch for replacement. (1). Verify all power is removed from
aircraft (Ref. Section 96-00-00).
(2). Install set screws (5) that secure
specific switches in place. (2). Open access panel R128.
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Rotorcraft Maintenance Manual
(3). Unplug and remove connector (8) at (3). Prepare surface for electrical bond (Ref.
lower end of wire harness - W135 (9) CSP-SPM).
(Ref. Section 98-00-00).
NOTE: Electrical bond preparation should be
(4). Remove cyclic grip assembly (2) Ref. made for outside surface of insert (10) to cy
Section 67-10-20). clic stick assembly (3), and inside surface of
insert (10) to wire harness (9).
NOTE: Cyclic centering strap (13) and washer
(12) are only installed on the pilots cyclic (4). Install cyclic stick insert (10) and wire
stick assembly (3). harness (9) upper connector into cyclic
(5). Remove nut (4), washers (5 and 12), stick (3).
radius blocks (7), cyclic stick centering NOTE: Cyclic centering strap (13) and washer
strap (13) and bolt (6) that secure upper (12) are only installed on the pilots cyclic
end connector of wire harness (9) and stick assembly (3).
cyclic stick insert (10) to cyclic stick (3).
(6). Pull wire harness (9) through cyclic (5). Install cyclic stick centering strap (13),
stick (3) to remove. bolt (6), radius blocks (7), washers (5
and 12) and nut (4).
B. Wire Harness W135, Cyclic Controls
Installation (6). Install cyclic grip assembly (2) Ref.
Section 67-10-20).
(Ref. Figure 403)
(7). Re-attach lower connector (8) onto wire
Power Off harness (9) (Ref Section 98-00-00) and
reattach at lower connection point
under cabin floor.
(8). Ensure bonding jumper assembly (11)
(1). Verify all power is removed from is secure to cyclic stick assembly (3).
aircraft (Ref. Section 96-00-00).
(9). Close access panel R128.
(2). Route wire harness - W135 (9) through
cyclic stick assembly (3) from upper end (10). Restore power to aircraft (Ref. Section
to lower end. 96-00-00).
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REF. 1
REF. 13
10 2
6
1
7
12
13
7
4
REF. 3
3
11
9
8
9G67031A
1. COLLAR 8. LOWER CONNECTOR
2. CYCLIC GRIP ASSEMBLY 9. WIRE HARNESS W135
3. CYCLIC STICK ASSEMBLY 10. INSERT
4. NUT 11. JUMPER ASSEMBLY
5. WASHER 12. WASHER
6. BOLT 13. CYCLIC STICK CENTERING STRAP
7. RADIUS BLOCK
Figure 403. Cyclic Grip Installation
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67-10-20 Original
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Rotorcraft Maintenance Manual
6 (5 PL)
2 (4 PL)
9G67044
1. CYCLIC GRIP ASSEMBLY 4. HANDLE COVER
2. SCREW 5. SET SCREW
3. SWITCHPLATE COVER 6. SCREW
Figure 404. Cyclic Grip Assembly
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Rotorcraft Maintenance Manual
Section
672000
AntiTorque/Directio
nal Flight Controls
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
NOTE: Both left and right side heel rest assem (1). Apply sealant (C216) to mating sur
blies are typical. faces of directional control pedal (12)
and pedal shaft assembly (13 or 17).
(1). Remove nuts (1), washers (2), and bolts (2). Install bolt (11), washer (10) and nut (8)
(3) that attach heel rest support (4) to attaching control pedal (12) to shaft
pedals bracket assembly (5). assembly (13 or 17).
(2). Remove screws (6), washers (7) and (3). Torque nut.
nuts (8) from the top of the heel rest
assembly (9). Remove heel rest. 3. Pedal Adjustment Handle
NOTE: Right and Left sides are typical (Ref. Figure 401)
(1). Remove rivets (14) from pedal adjust
(1). Remove nut (8), washer (10) and bolt ment handle (15).
(11) that attach directional control
pedal (12) to pedal shaft assembly (13 (2). Remove pedal adjustment pin (16).
or 17).
B. Pedal Adjustment Pin Installation
B. Directional Control Pedals Installation (Ref. Figure 401)
(Ref. Figure 401) (1). Install pedal adjustment pin (16).
(2). Position pedal adjustment handle (15)
Consumable Materials on adjustment pin (16) and install
(Ref. CSPSPM) rivets (14).
Item Nomenclature
5. Longitudinal Pivot Bolt
C216 Sealant, Fuel Resistant
A. Longitudinal Pivot Bolt Removal
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Rotorcraft Maintenance Manual
Page 402
Revision 12 67-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
7. Crank Assembly, Right Pedal Pilot 8. Crank Assembly, Left Pedal Pilot
A. Crank Assembly (Left Pedal) Removal
A. Crank Assembly (Right Pedal) Removal
(Ref. Figure 401)
(Ref. Figure 401) NOTE: Position shaft assembly (13) in crank
assembly (39) to minimize tension on pedal
NOTE: Position shaft assembly (17) in crank return spring (27).
assembly (18) to minimize tension on pedal
(1). Remove and discard cotter pin (19).
return spring (27).
Remove nut (23), washers (24), bushing
(25) and bolt (26) that attach upper end
(1). Remove and discard cotter pin (19). of pedal return spring (27) to direction
Remove nut (23), washers (24), bushing al pedal shaft assembly (13).
(25) and bolt (26) that attach upper end
of pedal return spring (27) to direction (2). Remove and discard cotter pin (19).
al pedal shaft assembly (17). Remove nut (20) washers (29) and bolt
(30) that attach directional link
(2). Remove and discard cotter pin (19). assembly (31) to crank assembly (39).
Remove nut (20) washers (29) and bolt (3). Remove nut (32), washers (29 and 33),
(30) that attach directional link friction retainer (34), compression
assembly (31) to crank assembly (18). spring (35) friction disks (36) and bolt
(37) that attach friction links (38) to
(3). Remove and discard cotter pin (19). crank assembly (39).
Remove nut (20), washer (21) and bolt
(4). Remove and discard cotter pin (19).
(22) that attach pedal pivot support
Remove nut (20), washer (21) and bolt
(28).
(22) that attach pedal pivot support
(28).
(4). Slide pivot support (28) out of pedal
assembly. (5). Slide pivot support (28) out of pedal
assembly.
(5). Raise pedal adjustment handle (15) and (6). Raise pedal adjustment handle (15) and
remove crank assembly (18). remove crank assembly (39).
B. Crank Assembly (Left Pedal) Installation
B. Crank Assembly, (Right Pedal)
Installation (Ref. Figure 401)
(1). Position crank assembly (39) and
(Ref. Figure 401) install pedal pivot support (28).
(1). Position crank assembly (18) and (2). Install bolt (22), washer (21) and nut
install pedal pivot support (28). (20) attaching pedal pivot support (28).
(3). Install bolt (37), friction disks (36),
(2). Install bolt (22), washer (21) and nut compression spring (35), friction
(20) attaching pedal pivot support (28). retainer (34), washers (29 and 33) and
nut (32) attaching friction links (38) to
(3). Install bolt (30), washers (29) and nut crank assembly (39).
(20) attaching link assembly (31) to (4). Install bolt (30), washers (29) and nut
crank assembly (18). (20) attaching link assembly (31) to
crank assembly (39).
(4). Install bolt (26), bushing (25), washers
(24) and nut (23) attaching upper end of (5). Install bolt (26), bushing (25), washers
pedal return spring (27) to directional (24) and nut (23) attaching upper end of
pedal shaft assembly (17). pedal return spring (27) to directional
pedal shaft assembly (13).
(5). Torque nuts and install new cotter pins. (6). Torque nuts and install new cotter pins.
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CSP900RMM2 MD Helicopters, Inc.
Rotorcraft Maintenance Manual
(2). Remove and discard cotter pin (19). B. Pedal Spring Support Installation
Remove nut (20), washer (21) and bolt (Ref. Figure 401)
(22) that attach pedal pivot support
(28). (1). Install pedal spring (40), spring support
(41) and adjustment pin (16).
(3). Remove pedal pivot support (28) from (2). Install adjustment handle (15) with
pedal assembly. rivets (14).
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Original 67-20-00
MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
(Ref. Figure 401) (1). Remove and discard cotter pins (19).
Remove nuts (20), washers (29) and
bolts (30) that attach both left and
(1). Remove nuts (42), washers (24 and 43) right side link assemblies (31) to lower
and screws (44) that attach lower ends directional crank assembly (48).
of pedal return springs (27) to crank
assemblies (18 or 39). (2). Remove and discard cotter pin (19).
Remove nut (20), washers (29) and bolt
(2). Remove and discard cotter pins (19). (47) that attach crank assembly (48) to
Remove nuts (23), washers (24), pedals bracket assembly (5).
bushings (25) and bolts (26) that attach B. Lower Directional Crank Assembly
upper ends of return springs (27) to Installation
pedal shaft assemblies (13 or 17).
(Ref. Figure 401)
(3). Remove and discard cotter pins (19). (1). Install bolt (47), washers (29) and nut
Remove nuts (23), washers (24) and (20) attaching lower directional crank
bolts (45) that attach spring return assembly (48) to pedals bracket
arbors (46) to crank assemblies (18 or assembly (5).
39).
(2). Install bolts (30), washers (29) and nuts
(4). Remove pedal return spring (27). (20) attaching both left and right side
link assemblies (31) to crank assembly
(48).
B. Pedal Return Springs Installation
(3). Torque nuts and install new cotter pin.
(Ref. Figure 401) 15. Directional Pedal Link Assembly
(1). Install pedal return spring (27) around A. Directional Pedal Link Assembly
spring return arbors (46). Removal
(Ref. Figure 401)
(2). Install bolts (45), washers (24) and nuts
(23) attaching spring return arbors (46) (1). Remove and discard cotter pins (19).
to crank assemblies (18 or 39). Remove nuts (20), washers (29) and
bolts (30) that attach both upper and
lower ends of link assemblies (31).
(3). Install screws (44), washers (24 and 43)
and nuts (42) attaching the lower ends (2). Remove link assembly (31).
of return springs (27) to crank assem
blies (18 or 39). B. Directional Pedal Link Assembly
Installation
(4). Install bolts (26), bushings (25), (Ref. Figure 401)
washers (24) and nuts (23) attaching
upper ends of return springs (27) to (1). Install bolts (30), washers (29) and nuts
pedal shaft assemblies (13 or 17). (20) attaching both upper and lower
ends of link assemblies (31).
(5). Torque nuts and install new cotter pins. (2). Torque nuts and install new cotter pins.
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Rotorcraft Maintenance Manual
(Ref. Figure 401) (1). Install bolt (30), bushing (51), washers
(49 and 50) and nut (20) attaching
(1). Remove nut (32), washers (29 and 33), friction links (38) to pedals bracket
bolt (37), compression spring (35), assembly (5).
friction retainer (34) and friction disks
(36). (2). Install bolt (37), friction disks (36),
friction retainer (34), compression
B. Friction Disk Installation spring (35), washers (29 and 33) and
nut (32) attaching lower end of friction
(Ref. Figure 401) links (38).
(1). Install bolt (37), friction disks (36), 19. Directional Interconnect Control Rod
friction retainer (34), compression Assembly
spring (35), washers (29 and 33) and
nut (32). Torque nut. A. Directional Interconnect Control Rod
Assembly Removal
17. Friction Adjusting Retainer
(Ref. Figure 401)
A. Friction Adjusting Retainer Removal
(1). Remove either right or left side chin
(Ref. Figure 401) windscreen to gain access to directional
pedal assembly area (Ref. Section
(1). Remove nut (32), washers (29 and 33), 53-10-00).
bolt (37), compression spring (35) and
friction adjusting retainer (34). (2). Remove and discard cotter pins (19).
Remove nuts (20), washers (29 and 50)
B. Friction Adjusting Retainer Installation and bolts (55) that attach directional
interconnect control rod assembly (64)
(Ref. Figure 401) to pilots lower directional crank
assembly (48) and co-pilots lower crank
(1). Install bolt (37), friction adjusting
assembly (65).
retainer (34), compression spring (35),
washers (29 and 33) and nut (32). (3). Remove interconnect control rod (64).
Torque nut.
B. Directional Interconnect Control Rod
18. Friction Link Assembly Installation
A. Friction Link Removal (Ref. Figure 401)
(Ref. Figure 401) (1). Install bolts (55), washers (29 and 50)
and nuts (20) attaching directional
(1). Remove nut (32), washers (29 and 33), interconnect control rod assembly (64)
bolt (37), compression spring (35), to pilots lower directional crank
friction retainer (34) and friction disks assembly (48) and co-pilots lower crank
(36). assembly (65).
(2). Remove and discard cotter pins (19). (2). Verify directional control system
Remove nut (20), washers (49 and 50), rigging. (Ref. Section 67-20-00)
bushing (51) and bolt (30) that attach
friction links (38) to pedals bracket (3). Torque nuts and install new cotter pins.
assembly (5).
(4). Install right or left side chin windscreen
(3). Remove friction links (38). (Ref. Section 53-10-00).
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20. Directional Crank Assembly (FS 109.000) 21. Pedal Directional Control Clevis
Assembly
A. Directional Crank Assembly Removal
(Ref. Figure 401) A. Pedal Directional Control Clevis
Assembly Removal
(1). Open access panel R128 (Ref. Section
06-00-00).
(Ref. Figure 401)
(2). Remove and discard cotter pin (19).
Remove nut (20), washers (50 and 52)
and bolt (53) that attach Fwd cockpit (1). Open access panel R128 (Ref. Section
directional control rod assembly (59) to 06-00-00).
FS 109.000 directional crank assembly
(58).
(2). Remove and discard cotter pin (19).
(3). Remove and discard cotter pin (19). Remove nut (20), washers (29 and 50),
Remove nut (20), washers (50 and 52), and bolt (54) that attach FS 109.000
and bolt (53) that attach Aft cockpit directional crank assembly (58) to pedal
directional control rod assembly (57) to directional control clevis assembly (60).
crank assembly (58).
(4). Remove and discard cotter pin (19). (3). Remove nuts (67), washers (50), and
Remove nut (20), washers (29 and 50), bolts (66) that attach pedal directional
and bolt (54) that attach crank assem control clevis assembly (60) to bulk
bly (58) to pedal directional control head.
clevis assembly (60).
(4). Remove pedal directional control clevis
(5). Remove directional crank assembly (58) assembly (60).
B. Directional Crank Assembly Installation
(Ref. Figure 401) B. Pedal Directional Control Clevis
Assembly Installation
(1). Install bolt (54), washers (29 and 50),
and nut (20) attaching FS 109.000 (Ref. Figure 401)
directional crank assembly (58) to pedal
directional control clevis assembly (60).
(1). Install bolts (66), washers (50) and nuts
NOTE: Adjustment of control rod might be re (67) attaching pedal directional control
quired for installation. clevis assembly (60) to bulkhead.
(2). Install bolt (53), washers (50 and 52)
and nut (20) attaching aft cockpit (2). Install bolt (54), washers (29 and 50)
directional control rod assembly (57) to and nut (20) attaching FS 109.000
crank assembly (58). directional crank assembly (58) to pedal
directional control clevis assembly (60).
(3). Install bolt (53), washers (50 and 52)
and nut (20) attaching Fwd cockpit
directional control rod assembly (59) to (3). Verify directional control system rigging
crank assembly (58). (Ref. Section 67-20-00).
(4). Verify directional control system rigging
(Ref. Section 67-20-00). (4). Torque all nuts and install new cotter
pins.
(5). Torque nuts and install new cotter pins.
(6). Close access panel R128 (Ref. Section (5). Close access panel R128 (Ref. Section
06-00-00). 06-00-00).
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Rotorcraft Maintenance Manual
22. Forward Cockpit Directional Control Rod 23. Aft Cockpit Directional Control Rod
Assembly Assembly
A. Forward Cockpit Directional Control Rod A. Aft Cockpit Directional Control Rod
Assembly Removal Assembly Removal
(1). Remove pilot crew seat (Ref. Section (1). Remove pilot crew seat (Ref. Section
25-10-00). 25-10-00).
(6). Install pilot crew seat (Ref. Section (6). Install pilot crew seat (Ref. Section
25-10-00). 25-10-00).
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MD Helicopters, Inc. CSP900RMM2
Rotorcraft Maintenance Manual
24. Directional Lower Closet Bellcrank (3). Install bolt (56), washers (50 and 52),
Assembly and nut (20) attaching closet control
rod assembly (63) to lower closet
A. Lower Closet Bellcrank Assembly bellcrank assembly (61).
Removal
(4). Verify directional control system
(Ref. Figure 401)
rigging. (Ref. Section 67-20-00)
(1). Remove pilot crew seat (Ref. Section
25-10-00). (5). Torque nuts and install new cotter pins.
(2). Remove floor access panel AR138 (Ref. (6). Install controls closet panel behind
Section 53-20-00). right crew seat (Ref. Section 25-10-00).
(3). Remove insulation panels behind right (7). Install insulation panels behind right
crew seat (Ref. Section 25-10-00). crew seat (Ref. Section 25-10-00).
(4). Remove controls closet panel behind (8). Install floor access panel AR138 (Ref.
right crew seat (Ref. Section 25-10-00). Section 53-20-00).
(5). Remove and discard cotter pin (19).
Remove nut (20), washers (50 and 52), (9). Install pilot crew seat (Ref. Section
and bolt (55) that attach Aft cockpit 25-10-00).
directional control rod assembly (57) to
lower closet bellcrank assembly (61). 25. Directional Closet Control Rod Assembly
(6). Remove and discard cotter pin (19). A. Directional Closet Control Rod Assembly
Remove nut (20), washers (50 and 52) Removal
and bolt (56) that attach closet control
rod assembly (63) to bellcrank assembly (Ref. Figure 401)
(61).
(1). Remove pilot crew seat (Ref. Section
(7). Remove and discard cotter pin (19).
25-10-00).
Remove nut (20), washers (29), and bolt
(62) that attach lower closet bellcrank
assembly (61) to lower closet bracket (2). Remove floor access panel AR138 (Ref.
assembly. Section 53-20-00).
(8). Remove directional lower closet (3). Remove insulation panels behind right
bellcrank assembly (61). crew seat (Ref. Section 25-10-00).
B. Directional Lower Closet Bellcrank (4). Remove controls closet panel behind
Assembly Installation right crew seat (Ref. Section 25-10-00).
(Ref. Figure 401) (5). Remove and discard cotter pin (19).
Remove nut (20), washers (50 and 52),
(1). Install bolt (62), washers (29), and nut
and bolt (56) that attach closet control
(20) attaching lower closet bellcrank
rod assembly (63) to lower closet
assembly (61) to lower closet bracket
bellcrank assembly (61).
assembly.
NOTE: Adjustment of control rods might be re (6). Remove and discard cotter pin (19).
quired for installation. Remove nut (20), washers (50), and bolt
(56) that attach closet control rod
(2). Install bolt (55), washers (50 and 52), assembly (63) to upper closet direction
and nut (20) attaching Aft cockpit al bellcrank assembly.
directional control rod assembly (57) to
lower closet bellcrank assembly (61). (7). Remove control rod (63).
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B. Directional Closet Control Rod Assembly (4). Remove pedal pivot support (28), pedal
Installation shaft assemblies (13 and 17) and pedal
crank assemblies (18 and 39) (Ref.
(Ref. Figure 401) Section 67-20-00).
NOTE: Adjustment of control rods might be re (5). Remove attaching hardware that
quired for installation. secures directional pedal bracket
assembly (5) to airframe structure.
(1). Install bolt (56), washers (50), and nut
(6). Remove bracket assembly (5).
(20) attaching closet control rod
assembly (63) to upper closet bellcrank B. Directional Pedals Bracket Assembly
assembly. Installation
(2). Install bolt (56), washers (50 and 52), (Ref. Figure 401)
and nut (20) attaching closet control
rod assembly (63) to lower closet Consumable Materials
bellcrank assembly (61). (Ref. CSPSPM)
Item Nomenclature
(3). Verify directional control system
rigging. (Ref. Section 67-20-00) C216 Sealant, Fuel Resistant
(4). Torque nuts and install new cotter pins. (1). Prepare surface for electrical bond (Ref.
CSP-SPM).
(5). Install controls closet panel behind
right crew seat (Ref. Section 25-10-00). (2). Align directional pedal bracket assem
bly (5) with airframe structure and
(6). Install insulation panels behind right secure with attaching hardware.
crew seat (Ref. Section 25-10-00). Torque nuts.
(7). Install floor access panel AR138 (Ref. Sealant, Fuel Resistant (C216)
Section 53-20-00).
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27. Pedal Anticipator Assembly (1). Align hole in arm with hole in bracket
Potentiometer (Transducer) (902 CONFIG) and install potentiometer. Tighten nut
sufficiently to prevent movement.
A. Potentiometer Removal
(2). Connect electrical wires to potentiome
(Ref. Figure 401) ter (Ref. CSP-SPM).
(1). Tag wires connected to potentiometer (3). Do the pedal anticipator rigging.
(69) for reference during installation.
28. Bracket, Potentiometer Pedal
Anticipator (902 CONFIG)
(2). Disconnect electrical wires from
potentiometer (69) (Ref. CSP-SPM). A. Potentiometer Bracket Removal
(3). Remove cotter pin (71) from bolt (81). (1). Remove potentiometer.
(4). Loosen nut (79) sufficiently to remove (2). Remove cotter pins (71), nuts (79),
potentiometer (69).Remove potentiome washers (80), and bolts (83). Remove
ter. bracket (77).
B. Potentiometer Bracket Installation
B. Potentiometer Installation
(1). Install bracket, bolts, washers, and
(Ref. Figure 401) nuts. Torque nuts and install new
cotter pins
NOTE: Make sure you push potentiometer fully
against bracket before you tighten nut. (2). Install potentiometer.
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17
10
8
12 13
12
11
10
8
15 14
22
28 11
16
5
40
21 20 19
41 39
50 20
19 18 46
23 55
24
19
24
26 48 29
24 64
42 68
25
24 24
50 20
55
30 45
29 19 19
27
19 23
44
43 39 29
31 65
29 20 17 29
19 30
19 50
20
51
29 20
19
29 29
29 37 30 38
20 49
30 19 49
38
48 50
20
29 19
29 33
29 30 36
47
48 36 32
31
5
34 35 29
9G670291C
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81
80
82
78 80
71 80
79
71
77
79 16 80 71
80 83
73 6
6 9
76 3 9
74 52
69 4 20
75 72
72
70 19
2 50 4
1 66
72 80 71 67
72
79 54 REF. 18
48 7 50
50
902 CONFIG 58 29
8 20
53 55
19
7 59
50 60
8
20 29 29 52
62 53
19
20
50
19
52
57 20
56 19
50 2x
20
19
63
61
56 50 19
VIEW ROTATED
LOOKING FORWARD
20
52 19
55 20 52
50
9G670292A
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29. Directional Upper Closet Bellcrank (6). Install roof panels (Ref. Section
Assembly 25-20-00).
A. Directional Upper Closet Bellcrank (7). Close access panels T155 and R155
Assembly Removal (Ref. Section 53-30-00).
(Ref. Figure 402)
30. Directional Actuator Input Control Rod
(1). Remove access panels T155 and R155 Assembly
(Ref. Section 53-30-00).
A. Directional Actuator Input Control Rod
(2). Remove roof panels (Ref. Section Assembly Removal
25-20-00).
(Ref. Figure 402)
(3). Remove FS 155.500 FOD cover (1) (Ref.
Section 67-10-00). (1). Remove roof panels (Ref. Section
25-20-00).
(4). Remove and discard cotter pins (2).
Remove nuts (3), washers (4), and bolts (2). Remove and discard cotter pin (2).
(5) that attach closet control rod Remove nut (3), washers (4), and bolt
assembly (63, Ref. Figure 401) and (5) that attach directional actuator
directional actuator input control rod input control rod assembly (6) to
assembly (6) to directional upper closet directional upper closet bellcrank
bellcrank assembly (7). assembly (7).
(5). Remove and discard cotter pin (2). (3). Remove and discard cotter pin (2).
Remove nuts (3), washers (4), and bolt Remove nut (3) and washer (10) that
(8) that attach bellcrank assembly (7) attach control rod assembly (6) to
to control deck bracket assembly (9). directional actuator (11).
(6). Remove bellcrank assembly (7). (4). Remove control rod assembly (6).
B. Directional Upper Closet Bellcrank B. Directional Actuator Input Control Rod
Assembly Installation Assembly Installation
(Ref. Figure 402) (Ref. Figure 402)
(1). Install bolt (8), washers (4), and nuts
NOTE: Adjustment of control rods might be re
(3) attaching directional upper closet quired for installation.
bellcrank assembly (7) to control deck
bracket assembly (9). (1). Install washers (10) and nut (3)
NOTE: Adjustment of control rods might be re attaching directional actuator input
quired for installation. control rod assembly (6) to directional
actuator (11).
(2). Install bolts (5), washers (4), and nuts
(3) attaching directional actuator input (2). Install bolt (5), washers (4), and nut (3)
control rod assembly (6) and closet attaching control rod assembly (6) to
control rod assembly (63, Ref. directional upper closet bellcrank
Figure 401) to bellcrank assembly (7). assembly (7).
(3). Verify directional control system (3). Verify directional control system rigging
rigging. (Ref. Section 67-20-00) (Ref. Section 67-20-00).
(4). Torque nuts and install new cotter pins. (4). Torque nuts and install new cotter pins.
(5). Install FS 155.500 FOD cover (1) (Ref. (5). Install roof panels (Ref. Section
Section 67-10-00). 25-20-00).
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(2). Remove and discard cotter pin (2). (2). Remove pressure from hydraulic
Remove nut (3) washers (4) and bolt system (Ref. Section 29-00-00).
(13) that attach directional actuator (3). Disconnect hydraulic lines from
output control rod assembly (12) to directional actuator (11) (Ref. Section
splitter assembly (14). 29-00-00).
(3). Remove and discard lockwire. Remove (4). Remove actuator input control rod
jam nut (15) and lockwasher (16) that assembly (6) (Ref. Section 67-20-00).
attach control rod assembly (12) to
directional actuator (11). (5). Remove actuator output control rod
assembly (12) (Ref. Section 67-20-00).
(4). Remove control rod (12).
(6). Remove and discard cotter pin (2).
B. Directional Actuator Output Control Rod Remove nut (3), washer (4) and bolt
Assembly Installation (17) that attach actuator (11) to
actuator attach bracket assembly (18).
(Ref. Figure 402)
(7). Remove bolts (19) and washers (10)
Consumable Materials that attach anti-rotation actuator
(Ref. CSPSPM) bracket (20) and remove actuator (11).
Item Nomenclature B. AntiTorque/Directional Actuator
C702 Lockwire Installation
(Ref. Figure 402)
NOTE: Adjustment of control rods might be re
quired for installation. Consumable Materials
(1). Hand tighten cap of directional actua (Ref. CSPSPM)
tor output control rod assembly (12) Item Nomenclature
until it bottoms out onto stud of C702 Lockwire
directional actuator (11). Install
lockwasher (16) and jam nut (15).
(1). Install anti-torque/directional actuator
(2). Install bolt (13), washers (4) and nut (3) (11) while installing anti-rotation
attaching control rod assembly (12) to actuator bracket (20) and attach with
splitter assembly (14). washers (10) and bolts (19). Torque
bolts.
(3). Verify directional control system rigging
(Ref. Section 67-20-00). (2). Install bolt (17), washer (4) and nut (3)
attaching actuator (11) to actuator
(4). Torque jam nut and safety with attach bracket assembly (18). Torque
lockwire (C702) for step 1. nut and install new cotter pin.
(5). Torque nut and install new cotter pin (3). Install actuator output control rod
for step 2. assembly (12, Ref. Section 67-20-00).
(6). Install roof panels (Ref. Section (4). Install actuator input control rod
25-20-00). assembly (6) (Ref. Section 67-20-00).
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attach bracket assembly (18) to mounting surface, and bolts (19) and
mounting surface. washers (4, 23 and 29) to vertical
mounting surface. Torque bolts.
(3). Install bolts (21) and washers (10)
attaching other side of attach bracket (2). Connect force limiting control rod
assembly (18) to mounting surface. assembly (26) (Ref. Section 67-20-00)
Torque all bolts. to splitter cam (28).
(4). Install bolt (17), washer (4) and nut (3), (3). Connect FS 231.500 directional control
attaching directional actuator (11) to rod assembly (25) (Ref. Section
actuator attach bracket assembly (18). 67-20-00) to splitter assembly (14).
(5). Verify directional control system rigging (4). Connect actuator output control rod
(Ref. Section 67-20-00). assembly (12) (Ref. Section 67-20-00)
to splitter assembly (14).
(6). Torque nut and install new cotter pin.
(5). Verify directional control system rigging
(7). Install roof panels (Ref. Section (Ref. Section 67-20-00).
25-20-00).
(6). Secure baggage compartment soft
35. Splitter Assembly insulation roof panels (Ref. Section
25-50-00).
A. Splitter Assembly Removal
36. Splitter Cam
(Ref. Figure 402)
A. Splitter Cam Removal
(1). Gain access to splitter assembly (14)
through baggage compartment soft (Ref. Figure 402)
insulation roof panels (Ref. Section
(1). Gain access to splitter assembly (14)
25-50-00).
through baggage compartment soft
(2). Disconnect actuator output control rod insulation roof panels (Ref. Section
assembly (12) Ref. Section 67-20-00) 25-50-00).
from splitter assembly (14). (2). Disconnect force limiting control rod
(3). Disconnect FS 231.500 directional assembly (26) Ref. Section 67-20-00)
control rod assembly (25) Ref. Section from splitter cam (28).
67-20-00) from splitter assembly (14). (3). Disconnect lateral control rod assembly
(33, Ref. Section 67-20-00) from
(4). Disconnect force limiting control rod
splitter cam (28).
assembly (26) and lateral control rod
assembly (33) Ref. Section 67-20-00) (4). Remove bolts (30) and washers (31 and
from splitter cam (28). 32) that attach splitter cam (28) to
splitter assembly (14).
(5). Remove bolts (27) and washers (4) that
attach splitter assembly (14) to roof (5). Remove splitter cam (28).
mounting surface, and bolts (19) and
washers (4, 23 and 29) from vertical B. Splitter Cam Installation
mounting surface.
(Ref. Figure 402)
(6). Remove splitter assembly (14).
(1). Install bolts (30) and washers (31 and
B. Splitter Assembly Installation 32) attaching splitter cam (28) to
splitter assembly (14). Torque bolts.
(Ref. Figure 402)
(2). Connect force limiting control rod
(1). Install bolts (27) and washers (4) assembly (26) Ref. Section 67-20-00) to
attaching splitter assembly (14) to roof splitter cam (28).
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(3). Connect lateral control rod assembly 38. Lateral Control Rod Assembly
(33) Ref. Section 67-20-00) to splitter
cam (28). A. Lateral Control Rod Assembly Removal
(2). Verify directional control system rigging (2). Install bolt (37), washers (4) and nut (3)
(Ref. Section 67-20-00). attaching lateral control rod (33) to
splitter assembly (14).
(3). Torque nuts and install new cotter pins.
(3). Verify directional control system rigging
(4). Secure baggage compartment soft (Ref. Section 67-20-00).
insulation roof panels (Ref. Section
25-50-00). (4). Torque nuts and install new cotter pins.
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Rotorcraft Maintenance Manual
39. Force Limiting Control Rod Assembly (2). Install bolt (38), washers (4) and nut (3)
to secure control rod (26) to outer
A. Force Limiting Control Rod Assembly bellcrank assembly (39).
Removal
(3). Verify directional control system rigging
(Ref. Figure 402) (Ref. Section 67-20-00).
(1). Remove tailboom, (Ref. Section (4). Torque nuts (3 and 61).
53-40-00).
(5). Install new cotter pin (2), and safety
(2). Remove diverter plate and aft diffuser lock washer (62) using lockwire (C702).
assembly (Ref. Section 53-30-00).
(6). Apply torque stripe (Ref. CSP-SPM,
(3). Lower hinged avionics shelf containing Section 20-10-00, Identification
right hand electronic engine control Stripe).
(EEC) (Ref. Section 25-70-00).
40. FS 234.000 Directional Bellcrank
(4). Detach electrical connectors from EEC Assembly
(Ref. Section 76-00-00), and stow away
from work area. A. Directional Bellcrank Assembly Removal
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(4). Secure baggage compartment soft 42. FS 234.000 Directional Control Rod
insulation roof panels (Ref. Section Assembly
25-50-00).
A. Directional Control Rod Assembly
41. FS 234.000 Directional Bracket Assembly Removal
A. Directional Bracket Assembly Removal (Ref. Figure 402)
(Ref. Figure 402) (1). Gain access to directional control rod
assembly (41) through baggage
(1). Gain access to directional bracket
compartment soft insulation roof panels
assembly (43) through baggage
(Ref. Section 25-50-00).
compartment soft insulation roof panels
(Ref. Section 25-50-00). (2). Remove and discard cotter pins (2).
(2). Remove FS 234.000 bellcrank assembly Remove nuts (3), washers (4) and bolts
(40) (Ref. Section 67-20-00). (13) that attach both ends of FS
234.000 control rod assembly (41).
(3). Remove bolts (44) and washers (4) that
attach FS 234.000 directional bracket (3). Remove control rod assembly (41).
assembly (43) to airframe mounting
B. Directional Control Rod Assembly
surface.
Installation
B. Directional Bracket Assembly Installation
(Ref. Figure 402)
(Ref. Figure 402)
(1). Install bolts (13), washers (4) and nuts
(1). Install bolts (44) and washers (4) (3) attaching both ends of FS 234.000
attaching FS 234.000 directional control rod assembly (41).
bracket assembly (43) to airframe
mounting surface. Torque bolts. (2). Verify directional control system rigging
(Ref. Section 67-20-00).
(2). Install FS 234.000 bellcrank assembly
(40) (Ref. Section 67-20-00). (3). Torque nuts and install new cotter pins.
(3). Secure baggage compartment soft (4). Secure baggage compartment soft
insulation roof panels (Ref. Section insulation roof panels (Ref. Section
25-50-00). 25-50-00).
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(1). Install bolt (47), washer (4) and nut (3) A. Directional Fwd Cable Bracket Removal
attaching FS 277.723 directional
(Ref. Figure 402)
bellcrank assembly (48) to FS 277.723
directional bracket assembly (49). (1). Gain access to Fwd cable bracket (50)
through baggage compartment soft
(2). Install hardware attaching Fwd insulation roof panels (Ref. Section
directional controls cable assembly (Ref. 25-50-00).
Section 67-20-00) to bellcrank assem
bly (48). (2). Remove hardware that attaches Fwd
directional controls cable assembly (Ref.
(3). Install bolt (13), washers (4) and nut (3) Section 67-20-00) to FS 277.723
attaching FS 234.000 control rod directional bellcrank assembly (48) and
assembly (41) to bellcrank assembly directional Fwd cable bracket (50).
(48).
(3). Remove bolts (51 and 52) and washers
(4). Torque nuts and install new cotter pins. (4 and 23) that attach Fwd cable
bracket (50) to airframe mounting
(5). Secure baggage compartment soft surface.
insulation roof panels (Ref. Section
25-50-00). (4). Remove cable bracket (50).
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48. Fan Control Inner Bellcrank Assembly 49. NOTAR Fan Control Shaft Assembly
A. Fan Control Inner Bellcrank Assembly A. Fan Control Shaft Assembly Removal
Removal
(Ref. Figure 402)
(Ref. Figure 402)
(1). Gain access to diverter plate area (Ref.
(1). Gain access to diverter plate area (Ref. Section 53-30-00).
Section 53-30-00).
(2). Remove and discard cotter pin (2).
(2). Remove and discard cotter pin (2). Remove nut (3), washers (4) and bolt
Remove nut (3), washers (4) and bolt (13) that attach forward end of fan
(53) that attach fan control shaft control shaft assembly (54) to NOTAR
assembly (54) to fan control inner fan assembly (Ref. Section 53-30-00).
bellcrank assembly(45). (3). Remove and discard cotter pin (2).
(3). Remove and discard cotter pin (55). Remove nut (3), washers (4) and bolt
Remove nut (56), washers (57) and bolt (53) that attach Aft end of fan control
(58) that attach bellcrank assembly (45) shaft assembly (54) to fan control inner
to diverter plate assembly (Ref Section bellcrank assembly (45).
53-30-00). (4). Remove shaft assembly (54).
(4). Remove inner bellcrank assembly (45). B. Fan Control Shaft Assembly Installation
B. Fan Control Inner Bellcrank Assembly (Ref. Figure 402)
Installation
(1). Install bolt (53), washers (4) and nut (3)
(Ref. Figure 402) attaching Aft end of fan control shaft
assembly (54) to fan control inner
(1). Install bolt (58), washers (57) and nut
bellcrank assembly (45).
(56) attaching fan control inner bell
crank assembly (45) to diverter assem (2). Install bolt (13), washers (4) and nut (3)
bly (Ref. Section 53-30-00). attaching forward end of fan control
shaft assembly (54) to NOTAR fan
(2). Install bolt (53), washers (4) and nut (3) assembly (Ref. Section 53-30-00).
attaching fan control shaft assembly
(54) to fan control inner bellcrank (3). Verify directional control system rigging
assembly (45). (Ref. Section 67-20-00).
(3). Torque nuts and install new cotter pins. (4). Torque nuts and install new cotter pins.
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12 26
1
6
25
41
DIVERTER
PLATE ASSEMBLY
3
7
2 9 2
4
8
4 10 2
3 4 4
3 REF. 6
4 5 11
3 3
24
2
5 4
REF. 6
REF. CLOSET REF. 6
CONTROL ROD
9G67 063
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3 2
REF. 12 4 37
14
4
27
4 95 -110 in-lb
(4 PL) 36 10.73 - 12.43 Nm
4 33 61
13 60 62 REF. 26
34
13
4 4
4
35
3
4 REF. 63
3 2 35
64 (2 PL)
2 REF. 25 31 4
(2 PL) 28 32
32 (2 PL) 34
42
30 (2 PL) 3
19 2 3
4 2
REF. 30 (2 PL)
STRUCTURE 44 4
4
4
29 13
29 43
REF. 14
23
26 39 13
4 4
4
4 29 4
2
3 4 3 58
48 3
2 29 2
19 57
3 59
55 56 57 2 53
46 29
29 4
REF. 41 2
45
2
3 4
4 3 57 3
13 54 55 56 2
9G67064
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Consumable Materials
(Ref. CSPSPM) Consumable Materials
Item Nomenclature (Ref. CSPSPM)
C229 Sealant, Conductive Item Nomenclature
C235 Release Agent, Fluorocarbon C310 Primer
C702 Lockwire
A. Rotating Cone Cover Removal
(1). Remove screws (6) and washers (7). A. Rotating Cone Assembly Removal
Primer (C310)
(2). Apply fluorocarbon release agent
(C235) to rotating cone cover.
(3). Apply sealant (C229) to cone cover (3). Torque bolts and safety with lockwire
mating surface of rotating cone. (C702).
(4). Install cover on rotating cone and (4). Check that there is a gap between
maintain constant pressure of up to 50 contact (10) and cone surface.
psi (344.7 kPa). Remove excess sealant.
(5). Cure sealant for 7 days at room (5). Test contact for class L electrical bond
temperature or 4 hours at room (Ref. CSP-SPM, Section 20-50-00).
temperature followed by 2 hours at
190-210 5F (87.7-98.9 5C). (6). Install rotating cone cover.
(6). Torque cover attach screws.
(7). Make sure there is clearance of
(7). Test cover for class R electrical bond 0.12-0.25 in. (3.05-6.35 mm) between
(Ref. CSP-SPM, Section 20-50-00). rotating cone and fairings.
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52. Bearing Race, Rotating Cone Assembly Adhesive Promoter, Epoxy (C412)
(Ref. Figure 403)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature (5). Apply adhesive promoter (C412) to
bearing race.
C412 Adhesive Promoter, Epoxy
C402 Adhesive, Epoxy Adhesive, Epoxy (C402)
C429 Solvent Cleaner
(3). Break bond between race (2) and cone Unconstrained roundness of assembly ID
(1). Remove race. shall not exceed 0.100 in (2.540 mm).
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1 7
2
5
9 (3 PL)
NOTE 3
10
3(3PL)
(NOTE 2)
NOTE 4 VIEW ROTATED
4 (NOTE 1) NOTES:
1. RIVET IS ALIGNED WITH CENTER OF OPENING.
2. RIVETS EQUALLY SPACED.
3. ANY MEASURABLE GAP.
4. LIQUID SHIM. 9G67-047B
(3). Remove and discard cotter pin (25). (5). Do the Anti-Torque/Directional
Remove nut (24) and washer (16). Controls Travel/Rigging Verification.
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(1). Cut glass fiber laminate (C502) to (3). Remove and discard lockwire. Remove
dimension necessary to give dissimilar bolt (4) and washer (3).
material protection between sector
(4). Disconnect rotating cone control rod (2)
guard clip and sector support bracket.
(5). Remove bushing (40) and sector (36).
Primer (C310)
B. Sector Installation
(1). Install sector and bushing.
(2). Connect rotating cone control rod and
(2). Put sector guard clip and glass fiber install bolt and washer. Torque bolt and
laminate (C502) in their installed safety with lockwire (C702).
position. Install rivets wet with primer
(C310). (3). Install sector support bracket.
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Consumable Materials
(Ref. CSPSPM)
Item Nomenclature (1). Apply sealing compound (C205) to
C205 Sealing Compound mating surfaces of sector rigging plate,
sector support shaft, and sector brack
et.
A. Sector Rigging Plate Removal
(2). Install sector support shaft, sector
(1). Remove sector. rigging plate, bolts, and washers.
Torque bolts.
(2). Remove bolts (38), washers (16), and (3). Install washers.
sector rigging plate (39).
(4). Install sector.
B. Sector Rigging Plate Installation
58. Sector Support Shaft Bracket
Sealing Compound (C205)
(Ref. Figure 404)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
(1). Apply sealing compound (C205) to
C205 Sealing Compound
mating surfaces of sector rigging plate
and sector support shaft. C310 Primer
(2). Install sector rigging plate, bolts, and A. Sector Support Shaft Bracket Removal
washers. Torque bolts.
(1). Remove sector support shaft.
(3). Install sector.
(2). Remove rivets (44) and sector support
57. Sector Support Shaft bracket (42).
B. Sector Support Shaft Bracket Installation
(Ref. Figure 404)
Sealing Compound (C205)
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C205 Sealing Compound (1). Apply sealing compound (C205) to
mating surfaces of sector support shaft
bracket and thruster.
A. Sector Support Shaft Removal
Primer (C310)
(1). Remove sector.
(3). Remove sector rigging plate. (2). Install sector support shaft and rivets.
Install rivets wet with primer (C310).
(4). Remove bolts (43), washers (16), and
sector support shaft (41),. (3). Install sector support shaft.
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59. Rotating Cone Forward Control Cable (2). Connect forward and aft control cables
to turnbuckles.
(Ref. Figure 404) (3). Adjust tension of rotating cone control
cable to 36-44 lbs. (16.33-19.96 kg),
use tensiometer (T2015). Install
turnbuckle locking clips.
Consumable Materials
(Ref. CSPSPM) (4). Install rotating cone
Item Nomenclature (5). Do the Anti-Torque/Directional
C702 Lockwire Controls Travel/Rigging Verification.
60. Rotating Cone Aft Control Cable
Special Tools (Ref. Figure 404)
(Ref. CSPSPM)
Item Nomenclature Consumable Materials
(Ref. CSPSPM)
T2015 Tensiometer
Item Nomenclature
C225 Sealing and Locking Compound
(2). Remove locking clips from control cable (1). Remove lightening strike shield.
turnbuckle (5). (2). Remove locking clips from control cable
turnbuckle (5).
(3). Disconnect rotating cone forward (3). Disconnect rotating cone aft control
control cable (6) from turnbuckle (5). cable (7) from turnbuckle (5).
(4). Remove cable retaining pins (49).
(4). Remove and discard lockwire. Remove (5). Remove screw (26).
screw (35) and washer (16). Disconnect (6). Remove aft control cable.
forward control cable (6).
B. Rotating Cone Aft Control Cable
Installation
(5). Remove forward control cable. NOTE: This task is typical for left or right ro
tating cone aft control cable.
B. Rotating Cone Forward Control Cable (1). Put aft control cable on control cable
Installation. drum.
Sealing and Locking Compound (C225)
NOTE: This task is typical for left or right ro
tating cone forward control cable.
(1). Connect forward control cable to sector (2). Install screw, install wet with sealing
and install screw and washer. Torque and locking compound (C225). Torque
screw and safety with lockwire (C702). screw.
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(5). Adjust tension of rotating cone control (1). Install pulley bracket, laminated
cable to 36-44 lbs. (16.33-19.96 kg), washers, bolts, and washers. Install
use tensiometer (T2015). Install bolts wet with primer (C310). Torque
turnbuckle locking clips. bolts.
NOTE: It is not necessary to remove cable from (1). Install cable pulley, bolt, washers, and
control cable drum. nut. Torque nut and install new cotter
pin.
(1). Remove rotating cone aft control cables. (2). Install rotating cone aft control cable.
(2). Remove bolts (47), washers (16), and 62. Control Cable Drum
laminated washers (48). Remove pulley
bracket (46). (Ref. Figure 404)
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(1). Install control cable drum, washers, collar, use sealing compound (C205)
and nut. Torque nut and install new (Ref. CSP-SPM).
cotter pin.
(5). Install washers on drum bracket shaft.
(2). Install rotating cone aft control cables.
(6). Install drum.
63. Drum Bracket (7). Do the Anti-Torque/Directional
Controls Travel/Rigging Verification.
(Ref. Figure 404)
64. Wire Braid Ground Jumper
Consumable Materials
(Ref. Figure 404)
(Ref. CSPSPM)
Item Nomenclature
C205 Sealing Compound Consumable Materials
(Ref. CSPSPM)
C310 Primer Item Nomenclature
C205 Sealing Compound
A. Drum Bracket Removal. C310 Primer
(1). Remove drum.
A. Wire Braid Ground Jumper Removal
(2). Remove washers (19 and 20).
(1). Remove rotating cone.
(3). Remove collars (27), washer (16),
ground jumper (14), wire braid ground (2). Remove collar (27), washer (16), ground
jumper (55), and pin rivets (28 and 29). jumper (14), and wire braid jumper
Remove drum bracket (8). assembly (55).
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(3). Prepare mating surfaces of the two B. Rotating Cone Support Bearing
ground jumper terminal lugs and Installation
control cable drum bracket for electrical
bond (Ref. CSP-SPM). (1). Install support bearing, washers, and
bolt. Torque bolt.
Sealing Compound (C205)
Before you install rotating cone,
CAUTION make sure all support bearings
turn freely.
(2). Install rotating cone.
(4). Apply sealing compound (C205) at
necessary locations. 66. Lightning Strike Shield
Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
(5). Install pin rivet in thruster and control C205 Sealing Compound
cable drum bracket. Install wet with C502 Glass Fiber, Sheet, Laminate
primer (C310).
C717 Tape, Polyethylene
(6). Install wire braid jumper, ground
jumper, washer, and collar.
A. Lightning Strike Shield Removal
Sealing Compound (C205)
(1). Remove rotating cone.
NOTE: Ground jumper removal is not neces
sary if lightening strike shield is not re
placed.
(7). Install rivet, washer, and wire braid
(2). Remove rivet (18) and washer (16).
jumper terminal lug. Install wet with
sealing compound (C205). (3). Disconnect ground jumper (14).
(8). Install rivets and washers that attach (4). Remove bolts (17), washers (16), and
wire braid to thruster. Install wet with lightning shield (15).
sealing compound (C205).
B. Lightning Strike Shield Installation
(9). Test between thruster attach frame and
drum bracket for Class L electrical Glass Fiber, Sheet, Laminate (C502)
bond (Ref. CSP-SPM).
(10). Environmentally seal rivet and collar
with sealing compound (C205) (Ref.
CSP-SPM). (1). Cut glass fiber laminate (C502) or
(11). Install rotating cone polyethylene tape (C717) to 1.0 X 1.0 in
(25.4 X 25.4 mm), and cut 0.191 in
65. Rotating Cone Support Bearing (4.85 mm) hole in center.
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(5). If ground jumper was removed, prepare (3). Remove collar (27), washer (16), and
mating surfaces of lightening strike jumper assembly (14).
shield and ground jumper for electrical
bond (Ref. CSP-SPM). B. Ground Jumper Installation
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2 4 15
3 NOTE
16 (6 PL)
6
17 (6 PL)
7
18
13 10 11 10 9
VIEW ROTATED 8 14
16 PL 5
16
3 PLACES 27
20
21
22
28
53 25
16 19
53 (5 PL) 24
12 23
54 16 (5 PL)
26 26
16 55
REF 8
LOOKING INBOARD
LOWER LEFT SIDE 29
REF 14
16
27
25 24 32 (2 PL) 51 (2 PL)