MAINTENANCE MANUAL MBB B 0 105 -

21 F U S E L A G E

Table of Contents

Paragraph Title Paqe

21 - 1 DESCRIPTION - FUSELAGE . . . . . . . . . . .. . . . . . . . 3
21 - 2 REPAIR - FUSELAGE . . . . . . . . . . . .. . . . . . . .. 3
INSPECTION FOR CONDITION - FUSELAGE . . . . . . . . . . . . . 15
F o l d i n g d o o r . . . . . . . . . . . . . . . . . . 25
21 - 5 Removal - f o l d i n g door . . . . . . . . . . . . . . . . . . . 25
21 - 6 ~ n s p e c t i o nand r e p a i r - f o l d i n g door . . . . . . . .. . . . 25
21 - 7 Installation - foldingdoor . . . . . . . . . . . .. . . . . 25
21 - 7A Removal - door handle ( f o l d i n g door) . . . . . . ... . . . 26A **
21 - 7B I n s t a l l a t i o n - door handle ( f o l d i n g door) . . . . . . . . . . 2 6 *~
*
21 - 8 S l i d i n g d o o r . . . . . . . . . . . . . . . . . . 27
21 - 9 Removal - s l i d i n g door . . ... . . . . . . . ... . . . 27
21 - 10 I n s p e c t i o n and r e p a i r - s l i d i n g door . .
' . . . . ... . . . 27
21 - 11 Installation - slidingdoor .. . . .. . . . . . .. . . . 27 *
*
21 - 11A Removal - door handle ( s l i d i n g door) . . . . . . . . . . . . 29 *
*
21 - 11B I n s t a l l a t i o n - door handle ( s l i d i n g door) . .. . ... . . . 29 *
*
21 - 12 R e a r d o o r . . . . . . . . . . . . . . . . . . . . . 29
21 - 13 Removal- r e a r d o o r . . . . . . . . . . . . . .... . . . 29
21 - 14 I n s p e c t i o n and r e p a i r - r e a r door . . . . . . . ... . . . 29
21 - 15 I n s t a l l a t i o n - r e a r door . . . . . . . . . . . . . . . . . . 30
21 - 16 S p o i l e r . . . . . . . . . . . . . . . . . . . . . . . 33
21 - 17 Removal - s p o i l e r . . . . . . .. . . . ... . . . . . . . 33

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Paragraph Title Page

21 .18 I n s p e c t i o n and r e p a i r .s p o i l e r . . . . . . . . . . . . . . 33

. . . .
I n s t a l l a t i o n .s p o i l e r . . . .
W i n d o w s . . . . . . . . . . . .
Cleaning .windows . . . . . . . . . .
Removal .upper windshield . . . . . .
I n s t a l l a t i o n .upper windshield ...
Removal .lower windshield . . . . . .
I n s t a l l a t i o n .lower windshield . . .
Removal .c a b i n roof window . . . . .
I n s t a l l a t i o n .c a b i n roof window . . .
Removal .f o l d i n g door window ....
I n s t a l l a t i o n .f o l d i n g door window . .
Removal and i n s t a l l a t i o n .s l i d i n g door window . . . . . . . 48

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21 - 1 DESCRIPTION - FUSELAGE
The fuselage is a light-alloy, semi-monocoque construction, comprising
airframe, folding doors, sliding doors, rear clamshell door, windows and
floor panels.

21 - 2 REPAIR - FUSELAGE

1. For fuselage material identification, refer to figure 21-1.

2. Repair local damage according to FAA Publication, AC 43.13-lA, AIRCRAFT *
INSPECTION AND REPAIR, REM 201 and SI-B0105-142. If damage is more *
extensive, refer to manufacturer. k

3. Repair KEVLARIEPOXY sandwich panels using standard approved methods for

glass-fiber structures, whereby one ply of KEVLAR can be replaced by two
plies of glass fiber WL 8.4548.6.

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Conf igi

Configuration
B0 105 S

Figure 21-1 Material identification - fuselage (1 of 11)

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Figure 21-1 Material identification - fuselage (3 of 11)

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Figure 21-1 Material identification - fuselage (4 of 11)

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Item Structural Material German Industrial Material US Standards Material
components identification Standards thickness thickness
nun inches

Skin:
PREPREG
1 ply per side WL 8.2320.1 -- glass fabric 181 --
MIL-C-9084C
type VI/class 2

PREPREG
1 ply per side WL 8.2320.2 -- glassfabric181 --
MIL-P-25421B
type 1 and 2
class 1 and 2
Rear fuselage KEVLAR EPOXY
shell sandwich
Core :
NOMEX honeycomb LN29969AO 6.0 NOMEX core 0.24
Outer skin - 1 ply
KEVLAR ATLAS 1/7 WL 5.2230.30 -- KEVLAR-49-181 --
Inner skin - 1 ply
KEVLAR ATLAS 117 WL 5.2230.30 -- KEVLAR-49-181 --
 MBB HELICOPTERS
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MAINTENANCE MANUAL MBB B0 105

Figure 21-1 Material identification - fuselage (6 of 11)

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n
0
W
rl U I U
rl -44 -d
m ~ r l - r u
P @-da
g m c r m
W m m W

Figure 21-1 Material identification - fuselage ( 7 of 11)

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Figure 21-1 Material i d e n t i f i c a t i o n - fuselage (8 of 11)

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 -

Item Structural Material German Industrial Material US Standards Material

C3 0 components identification Standards thickness thickness
rmcn
bJ S1 mm inches

19 Floor, Aluminum
forward sandwich
Core :
aluminum honeycomb LN29975-1 20.0 MIL-C-7438B 0.8
Outer skin:
aluminum alloy -- 0.635 2024T3QQ-A-250/5d 0.025
(rigidized) or .
aluminum alloy LN9073 3.136413 0.5 2024T3QQ-A-250/5d 0.02
Inner skin:
aluminum alloy LN9073 3.1364T3 0.3 2024T3QQ-A-250/5d 0.012
20 Nose sheil KEVLAR EPOXY
sandwich shell
Core :
NOMEX honeycomb LN29969AO 6.0 NOMEX core 0.24
Outer skin-1 ply
KEVLAR ATLAS 1/7 WL 5.2230.30 -- KEVLAR-49-181 --
Inner skin-1 ply
KEVLAR ATLAS 1/7 WL 5.2230.30 -- KEVLAR-49-181 --
 Item Structural Material German Industrial Material US Standards Material
components identification Standards thickness thickness
mm inches

21 Nose shell Glass fabric

door (control EPOXY sandwich
linkage access) Core :
Hard foam panel LN29898C6
Outer skin-3 ply:
glass fabric LN9169 8.4548.6 -- glass fabric 181 --
MIL-C-9084C
type VII, class 2
Ci-

Inner skin-2 ply:

glass fabric LN9169 8.4548.6 -- glass fabric 181 --
MIL-P-25421B
type I and I1
class 1 and 2
 MBB HELICOPTERS
MAINTENANCE MANUAL MBB -
B0 105

m * -.W
m x a a
Li m
aim
m o u u u m
rlpiom 1-l
U W U C Ob,

Figure 21-1 Material identification - fuselage (11 of 11)

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21 - 3 INSPECTION FOR CONDITION - FUSELAGE

1. Wherever possible, inspect installed doors for condition in accordance with inspection criteria set forth in
paras 21--6, 21--10 and 21--14.

2. Visually inspect windows for cracks, crazing and other obstructions to vision.

a. Polish out scratches to max. 0.1 mm in depth using a flannel buffing wheel with polishing wax (CM 759).

b. Cracks, holes or other damage may be temporarily repaired by stop drilling, patching or other approved
methods (see paragraph 21--2), but window must be replaced at earliest opportunity.
Refer to para 21--20 for window replacement procedure.

c. Inspect the sliding window for correct function and damage. If damage is found, repair the sliding window
or replace the window according to paragraph 21--28 to 21--30.

3. Inspect fuselage skin, stringer and frames for cracks, dents and corrosion.

a. If cracks and dents are visible, refer to paragraph 21--2.

b. Polish out corrosion not exceeding 10% of material thickness in depth and not exceeding 10% of compo-
nent surface area using 400 grit abrasive cloth. Touch up surface protection in accordance with Chapter
02.

4. Inspect drain holes (see figure 21--5) for obstruction. Clear clogged holes with a suitable tool or compressed
air.

5. Wherever possible with transmission struts installed, inspect main transmission mounts (3, figure
21LEERER MERKER) for mechanical damage, corrosion and loose rivets. Inspect the area around the
main transmission mounts for cracks and loose rivets.

a. Repair cracks and loose rivets as outlined in paragraph 21--2.

b. Polish out mechanical damage and corrosion, not exeeding 0.2 mm in depth with 400 grit polishing cloth.
Touch up surface protection in accordance with Chapter 02.

6. Perform this steps if the transmission supporting struts have been removed.
Inspect spherical bearings (16, figure 21LEERER MERKER) and bushings (14) in the main transmission
mounts (3) for play and evidence of corrosion.

a. Replace spherical bearings with axial play in excess of 1.0 mm or radial play in excess of 0.5 mm, and
replace corroded spherical bearings. Refer to Chapter 02.

b. Press in claw bushing with axial play not exceeding 0.2 mm using tool, P/N 105--21832 W1; otherwise
replace according to Chapter 02.

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 MAINTENANCE MANUAL BO 105

7. Wherever possible with engines installed, inspect engine mounts (4) and attach fittings (6, 8 and 9) for me-
chanical damage and corrosion. Inspect the area around the attach fittings for cracks and loose rivets.

a. Polish out mechanical damage and corrosion on the engine mounts with 400 grit abrasive cloth. Refer to
Chapter 61 for damage and repair limits.

b. Polish out mechanical damage and corrosion not exceeding 0.2 mm depth on attach fittings (6, 8 and 9)
with grit abrasive cloth, and apply surface protection according to Chapter 02.

c. Repair cracks and loose rivets according to paragraph 21--2.

8. Perform this step only if the engine has been removed.

Inspect the bores of attach fittings (6, 8 and 9) for wear; if excessively worn boreholes have been bushed,
also inspect bushing boreholes. If bores show signs of wear, check bore dimensions.

a. Maximum allowable diameter of bore in the aft attach fitting and in the attach fitting of the engine hinged
support strut is 8.07 mm, and 10.07 mm for bore in the forward attach fitting.

b. If the maximum diameter is exceeded, install bushing (refer to step 12. and 14.) or replace bushing (refer
to step 13.).

9. Visually inspect tail boom connecting ring flange and adjacent fuselage areas (10) for cracks, other me-
chanical damage, corrosion and loose rivets. In particular inspect areas between the necked--down bolts,
using a magnifying glass.

a. Repair cracks according to paragraph 21--2.

If there are more than 10 loose rivets, replace these with solid rivets LN9198 DU or MS20470 DD of the
appropriate length and diameter. It is recommended that all rivets in the ring flange be replaced at the
same time.

b. Polish out other mechanical damage and corrosion not exceeding 0.2 mm in depth with 400 grit abrasive
cloth. Touch up surface protection in accordance with Chapter 02.

c. If tail boom is removed, inspect bore areas of flange (10) for corrosion.

1) Using 12 mm dia. spotface tool and 6 mm dia. pilot pin, remove corrosion to the depth of 0.1 mm
below bare metal surface.
The remaining wall thickness of the ring flange must be at least 5.4 mm (see figure
21LEERER MERKER, section A--A).

2) Clean reworked area with tetrachloroethylene (CM 205), then brush--coat with chemical conversion
material (CM 316).

3) Apply paint to match existing paint finish on tail boom. Keep front of ring flange free of paint.

CHAPTER 21 Revision 14
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 MAINTENANCE MANUAL B 0 105

10. Visually inspect landing gear fittings (12) and adjacent fuselage areas for deformation, corrosion, loose riv-
ets, paint damage, and cracks (using magnifying glass).

a. Repair deformation, cracks and loose rivets.

b. Polishoutcorrosionto adepthof 0.2 mmwith400 grit abrasivecloth. Touch up surface protectioninaccor-

dance with Chapter 02.

11. If tail boom has been removed, inspect frame 2Lfor cracks. Stop-drill any existing cracks and inspect them
for propagation at the next inspection. Repair cracks which have propagated.

12. If necessary, install bushings in attach fittings (6 and 8, figure 21-4) as follows:
Special tool:
Milling tool 105-20001 W2

a. Position guide block (1, figure 21-2) over attach fitting (3) and insert centering pin (2).

b. Presscentering pin (2) up against original bore edge, secure guide block with setscrews (4), and remove
centering pin.

C. -
Rework attachfitting bore to 11.5 mm f0.1 mm diameter using roughing cutter, then to 12 0.005 mm
diameter using finishing cutter.
During milling, apply coolant (CM 109) or equivalent.

d. Remove guide block and deburr holes as necessary.

e. Bruch-coat bushing (4, figure 21-3) with corrosion preventive compound (CM 502) and press it into at-
tach fitting (5) using the pressing-in device of the millingtool105-20001 W2 (figure21-3). The bushing
must beflush with the sutface of the attach fitting.

f. Check bore dimension of installed bushing. The required diameter is 8 + 0.015 mm for attach fitting
(8, figure 21-4) and 10 + 0.01 5 mm for attach fitting (6). Hone to size and deburr if necessary.

13. If necessary, replace bushing as follows:

Special tools:
Pressing-out tool Tool no. 33 (105-20001 W4) Refer to Chapter 04
Milling tool 105-20001 W2

a. Drive bushing out with pressing-out tool, No. 33.

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 MAINTENANCE MANUAL B 0 105

b. Apply a brush coating of corrosion preventive compound (CM 502) to the bushing and install it in attach
fiing usingpressing-indeviceof millingtool105-20001 W2 (seefigure21-3).The bushingmust beflush
with attach fitting surface.

C. Check bore dimension of installed bushing. The required diameter is 8 + 0.015 mm for attach f i i n g
(8,figure 21-4 and 10 + 0.015 mm for attach fitting (6) respectively. Honeto size and deburr if necessary.

14. Install bushing in attach fitting (9, figure 21-4 as follows:

Special tools: Milling Tool 105-20001 W2
Milling cutter
Cherry hand riveter

a. Usinga milling cutter, cut a section (see cutout infigure 21-lA) out of thesheet metalstructurejust large
enough to allow milling tool105-20001 W2 to be mounted on the attach fitting.

b. For milling tool mounting procedure and milling of hole, refer to step 12, sub-steps a. thru d.

' C. Insert bushing per step 12, sub-step e.

d. Check bushing for inner diameter of 8 + 0.015 mm. Hone to size and deburr as necessary.
'

Figure 21- l A Cutout in sheet metal structure

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e. F a b r i c a t e a n g l e p l a t e from s h e e t metal, t a k i n g account of t h e r i v e t *

s p a c i n g shown i n f i g u r e 21-1B. *
*
f. D r i l l o u t e x i s t i n g r i v e t s (2 o f f ) . *
*
g. ~ l i g na n g l e p l a t e over c u t o u t and d r i l l 3.6-mm-dia. h o l e s i n outboard *
and inboard l e g s of a n g l e p l a t e , u s i n g t h e e x i s t i n g r i v e t h o l e s i n *
t h e f i r e w a l l and t h e s p e c i f i e d edge d i s t a n c e s r e s p e c t i v e l y , a s a *
guide . *
*
h. Deburr h o l e s . *
*
i . Brushcoat mating f a y i n g s u r f a c e s of a n g l e p l a t e and s h e e t meta1 *
s t r u c t u r e w i t h s i l i c o n e rubber (CM 6 1 9 ) and a t t a c h a n g l e p l a t e . *
*
j. Rivet a n g l e p l a t e i n p l o c e u s i n g c h e r r y hand r i v e t e r . *
*
*
SECTION A A - **

m
('1

*
*
1 *
*
SECTION B 'B 1
2
Rivet (NAS 1738M-4-1)
Sheet meta1 (3.7024.1 0.4 mm thick)
**
i

I
O
**
N
t? *
Drill out existing rivets *
t and transfer rivet hole
Pattern to angle plate
*
*
L Dimensions in mm

F i g u r e 21-1B Patching t h e cutout

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Out of
central

1 Guide block
2 Centering pin
3 Attach f i t t i n g
4 Setscrews

Figure 21-2 Attachment of mi1l.in.g t o o l f o r bore enlargement

1 Hex n u t
2 Washer
3 Stepped washer
4 Bushing
5 Attach f i t t i n g
6 Hex b o l t

Figure 21-3 I n s t a l l a t i o n of bushing u s i n g p r e s s i n g - i n d e v i c e

of m i l l i n g t o o l 105-20001 W2
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A7 8
I I DETAIL E

DETAIL C

1 Cabin frame attachment 10 Tailboom c o n n e c t i n g

points flange
2 Spherical bearing 11 T a i l r o t o r d r i v e s h a f t
Bushing i s i n s t a l l e d only 3 Main t r a n s m i s s i o n mount bearing bracket
i f repaired according t o 4 E n g i n e mount 12 Landing g e a r f i t t i n g
p a r a 21-3 - 5 Bushing 13 DU b u s h i n g ( l a n d i n g
6 Engine a t t a c h f i t t i n g g e a r mount)
/2\ Rework p e r r n i s s i b l e on t h i s - 7 Bushing 1 4 Bushing
side only 8 Attach f i t t i n g 15 Back-up d i s k
9 Attach f i t t i n g 16 Spherical bearing

Figure 21-4 Inspection areas - fuselage

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Figure 21-5 Location of drain holes

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21-4 F o l d i n g d o o r

NOTE Refer t o paragraph 21-5 f o r f u n c t i o n a l check of

j e t t i s o n mechanism.

21 - 5 Removal - f o l d i n g door

1. Open f o l d i n g door (I, f i g u r e 21-6) .

2. Remove s a f e t y wire from door j e t t i s o n l e v e r ( 7 ) .

3. Support f o l d i n g door t o prevent i f from f a l l i n g and g e t t i n g damaged; pul1

door j e t t i s o n l e v e r and remove f o l d i n g door.

21 - 6 Inspection and r e p a i r - f o l d i n g door

1. Inspect f o l d i n g door f o r cracks, dents and o t h e r damage. Repair a s
necessary i n accordance with paragraph 21-2.

2. Inspect bulb s e a l s (10, f i g u r e 21-6) and s e a l s on window s l i d i n g vents

f o r damage, d e t e r i o r a t i o n and bond s e p a r a t i o n . Remove o l d adhesive from
separated s e a l s and clean t h e bonding s u r f a c e s with acetone (CM 203).
Bond rubber s e a l s w i t h adhesive (CM 673). Replace damaged s e a l s .

3. Inspect f o l d i n g door windows i n accordance with paragraph 21-3.

4. Inspect door l a t c h i n g mechanism ( 3 ) f o r proper operation and freedom of

movement. I f t h e r e i s evidence of binding, remove l a t c h i n g mechanism and
i n s p e c t f o r worn and d i r t y p a r t s . Replace damaged p a r t s .

5. Inspect door hinges f o r evidence of damage and freedom of movement.

Remove binding hinges, c l e a n them with dry cleaning solvent (CM 202) and
l u b r i c a t e them with grease (CM 1 0 1 ) . Replace damaged p a r t s .

21 - 7 Installation - f o l d i n g door

1. Coat hinge b o l t s ( 4 , f i g u r e 21-6) and p i n s of j e t t i s o n mechanism with

grease (CM 101) .

2. I n s t a l l door so t h a t t h e hinge b o l t s ( 4 ) s l i d e i n t o t h e mating sleeves i n

t h e cabin s t r u c t u r e .

3. Push door j e t t i s o n l e v e r ( 7 ) up a g a i n s t t h e frarne t o lock t h e - h i n g e b o l t s

( 4 ) i n place.

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1 Folding door
/i\ - 2 Window
3 Door l a t c h i n g mechanism
4 Hinge b o l t s
5 Window
6 Cockpit frame
&J - Folding door may 7 Door j e t t i s o n l e v e r
incorporate window 8 Window
2, 8, o r 9, depending 19 Window
on configuration 10 Bulb s e a l

Figure 21-6 Cockpit door

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21 - 7A Removal - door handle (folding door)

1. Remove screw (1, f i g . 21-6A) and washer ( 2 ) .

2. P u l l inner handle (3) of f o u t e r handle (5) .

3. P u l l out o u t e r handle (5) .

Dimension "X" 1 Location

28 mm 1 Sliding door
38 mm I~oidingdoor I

1 Screw 4 Folding door

2 Washer 5 Outer handle
3 Inner handle 6 Window

Figure 21-6A Removal and i n s t a l l a t i o n - door handle

21 - 7B Installation - door handle (folding door)

1. Before i n s t a l l i n g o u t e r handle ( S ) , check t h a t it belongs t o folding door
( 4 ) by measuring t h e length of i t s Square shank (dimension "X" i n f i g .
21-6A). Only door handles with a 38-mm-long shank may be i n s t a l l e d i n t h e
f o l d i n g door.
2. I n s e r t o u t e r handle (5) through folding door ( 4 ) and f i t i n n e r handle (3)
on t h e end of it i n accordance with f i g u r e 21-6A.
3. Brushcoat screw (1) with l o c t i t e (CM 676) and i n s t a l l handtight together
with washer ( 2 ) .

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4. If t h e door lock i s replaced, e n s u r e t h a t a s s o c i a t e d g r u b screw f o r

s e c u r i n g t h e l o c k i n g c y l i n d e r i s of t h e c o r r e c t l e n g t h .
Apply l o c t i t e (CM 651) t o g r u b screw. I n s t a l l grub screw t o f u l l e x t e n t ,
.
then back of f 118 of a t u r n . I n t h i s p o s i t i o n , t h e grub screw must not
p r o t r u d e from t h e g r i p s h a f t . T h i s would cause damage t o t h e c o l l e r . Also
t h e l o c k i n g b a r r e 1 must b e a b l e t o r o t a t e .

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21-8 S l i d i n g d o o r

21 - 9 Removal - s l i d i n g door
1. Close s l i d i n g door (1, f i g u r e 21-7) .
2. Remove rubber s t o p (8) and, i f i n s t a l l e d , angle bracket (3) from door
rails .
3. Open s l i d i n g door and c a r e f u l l y s l i d e it a f t out of t h e door r a i l s .

21 - 10 Inspection and r e p a i r - s l i d i n g door

1. Inspect s l i d i n g door f o r cracks, dents and o t h e r damage. Repair a s
necessary i n accordance with paragraph 21-2.

2. Inspect s l i d i n g door windows i n accordance with paragraph 21-3.

3. Inspect door s e a l s , door frame s e a l s and s e a l s on lower door r a i l f o r

damage, d e t e r i o r a t i o n and bond separation. Remove old adhesive from
separated s e a l s and clean t h e bondinq surfaces w i t h acetone (CM 203).
Bond rubber s e a l s with adhesive (CM 673) and other s e a l s with adhesive
(CM 672). Replaced damaged s e a l s .

4. Inspect door l a t c h i n g mechanism f o r proper operation and freedom of

movement. I f t h e r e i s evidence of binding, remove latching mechanism,
clean it with dry cleaning solvent (CM 202) and coat it w i t h grease
(CM 101). Replace damaged p a r t s .

5. Check s l i d e r s (12, f i g u r e 21-7) f o r t i g h t s e a t and inspect f o r condi- *

t i o n . Replace i f damaged. Tighten loose hardware and secure with Loctite *
(CM 651). I f s l i d e r has t o be replaced, secure hardware a f t e r *
i n s t a l l a t i o n with Loctite (CM 651). *

21 - 11 Installation - s l i d i n g door
1. Clean upper and lower door r a i l s , upper s l i d e r (11, f i g u r e 21-7) and
lower s l i d e r s ( 1 2 ) .
2. Position forward lower edge of s l i d i n g door i n the a f t end of lower door
r a i l and then guide t h e upper s l i d e r (11) over upper door r a i l .
3. Push s l i d i n g door forward. Close and lock.
4. Check s l i d i n g door f o r f i t t o s t r u c t u r e . I t must b u t t against t h e
cockpit door and fuselage. I f necessxy, a d j u s t l a t c h s t r i k e r ( 1 4 ) .
5. I n s t a l l rubber s t o p (8) and angle brzcket (3) .
6. Rub talcum powder (CM 108) onto t h e coor s e a l s and o t h e r s e a l s .

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DETAIL B

DETAIL A

1 S l i d i n g door
2 Screw
3 Angle bracket
4 Spacer
5 Washer
7 8 9 10 6 Nut
7 Door r a i l
8 Rubber stop
9 Washer
10 Screw
11 Upper s l i d e r
12 Lower s l i d e r
13 P l a t e
1 4 Latch s t r i k e r
15 Screw
16 Washer

Figure 21-7 Sliding door

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21 - 11A Removal - door handle ( s l i d i n g door)

Removal i s i n accordance with paragraph 21-7A.

21 - 11B I n s t a l l a t i o n - door handle ( s l i d i n g door)

I n s t a l l a t i o n i s i n accordance with paragraph 21-7B. Take note t h a t only o u t e r *

handles with a Square shank l e n g t h of 28 mrn may be i n s t a l l e d (See f i g u r e *
21-6A). *

21-12 R e a r d o o r

21 - 13 Removal - r e a r door

1. Remove s p l i t p i n s (12, f i g u r e 21-8) and washers (11).

2. Open and s e c u r e door (1).
3. Withdraw b o l t ( 1 0 ) and remove door.

21 - 14 I n s p e c t i o n and r e p a i r - r e a r door

1. I n s p e c t door f o r c r a c k s , d e n t s and o t h e r damage. Repair a s necessary i n

accordance with paragraph 21-2.
2. I n s p e c t rubber s e a l s (7, f i g u r e 21-8) f o r damage, d e t e r i o r a t i o n and bond
s e p a r a t i o n . Remove r e s i d u a l adhesive from s e p a r a t e d s e a l s and c l e a n t h e
bonding s u r f a c e s with acetone (CM 2 0 3 ) . Rebond s e a l s with adhesive
(CM 6 7 3 ) . Replace damaged s e a l s .

3. I n s p e c t l a t c h i n g mechanisms ( 3 and 5) f o r proper o p e r a t i o n and freedom of

movement. I f t h e r e i s evidence of binding, remove l a t c h i n g mechanisms,
c l e a n them with d r y c l e a n i n g s o l v e n t (CM 202), and c o a t them with g r e a s e
(CM 1 0 1 ) .

4. I n s p e c t door s t r u t s ( 8 ) and n e t t i n g ( 4 ) f o r damage. Replace i f damaged.

5. I n s p e c t hinges ( 9 ) f o r c r a c k s and mechanical damage. Replace i f cracked
o r badly worn.

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21 - 15 Installation - rear door

1. Clean bolts (10, figure 21-8) and coat with grease (CM 101).
2. Support door on hinge fittings of fuselage and install bolts (10) and
shim washer (11). Install split pins (12).
3. Treat rubber seal with talkum powder.
4. Close both doors and check for flush fit with fuselage. Open doors and
rub talcum powder (CM 108) on the door seals. Close doors.

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DETAIL A /

\ /' Rear door

Door lock
200171 Upper l a t c h mechanism
Netting
Lower l a t c h mechanisrn
Placard
Rubber s e a l
Door s t r u t s
Hinge
Bolt
Washer
S p l i t pin

Figure 21-8 Rear door

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21-16 S p o i l e r

21 - 17 Removal - spoiler

1. Unscrew n u t s (4, f i g u r e 21-9) from screws (6) and remove screws.

2. Detach s p o i l e r (1) from angle b r a c k e t s (3) .

3. Remove a t t a c h i n g screws ( 2 ) , angle b r a c k e t s ( 3 ) , p l a t e s (5) and
wedge-shaped shims (7) from t h e fuselage.

21 - 18 Inspection and r e p a i r - spoiler

1. Inspect s p o i l e r (1, f i g u r e 21-9) f o r cracks, dents and o t h e r damage.
Repair a s necessary i n accordance with paragraph 21-2.
2. Inspect angle b r a c k e t s ( 3 ) , p l a t e s (5) and wedge-shaped shims (7) f o r
mechanical damage. Replace i f badly worn.

3. V i s u a l l y i n s p e c t s p o i l e r f o r p a i n t damage, touch up p a i n t f i n i s h a s
necessary i n accordance with Chapter 02.

21 - 19 Installation - spoiler

1.- I n s t a l l angle b r a c k e t s (3, f i g u r e 21-9) and p l a t e s (5) on t h e fuselage

with screws ( 2 ) ; i n a d d i t i o n , i n s t a l l t h e wedge-shaped shims on t h e o u t e r
angle bracket s .
2. F i t s p o i l e r (1) i n angle bracket (3) and secure with screws ( 6 ) .

3. Align angle b r a c k e t s (3) and t i g h t e n screws (2) .

4. I n s t a l l n u t s ( 4 ) t i g h t l y on screws ( 6 ) .

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Additionally install wedge- 1 Spoiler

shaped shims on outer angle 2 Screw
bracket 3 Angle bracket
4 Nut
5 Plate
6 Screw
7 Wedge-shaped shim

Figure 21-9 Spoiler - removal and installation

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21-20 W i n d o w s

21 - 21 Cleaning - windows

CAUTION o D 0 NOT USE GASOLINE, ALCOHOL, KEROSENE, BENZENE,

XYLENE, TOLUENE, HEXANE, KETONES INCLUDING
ACETONE, CARBON TETRACHLORIDE, FIRE EXTINGUISHER
OR D E I C I N G FLUIDS, LACQUER THINNERS, WINDOW
CLEANING SPRAYS, OR OTHER UNAPPROVED SOLVENTS
BECAUSE THEY WILL SOFTEN ACRYLIC PLASTIC AND CAUSE
CRAZ I N G .
o D 0 NOT WEAR RINGS OR OTHER HARD OBJECTS LIKELY T0
CAUSE SCRATCHES DURING CLEANING.

1. Apply cleaning agent (CM 721) with a sponge o r chamois and remove t h e
dirt.

2. Rinse windows thoroughly with c l e a r water and dry using e i t h e r damp

chamois, c l e a n c o t t o n f l a n e l l c l o t h , o r s o f t f a c i a l - t i s s u e s . Do not rub
t h e windows a f t e r they a r e dry.
3. Apply a f i l m of water r e p e l l e n t (CM 722) t o t h e clean, dry windows.
4. Grease, o i l , o r p a i n t can be removed from t h e windows by rubbing l i g h t l y
with a c o t t o n f l a n e l l c l o t h s a t u r a t e d with cleaning agent (CM 222).

5. Remove e l e c t r o s t a t i c charge and r e s u l t a n t dust p a r t i c l e s by dabbing t h e

window with damp chamois.

21 - 22 Removal - upper windshield

1. Remove f o l d i n g door. Refer t o paragraph 21-5.

2. Remove b a t t e r y access door.
3. Remove i n t e r i o r p a n e l l i n g a s necessary. Refer t o Chapter 703.
4. I f necessary, remove windshield wiper converter. Refer t o Chapter 800.

5. Remove any components i n t h e cockpit t h a t o b s t r u c t t h e removal of t h e

upper windshield (13, f i g u r e 21-10).

6. Remove door holder (16); keep s l e e v e (14) and washer (15) f o r - r e u s e a t

assembly .
7. I f i n s t a l l e d , remove f i t t i n g f o r r o t o r blade f o l d i n g system.

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8. Remove hinge b o l t (31) t o g e t h e r with washers (33 and 34) and nut (35) .
9 . Drill out b l i n d r i v e t s (38) .

1 0 . Detach bulb s e a l (32) a s necessary.

11. Remove screws (1) with washers ( 2 ) , screws (3) with washer ( 4 ) and n u t s
(5) , screws (11) with washers (10), and screws (22 and 37) .
12. Detach windshield r e t a i n e r s (28 and 36) from upper windshield ( 1 3 ) .

13. Separate t h e upper windshield (13) from t h e cabin s t r u c t u r e using a

suitable tool.

1 4 . I f necessary, remove f i l l e r s t r i p (39) and keep f o r reuse a t assembly.

21 - 23 Installation - upper windshield

1. Remove aging s e a l a n t from t h e cabin s t r u c t u r e , windshield r e t a i n e r s (28

and 36, f i g u r e 21-10), and packing s t r i p ( 4 3 ) . Clean bonding surfaces
with dry cleaning solvent (CM 202).

2. I n s t a l l new upper windshield (13) a s follows:

a. S t r i p off p r o t e c t i v e covering from around t h e edges of t h e windshield
(13) only a s f a r a s necessary f o r f i t t i n g and subsequent rework.
b. Mount t h e windshield s o t h a t it has an all-round clearance of not
more t h a n 8 mm t o t h e adjacent windshield panels.
C. With a 3-mm-diameter d r i l l , d r i l l s e c u r i n g screw holes i n t o
windshield using hole p a t t e r n i n cabin frame a s a guide and then
s i z e d r i l l hole diameters according t o f i g u r e 21-10.
d. Temporarily i n s t a l l upper windshield (13) with t h e windshield
r e t a i n e r s and s e v e r a l of t h e a t t a c h i n g screws.
e. Transfer o u t l i n e of door mounting s l e e v e s i n cabin s t r u c t u r e onto
windshield edging (12) and cut out accordingly.
f. Remove upper windshield (13) from cabin s t r u c t u r e and deburr screw
hole s .
g. I f removed, i n s t a l l f i l l e r s t r i p ( 3 9 ) .

h. P o s i t i o n upper windshield i n p l a c e and secure it with i t s screws and

r e t a i n e r s . Before i n s t a l l a t i o n , brush-coat r e t a i n e r s (28 and 36),
contact s u r f a c e s on t h e cabin s t r u c t u r e , and packing s t r i p (43) with
s e a l a n t (CM 636) ( r e f e r t o s e c t i o n s A-B and G-H), and brush-coat a l l
screw heads with s e a l a n t (CM 662).

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i. I n s t a l l f o l d i n g door ( r e f e r t o paragraph 21-7).

j. T r i m excess m a t e r i a l from windshield edging (12) so t h a t t h e r e i s

clearance of 1 t o 3 mrn between t h e cabin s t r u c t u r e and t h e f o l d i n g
door .
k. I n s t a l l f a i r i n g (6 o r 7 ) , according t o configuration, on windshield
edging (12) with screws. There must be no contact between f a i r i n g
and f o l d i n g door when t h e l a t t e r i s opened. I f t h e r e i s contact, l i n e
t h e mounting s i d e of t h e f a i r i n g with a l a y e r of g l a s s f a b r i c
s u f f i c i e n t t o eliminate c o n t a c t .
1. Remove f a i r i n g ( 6 o r 7) and brush-coat contact surface with adhesive
(CM 601). Secure f a i r i n g t o windshield edging with screws ( 9 ) and
washers ( 8 ) . Rernove excess adhesive.

m. I f necessary, determine bore diameter f o r windshield wiper converter

s h a f t and mark i t s l o c a t i o n on t h e windshield panel.

NOTE o The bore diameters f o r t h e s i n g l e and dual

windshield wiper c o n f i g u r a t i o n s a r e 26 mm
and 18 mm r e s p e c t i v e l y .
o Use a slow-running d r i l l i n g t o o l f o r d r i l l i n g
t h e holes. I n t e r r u p t d r i l l i n g repeatedly t o
prevent damage t o windshield by overheating.

n. D r i l l hole f o r windshield wiper converter s h a f t i n windshield using

hole c u t t e r of t h e appropriate s i z e .
o. D r i l l converter d r i v e s h a f t s e a l mounting holes (6.2 mm d i a ) i n t h e
windshield t o match hole p a t t e r n i n a s s o c i a t e d washer.

p. F i l l upper windshield ( 1 3 ) - t o - r e t a i n e r(28 and 36) j o i n t s and packing

s t r i p (43)-to-cabin s t r u c t u r e j o i n t s with s e a l a n t (CM 636).

q. F i n i s h rework area t o match o r i g i n a l p a i n t f i n i s h .

r. Clean bulb s e a l (32) w i t h acetone (CM 203) and remove a l l t r a c e s of
adhesive from i t s mounting s u r f a c e on t h e cabin s t r u c t u r e . Bond bulb
s e a l with adhesive (CM 605) .
s. I n s t a l l components removed from t h e cabin i n reverse order of t h e
sequence, s t e p s 1. t h r u 9., i n paragraph 21-22. Brush-coat door
holder (16) with s e a l a n t (CM 636) p r i o r t o i n s t a l l a t i o n .
t. Peel off windshield p r o t e c t i v e covering and clean windshield a s
described i n paragraph 21-21.

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21 - 24 Removal - lower windshield

1. Remove folding door ( r e f e r t o paragraph 21-5).

2. Remove battery access door.

3. Remove i n t e r i o r panelling as necessary ( r e f e r t o Chapter 703).

4. Remove any components i n the cockpit t h a t obstruct the removal of the
lower windshield (23, figure 21-10) .

5. Remove door holder (16) ; keep sleeve (14) and washer (15) f o r reuse a t
assembly .
6. I f i n s t a l l e d , remove f i t t i n g f o r main rotor blade folding system.
7. Remove hinge bolt (31) together w i t h washers (33 and 34) and nut ( 3 5 ) .
8. Detach bulb s e a l (32) as necessary.
9. Remove screws (19) w i t h washers ( 2 0 ) , screws (22), screws (24) with
washers (25) and nuts (26), and screws (30) .
1 0 . Detach r e t a i n e r s (28 and 29) from lower windshield.

11. Separate lower windshield (23) from cabin s t r u c t u r e using suitable t o o l .

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21 - 25 Installation - lower windshield

1. Remove o l d s e a l a n t from t h e cabin s t r u c t u r e and r e t a i n e r . Clean s e a l i n g
s u r f a c e s with dry cleaning solvent (CM 202).

2. I n s t a l l new lower windshield a s follows:

a. S t r i p off p r o t e c t i v e covering from around t h e edges of t h e lower

windshield only a s f a r a s necessary f o r f i t t i n g and subsequent
rework .
b. Mount t h e lower windshield (23, f i g u r e 21-10) s o t h a t t h e r e i s a
clearance of 2 mm between t h e windshield edging (27) and t h e f l o o r ,
and a clearance not exceeding 8 m between windshield and both t h e
l i n e r ( 4 1 ) and windshield ( 1 3 ) .
C. With a 3-mm-diameter d r i l l , d r i l l securing screw holes i n t o
windshield using hole p a t t e r n i n cabin frame a s a guide and then
d r i l l hole diameters according t o f i g u r e 21-10.
d. Temporarily i n s t a l l lower windshield (23) with t h e r e t a i n e r s (28 and
29) and s e v e r a l of t h e a t t a c h i n g screws.
e. Transfer o u t l i n e of door mounting s l e e v e s onto t h e windshield edging
(21) and c u t out accordingly.
f. Remove lower windshield (23) from cabin s t r u c t u r e and deburr holes.
g. P o s i t i o n lower windshield (23) i n place and secure t o cabin s t r u c t u r e
with t h e a p p r o p r i a t e screws and r e t a i n e r s . Before i n s t a l l a t i o n ,
brush-coat t h e r e t a i n e r s (28 and 29) and mating s u r f a c e s on t h e cabin
s t r u c t u r e with s e a l a n t (CM 636), and brush-coat a l l screw heads w i t h
s e a l a n t (CM 662).
h. I n s t a l l f o l d i n g door ( r e f e r t o paragraph 21-7).
i. T r i m excess m a t e r i a l from windshield edging (21) s o t h a t t h e r e i s a
clearance of 1 t o 3 mm between t h e cabin s t r u c t u r e and t h e cockpit
door .
j. F i l l lower windshield (23) t o r e t a i n e r (28 and 29) j o i n t s and
windshield edging (27 and 21) t o cabin s t r u c t u r e j o i n t s with
s e a l a n t (CM 636) .

k. F i n i s h rework a r e a t o match o r i g i n a l p a i n t f i n i s h .
1. Clean bulb s e a l (32) with acetone (CM 203) and remove r e s i d u a l
adhesive from t h e cabin s t r u c t u r e . Bond bulb s e a l with adhesive
(CM 605).

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m. R e i n s t a l l components removed from t h e cabin i n r e v e r s e order of t h e

sequence, s t e p s 1. t h r u 7 . , i n paragraph 21-24. Brush-coat door
holder (16) with s e a l a n t (CM 636) p r i o r t o i n s t a l l a t i o n .

n. S t r i p o f f rernainder of windshield p r o t e c t i v e covering and c l e a n

windshield a s described i n paragraph 21-21.

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Screw
Washer
Screw
Washer
Nut
Fairing
Fairing
Washer
Screw
Washer
Screw SECTlON C 'D
Windshield edging
Upper w i n d s h i e l d
si&e 23
Washer
Door h o l d e r SECTION A mB
Screw
Washer
Screw 40
Washer
Windshield edging
Screw
Lower w i n d s h i e l d
Screw
Washer
Nut
Windshield edging 43
Windshield r e t a i n e r
Windshield r e t a i n e r
Screw
Hinge b o l t
Bulb s e a l
Washer
39
Washer
Nut
Windshield r e t a i n e r
Screw
Blind r i v e t
SECTlON G 'H
Filler strip
S e a l a n t (CM- 6 3 6 )
Liner
S e a l a n t (CM 662)
Packing s t r i p
U-profile (cabin s t r u c t u r e )

/\ I n s t a l l e d d e p e n d i n g on c o n f i g u r a t i o n
. .

DETAIL A 30 29 24 25 26 23 22 27 21 20 19 18 17

Figure 21-10 Upper/lower windshield - removal and i n s t a l l a t i o n

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21 - 26 Removal - cabin roof window

1. Remove i n t e r i o r p a n e l l i n g a s necessary, r e f e r t o Chapter 703.

2. Remove any components o b s t r u c t i n g removal of t h e window.

3. I f necessary, remove OAT thermometer (5, f i g u r e 21-11).

4. Remove screws (11), washers ( 4 ) , and n u t s (3) .

5. Separate window from cabin roof using a s u i t a b l e t o o l .

21 - 27 Installation - cabin roof window

1. Remove o l d s e a l a n t from cabin roof and clean bonding surfaces with dry
cleaning solvent (CM 202) .
2. I n s t a l l new window a s follows:

a. S t r i p off window p r o t e c t i v e covering from t h e edges of t h e window

only a s f a r a s required f o r d i t t i n g and subsequent rework.
b. Mount window i n cabin roof so t h a t t h e r e i s an all-round clearance of
2 mm between t h e window and cabin r o o f .

C. Transfer hole P a t t e r n from t h e o l d window t o t h e new window.

d. Remove window and d r i l l t h e securing screw holes a t t h e marked

l o c a t i o n s using a 4.3-mm-diameter d r i l l .
e. Apply s e a l a n t (CM 636) t o window mounting s t r u c t u r e .
f. Brush-coat heads of screws (11, f i g u r e 21-11) with s e a l a n t (CM 662).
P o s i t i o n window on t h e supporting frame from within t h e cabin. Align
screw holes of window and frame, and secure w i t h washers ( 4 ) and
nuts ( 3 ) .
g. Apply a bead of s e a l a n t (CM 636) around t h e edge of t h e window a t
i n t e r s e c t i o n with t h e cabin roof and t h e upper windshield edging
(12) . Smooth out s e a l a n t .
h. F i n i s h rework a r e a t o match o r i g i n a l p a i n t f i n i s h .
i . R e i n s t a l l components removed from t h e cabin i n reverse order of t h e
sequence, s t e p s 1. t h r u 3 . , i n paragraph 21-26.

j. S t r i p o f f remainder of window p r o t e c t i v e covering and clean window a s

described i n paragraph 21-21.

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Cabin roof
Left window
Nut
Washer
OAT thermometer
Washer
Right window
Rubber washer
Washer
Shield
Screw
Upper windshield edging

Figure 21-11 Cabin roof windows - removal and i n s t a l l a t i o n

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21 - 28 Removal - f o l d i n g door window

1. Remove f o l d i n g door, r e f e r t o paragraph 21-5.

2. Remove f o l d i n g door window:

a. Window ( a t t a c h e d with screws)
1) Remove a t t a c h i n g screws (5, f i g u r e 21-13) with washers ( 4 and 6)
and nuts ( 7 ) , and remove window (3) from f o l d i n g door.

2) Remove double-backed adhesive t a p e from f o l d i n g door, and clean

bonding surface with acetone (CM 203) .
b. Window (bonded with cement)

1) Cut out t h e damaged window within t h e o p t i c a l a r e a using a

compass saw, leaving a narrow edging of approx. 5 mm wide.
2) Mask t h e a r e a s of t h e f o l d i n g door ( 4 , f i g . 21-12) adjacent t o
t h e window with t h i n wooden s t r i p s (5) t o provide a heat s h i e l d .
3) Cut a s l i t i n t o t h e r e s i d u a l edging (2) a t any p o i n t .

CAUT ION WHEN HEATING THE RESIDUAL WINDOW EDGING, TAKE

CARE NOT T 0 DAMAGE THE ADJACENT LAMINATE (HEAT-
RESISTANT T 0 W . 80 'C) .
4) Using a handblower ( I ) , heat t h e window edging a t t h e s l i t u n t i l
it begins t o soften, then g r i p t h e window edging with a p a i r of
p l i e r s and c a r e f u l l y p e e l it off ( s e e f i g . 21-12). By a l t e r n a t e l y
heating and peeling, it i s p o s s i b l e t o remove t h e e n t i r e edging
i n a s i n g l e operation.
5) Remove o l d adhesive with acetone (CM 203).

21 - 29 Installation - f o l d i n g door window

1. S t r i p o f f p r o t e c t i v e covering from t h e edges of window (3, f i g u r e 21-13)
a s required t o i n s t a l l t h e window.
2. P o s i t i o n new window i n f o l d i n g door (1). If required, t r i m window edges
s o t h a t t h e r e i s an all-round clearance of 1 t o 3 mm.
3. P o s i t i o n window (3) i n place, and b a c k - d r i l l screw holes (3.0 - 3.4 mm
d i a . ) using holes i n f o l d i n g door a s a guide.
4. Remove window (3) and deburr holes.

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1 - Handblower
2 Residual edging
of window
3 Pliers
4 Folding door
5 Wooden s t r i p

Figure 21-12 Peeling o f f r e s i d u a l window edging

5. Degrease bonding surfaces on f o l d i n g door with acetone (CM 203).

6. Roughen window faying s u r f a c e s with s t e e l wo01 and c l e a n with dry

cleaning solvent (CM 202) .
7. I n s t a l l double-backed adhesive t a p e ( 2 ) on f o l d i n g door, p r e s s down
l i g h t l y , and pul1 away t h e t a p e backing.

8. P o s i t i o n window (3) i n f o l d i n g door, p r e s s i n g it l i g h t l y a g a i n s t t h e

f o l d i n g door, and secure with screws ( 5 ) , washers ( 4 and 6 ) , and n u t s
( 7 ) . Torque opposite screws a l t e r n a t e l y , working round t h e window s e v e r a l
times.
9. Using dry cleaning solvent (CM 202), clean window edging and f o l d i n g door
where p a i n t i s required ( r e f e r t o f i g u r e 21-13).
10. Apply a coat of primer (CM 423) t o window edging and f o l d i n g door, and
restore original paint finish.
11. Remove remainder of p r o t e c t i v e covering from t h e window, and c l e a n window
according t o paragraph 21-21.
12. I n s t a l l f o l d i n g door, r e f e r t o paragraph 21-7.

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1 Folding door
2 Double-backed adhesive tape
3 Window
/i\ Clearance between edge of 4 Washer
window panel and folding door 5 Screw
s h a l l be 1-3 mm a l l round 6 Washer
7 Nut

Figure 21-13 Removal and i n s t a l l a t i o n - ~ 6 l d i ndoor

~ window,
attached w i t h screws

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21 - 30 Removal and'installation - sliding door window

The procedures for removing and installing the sliding door windows are
similar to those for the folding door windows and will not be described
separately here.
Remove and install the sliding door window in accordance with paragraphs
21-28 and 21-29. Refer to paragraphs 21-9 and 21-11 for procedural steps
to remove and install the sliding door.

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