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MD Helicopters, Inc.

MAINTENANCE MANUAL

MD HELICOPTERS, INC.

CSPCOM5
COMPONENT OVERHAUL MANUAL

FOR

MDHI 369D/E/FF 500/600N HELICOPTERS


ISSUED: 17 AUGUST 1991

NOTE
This manual has been reprinted and now contains
Revisions 1 through 17 (28 July 2007),
Temporary Revision TR07001 (14 November 2007),
Temporary Revision TR08001 (2 October 2008),
Temporary Revision TR09001 (25 March 2009) and
Temporary Revision TR09002 (24 August 2009)
This Page Intentionally Left Blank
MDHI MODEL HELICOPTERS
MODELS 369D/E/FF 500/600N
CSPCOM5
COMPONENT OVERHAUL MANUAL

MD Helicopters, Inc.
4555 East McDowell Road
Mesa, Arizona 852159734

Issued: August 17, 1991


Copyright E 19992007 by MD Helicopters, Inc.
All rights reserved under the copyright laws. Revision No. 17: July 28, 2007
PROPRIETARY RIGHTS NOTICE
The technical data and information contained in this publication is the property of
and proprietary to MD Helicopters, Inc. and is not to be disclosed or reproduced in
whole or in part without the written consent of MD Helicopters, Inc.

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 customers 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 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 85215-9734
Telephone: (800) 310-8539
Technical Publications Order Desk: (480) 346-6372; FAX: (480) 346-6821
Technical Publications Changes: (480) 346-6212; FAX: (480) 346-6809

Date:
Originator:

Address:

E- Mail:
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:

Page CRi
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Page CRii
MD HELICOPTERS INC.

RECORD OF TEMPORARY REVISIONS

MANUAL TITLE: CSPCOM5 COMPONENT OVERHAUL MANUAL

REV. DATE REMOVED BY REV. DATE REMOVED BY


NO. INSERTED BY INCORPORATING NO. INSERTED BY INCORPORATING
93001
93002
93003 Revision 2
93004
93005
94001
94002
Revision 3
94003
97001
98001 Revision 9
99001
Revision 10
99002
00001 15 Dec 00
Revision 12
01001 29 Jan 01
01002 15 Oct 01
02001 28 Jan 02 Revision 13
02002 19 Mar 02
03001 26 Mar 03
Revision 14
03002 12 Sept 03
04001 12 Aug 04 Revision 15
07001 14 Nov 07
08001 02 Oct 08 T.O.
09001 25 Mar 09 T.O.
09002 24 Aug 09 G.H.

Page 1
TR TR09002
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Page 2
Revision 16 TR
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL

LIST OF EFFECTIVE PAGES


INSERT LATEST CHANGE PAGES, DESTROY SUPERSEDED PAGES
The highest revision number indicates pages changed, added or removed by the current change.
Date of original and revision pages are:
Original . . . . . . . . . . . . . . . . . . . . . 17 August 1991 Revision 9 . . . . . . . . . . . . . . . . . 5 November 1998
Revision 1 . . . . . . . . . . . . . . . . . . . 14 August 1992 Revision 10 . . . . . . . . . . . . . . . 30 September 1999
Revision 2 . . . . . . . . . . . . . . . . . . . . . . 19 April 1994 Revision 11 . . . . . . . . . . . . . . . 13 November 2000
Revision 3 . . . . . . . . . . . . . . . . . . . . . . 29 July 1997 Revision 12 . . . . . . . . . . . . . . . . . . . . . 23 July 2001
Revision 4 . . . . . . . . . . . . . . . . . . . 29 August 1997 Revision 13 . . . . . . . . . . . . . . . 17 December 2002
Revision 5 . . . . . . . . . . . . . . . . 24 November 1997 Revision 14 . . . . . . . . . . . . . . . . . . . . . 28 July 2004
Revision 6 . . . . . . . . . . . . . . . . . . . 9 February 1998 Revision 15 . . . . . . . . . . . . . . . . . . . . . 24 Aug 2005
Revision 7 . . . . . . . . . . . . . . . . . . . . . . 4 June 1998 Revision 16 . . . . . . . . . . . . . . . . . . . . . 10 April 2007
Revision 8 . . . . . . . . . . . . . . . . . . . . . . . 9 July 1998 Revision 17 . . . . . . . . . . . . . . . . . . . . . 28 July 2007

Cover/Title 715/(716 blank) . . . . . . . . . . . . . . . . . . Revision 12


Cover/Title . . . . . . . . . . . . . . . . . . . . . . Revision 17 901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
Change Request 902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
CRi and CRii . . . . . . . . . . . . . . . . . . . . . . . No Date 903 and 904 . . . . . . . . . . . . . . . . . . . . . . Revision 5
1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
Temporary Revision
1002 thru 1006 . . . . . . . . . . . . . . . . . . . Revision 15
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16
321015
List of Effective Pages
a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
A thru F . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
Table of Contents 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13 301 and 302 . . . . . . . . . . . . . . . . . . . . . . Revision 4
010000 401 and 402 . . . . . . . . . . . . . . . . . . . . . . Revision 4
a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 11 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
i/(ii blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 11 502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
1 ............................... Revision 11 601 and 602 . . . . . . . . . . . . . . . . . . . . . . Revision 4
2 ............................... Revision 12 701 thru 709 . . . . . . . . . . . . . . . . . . . . . . Revision 4
321010 710 thru 713/(714 blank) . . . . . . . . . . . Revision 5
a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . . Revision 4 901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 903/(904 blank) . . . . . . . . . . . . . . . . . . . Revision 5
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4 1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 1002 and 1003 . . . . . . . . . . . . . . . . . . . Revision 15
301 thru 303/(304 blank) . . . . . . . . . . . Revision 4 1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
401/(402 blank) . . . . . . . . . . . . . . . . . . . Revision 4 623010
501 and 502 . . . . . . . . . . . . . . . . . . . . . . Revision 4 a and b . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
503/(504 blank) . . . . . . . . . . . . . . . . . . Revision 11 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
601 and 602 . . . . . . . . . . . . . . . . . . . . . . Revision 4 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
701 thru 708 . . . . . . . . . . . . . . . . . . . . . . Revision 4 3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
709 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 5 301 thru 303/(304 blank) . . . . . . . . . . . Revision 3
710 thru 713 . . . . . . . . . . . . . . . . . . . . . . Revision 4 401 and 402 . . . . . . . . . . . . . . . . . . . . . . Revision 3
714 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 5 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3

Page A
LOEP Revision 17
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL

502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3


503 and 504 . . . . . . . . . . . . . . . . . . . . . Revision 12 602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
601 and 602 . . . . . . . . . . . . . . . . . . . . . . Revision 3 603/(604 blank) . . . . . . . . . . . . . . . . . . . Revision 3
701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 7 701 and 702 . . . . . . . . . . . . . . . . . . . . . . Revision 3
702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 703/(704 blank) . . . . . . . . . . . . . . . . . . . Revision 5
703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3 901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
704 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 902 and 903/(904 blank) . . . . . . . . . . Revision 12
705/(706 blank) . . . . . . . . . . . . . . . . . . . Revision 5 1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3 1002 and 1003 . . . . . . . . . . . . . . . . . . . Revision 16
902 thru 904 . . . . . . . . . . . . . . . . . . . . . Revision 16 1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 631015
1002 thru 1004 . . . . . . . . . . . . . . . . . . . Revision 15 a and b . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
623060 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
a and b . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 2 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 301 and 302 . . . . . . . . . . . . . . . . . . . . . Revision 13
2 and 3/(4 blank) . . . . . . . . . . . . . . . . . . Revision 3 401/(402 blank) . . . . . . . . . . . . . . . . . . . Revision 6
301 and 302 . . . . . . . . . . . . . . . . . . . . . . Revision 3 501 thru 510 . . . . . . . . . . . . . . . . . . . . . Revision 13
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 6
401 and 402 . . . . . . . . . . . . . . . . . . . . . . Revision 3
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3
701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 6
502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
702 thru 704 . . . . . . . . . . . . . . . . . . . . . Revision 14
503 and 504 . . . . . . . . . . . . . . . . . . . . . Revision 12
901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
601 and 602 . . . . . . . . . . . . . . . . . . . . . . Revision 3
902 and 903/(904 blank) . . . . . . . . . . Revision 12
701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3
1001 thru 1003 . . . . . . . . . . . . . . . . . . . Revision 13
702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
632000
704 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 5
a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3
i thru vi . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
903/(904 blank) . . . . . . . . . . . . . . . . . . . Revision 5
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17
1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
3 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3
1002 and 1003 . . . . . . . . . . . . . . . . . . . Revision 15
7 and 8 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17
1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
9 thru 12 . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
631010 301 thru 306 . . . . . . . . . . . . . . . . . . . . . Revision 17
a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 11 401 and 402 . . . . . . . . . . . . . . . . . . . . . Revision 13
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 403/(404 blank) . . . . . . . . . . . . . . . . . . . Revision 3
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 501 thru 522 . . . . . . . . . . . . . . . . . . . . . Revision 17
2 and 3/(4 blank) . . . . . . . . . . . . . . . . . . Revision 3 601 and 602 . . . . . . . . . . . . . . . . . . . . . . Revision 3
301 and 302 . . . . . . . . . . . . . . . . . . . . . . Revision 3 603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10
401/(402 blank) . . . . . . . . . . . . . . . . . . . Revision 3 604 thru 607 . . . . . . . . . . . . . . . . . . . . . . Revision 3
501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 8 608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 6
502 thru 504 . . . . . . . . . . . . . . . . . . . . . . Revision 3 609 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3
505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11 610 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 5
506 thru 509 . . . . . . . . . . . . . . . . . . . . . . Revision 3 611 and 612 . . . . . . . . . . . . . . . . . . . . . . Revision 3
510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12 701 thru 707 . . . . . . . . . . . . . . . . . . . . . . Revision 3
511/(512 blank) . . . . . . . . . . . . . . . . . . . Revision 3 708 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13

Page B
Revision 17 LOEP
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL

709 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3 501 thru 504 . . . . . . . . . . . . . . . . . . . . . Revision 13


710 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12 601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 13
711 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3 701 thru 706 . . . . . . . . . . . . . . . . . . . . . Revision 13
712 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10 901 and 902 . . . . . . . . . . . . . . . . . . . . . Revision 13
713 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3 1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
714 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10 1002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
715 and 716 . . . . . . . . . . . . . . . . . . . . . . Revision 3 1003 and 1004 . . . . . . . . . . . . . . . . . . . Revision 13
717 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12 632025
718 thru 722 . . . . . . . . . . . . . . . . . . . . . Revision 17 a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 12
901 thru 904 . . . . . . . . . . . . . . . . . . . . . . Revision 3 i thru vi . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17
905 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 9
907 and 908 . . . . . . . . . . . . . . . . . . . . . . Revision 3 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 5 thru 9/(10 blank) . . . . . . . . . . . . . . . . . Revision 9
1002 thru 1004 . . . . . . . . . . . . . . . . . . . Revision 15 11 thru 16 . . . . . . . . . . . . . . . . . . . . . . . . Revision 9
1005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
1006 thru 1008 . . . . . . . . . . . . . . . . . . . Revision 15 18 thru 20 . . . . . . . . . . . . . . . . . . . . . . . . Revision 9
1009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 21 and 22 . . . . . . . . . . . . . . . . . . . . . . . Revision 14
1010 thru 1012 . . . . . . . . . . . . . . . . . . . Revision 15 23 thru 25/(26 blank) . . . . . . . . . . . . . . . Revision 9
1013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 301 thru 306 . . . . . . . . . . . . . . . . . . . . . Revision 17
1014 and 1015 . . . . . . . . . . . . . . . . . . . Revision 15 401 thru 405/(406 blank) . . . . . . . . . . Revision 11
1016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16 501 thru 524 . . . . . . . . . . . . . . . . . . . . . Revision 17
1017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 601 thru 603 . . . . . . . . . . . . . . . . . . . . . Revision 11
1018 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17 604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
632001
702 thru 705 . . . . . . . . . . . . . . . . . . . . . Revision 11
a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
706 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
707 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
708 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
709 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
301/(302 blank) . . . . . . . . . . . . . . . . . . . Revision 4
710 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
401/(402 blank) . . . . . . . . . . . . . . . . . . . Revision 4
711 thru 715 . . . . . . . . . . . . . . . . . . . . . Revision 11
501 and 502 . . . . . . . . . . . . . . . . . . . . . . Revision 4
716 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
601/(602 blank) . . . . . . . . . . . . . . . . . . . Revision 4
717 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
718 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16
702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 5 719 thru 729 . . . . . . . . . . . . . . . . . . . . . Revision 11
901/(902 blank) . . . . . . . . . . . . . . . . . . . Revision 5 730 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 731 and 732 . . . . . . . . . . . . . . . . . . . . . Revision 11
1002 and 1003 . . . . . . . . . . . . . . . . . . . Revision 15 733 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 734 and 735/(736 blank) . . . . . . . . . . Revision 11
632002 901 thru 905/(906 blank) . . . . . . . . . . Revision 12
a and b . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13 1001 and 1002 . . . . . . . . . . . . . . . . . . . Revision 11
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13 1003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13 1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
301 and 302 . . . . . . . . . . . . . . . . . . . . . Revision 13 1005 thru 1007 . . . . . . . . . . . . . . . . . . . Revision 14
401 and 402 . . . . . . . . . . . . . . . . . . . . . Revision 13 1008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16

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1009 and 1010 . . . . . . . . . . . . . . . . . . . Revision 14 1002 thru 1005 . . . . . . . . . . . . . . . . . . . Revision 15


632026 1006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 12 632520
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12 a and b . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
1/(2 blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 11 i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17
301/(302 blank) . . . . . . . . . . . . . . . . . . Revision 11 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
401/(402 blank) . . . . . . . . . . . . . . . . . . Revision 11 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
501 and 502 . . . . . . . . . . . . . . . . . . . . . Revision 11 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 5
601/(602 blank) . . . . . . . . . . . . . . . . . . Revision 12 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 7
701 thru 704 . . . . . . . . . . . . . . . . . . . . . Revision 11 6 and 7/(8 blank) . . . . . . . . . . . . . . . . . . Revision 4
901 and 902 . . . . . . . . . . . . . . . . . . . . . Revision 13 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17
1001 and 1002 . . . . . . . . . . . . . . . . . . . Revision 11 302 and 303/(304 blank) . . . . . . . . . . . Revision 4
1003 and 1004 . . . . . . . . . . . . . . . . . . . Revision 14 401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 7
632027
501 thru 513/(514 blank) . . . . . . . . . . Revision 17
a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 11
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
602 and 603 . . . . . . . . . . . . . . . . . . . . . Revision 14
1/(2 blank) . . . . . . . . . . . . . . . . . . . . . . . Revision 11
604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
301/(302 blank) . . . . . . . . . . . . . . . . . . Revision 11
701 and 702 . . . . . . . . . . . . . . . . . . . . . . Revision 4
401/(402 blank) . . . . . . . . . . . . . . . . . . Revision 11
703 thru 713/(714 blank) . . . . . . . . . . Revision 17
501 and 502 . . . . . . . . . . . . . . . . . . . . . Revision 11
901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
601/(602 blank) . . . . . . . . . . . . . . . . . . Revision 11
902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
701 thru 704 . . . . . . . . . . . . . . . . . . . . . Revision 11
903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16
901 and 902 . . . . . . . . . . . . . . . . . . . . . Revision 13
904 and 905/(906 blank) . . . . . . . . . . . Revision 4
1001 thru 1003/(1004 blank) . . . . . . . Revision 11
1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
632510 1002 and 1003 . . . . . . . . . . . . . . . . . . . Revision 15
a and b . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 1004 and 1005 . . . . . . . . . . . . . . . . . . . Revision 16
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17 1006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 632530
2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4 a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . . Revision 8
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 5 i thru iii/(iv blank) . . . . . . . . . . . . . . . . . Revision 12
5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 7 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
6 and 7/(8 blank) . . . . . . . . . . . . . . . . . . Revision 4 2 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 8
301 thru 303/(304 blank) . . . . . . . . . . . Revision 4 301/(302 blank) . . . . . . . . . . . . . . . . . . . Revision 8
401 and 402 . . . . . . . . . . . . . . . . . . . . . . Revision 4 401 thru 403/(404 blank) . . . . . . . . . . . Revision 8
501 thru 514 . . . . . . . . . . . . . . . . . . . . . Revision 17 501 thru 504 . . . . . . . . . . . . . . . . . . . . . . Revision 8
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10 505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11
602 and 603 . . . . . . . . . . . . . . . . . . . . . . Revision 7 506 thru 509/(510 blank) . . . . . . . . . . . Revision 8
604 thru 608 . . . . . . . . . . . . . . . . . . . . . Revision 14 601 and 602 . . . . . . . . . . . . . . . . . . . . . . Revision 8
701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4 603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
702 thru 714 . . . . . . . . . . . . . . . . . . . . . Revision 17 604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 8
901 and 902 . . . . . . . . . . . . . . . . . . . . . . Revision 4 701 and 702 . . . . . . . . . . . . . . . . . . . . . Revision 12
903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12 703 and 704 . . . . . . . . . . . . . . . . . . . . . Revision 16
904 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10 705 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
905 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 5 706 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16
906 and 907/(908 blank) . . . . . . . . . . . Revision 4 707 thru 714 . . . . . . . . . . . . . . . . . . . . . Revision 12
1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16

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902 and 903 . . . . . . . . . . . . . . . . . . . . . Revision 10 701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4


904 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 8 702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10
1001 and 1002 . . . . . . . . . . . . . . . . . . . Revision 12 703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
1003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16 704 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 705 and 706 . . . . . . . . . . . . . . . . . . . . . Revision 13
1005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16 901 and 902 . . . . . . . . . . . . . . . . . . . . . Revision 12
1006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
642010 904 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16
a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . . Revision 4 1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 1002 thru 1008 . . . . . . . . . . . . . . . . . . . Revision 15
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 643000
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17 a and b . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
3 thru 5/(6 blank) . . . . . . . . . . . . . . . . . . Revision 3 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
301 thru 304 . . . . . . . . . . . . . . . . . . . . . . Revision 3 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
401/(402 blank) . . . . . . . . . . . . . . . . . . . Revision 3 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10
501 thru 505 . . . . . . . . . . . . . . . . . . . . . . Revision 3 301/(302 blank) . . . . . . . . . . . . . . . . . . . Revision 3
506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11 401/(402 blank) . . . . . . . . . . . . . . . . . . . Revision 3
507/(508 blank) . . . . . . . . . . . . . . . . . . . Revision 3 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16
601 thru 604 . . . . . . . . . . . . . . . . . . . . . Revision 16
502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3
503/(504 blank) . . . . . . . . . . . . . . . . . . . Revision 3
606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
601 and 602 . . . . . . . . . . . . . . . . . . . . . . Revision 3
607 and 608 . . . . . . . . . . . . . . . . . . . . . . Revision 3
701 and 702 . . . . . . . . . . . . . . . . . . . . . Revision 12
701 thru 703 . . . . . . . . . . . . . . . . . . . . . . Revision 3
703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3
704 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 10
704 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16
705 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3
706 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
707 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
903/(904 blank) . . . . . . . . . . . . . . . . . . . Revision 5
708 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3
1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
709/(710 blank) . . . . . . . . . . . . . . . . . . . Revision 5
901 and 902 . . . . . . . . . . . . . . . . . . . . . Revision 12 1002 and 1003 . . . . . . . . . . . . . . . . . . . Revision 16
903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13 1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
904 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16 671010
1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
1002 thru 1010 . . . . . . . . . . . . . . . . . . . Revision 15 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
642020 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
a/(b blank) . . . . . . . . . . . . . . . . . . . . . . . . Revision 4 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 301 and 302 . . . . . . . . . . . . . . . . . . . . . . Revision 4
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 401/(402 blank) . . . . . . . . . . . . . . . . . . . Revision 4
2 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 5
301 thru 304 . . . . . . . . . . . . . . . . . . . . . . Revision 4 502 thru 504 . . . . . . . . . . . . . . . . . . . . . . Revision 4
401/(402 blank) . . . . . . . . . . . . . . . . . . . Revision 4 601/(602 blank) . . . . . . . . . . . . . . . . . . . Revision 4
501 thru 504 . . . . . . . . . . . . . . . . . . . . . . Revision 4 701 thru 706 . . . . . . . . . . . . . . . . . . . . . . Revision 4
505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16 707/(708 blank) . . . . . . . . . . . . . . . . . . . Revision 5
506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11 901 and 902 . . . . . . . . . . . . . . . . . . . . . . Revision 5
507/(508 blank) . . . . . . . . . . . . . . . . . . . Revision 4 1001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
601 thru 603 . . . . . . . . . . . . . . . . . . . . . Revision 16 1002 and 1003 . . . . . . . . . . . . . . . . . . . Revision 16
604 thru 607/(608 blank) . . . . . . . . . . . Revision 4 1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14

Page E/(F blank)


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TABLE OF CONTENTS

Cover

Technical Manual Recommended Change Report

Record of Temporary Revisions

List of Effective Pages

01-00-00 . INTRODUCTION

32-10-10 . . LANDING GEAR DAMPER (369D26300 / 369D26301)

32-10-15 . . LANDING GEAR DAMPER (600N6050)

62-30-10 . . MAIN ROTOR SWASHPLATE (FIVE-BLADED) (369D27609)

62-30-60 . . MAIN ROTOR SWASHPLATE (SIX-BLADED) (600N7632)

63-10-10 . . OVERRUNNING CLUTCH (369A5350-603)

63-10-15 . . OVERRUNNING CLUTCH (369F5450)

63-20-00 . . MAIN TRANSMISSION (369D25100)

63-20-01 . . LUBRICATION PUMP (369D25167)

63-20-02 . SCAVENGE PUMP (369A5266)

63-20-25 . . MAIN TRANSMISSION (369F5100)

63-20-26 . . LUBRICATION PUMP (369F5135)

63-20-27 . . SCAVENGE PUMP (369F5136)

63-25-10 . . TAIL ROTOR TRANSMISSION (369D25400)

63-25-20 . . TAIL ROTOR TRANSMISSION (369D25300)

63-25-30 . FAN TRANSMISSION (500N5400)

64-20-10 . . TAIL ROTOR ASSEMBLY (TWO-BLADED) (369D21600)

64-20-20 . . TAIL ROTOR ASSEMBLY (FOUR-BLADED) (369D21610)

64-30-00 . . PITCH CONTROL ASSEMBLY (TWO AND FOUR-BLADED) (369D21800 / 369D21820)

67-10-10 . . ONE-W AY LOCK (369A7010)

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Section

01-00-00
Introduction

Page a/(b blank)


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TABLE OF CONTENTS
Para/Figure/Table Title Page

010000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Proprietary Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Use of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. ATA Numbering System and Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Division of Subject Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Page Number Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Figure and Table Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. MDHI Publications Changes and Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Reissue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Application of Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Service and Operations Report Form 853A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 1. ATA Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

010000 Page i/(ii blank)

Contents Revision 11
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL

INTRODUCTION
DESCRIPTION
1. Proprietary Rights three elements, which consist of two digits
each (Ref. Figure 1). The chapter and section
MD Helicopters, Inc. proprietary rights are elements (subassembly 10, 20, 30, etc.) are
included in the information disclosed herein. assigned by ATA100. Subject/Unit element
Recipient, by accepting this document, agrees numbers are assigned by MDHI.
that neither this document nor any part
thereof shall be reproduced or transferred to A. Division of Subject Matter
other documents or used or disclosed to others This Component Overhaul Manual is con
for manufacturing or any other purpose, tained in accordance with ATA Specification
except as specifically authorized in writing by 100, 112, Page 2.
MD Helicopters, Inc. All rights are reserved
under the copyright laws by MD Helicopters, B. Page Number Blocks
Inc.
Page number blocks used for each section in
2. Introduction the Component Overhaul Manual logically
arrange the material as follows:
This manual provides complete or specific
repair of the major helicopter components (1). Description and Operation . . . . . . . . . . 1
listed in the table of contents. (2). Disassembly . . . . . . . . . . . . . . . . . . . . 301
Procedures given are applicable to those (3). Cleaning/Painting . . . . . . . . . . . . . . . 401
components used on models 369D/E/FF
500/600N Series helicopters. All helicopters (4). Inspection/Check . . . . . . . . . . . . . . . . 501
described in this manual are manufactured by (5). Repair/Modification . . . . . . . . . . . . . 601
MD Helicopters, Inc. (MDHI), Mesa, Arizona.
(6). Reassembly/Shipping . . . . . . . . . . . . 701
A. Use of This Manual
(7). Special Tools, Fixtures &
This manual is only to be used for overhaul or Equipment . . . . . . . . . . . . . . . . . . . . . 901
repair of standard components of 369D/E/FF
(8). Illustrated Parts List . . . . . . . . . . . 1001
500/600N Series helicopters. For procedures
provides a parts list supplement to
applicable to optional equipment, refer to
identify part numbers and configura
appropriate Optional Equipment Supplement
tion differences for the main transmis
(CSP) for the specific equipment. Do not use
sion lubrication pump.
this manual for overhaul or repair of compo
nents used on any other model helicopter. C. Figure and Table Numbering
B. Organization Illustrations and tables use the same number
ing as the page block in which they appear.
Each section of this manual contains complete For example, Figure 302 would be the second
instructions for disassembly, cleaning, inspec figure in the Disassembly section. When
tion, repair, reassembly and testing of a referring to a figure or table within the same
specific component. section, it is referenced as follows; (Ref. Table
601).
3. ATA Numbering System and Format
4. Reference Data
This MDHI Component Overhaul Manual and
associated MDHI manuals are prepared in Reference is made throughout the Overhaul
general compliance with Air Transport Manual to the PFM, CSPHMI2 and
Association Specification for Manufacturers CSPHMI3. These manuals should be used
Technical Data (ATA100). The uniform as noted throughout the overhaul/repair. The
numbering system provides a means for Illustrated Parts Catalog (CSPIPC4) should
dividing material into Chapter, Section, be used for ordering any replacement parts
Subject and Page. The number is composed of required.

Page 1
010000 Revision 11
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL

5. MDHI Publications Changes and use of Notes, Cautions and Warnings


Revisions are defined by the following:
Changes in the helicopter, equipment, proce (2). A NOTE may appear in the text either
dures and additional information developed by before or after instructions to which it
experience affect manual content. To ensure applies, depending on the relative
that MDHI manuals continue to reflect significance of the information.
current changes, revised information is
provided by one or more of the following Operating procedures and
communications.
WARNING practices which, if not
strictly observed, may result in person
A. Revision al injury, or loss of life.
Alteration of portions of the manual by the Operating procedures and prac
replacement, addition and/or deletion of pages CAUTION tices which, if not strictly ob
is accomplished by revision. The List of served, may result in damage to or destruc
Effective pages (A page) that accompany each tion of equipment.
revision identifies all affected pages. Such
pages should be removed from the manual and NOTE: An operating procedure or condition
destroyed. Added or replaced pages should be that is essential to highlight.
inserted and checked against the A page.
7. Service and Operations Report Form
B. Reissue 853A
When large numbers of changes are involved, MDHI Service and Operations Report Form
the manual is reissued. The preceding issue of 1601 may be used to report to MD Helicopters,
the manual then becomes obsolete and should Inc. in detail, any service difficulties encoun
be discarded. tered with any MDHI helicopter.
6. Application of Notes, Cautions and (1). Use of the form is encouraged and
Warnings recommended to enable MDHI to
provide owners and operators improved
Throughout this manual, and associated service, support and product improve
MDHI manuals, Notes, Cautions and Warn ments.
ings are used to emphasize instructions or
information considered to be unusual or (2). The form also serves as a convenient
critical. detailed record for owners and opera
tors.
(1). CAUTION and WARNING state
ments are always placed before the (3). Copies of the form may be procured by
information or instructions to which contacting the Product Support Dept.
they apply. The conditions that warrant Technical Publications, Mesa, Arizona.
2ND ELEMENT
1ST ELEMENT 3RD ELEMENT

32 10 10

CHAPTER/SYSTEM LANDING SUBJECT/UNIT


GEAR SYSTEM SECTION/SUBASSEMBL Y LAND LANDING GEAR DAMPER
ING GEAR

Figure 1. ATA Numbering System

Page 2
Revision 12 010000
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL

Section

32-10-10
Landing Gear
Damper
Part Number
369D26300-BSC, -11, -21, -31, -41, -61, -71, -81, -91, -101,
-1 11, 121, -131, -141, -151, -161, 171, -181, -191, 201, -211,
-221, -231, -241, -251
369D26301-BSC, -11, -21, -31, -41, -61, -71, -81, -91, -101,
-1 11, 121, -131, -141, -151, -161, 171, -181, -191, 201, -211,
-221, -231, -241, -251

Page a/(b blank)


Revision 4
MD Helicopters, Inc. CSP-COM-5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
TABLE OF CONTENTS
Para/Figure/Table Title Page

321010 Landing Gear Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. Gas Pressure BleedOff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
A. Gas BleedOff Schrader Valve Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
B. Gas BleedOff (NonSchrader Valve Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 301. Use of Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3. Damper Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Cleaning/Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Paint, Torque Stripe and
Decal/Plate Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
A. Poppet and Poppet Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
B. Disassembled Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Table 501. Detailed Inspection Landing Gear Damper and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Table 502. Process Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Repair/Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Poppet and Poppet Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Piston Replating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
D. Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Upper and Lower Cap Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Schrader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
3. Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 601. Replating of Landing Gear Damper Piston . . . . . . . . . . . . . . . . . . . . . 602

321010 Page i
Contents Revision 15
CSP-COM-5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page

Assembly/Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
2. Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
Table 701. Fluid Level Below Piston Rod End Ambient Service Standard
Landing Gear Damper P/N 369D26300BSC, 61, 111, 161,
or 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Table 702. Fluid Level Below Piston Rod End Winterized Service Standard
Landing Gear Damper P/N 369D2630011, 21, 71, 81, 121,
131, 171, 181, 221 or 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Table 703. Fluid Level Below Piston Rod End MidTemp Service Standard
Landing Gear Damper P/N 369D2630031, 41, 91, 101, 141,
151, 191, 201, 241, or 251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
Table 704. Fluid Level Below Piston Rod End Ambient Service Extended
Landing Gear Damper P/N 369D26301BSC, 61, 111, 161
or 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
Table 705. Fluid Level Below Piston Rod End Winterized Service Extended
Landing Gear Damper P/N 369D26301011, 21, 71, 81, 121,
131, 171, 181 221, or 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
Table 706. Fluid Level Below Piston Rod End MidTemp Service Extended
Landing Gear Damper P/N 369D26301031, 41, 91, 101, 141,
151, 191, 201, 241, or 251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
Figure 701. Damper Assembly CrossSection View . . . . . . . . . . . . . . . . . . . . . . . 706
Figure 702. Damper Assembly Barrel Seal Installation . . . . . . . . . . . . . . . . . . . . 707
3. Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
A. NonSchrader Valve Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
B. Schrader Valve Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709
Figure 703. Servicing Schrader Valve Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
Table 707. Nitrogen Charge Ambient Service Standard Landing Gear Damper
P/N 369D26300BSC, 61, 111, 161 or 211 . . . . . . . . . . . . . . . . . . . 711
Table 708. Nitrogen Charge Winterized Service Standard Landing Gear Damper
P/N 369D2630011, 21, 71, 81, 121, 131, 171, 181, 221,
or 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
Table 709. Nitrogen Charge MidTemp Standard Landing Gear Damper
P/N 369D2630031, 41, 91, 101, 141, 151, 191, 201, 241
or 251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Table 710. Nitrogen Charge Ambient Service Extended Landing Gear Damper
P/N 369D26301BSC, 61, 111, 161, or 211 . . . . . . . . . . . . . . . . . . 712
Table 711. Nitrogen Charge Winterized Service Extended Landing Gear Damper
P/N 369D2630111, 21, 71, 81, 121, 131, 171, 181, 221
or 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
Table 712. Nitrogen Charge MidTemp Extended Landing Gear Damper
P/N 369D2630131, 41, 91, 101, 141, 151, 191, 201, 241
or 251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
4. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714

Page ii 321010
Revision 15 Contents
MD Helicopters, Inc. CSP-COM-5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page
5. Packing and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
6. Damper Application Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
Table 713. 369D26300 and 369D26301 Landing Gear Damper Application . . . 715
Special Tools, Fixtures & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
1. Damper Overhaul Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
2. Special Tool Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Table 901. Landing Gear Damper Assembly Overhaul Special Tools . . . . . . . 901
Table 902. Landing Gear Damper Assembly Special Torques . . . . . . . . . . . . . . . . 901
Table 903. Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 901. Special Tools Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Indenture Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Figure 1001. Damper Assembly 369D/E/FF/500N . . . . . . . . . . . . . . . . . . . . . . . . 1002

321010 Page iii


Contents Revision 15
CSP-COM-5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page

This Page Intentionally Left Blank

Page iv 321010
Revision 15 Contents
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
LANDING GEAR DAMPER
DESCRIPTION AND OPERATION
NOTE: Before attempting any repair or over replacement information and autho
haul of this component, ensure the required rized modifications for the landing gear
special tools and processes are available to damper.
assure completion of the work.
(6). Assembly/Shipping . . . . . . . . . . . . . . . 701
1. General provides landing gear damper reas
sembly, procedures for charging the
This section of the Overhaul Manual describes landing gear damper with dry nitrogen
overhaul procedures for the 369D26300 and gas and testing the damper for leaks,
369D26301 Series Landing Gear Dampers. and shipping instructions.
Procedures given are the approved methods to
be used for specific repair or complete overhaul (7). Special Tools, Fixtures
of the component. The procedures apply to all & Equipment . . . . . . . . . . . . . . . . . . . . 901
versions of the 369D26300 and 369D26301 provides procedures for fabricating
series landing gear dampers, except as noted. special tools required for overhaul of
the landing gear damper.
2. Organization
(8). Illustrated Parts List . . . . . . . . . . . . 1001
The landing gear damper section of the provides a parts list supplement to
Component Overhaul Manual is made up of identify part numbers and configura
seven parts, listed below. This section contains tion differences for the landing gear
complete instructions for disassembly, clean damper.
ing, inspection, repair, reassembly and testing
of the component. Page number blocks used for
this section in the Component Overhaul 3. Reference Data
Manual logically arrange the material as
follows: (1). Reference is made throughout this part
of the Overhaul Manual to CSP
(1). Description and Operation . . . . . . . . . . 1 HMI2. This manual should be used as
provides a description and operation of noted throughout the overhaul/repair.
the component and describes proce Use the Illustrated Parts Catalog
dures for complete use of the landing (CSPIPC4) when ordering any
gear damper section. replacement parts for 369D26300 and
369D26301 series damper assemblies.
(2). Disassembly . . . . . . . . . . . . . . . . . . . . . 301
gives procedures for complete disassem (2). Table 901 and Table 902 provide
bly of the landing gear damper specifications, and when appropriate,
procurement information, regarding
(3). Cleaning/Painting . . . . . . . . . . . . . . . . 401 special tools and equipment, and
contains cleaning and painting require expendable items and materials
ments for landing gear damper compo required for overhaul/repair. Torque
nents and parts. values are contained in Table 903.

(4). Inspection/Check . . . . . . . . . . . . . . . . . 501 (3). Figure 1 shows an exploded view of a


provides visual and dimensional landing gear damper, with all parts
inspection requirements. indexed. The index numbers are used
throughout the text with the part
(5). Repair/Modification . . . . . . . . . . . . . . 601 nomenclature to make part identifica
provides allowable repairs and parts tion easier.

Page 1
321010 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301

2
1 33
(NOTE 3)

34
(NOTE 3)

36 *
(NOTE 3)
35 3
(NOTE 3) 4* 15 *
32 *
(NOTE 3) 5* 16 *

17
15 *
18

19 *
13 *

8
20 *
14 *

21
6

28 *
(NOTE 1)
29

11 * 7
30
12
31
26

10
(NOTE 1)
27

25
9

24
23
22

NOTES:
1. DRAIN HOLE.
2. ASTERISK (*) INDICATES ITEM IS PART OF OVERHAUL KIT.
3. SCHRADER VALVE DAMPER ONLY. H321004

Figure 1. Damper Assembly

Page 2
Revision 4 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Legend (Ref. Figure 1)
1. UPPER CAP ASSEMBLY 19. *SCRAPER RING
2. UPPER CAP BEARING 20. *SEAL
3. PLUG 21. BARREL
4. *PACKING 22. MAIN POPPET RETAINING RING
5. *PACKING 23. RETAINER
6. LOWER CAP ASSEMBLY 24. SPRING
7. LOWER CAP BEARING 25. MAIN POPPET
8. PISTON 26. REBOUND POPPET RETAINING RING
9. SPRING 27. REBOUND POPPET
10. HOUSING 28. *SERVICE DECAL
11. *PACKING 29. SERIAL NUMBER PLATE
12. BAFFLE 30. WARNING PLATE
13. *LOWER BACKUP RING 31. CAUTION DECAL
14. *PACKING 32. *SIGHT GLASS (SCHRADER VALVE DAMPER)
15. *UPPER BACKUP RING 33. SCHRADER VALVE UPPER CAP ASSY
16. *PACKING 34. *PLUG (SCHRADER VALVE DAMPER)
17. RETAINER RING 35. SCHRADER VALVE
18. WASHER 36. *O-RING
*Parts requiring replacement during overhaul, for most current M50032 overhaul kit, (Ref.
Illustrated Parts List).

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COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301

This Page Intentionally Left Blank

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Revision 15 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
LANDING GEAR DAMPER
DISASSEMBLY
1. General (6). Remove sight glass (32) from upper
barrel (21).
This section describes procedures for complete
disassembly of the landing gear damper. When (7). Remove seal (5) from upper piston (8).
specific repair of the damper requires only
partial disassembly, follow procedures to the B. Gas Bleed-Off (Non-Schrader Valve
point required. Damper)

A charged landing gear (1). For standard landing gear damper,


WARNING damper is under high gas place damper in cylinder holding block
pressure and must be treated cautious (6, Table 901) as shown in. Place block
ly or personal injury may result. Before in vise with damper in vertical position,
beginning disassembly, read entire gas upper cap assembly (1, Figure 1)
bleedoff procedures and then bleed off upward.
gas from landing gear damper.
NOTE: Gas may escape from damper when up
2. Gas Pressure Bleed-Off per cap assembly is loosened if plug packing
(4) is damaged.
Bleedoff gas pressure from schrader and
nonschrader valve landing gear dampers prior (2). Engage wrench flats on piston (8) with
to disassembly, as follows: piston wrench (6, Table 901). Place
wrench adapter (4) on upper cap
Wear face shield or safety assembly (1, Figure 1) and slowly
WARNING eyeglasses. Read the follow unscrew and remove cap assembly,
ing instructions thoroughly before be while holding piston. Do not remove
ginning bleed off procedure. Do not packing (5) from piston at this time.
deviate from procedures given.
(3). Thread charging tool (3, Table 901) onto
A. Gas Bleed-Off - Schrader Valve Damper exposed piston threads and tighten
securely.
(1). Place damper in cylinder holding block
(5, Table 901) as shown in Figure 301. (4). Install short length of hose between
Place block in vise with damper in charging tool gas port and waste
vertical position, upper cap assembly (1, container for hydraulic fluid. Secure
Figure 1) up. end of hose to waste container to
prevent whipping when gas pressure is
(2). Install a piece of tygon tubing over released.
schrader valve gas outlet and other end
into a suitable waste container, to allow (5). Press down and rotate Thandle of
overflow of damper fluid when valve is charging tool until slot in head of plug
opened. (3, Figure 1) is engaged.

(3). Carefully open valve, allowing gas (6). Slowly loosen plug (3) until damper gas
pressure to bleedoff slowly. pressure begins to escape through drain
hose. Do not loosen plug too quickly;
(4). Remove schrader valve (35) from upper escaping gas can cause hose to whip.
cap (33) and discard Oring (36).
(7). After all gas is discharged, remove
(5). Remove upper cap assembly (33, charging tool and drain hose; remove
Figure 1) using torque wrench adapter damper from vise and cylinder holding
(4, Table 901) and wrench (6). block.

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321010 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301

WRENCH ADAPTER

CHARGING TOOL

(GAS PORT)

CYLINDER
HOLDING
BLOCK

CYLINDER
HOLDING
BLOCK

PISTON WRENCH

HOUSING
SPANNER WRENCH

H321006

Figure 301. Use of Special Tools

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Revision 4 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
3. Damper Disassembly (6). Using housing spanner wrench (4,
Table 901) and piston wrench (6),
Disassemble the landing gear damper as loosen and unthread housing (10,
follows: Figure 1) and its attached parts from
Ensure all gas pressure in piston.
WARNING damper has been bled off
Do not remove poppets and re
prior to disassembly, according to (Ref. CAUTION lated parts (22 through 27) at
Gas Pressure BleedOff). this time. Poppets must be removed one at a
NOTE: During disassembly, place all parts in a time during inspection procedure.
clean container to prevent damage from im (7). Remove packing (11) and baffle (12)
proper handling or exposure. Wrap piston, from housing.
barrel, housing and cap assemblies in pro
tective cloth to prevent damage. Discard all (8). Remove two backup rings (15) and
packings, oil seals and backup rings at re packing (16) from housing grooves.
moval.
(9). Remove backup ring (13) and packing
(1). Remove damper from vise and cylinder (14) from lower cap assembly grooves,
holding block. and packing (5) from piston (8).
(2). Unthread plug (3, or 34 Figure 1) and (10). Remove retaining ring (17), washer (18)
packing (4); drain hydraulic fluid into and scraper ring (19) from barrel (21).
waste container by inverting damper.
(11). Remove seal (20) from groove inside
(3). Install damper in cylinder holding block mouth of barrel (21).
(5, Table 901); clamp block in vise with
open end of piston down. NOTE: Poppets and related parts (22 through
27) are to be removed at inspection (Ref. In
(4). Using wrench adapter (4), loosen and spection/Check). Bearings (2 and 7) and de
remove lower cap assembly (6, Figure 1) cals (28 through 31) should not be removed
from barrel (21). Remove damper from or detached unless replacement is neces
vise and cylinder holding block; invert sary.
damper over waste container to drain
oil. (12). Discard seal (20), scraper ring (19),
Oring back up rings (13, 15) and
(5). With damper still over waste container, Orings (4, 11, 14, 5, and 1).
carefully push piston (8) and attached
parts out of barrel (21); do not allow (13). Clean and inspect parts which may be
rebound spring (9) to drop. reused (Ref. Cleaning and Inspection).

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321010 Revision 4
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
LANDING GEAR DAMPER
CLEANING/PAINTING
1. Cleaning 3. Markings
Clean all parts of the disassembled landing Install new service decal, warning plate or
gear damper as follows: caution decal, when necessary, as follows:
Most cleaning solvents are (1). Clean mounting surface with solvent (4,
WARNING flammable and must be kept Table 903), or equivalent.
away from heat or open flame. Avoid
inhalation of fumes and extended con (2). Place replacement decal/plate at
tact with skin. approximate location shown in
Figure 401.
(1). Clean upper cap assembly (1 or 33
Figure 1), schrader valve (34) and lower (3). Press decal/plate firmly to mounting
cap assembly (6) using cloth dampened surface.
with solvent (4, Table 903) or naphtha
(4). Seal edges of decal/plate with fillet of
(5). If bearings are installed in caps, do
plastic epoxy adhesive (10, Table 903).
not submerge caps in solvent.
(2). Submerge remaining parts in solvent NOTE 2 TORQUE STRIPE
(4) or naphtha (5). (NOTE 1)

(3). Using bristle brush, remove clinging


residue from parts. Pay particular
attention to packing grooves and
PISTON
threaded areas.
0.370.62 INCH
(4). Dry parts with clean cloth or com (9.415.7 MM)
pressed air.
(5). Wrap cleaned parts to prevent contami
BARREL
nation between work operations. SERVICE
DECAL

2. Painting SERIAL
NUMBER CAUTION
Touch up or repaint damper assembly, as PLATE DECAL
necessary. Repaint damper original color to
maintain distinction between standard (white) WARNING
and extended (black) landing gear dampers. PLATE

Keep upper and lower cap bear


CAUTION ings clean and free of paint.
0.370.62 INCH
(1). Prepare surface for painting (Ref. (9.415.7 MM)
CSPHMI2).
TORQUE STRIPE
(2). Paint standard landing gear dampers NOTE 2 (NOTE 1)
white (11, Table 903) and extended
landing gear dampers black (12) (Ref. NOTES:
1. TORQUE STRIPES PAINTED CONTRASTING BLACK
CSPHMI2).
OR WHITE, AS APPLICABLE.
2. BEARINGS NOT TO BE PAINTED. H32.1010A
(3). Paint torque stripe on damper caps,
piston and barrel, Figure 401, using Figure 401. Paint, Torque Stripe and
contrasting white or black lacquer. Decal/Plate Requirements

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321010 Revision 4
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
LANDING GEAR DAMPER
INSPECTION/CHECK
1. Inspection Do not remove both rebound
CAUTION poppets at the same time. Rein
Inspect landing gear damper parts after stall one before removing the other.
cleaning as described in the following proce
dures. (3). Remove one retaining ring (26) and
rebound poppet (27).
A. Poppet and Poppet Seats
Inspect main poppet (25, Figure 1), rebound (4). Inspect poppet and housing seating
poppets (27), and poppet seats in housing (10) surfaces; full uninterrupted 360 degree
as follows: seat should be evident on each part. If
seat surfaces are satisfactory, reinstall
(1). Remove main poppet retaining ring rebound poppet (27) and retaining ring
(22), retainer (23), spring (24) and main (26) in housing seat. If seat surfaces are
poppet (25) from housing (10). not satisfactory, reseat poppet (Ref.
Repair).
(2). Inspect main poppet seating surface
and mating housing seat; full, uninter (5). Repeat steps (3). and (4). for second
rupted 360 degree seat should be rebound poppet.
evident on each part. If seat surfaces
are satisfactory, reassemble main B. Disassembled Parts
poppet (25), spring (24), retainer (23)
and ring (22) before removing rebound Inspect all disassembled landing gear damper
poppet. If seat surfaces are not satisfac parts according to Table 501. Perform process
tory, reseat poppet (Ref. Repair). inspections according to Table 502.
Table 501. Detailed Inspection - Landing Gear Damper and Associated Parts
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
NOTE: All inspections are visual inspections unless otherwise indicated. For items listed in inspect column, see
Figure 1. After honing, lapping or abrasive polishing, re-clean parts.
Bearings (2 and 7, Figure 1) for:
Play or roughness be None allowed Not repairable Replace defective
tween bearing races (feel) bearing.
Rust, corrosion or binding None allowed Not repairable Replace defective
bearing.
Piston (8) for:
Nicks, scratches, and cuts None allowed Light scratches to 0.001 Polish with crocus cloth
inch (0.025 mm) depth (8, Table 903).
may be reworked
Hard Chrome; diameter OD: 1.308-1.310 inch Not to exceed hard Replate piston (Ref.
worn or damaged (3.322-3.327 cm) chrome thickness (Ref. Repair).
Figure 601)
Damaged threads None allowed Minor damage Re-thread with same size
tap and die.
Damper barrel (21) for:
Worn ID of bore ID: 2.180-2.182 inch Not repairable Replace barrel
(5.537-5.542 mm)

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321010 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Table 501. Detailed Inspection - Landing Gear Damper and Associated Parts (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Light scratches in barrel None allowed Light scratches to 0.010 Polish with crocus cloth
bore inch (0.254 mm) depth (8, Table 903).
may be reworked
Exterior corrosion, None allowed Light scratches may be Polish with crocus cloth
scratches removed (8).
Damaged threads None allowed Minor thread damage Re-thread with same size
die.
Clogged or plugged drain Clear hole.
hole
Sharp edges around bleed Break sharp edges.
holes in lower barrel assy.
Upper and lower cap assembly for:
Scratches, pits, cracks, None allowed Shallow defects may be Polish with crocus cloth
gouges removed (8).
Worn or scratched surface None allowed Treat with chemical film
anodizing (6, Table 903) and zinc
chromate primer (7).
Worn bearing bore None allowed Not repairable Replace cap assembly.
(bearing loose)
Clogged or plugged drain Clear hole.
hole
Rotational drag between:
Upper cap (33) schrader None allowed Minor thread damage Re-thread with same size
valve bore threads for die, chase threads with
burrs, nicks, or scratches same size tap.
Piston (8) and upper cap Nylon pellets in piston and Not repairable Replace defective part.
(1 or 33), Piston (8) and barrel threads must create
piston plug (3 or 34), enough rotational drag to
Piston (8) and housing prevent hand tightening of
(10), Barrel (21) and lower mating parts
cap (6)

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MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Table 502. Process Inspection Requirements
*Magnetic Particle (ASTM E1444) Fluorescent Penetrant (ASTM E1417)
Item Index No. (Ref. Figure 1) Item Index No. (Ref. Figure 1)
Piston 8 Upper cap assembly 1, 33
Spring 9 Plug 3, 34
Lower cap assembly 6
Barrel 21

NOTES:
* Paint removal is not required for magnetic particle inspection, but is necessary on nonferrous parts for
fluorescent penetrant inspection. Complete removal of epoxy primer is not required on normal overhaul.
When inspecting for or after crash damage, all areas should be visually inspected using minimum of
5-power magnifying glass and all suspected areas should have epoxy primer removed locally with paint
remover for added inspection. Prevent entry of paint remover into joint lines of bearings, bushings or
inserts still assembled with the part requiring paint removal.

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321010 Revision 11
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
LANDING GEAR DAMPER
REPAIR/MODIFICATION
1. Repair (3). Cadmium plate threaded area accord
ing to spec. QQP416, class 3 type II
Repair procedures described in the following (Figure 601).
paragraphs are the only repairs authorized for
landing gear damper parts and components. (4). Hard chrome plate center section per
Prior to making repairs on any part or spec QQC320 class 2, type II. Hard
component, ensure that the part or component chrome plate shall be 1.3161.315 inch
is within repairable limits (Ref. Cleaning and (3.3433.340 cm) dia. (Figure 601).
Inspection). After repairs are completed, the (5). Finish grind center section to
part or component must meet the dimensions 1.3101.308 inch (3.3273.322 cm) dia.
specified for the part (Ref. Inspection).
(6). Embrittlement relieve piston after
A. Poppet and Poppet Seat plating according to plating specifica
tions QQP416 and QQP320.
Repair poppets (25 and 27, Figure 1) and
poppet seats as follows: C. Barrel
Repair minor scratches, nicks or light scoring
When lapping poppets, do not
CAUTION permit lapping compound to en
on barrel (21, Figure 1) as follows:
ter other assembled poppets. (1). Remove damage from barrel (21,
Figure 1) by light honing.
(1). Lightly and carefully lap poppet and
seat using fine (220 grit) lapping (2). Reclean part (Ref. Cleaning).
compound (9, Table 903), until 360 D. Housing
degree contact is made between seat
and mating portion of poppet. Avoid Remove scratches from housing (10, Figure 1)
excess lapping and do not allow lapping as follows:
compound to contact sides of poppet. (1). Polish out scratches using crocus cloth
(8, Table 903).
(2). Wash housing and poppet with solvent
(9) or naphtha (5); dry with compressed (2). Reclean housing and poppets to remove
air. all traces of abrasive material.
(3). Coat poppet and seat with hydraulic (3). Treat reworked, external, anodized
fluid (1 or 2) and reinstall poppet with aluminum surfaces with chemical film
attaching parts. (6) and zinc chromate primer (7). Do not
treat internal surfaces.
B. Piston Replating
2. Parts Replacement
Repair worn or damaged plating (Ref. All parts and components not meeting
Figure 601) as follows: specifications (Ref. Inspection), which cannot
NOTE: The following procedures cover cad be repaired, must be replaced. Additionally, all
mium and chrome plating of threaded and parts marked with an asterisk (Ref. Figure 1)
center sections of piston. in key must be replaced. These parts are
included in the landing gear damper overhaul
(1). Strip existing plating of damaged area kit. The following procedures describe replace
by reverse current method. Diameter ment of parts which cannot be replaced as part
prior to replating shall be 1.3061.305 of the reassembly procedure.
inch (3.3173.315 cm). A. Upper and Lower Cap Bearings
(2). Magnetic particle inspect (MPI) per Replace upper and lower cap bearings (1, and
MILSTD1949 with plating removed. 7, Figure 1) as follows:

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CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
(1). Using arbor press and suitable adapter. (7). Apply 100 pound (445 N) force on
press on bearing outer race to remove bearing outer race to load bearing
bearing from cap. against stakes. Outer race must not
move.
(2). Remove any burrs or staking marks
from removal side of cap bore edge. B. Schrader Valve
(3). Coat outer race of replacement bearing Replacement of schrader valve at overhaul is
and cap bearing bore with zinc chro required only if it is suspected of being faulty
mate primer (7, Table 903). or inoperative.
NOTE: Install bearing in removal side of cap. (1). Using a suitable wrench, remove
defective schrader valve (35, Figure 1)
(4). While primer is wet, press bearing into from upper cap (33).
cap bore, using arbor press and adapter.
Do not press against bearing inner race.
(2). Install and lubricate (use damper oil)
Bearing must be installed flush to 0.005
new Oring (36) on replacement
inch (0.127 mm) below staking surface.
schrader valve (34).
(5). Check that bearing cannot be pressed
from cap bore with hand pressure. (3). Install schrader valve in upper cap
bore. Torque to 80 85 inchpounds
(6). Stake bearing in four places radially (9.04 9.60 Nm) and lockwire.
around cap. Stake grooves must be
approximately 0.250 inch (6.35 mm) 3. Modification
long, 0.060 inch (1.524 mm) from edge
of bore and 0.020 inch (0.508 mm) deep. Not applicable.
DIAMETER PRIOR TO PLATING 1.3051.306 INCH (3.3153.317 CM) DIA.
HARD CHROME PLATE 1.3161.315 INCH (3.3433.340 CM) DIA.
4 FINISH GRIND 1.3101.308 INCH (3.3273.322 CM) DIA.
1 5/16 12 UN 3A
THREAD
0.002 INCH
B (0.051 MM) T.I.R B

NOTE 5 NOTE 4

NOTES:
1. REPAIRABLE DAMAGE NOT TO EXCEED HARD CHROME THICKNESS.
2. STRIP EXISTING PLATING BY REVERSE CURRENT.
3. MAGNETIC PARTICLE INSPECT PER MILSTD1949 WITH PLATING REMOVED.
4. HARD CHROME PLATE PER QQC320 CLASS 2 TYPE II.
5. CADMIUM PLATE PER QQP416, CLASS 3, TYPE I.
6. EMBRITTLEMENT RELIEVE AFTER PLATING PER SPECIFICATIONS
(MATERIAL 4340 STEEL RC 3236). H321007A

Figure 601. Replating of Landing Gear Damper Piston

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MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
LANDING GEAR DAMPER
ASSEMBLY/SHIPPING
1. General (a). Place rubber (elastomer) in groove
and position as shown in Figure 701
Only dampers which, view C.
One have been stored less than 9 months,
Two have satisfactorily passed shelflife NOTE: Do not crease TFE seal ring during in
testing or stallation.
Three have been recharged, shall be (b). Collapse TFE seal ring as shown in
installed on helicopters or shipped as spare Figure 701 view A.
parts.
(c). Place TFE seal ring into groove as
NOTE: shown in Figure 701 view C.
D Assemble damper in a clean area free of (d). Using fingers, carefully smooth out
any grinding, cutting, filing or similar op I.D. of the TFE seal ring.
erations.
(e). Push while twisting installation tool
D Ambient room temperature should be (Ref. Figure 701 view B) into bore.
6085 F (1629 C) while reassembling Remove installation tool after one
damper. minute.
D Use hydraulic oil (1, Table 903) to fill
damper. Filter oil through a 10 micron (f). Repeat step (5). one time, to complete
filter prior to use. Keep oil container installation of TFE seal.
tightly covered when not in use. (6). Install new scraper ring (19, Figure 1)
D Replace all parts marked with an asterisk in barrel upper end, scraper edge
(Ref. Figure 1) at reassembly. Lubricate upward, at seal (20) ID. Secure scraper
packings with clean petroleum jelly (13, ring in position with washer (18) and
Table 903) prior to installation. retainer ring (17).
(7). Install packing (4) on piston plug (3).
2. Reassembly
(8). Install packing (5) in groove at piston
The following procedures cover both schrader (8), upper end.
and nonschrader valve damper. Reassemble
(9). Install packing (14) and backup ring
the landing gear damper as follows:
(13) in lower cap assembly (6) groove.
(1). Place baffle (12, Figure 1) in housing Packing must be located at innermost
(10) and position as shown. side (bottom) and backup ring at
outermost side (top) of groove.
(2). Install packing (11) in housing bore, If air is allowed to enter the
against baffle. CAUTION damper assembly while per
forming steps (10). thru (12). which follow,
(3). Thread piston (8) into housing. Using the damper cannot be correctly charged. To
spanner (2, Table 901) and piston prevent entry of air, keep all parts totally
wrenches (6), torque housing 400 450 and continually submerged in five gallon
inchpounds (45.19 50.84 Nm). container (minimum size) of hydraulic fluid
(1 or 2, Table 903) throughout the proce
(4). Install two new backup rings (15, dure.
Figure 1) in housing groove; install
packing (16) between rings. (10). Place spring (9, Figure 1) inside barrel
(21) and submerge parts in container of
(5). Install new seal (20) in barrel (21) hydraulic fluid. Tilt and rotate sub
internal groove. merged barrel to expel any trapped air.

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321010 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Use care when inserting piston Figure 1) to 500 600 inchpounds
CAUTION through seal (20). Piston (56.49 67.79 Nm).
threads can damage seal lip.
(18). Rotate damper assembly in vise so
(11). Submerge assembled piston (8) and piston plug is up and damper is verti
housing (10) in assembly container; cal.
rotate parts while tapping to remove
any trapped air. Insert piston inside (19). Remove plug from damper assembly.
spring and barrel, and through seal (20)
until lower edge of housing is flush (20). Slowly compress piston by hand until
with, or just inside, lower end of barrel. piston bottoms. Tap piston gently with
mallet to ensure it is completely
(12). Submerge lower cap assembly (6) in bottomed.
assembly container, open side up; tap
Pushing piston into barrel
gently to remove any air bubbles. CAUTION causes slight out flow of fluid
Thread cap onto barrel hand tight.
from piston. Fluid must be bubble free. If
(13). Submerge plug (3) or (34) with packing bubbles are present in fluid, damper must
(4) installed in assembly container; be disassembled and reassembled to ensure
rotate and tap part to expel trapped air. no air is in the damper.
Thread plug into piston finger tight.
(21). Using an eyedropper, small syringe or
(14). With damper assembly still submerged, similar tool, remove hydraulic fluid
measure and record hydraulic fluid until required level, determined in step
temperature. o., is reached. (Fluid level is distance
between upper surface (edge) of piston
Steps (15). thru (20). must be ac (8) and surface of fluid in piston.)
CAUTION complished within 15 minutes
after measuring hydraulic fluid tempera (22). Reinstall piston plug in accordance with
ture. If time limit is exceeded, resubmerge the following paragraphs:
damper in fluid container for thirty minutes
and re measure hydraulic fluid tempera (a). Install piston plug (3) on piston,
ture before accomplishing the following engaging one full thread only. Port
steps. through threads and wall of plug
must be clear to allow passage of
NOTE: Damper assembly hydraulic fluid level charging gas into piston.
is governed by hydraulic fluid temperature
at time of filling and temperature range at (b). Install piston plug (34) on piston (8)
which damper is intended to be used. Prior (for schrader valve equipped damp
to accomplishing step (14)., determine type ers). Torque to 20 30 inchpounds
service for which damper is being prepared (2.26 3.39 Nm).
and reference Table 701 thru Table 706 to
be used for determining damper fluid level. Damper Usage Chart
(Refer to chart which follows). Standard Extended
(15). Find hydraulic fluid temperature, (White) (Black)
recorded in step (14)., in appropriate Ambient: Table 701 Table 704
table and read corresponding oil level +10 to +125F
required for damper. (-12 to +52C)
(16). Remove damper assembly from hydrau Winterized: Table 702 Table 705
lic fluid and install in cylinder holding -40 to +70F
block (5, Table 901) and vise, with (-40 to +21.1C)
piston plug (3, Figure 1) down. Mid Temp: Table 703 Table 706
(17). Using wrench adapter (4, Table 901) -25 to +95F
torque cap assembly on barrel (21, (-32 to +35C)

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COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Table 701. Fluid Level Below Piston Rod End - Ambient Service - Standard Landing Gear
Damper P/N 369D26300-BSC, -61, -111, -161, or -211
Hydr Fluid Temp Oil Level Hydr Fluid Temp Oil Level
F (C) In.* (mm)** F (C) In.* (mm)**
50 (10.0) 1.66 (42.1) 76 (24.4) 1.54 (39.0)
52 (11.1) 1.65 (41.9) 78 (25.6) 1.53 (38.7)
54 (12.2) 1.64 (41.7) 80 (26.7) 1.52 (38.5)
56 (13.3) 1.63 (41.4) 82 (27.8) 1.51 (38.2)
58 (14.4) 1.62 (41.2) 84 (28.9) 1.50 (37.9)
60 (15.6) 1.61 (40.9) 86 (30.6) 1.49 (37.7)
62 (16.7) 1.60 (40.6) 88 (31.1) 1.48 (37.4)
64 (17.8) 1.59 (40.4) 90 (32.2) 1.47 (37.2)
66 (18.9) 1.58 (40.1) 92 (33.3) 1.47 (37.2)
68 (20.0) 1.57 (40.0) 94 (34.4) 1.46 (36.7)
70 (21.1) 1.57 (40.0) 96 (35.6) 1.45 (36.4)
72 (22.2) 1.56 (39.5) 98 (36.7) 1.44 (36.2)
74 (23.3) 1.55 (39.2) 100 (37.8) 1.43 (35.9)
*0.020 inch
**0.51 mm

Table 702. Fluid Level Below Piston Rod End - Winterized Service - Standard Landing Gear
Damper P/N 369D26300-11, -21, -71, -81, -121, -131, -171, -181, -221 or -231
Hydr Fluid Temp Oil Level Hydr Fluid Temp Oil Level
F (C) In.* (mm)** F (C) In.* (mm)**
50 (10.0) 1.39 (35.3) 76 (24.4) 1.25 (31.7)
52 (11.1) 1.38 (35.1) 78 (25.6) 1.24 (31.5)
54 (12.2) 1.37 (34.8) 80 (26.7) 1.23 (31.2)
56 (13.3) 1.36 (34.5) 82 (27.8) 1.22 (31.0)
58 (14.4) 1.35 (34.3) 84 (28.9) 1.21 (30.7)
60 (15.6) 1.34 (34.0) 86 (30.6) 1.20 (30.5)
62 (16.7) 1.33 (33.8) 88 (31.1) 1.19 (30.2)
64 (17.8) 1.32 (33.5) 90 (32.2) 1.18 (30.0)
66 (18.9) 1.31 (33.3) 92 (33.3) 1.17 (29.7)
68 (20.0) 1.30 (33.0) 94 (34.4) 1.16 (29.5)
70 (21.1) 1.29 (32.8) 96 (35.6) 1.15 (29.2)
72 (22.2) 1.28 (32.5) 98 (36.7) 1.14 (29.0)
74 (23.3) 1.26 (32.0) 100 (37.8)
*0.020 in.
**0.51 mm

Page 703
321010 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Table 703. Fluid Level Below Piston Rod End - Mid-Temp Service - Standard Landing Gear
Damper P/N 369D26300-31, -41, -91, -101, -141, -151, -191, -201, -241, or -251
Hydr Fluid Temp Oil Level Hydr Fluid Temp Oil Level
F (C) In.* (mm)** F (C) In.* (mm)**
50 (10) 1.46 (36.7) 76 (24.4) 1.29 (32.8)
52 (11.1) 1.45 (36.4) 78 (25.6) 1.28 (32.5)
54 (12.2) 1.43 (35.9) 80 (26.7) 1.27 (32.3)
56 (13.3) 1.42 (36.1) 82 (27.8) 1.25 (31.7)
58 (14.4) 1.41 (35.9) 84 (28.9) 1.24 (31.5)
60 (15.6) 1.39 (35.3) 86 (30.6) 1.23 (31.2)
62 (16.7) 1.38 (35.1) 88 (31.1) 1.21 (30.7)
64 (17.8) 1.37 (34.8) 90 (32.2) 1.20 (30.5)
66 (18.9) 1.36 (34.5) 92 (33.3) 1.19 (30.2)
68 (20.0) 1.34 (34.0) 94 (34.4) 1.18 (30.0)
70 (21.1) 1.33 (33.8) 96 (35.6) 1.16 (29.5)
72 (22.2) 1.32 (33.5) 98 (36.7) 1.15 (29.2)
74 (23.3) 1.30 (33.0) 100 (37.8) 1.14 (29.0)
*0.020 in.
**0.51mm

Table 704. Fluid Level Below Piston Rod End - Ambient Service Extended Landing Gear
Damper P/N 369D26301-BSC, -61, -111, -161 or -211
Hydr Fluid Temp Oil Level Hydr Fluid Temp Oil Level
F (C) In.* (mm)** F (C) In.* (mm)**
50 (10.0) 2.60 (66.0) 76 (24.4) 2.48 (63.0)
52 (11.1) 2.59 (65.8) 78 (25.6) 2.47 (62.7)
54 (12.2) 2.58 (65.5) 80 (26.7) 2.46 (62.5)
56 (13.3) 2.58 (65.5) 82 (27.8) 2.45 (62.2)
58 (14.4) 2.57 (65.3) 84 (28.9) 2.44 (62.0)
60 (15.6) 2.56 (65.0) 86 (30.6) 2.43 (61.7)
62 (16.7) 2.55 (64.8) 88 (31.1) 2.42 (61.5)
64 (17.8) 2.54 (64.5) 90 (32.2) 2.41 (61.2)
66 (18.9) 2.53 (64.3) 92 (33.3) 2.41 (61.2)
68 (20.0) 2.52 (64.0) 94 (34.4) 2.40 (61.0)
70 (21.1) 2.51 (63.8) 96 (35.6) 2.39 (60.7)
72 (22.2) 2.50 (63.5) 98 (36.7) 2.38 (60.5)
74 (23.3) 2.49 (63.2) 100 (37.8) 2.37 (60.2)
*0.020 in.
**0.51 mm

Page 704
Revision 4 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Table 705. Fluid Level Below Piston Rod End - Winterized Service Extended Landing Gear
Damper P/N 369D263010-11, -21, -71, -81, -121, -131, -171, -181 -221, or -231
Hydr Fluid Temp Oil Level Hydr Fluid Temp Oil Level
F (C) In.* (mm)** F (C) In.* (mm)**
50 (10.0) 2.28 (57.9) 76 (24.4) 2.22 (56.4)
52 (11.1) 2.27 (57.7) 78 (25.6) 2.21 (56.1)
54 (12.2) 2.27 (57.7) 80 (26.7) 2.20 (55.9)
56 (13.3) 2.27 (57.7) 82 (27.8) 2.19 (55.6)
58 (14.4) 2.26 (57.4) 84 (28.9) 2.17 (55.1)
60 (15.6) 2.26 (57.4) 86 (30.6) 2.16 (54.9)
62 (16.7) 2.26 (57.4) 88 (31.1) 2.15 (54.6)
64 (17.8) 2.25 (57.2) 90 (32.2) 2.14 (54.4)
66 (18.9) 2.25 (57.2) 92 (33.3) 2.13 (54.1)
68 (20.0) 2.25 (57.1) 94 (34.4) 2.12 (53.8)
70 (21.1) 2.25 (57.1) 96 (35.6) 2.11 (53.6)
72 (22.2) 2.24 (56.9) 98 (36.7) 2.10 (53.3)
74 (23.3) 2.23 (56.6) 100 (37.8)
*0.020 in.
**0.51 mm

Table 706. Fluid Level Below Piston Rod End - Mid-Temp Service Extended Landing Gear
Damper P/N 369D263010-31, -41, -91, -101, -141, -151, -191, -201, -241, or -251
Hydr Fluid Temp Oil Level Hydr Fluid Temp Oil Level
F (C) In.* (mm)** F (C) In.* (mm)**
50 (10) 2.40 (61.0) 76 (24.4) 2.26 (57.4)
52 (11.1) 2.39 (60.7) 78 (25.6) 2.24 (56.7)
54 (12.2) 2.38 (60.5) 80 (26.7) 2.23 (56.6)
56 (13.3) 2.37 (60.2) 82 (27.8) 2.22 (56.4)
58 (14.4) 2.36 (60.0) 84 (28.9) 2.21 (56.1)
60 (15.6) 2.34 (59.4) 86 (30.6) 2.20 (55.9)
62 (16.7) 2.33 (59.2) 88 (31.1) 2.19 (55.6)
64 (17.8) 2.32 (58.9) 90 (32.2) 2.18 (55.4)
66 (18.9) 2.31 (58.7) 92 (33.3) 2.17 (55.1)
68 (20.0) 2.30 (58.4) 94 (34.4) 2.16 (54.9)
70 (21.1) 2.29 (58.2) 96 (35.6) 2.14 (54.4)
72 (22.2) 2.28 (57.9) 98 (36.7) 2.13 (54.1)
74 (23.3) 2.27 (57.7) 100 (37.8)
*0.020 in.
**0.51 mm

Page 705
321010 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301

UPPER CAP
ASSEMBLY











PLUG
ORING









NOTE 2







RETAINING

WASHER





RING





SCRAPER



SEAL RING

PISTON





SIGHT GLASS
(NOTE 2)

BARREL
























BAFFLE













MAIN
POPPET SPRING



SPRING





HOUSING

SPRING












RETAINING
RETAINER RING
GASKET





BACKUP RING










LOWER BACKUP
RING

LOWER CAP
ASSEMBLY
UPPER BACKUP
RING

REBOUND
POPPET
RETAINING
NOTES: RING
1. DAMPER ASSEMBLY SHOWN COMPRESSED.
2. FOR SCHRADER VALVE EQUIPPED DAMPERS. H321008

Figure 701. Damper Assembly - Cross-Section View

Page 706
Revision 4 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301

TFE SEAL RING FREE FORM TFE SEAL RING COLLAPSED FORM

VIEW A

U
P

ONE PIECE GLAND SEAL


AND RING INSTALLED
ELASTOMER

20

TFE SEAL RING

PRESSURE SIDE

369H6314 BARREL
ASSY. (REF)

10.00 INCH
VIEW C VIEW B (25.4 CM)
INSTALLATION TOOL P/N 369D29938*
*NYLON LP410 TYPEOPTIONAL

1.30 0.001 INCH


(33.02 0.0254 MM)

H321009A

Figure 702. Damper Assembly - Barrel Seal Installation

Page 707
321010 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
3. Charging NOTE:
D Prior to accomplishing step (3)., deter
Procedures for charging the landing gear mine type service for which damper is be
damper with dry nitrogen gas and testing the ing prepared and (Ref. Table 707 thru
damper for leaks are described in the following Table 712) to be used for determining
paragraphs. charging pressure, using the following
chart.
Damper Usage Chart D If piston does not extend when gas pres
Standard Extended sure is increased, engage charging tool
(White) (Black) handle and loosen plug (3, Figure 1) slow
ly until piston begins to extend.
Ambient Service Table 707 Table 710
+10 to +125 F (4). Recheck damper for correct pressure.
(-12 to +52 C) Slowly, bleed off excess pressure.
Winterized Table 708 Table 711 If nitrogen is bled off quickly, for
-40 to +70 F CAUTION any reason, reassembly of the
(-40 to +21 C)
damper, beginning with (Ref. Reassembly)
Mid Temp Table 709 Table 712 step (11)., must be reaccomplished.
-25 to +95 F
(-32 to +35 C) (5). Once correct pressure is established,
engage slot of piston plug with charging
A. Non-Schrader Valve Damper tool handle and tighten plug until it
bottoms; do not tighten excessively.
The following procedure is for dampers (6). Set nitrogen gas pressure regulator to
without schrader valves. Charge the reas zero pressure. Raise Thandle of
sembled damper with dry nitrogen gas (3, charging tool and remove from damper.
Table 903). The correct charging pressure is
determined by the type service for which the (7). Torque piston plug to 18 22 inch
damper is being prepared and the temperature pounds (2.03 2.49 Nm).
of the room in which the damper is being
charged. Charge the damper as follows: (8). Using solvent (4, Table 903), thoroughly
clean threads of upper cap assembly (1,
Figure 1), mating piston threads and
Use dry nitrogen only, for charg
CAUTION ing damper. Store nitrogen
packing (5) dry thoroughly.
bottle in same room or area where charging (9). Install upper cap assembly on piston.
is to occur for minimum of 12 hours prior to Using wrench (6, Table 901) and
charging. wrench adapter (4), torque cap assem
bly to 500 600 inchpounds (56.49
(1). Verify that packing (5, Figure 1) is 67.79 Nm).
correctly positioned on piston (8).
(10). Wash entire damper assembly, except
(2). Thread charging tool (3, Table 901) onto end cap bearings (2 and 7, Figure 1),
piston threads; tighten securely, using using solvent (4, Table 903 ) or naphtha
wrench if necessary. Ensure that (5). Detach retaining ring (17, Figure 1)
charging tool Thandle is pulled out from recess, and carefully lift washer
(up) and has not engaged slot of piston (18) and scraper ring (19) along piston
plug (3, Figure 1). to allow complete cleaning.
(11). Blot any solvent from bearings and
(3). Connect nitrogen charging hose to gas allow remainder of damper to complete
port of charging tool; do not tighten ly dry.
connection. Ensure that low pressure
side of nitrogen regulator gage (1, (12). Reinstall scraper ring, washer and
Table 901) is at zero pressure. retainer ring.

Page 708
Revision 4 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
B. Schrader Valve Damper (7). Slowly turn regulator control until
nitrogen begins to flow at the loose
The following procedure is for nitrogen service servicing hoseschrader valve connec
of schrader valve equipped dampers. tion.
(1). Install sight glass (32) over piston on (8). Tighten servicing hose while nitrogen is
upper end of barrel. flowing. Allow nitrogen pressure to
(2). Install seal (5) on the outside of piston build to the valve according to dash
rod. number and part number of damper
(Ref. Table 707 thru Table 712).
(3). Install and lubricate (use damper oil)
To prevent damage to damper or
new Oring (36) on schrader valve (34). CAUTION loss of damper fluid, do not open
Install schrader valve in upper cap
bore. Torque to 80 85 inchpounds schrader valve without pressurizing the
(9.04 10.17 Nm) and lockwire. servicing line. If fluid loss occurs, damper
will require overhaul.
(4). Screw upper cap assembly (33) on the
piston rod. Using torque adapter (4, (9). Once pressure level is reached open
Table 901), torque upper cap to 500 schrader valve by turning outside nut
600 inchpounds (56.49 67.79 Nm) counter clockwise, allowing system and
plus runin torque. damper pressure to equalize for a
minimum of 2 minutes. If slightly over
NOTE: For installation or replacement of pressurized, bleed off excess very
schrader valve (Ref. Repair). slowly.
(5). Remove cap from schrader valve and (10). Close schrader valve by turning the
connect servicing hose, but do not outside nut clockwise. Torque nut to 60
tighten (Figure 703). inchpounds (6.78 Nm) and safety
wire.
(6). Ensure low side of nitrogen pressure
regulator is backed off to the unpres (11). Reduce charge pressure to zero, and
surized position. Slowly open the high remove servicing hose. Install cap on
pressure nitrogen bottle valve. schrader valve.

Page 709
321010 Revision 5
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301

DAMPER
CAP

OUTSIDE NUT
SCHRADER
VALVE

SERVICING HOSE

HIGH
PRESSURE
VALVE

REGULATOR
CONTROL

H321011

Figure 703. Servicing Schrader Valve Damper

Page 710
Revision 4 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Table 707. Nitrogen Charge - Ambient Service Standard Landing Gear Damper
P/N 369D26300-BSC, -61, -111, -161 or -211
Ambient Temperature Nitrogen Pressure Ambient Temperature Nitrogen Pressure
F (C) Psig (kPa) F (C) Psig (kPa)
50 (10) 857 (5,910) 76 (24) 920 (6,340)
52 (11) 862 (5,943) 78 (26) 924 (6,373)
54 (12) 867 (5,976) 80 (27) 929 (6,406)
56 (13) 872 (6,009) 82 (28) 934 (6,439)
58 (14) 876 (6,042) 84 (29) 939 (6,473)
60 (16) 881 (6,075) 86 (30) 994 (6,506)
62 (17) 886 (6,109) 88 (31) 948 (6,539)
64 (18) 891 (6,142) 90 (32) 953 (6,572)
66 (19) 896 (6,175) 92 (33) 958 (6,605)
68 (20) 900 (6,208) 94 (34) 963 (6,638)
70 (21) 905 (6,241) 96 (36) 968 (6,671)
72 (22) 910 (6,274) 98 (37) 972 (6,704)
74 (23) 915 (6,307) 100 (38) 977 (6,737)

Table 708. Nitrogen Charge - Winterized Service Standard Landing Gear Damper
P/N 369D26300-11, -21, -71, -81, -121, -131, -171, -181, -221, or -231
Ambient Temperature Nitrogen Pressure Ambient Temperature Nitrogen Pressure
F (C) Psig (kPa) F (C) Psig (kPa)
50 (10) 999 (6,888) 76 (24) 1,091 (7,523)
52 (11) 1,006 (6,937) 78 (26) 1,098 (7,572)
54 (12) 1,013 (6,986) 80 (27) 1,105 (7,621)
56 (13) 1,020 (7,035) 82 (28) 1,112 (7,669)
58 (14) 1,027 (7,084) 84 (29) 1,119 (7,718)
60 (15) 1,035 (7,133) 86 (30) 1,127 (7,767)
62 (17) 1,042 (7,181) 88 (31) 1,134 (7,816)
64 (18) 1,049 (7,230) 90 (32) 1,141 (7,865)
66 (19) 1,056 (7,279) 92 (33) 1,148 (7,914)
68 (20) 1,063 (7,328) 94 (34) 1,155 (7,962)
70 (21) 1,070 (7,377) 96 (36) 1,162 (8,011)
72 (22) 1,077 (7,425) 98 (37) 1,169 (8,060)
74 (23) 1,084 (7,474) 100 (38) 1,176 (8,109)

Page 711
321010 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Table 709. Nitrogen Charge - Mid-Temp Standard Landing Gear Damper
P/N 369D26300-31, -41, -91, -101, -141, -151, -191, -201, -241 or -251
Ambient Temperature Nitrogen Pressure Ambient Temperature Nitrogen Pressure
F (C) Psig (kPa) F (C) Psig (kPa)
50 (10) 983 (6,778) 76 (24) 1,067 (7,356)
52 (11) 990 (6,823) 78 (26) 1,073 (7,400)
54 (12) 996 (6,867) 80 (27) 1,080 (7,444)
56 (13) 1,002 (6,912) 82 (28) 1,086 (7,489)
58 (14) 1,009 (6,956) 84 (29) 1,093 (7,533)
60 (16) 1,015 (7,000) 86 (30) 1,099 (7,578)
62 (17) 1,022 (7,045) 88 (31) 1,106 (7,622)
64 (18) 1,028 (7,089) 90 (32) 1,112 (7,666)
66 (19) 1,035 (7,134) 92 (33) 1,118 (7,711)
68 (20) 1,041 (7,178) 94 (34) 1,125 (7,755)
70 (21) 1,048 (7,222) 96 (36) 1,131 (7,800)
72 (22) 1,054 (7,267) 98 (37) 1,138 (7,844)
74 (23) 1,060 (7,311) 100 (38) 1,144 (7,888)

Table 710. Nitrogen Charge- Ambient Service Extended Landing Gear Damper
P/N 369D26301-BSC, -61, -111, -161, or -211
Ambient Temperature Nitrogen Pressure Ambient Temperature Nitrogen Pressure
F (C) Psig (kPa) F (C) Psig (kPa)
50 (10) 1,277 (8,806) 76 (24) 1,370 (9,448)
52 (11) 1,284 (8,855) 78 (26) 1.377 (9,497)
54 (12) 1,292 (8,905) 80 (27) 1,385 (9,546)
56 (13) 1299 (8,954) 82 (28) 1,392 (9,596)
58 (14) 1,306 (9,003) 84 (29) 1,399 (9,645)
60 (16) 1,313 (9,053) 86 (30) 1,406 (9,695)
62 (17) 1,320 (9,102) 88 (31) 1,413 (9,744)
64 (18) 1,327 (9,152) 90 (32) 1,420 (9.793)
66 (19) 1,335 (9,201) 92 (33) 1,428 (9,843)
68 (20) 1,342 (9,250) 94 (34) 1,435 (9,892)
70 (21) 1,349 (9,300) 96 (36) 1,442 (9,941)
72 (22) 1,356 (9,349) 98 (37) 1,449 (9.991)
74 (23) 1,363 (9,398) 100 (38) 1,456 (10,040)

Page 712
Revision 4 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Table 711. Nitrogen Charge - Winterized Service Extended Landing Gear Damper
P/N 369D26301-11, -21, -71, -81, -121, -131, -171, -181, -221 or -231
Ambient Temperature Nitrogen Pressure Ambient Temperature Nitrogen Pressure
F (C) Psig (kPa) F (C) Psig (kPa)
50 (10) 1,391 (9,589) 76 (24) 1,513 (10,434)
52 (11) 1,400 (9,654) 78 (26) 1,523 (10,499)
54 (12) 1,410 (9,719) 80 (27) 1,532 (10,564)
56 (13) 1,419 (9,784) 82 (28) 1,542 (10,629)
58 (14) 1,428 (9,849) 84 (29) 1,551 (10,694)
60 (16) 1,438 (9,914) 86 (30) 1,560 (10,759)
62 (17) 1,447 (9,979) 88 (31) 1,570 (10,824)
64 (18) 1,457 (10,044) 90 (32) 1,579 (10,890)
66 (19) 1,466 (10,109) 92 (33) 1,589 (10,956)
68 (20) 1,476 (10,174) 94 (34) 1,598 (11,020)
70 (21) 1,485 (10,239) 96 (36) 1,608 (11,085)
72 (22) 1,494 (10,304) 98 (37) 1,617 (11,150)
74 (23) 1,503 (10,379) 100 (38)

Table 712. Nitrogen Charge - Mid-Temp Extended Landing Gear Damper


P/N 369D26301-31, -41, -91, -101, -141, -151, -191, -201, -241 or -251
Ambient Temperature Nitrogen Pressure Ambient Temperature Nitrogen Pressure
F (C) Psig (kPa) F (C) Psig (kPa)
50 (10) 1,258 (8,675) 76 (24) 1,356 (9,349)
52 (11) 1,266 (8,727) 78 (26) 1,364 (9,401)
54 (12) 1,273 (8,799) 80 (27) 1,371 (9,453)
56 (13) 1,281 (8,831) 82 (28) 1,379 (9,505)
58 (14) 1,288 (8,883) 84 (29) 1,386 (9,557)
60 (15) 1,296 (8,934) 86 (30) 1,394 (9,608)
62 (17) 1,303 (8,986) 88 (31) 1,401 (9,660)
64 (18) 1,311 (9,038) 90 (32) 1,409 (9,712)
66 (19) 1,318 (9,090) 92 (33) 1,416 (9,764)
68 (20) 1,326 (9,142) 94 (34) 1,424 (9,816
70 (21) 1,333 (9,194) 96 (36) 1,431 (9,868)
72 (22) 1,341 (9,246) 98 (37) 1,439 (9,920)
74 (23) 1,349 (9,297) 100 (38) 1,446 (9,971)

Page 713
321010 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
4. Testing (a). Wrap and package damper in suit
able material for protection from dirt
Test the overhauled damper for hydraulic fluid and moisture. Identify damper by
leakage as follows: part number and intended climatic
(1). Place damper on its side, on a clean dry service (summer, winterized or
surface, for approximately four hours. midtemp).

(2). Inspect entire assembly for leakage, (b). Apply a light layer of corrosion
particularly around piston scraper ring preventative (14, Table 903) and
(19, Figure 1). package or cover to keep dust off.

NOTE: Traces of fluid at lower cap (6) drain (2). Store damper in a clean dry area.
hole, or at piston (8) and scraper ring may be (3). Upon removal from storage or at
present. Such fluid may be residual fluid installation, reinspect damper for
trapped during reassembly and is not neces leakage.
sarily leakage. Wipe away fluid and observe
for further seepage. NOTE: Traces of fluid at lower cap (6, Figure 1)
drain hole, or at piston (8) and scraper ring
(3). If any leakage is noted, overhaul (19) may be present.
procedure must be repeated, beginning
with (Ref. Disassembly). (4). Residual fluid may be present during
reassembly and is not necessarily
5. Packing and Storage leakage.
If overhauled damper is not to be used (5). Wipe away fluid and observe for further
immediately, package and store the damper as seepage.
follows:
(6). If any leakage is noted, overhaul
(1). Protect damper with one of the follow procedure must be repeated in entirety,
ing methods. (Ref. Disassembly).

Page 714
Revision 5 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
6. Damper Application Matrix
The following is an application matrix for both
the schrader valve equipped dampers and the
nonschrader valve equipped dampers.
Table 713. 369D26300 and 369D26301 Landing Gear Damper Application
Ambient (1) Model Winter (1) Model Mid-T emp (1) Model
-BSC . . . . . . . . . . . . D/E/FF -21 . . . . . . . . . . . . . . D/E/FF -31 . . . . . . . . . . . . . . D/E/FF
-1 1 (4) . . . . . . . . D -81 . . . . . . . . . . . . . . D/E/FF -91 . . . . . . . . . . . . . . D/E/FF
-41 (3) . . . . . . . . FF -131 . . . . . . . . . . . . . D/E/FF -141 . . . . . . . . . . . . . D/E/FF
-61 . . . . . . . . . . . . . . D/E -181 (2) . . . . . . . . D/E/FF -191 (2) . . . . . . . . D/E/FF
-71 (4) . . . . . . . . D -231 (2) . . . . . . . . D/E/FF -241 (2) . . . . . . . . D/E/FF
-101 (3) . . . . . . . . FF -251 (2,3) . . . . . . D/E/FF/N
-1 11 . . . . . . . . . . . . . D/E
-121 (4) . . . . . . . . D
-151 (3) . . . . . . . . D/E/FF
-161 (2) . . . . . . . . D/E
-171 (2, 4) . . . . . . D
-201 (2, 3) . . . . . . D/E/FF
-21 1 (2) . . . . . . . . D/E/FF/N
-221 (2, 4) . . . . . . D
-251 (2, 3) . . . . . . D/E/FF/N
NOTE:
(1) 369H6322 Decal dash number: -3 Ambient . . . . . 10 F to 125 F
-5 Winter . . . . . . -40 F to 70 F
-7 Mid Temp . . . . -25 F to 90 F
(2) Schrader valve configuration.
(3) Mid-T emperature charge pressure approved for ambient temperature application.
(4) Winter charge pressure approved for ambient temperature application (3550 Configuration).

Page 715/(716 blank)


321010 Revision 12
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
LANDING GEAR DAMPER
SPECIAL TOOLS, FIXTURES & EQUIPMENT
1. Damper Overhaul Kit cylinder holding block (5) and piston
wrench (6) may be locally fabricated.
A damper overhaul kit (PN M50032) is Figure 901 illustrates requirement for
available for use when overhauling a landing fabrication of these tools.
gear damper. The kit contains damper parts
which must be replaced at overhaul. Each kit
contains parts required for one damper. (Ref. (2). Table 901 and Table 903 provide
Figure 1 for parts included in M50032 damper specifications, and when appropriate,
overhaul kit.) procurement information, regarding
special tools and equipment, and
2. Special Tool Fabrication expendable items and materials
required for overhaul/repair. Torque
(1). Torque wrench adapter (4, Table 901), values are contained in Table 902.

Table 901. Landing Gear Damper Assembly Overhaul - Special Tools


Item
No. Nomenclature Part No. Manufacturer
1 Pressure Gage, 0-2000 psi (0-14000 kPa) in Commercial
10-psi (0-50 kPa) increments
2 Housing Spanner Wrench 369H6340-80901 MDHI
3 Charging Tool 369D26300-80901 MDHI
4 Wrench Adapter 369A6300-80906 MDHI
(Locally fabricated;
Ref. Fig. 901)
5 Cylinder Holding Block (Locally fabricated;
Ref. Fig. 901)
6 Piston Wrench (Locally fabricated;
Ref. Fig. 901)
7 Seal Installation Tool 369D29938 MDHI
(Locally fabricated;
Ref. Fig. 702)

Table 902. Landing Gear Damper Assembly Special Torques


Torque
Item Figure 1, Index No. (In.-Lb.) (Nm)
Upper Cap Assembly 1 500600 56.49 - 67.79
Lower Cap Assembly 6 500600 56.49 - 67.79
Piston Plug 3 1822 2.03-2.49
*Schrader Valve Piston Plug 34 2030 2.26-3.39
Damper Housing 10 400450 45.19 - 50.84

*For schrader valve equipped landing gear dampers.

Page 901
321010 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Table 903. Repair Materials
Item
No. Material Specification No. Name/No. Manufacturer No.

1 Hydraulic oil, petroleum base MIL-H-5606 PQ Hydraulic oil American Oil


Company

Brayco 756C Bray Oil Company

Brayco 756D Bray Oil Company


3126 Hydraulic oil Exxon Co.
AeroShell fluid 4 Shell Oil Company
PED 3337 Standard Oil Compa-
ny
2 Preservative oil, hydraulic MIL-H-6083 UNIVIS PJ-44 Exxon Co.
Type I

Brayco 783 Bray Oil Company

3 Dry nitrogen (3)

4 Dry cleaning solvent P-D-680 (3)

5 Naptha TT-N-95 (3)

6 Chemical film xinc MIL-C-5541, (3)


Class 2

7 Primer MIL-P-85582 (3)

8 Crocus cloth P-C-458 (3)

9 Lapping compound, fine 220 Grit Commercial

10 Adhesive, epoxy MIL-A-52194 Scotch Weld EC1838 3M Company


(nonstructural) (Parts A and B)

11 Paint, white, lusterless Fed Std 595


(Color 17875)

12 Paint, black, semigloss Fed Std 595


(Color 27038)

13 Petrolatum VV-P-236 (3)


(petroleum jelly, white)

Page 902
Revision 12 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Table 903. Repair Materials (Cont.)
Item
No. Material Specification No. Name/No. Manufacturer No.
14 Corrosion Preventative MIL-C-81309 Corrosion X Corrosion Technolo-
Type II gies Corp.
Fluid Film Eureka Chemical Co.
NOTES:
(1) Numbers are U. S. A. Specifications and Standards. The prefix symbols are defined as follows:
AMS - American Material Standard; MS - Military Standard; MIL - Military Specification; single, double
or triple alpha prefix of the same letter - Federal Specification; AN - Air Force-NavyAeronautical
Standard; NAS - National Aerospace Standard.
(2) Primary selection. Any equivalent material may be used as an alternate selection.
(3) Use the best equivalent commercial grade material when the conformity of available materials of the
same type with the listed U. S. A. Specification No. cannot be determined.

Page 903
321010 Revision 5
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
0.75 INCH 1.25 INCH
(19.05 MM) (3.175 CM) 0.280 INCH
0.06 INCH 0.88 INCH (7.112 MM)

(1.524 MM) R (22.35 MM) SLOT


DIAMETER

1.88 INCH

(4.78 CM)


DIAMETER


1.50 INCH
(3.81 CM)
0.06 INCH
(1.524 MM) X 0.50 INCH SQUARE SOCKET 0.13 INCH
45 CHAMFER FIT TO TORQUE WRENCH (3.302 MM) X
(ORIENTATION NOT CRITICAL) 45 CHAMFER

TORQUE WRENCH ADAPTER UPPER END CAP


(MAKE FROM 2.00 INCH (5.08 CM) DIAMETER X 2.50 INCH (6.35 CM) IIA1 TOOL STEEL)

0.20 INCH
(5.08 MM)

2.38 INCH
(6.045 CM) 3.20 INCH
DIAMETER (8.128 CM)

0.180 INCH
(0.4.572 MM)
JAW THICKNESS
4.0 INCH
(10.16 CM)

PISTON WRENCH
(MAKE FROM 1 1/16 OPEN END WRENCH)
1.50 INCH
(3.81 CM)

CYLINDER HOLDING BLOCK


(MAKE FROM MAPLE OR EQUIVALENT HARDWOOD)

H32-1005A

Figure 901. Special Tools Fabrication

Page 904
Revision 5 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
LANDING GEAR DAMPER
ILLUSTRATED PARTS LIST
1. General Explanations of codes and abbreviations used
in this illustrated parts list can be found by
This section contains an illustrated parts list referring to the Introduction section of
to be used in conjunction with the 369D26300 CSPIPC4.
and 369D26301 Landing Gear Damper
overhaul manual. Correct part numbers and
nomenclature can be identified for specific 2. Indenture Level
configurations and effectivities.
Item numbers in this parts list refer to the The indenture level to a higher assembly is
figure preceding the parts list table. An item indicated by the amount of bullets in front of
number may be the same or different from the each item in the description column. An item
same part shown in a different illustration that has one more bullet than the part above it
elsewhere in the overhaul manual. is a sub part of that assembly.

Page 1001
321010 Revision 14
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301

2
2
1 3
(NOTE 3)

17
(NOTE 3)

4*
(NOTE 3)
5
(NOTE 3) 18
19* 31*

6*
(NOTE 3) 20* 32*

7
31*
8

9* 33*

21
10*
34*

11 35

12*
(NOTE 1)
13 **

22* 36
14 **
23
15
25

24
(NOTE 1)
26

27 **
16

28
29
30

NOTES:
1. DRAIN HOLE.
2. ASTERISK ( * ) INDICATES ITEM IS PART OF OVERHAUL KIT.
3. SCHRADER VALVE DAMPER ONLY
4 DOUBLE ASTERISK ( ** ) INDICATES DIFFERENCE BETWEEN 369D26300 AND 369D26301 SERIES DAMPERS. H321020

Figure 1001. Damper Assembly - 369D/E/FF/500N

Page 1002
Revision 15 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Qty.
Fig. &
Part Number Description per
Index
Assy.
1001- 369D26300-251 Damper Assy, (Color White) (Air Valve Turned 90 Degrees) . . . . . . . REF
369D26301-251 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
(Air Valve Turned 90 Degrees)
369D26300-241 Damper Assy, (Color White) (Air Valve Turned 90 Degrees) . . . . . . . REF
Mid Temperature
369D26301-241 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
(Air Valve Turned 90 Degrees) Mid Temperature
369D26300-231 Damper Assy, (Color White) (Air Valve Turned 90 Degrees) . . . . . . . REF
Winterized Temp
369D26301-231 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
(Air Valve Turned 90 Degrees) Winterized Temp
369D26300-221 Damper Assy, (Color White) (Air Valve Turned 90 Degrees) . . . . . . . REF
369D26301-221 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
(Air Valve Turned 90 Degrees)
369D26300-21 1 Damper Assy, (Color White) (Air Valve Turned 90 Degrees) . . . . . . . REF
369D26301-21 1 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
(Air Valve Turned 90 Degrees)
369D26300-201 Damper Assy, (Color White) (Cap With Added Air Valve) . . . . . . . . . . REF
369D26301-201 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
(Cap With Added Air Valve)
369D26300-191 Damper Assy, (Color White) (Cap With Added Air Valve) . . . . . . . . . . REF
Mid Temperature
369D26301-191 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
(Cap With Added Air Valve) Mid Temperature
369D26300-181 Damper Assy, (Color White) (Cap With Added Air Valve) . . . . . . . . . . REF
Winterized Temp
369D26301-181 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
(Cap With Added Air Valve) Winterized Temp
369D26300-171 Damper Assy, (Color White) (Cap With Added Air Valve) . . . . . . . . . . REF
369D26301-171 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
(Cap With Added Air Valve)
369D26300-161 Damper Assy, (Color White) (Cap With Added Air Valve) . . . . . . . . . . REF
369D26301-161 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
(Cap With Added Air Valve)
369D26300-151 Damper Assy, (Color White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369D26301-151 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
369D26300-141 Damper Assy, (Color White) Mid Temperature . . . . . . . . . . . . . . . . . . . REF
369D26301-141 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
Mid Temperature
369D26300-131 Damper Assy, (Color White) Winterized Temp . . . . . . . . . . . . . . . . . . . REF
369D26301-131 Damper Assy Extended Gear (Color Black) Winterized Temp . . . . . . REF
369D26300-121 Damper Assy, (Color White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369D26301-121 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
369D26300-1 11 Damper Assy, (Color White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369D26301-1 11 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF

Page 1003
321010 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Qty.
Fig. &
Part Number Description per
Index
Assy.
369D26300-101 Damper Assy, (Color White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369D26301-101 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
369D26300-91 Damper Assy, (Color White) Mid Temperature . . . . . . . . . . . . . . . . . . . REF
369D26301-91 Damper Assy Extended Gear (Color Black) Mid Temperature . . . . . . REF
369D26300-81 Damper Assy, (Color White) Mid Temperature . . . . . . . . . . . . . . . . . . . REF
369D26301-81 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
369D26300-71 Damper Assy, (Color White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369D26301-71 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
369D26300-61 Damper Assy, (Color White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369D26301-61 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
369D26300-41 Damper Assy, (Color White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369D26301-41 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
369D26300-31 Damper Assy, (Color White) Mid Temperature . . . . . . . . . . . . . . . . . . . REF
369D26301-31 Damper Assy Extended Gear (Color Black) Mid Temperature . . . . . . REF
369D26300-21 Damper Assy, (Color White) Winterized Temp . . . . . . . . . . . . . . . . . . . REF
369D26301-21 Damper Assy Extended Gear (Color Black) Winterized Temp . . . . . . REF
369D26300-1 1 Damper Assy, (Color White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369D26301-1 1 Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
369D26300-BSC Damper Assy, (Color White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369D26301-BSC Damper Assy Extended Gear (Color Black) . . . . . . . . . . . . . . . . . . . . . REF
1 369H6310-BSC Cap Assy (W/O Valve Assy Port) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(Used On -111 Thru -151 L/G Damper Replaced By 369H6310-9
Cap Assy
2 369A7951-49 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369H6310-BSC/ -5/ -9 Cap Assy
3 369H6310-5 Cap Assy (W/Valve Assy Port) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Used On -161 Thru -201 L/G Damper Replaced By 369H6310-9
3 369H6310-9 Cap Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(W/Valve Assy Port Turned 90) Used On -211 Thru -251 L/G
Damper
4 MS28775-015 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On -161 Thru -251 L/G Damper
5 MS28889-2 Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On -161 Thru -251 L/G Damper
6 G1901 Sight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTCH
Use On -161 Thru -251 L/G Damper
6 369D26305-1 Sight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On -161 Thru -251 L/G Damper
7 MS16625-181 Retainer Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 369H6306 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 S-1 1065-14-5 Scraper Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 369D26304-BSC Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaced By S34851-219P99 Seal

Page 1004
Revision 15 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Qty.
Fig. &
Part Number Description per
Index
Assy.
10 7219FS-972-P4 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Replaced By S34851-219P99 Seal
10 S34851-219P99 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 369H6314 Barrel Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 369H6322-3 Decal (Amb Temp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use With -BSC / -11 / -41 / -61 / -71 / -101 / -111 / -121 / -161 /
-171 / -201 / -211 / -221 And -251 L/G Damper
12 369H6322-5 Decal (Cold Temp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use With -21 / -81 / -131 / -181 And -231 L/G Damper
12 369H6322-7 Decal (Mid Temp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use With -31 / -91 / -141 / -191 And -241 L/G Damper
13 369D24000 Plate (Ser No) (used on 369D26300 series) . . . . . . . . . . . . . . . . . . . 1
13 369D24001 Plate (Ser No) (used on 369D26301 series) . . . . . . . . . . . . . . . . . . . 1
14 369H92017-5 Decal (Used On 369D26300 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 369H92017-3 Decal (Used On 369D26301 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 369H6319 Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
16 369H92133-3 Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 369D26303-3 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Used On 369D26300-161 Thru 369D26300-251 L/G Damper
18 369A6303 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaced By 369D26303-BSC Used On 369D26300-BSC Thru
369D26300-151 L/G Damper
18 369D26303-BSC Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Used On 369D26300-BSC Thru 369D26300-151 L/G Damper
19 MS28778-8 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20 MS2775-1 18 Gasket Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTCH
7118MR-964N Is Perferred Part
20 7118MR-964-N Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21 369H6312-BSC Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaced By 369H6312-3 Piston
21 369H6312-3 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22 MS28775-025 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23 369H6307 Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
24 369H6311 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
25 MS16625-43 Retainer Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
26 369H6309 Rebound Poppet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
27 369H6316 Main Poppet (Used On 369D26300 Series) . . . . . . . . . . . . . . . . . . . . 1
27 369H92132 Main Poppet (Used On 369D26301 Series) . . . . . . . . . . . . . . . . . . . . 1
28 369H6313 Poppet Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
29 369H6308 Spring Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
30 MS16625-56 Retainer Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
31 MS28774-136 Back-Up Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
32 MS28775-136 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
33 MS27595-142 Back-Up Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Page 1005
321010 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D26300/369D26301
Qty.
Fig. &
Part Number Description per
Index
Assy.
34 MS28775-142 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
35 369H6305-BSC Cap Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On -BSC Thru -41 L/G Damper Replaced By 369H6305-5
Cap Assy
35 369H6305-5 Cap Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On -61 Thru -251 L/G Damper
36 369A7951-49 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369H6305-BSC / -5 Cap Assy
M50032 Damper Overhaul Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
Not Procurable. Not Illustrated
M50032-3 Damper Overhaul Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
(Kit W/O Air Valve) Contains Parts And Instructions For Overhaul
Of Standard Hydarulic L/G Damper Part Numbers -BSC / -11 / -21
/ -31 / -41 / -61 / -71 / -81 / -91 / -101 / -111 / -121 / -131 / -141
/ -151 Replaced By M50032-7 O/H Kit. Not Illustrated
M50032-5 Damper Overhaul Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
(Kit With Air Valve) Contains Parts And Instructions For Overhaul
And Modification Of Standard L/G Dampers From 369D26300 (All
Version) To: -161 / -171 / -181 / -191 / -201 Damper Assembly
Replaced By M50032-9 O/H Kit. Not Illustrated
M50032-7 Damper Overhaul Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
(Kit W/O Air Valve) Contains Parts And Instructions For Overhaul
Of Standard L/G Dampers Part Numbers -BSC / -11 / -21 / -31 /
-41 / -61 / -71 / -81 / -91 / -101 / -111 / -121 / -131 / -141 /
-151. Not Illustrated
M50032-9 Damper Overhaul Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
(Cap With Air Vave Turned 90 Degree) Contains Parts And
Instructions For Overhaul And Modification Of Standard L/G
Dampers From 369D26300 (All Version) To: -211 / -221 / -231 /
-241 / -251 Damper Assy. Not Illustrated

Page 1006
Revision 15 321010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL

Section

32-10-15
Landing Gear
Damper
Part Number
600N6050-31, -33

Page a/(b blank)


Revision 4
MD Helicopters, Inc. CSP-COM-5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
TABLE OF CONTENTS
Para/Figure/Table Title Page

321015 Landing Gear Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. Gas Pressure BleedOff Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3. Damper Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 301. Use of Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Cleaning/Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Paint, Torque Stripe and Identification Plate Requirements . . . . . . 402
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
A. Disassembled Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Table 501. Detailed Inspection Landing Gear Damper and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Table 502. Process Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Repair/Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Piston Replating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Replating of Landing Gear Damper Piston . . . . . . . . . . . . . . . . . . . . . 602
Assembly/Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
2. Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
Table 701. Additional Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Figure 701. Damper Assembly CrossSection View . . . . . . . . . . . . . . . . . . . . . . . 704
Figure 702. Damper Assembly Barrel Seal Installation . . . . . . . . . . . . . . . . . . . . 705

321015 Page i
Contents Revision 15
CSP-COM-5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page
3. Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706
Table 702. Nitrogen Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
Figure 703. Servicing Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
4. Acceptance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709
A. Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709
B. LoadStroke Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709
Table 703. Allowable Compression Load at Initial Deflection . . . . . . . . . . . . . . . . 710
Table 704. Allowable Compression Load at 2.50 Inch (6.35 cm) Deflection . . . . 711
5. Packing and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
6. ReCharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Table 705. Nitrogen Recharge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
Special Tools, Fixtures & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
1. Damper Overhaul Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
2. Special Tools and Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Table 901. Landing Gear Damper Assembly Overhaul Special Tools . . . . . . . 901
Table 902. Landing Gear Damper Assembly Special Torques . . . . . . . . . . . . . . . . 902
Table 903. Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 901. Special Tools Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Indenture Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Figure 1001. Damper Assembly 600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002

Page ii 321015
Revision 15 Contents
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
LANDING GEAR DAMPER
DESCRIPTION AND OPERATION
NOTE: Before attempting any repair or over (6). Assembly/Shipping . . . . . . . . . . . . . . . 701
haul of this component, ensure the required provides landing gear damper reas
special tools and processes are available to sembly, procedures for charging the
assure completion of the work. landing gear damper with dry nitrogen
gas and testing the damper for leaks.
1. General Also included in this section are
packing, storage and shipping instruc
This section of the Overhaul Manual describes tions.
overhaul procedures for the 600N6050
Landing Gear Dampers. Procedures given are (7). Special Tools, Fixtures & Equip. . . . 901
the approved methods to be used for specific provides procedures for fabricating
repair or complete overhaul of the component. special tools required for overhaul of
the landing gear damper.
2. Organization

The landing gear damper section of the (8). Illustrated Parts List . . . . . . . . . . . . 1001
Component Overhaul Manual is made up of provides a parts list supplement to
seven parts, listed below. This section contains identify part numbers and configura
complete instructions for disassembly, clean tion differences for the landing gear
ing, inspection, repair, reassembly and testing damper.
of the component. Page number blocks used for
this section, in the Component Overhaul
Manual, logically arrange the material as 3. Reference Data
follows:

(1). Description and Operation . . . . . . . . . . 1 (1). Reference is made throughout this part
provides a description and operation of of the Overhaul Manual to CSP
the component and describes proce HMI2. This manual should be used as
dures for complete use of the landing noted throughout the overhaul/repair.
gear damper section. Use the Illustrated Parts Catalog
(CSPIPC4) when ordering any
(2). Disassembly . . . . . . . . . . . . . . . . . . . . . 301 replacement parts for the 600N6050
gives procedures for complete disassem series damper assembly.
bly of the landing gear damper
(2). Table 901 and Table 903 provide
(3). Cleaning/Painting . . . . . . . . . . . . . . . . 401 specifications, and when appropriate,
contains cleaning and painting require procurement information regarding
ments for landing gear damper compo special tools, equipment, expendable
nents and parts. items and materials required for
overhaul/repair. Torque values are
(4). Inspection/Check . . . . . . . . . . . . . . . . . 501 contained in Table 902.
provides visual and dimensional
inspection requirements.
(3). Figure 1 shows an exploded view of a
(5). Repair/Modification . . . . . . . . . . . . . . 601 landing gear damper, with all parts
provides allowable repairs and parts indexed. The index numbers are used
replacement information and autho throughout the text with the part
rized modifications for the landing gear nomenclature to make part identifica
damper. tion easier.

Page 1
321015 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050
Legend (Ref. Figure 1)
1. UPPER CAP
2. *O-RING
2* 1 3. LOCKWIRE
3 4. AIR VALVE ASSEMBLY
5* 5. *O-RING
6. *SCRAPER
6* 7. *SEAL
8. BARREL
7* 9. IDENTIFICATION (I.D.) PLATE
10. PISTON
4
11. NUT
12. WASHER
13. WASHER
8 14. HOUSING
9 15. *BEARING
16. NOZZLE
17. *BACKUP RING
18. *O-RING
19. LOWER CAP

*Parts requiring replacement during overhaul,


for most current K600N6050 overhaul kit,
(Ref. Illustrated Parts List).
10

12
11

13

14

15*

16

17*

18*

19

NOTE:
ASTERISK (*) INDICATES ITEM
IS PART OF OVERHAUL KIT. H321012
Figure 1. Damper Assembly

Page 2
Revision 15 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
LANDING GEAR DAMPER
DISASSEMBLY
1. General Ensure all gas pressure in
WARNING damper has been bled off
This section describes procedures for complete prior to disassembly, according to (Ref.
disassembly of the landing gear damper. When Gas Pressure BleedOff Procedure).
specific repair of the damper requires only
partial disassembly, follow procedures to the NOTE: During disassembly, place all parts in a
point required. clean container to prevent damage from im
proper handling or exposure. Wrap piston,
A charged landing gear barrel, housing and cap assemblies in pro
WARNING damper is under high gas tective cloth to prevent damage. Discard all
pressure and must be treated cautious scrapers, seals and backup rings upon re
ly or personal injury may result. Before moval.
beginning disassembly, read entire gas
bleedoff procedures and then bleed off (1). Remove and discard lockwire wire (3,
gas from landing gear damper. Figure 1) from air value (4).

2. Gas Pressure Bleed-Off Procedure (2). Remove air valve from upper cap
assembly (1) and discard Oring (2).
Bleedoff gas pressure from landing gear
dampers prior to disassembly, as follows: (3). Remove upper cap using piston wrench
(3, Table 901) and torque wrench
Wear face shield or safety adapter (9).
WARNING eyeglasses. Read the follow
ing instructions thoroughly before be (4). Drain hydraulic fluid into waste
ginning bleed off procedure. Do not container by inverting damper.
deviate from procedures given.

(1). Place damper in cylinder holding block (5). Remove lower cap assembly (19,
as shown in Figure 301. Place block in Figure 1) using torque wrench adapter
vise with damper in vertical position, (9, Table 901).
upper cap (1, Figure 1) upward.
(6). With damper still over waste container,
(2). Remove dust cap from air valve assem separate piston assembly (10, Figure 1)
bly (4). from barrel assembly (8).

(3). Install a piece of tygon tubing over (7). Remove housing assembly (14) from
valve (gas outlet) and other end into a piston using piston wrench (3,
suitable waste container, to allow Table 901) and torque wrench adapter
overflow of damper fluid when valve is (8).
opened.
(8). Remove nozzle (16, Figure 1) from
(4). Carefully open air valve (4) in a counter housing.
clockwise direction, allowing gas
pressure to bleedoff slowly. (9). Upon removal, discard used Orings,
scraper ring, back up rings, seal and
3. Damper Disassembly bearing.

Disassemble the landing gear damper as (10). Clean and inspect parts which may be
follows: reused (Ref. Cleaning and Inspection).

Page 301
321015 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050

CYLINDER
HOLDING BLOCK

CYLINDER
HOLDING BLOCK

PISTON WRENCH

H321015

Figure 301. Use of Special Tools

Page 302
Revision 4 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
LANDING GEAR DAMPER
CLEANING/PAINTING
1. Cleaning 2. Painting
Touch up or repaint damper assembly, as
Clean all parts of the disassembled landing necessary. Repaint damper original color to
gear damper as follows: maintain distinction between standard (white)
and extended (black) landing gear dampers.
Keep upper and lower cap bear
Most cleaning solvents are CAUTION
WARNING flammable and must be kept ings clean and free of paint.
away from heat or open flame. Avoid (1). Prepare surface for painting (Ref.
inhalation of fumes and extended con CSPHMI2).
tact with skin.
(2). Paint standard landing gear dampers
white (9, Table 903) and extended
(1). Clean upper cap assembly (1, Figure 1), landing gear dampers black (10) (Ref.
air valve assembly (4) and lower cap CSPHMI2).
assembly (19) using cloth dampened
with naphtha (5, Table 903) or equiva (3). Paint torque stripe on damper caps,
lent solvent. If bearings are installed in piston and barrel, using contrasting
caps, do not submerge caps in solvent. white or black lacquer.
3. Markings
(2). Submerge remaining parts in naphtha Install new identification plate (9, Figure 1),
or equivalent solvent. when necessary, as follows:
(1). Type on new I.D. plate (9), part number
(3). Using bristle brush, remove clinging and serial number as shown on original
residue from parts. Pay particular I.D. plate. Discard original plate.
attention to packing grooves and
threaded areas. (2). Clean mounting surface with naphtha
(5, Table 903), or equivalent solvent.

(4). Dry parts with clean cloth or com (3). Place replacement plate at approximate
pressed air. location shown in Figure 401.
(4). Press plate firmly to mounting surface.
(5). Wrap cleaned parts to prevent contami (5). Seal edges of plate with fillet of plastic
nation between work operations. epoxy adhesive (8, Table 903).

Page 401
321015 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050
(NOTE 2) TORQUE STRIPE
(NOTE 1)

PISTON

0.370.62 INCH
(9.3915.75 MM)
I.D. PLATE

BARREL

0.370.62 INCH
(9.3915.75 MM)

TORQUE STRIPE
(NOTE 2) (NOTE 1)

NOTES:
1. TORQUE STRIPES PAINTED CONTRASTING BLACK
OR WHITE, AS APPLICABLE.
2. BEARINGS NOT TO BE PAINTED. H321016

Figure 401. Paint, Torque Stripe and Identification Plate Requirements

Page 402
Revision 4 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
LANDING GEAR DAMPER
INSPECTION/CHECK
1. Inspection A. Disassembled Parts

Inspect landing gear damper parts after Inspect all disassembled landing gear damper
cleaning, as described in the following proce parts according to Table 501. Perform process
dures. inspections according to Table 502.
Table 501. Detailed Inspection - Landing Gear Damper and Associated Parts
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
NOTE: All inspections are visual inspections unless otherwise indicated. For items listed in inspect column, see
Figure 1. After honing, lapping or abrasive polishing; re-clean parts.
Piston (10, Figure 1) for:
Nicks, and cuts on None allowed Light scratches to 0.005 Blend out defect
non-sealing surfaces inch depth may be
repaired

Hard Chrome, worn OD: 1.873-1.871 inch Not to exceed hard Replate piston (Ref.
(4.757-4.752 cm) chrome thickness (Ref. Repair)
Figure 601)

Hard Chrome, nicked, None allowed Not to exceed hard Replate piston (Ref.
scratched or cut chrome thickness (Ref. Repair)
Figure 601)
Damaged threads Repair all damage within Length of damaged thread Re-thread with same size
limits not to exceed 0.20 inch die
(5.08 mm) per 360
degrees of full thread

Damaged O-ring groove None allowed Light scratches to 0.001 Replace piston
inch (0.025 mm) Dents not
repairable (Ref. Repair)
Barrel (8, Figure 1) for:
Worn ID of bore ID: 2.250-2.243 inch Not repairable Replace barrel
(5.715-5.697 mm)

Light scratches in barrel None allowed Light scratches to 0.010 Polish with crocus cloth
bore inch (0.254 mm) depth
may be repaired

Exterior corrosion, Dents to 0.030 inch (0.762 Light scratches to 0.030 Polish with crocus cloth
scratches or dents mm) depth inch (0.762 mm) depth
may be repaired

Damaged threads Repair all damage within Length of damaged thread Re-thread with same size
limits not to exceed 0.30 inch die
(7.62 mm) per 360
degrees of full thread

Page 501
321015 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050
Table 501. Detailed Inspection - Landing Gear Damper and Associated Parts (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Clogged or plugged bleed Clear hole
holes

Upper and lower cap assembly (1, 19, Figure 1) for:


Scratches, pits, cracks, None allowed Shallow defects to 0.030 Polish with crocus cloth
gouges inch (0.762 mm) depth
may be removed

Worn or scratched surface None allowed Treat with chemical film


anodizing (6, Table 903) and zinc
chromate primer (7)

Loose or cracked bearing No freeplay Cap bore dia. not to Remove and replace
exceed 0.9054 inch bearing. Proof load to 100
(22.9972 mm) lbs. (444.8 N)

Clogged or plugged bleed Clear hole


holes

Upper cap air valve bore None allowed Not repairable Replace defective part
threads for burrs, nicks, or
scratches

Rotational drag between:


Piston (10) and upper cap Nylon pellets in piston and Replace nylon pellets
(1), Piston (10) and barrel threads must create
housing (14), Barrel (8) enough rotational drag to
and lower cap (19) prevent hand tightening of
mating parts

Table 502. Process Inspection Requirements


*Magnetic Particle (ASTM E1444) Fluorescent Penetrant (ASTM E1417)
Item Index No. (Figure 1) Item Index No. (Figure 1)
Piston 10 Upper cap assembly 1

Barrel 8

Housing 14
Lower cap assembly 19

NOTES:
* Paint must be removed for magnetic particle inspection but is not necessary on nonferrous parts for
fluorescent inspection. Complete removal of epoxy primer is not required on normal overhaul. For added
inspection, when inspecting for or after crash damage, all areas should be visually inspected using
minimum of 5-power magnifying glass and all suspected areas should have epoxy primer removed
locally with paint remover. Prevent entry of paint remover into joint lines of bearings, bushings or inserts
still assembled with part requiring paint removal.

Page 502
Revision 11 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
LANDING GEAR DAMPER
REPAIR/MODIFICATION
1. Repair B. Barrel
Repair procedures described in the following Repair minor scratches, nicks or light scoring
paragraphs are the only repairs authorized for on barrel (1, Figure 1) as follows:
landing gear damper parts and components.
Prior to making repairs on any part or (1). Blend out damaged area.
component, ensure that the part or component
is within repairable limits (Ref. Cleaning and (2). Reclean part (Ref. Cleaning).
Inspection). After repairs are completed, the
part or component must meet the dimensions C. Housing
specified for the part (Ref. Inspection).
Remove scratches from housing (3, Figure 1)
A. Piston Replating as follows:
Repair worn or damaged plating (Ref.
Figure 601) as follows: (1). Polish out scratches using crocus cloth.

NOTE: The following procedures cover cad (2). Reclean housing to remove all traces of
mium and chrome plating of threaded and abrasive material.
center sections of piston.
(3). Treat reworked, anodized aluminum
(1). Strip existing plating of damaged area surfaces with chemical film (6,
by reverse current method. Diameter Table 903).
prior to replating shall be 1.8671.864
inch (4.7424.735 cm). 2. Parts Replacement
(2). Magnetic particle inspect (MPI) per
MILSTD1949 with plating removed. All parts and components not meeting
specifications (Ref. Inspection), which cannot
(3). Cadmium plate threaded area accord be repaired, must be replaced. The following
ing to spec. QQP416, class 3 type II procedures describe replacement of parts
(Figure 601). which cannot be replaced as part of the
reassembly procedure.
(4). Hard chrome plate center section per
spec QQC320 class 2, type II. Hard A. Air Valve
chrome plate shall be 1.8821.878 inch
(4.7804.770 cm) dia. (Figure 601). Replacement of air valve at overhaul is
(5). Finish grind center section to required only if it is suspected of being faulty
1.8731.871 inch (4.7574.752 cm) dia. or inoperative (Ref. Assembly).

(6). Embrittlement relieve piston after 3. Modification


plating according to plating specifica
tions QQP416 and QQP320. Not applicable.

Page 601
321015 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050
DIAMETER PRIOR TO PLATING 1.3051.306 INCH (3.3153.317 CM) DIA.
HARD CHROME PLATE 1.3161.315 INCH (3.3433.340 CM) DIA.
4 FINISH GRIND 1.3101.308 INCH (3.3273.322 CM) DIA.
1 5/16 12 UN 3A
THREAD
0.002 INCH
B (0.051 MM) T.I.R B

NOTE 5 NOTE 4

NOTES:
1. REPAIRABLE DAMAGE NOT TO EXCEED HARD CHROME THICKNESS.
2. STRIP EXISTING PLATING BY REVERSE CURRENT.
3. MAGNETIC PARTICLE INSPECT PER MILSTD1949 WITH PLATING REMOVED.
4. HARD CHROME PLATE PER QQC320 CLASS 2 TYPE II.
5. CADMIUM PLATE PER QQP416, CLASS 3, TYPE I.
6. EMBRITTLEMENT RELIEVE AFTER PLATING PER SPECIFICATIONS
(MATERIAL 4340 STEEL RC 3236). H321007A

Figure 601. Replating of Landing Gear Damper Piston

Page 602
Revision 4 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
LANDING GEAR DAMPER
ASSEMBLY/SHIPPING
1. General 2, Table 903) and install into lower cap
assembly (19, Figure 1).
Only dampers which,
One have been stored less than 9 months, (5). Examine the elastomeric seal ring and
Two have satisfactorily passed shelflife plastic seal ring components (Ref.
testing or Figure 702) of seal (7, Figure 1) for
Three have been recharged, shall be nicks, scratches or other damages.
installed on helicopters or shipped as spare
parts. (6). Lubricate both components of seal (7)
with hydraulic oil.
NOTE:
(a). Install the elastomeric component of
D Assembly and testing of damper shall be ring into barrel (8) and position as
accomplished in an area of minimum con shown in Figure 702.
tamination, free of any grinding, cutting,
filing or similar contaminant producing NOTE: Care should be taken not to crease plas
operations. tic ring component during installation.
D Clean all equipment and damper compo (b). Collapse plastic ring component and
nents with naphtha or equivalent solvent place into barrel as shown in
as required to prevent contamination of Figure 702. Use fingers to smooth the
the damper assembly. inside diameter of seal ring.
D Ambient room temperature should be 60
85F (16 29C) while reassembling (7). Lubricate sizing tool (7, Table 901) with
damper. hydraulic oil and insert into bore of
barrel (8, Figure 1) with a twisting
D Oil shall be kept clean and free from con motion (Ref. Figure 702).
taminants and shall be filtered through a
10micron filter for a minimum of 15 min (8). After one minute, remove tool by
utes prior to filling each lot of dampers. pushing it out of opposite end of barrel
D Use hydraulic oil (1 or 2, Table 903) to fill with a twisting motion.
damper.
NOTE: Repeat procedure in steps (7). and (8).
D Lubricate packings with clean hydraulic again.
oil prior to installation.
(9). Examine the elastomeric scraper ring
2. Reassembly and plastic scraper ring components
(Ref. Figure 702) of scraper (6,
(1). Assemble housing (14, Figure 1), nozzle Figure 1) for nicks, scratches or other
(16), washer (13) and nut (11). Torque damages.
to 30 40 inchpounds (3.39 4.51
Nm) plus drag torque. (10). Lubricate both components of scraper
with hydraulic oil.
(2). Install bearing (15) onto housing
assembly. (a). Install the elastomeric component of
ring into barrel (8) and position as
(3). Assemble piston (10) and washer (12) shown in Figure 702.
into housing assembly. Torque to 400
450 inchpounds (45.18 50.83 Nm) NOTE: Care should be taken not to crease plas
plus drag torque, using torque wrench tic ring component during installation.
adapter (8, Table 901) and piston
wrench (3). (b). Collapse plastic ring component and
place into barrel as shown in
(4). Lubricate Oring (18, Figure 1) and Figure 702. Use fingers to smooth the
backup ring (17) with hydraulic oil (1 or inside diameter of scraper ring.

Page 701
321015 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050
(11). Place piston assembly (10) and barrel (b). Remove bolt from piston and extend
assembly into a container filled with piston approximately one inch (2.54
hydraulic oil. cm).
(a). With both assemblies immersed, (c). Determine the temperature of the
insert the piston into the barrel so fluid in the damper and add fluid in
that housing (14) is flush or below accordance with Table 701.
the end surface of barrel.
(b). With the unit still immersed, thread NOTE: Deviation from the fluid volume listed
on lower cap (19) ensuring that no air in Table 701 is allowed, but not recom
is trapped between the outer wall of mended.
piston and inner wall of barrel.
(15). With the unit still in fixture, lubricate
(12). Remove unit from container and install Oring (5, Figure 1) with hydraulic oil
extension cap (10, Table 901) over the (1 or 2, Table 903) and install onto
piston to prevent contamination. upper end of piston.
(13). Place unit in clamping fixture (4, (16). Install upper cap (1) and torque to 500
Table 901) and torque lower cap (19, 600 inchpounds (56.48 67.77
Figure 1) to 500 600 inchpounds Nm) plus drag torque, using piston
(56.48 67.77 Nm) plus drag torque, wrench (3, Table 901) and torque
using torque wrench adapter (9, wrench adapter (9).
Table 901).
(17). Lubricate Oring (2, Figure 1) with
(14). Remove extension cap and insert bolt hydraulic oil and insert onto air valve
(15, Table 901) into top of piston. (4).
NOTE: Alternate bolt may be used provided it
is 9/16 inch (14.28 mm) in diameter, and the (18). Install air valve (4) into upper cap and
overall length minus the head length is torque to 80 85 inchpounds (9.03
2.0222.042 inch (5.1365.187 cm) and the 9.60 Nm). Safety wire air valve to cap
shank has no holes. assembly with lockwire (3, Table 903).

(a). Fully compress piston by pushing (19). Clean damper assembly with naphtha
down on bolt. (5) or equivalent solvent.

Page 702
Revision 4 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
Table 701. Additional Hydraulic Fluid
600N6050-33 600N6050-31
Hydr Fluid Temp Fluid Volume Fluid Volume
F ( C) Oz 0.020 (cc 0.5) Oz 0.020 (cc 0.5)
50 (10.0) 0.216 (6.4) 0.125 (3.7)
52 (11.1) 0.223 (6.6) 0.135 (4.0)
54 (12.2) 0.233 (6.9) 0.145 (4.3)
56 (13.3) 0.243 (7.2) 0.156 (4.6)
58 (14.4) 0.254 (7.5) 0.166 (4.9)
60 (15.6) 0.263 (7.8) 0.172 (5.1)
62 (16.7) 0.274 (8.1) 0.183 (5.4)
64 (17.8) 0.281 (8.3) 0.193 (5.7)
66 (18.9) 0.291 (8.6) 0.203 (6.0)
68 (20.0) 0.301 (8.9) 0.213 (6.3)
70 (21.1) 0.311 (9.2) 0.220 (6.5)
72 (22.2) 0.321 (9.5) 0.230 (6.8)
74 (23.3) 0.331 (9.8) 0.240 (7.1)
76 (24.4) 0.338 (10.0) 0.250 (7.4)
78 (25.6) 0.348 (10.3) 0.260 (7.7)
80 (26.7) 0.358 (10.6) 0.271 (8.0)
82 (27.8) 0.369 (10.9) 0.277 (8.2)
84 (28.9) 0.379 (11.2) 0.287 (8.5)
86 (30.6) 0.389 (11.5) 0.298 (8.8)
88 (31.1) 0.396 (11.7) 0.308 (9.1)
90 (32.2) 0.406 (12.0) 0.318 (9.4)

Page 703
321015 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050

UPPER CAP ASSEMBLY

ORING
SCHRADER VALVE
ASSEMBLY
ORING

SCRAPER
ELASTOMER

SEAL

ELASTOMER

BARREL

PISTON

HOUSING

WASHER
NUT
WASHER
NOTE:
DAMPER ASSEMBLY SHOWN COMPRESSED.
BACKUP RING

ORING

BEARING
NOZZLE

LOWER CAP ASSEMBLY


H321013

Figure 701. Damper Assembly - Cross-Section View

Page 704
Revision 4 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050

COLLAPSED PLASTIC RINGS

PLASTIC SCRAPER RING



BARREL




ELASTOMERIC
SCRAPER RING
TWIST





ELASTOMERIC
SEAL RING
PLASTIC SEAL RING

SIZING TOOL

H321014

Figure 702. Damper Assembly - Barrel Seal Installation

Page 705
321015 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050
3. Charging (a). While the gas is still flowing, tighten
coupling and slowly increase the
Procedures for charging the landing gear nitrogen pressure by turning the
damper with dry nitrogen gas and testing the regulator control.
damper for leaks are described in the following
paragraphs. NOTE: As the pressure increases, the piston
rod will extend from the cylinder. Allow am
NOTE: Onaircraft charging of installed damp ple room for full extension of the damper as
ers shall be performed as specified in Ap sembly.
pendix A (Ref. Table 705).
(b). When the pressure reaches the
The following steps shall be performed when desired level stipulated in Table 702
charging the unit before installation on in accordance with temperature, stop
aircraft. increasing pressure and allow two
Use dry nitrogen only, for charg minutes for the pressure to stabilize.
CAUTION ing damper. Store nitrogen
(6). Recheck the correct pressure.
bottle in same room or area where charging
is to occur for minimum of 12 hours prior to (7). If the damper is slightly over pressur
charging. Failure to observe these precau ized, bleed off the excess nitrogen very
tions may result in injury to personnel. slowly by reducing the regulator
pressure slightly and loosening cou
(1). Connect coupling (5, Table 901) on the
pling.
charging hose to air valve (4, Figure 1)
but do not tighten (Ref. Figure 703). If nitrogen is bled off quickly, re
CAUTION sulting in loss of oil, back off the
(2). Ensure the low side of the gas pressure
regulator has been backed off to the low side of the pressure regulator to the un
unpressurized position. pressurized position. Close the high pres
sure bottle valve, close the damper air valve
(3). Open air valve by turning the outside (4, Figure 1) and disconnect the charging
nut counterclockwise. hose. The damper assembly shall be dis
charged, disassembled and reassembled.
(4). Slowly open the highpressure bottle
valve. (8). Close air valve by turning the outside
nut clockwise. Torque nut to 50 60
(5). Slowly turn regulator control until inchpounds (5.64 6.77 Nm).
there is a flow of gas at the loose
coupling. Allow this flow to continue for (9). Reduce the system charge pressure to
approximately 30 seconds to purge air zero and remove the charging hose from
from system. the air valve.

Page 706
Revision 4 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
Table 702. Nitrogen Charge Pressure
600N6050-33 600N6050-31
Ambient Temperature Nitrogen Pressure Nitrogen Pressure
F ( C) Psig (kPa) Psig (kPa)
50 (10.0) 372 (2565) 202 (1393)
52 (11.1) 374 (2579) 203 (1400)
54 (12.2) 376 (2592) 205 (1413)
56 (13.3) 379 (2613) 206 (1420)
58 (14.4) 381 (2627) 208 (1434)
60 (15.6) 384 (2648) 209 (1441)
62 (16.7) 386 (2661) 210 (1448)
64 (17.8) 389 (2682) 211 (1455)
66 (18.9) 391 (2696) 213 (1469)
68 (20.0) 394 (2717) 214 (1475)
70 (21.1) 396 (2730) 215 (1482)
72 (22.2) 399 (2751) 217 (1496)
74 (23.3) 401 (2765) 218 (1503)
76 (24.4) 404 (2785) 219 (1510)
78 (25.6) 406 (2799) 221 (1524)
80 (26.7) 409 (2820) 222 (1531)
82 (27.8) 411 (2834) 223 (1538)
84 (28.9) 414 (2854) 225 (1551)
86 (30.0) 416 (2868) 226 (1558)
88 (31.1) 419 (2889) 227 (1565)
90 (32.2) 422 (2910) 229 (1579)

Page 707
321015 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050

CAP
UPPER
DAMPER CAP

COUPLING

OUTSIDE
AIR NUT
VALVE

HIGH PRESSURE
VALVE

REGULATOR
CONTROL

H321017

Figure 703. Servicing Damper

Page 708
Revision 4 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
4. Acceptance Testing (1). Install damper assembly into the load
test fixture (11, Table 901).
All damper assemblies shall be tested in
accordance with the following procedures. (2). Set and activate the load measurement
Failure to meet these requirements shall be system (13).
cause for rejection. Complete records of all
testing and recharging of each damper (3). Slowly compress damper assembly until
assembly shall be permanently retained in a load of 57006300 pounds
inspection files. (2535428022 N) is obtained.

High pressures will be gen NOTE: The recommended time to compress is


WARNING erated in the damper assem 30 seconds.
bly throughout the acceptance testing.
Do not exceed a load of 6300
Observe proper safety precautions to CAUTION pounds (28022 N). Failure to ob
prevent injury.
serve this precaution may result in damage
A. Leakage Test to equipment and failure of parts.
(1). Using the cycle fixture (6, Table 901), (4). Slowly extend damper assembly until
cycle each damper assembly through 50 the compression load is completely
compression strokes of 1.201.80 inch removed
(3.044.57 cm), while in a vertical
position. NOTE: The recommended time to extend is 30
seconds.
(2). All compression strokes shall be
accomplished within 30 seconds. (5). Remove damper assembly from the test
fixture.
NOTE: Do not pull the unit on the extension
stroke. NOTE:
(3). After cycling, place the assembly on a D Examine the loadversusstroke plot for
clean surface in a position best suited to irregularities. The extension curve shall
note leakage past the main piston seal. closely follow the compression curve, ex
cept for hysteresis, and both curves shall
(4). Check for leakage after a minimum of 1 be smooth and regular.
hour. D If jerkiness or irregularity on either the
extension or compression curve is ob
NOTE: Minor seepage (wetting of the surface)
served, damper assembly shall be dis
shall be considered normal and shall not be
charged and disassembled to determine
cause for rejection.
the cause of binding.
B. Load-Stroke Test D Examine the loadversusstroke plot for
load values. Compare the actual initial
NOTE: deflection load with the minimum and
D A load versus stroke plot shall be maximum allowable loads listed in
created for each damper assembly while Table 703, for the appropriate tempera
in a vertical position. ture. The actual initial deflection load for
D A permanent record shall be made of both the compression and extension stroke
the compression and extension strokes. shall be within the allowable load limits.
D The record shall be identified with the se D Compare the actual 2.50 inch (6.35 cm)
rial number, lot number, and temperature deflection load with the minimum and
of the damper assembly. The record shall maximum allowable loads listed in
be permanently retained in the inspection Table 704, for the appropriate tempera
files. ture. The actual 2.50 inch (6.35 cm)
deflection load for the compression and
Perform the loadversusstroke test as extension stroke shall be within the al
follows: lowable load limits.

Page 709
321015 Revision 4
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050
(6). If the damper assembly fails the
loadstroke test, recharge in accordance
with Table 705 and repeat the loadver
susstroke test. Damper assemblies
that have been recharged a second time
and fail the loadversusstroke test,
shall have all seals replaced.
Table 703. Allowable Compression Load at Initial Deflection
600N6050-33 600N6050-31
Ambient Temperature lbs. (N) lbs. (N)
F ( C) min.-max. min.-max.
50 (10.0) 804-1064 (3576-4733) 442-584 (1966-2598)
52 (11.1) 809-1070 (3598-4759) 445-589 (1979-2620)
54 (12.2) 814-1076 (3621-4786) 448-592 (1993-2633)
56 (13.3) 819-1083 (3643-4817) 450-596 (2002-2651)
58 (14.4) 824-1090 (3665-4848) 454-600 (2019-2669)
60 (15.6) 830-1097 (3692-4879) 457-604 (2033-2687)
62 (16.7) 835-1 104 (3714-4911) 459-607 (2042-2700)
64 (17.8) 840-1 111 (3736-4942) 462-61 1 (2055-2718)
66 (18.9) 845-1 118 (3759-4973) 465-615 (2068-2736)
68 (20.0) 850-1 125 (3781-5004) 468-619 (2082-2753)
70 (21.1) 856-1 132 (3807-5035) 471-623 (2095-2771)
72 (22.2) 861-1 139 (3830-5066) 474-627 (2108-2789)
74 (23.3) 866-1 145 (3852-5093) 477-630 (2122-2802)
76 (24.4) 871-1 152 (3874-5124) 480-635 (2135-2824)
78 (25.6) 877-1 159 (3901-5155) 483-638 (2148-2838)
80 (26.7) 882-1 166 (3923-5186) 486-643 (2162-2860)
82 (27.8) 888-1 174 (3950-5222) 489-646 (2175-2873)
84 (28.9) 893-1 181 (3972-5253) 491-650 (2184-2891)
86 (30.0) 898-1 188 (3994-5284) 495-654 (2202-2909)
88 (31.1) 903-1 195 (4017-5315) 497-658 (2211-2927)
90 (32.2) 910-1203 (4048-5351) 501-662 (2228-2945)

Page 710
Revision 5 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
Table 704. Allowable Compression Load at 2.50 Inch (6.35 cm) Deflection
600N6050-33 600N6050-31
Ambient Temperature lbs. (N) lbs. (N)
F ( C) min.-max. min.-max.
50 (10.0) 3261-4313 (14505-19184) 1797-2376 (7993-10568)
52 (11.1) 3300-4364 (14678-19411) 1817-2404 (8082-10693)
54 (12.2) 3340-4417 (14856-19647) 1838-2431 (8175-10813)
56 (13.3) 3380-4470 (15034-19883) 1860-2460 (8273-10942)
58 (14.4) 3422-4525 (15221-20127) 1882-2489 (8371-11111)
60 (15.6) 3463-4580 (15403-20372) 1904-2519 (8469-11205)
62 (16.7) 3506-4637 (15595-20625) 1927-2548 (8571-11334)
64 (17.8) 3549-4693 (15786-20874) 1950-2578 (8674-11467)
66 (18.9) 3592-4751 (15977-21132) 1973-2609 (8776-11605)
68 (20.0) 3637-4809 (16177-21390) 1997-2640 (8883-11743)
70 (21.1) 3682-4869 (16378-21657) 2020-2671 (8985-11881)
72 (22.2) 3728-4930 (16582-21929) 2044-2704 (9092-12027)
74 (23.3) 3774-4991 (13787-22200) 2069-2736 (9203-12170)
76 (24.4) 3822-5054 (17000-22480) 2094-2769 (9314-12317)
78 (25.6) 3870-51 18 (17214-22765) 2121-2805 (9434-12477)
80 (26.7) 3918-5182 (17427-23050) 2145-2837 (9541-12619)
82 (27.8) 3968-5247 (17650-23339) 2171-2872 (9657-12775)
84 (28.9) 4017-5313 (17868-23632) 2198-2907 (9777-12930)
86 (30.0) 4069-5381 (18099-23935) 2225-2943 (9897-13090)
88 (31.1) 4168-5512 (18539-24517) 2253-2980 (10021-13255)
90 (32.2) 4174-5520 (18566-24553) 2281-3016 (10146-13415)

Page 711
321015 Revision 5
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050
5. Packing and Storage (2). Connect charging hose to air valve (4,
Figure 1), but do not tighten.
Overhauled dampers that will not be used
immediately should be packaged and stored as (3). Ensure low side of gas pressure
follows: regulator has been backed off to the
unpressurized position. Slowly open the
(1). After each completed shipset has been high pressure bottle valve.
tested and found satisfactory, each
damper assembly shall be packaged in (4). Slowly turn regulator control until
a sealed transparent container until there is a flow of gas at the loose
installation on the aircraft. A tag shall connection between the hose and air
be attached to each damper showing valve.
date of test.
Do not open air valve without
CAUTION pressurizing the charge line.
(2). Each damper assembly removed from
storage for use in production aircraft or Opening the air valve without pressurizing
for shipment as spares, shall be tested the charge line will cause loss of damper
in accordance with the loadstroke test, fluid. If loss of fluid occurs, damper assem
when the unit has been in storage for bly must be overhauled.
more than 9 months.
(a). While gas is flowing, tighten hoseair
(3). If the unit meets test requirements, valve connection and slowly increase
repackage in accordance with step the nitrogen pressure by turning
5.(1)., above. If the unit fails, proceed as regulator control.
specified in step B.(6). (b). Before opening air valve, allow
6. Re-Charging pressure to increase to the level
stipulated in Table 705.
NOTE: These procedures shall be used only as (5). Open air valve by turning the outside
specified in this section. Initial damper
nut counterclockwise, allowing system
charging shall be performed per the Charg
and damper pressures to equalize.
ing procedure (Ref. Charging).
(a). If damper assembly is slightly over
The need to increase damper charge pressure pressurized, bleed off excess nitrogen
shall be determined by damper extension very slowly by reducing regulator
checks in accordance with the Acceptance pressure slightly and loosening hose
Testing procedure (Ref. Acceptance Testing). coupling (5, Table 901).
Do not attempt to recharge a
CAUTION damper that shows evidence of
(6). Close air valve by turning the outside
nut clockwise. Torque nut to 50 60
leaking. Recharging a leaking damper will inchpounds (5.64 6.77 Nm).
cause further leakage of both gas and damp
er fluid and may pose a danger to the air (7). Back off low side of pressure regulator
craft and/or personnel. to the unpressurized position, close
high pressure bottle valve and discon
(1). If damper is installed on aircraft, place nect the charging hose.
the aircraft on jacks so that the damper
assemblies are in full extension. (8). After 2 hours, inspect for leakage.

Page 712
Revision 5 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
Table 705. Nitrogen Recharge Pressure
Ambient Temperature 600N6050-33 600N6050-31
F ( C) Psig (kPa) Psig (kPa)
-40 (-40) 263 (1813) 151 (1041)
-35 (-37) 268 (1848) 153 (1055)
-30 (-34) 272 (1875) 156 (1076)
-25 (-32) 277 (1910) 158 (1089)
-20 (-29) 281 (1937) 161 (1110)
-15 (-26) 286 (1972) 163 (1124)
-10 (-23) 291 (2006) 166 (1145)
-5 (-21) 295 (2034) 169 (1165)
0 (-18) 300 (2068) 171 (1179)
5 (-15) 305 (2103) 174 (1200)
10 (-12) 310 (2137) 177 (1220)
15 (-9) 315 (2172) 179 (1234)
20 (-7) 320 (2206) 182 (1255)
25 (-4) 325 (2241) 185 (1276)
30 (-1) 330 (2275) 188 (1296)
35 (2) 335 (2310) 191 (1317)
40 (4) 340 (2344) 194 (1338)
45 (7) 345 (2379) 197 (1358)
50 (10) 351 (2420) 199 (1372)
55 (13) 356 (2455) 202 (1393)
60 (16) 361 (2489) 205 (1413)
65 (18) 367 (2530) 208 (1434)
70 (21) 372 (2565) 211 (1455)
75 (24) 378 (2606) 215 (1482)
80 (27) 383 (2641) 218 (1503)
85 (29) 389 (2682) 221 (1524)
90 (32) 395 (2723) 224 (1544)
95 (35) 400 (2758) 227 (1565)
100 (38) 406 (2799) 230 (1586)
105 (41) 412 (2841) 234 (1613)
110 (43) 418 (2882) 237 (1634)
115 (46) 424 (2923) 240 (1655)
120 (49) 430 (2965) 244 (1682)
125 (52) 436 (3006) 247 (1703)

Page 713/(714 blank)


321015 Revision 5
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
LANDING GEAR DAMPER
SPECIAL TOOLS, FIXTURES & EQUIPMENT
1. Damper Overhaul Kit wrench may be locally fabricated.
Figure 901 illustrates requirement for
A damper overhaul kit (PN K600N6050) is fabrication of these tools.
available for use when overhauling a landing
gear damper. The kit contains damper parts
which must be replaced at overhaul. Each kit (2). Table 901 and Table 903 provide
contains parts required for one damper. (Ref. specifications, and when appropriate,
Figure 1 for parts included in K600N6050 procurement information, regarding
damper overhaul kit.) special tools and equipment, and
2. Special Tools and Repair Materials expendable items and materials
required for overhaul/repair. Torque
(1). Cylinder holding block and piston values are contained in Table 902.

Table 901. Landing Gear Damper Assembly Overhaul - Special Tools


Item
No. Nomenclature Part No. Manufacturer
1 Pressure Gage, 0-2000 psi (0-14000 kPa) in Commercial
10-psi (0-50 kPa) increments
2 Charging Tool 369D26300-80901 MDHI
3 Piston Wrench 600N6052-1-A TP1 MDHI
4 Clamping Fixture 600N6051-1-CF1 MDHI
5 Coupling SK2043C Ryder System Company
Avial Branch
215 S. 28th St.
Phoenix, AZ 85034
6 Cycle Test Fixture 269A3103-32501
7 Sizing Tool 600N6051-1-A TP1 MDHI
8 Torque Wrench Adapter 600N6053-1-A TP1 MDHI
9 Torque Wrench Adapter 600N6054-1-A TP1 MDHI
10 Extension Cap 600N6052-1-A TP2 MDHI
11 Load Test Fixture 269A3103-32502
12 Load Fixture Adapter 600N6050-1-A TP1 MDHI
13 Load Measurement System 600N6050-1-A TP2 MDHI
14 Cycle Fixture Adapter 600N6050-1-A TP3 MDHI
15 Bolt NAS6209-23 or Locally Available
NAS6209-23H

Page 901
321015 Revision 10
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050
Table 902. Landing Gear Damper Assembly Special Torques
Torque
Item Figure 1, Index No. (In.-Lb.) (Nm)
Upper Cap Assembly 4 500 - 600 56.49 - 67.79
Lower Cap Assembly 9 500 - 600 56.49 - 67.79
Air Valve 16 80 - 85 9.04 - 9.60
Housing 3 400 - 450 45.19 - 50.84

Table 903. Repair Materials


Item
No. Material Specification No. Name/No. Manufacturer
1 Hydraulic
y Fluid (oil),
( ) MIL-H-5606 PQ Hydraulic oil American Oil Co.
petroleum
l base
b
Brayco 756C Bray Oil Company
Brayco 756D Bray Oil Company
3126 Hydraulic oil Exxon Company
AeroShell fluid 4 Shell Oil Company
PED 3337 Standard Oil Co.
2 Hydraulic
y Fluid (oil),
( ) MIL-H-6083 UNIVIS PJ-44 Exxon Company
preservation
i and d operation
i Type
T I
Brayco 783 Bray Oil Company
3 Dry nitrogen (pressure regulated) Ultra Pure, Grade 5 (3)
or equivalent
4 Dry cleaning solvent P-D-680 (3)
5 Naphtha TT-N-95 (3)
6 Chemical film zinc MIL-C-5541, (3)
Class 2
7 Primer MIL-P-85582 (3)
8 Adhesive, epoxy MIL-A-52194 Scotch Weld EC1838 3M Company
(nonstructural) (Parts A and B)
9 Paint, white, lusterless Fed Std 595 (3)
(Color 17875)
10 Paint, black, semigloss Fed Std 595 (3)
(Color 27038)
11 Filter, 10 micrometer

Page 902
Revision 12 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
Table 903. Repair Materials (Cont.)
Item
No. Material Specification No. Name/No. Manufacturer
12 Corrosion Preventative MIL-C-81309 Corrosion X Corrosion Technolo-
Type II gies Corp.
Fluid Film Eureka Chemical Co.

NOTES:
(1) Numbers are U. S. A. Specifications and Standards. The prefix symbols are defined as follows:
AMS - American Material Standard; MS - Military Standard; MIL - Military Specification; single, double or
triple alpha prefix of the same letter - Federal Specification; AN - Air Force-NavyAeronautical Standard;
NAS - National Aerospace Standard.
(2) Primary selection. Any equivalent material may be used as an alternate selection.
(3) Use the best equivalent commercial grade material when the conformity of available materials of the
same type with the listed U. S. A. Specification No. cannot be determined.

0.10 INCH
(0.254 MM)

2.52 INCH 3.20 INCH


(6.40 CM) DI (8.13 CM)
AMETER

4.0 INCH
(10.16 CM) 0.215 INCH
(5.461 MM)
JAW THICKNESS

1.50 INCH
(3.81 CM)

CYLINDER HOLDING BLOCK PISTON WRENCH


(MAKE FROM MAPLE OR EQUIVALENT HARDWOOD) (MAKE FROM 1 1/2 INCH (38 MM)
OPEN END WRENCH)

H3210051

Figure 901. Special Tools Fabrication

Page 903/(904 blank)


321015 Revision 5
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
LANDING GEAR DAMPER
ILLUSTRATED PARTS LIST
1. General Explanations of codes and abbreviations used
in this illustrated parts list can be found by
This section contains an illustrated parts list referring to the Introduction section of
to be used in conjunction with the 600N3050 CSPIPC4.
Landing Gear Damper overhaul manual.
Correct part numbers and nomenclature can
be identified for specific configurations and 2. Indenture Level
effectivities.
Item numbers in this parts list refer to the The indenture level to a higher assembly is
figure preceding the parts list table. An item indicated by the amount of bullets in front of
number may be the same or different from the each item in the description column. An item
same part shown in a different illustration that has one more bullet than the part above it
elsewhere in the overhaul manual. is a sub part of that assembly.

Page 1001
321015 Revision 14
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050

9
6
10

11
7

13
18

12

16

15

17

14

321021

Figure 1001. Damper Assembly - 600N

Page 1002
Revision 15 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N6050
Qty.
Fig. &
Part Number Description per
Index
Assy.
1001- 600N6050-33 Damper, Assy, Aft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
600N6050-31 Damper Assy, Fwd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
1 MS28889-2 Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 MS28775-015 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 600N6054-5 Cap Assy, Upr Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 600N6050-31
3 600N6054-1 Cap Assy, Upr Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 600N6050-33
4 MS28775-1 18 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 600N6052-1 Piston, Damper - L/G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 S32925-20G99 Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 S34851-225BAK99 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 600N6057-3 Washer, Damper - L/G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 MS21042L4 Nut, Self Locking, Reduced Hexagon . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 600N6057-1 Washer, Damper - L/G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 600N6055-1 Nozzle, Damper - L/G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 S34546-328-04-8 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 600N6053-19 Housing, Damper - L/G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 600N6050-33
13 600N6053-15 Housing, Damper - L/G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 600N6050-35
14 600N6059-1 Cap Assy, Lwr Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 MS27595-144 Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
16 MS28775-144 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 600N6058-7 Plate, I.D. - L/G Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 600N6050-31
17 600N6058-5 Plate, I.D. - L/G Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 600N6050-33
18 600N6051-1 Barrel, Damper - L/G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
K600N6050 Damper Overhaul Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF

Page 1003
321015 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N6050

This Page Intentionally Left Blank

Page 1004
Revision 14 321015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL

Section

62-30-10
Main Rotor
Swashplate
Part Number
369D27609-BSC, -501, -503

Page a
Revision 14
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL

This Page Intentionally Left Blank

Page b
Revision 14
MD Helicopters, Inc. CSP-COM-5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
TABLE OF CONTENTS
Para/Figure/Table Title Page

623010 Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. General Disassembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. Double Row Ball Bearing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3. Main Rotor Swashplate Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
4. Double Row Ball Bearing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Figure 301. Main Rotor Swashplate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 302
Figure 302. Main Rotor Swashplate CrossSection View . . . . . . . . . . . . . . . . . . 303
Cleaning/Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Preparation and Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Table 401. Cleaning Main Rotor Swashplate Parts and Components . . . . . . . . . 401
Table 402. Painting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Table 501. Detailed Inspection After Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Table 502. Process Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 501. Service Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Repair/Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Minor Nicks, Scratches and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Surface Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Rotating and Stationary Swashplate Repair Rodend Bolt Holes . . . . . . . . . . . . 601
3. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4. Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Rotating and Stationary Swashplate RepairRodend Bolt
Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Assembly/Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
1. Swashplate Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
2. Regreasing Swashplate Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
3. Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702

623010 Page i
Contents Revision 15
CSP-COM-5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page
4. Counterweight and Interrupter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
5. RunIn Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Figure 701. Regreasing Bearing with Regreasing Tool Exploded View . . . . . . 703
Figure 702. Bearing Installation Rotating Swashplate . . . . . . . . . . . . . . . . . . . . . . 704
Figure 703. Main Rotor Swashplate CrossSection View . . . . . . . . . . . . . . . . . . 704
Figure 704. Swashplate Bearing Disassembly Assembly . . . . . . . . . . . . . . . . . . . 705
6. Packing and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
Special Tools, Fixtures & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
1. Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Table 901. Main Rotor Swashplate Assembly Overhaul Special Tools . . . . . . 901
Table 902. Main Rotor Swashplate Assembly Special Torques . . . . . . . . . . . . . . . 901
Table 903. Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Bearing Regreasing Tool Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . 903
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Indenture Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Figure 1001. Main Rotor Control Swashplate Assembly . . . . . . . . . . . . . . . . . . . . . 1002

Page ii 623010
Revision 15 Contents
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
MAIN ROTOR SWASHPLATE
DESCRIPTION AND OPERATION
NOTE: Before attempting any repair or over replacement information and autho
haul of this component, ensure the required rized modifications for the main rotor
special tools and processes are available to swashplate.
assure completion of the work.
(6). Assembly/Shipping . . . . . . . . . . . . . . . 701
1. General provides main rotor swashplate
reassembly and shipping instructions.
This section of the Overhaul Manual describes
overhaul procedures for the Main Rotor (7). Special Tools, Fixtures
Swashplate Assembly used in conjunction with & Equipment . . . . . . . . . . . . . . . . . . . . 901
the fivebladed main rotor system. Procedures provides procedures for fabricating
given are the approved methods to be used for special tools required for overhaul of
specific repair or complete overhaul of the the main rotor swashplate.
component. (8). Illustrated Parts List . . . . . . . . . . . . 1001
A. Organization provides a parts list supplement to
identify part numbers and configura
The Main Rotor Swashplate section of the tion differences for the main rotor
Component Overhaul Manual is made up of swashplate.
seven parts, listed below. These sections
contain complete instructions for disassembly, B. Reference Data
cleaning, inspection, repair, reassembly and (1). Reference is made throughout this
testing of the component. The following section of the Overhaul Manual to
describes the topic and content of each part CSPHMI2. This manual should be
with appropriate page numbers: used as noted throughout the overhaul/
(1). Description and Operation . . . . . . . . . . 1 repair. The Illustrated Parts Catalog
describes procedures for complete use of (CSPIPC4) should be used for
the main rotor swashplate section. ordering any replacement parts
required.
(2). Disassembly . . . . . . . . . . . . . . . . . . . . . 301
(2). Table 901 and Table 903 provide
gives procedures for complete disassem
specifications, and when appropriate,
bly of the main rotor swashplate.
procurement information regarding
(3). Cleaning/Painting . . . . . . . . . . . . . . . . 401 special tools and equipment, and
contains cleaning requirements for expendable items and materials
main rotor swashplate components and required for overhaul and repair.
parts. Torque values are in Table 902.

(4). Inspection/Check . . . . . . . . . . . . . . . . . 501 (3). Figure 1 shows an exploded view of the


provides visual and dimensional main rotor swashplate assembly, with
inspection requirements. all parts indexed. The index numbers
are used throughout the text with the
(5). Repair/Modification . . . . . . . . . . . . . . 601 part nomenclature to make part
provides allowable repairs and parts identification easier.

Page 1
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CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609
5

26
6
24
8
3
23
4
22
9
11
23 9 10

24 14
15 12
(NOTE 4)
25 13
(NOTE 2) 16

26 18

16 17
15 13
(NOTE 4) (NOTE 2)
19
(NOTE 3)

13 (NOTE 1)
(NOTE 2) 17
14 18

10

11

21
13 7
(NOTE 2)

12 20

NOTES: 1 2 2
1. INTERRUPTER USED AT THIS LOCATION IS NOT PART
OF SWASHPLATE: INSTALLED AT INSTALLATION OF 1
SWASHPLATE ON HELICOPTER.
2. MARK INTERRUPTERS FOR CORRECT REINSTALLED.
3. INSTALL ROTATING SWASHPLATE LIP SIDE DOWN.
4. COUNTERWEIGHTS ARE INSTALLED ON CURRENT
MODEL SWASHPLATES. IF COUNTERWEIGHTS ARE TO
BE REMOVED, MAIN ROTOR HUB IS TO BE REBALANCED. H623011D

Figure 1. Main Rotor Swashplate

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Revision 15 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
Legend (Ref. Figure 1)
1. NUT (BEARING FLANGE) 14. BOLT
2. WASHER 15. COUNTERWEIGHTS
3. BOLT 16. WASHER
4. BOLT 17. NUT (COUNTERWEIGHT)
5. NUT (BEARING RETAINER) 18. COTTER PIN
6. WASHER 19. ROTATING SWASHPLATE
7. BOLT 20. STATIONARY SWASHPLATE
8. BEARING RETAINER 21. IDENTIFICATION
9. BEARING ASSEMBLY 22. ROLLER BEARING
10. NUT (INTERRUPTER) 23. SEAL
11. WASHER 24. SNAP RING
12. BOLT 25. SPHERICAL BEARING
13. INTERRUPTER 26. SNAP RING

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This Page Intentionally Left Blank

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Revision 14 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
MAIN ROTOR SWASHPLATE
DISASSEMBLY
1. General Disassembly Information When bolts (3 and 4, Figure 1)
CAUTION are removed, bearing assembly
(9) must be swiveled. Use care when swivel
This section describes procedures for complete ing bearing to prevent dirt and foreign mat
disassembly of the main rotor swashplate. ter from entering between balls and Teflon
When specific repair of the swashplate liner.
requires only partial disassembly, follow the
procedures to the point required. (1). Remove four nuts (1), washers (2) and
close tolerance bolts (3 and 4) attaching
flange of bearing assembly (9) to
2. Double Row Ball Bearing Check
stationary swashplate (20).

Prior to disassembly, check bearing assembly NOTE: It may be necessary to heat swashplate
(9, Figure 1) for axial or radial play as follows: assembly to 27525 (135C 12) when
disassembling. Heat gun may be used, en
sure heat is not localized on one area of
(1). Clamp stationary swashplate (20) to swashplate. Use gloves to protect hands
prevent movement. when handling heated components.

NOTE: The slotted bushing used in each clevis (2). Position stationary swashplate tool (1,
of main rotor swashplate to attach upper Table 901) against lower end of bearing
end of mixer links (CSPHMI2) must be in assembly (9, Figure 1) as shown in
stalled when checking double row ball bear Figure 301. Press on stationary swash
ing for axial and radial play. plate arms to separate rotating swash
plate and bearing assembly from
stationary swashplate. Little pressure
(2). Using dial gage, measure axial play is required except in cases of corroded
between one arm of rotating swashplate or damaged parts.
and slotted bushing in stationary
swashplate. (3). Remove four nuts (5, Figure 1), washers
(6), bolts (7) and bearing retainer (8).
(3). Using dial gage, measure radial play
Bearing assembly will be dam
between one arm of rotating swashplate CAUTION aged if pressure is applied to
and slotted bushing in stationary
swashplate. bearing inner race while pressing bearing
assembly out of rotating swashplate.

NOTE: If measurable axial or radial play ex (4). Position rotating swashplate tool (2,
ists, double row bearings are not serviceable Table 901) against lower side of bearing
and replacement is required. assembly (9) outer race as shown in
Figure 301. Carefully press bearing
assembly from sealed position in
(4). Remove slotted bushing from clevis and
rotating swashplate (19, Figure 1).
unclamp stationary swashplate.
NOTE: Mark interrupters (13) to ensure reas
3. Main Rotor Swashplate Disassembly sembly on same swashplate arm.

(5). Remove cotter pins (18), nuts (17),


Disassemble the main rotor swashplate washers (16), bolts (14) and interrupt
assembly as follows: ers (13).

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CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609
NOTE: (7). Remove nuts (10), washers (11), bolts
D If installed, mark or tag counterweights (12) and interrupters (13).
and all attaching hardware at removal.
Counterweight is matched (balanced) 4. Double Row Ball Bearing Disassembly
with rotating swashplate and must be re
installed in same swashplate arm with Disassemble bearing assembly (9, Figure 1) as
hardware removed. follows:
D Counter weights can be removed from
swashplate, but main rotor hub must be NOTE: Do not use excessive force when remov
rebalanced per CSPHMI2. ing snap ring.
D If installing new counterweights, a com
bination of one thin and one thick coun (1). Remove the upper snap ring from
terweight is recommended (this will get bearing assembly using screw driver
balance within 5 15 grams); Main rotor (Ref. Figure 704).
hub must be rebalanced.
(2). Position bearing assembly on a suitable
(6). If counterweights (15) show evidence of press. Apply force to outer race of
corrosion or looseness in bore, remove spherical bearing to separate from
using suitable press and adapters. roller bearing (Ref. Figure 704).

PRESS DOWNWARD
AGAINST STATIONARY
SWASHPLATE ARMS

PRESS AGAINST OUTER RACE


OF BALL BEARING ASSY
ROTATING SWASHPLATE
STATIONARY SWASHPLATE BEARING TOOL (2, TABLE 901)
TOOL (1, TABLE 901)
0.15 IN. (3.81 MM) 0.25 IN. (6.35 MM)
WALL THICKNESS WALL THICKNESS

4.28 IN. 5.10 IN.


(10.87 CM) OD (12.95 CM) OD
BEARING REMOVAL WITH STATIONARY BEARING REMOVAL FROM
SWASHPLATE INSTALLED ROTATING SWASHPLATE

CAUTION: Figure 301. Main Rotor Swashplate - Replacement


USED TO AVOID NICKING OR DENTING SPHERICAL BALL.
H623012

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Revision 3 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
NO ROTATION AT
THIS SURFACE IDENTIFICATION PLATE

ROTATING SWASHPLATE
DOUBLE ROW
BALL BEARING

SPHERICAL BALL BEARING STATIONARY SWASHPLATE


H623013

Figure 302. Main Rotor Swashplate - Cross-Section View

Page 303/(304 blank)


623010 Revision 3
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
MAIN ROTOR SWASHPLATE
CLEANING/PAINTING

1. Cleaning 2. Preparation and Painting

Clean all reusable swashplate assembly parts Prepare and paint assembly surfaces specified
and components as described in Table 401. in Table 402 as follows.

(1). Using acetone (6, Table 903), clean


Most cleaning solvents are external surface of rotating and
WARNING flammable and must be kept stationary swashplates (19 and 20,
away from heat or open flame. Avoid Figure 1).
inhalation of fumes and extended con
tact with skin. (2). Using masking tape (12, Table 903),
mask off all bearing bores, bolt and
Do not use over 50 psig (3.52 bushing holes.
CAUTION kgm) air pressure for abrasive
cleaning method. Mask or shield threaded (3). Paint according to Table 402. (For
areas or surfaces where damage may result corrosion control and paint touchup
from abrasive blasting. procedures, Ref. CSPHMI2).

Table 401. Cleaning Main Rotor Swashplate Parts and Components


Nomenclature (Ref. Figure 1) Cleaning Method (Ref.Table 903 ) Remarks
All parts except bearing assembly Use agitated immersion, pressure Protect all cleaned parts by
(9) spray and vapor de-greasing wrapping in paper and storing in
equipment for general cleaning. Dry safe place.
with compressed air.
Rotating and stationary swashplate Solvent (2) and bristle brush. Remove oil sludge and other
assemblies (19 and 20) foreign materials.
Poly bead blast (20) or paint Remove damaged paint
remover (1)
NOTE: Complete removal of epoxybased primer is unnecessary. Stripping of paint is necessary on nonfer
rous parts that are to be fluorescent penetrant inspected.
Bearing assembly (9) Cloth moistened with alcohol (10) Wipe clean.
Do not allow solvents of any type to enter bearing double row balls or spherical race area. Dirt
CAUTION may be washed into bearings causing damage.
Paint remover (1) Carefully remove zinc chromate
primer residue from bearing flange.
Comply with preceding caution.
Spherical ball (25) Remove locking compound with Clean mating surface, outer race of
cloth dampened in Oakite 156 (17). spherical ball.
Then wipe spherical ball using cloth
moistened with isopropyl alcohol.
Roller bearing (22) Remove locking compound. Wipe Clean mating surface, inner race
with cloth dampened in Oakite 156 roller bearing
(17)

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623010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609
Table 402. Painting Requirements
Item Name Method of No. of
(Ref. Figure 1) Paint Type and Specification (Ref. Table 903) Application Coats
Rotating swash- Primer (7) Spray 1
plate (19)
Stationary Primer (7) Spray 1
swashplate (20)
Bearing retainer Nonspecular black acrylic lacquer (9) Spray 2
(9)

Page 402
Revision 3 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
MAIN ROTOR SWASHPLATE
INSPECTION/CHECK
1. Inspection limits are shown in Figure 501. Process
Visual and dimensional inspection require inspection requirements are described in
ments are described in Table 501 and service Table 502.

Table 501. Detailed Inspection After Cleaning


Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Rotating and stationary swashplates (19 and 20, Figure 1) for surface defects as follows:
All surfaces (FPI) No cracks Not repairable Replace part
Flat machined surfaces Minor surface defect 0.015 inch (0.381 mm) of Repair damage (Ref.
(except fork inner ear material removed Repair)
surfaces)
Fork ear inner surface Minor surface defect (Ref. Figure 501) Repair damage (Ref.
wear caused by rod end Repair)
abrasion
Forged or cast surfaces Minor surface defect 0.020 inch (0.508 mm) of Repair damage (Ref.
(except parting line ridge) material removed Repair)
Forged or cast surfaces at Minor surface defect Complete removal of Repair damage (Ref.
parting line ridge parting line ridge plus Repair)
0.020 inch(0.508 mm) of
material
Intersecting edges (corner Minor surface defect 0.030 inch (0.762 mm) of Repair damage (Ref.
edges except edges of material removed Repair)
bolt and bushing holes)
Edges of bolt and bushing Minor surface defect 0.010 inch (0.254 mm) Repair damage (Ref.
holes chamfer Repair)
Bolt and bushing bores Minor surface defect 0.030 inch (0.762 mm) of If rework area of
material removed with unbushed bore exceeds
rework area limited to these figures, ream bore,
15% radially and 50% fabricate and install plain
axially of hole bore. (Ref. bushing (Ref. Repair)
Figure 501) (Ref. Repair).
Inside bore (center) of Minor surface defect 0.030 inch (0.762 mm) of Repair damage (Ref.
both swashplates localized material Repair)
removed
Bearing assembly (9, Figure 1) for wear and damage:
Radial or axial play in No measurable play Not repairable Replace double row
double row ball bearing bearing
(checked prior to
disassembly by turning
rotating swashplate.
Wobble or axial play
between rotating and
stationary swashplates
indicates faulty bearings).

Page 501
623010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609
Table 501. Detailed Inspection After Cleaning (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Spherical bearing axial 0.010 inch (0.254 mm) Not repairable Replace spherical bearing
play in Teflon liner (between spherical ball
and Teflon liner)

Spherical bearing ID 3.010 inch (7.645 cm) Not repairable Replace spherical bearing
(bore) max

Spherical bearing fabric No visible defects Not repairable Replace spherical bearing
liners

Spherical bearing preload. Torque should be no more Not repairable Replace spherical bearing
(Secure ball flats in than 30 inch-pounds
padded vise and use (3.39 Nm) at 68 6 with
spring scale to rotate spherical race in motion.
spherical race.) (Average four readings
taken 90 apart on
spherical bearing.)

Spherical ball for nicks Minor surface defects any Not applicable Stone (15, Table 903) off
and dents width on ball flats not raised metal and smooth
more than 0.10 inch (2.54 edges only within
mm) deep from edge of serviceability limits.
flats, and that do not Replace spherical bearing
deform ID of ball chamfer with more extensive
(Ref. Figure 501). damage. Take care not to
remove more hard
anodize than necessary.
Touch up bare surface
with Alodine (13)

Spherical ball for None deeper than 0.010 Not repairable Stone (15) off high spots,
scratches inch (0.254 mm) or wider take care not to remove
than 0.060 inch (1.524 more hard anodize than
mm), or that do not necessary. Touch up bare
increase rotational torque metal with Alodine (13).
or harm Teflon liner. No
more than two scratches
in an area one inch wide
are allowed

Double row ball bearing Seals in place and Not repairable Replace seal
grease seals for unbroken
serviceability

Double row ball bearing Chipped lip edges not Not applicable Use very fine rat-tail file
grease seal retainer lip for more than 0.50 inch or stone (15) to smooth
breaks (12.70 mm) in length in out sharp edges and
any 1 inch of circumfer- corners or replace seal.
ence. Maximum of five Use care to avoid
chipped areas per side damaging grease seal and
(top and bottom) (Ref. prevent filings or dust from
Figure 501). entering races.

Page 502
Revision 14 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
Table 501. Detailed Inspection After Cleaning (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Double row ball bearing Bearing to rotate smoothly Lack of lubrication Not Regrease bearing
for correct operation and and without roughness or repairable assembly Replace double
lubrication evidence of lack of row bearing.
lubrication
Double row ball bearing No rotation permitted. No Not applicable Replace spherical
(I.D. surface) for vertical play permitted bearing.
movement against the
spherical ball bearing
outer race (O.D. surface).
Ensure penetrant solution does not permeate bearings.
CAUTION
NOTE: If indications of cracks are discovered by dye penetrant inspection that cannot be confirmed, reinspect
using magnetic particle method.
Cracks; particularly No cracks Not repairable Replace bearing assembly
around mounting holes on
sleeve using dye
penetrant method.
Bearing retainer (9) for:
Cracks (FPI) No cracks Not repairable Replace retainer
Nicks and dents Minor surface defects Minor surface repair Repair damage (Ref.
Repair)

Table 502. Process Inspection Requirements


*Magnetic Particle (ASTM E1444) *Fluorescent Penetrant (ASTM E1417)
Item Index No. Item Index No.
Ensure penetrant solution does not permeate bearings.
CAUTION
Bearing retainer 8, Figure 1
Bearing assembly 9, Figure 1
Rotating swashplate 19, Figure 1
Stationary swashplate 20, Figure 1

NOTES:
* Paint removal is not required for magnetic particle inspection, but is necessary on nonferrous parts for
fluorescent penetrant inspection. Complete removal of epoxy primer is not required on normal overhaul.
When inspecting for or after crash damage, all areas should be visually inspected using minimum of
5-power magnifying glass and all suspected areas should have epoxy primer removed locally with Poly
bead blast (19, Table 903) or paint remover (1) for added inspection. Prevent entry of paint remover into
joint lines of bearings, bushings or inserts still assembled with the part requiring paint removal.

Page 503
623010 Revision 12
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609

ROD END ABRASION


60 MAX ANY SECTOR OF
CIRCLE AROUND CL OF HOLE

SMOOTH TRANSITION WITH


0.250 IN. (6.35 MM) RADIUS MIN

0.020 IN. (0.508 MM) MAX.


MATERIAL REMOVAL

FORK INNER EAR SURFACE (TYPICAL)

50% MAX AXIALLY

0.010 IN. (0.254 MM)


MAX EDGE CHAM
FERALL BOLT AND
15% MAX RADIALLY BUSHING BORES

MAX 0.003 IN. (0.076 MM) DEPTH

BORE REWORK (TYPICAL)


CHAMFER I.D.
(NO DEFORMATION)

0.50 IN. (12.70 MM) MAX


(PER IN.) AND FIVE
BREAKS MAX PER SIDE

0.10 IN. (2.54 MM) MAX


DAMAGE DEPTH
FROM EDGE OF FLAT

SEAL RETAINER LIP BREAKS FLAT

SPHERICAL BALL SURFACE


H623014A

Figure 501. Service Limits

Page 504
Revision 12 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
MAIN ROTOR SWASHPLATE
REPAIR/MODIFICATION
1. General Repair Information with chemical film solution (13,
Table 903) according to CSPHMI2.
This section describes allowable repairs and
parts replacement for the main rotor swash C. Rotating and Stationary Swashplate
plate. Repair - Rodend Bolt Holes

2. Repair (1). Ream oversized bolt hole of swashplate


clevis (unbushed side) to 0.3140.315
The repair procedures which follow are the in. (7.9768.001 mm) (Figure 601).
only repairs authorized for main rotor swash
(2). Fabricate plain bushing from alumi
plate parts and components. Prior to making
num alloy (21, Table 903).
repairs on any part or component, ensure that
the part or component is within the repairable Use protective gloves when
limits given in (Ref. Inspection/Check). After WARNING handling heated parts.
repairs are completed, the part or component
must meet the dimensions specified for the (3). Heat swashplate oversized bolt hole to
part in (Ref. Inspection/Check). 275 25F (135 12C).
A. Minor Nicks, Scratches and Corrosion (4). Cool fabricated bushing.
Remove and repair minor nicks, scratches, (5). Coat O.D. of bushing with zinc chro
corrosion and other surface defects from mate primer and install while still wet.
stationary swashplate (20, Figure 1), rotating Bushing must be flush both sides
swashplate (19) and bearing retainer (8) as +0.000/0.001 in. (+0.000/0.025mm).
follows:
3. Parts Replacement
(1). Using abrasives (3, 4 and 5, Table 903),
remove damage and blend damaged (1). At reassembly of the main rotor
area into adjacent surfaces; eliminate swashplate assembly, replace all parts
sharp edges. that do not meet specifications in
Table 501 and Figure 501. Repair main
(2). Reclean repaired area (Ref. Cleaning). rotor swashplate assembly according to
Table 501 and the procedures in the
(3). Apply surface treatment to bare metal Repair section.
(Ref. Surface Treatment).
NOTE: If replacement of a large number of
B. Surface Treatment parts is required, consider replacement of
the complete swashplate assembly.
Treat all bare metal surfaces according to (1).
(magnesium) or (2). (aluminum) which follows: 4. Modification
(1). Treat all reworked (bare metal) areas of The current swashplates are now being
magnesium alloy stationary swashplate produced with counterweights installed.
(20, Figure 1) with chromic acid
solution (14, Table 903) according to (1). To modify to a balanced swashplate,
CSPHMI2. bond one thin and one thick counter
weight in place (any position) using
(2). Treat all reworked (bare metal) areas of adhesive (8, Table 903).
aluminum alloy rotating swashplate
(19, Figure 1) and bearing retainer (8) (2). Rebalance main rotor hub.

Page 601
623010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609

OVERSIZED REAM TO 0.3140.315 IN.


(7.9768.001 MM) DIA
IN LINE WITH SLOTTED HOLE
WITHIN 0.002 IN. (0.051 MM)

SWASHPLATES
(ROTATING AND STATIONARY)

SLOTTED BUSH
ING SIDE
SWASHPLATE
FORK

(NOTE 3)


0.00050.0015 IN.


(0.01270.0381 MM) 0.24950.2505 IN.
LARGER THAN (6.33736.3627 MM) DIA


REAMED HOLE

FABRICATED BUSHING

NOTES:
1. MATERIAL ALUMINUM ALLOY 2024T4.
2. BREAK SHARP EDGES 0.001/0.005.
3. MACHINE FINISH 63 RMS.
4. BUSHING COCENTRIC TO O.D. +0.000/0.001 IN. (+0.000/0.0254 MM). 623015

Figure 601. Rotating and Stationary Swashplate Repair - Rodend Bolt Holes

Page 602
Revision 3 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
MAIN ROTOR SWASHPLATE
ASSEMBLY/SHIPPING
1. Swashplate Bearing Assembly Do not intermix different types
CAUTION of grease. When regreasing
Do not allow solvents or any swashplate bearing, ensure old grease is
CAUTION type of cleaning fluids to contact completely purged from bearings.
bearings or spherical ball.
(1). Use the following procedure for regreas
(1). Clean spherical bearing (Figure 704) ing swashplate bearings using special
outer race and roller bearing inner race regreasing tool (Figure 701):
mating surfaces as specified in
Table 401. Next wipe mating surfaces (a). Lubricate packing in greasing tool
with a cloth dampened in solvent (16, with grease (11, Table 903).
Table 903).
(b). Install tool over bearing, long inner
Do not allow primer or locking race skirt, so that lower packing
CAUTION compound to contact roller bear
engages bearing.
ing or spherical ball.
(c). Position and hold bearing to allow
(2). Apply surface primer (18) to mating hand rotation of inner race during
surfaces of spherical bearing and roller regreasing.
bearing. Allow primer to air dry for 30
minutes minimum at ambient tempera (d). Pump grease through tool grease
ture. fitting while rotating bearing inner
race, until clean grease is forced out
(3). Apply locking compound (19) to mating from bearing upper seal area.
surfaces of roller bearing and spherical
bearing. (e). Remove bearing from greasing tool.
(4). Install lower snap ring on bottom side (f). While holding one bearing race,
of spherical bearing. rapidly spin the other race; remove
any excess grease that is forced out.
(5). Position roller bearing on a suitable Continue alternate spinning and
press top side down. While locking grease removal until grease no longer
compound is still wet, aline spherical surfaces when bearing race is spun.
ball within roller bearing. Press on
outer race of spherical bearing until (g). Using thin piece of wood or similar
firmly seated within roller bearing. material, carefully remove grease
from between outer race and cage of
Uneven pressure on the race of
CAUTION the roller bearing may crack
bearing.
flange in the area of the seal snap ring. (h). Apply thin coat of grease to seals and
retainer surfaces; install seals and
(6). Install upper snap ring on the top side secure with retainers.
of spherical bearing. Allow 2 hours
minimum cure time for bearing assem (2). Use the following procedure for regreas
bly prior to installation in swashplate. ing swashplate bearings by hand
packing:
2. Regreasing Swashplate Bearing
(a). Position and hold bearing to permit
Prior to reassembly of the swashplate, remove hand rotation of bearing inner race.
seal retainers and bearing seals from swash
plate bearing assembly and regrease bearings (b). While rotating bearing inner race,
as follows: (Use procedure (1). when using hand pack bearings with grease until
special greasing tool and procedure (2). when clean grease is forced from seal
hand packing bearings). around bearing.

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623010 Revision 7
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609
(c). While holding one bearing race, mating holes in bearing assembly and
rapidly spin the other race; remove stationary swashplate, then press on
any excess grease that is forced out. outer race of bearing assembly using
Continue alternate spinning and stationary swashplate tool (1,
grease removal until grease no longer Table 901) as shown in Figure 703.
surfaces when bearing is spun.
(5). Position bearing retainer (8, Figure 1)
(d). Using thin piece of wood or similar over bearing assembly (9); install using
material, carefully remove grease bolts (7), washers (6) and nuts (5).
from between outer race and cage of Torque nuts to 50 70 inchpounds
bearing. (5.56 7.91 Nm).
(e). Apply thin coating of grease to seals (6). Install bolts (3 and 4), washers (2) and
and retainer surfaces; install seals nuts (1) with wet primer. Install two
and secure with retainers. shorter bolts then longer bolts. Torque
nuts (1) to 30 40 inchpounds (3.39
3. Bearing Installation 4.52 Nm).
Install bearing assembly (9, Figure 1) in NOTE: When installing bolts (3 and 4) Check
swashplate assembly as follows: for interference between bolt heads and
Protect Teflon liner in spherical counterbore of bearing skirt. If required in
CAUTION bearing bore during reassembly. stall washers under head of bolt.
Ensure that bearing assembly is started (7). Check spherical bearing preload. Hook
straight and is not cocked while being spring scale over one bolt securing
pressed into position. stationary swashplate to bearing
(1). Clean outside diameter (OD) of bearing flange. With rotating swashplate in
assembly (9) and inner diameter (ID) of motion, drag should be 2 30 pounds
rotating swashplate (19) using clean (0.91 13.61 kg). (Use average of two
cloth dampened with acetone (6, readings 90 degrees apart.)
Table 903). (8). Turn rotating swashplate to align arm
(2). Apply coat of primer (7) to bearing with arm of stationary swashplate.
assembly (9, Figure 1) OD and rotating Check vertical movement between arms
swashplate (19) ID; air dry 5 10 at control bolt in stationary swashplate;
minutes. maximum of 0.015 inch (0.381 mm)
total vertical movement is allowable.
NOTE: It may be necessary to heat swashplate
assembly to 275 F 25 F (135 C 12 C) 4. Counterweight and Interrupter Installation
when assembling. Heat gun may be used,
ensure heat is not localized on one area of Install counterweights and interrupters as
swashplate. Use gloves to protect hands follows:
when handling heated components. NOTE:
(3). Using rotating swashplate bearing D Counterweights and washers removed at
installation tool (2, Table 901), install disassembly must be reinstalled in the
bearing assembly in bore of swashplate same position from which they were re
until bearing contacts retaining lip in moved to ensure rotating swashplate bal
bottom of bearing bore as shown in ance.
Figure 702. Apply pressure to bearing D If counter weights are removed from
outer race only. Remove any excess swashplate main rotor hub must be reba
primer and ensure primer does not lanced per CSPHMI2.
enter bearing race.
D If counterweights are to be added, one
(4). Apply primer (7, Table 903) to bore of thick and one thin (any position) is recom
stationary swashplate (20, Figure 1). mended for ease of balancing; Hub must
While primer is wet, carefully align be rebalanced.

Page 702
Revision 14 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
(1). Apply coat of adhesive (8, Table 903) to (2). Install interrupters (13), beveled edges
counterweight OD. Reinstall weight inboard, with bolts (14), washers (16),
with smaller hole outboard, using nuts (17) and new cotter pins (18). Coat
dummy bolt to align weight to rotating bolts with grease (11, Table 903) prior
swashplate (19, Figure 1). Remove bolt to installation. Torque nuts to 30 60
and allow adhesive to cure according to inchpounds (3.39 6.79 Nm).
container instructions.
(3). Install interrupters (13) using bolts
NOTE: Ensure interrupters are installed with (12), washers (11) and nuts (10); torque
same type and number of washers removed nuts to 15 20 inchpounds (1.69
at disassembly, and that correct part num 2.26 Nm).
ber interrupter is installed in each swash
plate arm. (Ref. CSP HMI 2 and CSP 5. Run-In Inspection Procedures
IPC 4 for correct part numbers and
corresponding locations). Not applicable.
RETAINER

SEAL

SEAL AREA

BEARING

SEAL

LONG SKIRT

RETAINER BEARING GREASING TOOL

ORING SEAL
LOCATIONS
GREASE FITTING
H623016

Figure 701. Regreasing Bearing with Regreasing Tool - Exploded View

Page 703
623010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609
5.10 IN. 0.25 IN.
(12.95 CM) OD (6.35 MM)




INSTALLATION TOOL
(2, TABLE 901)




PRESS AGAINST OUTER RACE





OF BALL BEARING ASSY


























ROTATING SWASHPLATE

H623017A

Figure 702. Bearing Installation Rotating Swashplate


NO ROTATION AT
THIS SURFACE IDENTIFICATION PLATE

ROTATING SWASHPLATE
DOUBLE ROW
BALL BEARING

SPHERICAL BALL BEARING STATIONARY SWASHPLATE


H623013

Figure 703. Main Rotor Swashplate - Cross-Section View

Page 704
Revision 14 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609


SNAP RING



NOTE


NOTE


INSTALL THIS DIRECTION








NOTE NOTE







REMOVE SPHERICAL




BEARING THIS DIRECTION
REMOVAL
INSTALLATION

NOTE:
APPLY SURFACE PRIMER AND LOCKING COMPOUND TO THESE AREAS. 623018

Figure 704. Swashplate Bearing Disassembly - Assembly


6. Packing and Storage (1). Apply a light layer of corrosion preven
If overhauled swashplate assembly is not to be tative (22, Table 903) and package or
used immediately, package and store the cover to keep dust off.
swashplate as follows:

Page 705/(706 blank)


623010 Revision 5
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
MAIN ROTOR SWASHPLATE
SPECIAL TOOLS, FIXTURES & EQUIPMENT
1. Reference (2). Table 901 provides specifications, and
when appropriate, procurement
(1). Reference is made throughout this information regarding special tools and
section of the Overhaul Manual to equipment required for overhaul and
CSPHMI2. This should be used as repair. Torque values are in Table 902.
noted throughout the overhaul. The
Illustrated Parts Catalog (CSPIPC4) (3). Figure 901 shows fabrication of a
should be used for ordering any bearing regreasing tool for use at
replacement parts required. overhaul.
Table 901. Main Rotor Swashplate Assembly Overhaul Special Tools
Item
No. Nomenclature Part No. Manufacturer
1 Stationary swashplate tool Fabricate locally
See Figure 301.
2 Rotating swashplate bearing tool Fabricate locally
See Figure 301.
3 Bearing regreasing tool Fabricate locally
See Figure 901.

Table 902. Main Rotor Swashplate Assembly Special Torques


Torque
Item Figure 1, Index No. (In.Lb.) (Nm)
Bearing flange nuts 1 30 40 3.39 4.52
Bearing retainer nuts 5 50 70 5.65 7.91
Interrupter nuts 10 15 20 1.69 2.26
Counterweight nuts 17 30 60 3.39 6.78

Table 903. Repair Materials


Item
No. Material Specification No. Name/No. Manufacturer
1 Paint remover TTR248 Turco 5351 Turco products, Inc.,
Westminster, CA
926843600
No. A202 CeeBee Chemical
Co. Downey, CA
2 Solvent, drycleaning PD680 (3)
3 India stone (fine) (3)
4 Cloth, abrasive, crocus grade PC458 (3)
5 Cloth, abrasive, aluminum PC451 (3)
oxide (grade No. 320 or 400)
6 Acetone OA51 (3)

Page 901
623010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609
Table 903. Repair Materials (Cont.)
Item
No. Material Specification No. Name/No. Manufacturer
7 Primer MILP85582 (3)
8 Adhesive (epoxy) EA9330.3 Hysol Division
Dexter Corporation
P.O. Box 312
Pittsburg, CA
9 Flat black lacquer (color No. Fed Std 595 (3)
37038)
10 Alcohol, isopropyl TTI735 (3)
11 Grease, aircraft and instrument MILPRF81322 Mobil Grease 28 Mobil Oil Co.
(4) Aero Shell 22 Shell Oil Company
Braycote 622 Castrol Industrial
12 Masking tape MILT23397 (3)
13 Chemical conversion film solution MILC5541 Iridite 142 Richardson Co.,
(Iridite, Alodine or equivalent) Class 2 Alcoat AlliedKelite
Product Div.
2400 E. Devon Ave.
Des Plaines, IL
Iridite 142 Alcoat
14 Chromic acid solution (pH 2.6 to MILM3171 Dow #19 Dow Chemical Co.
3.4) Type VI or equivalent
15 Arkansas polishing stone (3)
16 Trichloroethane OT620 (3)
17 Loctite remover Oakite 156 Oakite Products Inc.
50 Valley Road
Berkley Heights, NJ
079222712
18 Surface primer, Locking MILS22473 Locquic Loctite, Inc.
Compound (grade and form 705 N. Mountain Rd.
optional) Newington, CT 06111
Hernon Mfg. Inc.
Samford, FL
4073224000
19 Sealing, locking and retaining MILR46082 Loctite R/C 609 Loctite Inc.
compounds, single component or No. 35
(grade as noted)

Page 902
Revision 16 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
Table 903. Repair Materials (Cont.)
Item
No. Material Specification No. Name/No. Manufacturer
20 Plastic bead, spherical 2030 Poly Plus 20/30 Polyrock Company
mesh 4763 Murrita Ave
Chino, CA 91710
Abrasive Cleaning
20122 State Rd.
Cerritos, CA 92701
Abrasive Unlimited
4653 S. 33 RD. St.
Suite #1
Phoenix, AZ 85040
21 Aluminum Alloy 2024T4 (3)
22 Corrosion Preventative MILC81309 Corrosion X Corrosion Technolo-
Type II gies Corp.
Fluid Film Eureka Chemical Co.
NOTES:
(1) Numbers are U. S. A. Specifications and Standards. The prefix symbols are defined as follows:
AMS American Material Standard; MS Military Standard; MIL Military Specification; single, double or
triple alpha prefix of the same letter Federal Specification; AN Air ForceNavy Aeronautical Standard;
NAS National Aerospace Standard.
(2) Primary selection. Any equivalent material may be used as an alternate selection.
(3) Use the best equivalent commercial grade material when the conformity of available materials of the
same type with the listed U. S. A. Specification No. cannot be determined.
(4) Do not intermix grease from different manufacturers or grease of different types. Thoroughly clean all
components/bearings before relubricating with grease from a different manufacturer or a different type
grease.

Page 903
623010 Revision 16
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609

6.000 IN. (15.24 CM) DIAMETER

5.520 IN. (14.021 CM) DIAMETER

MS9021354 5.000 IN. (12.700CM) DIAMETER


ORING 0.100 IN. 0.1520.162 IN.
0.500 IN.
0.100 IN. (2.54 MM) (12.70 MM) 0.255 IN. (3.8614.115 MM)


(2.54 MM) (6.477 MM)



1.500 IN.


3.81 CM)


MS28775349
ORING

HOLE FOR
LUBRICATION
FITTING (FOR
THREADED OR
4.5024.510 IN. (11.43511.455 CM) DIAMETER PRESS FIT)

4.8694.871 IN. (12.36712.372 CM) DIAMETER

H623010

Figure 901. Bearing Regreasing Tool Fabrication

Page 904
Revision 16 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
MAIN ROTOR SWASHPLATE
ILLUSTRATED PARTS LIST
1. General Explanations of codes and abbreviations used
in this illustrated parts list can be found by
This section contains an illustrated parts list referring to the Introduction section of
to be used in conjunction with the 369D27609 CSPIPC4.
Main Rotor Swashplate overhaul manual.
Correct part numbers and nomenclature can
be identified for specific configurations and 2. Indenture Level
effectivities.
Item numbers in this parts list refer to the The indenture level to a higher assembly is
figure preceding the parts list table. An item indicated by the amount of bullets in front of
number may be the same or different from the each item in the description column. An item
same part shown in a different illustration that has one more bullet than the part above it
elsewhere in the overhaul manual. is a sub part of that assembly.

Page 1001
623010 Revision 14
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609
1

19
3
18
25
24
17
23
15

10
17 11

18 8
9
12
16 5
3

19 14

3 1
12 2 6
(NOTE 3)
20
(NOTE 2)

4 (NOTE 1)
1
2
8 14

11

10

22
7 13

9 21

NOTES: 1 3 3
1. INTERRUPTER USED AT THIS LOCATION IS NOT PART
OF SWASHPLATE: INSTALLED AT INSTALLATION OF 1
SWASHPLATE ON HELICOPTER.
2. INSTALL ROTATING SWASHPLATE LIP SIDE DOWN.
3. COUNTERWEIGHTS ARE INSTALLED ON CURRENT
MODEL SWASHPLATES. IF COUNTERWEIGHTS ARE TO
BE REMOVED, MAIN ROTOR HUB IS TO BE REBALANCED.
H623022

Figure 1001. Main Rotor Control Swashplate Assembly

Page 1002
Revision 15 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D27609
Qty.
Fig. &
Part Number Description per
Index
Assy.
1001- 369D27609-503 Swashplate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
Replaced By 369D27609-501 (Returned To -501
Mixer-Swashplate Configuration With Counter Weights)
369D27609-501 Swashplate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369D27609-BSC Swashplate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
Replaced By 369D27609-501
1 MS21042L4 Nut, Self Locking, Reduced Hexagon . . . . . . . . . . . . . . . . . . . . . . . . . 4
Use On 369D27609-503 Swash Plate Assy With No Weight
Installed
2 MS17826-4 Nut, Self-Locking, Castellated, Hexagon . . . . . . . . . . . . . . . . . . . . . . 2
Installed 369D27609-501 With Weight
2 AN320-4 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intrch With MS17826-4
3 AN960KD416L Washer, Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 369D29946-903 Interrupter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(-101, -111, -121, -131, -141)
4 369D29946-101 Interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaces -31 Interrupter
5 369D29946-1 11 Interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaces -41 Interrupter
6 369D29946-121 Interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaces -51 Interrupter
7 369D29946-141 Interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaces -71 Interrupter
8 NAS6204-42D Bolt, Hex Head, Close Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Install 369D27609-501 With Weight -40D, -41D, -44D Alternates
For Balancing Purposes Only
8 NAS6204-10 Bolt, Hex Head, Close Tolerance, Alloy Steel . . . . . . . . . . . . . . . . . . 2
Use On 369D27609-503 With No Weight Installed
9 NAS1303-8 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9 NAS1103-8 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTN
10 AN960KD10L Washer, Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
11 MS21042L3 Nut, Self-Locking, Reduced Hexagon . . . . . . . . . . . . . . . . . . . . . . . . 2
11 MS21044N3 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intrch With MS21042L3
12 369D27614-3 Counter Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTN
12 369D27614 Counter Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
13 NAS517-4-23 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
14 MS24665-153 Pin, Cotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 369A7003-9 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369A7003-3
15 369A7003-3 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369A7003-9
16 369A7013 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 BMC 12417-2 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
18 BMC 12417-1 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
19 PSB420CD Ring, Snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Page 1003
623010 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D27609
Qty.
Fig. &
Part Number Description per
Index
Assy.
20 369D27611-BSC Swashplate, Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaced By 369D27611-501
20 369D27611-501 Swashplate, Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaced By 369D27611-503
20 369D27611-503 Swashplate, Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21 369A7612 Swashplate, Stationary (Mag) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369N2628
21 369N2628 Swashplate, Stationary (Alum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTN
Intrch With 369A7612
22 369A4007-87 Plate, Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23 NAS6204-15 Bolt, Hex Head, Nonlockin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
23 NAS1104-15 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTN
24 NAS6204-16 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
24 NAS1104-16 Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTN
25 369A7615 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Page 1004
Revision 15 623010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL

Section

62-30-60
Main Rotor
Swashplate
Part Number
600N7632-1

Page a
Revision 14
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL

This Page Intentionally Left Blank

Page b
Revision 14
MD Helicopters, Inc. CSP-COM-5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
TABLE OF CONTENTS
Para/Figure/Table Title Page

623060 Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. Double Row Ball Bearing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
4. Double Row Ball Bearing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 301. Main Rotor Swashplate Bearing Removal . . . . . . . . . . . . . . . . . . . . . . 302
Figure 302. Main Rotor Swashplate CrossSection View . . . . . . . . . . . . . . . . . . 302
Cleaning/Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Preparation and Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Table 401. Cleaning Main Rotor Swashplate Parts and Components . . . . . . . . . 401
Table 402. Painting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Table 501. Detailed Inspection After Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Table 502. Process Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 501. Service Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Repair/Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Minor Nicks, Scratches and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Surface Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Stationary Swashplate Repair Rodend Bolt Holes . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Stationary Swashplate RepairRodend Bolt Holes . . . . . . . . . . . . 602
Assembly/Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
1. Swashplate Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
2. Regreasing Swashplate Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
3. Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
4. Interrupter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702

623060 Page i
Contents Revision 15
CSP-COM-5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page
5. RunIn Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Figure 701. Regreasing Bearing with Regreasing Tool Exploded View . . . . . . 703
Figure 702. Bearing Installation Rotating Swashplate . . . . . . . . . . . . . . . . . . . . . . 703
Figure 703. Main Rotor Swashplate CrossSection View . . . . . . . . . . . . . . . . . . 704
Figure 704. Swashplate Bearing Disassembly Assembly . . . . . . . . . . . . . . . . . . . 704
6. Packing and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
Special Tools, Fixtures & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
1. Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Table 901. Main Rotor Swashplate Assembly Overhaul Special Tools . . . . . . 901
Table 902. Main Rotor Swashplate Assembly Special Torques . . . . . . . . . . . . . . . 901
Table 903. Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Bearing Regreasing Tool Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . 903
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Indenture Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Figure 1001. Main Rotor Control Swashplate Assembly . . . . . . . . . . . . . . . . . . . . . 1002

Page ii 623060
Revision 15 Contents
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
MAIN ROTOR SWASHPLATE
DESCRIPTION AND OPERATION
NOTE: Before attempting any repair or over replacement information and autho
haul of this component, ensure the required rized modifications for the main rotor
special tools and processes are available to swashplate.
assure completion of the work.
(6). Assembly/Shipping . . . . . . . . . . . . . . . 701
1. General provides main rotor swashplate
reassembly and shipping instructions.
This section of the Overhaul Manual describes
overhaul procedures for the Main Rotor (7). Special Tools, Fixtures
Swashplate Assembly used in conjunction with & Equipment . . . . . . . . . . . . . . . . . . . . 901
the sixbladed main rotor system. Procedures provides procedures for fabricating
given are the approved methods to be used for special tools required for overhaul of
specific repair or complete overhaul of the the main rotor swashplate.
component. (8). Illustrated Parts List . . . . . . . . . . . . 1001
A. Organization provides a parts list supplement to
identify part numbers and configura
The Main Rotor Swashplate section of the tion differences for the main rotor
Component Overhaul Manual is made up of swashplate.
seven parts, listed below. These sections
contain complete instructions for disassembly, B. Reference Data
cleaning, inspection, repair, reassembly and (1). Reference is made throughout this
testing of the component. The following section of the Overhaul Manual to
describes the topic and content of each part CSPHMI2. This manual should be
with appropriate page numbers: used as noted throughout the overhaul/
(1). Description and Operation . . . . . . . . . . 1 repair. The Illustrated Parts Catalog
describes procedures for complete use of (CSPIPC4) should be used for
the main rotor swashplate section. ordering any replacement parts
required.
(2). Disassembly . . . . . . . . . . . . . . . . . . . . . 301
(2). Table 901 and Table 903 provide
gives procedures for complete disassem
specifications, and when appropriate,
bly of the main rotor swashplate.
procurement information regarding
(3). Cleaning/Painting . . . . . . . . . . . . . . . . 401 special tools and equipment, and
contains cleaning requirements for expendable items and materials
main rotor swashplate components and required for overhaul and repair.
parts. Torque values are in Table 902.

(4). Inspection/Check . . . . . . . . . . . . . . . . . 501 (3). Figure 1 shows an exploded view of the


provides visual and dimensional main rotor swashplate assembly, with
inspection requirements. all parts indexed. The index numbers
are used throughout the text with the
(5). Repair/Modification . . . . . . . . . . . . . . 601 part nomenclature to make part
provides allowable repairs and parts identification easier.

Page 1
623060 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632

2
24
4
23

22
9

21

6 5
22
15
(NOTE 1)
23 17 4
2 4 16

25 10
11
12
4
24

19

13
4 14
1 18 20
(NOTE 2)

3 4

NOTES:
1. INTERRUPTER AT THIS LOCATION IS USED AS BALANCE
WEIGHT IN THIS INSTALLATION.
2. INSTALL ROTATING SWASHPLATE LIP SIDE DOWN. H623019

Figure 1. Main Rotor Swashplate

Page 2
Revision 3 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
Legend (Ref. Figure 1)
1. ROTATING SWASHPLATE 14. INTERRUPTER
2. NUT 15. INTERRUPTER
3. NUT 16. BOLT
4. WASHER 17. BALANCE WEIGHT
5. BOLT 18. IDENTIFICATION PLATE
6. BOLT 19. FLANGED BUSHING
7. STATIONARY SWASHPLATE 20. BUSHING
8. BOLT 21. DOUBLE-ROW BALL BEARING
9. BEARING RETAINER 22. SEAL
10. BEARING ASSEMBLY 23. SNAP RING
11. NUT 24. SNAP RING
12. COTTER PIN 25. SPHERICAL BALL
13. BOLT

Page 3/(4 blank)


623060 Revision 3
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
MAIN ROTOR SWASHPLATE
DISASSEMBLY
1. General NOTE: It may be necessary to heat swashplate
assembly to 27525 (135C 12) when
This section describes procedures for complete disassembling. Heat gun may be used, en
disassembly of the main rotor swashplate. sure heat is not localized on one area of
When specific repair of the swashplate swashplate. Use gloves to protect hands
requires only partial disassembly, follow the when handling heated components.
procedures to the point required.
(2). Position stationary swashplate tool (1,
2. Double Row Ball Bearing Check Table 901) against lower end of bearing
assembly (10, Figure 1) as shown in
Prior to disassembly, check bearing assembly Figure 301. Press on stationary swash
(10, Figure 1) for axial or radial play as plate arms to separate rotating swash
follows: plate and bearing assembly from
stationary swashplate. Little pressure
(1). Clamp stationary swashplate (7) to is required except in cases of corroded
prevent movement. or damaged parts.
(3). Remove four nuts (2, Figure 1), washers
NOTE: The slotted bushing used in each clevis (4), bolts (8) and bearing retainer (9).
of main rotor swashplate to attach upper
end of mixer links (Ref. CSPHMI2) must Bearing assembly will be dam
be installed when checking double row ball CAUTION aged if pressure is applied to
bearing for axial and radial play. bearing inner race while pressing bearing
assembly out of rotating swashplate.
(2). Using dial gage, measure axial and
radial play between one arm of rotating (4). Position rotating swashplate tool (2,
swashplate and slotted bushing in Table 901) against lower side of bearing
stationary swashplate. assembly (10, Figure 1) outer race as
shown in Figure 301. Carefully press
NOTE: If measurable axial or radial play ex bearing assembly from sealed position
ists, double row bearings (21) are not ser in rotating swashplate (1, Figure 1).
viceable and replacement is required.
NOTE: Mark interrupters (14 and 15) to ensure
(3). Remove slotted bushing from clevis and reassembly on same swashplate arms.
unclamp stationary swashplate. (5). Remove cotter pin (12), nuts (2 and 11),
washers (4), bolts (13 and 16) and
3. Disassembly interrupters (14 and 15).
Disassemble the main rotor swashplate 4. Double Row Ball Bearing Disassembly
assembly as follows:
Disassemble bearing assembly (10, Figure 1)
When bolts (5 and 6, Figure 1) as follows:
CAUTION are removed, bearing assembly
(10) must be swiveled. Use care when swiv NOTE: Do not use excessive force when remov
eling bearing to prevent dirt and foreign ing snap ring.
matter from entering between balls and Te (1). Remove the upper snap ring (24) from
flon liner. bearing assembly (Ref. Figure 704).
(1). Remove four nuts (3), washers (4) and (2). Position bearing assembly on a suitable
bolts (5 and 6) from attaching flange of press. Apply force to outer race of
bearing assembly (10) to stationary spherical bearing to separate from
swashplate (7). roller bearing.

Page 301
623060 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632

PRESS DOWNWARD
AGAINST STATIONARY
SWASHPLATE ARMS

PRESS AGAINST OUTER RACE


OF BALL BEARING ASSY
ROTATING SWASHPLATE
STATIONARY SWASHPLATE BEARING TOOL (2, TABLE 901)
TOOL (1, TABLE 901)
0.15 IN. (3.81 MM) 0.25 IN. (6.35 MM)
WALL THICKNESS WALL THICKNESS

4.28 IN. 5.10 IN.


(10.87 CM) OD (12.95 CM) OD
BEARING REMOVAL WITH STATIONARY BEARING REMOVAL FROM
SWASHPLATE INSTALLED ROTATING SWASHPLATE

CAUTION: Figure 301. Main Rotor Swashplate Bearing Removal


USED TO AVOID NICKING OR DENTING SPHERICAL BALL.
H623012
NO ROTATION AT
THIS SURFACE IDENTIFICATION PLATE

ROTATING SWASHPLATE
DOUBLE ROW
BALL BEARING

SPHERICAL BALL BEARING STATIONARY SWASHPLATE


H623013

Figure 302. Main Rotor Swashplate - Cross-Section View

Page 302
Revision 3 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
MAIN ROTOR SWASHPLATE
CLEANING/PAINTING
1. Cleaning in Table 402 as follows.
Clean all reusable swashplate assembly parts
and components as described in Table 401.
(1). Using acetone (6, Table 903), clean
Most cleaning solvents are external surface of rotating and
WARNING flammable and must be kept stationary swashplates (1 and 7,
away from heat or open flame. Avoid Figure 1).
inhalation of fumes and extended con
tact with skin.
Do not use over 50 psig (3.52 (2). Using masking tape (11, Table 903),
CAUTION kgm) air pressure for abrasive mask off all bearing bores, bolt and
cleaning method. Mask or shield threaded bushing holes.
areas or surfaces where damage may result
from abrasive blasting.
(3). Paint according to Table 402. (For
2. Preparation and Painting
corrosion control and paint touchup
Prepare and paint assembly surfaces specified procedures, Refer to CSPHMI2).

Table 401. Cleaning Main Rotor Swashplate Parts and Components


Nomenclature (Ref. Figure 1) Cleaning Method (Ref. Table 903) Remarks
All parts except bearing assembly Use agitated immersion, pressure Protect all cleaned parts by
(10) spray and vapor de-greasing wrapping in paper and storing in
equipment for general cleaning. Dry safe place.
with compressed air.
Rotating and stationary swashplate Solvent (2) and bristle brush. Remove oil sludge and other
assemblies (1 and 7) foreign materials.
Poly bead blast (19) or paint Remove damaged paint
remover (1)
NOTE: Complete removal of epoxy-based primer is unnecessary. Stripping of paint is necessary on
nonferrous parts that are to be fluorescent penetrant inspected.
Bearing assembly (10) Cloth moistened with alcohol (9) Wipe clean.
Do not allow solvents of any type to enter bearing double row balls or spherical race area. Dirt
CAUTION may be washed into bearings causing damage.
Paint remover (1) Carefully remove zinc chromate
primer residue from bearing flange.
Comply with preceding caution.
Spherical ball (25) Remove locking compound with Clean mating surface, outer race of
cloth dampened in Oakite 156 (17). spherical ball.
Then wipe spherical ball using cloth
moistened with isopropyl alcohol.
Bearing (21) Remove locking compound. Wipe Clean mating surface, inner race
with cloth dampened in Oakite 156 roller bearing.
(17)

Page 401
623060 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632
Table 402. Painting Requirements
Item Name Method of No. of
(Ref. Figure 1) Paint Type and Specification (Ref. Table 903) Application Coats
Rotating Primer (7) Spray 1
swashplate (1)
Stationary Primer (7) Spray 1
swashplate (7)
Bearing retainer Nonspecular black acrylic lacquer (8) Spray 2
(9)

Page 402
Revision 3 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
MAIN ROTOR SWASHPLATE
INSPECTION/CHECK
1. Inspection limits are shown in Figure 501. Process
Visual and dimensional inspection require inspection requirements are described in
ments are described in Table 501 and service Table 502.

Table 501. Detailed Inspection After Cleaning


Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Rotating and stationary swashplates (1 and 7, Figure 1) for surface defects as follows:
All surfaces (FPI) No cracks Not repairable Replace part
Flat machined surfaces Minor surface defect 0.015 inch (0.381 mm) of Repair damage (Ref.
(except fork inner ear material removed Repair)
surfaces)
Fork ear inner surface Minor surface defect (Ref. Figure 501) Repair damage (Ref.
wear caused by rod end Repair)
abrasion
Forged or cast surfaces Minor surface defect 0.020 inch (0.508 mm) of Repair damage (Ref.
(except parting line ridge) material removed Repair)
Forged or cast surfaces at Minor surface defect Complete removal of Repair damage (Ref.
parting line ridge parting line ridge plus Repair)
0.020 inch (0.508 mm) of
material
Intersecting edges (corner Minor surface defect 0.030 inch (0.762 mm) of Repair damage (Ref.
edges except edges of material removed Repair)
bolt and bushing holes)
Edges of bolt and bushing Minor surface defect 0.010 inch (0.254 mm) Repair damage (Ref.
holes chamfer Repair)
Bolt and bushing bores Minor surface defect 0.030 inch (0.762 mm) of If rework area of
material removed with unbushed bore exceeds
rework area limited to these figures, ream bore,
15% radially and 50% fabricate and install plain
axially of hole bore. (Ref. bushing (Ref. Repair)
Figure 501) (Ref. Repair).
Inside bore (center) of Minor surface defect 0.030 inch (0.762 mm) of Repair damage (Ref.
both swashplates localized material Repair)
removed
Bearing assembly (9, Figure 1) for wear and damage:
Radial or axial play in No measurable play Not repairable Replace double row
double row ball bearing bearing
(checked prior to
disassembly by turning
rotating swashplate.
Wobble or axial play
between rotating and
stationary swashplates
indicates faulty bearings)

Page 501
623060 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632
Table 501. Detailed Inspection After Cleaning (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Spherical bearing axial 0.010 inch (0.254 mm) Not repairable Replace spherical bearing
play in Teflon liner (between spherical ball
and Teflon liner)

Spherical bearing ID 3.010 inch (7.645 cm) Not repairable Replace spherical bearing
(bore) max

Spherical bearing fabric No visible defects Not repairable Replace spherical bearing
liners

Spherical bearing preload. Torque should be no more Not repairable Replace spherical bearing
(Secure ball flats in than 30 inch-pounds
padded vise and use (3.39 Nm) at 68 6 with
spring scale to rotate spherical race in motion.
spherical race.) (Average four readings
taken 90 apart on
spherical bearing.)

Spherical ball for nicks Minor surface defects any Not applicable Stone (14, Table 903) off
and dents width on ball flats not raised metal and smooth
more than 0.10 inch (2.54 edges only within
mm) deep from edge of serviceability limits.
flats, and that do not Replace spherical bearing
deform ID of ball chamfer. with more extensive
(Ref. Figure 501). damage. Take care not to
remove more hard
anodize than necessary.
Touch up bare surface
with Alodine (12)

Spherical ball for None deeper than 0.010 Not repairable Stone (14) off high spots,
scratches inch (0.254 mm) or wider take care not to remove
than 0.060 inch (1.524 more hard anodize than
mm), or that do not necessary. Touch up bare
increase rotational torque metal with Alodine (12).
or harm Teflon liner. No
more than two scratches
in an area one inch wide
are allowed

Double row ball bearing Seals in place and Not repairable Replace seal
grease seals for unbroken
serviceability

Double row ball bearing Chipped lip edges not Not applicable Use very fine rat-tail file
grease seal retainer lip for more than 0.50 inch or stone (14) to smooth
breaks (12.70 mm) in length in out sharp edges and
any 1 inch of circumfer- corners or replace seal.
ence. Maximum of five Use care to avoid
chipped areas per side damaging grease seal and
(top and bottom) (Ref. prevent filings or dust from
Figure 501). entering races.

Page 502
Revision 14 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
Table 501. Detailed Inspection After Cleaning (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Double row ball bearing Bearing to rotate smoothly Lack of lubrication Regrease bearing
for correct operation and and without roughness or assembly
lubrication evidence of lack of Not repairable Replace double row
lubrication bearing.
Double row ball bearing No radial play permitted. Not applicable Replace spherical
(I.D. surface) for No axial play permitted. bearing.
movement against the
spherical bearing outer
race (O.D. surface).
Ensure penetrant solution does not permeate bearings.
CAUTION
NOTE: If indications of cracks are discovered by dye penetrant inspection that cannot be confirmed, reinspect
using magnetic particle method.
Cracks; particularly No cracks Not repairable Replace bearing assembly
around mounting holes on
sleeve using dye
penetrant method.
Bearing retainer (9) for:
Cracks (FPI) No cracks Not repairable Replace retainer
Nicks and dents Minor surface defects Minor surface repair Repair damage (Ref.
Repair)

Table 502. Process Inspection Requirements


*Magnetic Particle (ASTM E1444) *Fluorescent Penetrant (ASTM E1417)
Item Index No. Item Index No.
Ensure penetrant solution does not permeate bearings.
CAUTION
Rotating swashplate 1, Figure 1
Stationary swashplate 7, Figure 1
Bearing retainer 9, Figure 1
Bearing assembly 10, Figure 1

NOTES:
* Paint removal is not required for magnetic particle inspection, but is necessary on nonferrous parts for
fluorescent penetrant inspection. Complete removal of epoxy primer is not required on normal overhaul.
When inspecting for or after crash damage, all areas should be visually inspected using minimum of
5-power magnifying glass and all suspected areas should have epoxy primer removed locally with Poly
bead blast (19, Table 903) or paint remover (1) for added inspection. Prevent entry of paint remover into
joint lines of bearings, bushings or inserts still assembled with the part requiring paint removal.

Page 503
623060 Revision 12
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632

ROD END ABRASION


60 MAX ANY SECTOR OF
CIRCLE AROUND CL OF HOLE

SMOOTH TRANSITION WITH


0.250 IN. (6.35 MM) RADIUS MIN

0.020 IN. (0.508 MM) MAX.


MATERIAL REMOVAL

FORK INNER EAR SURFACE (TYPICAL)

50% MAX AXIALLY

0.010 IN. (0.254 MM) MAX


EDGE CHAMFER ALL BOLT
AND BUSHING BORES
15% MAX RADIALLY

MAX 0.003 IN. (0.076 MM) DEPTH

BORE REWORK (TYPICAL)


CHAMFER I.D.
(NO DEFORMATION)

0.50 IN. (12.70 MM) MAX


(PER IN.) AND FIVE
BREAKS MAX PER SIDE

0.10 IN. (2.54 MM) MAX


DAMAGE DEPTH FROM
EDGE OF FLAT

SEAL RETAINER LIP BREAKS FLAT

SPHERICAL BALL SURFACE


H623020A

Figure 501. Service Limits

Page 504
Revision 12 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
MAIN ROTOR SWASHPLATE
REPAIR/MODIFICATION
1. General Repair Information with chromic acid solution (13,
Table 903) according to CSPHMI2.
This section describes allowable repairs and
parts replacement for the main rotor swash (2). Treat all reworked (bare metal) areas of
plate. aluminum alloy rotating swashplate (1,
Figure 1) and bearing retainer (9) with
2. Repair chemical film solution (12, Table 903)
according to CSPHMI2.
The repair procedures which follow are the
only repairs authorized for main rotor swash C. Stationary Swashplate Repair - Rodend
plate parts and components. Prior to making Bolt Holes
repairs on any part or component, ensure that (1). Ream oversized bolt hole of swashplate
the part or component is within the repairable clevis (unbushed side) to 0.3140.315
limits given in (Ref. Inspection/Check). After in. (7.9768.001 mm) (Ref. Figure 601).
repairs are completed, the part or component
must meet the dimensions specified for the (2). Fabricate plain bushing from alumi
part in (Ref. Inspection/Check). num alloy (20, Table 903).

A. Minor Nicks, Scratches and Corrosion Use protective gloves when


WARNING handling heated parts.
Remove and repair minor nicks, scratches,
corrosion and other surface defects from (3). Heat swashplate oversized bolt hole to
stationary swashplate (7, Figure 1), rotating 275 25F (135 12C).
swashplate (1) and bearing retainer (9) as (4). Cool fabricated bushing.
follows:
(5). Coat O.D. of bushing with zinc chro
(1). Using abrasives (3, 4 and 5, Table 903), mate primer and install while still wet.
remove damage and blend damaged Bushing must be flush both sides
area into adjacent surfaces; eliminate +0.000/0.001 in. (+0.000/0.025mm).
sharp edges.
3. Parts Replacement
(2). Reclean repaired area (Ref. Cleaning).
(1). At reassembly of the main rotor
(3). Apply surface treatment to bare metal swashplate assembly, replace all parts
(Ref. Surface Treatment). that do not meet specifications in
Table 501 and Figure 501. Repair main
B. Surface Treatment rotor swashplate assembly according to
Table 501 and the procedures in the
Treat all bare metal surfaces according to (1). Repair section.
(magnesium) or (2). (aluminum) which follows:
NOTE: If replacement of a large number of
(1). Treat all reworked (bare metal) areas of parts is required, consider replacement of
stationary swashplate (7, Figure 1) the complete swashplate assembly.

Page 601
623060 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632

SWASHPLATES
(ROTATING AND STATIONARY)

OVERSIZED REAM TO 0.3140.315


IN. (7.9768.001 MM) DIA
IN LINE WITH SLOTTED HOLE
WITHIN 0.002 IN. (0.051 MM)

SLOTTED
BUSHING SIDE
SWASHPLATE
FORK

(NOTE 3)

0.00050.0015 IN.

(0.01270.0381 MM) 0.24950.2505 IN.
LARGER THAN (6.33736.3627 MM) DIA


REAMED HOLE

FABRICATED BUSHING

NOTES:
1. MATERIAL ALUMINUM ALLOY 2024T4.
2. BREAK SHARP EDGES 0.001/0.005.
3. MACHINE FINISH 63 RMS.
4. BUSHING COCENTRIC TO O.D. +0.000/0.001 IN. (+0.000/0.0254 MM). H623021

Figure 601. Stationary Swashplate Repair - Rodend Bolt Holes

Page 602
Revision 3 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
MAIN ROTOR SWASHPLATE
ASSEMBLY/SHIPPING
1. Swashplate Bearing Assembly Do not intermix different types
CAUTION of grease. When regreasing
Do not allow solvents or any swashplate bearing, ensure old grease is
CAUTION type of cleaning fluids to contact completely purged from bearings.
bearings or spherical ball.
(1). Use the following procedure for regreas
(1). Clean spherical bearing (Ref. ing swashplate bearings using special
Figure 704) outer race and roller regreasing tool (Ref. Figure 701):
bearing inner race mating surfaces as
specified in Table 401. Next wipe (a). Lubricate packing in greasing tool
mating surfaces with a cloth dampened with grease (10, Table 903).
in solvent (15, Table 903).
(b). Install tool over bearing, long inner
Do not allow primer or locking race skirt, so that lower packing
CAUTION compound to contact roller bear
engages bearing.
ing or spherical ball.
(c). Position and hold bearing to allow
(2). Apply surface primer (17) to mating hand rotation of inner race during
surfaces of spherical bearing and roller regreasing.
bearing. Allow primer to air dry for 30
minutes minimum at ambient tempera (d). Pump grease through tool grease
ture. fitting while rotating bearing inner
race, until clean grease is forced out
(3). Apply locking compound (17) to mating from bearing upper seal area.
surfaces of roller bearing and spherical
bearing. (e). Remove bearing from greasing tool.
(4). Install lower snap ring on bottom side (f). While holding one bearing race,
of spherical bearing. rapidly spin the other race; remove
any excess grease that is forced out.
(5). Position roller bearing on a suitable Continue alternate spinning and
press top side down. While locking grease removal until grease no longer
compound is still wet, aline spherical surfaces when bearing race is spun.
ball within roller bearing. Press on
outer race of spherical bearing until (g). Using thin piece of wood or similar
firmly seated within roller bearing. material, carefully remove grease
from between outer race and cage of
Uneven pressure on the race of
CAUTION the roller bearing may crack
bearing.
flange in the area of the seal snap ring. (h). Apply thin coat of grease to seals and
retainer surfaces; install seals and
(6). Install upper snap ring on the top side secure with retainers.
of spherical bearing. Allow 2 hours
minimum cure time for bearing assem (2). Use the following procedure for regreas
bly prior to installation in swashplate. ing swashplate bearings by hand
packing:
2. Regreasing Swashplate Bearing
(a). Position and hold bearing to permit
Prior to reassembly of the swashplate, remove hand rotation of bearing inner race.
seal retainers and bearing seals from swash
plate bearing assembly and regrease bearings (b). While rotating bearing inner race,
as follows: (Use procedure (1). when using hand pack bearings with grease until
special greasing tool and procedure (2). when clean grease is forced from seal
hand packing bearings). around bearing.

Page 701
623060 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632
(c). While holding one bearing race, mating holes in bearing assembly and
rapidly spin the other race; remove stationary swashplate, then press on
any excess grease that is forced out. outer race of bearing assembly using
Continue alternate spinning and stationary swashplate tool (1,
grease removal until grease no longer Table 901) as shown in Figure 703.
surfaces when bearing is spun.
(5). Position bearing retainer (9, Figure 1)
(d). Using thin piece of wood or similar over swashplate bearing (10); install
material, carefully remove grease using bolts (8), washers (4) and nuts
from between outer race and cage of (2). Torque nuts to 50 60 inch
bearing. pounds (5.56 6.78 Nm) plus drag
torque.
(e). Apply thin coating of grease to seals
and retainer surfaces; install seals (6). Install bolts (5 and 6), washers (4)
and secure with retainers. (under nuts) and nuts (3) with wet
primer. Install two shorter bolts then
3. Bearing Installation longer bolts. Torque nuts to 30 40
inchpounds (3.39 4.52 Nm) plus
Install bearing assembly (10, Figure 1) in drag torque.
swashplate assembly as follows:
NOTE: Check for interference between bolt
Protect Teflon liner in spherical heads (5 and 6) and counterbore of bearing
CAUTION bearing bore during reassembly. skirt.
Ensure that bearing assembly is started
straight and is not cocked while being (7). Check spherical bearing preload. Hook
pressed into position. spring scale over one bolt securing
stationary swashplate to bearing
(1). Clean outside diameter (OD) of bearing flange. With rotating swashplate in
assembly (10) and inner diameter (ID) motion, drag should be 2 30 pounds
of rotating swashplate (1) using clean (0.91 13.61 kg). (Use average of two
cloth dampened with acetone (6, readings 90 degrees apart.)
Table 903). (8). Turn rotating swashplate to align arm
(2). Apply coat of primer (7) to bearing with arm of stationary swashplate.
assembly (10, Figure 1) OD and Check vertical movement between arms
rotating swashplate (1) ID; air dry 5 at control bolt in stationary swashplate;
10 minutes. maximum of 0.015 inch (0.381 mm)
total vertical movement is allowable.
NOTE: It may be necessary to heat swashplate
assembly to 275 F 25 F (135 C 12 C)
when assembling. Heat gun may be used, 4. Interrupter Installation
ensure heat is not localized on one area of Install interrupters as follows:
swashplate. Use gloves to protect hands
when handling heated components. NOTE: Ensure interrupters are installed with
same type and number of washers removed
(3). Using rotating swashplate bearing at disassembly, and that correct part num
installation tool (2, Table 901), install ber interrupter is installed in each swash
bearing assembly in bore of swashplate plate arm. (Ref. CSP HMI 2 and CSP
until bearing contacts retaining lip in IPC 4 for correct part numbers and
bottom of bearing bore as shown in corresponding locations).
Figure 702. Apply pressure to bearing
outer race only. Remove any excess (1). Install interrupter (14, Figure 1),
primer and ensure primer does not beveled edges inboard, with bolt (13),
enter bearing race. washers (4), nut (11). Coat bolt with
grease (10, Table 903) prior to installa
(4). Apply primer (7, Table 903) to bore of tion. Torque nut to 15 20 inch
stationary swashplate (7, Figure 1). pounds (1.69 2.26 Nm) and install
While primer is wet, carefully align cotter pin (12, Figure 1).

Page 702
Revision 13 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
(2). Install interrupter (15), beveled edges 6.78 Nm) plus drag torque.
inboard, and balance weight (17) with
5. Run-In Inspection Procedures
bolt (16), washers (4), nut (2). Torque
nut to 50 60 inchpounds (5.56 Not applicable.
RETAINER

SEAL

SEAL AREA

BEARING

SEAL

LONG SKIRT

RETAINER BEARING GREASING TOOL

ORING SEAL
LOCATIONS
GREASE FITTING
H623016

Figure 701. Regreasing Bearing with Regreasing Tool - Exploded View

5.10 IN. 0.25 IN.


(12.95 CM) OD (6.35 MM)



INSTALLATION TOOL
(2, TABLE 901)




PRESS AGAINST OUTER RACE
OF BALL BEARING ASSY













ROTATING SWASHPLATE

H623017A

Figure 702. Bearing Installation Rotating Swashplate

Page 703
623060 Revision 14
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632
NO ROTATION AT
THIS SURFACE IDENTIFICATION PLATE

ROTATING SWASHPLATE
DOUBLE ROW
BALL BEARING

SPHERICAL BALL BEARING STATIONARY SWASHPLATE


H623013

Figure 703. Main Rotor Swashplate - Cross-Section View

SNAP RING





NOTE NOTE


INSTALL THIS DIRECTION























NOTE NOTE











REMOVE SPHERICAL
BEARING THIS DIRECTION
REMOVAL
INSTALLATION

NOTE:
APPLY SURFACE PRIMER AND LOCKING COMPOUND TO THESE AREAS. 623018

Figure 704. Swashplate Bearing Disassembly - Assembly


6. Packing and Storage (1). Apply a light layer of corrosion preven
If overhauled swashplate assembly is not to be tative (21, Table 903) and package or
used immediately, package and store the cover to keep dust off.
swashplate as follows:

Page 704
Revision 5 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
MAIN ROTOR SWASHPLATE
SPECIAL TOOLS, FIXTURES & EQUIPMENT
1. Reference (2). Table 901 provides specifications, and
when appropriate, procurement
(1). Reference is made throughout this information regarding special tools and
section of the Overhaul Manual to equipment required for overhaul and
CSPHMI2. This should be used as repair. Torque values are in Table 902.
noted throughout the overhaul. The
Illustrated Parts Catalog (CSPIPC4) (3). Figure 901 shows fabrication of a
should be used for ordering any bearing regreasing tool for use at
replacement parts required. overhaul.
Table 901. Main Rotor Swashplate Assembly Overhaul Special Tools
Item
No. Nomenclature Part No. Manufacturer
1 Stationary swashplate tool Fabricate locally
See Figure 301.
2 Rotating swashplate bearing tool Fabricate locally
See Figure 301.
3 Bearing regreasing tool Fabricate locally
See Figure 901.

Table 902. Main Rotor Swashplate Assembly Special Torques


Torque
Item Figure 1, Index No. (In.Lb.) (Nm)
Interrupter nut 11 50 60 5.65 6.78
Interrupter nut 2 15 20 1.69 2.26
Bearing retainer nuts 2 50 60 5.65 6.78
Bearing flange nuts 3 30 40 3.39 4.52

Table 903. Repair Materials


Item
No. Material Specification No. Name/No. Manufacturer
1 Paint remover TTR248 Turco 5351 Turco products, Inc.,
Westminster, CA
926843600
No. A202 CeeBee Chemical
Co. Downey, CA
2 Solvent, drycleaning PD680 (3)
3 India stone (fine) (3)
4 Cloth, abrasive, crocus grade PC458 (3)
5 Cloth, abrasive, aluminum PC451 (3)
oxide (grade No. 320 or 400)
6 Acetone OA51 (3)

Page 901
623060 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632
Table 903. Repair Materials (Cont.)
Item
No. Material Specification No. Name/No. Manufacturer
7 Primer MILP85582 (3)
8 Flat black lacquer (color No. Fed Std 595 (3)
37038)
9 Alcohol, isopropyl TTI735 (3)
10 Grease, aircraft and instrument MILPRF81322 Mobil Grease 28 Mobil Oil Co.
(4) Aero Shell 22 Shell Oil Company
Braycote 622 Castrol Industrial
11 Masking tape MILT23397 (3)
12 Chemical conversion film solution MILC5541 Iridite 142 Richardson Co.,
(Iridite, Alodine or equivalent) Class 2 Alcoat AlliedKelite
Product Div.
2400 E. Devon Ave.
Des Plaines, IL
13 Chromic acid solution MILM3171 Dow #19 Dow Chemical Co.
(pH 2.6 to 3.4) Type VI or equivalent
14 Arkansas polishing stone (3)
15 Trichloroethane OT620 (3)
16 Loctite remover Oakite 156 Oakite Products Inc.
50 Valley Road
Berkley Heights, NJ
079222712
17 Surface primer, Locking MILS22473 Locquic Loctite, Inc.
Compound (grade and form 705 N. Mountain Rd.
optional) Newington, CT 06111
Hernon Mfg. Inc.
Samford, FL
4073224000
18 Sealing, locking and retaining MILR46082 Loctite R/C 609 Loctite Inc.
compounds, single component or No. 35
(grade as noted)
19 Plastic bead, spherical 2030 Poly Plus 20/30 Polyrock Company
mesh 4763 Murrita Ave
Chino, CA 91710
Abrasive Cleaning
20122 State Rd.
Cerritos, CA 92701
Abrasive Unlimited
4653 S. 33 RD. St.
Suite #1
Phoenix, AZ 85040
20 Aluminum Alloy 2024T4 (3)

Page 902
Revision 16 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
Table 903. Repair Materials (Cont.)
Item
No. Material Specification No. Name/No. Manufacturer
21 Corrosion Preventative MIL-C-81309 Corrosion X Corrosion Technolo-
Type II gies Corp.
Fluid Film Eureka Chemical Co.
NOTES:
(1) Numbers are U. S. A. Specifications and Standards. The prefix symbols are defined as follows:
AMS - American Material Standard; MS - Military Standard; MIL - Military Specification; single, double or
triple alpha prefix of the same letter - Federal Specification; AN - Air Force-NavyAeronautical Standard;
NAS - National Aerospace Standard.
(2) Primary selection. Any equivalent material may be used as an alternate selection.
(3) Use the best equivalent commercial grade material when the conformity of available materials of the
same type with the listed U. S. A. Specification No. cannot be determined.
(4) Do not intermix grease from different manufacturers or grease of different types. Thoroughly clean
all components/bearings before relubricating with grease from a different manufacturer or a
different type grease.

6.000 IN. (15.24 CM) DIAMETER

5.520 IN. (14.021 CM) DIAMETER

MS9021354 5.000 IN. (12.700CM) DIAMETER


ORING 0.100 IN. 0.1520.162 IN.
0.500 IN.
0.100 IN. (2.54 MM) (12.70 MM) 0.255 IN. (3.8614.115 MM)
(2.54 MM) (6.477 MM)




1.500 IN.
3.81 CM)





MS28775349
ORING
HOLE FOR
LUBRICATION
FITTING (FOR
THREADED OR
4.5024.510 IN. (11.43511.455 CM) DIAMETER PRESS FIT)

4.8694.871 IN. (12.36712.372 CM) DIAMETER

H623010

Figure 901. Bearing Regreasing Tool - Fabrication

Page 903/(904 blank)


623060 Revision 5
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
MAIN ROTOR SWASHPLATE
ILLUSTRATED PARTS LIST
1. General Explanations of codes and abbreviations used
in this illustrated parts list can be found by
This section contains an illustrated parts list referring to the Introduction section of
to be used in conjunction with the 600N7632 CSPIPC4.
Main Rotor Swashplate overhaul manual.
Correct part numbers and nomenclature can
be identified for specific configurations and 2. Indenture Level
effectivities.
Item numbers in this parts list refer to the The indenture level to a higher assembly is
figure preceding the parts list table. An item indicated by the amount of bullets in front of
number may be the same or different from the each item in the description column. An item
same part shown in a different illustration that has one more bullet than the part above it
elsewhere in the overhaul manual. is a sub part of that assembly.

Page 1001
623060 Revision 14
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632

20
7
21
8

9
11

15 16
9 5
14
(NOTE 1)
8 13 21
20 21 17
5
6
23
22
21
7 25

19
21 12
1 24 2
(NOTE 2)

18

10

21

20

20 21

NOTES:
1. INTERRUPTER AT THIS LOCATION IS USED AS BALANCE
WEIGHT IN THIS INSTALLATION.
2. INSTALL ROTATING SWASHPLATE LIP SIDE DOWN. H623023A

Figure 1001. Main Rotor Control Swashplate Assembly

Page 1002
Revision 15 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 600N7632
Qty.
Fig. &
Part Number Description per
Index
Assy.
1001- 600N7630-3 Swashplate Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
1 600N7632-1 Swashplate Assy, M/R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 NAS75-4-1 1 Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 NAS75-4-10 Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replaced By NAS75-4-11
3 NAS77-4-023 Bushing-Flanged, Press Fit, Steel . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 NAS77-4-032 Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 369A7003-9 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 369A7013 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 PSB420CD Ring, Snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8 BMC-12417-1 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9 BMC-12417-2 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 369N2628-BSC Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 369N2628-3 Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALT
11 369A7615-BSC Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 369D29946-131 Interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 600N7631-1 Balance Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 369D29946-1 11 Interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 NAS6204-15 Bolt, Hex Head, Non-locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
16 NAS6204-16 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 NAS6204-14 Bolt, Hex Head, Close Tolerance, Alloy Steel . . . . . . . . . . . . . . . . . . 1
18 NAS517-4-23 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
19 NAS6204-26D Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20 MS21042L4 Nut, Self Locking, Reduced Hexagon . . . . . . . . . . . . . . . . . . . . . . . . . 9
21 NAS1149D0416K Washer, Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
22 MS24665-153 Pin, Cotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23 MS17826-4 Nut, Self-Locking, Castellated, Hexagon . . . . . . . . . . . . . . . . . . . . . . 1
24 HS4951-1 I.D. Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
25 HS626-4-400 Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Page 1003
623060 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 600N7632

This Page Intentionally Left Blank

Page 1004
Revision 14 623060
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL

Section

63-10-10
Overrunning Clutch
Part Number
369A5350-603, -605

Page a/(b blank)


Revision 11
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
TABLE OF CONTENTS
Para/Figure/Table Title Page

631010 Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Overrunning Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. General Disassembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 301. Clutch Assembly Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Cleaning/Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Component Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Preparation and Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Table 401. Painting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. Ball Bearing Inspection and Grease Repack (300 Hour) . . . . . . . . . . . . . . . . . . . . . . . 501
3. Overrunning Clutch Sprag Inspection (300 Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
4. Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Table 501. Detailed Inspection After Cleaning (with 369A5364 Sprag
Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Table 502. Process Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Figure 501. Service Limits Clutch Outer Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Figure 502. Service Limits Clutch Inner Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Figure 503. Service Limits Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Figure 504. Sprag Torque Load Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Table 503. Detailed Inspection after Cleaning (369D25351 Sprag
Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Figure 505. Inspection Requirements of 369D25351 Sprag Assembly . . . . . . . . . 510
Figure 506. Dimension Criteria for 369A535031, 41 or 51 Overrunning
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Repair/Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. General Repair and Modification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Removal of Minor Nicks, Scratches and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . 601

631010 Page i

Contents Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page
B. General Part Replacement Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4. Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Seal Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Overrunning Clutch Modification, Early to Current 51 Configuration . . . . . . . 601
Table 601. Overrunning Clutch Configuration Conversions . . . . . . . . . . . . . . . . . 602
Table 602. Overrunning Clutch Modification Criteria . . . . . . . . . . . . . . . . . . . . . . 602
Table 603. Overrunning Clutch Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 601. Overrunning Clutch Assembly Cutaway View . . . . . . . . . . . . . . . . . 603
Assembly/Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
1. Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
2. Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
3. Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
4. RunIn Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
A. Torque Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
Figure 701. Clutch Reassembly of Races . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
5. Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
6. Packing and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Special Tools, Fixtures & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
1. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Table 901. Overrunning Clutch Assembly Overhaul Special Tools . . . . . . . . . . 901
Table 902. Overrunning Clutch Assembly Special Torques . . . . . . . . . . . . . . . . . . 901
Table 903. Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Indenture Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Figure 1001. Overrunning Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002

Page ii 631010
Revision 15
Contents
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
OVERRUNNING CLUTCH
DESCRIPTION AND OPERATION
NOTE: Before attempting any repair or over rized modifications for the overrunning
haul of this component, ensure the required clutch.
special tools and processes are available to
assure completion of the work. (6). Reassembly/Shipping . . . . . . . . . . . . . 701
provides overrunning clutch reassembly
1. General and procedures for runin of the
overhauled overrunning clutch.
This section of the Overhaul Manual describes
overhaul procedures for the 369A5350 (7). Special Tools, Fixtures
Overrunning Clutch Assembly. Procedures & Equipment . . . . . . . . . . . . . . . . . . . . 901
given are the approved methods to be used for provides procedures for fabricating
specific repair or complete overhaul of the special tools required for overhaul of
component. the overrunning clutch.

A. Organization (8). Illustrated Parts List . . . . . . . . . . . . 1001


provides a parts list supplement to
The Overrunning Clutch section of the identify part numbers and configura
Component Overhaul Manual is made up of tion differences for the overrunning
seven parts, listed below. These sections clutch.
contain complete instructions for disassembly,
cleaning, inspection, repair, reassembly and B. Reference Data
testing of the component. The following (1). Reference is made throughout this Part
describes the topic and content of each part of the Overhaul Manual to CSP
with appropriate page numbers: HMI2. This manual should be used as
(1). Description and Operation . . . . . . . . . . 1 noted throughout the overhaul/repair.
describes procedures for complete use of Use the Illustrated Parts Catalog
the overrunning clutch section. (CSPIPC4) when ordering any
replacement parts for 369A5350603
(2). Disassembly . . . . . . . . . . . . . . . . . . . . . 301 overrunning clutch assembly.
gives procedures for complete disassem
(2). Table 901 and Table 903 provide
bly of the overrunning clutch.
specifications, and when appropriate,
(3). Cleaning/Painting . . . . . . . . . . . . . . . . 401 procurement information, regarding
contains cleaning and painting require special tools and equipment, and
ments for the overrunning clutch expendable items and materials
components and parts. required for overhaul/repair. Torque
values are contained in Table 902.
(4). Inspection/Check . . . . . . . . . . . . . . . . . 501
provides visual and dimensional (3). Figure 1 shows an exploded view of the
inspection requirements. overrunning clutch, with all parts
indexed. The index numbers are used
(5). Repair/Modification . . . . . . . . . . . . . . 601 throughout the text with the part
provides allowable repairs and parts nomenclature to make part identifica
replacement information and autho tion easier.

Page 1
631010 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350

NOTE 3
NOTES: NOTE 4
1. BONDED IN PLACE IN NUT (10).
2. ONLY FOR SHIPPING AND STORAGE.THREADED
PLUG OR CAP PLUG MAY BE USED.
3. FORMSPRAG 369D25351 INSTALL WITH 22
DIRECTIONAL ARROW TOWARDS SPLINES (NOTE 5)
ON SHAFT 18.
4. BORGEWARNER 269A5364 INSTALL WITH
FLANGED END TOWARDS SPLINES ON SHAFT 18.
5. 51 CONFIGURATION ONLY.
CAUTION: DO NOT USE 369A5363 BEARING,
MARKED SKF/MRC, P/N R12, IN 51 CONFIGURATION.
16

2 15

14
19 (CAUTION:)

12

11

9 6

8 21
(NOTE 2)

10
5
(NOTE1)
13

17
18 5

8 20

9
1

3
4

H631016C

Figure 1. Overrunning Clutch Assembly

Page 2
Revision 3 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Legend (Ref. Figure 1)
1. RETAINER RING 12. LOCKWASHER
2. CLUTCH HOUSING 13. PACKING
3. CLUTCH RETAINER 14. BALL BEARING
4. PACKING 15. SPRAG ASSEMBLY
5. SEAL (2) 16. RING SPACER
6. BEARING CARRIER 17. BALL BEARING
7. BALL BEARING 18. CLUTCH INNER RACE
8. SLEEVE SPACER (2) 19. IDENTIFICATION PLATE
9. PACKING (2) 20. PACKING
10. RETAINING NUT 21. SHIPPING PLUG OR CAP PLUG
11. CLUTCH OUTER RACE 22. WAVE WASHER (-51 CONFIGURATION ONLY)

Page 3/(4 blank)


631010 Revision 3
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
OVERRUNNING CLUTCH
DISASSEMBLY
1. General Disassembly Information outboard sleeve spacer (8), from output
shaft of clutch inner race.
Information given in this section provides
procedures for complete disassembly of the Prying on outer race of bearing
CAUTION when removing from bearing
overrunning clutch assembly. Many specific
repairs require only partial disassembly, follow carrier can damage bearing.
procedures to the point required.
(9). Press ball bearing from bearing carrier.
2. Disassembly (10). Secure input shaft of clutch outer race
(11) in aluminum jawed vise or equiva
Disassemble the overrunning clutch according lent spline holding fixture.
to the following procedure and as shown in
Figure 1 and Figure 301. (11). Remove crimps (5 places) in lockwasher
(12). Using strap wrench, loosen, but do
(1). Secure input shaft or clutch outer race not remove retaining nut (10).
(Figure 301) in aluminum jawed vise or
equivalent spline holding fixture. (12). Pull out and remove inboard sleeve
spacer (8). Remove packing (9) from
(2). If installed, remove shipping plug or sleeve spacer; discard packing.
cap (21, Figure 1), and packing (20)
from output shaft of clutch inner race (13). Remove retaining nut and lockwasher
(18). from clutch outer race; discard lock
washer.
(3). Remove clutch from vise or holding
fixture and drain oil; reinstall clutch in Use care when prying seal (5)
CAUTION out of retaining nut. Nut must
vise or retaining fixture.
be replaced if seal groove is damaged.
(4). Using snap ring pliers, remove retain
ing ring (1) from housing (2); remove (14). Remove packing (13) and seal (5) from
clutch from vise. retaining nut. Seal is bonded in groove
of nut and must be pryed free.
(5). Holding output shaft of clutch inner
race, remove housing from clutch (15). Rotate output shaft of clutch outer race
subassembly . counterclockwise and remove outer race
from inner race; remove outer race from
Use care when prying seal (5) vise.
CAUTION out of clutch retainer (3). Re
(16). On 51 clutches, remove wave washer
tainer must be replaced if seal groove is
(22).
damaged.
(17). Remove bearing (14).
(6). Remove sleeve spacer (8) from clutch
retainer; remove packing (9) from If any sprags or clips fall out of
sleeve spacer; discard packing. CAUTION cages when sprag assembly (15)
is removed, sprag assembly must be re
(7). Remove packing (4) and carefully pry placed.
seal (5), which is bonded in groove, from
retainer. (18). Remove sprag assembly (15) and ring
spacer (16) from clutch inner race.
(8). Using arbor press and bearing puller (1,
Table 901), remove bearing carrier (6, (19). Using suitable bearing puller, remove
Figure 1) with ball bearing (7) and ball bearing (17) from clutch inner race.

Page 301
631010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350

W1593018 WAVE WASHER


NOTES 1 AND 2 (51 CLUTCH ASSEMBLY)

CLUTCH INNER CLUTCH OUTER


RACE RACE

OUTPUT DRIVE INPUT DRIVE

NOTES:
1. 51 SAME AS 41 EXCEPT FOR 369A53525 OUTER RACE
AND W1593018 WAVE WASHER.
2. 369A53525 OUTER RACE CAN BE USED IN OTHER CLUTCH
SUBASSEMBLIES PROVIDED WAVE WASHER IS USED.
H631017A

Figure 301. Clutch Assembly - Cutaway View

Page 302
Revision 3 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
OVERRUNNING CLUTCH
CLEANING/PAINTING
1. Cleaning (1). Clutch Housing (2, Figure 1)
Clean all parts except those to be replaced (a). Remove all oil sludge and any other
prior to inspection as follows: foreign materials from exposed parts.
A. General Cleaning (b). Remove paint as required using
plastic bead blast (17, Table 903) or
The following cleaning information applies to paint remover (1).
all reuseable parts and components of the
overrunning clutch assembly. (c). Rinse thoroughly in clean water after
paint removal.
Most cleaning solvents are
WARNING flammable and must be kept (2). Clutch Retainer (3, Figure 1)
away from heat or open flame. Avoid (a). Clean seal groove using cotton swab
inhalation of fumes and extended con and MEK (15, Table 903).
tact with skin.
(3). Retaining Nut (10, Figure 1)
(1). Use agitated immersion, pressure spray
or vapor degreasing to clean all compo (a). Clean seal groove using cotton swab
nents. and MEK (15, Table 903).
(2). Dry all parts with compressed air after (b). Clean nut using ultrasonic method
cleaning. and cleaning solvent (2).

(3). Wrap all cleaned parts in suitable paper (4). All Metal Parts
or store in a safe place while not in use.
(a). Rinse in dry cleaning solvent (2).
B. Component Cleaning
2. Preparation and Painting
Cleaning requirements for specific parts of the
Prepare and paint the overhauled overrunning
overrunning clutch are described in the
clutch as follows:
following paragraphs.
(1). Clean external housing (2, Figure 1)
Do not use over 50 psig air pres
CAUTION sure for abrasive cleaning meth
surface (Ref. Cleaning).
od. Mask or shield threaded areas or critical (2). Using masking tape (14, Table 903),
surfaces where damage may result from mask off input drive, output drive, seal
abrasive blasting. areas and flange mating surfaces at
each end of housing.
NOTE: Complete removal of epoxybased prim
er is unnecessary. Stripping is necessary on (3). Paint according to Table 401. For
nonferrous parts that are to be fluorescent corrosion control and painting proce
penetrant inspected. dures, (Ref. CSPHMI2).
Table 401. Painting Requirements
Method of No. of
Item Name Paint Type and Specification Application Coats
Housing Primer (9, Table 903) Spray 1
(2, Figure 1)
Non-specular black acrylic lacquer (10, Table 903) Spray 2

Page 401/(402 blank)


631010 Revision 3
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
OVERRUNNING CLUTCH
INSPECTION/CHECK
1. Inspection (d). Repack grease on riveted cage side of
bearing by hand and rotate bearing.
Inspect all overrunning clutch components and Repeat procedure until grease is
parts that are not to be replaced according to visibly working its way out other side
the following instructions. of bearing.

2. Ball Bearing Inspection and Grease (e). Fill void in clutch retainer 75 percent
Repack (300 Hour) full with grease.
(6). Open Faced 369A5361 Ball Bearing
(1). Remove clutch assembly per CSP
HMI2. (a). Check open faced ball bearing for
excessive loss of grease.
(2). Temporarily install coupling bolt, to
maintain internal fluid. NOTE: If excessive loss of grease is noted in
ball bearing, perform enginetotransmis
(3). Remove clutch retainer (3, Figure 1) to sion alignment check per Structural Repair
expose ball bearing (7). Manual. Remedy cause of misalignment
where noted.
NOTE: There are two different 369A5361 ball
bearings currently in use. One type has an (b). If ball bearing is dry or grease is
open face where the cage and bearings are caked, inspect bearing as follows:
visible, the other type has a brass riveted
cage. 1). Clean bearing with solvent and
brush.
(4). Remove bearing from clutch inner race
(18). 2). Inspect for roughness, pitting,
scoring or overheat discoloration.
(5). Riveted Cage 369A5361 Ball Bearing Replace bearing if any of the above
are noted.
(a). On riveted cage ball bearing rotate
3). Check for bearing radial play. If no
and check for binding or roughness.
radial play is discerned in the
If roughness or binding is apparent,
bearing, remove bearing (Ref
replace bearing.
Disassembly), and measure journal
outer diameter. If outside diameter
(b). Check for bearing radial play. If no
of journal exceeds 1.2505 inch
radial play is discerned in the
(3.1763 cm), return clutch subas
bearing, remove bearing (Ref Disas
sembly to MDHS for rework.
sembly), and measure journal outer
diameter. If outside diameter of (c). Using solvent (2, Table 903) and
journal exceeds 1.2505 inch (3.1763 brush, thoroughly remove existing
cm), return clutch subassembly to grease from both bearing and retain
MDHS for rework. er. (Do not use compressed air to
remove grease from ball bearing).
(c). Inspect seal (5) in retainer. Replace if
cracked, broken, worn or shows (d). Inspect bearing for roughness,
evidence of excessive heat. pitting, scoring or discoloration
(Table 501).
NOTE: Installation of 369A53683 seal (with
out garlock spring) upgrades 369A535011 (e). Inspect seal (5, Figure 1) in retainer.
clutch subassembly to 21 configuration, re Replace if cracked, broken, worn or
identify ID plate if necessary. shows evidence of excessive heat.

Page 501
631010 Revision 8
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350
NOTE: Installation of 369A53683 seal (with surface measurement is less than 0.050
out garlock spring) upgrades 369A535011 inch (1.27 mm) or outer surface mea
clutch subassembly to 21 configuration, re surement is less than 0.070 inch (1.78
identify ID plate if necessary. mm), the sprag assembly must be
replaced.
(f). Repack bearing 50 percent of capac
ity with grease (8, Table 903), by (5). On the sprag inner contact surface, of
packing open side of bearing level all the sprags in a sprag assembly, the
without forcing grease through variation in distance from edge of sprag
bearing cage. to load pattern should not exceed 0.030
inch (0.76 mm) (Ref. Figure 504).
(g). Fill void in clutch retainer 75 percent
full with grease. (6). Using an outside micrometer, check
dimension of inner race (369A5353),
(h). Reinstall retainer ring: flat side of 1.4990 inch (3.807 cm) minimum.
retainer ring faces unit; bevel side is
out. (7). Using an inside micrometer, check
dimension of outer race (369A5352),
3. Overrunning Clutch Sprag Inspection (300 2.1565 inch (5.4775 cm) maximum.
Hour)
(8). Using a 4x magnifying lens, visually
The following inspection is forhelicopters inspect inner and outer races for
equippedwitha cargohook (Ref. Table 503 brinelling, scoring or pitting.
for 369D25351 Inspection).
NOTE: On the inner race, pay particular atten
(1). Visually inspect sprag assembly, tion to area around drain holes for cracks.
Table 501, for broken drag clips, broken No defects are allowed. If any are found, re
drag strips, cracked cages, broken or place inner race or outer race as applicable.
distorted ribbon spring or cracked,
If the 369A5364 sprag assembly
broken or missing sprags. CAUTION is replaced for any reason other
Do not remove sprags and clips than broken drag clips or drag strips of dis
CAUTION from sprag assembly. Removal torted ribbon springs, magneflux inner race
requires replacement of sprag assembly. and outer race per Table 502. Disclosure of
any defect requires replacement of inner
(2). Inspect cages, Table 501, for peening or race or outer race as applicable.
wear; maximum permissible width
across inner cage and outer cage (9). Record compliance of this inspection in
windows is 0.208 inch (5.283 mm) (Ref. helicopter log book.
Figure 504).
4. Inspection Requirements
NOTE: The most pronounced inner and outer Table 501 and Table 503 contains visual and
cage wear occurs in the outside diameter dimensional inspection requirements for
corners of the crossbars. Wear should be overrunning clutch parts. Serviceable dimen
measured at the worst point. sions for parts and components, and service
(3). Using 4x magnifying lens, inspect sprag ability criteria for clutch inner and outer races
load surfaces, Table 501, for flats, are shown in Figure 501 thru Figure 504
scoring, heavy pitting or scratches (Ref. (when using Table 501) and Figure 505 and
Figure 504). Figure 506 (when using Table 503). Parts
requiring magnetic particle inspection (MPI)
(4). Measure distance from edge of sprags or fluorescent penetrant inspection (FPI) are
to load pattern, Figure 504. If inner listed in Table 502.

Page 502
Revision 3 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Table 501. Detailed Inspection After Cleaning (with 369A5364 Sprag Assembly)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
NOTE: All inspections are visual inspections unless otherwise specified.
Retaining ring (1, Figure 1) for:
Cracks No defects Not repairable Replace ring.
Nicks or burrs Minor surface defects Minor surface repair Polishing.
Clutch retainer (3) for:
Seal groove damage Not repairable Replace Retainer.
Nicks, burrs, or corrosion Minor surface repair Polishing.
Sleeve spacers (8) for:
Cracks No defects Not repairable Replace sleeve.
Seal surface damage Not repairable Replace sleeve.
Nicks, scratches or burrs Minor surface repair Polishing.
Ball bearings (7, 14 and 17) for:
Pitting or scoring Not repairable Replace bearing.
Discoloration from Not repairable Replace bearing.
overheating
Bearing carrier (6) for:
Damage to bearing mating Only bearing removal Not repairable Replace carrier.
surfaces marks allowed
Nicks, pitting or gouges Minor surface repair Polishing.
Cracks (FPI) No defects Not repairable Replace carrier.
Retaining nut (10) for:
Cross-threading or No defects Not repairable Replace nut.
damaged threads
Seal groove damage Burnishing allowed Not repairable Replace nut.
Nicks, burrs or minor Minor surface repair Polishing.
scoring
Clutch outer race (11) for:
Worn splines, bearing If wear is evident, Minor nicks, scratches or Dress with stone.
bores and clutch race (Figure 501) burrs
Cracks (MPI) No defects Not repairable Replace clutch outer race.
Damage to large end No defects Not repairable Replace clutch outer race.
sealing face
Wear on functional If wear is evident, for Not repairable Replace clutch outer race.
surfaces tolerances (Figure 501)
Brinelling, scoring or No defects Not repairable Replace clutch outer race.
pitting

Page 503
631010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Table 501. Detailed Inspection After Cleaning (with 369A5364 Sprag Assembly) (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Do not remove sprags and clips from sprag assembly. Removal requires replacement of sprag
CAUTION assembly.
Sprag assembly (15) for:
NOTE: Use 4X magnifying lens for inspection.
Evidence of overheating No defects Not repairable Replace sprag assembly.
Galling and scoring No defects Not repairable Replace sprag assembly.
Distorted or broken drag No defects Not repairable Replace sprag assembly.
clips or drag strips
Broken or distorted ribbon No defects Not repairable Replace sprag assembly.
springs
Cages for any cracks No defects Not repairable Replace sprag assembly.
peening, or damage
Edge of cage or flange for No indications None Replace sprag assembly.
wear
Cage windows for wear max width across inner Not repairable Replace sprag assembly.
and outer cage window is
0.208 inch (5.283 mm)
(Figure 504)
Cracked, broken or No defects Not repairable Replace sprag assembly.
missing sprags
Incorrect sprag torque No defects Not repairable Replace sprag assembly.
load pattern on inner and
outer surface (Figure 504)
Sprag load surface for None None Replace sprag assembly.
flats, scoring, heavy pitting
or scratches
Load pattern width Not more than 0.030 inch None Replace sprag assembly.
variation (0.762 mm) difference
from any sprag to load
pattern
Ring spacer (16) for:
Scoring, nicks, cracks, No defects Minor nicks, scratches or Dress with stone.
scratches or burrs on burrs
mating surfaces
Clutch inner race (18) for:
Worn splines, bearing If wear is evident, Minor nicks scratches or Dress with stone.
journals and clutch race (Figure 502) burrs
Cross-threading or No defects Not repairable Replace clutch inner race.
damaged threads
Wear or functional If wear is evident, Not repairable Replace clutch inner race.
surfaces (Figure 502)

Page 504
Revision 3 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Table 501. Detailed Inspection After Cleaning (with 369A5364 Sprag Assembly) (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Clogged oil holes Not required Not required Cleaning.
On inner race, pay particular attention to area around oil drain holes for cracks.
CAUTION
Cracks (MPI) No defects Not repairable Replace clutch inner race.
Brinelling, scoring or No defects Not repairable Replace clutch inner race.
pitting
Housing (2) for:
NOTE: Engine must be removed to inspect housing.
Cracks (FPI) No defects Not repairable Replace housing.
Paint damaged No defects Not required Repaint.
Identification plate (19) No defects Not repairable Replace plate.
damage or illegible
condition
Mating surfaces damaged If defects are evident, Not repairable Replace housing.
(Figure 503)
Minor nicks, scratches or No defects Minor repair Polishing.
gouges

Table 502. Process Inspection Requirements


*Magnetic Particle (ASTM E1444) Fluorescent Penetrant (ASTM E1417)
Item Index No. Item Index No.
Clutch inner race 18 Clutch housing 2
Clutch outer race 11 Bearing carrier 6

NOTES:
* Paint removal is not required for magnetic particle inspection, but is necessary on nonferrous parts for
fluorescent penetrant inspection. Complete removal of epoxy primer is not required on normal overhaul.
When inspecting for or after crash damage, all areas should be visually inspected using minimum of
5-power magnifying glass and all suspected areas should have epoxy primer removed locally with Poly
bead blast (17, Table 903) or paint remover (1) for added inspection. Prevent entry of paint remover into
joint lines of bearings, bushings or inserts still assembled with the part requiring paint removal.

Page 505
631010 Revision 11
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350
1.62561.6250 IN
(4.12904.1275 CM)

0.75050.7501 IN
1.25051.2501 IN (19.062719.0525 CM)
(3.17633.1753 CM) 1.50001.4990 IN
(3.81003.8075 CM)
2.25072.2500 IN 2.15502.1565 IN
(5.71685.7150 CM) (5.47375.4775 CM) PIN DIAMETER 0.096 IN (2.438 MM)

PIN DIAMETER 0.0864 IN (2.1946 MM)

1.2891 IN (3.2743 CM) MIN


MEASURE OVER PINS

1.3054 IN (3.3157 CM) MIN


MEASURE OVER PINS

PIN DIAMETER 0.096 IN (2.438 MM)

PIN DIAMETER 0.0864 IN (2.1946 MM) H631018A H631019A

Figure 501. Service Limits - Clutch Outer Figure 502. Service Limits - Clutch Inner


Race Race








2.9022.900 IN 2.5002.501 IN
(7.3717.366 CM) (6.3506.3525 CM)






H631020A

Figure 503. Service Limits - Clutch Housing

Page 506
Revision 3 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350

OUTER INNER
CAGE CAGE DRAG CLIP
(3 REQD)

SPRAG 18 REQD
(REFER TO CAUTION) DRAG STRIP OUTER CAGE FLANGE
(3 REQD)

RIBBON SPRING

0.208 IN (5.283 MM) MAX


(NOTE 1, 2)
TORQUE LOAD PATTERN REFER TO CAUTION
INNER SURFACE

TORQUE LOAD
OUTER CAGE PATTERN OUTER
INNER CAGE FLANGE SURFACE
0.208 IN (5.283 MM) MAX FLANGE
(NOTE 1, 2)

CROSS BAR
CROSS
BAR

WINDOW
DRAG CLIP

WINDOW CHECK FOR WEAR 0.070 IN (1.778 MM) MIN


DRAG STRIP ON EDGE OF CAGE
0.50 IN (12.70MM) MIN

INNER CAGE INNER DIAMETER OUTER CAGE OUTER DIAMETER

NOTE: CAUTION:
1. SPRAG REMOVED FOR CLARITY, REFER TO CAUTION. DO NOT REMOVE SPRAGS AND CLIPS FROM SPRAG
2. GREATEST WEAR OCCURS IN OUTSIDE DIAMETER ASSEMBLY. REMOVAL REQUIRES REPLACEMENT OF
CORNERS OF CROSSBARS. MEASURE WEAR AT THE SPRAG ASSEMBLY.
WORST POINT.

H631021

Figure 504. Sprag Torque Load Pattern

Page 507
631010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Table 503. Detailed Inspection after Cleaning (369D25351 Sprag Assembly)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
NOTE: This table is for inspection of the 369D25351 sprag assembly only. For inspection requirements of
complete clutch assembly, refer to Table 501.
Do not remove more than one sprag from sprag assembly at a time. Sprags must stay in the
CAUTION same windows because of wear patterns. Interchanging of sprags requires replacement of
sprag assembly.
Sprag assembly (15) for:
Cross bar straightness No defects Not repairable Replace sprag assembly.
and uniformity
Retainer assembly for Must slip into outer race Not repairable Replace sprag assembly.
roundness without forcing
Retainer flanges for No defects Minor surface repair Polishing.
excessive gouging or
steps from adjacent
contact surfaces
Outside diameter of No defects Not repairable Replace sprag assembly.
retainer contact surface
with outer race sprag
diameter for excessive
wear
Sprags for freedom of No binding allowed Not repairable Replace sprag assembly.
movement in slots
Sprag retainer spring No defects Not repairable Replace sprag assembly.
(installed) for separation
of coils, kinking, and
corrosion
NOTE: Lightly polished areas are acceptable. Do not reinstall sprag assembly if one sprag is not acceptable.
Window surfaces on 0.004 inch (0.102 mm) Not repairable Replace sprag assembly.
flange and bar surfaces max from original flat
on retainer for wear surface and/or sharp
corner wear at interface
of bars to flanges

Sprags (Figure 505) for:


NOTE: It is common to see some flaking or spalling of Formchrome on sprag surfaces after some service hours
at the higher area of load cam. Formchrome is a very thin diffusion layer and this flaking condition does
not alter the sprag geometry as long as the change to surface contour is not over 0.0002 inch (0.0051 mm).
Bare surfaces altered by scoring, scrubbing, or other severe clutch conditions is cause for sprag rejection.
Chips or surface break None None Replace sprag retainer
up (resulting from assembly.
scuffing or scoring) that
do not conform to
original cam profile
(Figure 505)

Page 508
Revision 3 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Table 503. Detailed Inspection after Cleaning (369D25351 Sprag Assembly) (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Flat wear bands at 0.020 inch (0.508 mm) Not repairable Replace sprag retainer
overrunning cam portion max assembly.
of sprag
Sprags and retainer for None Not repairable Replace sprag retainer
corrosion assembly.
Sprag retainer spring None Not repairable Replace sprag retainer
(removed) for kinks or assembly.
circular arcs
Spring coil sprag contact Wear must not exceed 30 Not repairable Replace sprag retainer
surface for wear percent of wire section assembly.
Sprags for chips or loss of 0.002 inch (0.051 mm) Not repairable Replace sprag retainer
material on profile max from original assembly.
surface on front flat and
back bumper
Inner race sprag cam for 0.030 inch (0.762 mm) Not repairable Replace sprag retainer
working or loading of max at high load corner assembly.
high loading corner
Sprag inner race and/or None Not repairable Replace sprag retainer
other supporting surfaces assembly.
for wear and loss of
clutch concentricity

Page 509
631010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350
SPRING

CHECK FOR CHIPPED


CORNERS OR LOSS
OF MATERIAL

SEE ITEM C
FOR DETAIL

ITEM B

ITEM A


INNER RACE OF
INDIVIDUAL SPRAG


0.004 IN (0.0102 MM) MAX.
WEAR FROM ORIGINAL
FLAT SURFACE (NOTE)



ITEM C
0.030 MINIMUM

0.004 IN (0.0102 MM) MAX. WEAR


FROM ORIGINAL FLAT SURFACE


AND/OR SHARP CORNERS (NOTE)


0.004 IN (0.0102 MM) MAX.


(NOTE)
STEP CAUSED BY WEAR
(NOTE)

ITEM E

NOTE: USE TOOL (3, TABLE 901) FOR
INSPECTING OF SPRAG WINDOW WEAR.
ITEM D
H631022C

Figure 505. Inspection Requirements of 369D25351 Sprag Assembly

Page 510
Revision 12 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350

*1.50001.4991 IN
(*3.81003.8077 CM)
1.25051.2501 IN


(3.17633.1753 CM)


0.75050.7501 IN
(19.062719.0525 CM)





MAXIMUM TAPER OVER LENGTH
IS 0.0010 IN (0.0254 MM)

NOTE

2.25072.2500 IN


(5.71685.7150 CM)







1.62561.6250 IN
(4.12904.1275 CM)






2.1550*2.1564 IN
(5.4737*5.4773 CM)

*NEW DIMENSION CRITERIA

NOTE:
DIMENSIONS FOR IDENTIFICATION OF THE OUTER RACE ONLY
369A5352BSC 1.271 INCH (3.228 CM)
369A53525 1.311 INCH (3.329 CM).
H631023C

Figure 506. Dimension Criteria for 369A5350-31, -41 or -51 Overrunning Clutch Assembly

Page 511/(512 blank)


631010 Revision 3
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
OVERRUNNING CLUTCH
REPAIR/MODIFICATION
1. General Repair and Modification 3. Parts Replacement
Information
The following paragraph contains part
This section provides allowable repairs and replacement requirements.
part replacement requirements and modifica (1). Replace all packings and seals.
tion upgrades for overhaul of the overrunning
clutch. (2). Replace lockwasher (12, Figure 1).

2. Repair (3). Replace all parts not within tolerances


specified in Table 501 and Figure 501
The only repairs authorized for overrunning thru Figure 503.
clutch components are those given in the NOTE: If a large number of clutch parts are be
following paragraph. yond tolerance, consider replacement of the
complete clutch subassembly.
A. Removal of Minor Nicks, Scratches and
Corrosion 4. Modification
All parts must meet the tolerances specified in A. Seal Modification
Table 501 and Figure 501 thru Figure 503
after repair. All parts are to be recleaned and New 369A5368 seals may be upgraded to
spot painted as required (Ref. CSPHMI2) 369A53683 configuration by removal of
prior to reassembly. garlock spring from seal.
Used seals may not be reworked
(1). Splines CAUTION to the 369A5368 3 configura
tion.
(a). Dress minor nicks, scratches and
burrs with fine India stone (3, B. Overrunning Clutch Modification, Early to
Table 903). Current -51 Configuration
(2). Nonsealing Ferrous Parts Modify an early overrunning clutch to the
most current configuration by performing all
(a). Polish out minor scoring with crocus applicable modifications listed by item
cloth (4). numbers in Table 601. All parts to be removed
and replaced are listed by part number in
(3). Aluminum Parts Table 602. Ensure that all parts listed in
Table 602 for removal and replacement are
(a). Polish out minor scoring with abra accomplished. Removal procedures for the
sive cloth (5). Apply chemical film parts are furnished in (Ref. Disassembly).
(13) to polish surface (Ref. CSP Similarly, replacement procedures, are in (Ref.
HMI2). Repair) and reassembly procedures are in (Ref.
Assembly).
B. General Part Replacement Requirements
Do not use 369A5363 bearing,
Replace the following parts with new parts at CAUTION marked SKF/MRC, P/N R12,
reassembly of the overrunning clutch: when converting to 51 configuration.

Page 601
631010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Table 601. Overrunning Clutch Configuration Conversions
369A5350-( ) Configuration Modification Required
From To (Item No. Table 602)
-1 1 -51 1, 2, 3, 4, 5, 6
-21 -51 1, 3, 4, 5, 6
-31 -51 3, 4, 5, 6
-41 -51 5, 6

Table 602. Overrunning Clutch Modification Criteria


Item Parts to be Parts to be
No. Quantity Removed Installed Nomenclature
1 1 369A5364 369D25351 Sprag Assembly
2 1 369A5368 369A5368-3 Seal, Oil (Note)
3 1 369A5365 369A5365-3 Nut Retainer
4 1 369A5353 369A5353-3 Race, Inner Clutch
5 1 369A5352 369A5352-5 Race, Outer Clutch
6 1 W1593-018 Washer, Wave
Do not use 369A5363 bearing, marked SKF/MRC, P/N R12, when converting to -51 configura-
CAUTION tion.
NOTE: Conversion of -11 configuration to -51 configuration overrunning clutch requires the 369A5368 oil seal on
inner race be removed and replaced by 369A5368-3 oil seal (Ref. Figure 601).

Table 603. Overrunning Clutch Oil Capacity


Overrunning Clutch Capacity
1 1, 21, 31 1.52 U.S. Oz. (45 cc)
41, 51 1.01 U.S. Oz. (30 cc)

Page 602
Revision 11 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350

WAVE WASHER
(51 CLUTCH ONLY)
NUT RETAINER (CAUTION:)
OIL SEAL (NOTE)
SPRAG

CLUTCH OUTER RACE


CLUTCH INNER RACE

OUTPUT DRIVE INPUT DRIVE

NOTE:
REMOVE AND REPLACE THIS SEAL ON 11 CONFIGURATION
CLUTCH. REFER TO TABLE 602, ITEM 2.
CAUTION:
DO NOT USE 369A5363 BEARING, MARKED SKF, P/N R12,
WHEN CONVERTING TO 51 CONFIGURATION. H631024C

Figure 601. Overrunning Clutch Assembly - Cutaway View

Page 603/(604 blank)


631010 Revision 3
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
OVERRUNNING CLUTCH
ASSEMBLY/SHIPPING
1. Seal Installation bearing level without forcing grease
through bearing cage.
Prior to reassembly of overrunning clutch
parts and subassemblies, install new seals (5, (2). Lubricate all packings with oil (12).
Figure 1) in potting compound applied in seal
grooves of retaining nut (10) and clutch (3). Install packing (4, Figure 1) in retainer
retainer (3) as follows: (3); one packing (9) in each sleeve
spacer (8); and packing (13) in retaining
(1). Ensure seal grooves in retaining nut nut (10).
and clutch retainer are clean (Ref.
(4). Apply light film of oil (12, Table 903) to
Cleaning).
sprag assembly (15, Figure 1).
NOTE: Mix potting compound (6, Table 903), (5). Press bearing (17) on clutch inner race
one ounce compound to 60 drops hardener. (18) until bearing inner race bottoms on
Apply compound in seal grooves evenly. shoulder of clutch inner race.
Avoid excess application. Allow potting com
pound to dry at room temperature, accord (6). Install ring spacer (16) on clutch inner
ing to container instructions. race (18).
(2). Apply potting compound in seal groove (7). Install sprag assembly on clutch inner
of retaining nut. race (Ref. Figure 1).
(3). Install one seal in potting compound (a). For 369A5364 sprag assembly, install
with lip of seal toward threads of nut. with flanged end of clutch assembly
Ensure seal is correctly seated against toward splined end of race.
gland seat and that side and inside
diameter is free of potting compound. (b). For 369D25351 sprag assembly,
install with arrow toward splines,
(4). Wipe away any potting compound facing in a clockwise direction.
squeeze out.
Do not use 369A5363 bearing,
CAUTION marked, SKF/MRC, P/N R12,
(5). Apply potting compound in seal groove
of clutch retainer. when converting to 51 configuration.

(6). Install one seal in potting compound (8). Press bearing (14) on clutch inner race
with seal lip toward packing. Ensure until bearing inner race bottoms on
seal is correctly seated against gland shoulder of clutch inner race.
seat and side and inside diameter is (9). Install new lockwasher (12) on threads
free of potting compound. of clutch outer race (11).
(7). Wipe away any potting compound NOTE: A small amount of oil (12, Table 903) in
squeeze out. clutch outer race housing aids reassembly.
2. Reassembly (10). Clamp splined shaft of clutch outer race
in aluminum jawed vise.
Reassemble the overrunning clutch as follows:
(11). On 51 clutches, insert wave washer
NOTE: Packing bearing to 50 percent of its ca (22, Figure 1) into clutch outer race
pacity, applies only to the open face bearing. (ensure wave washer seats into inner
recess).
(1). Pack ball bearing (7, Figure 1) to 50
percent of its capacity with grease (8, (12). Using waxed cord to compress outer
Table 903), by packing open side of diameter of sprag assembly, and while

Page 701
631010 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350
rotating clutch inner race counterclock 3. Final Inspection
wise, insert clutch inner race into
clutch outer race. After reassembly, perform a final inspection as
follows. Repair any damage as required (Ref.
(13). Apply antiseize compound (16, Repair).
Table 903) to threads of retaining nut (1). Visually inspect clutch assembly
(10, Figure 1) and install nut on clutch exterior for damage.
outer race (11). Ensure packing remains
in gland seat of nut during installation. (2). Check attachment of identification
plate.
(14). Using standard strap wrench. Torque
retaining nut (10) to 100 150 inch (3). Check splines on inner and outer races
pounds (11.30 16.95 Nm); back nut for chips or burrs.
off and retorque. Do not crimp lock
washer (12) at this time. 4. Run-In Procedures
Runin and test the overhauled overrunning
(15). Slide inner sleeve spacer (8) on shaft,
clutch according to the following procedures.
with flange toward splines of clutch
inner race. Press sleeve spacer past seal A. Torque Test
lip until it seats against inner race of
bearing (17). The following torque test is the only runin
and test required for the overrunning clutch.
(16). Press bearing (7) grease packed side up,
(1). Lock output shaft, and using socket and
into bearing carrier (6).
anchor assembly (2, Table 901), apply
(17). Press bearing carrier on clutch inner 218 55 footpounds (24.63 6.21
race (18) until bearing seats against Nm) torque to input shaft. There must
inner sleeve spacer. be no clutch slippage.

(18). Install outer sleeve spacer (8) with NOTE:


flange against bearing (7). D When initially servicing an overhauled or
new overrunning clutch, the recom
(19). Fill void of clutch retainer (3) 75 mended amount of lubricant must be
percent full with grease (8, Table 903); used. This will overfill the assembly, but
install retainer on outer sleeve spacer. after 30 minutes of helicopter operation
the lubricant level should drop to the nor
To prevent damage to lockwash
CAUTION er when crimping, do not use
mal level.
sharp tools or excessive force. D The 11, 21 and 31 clutch assembly oil
capacity is 1.52 U.S. Oz. (45cc).
(20). Crimp lockwasher (12, Figure 1) into D The 41 and 51 clutch assembly oil ca
notches (5 places) in clutch outer race pacity is 1.01 U.S. Oz. (30cc).
(11) and retaining nut (10). Inspect
crimped areas for cracks with a 10X (2). Install clutch in helicopter; service
glass. Replace lockwasher if cracked. clutch with lubricating oil (12,
Table 903), (Ref. CSPHMI2).
(21). Coat clutch splines with grease (8,
Table 903). Helicopter must be operated
WARNING in accordance with ap
NOTE: Flat side of retaining ring (1, Figure 1) proved Rotorcraft Flight Manual.
faces unit; bevel side is out.
(3). Run helicopter at 100 percent N2 for 5
(22). Carefully insert subassembly into minutes. Shut down helicopter and
housing (2); secure with retaining ring. examine clutch for leakage. If oil
leakage is evident at seals, assembly
(23). Reattach identification plate (19), if joint lines, or housing drain holes,
removed, by bonding to clutch housing remove and disassemble clutch for
with adhesive (11, Table 903). inspection and rework as required.

Page 702
Revision 3 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
NOTE: Leakage from clutch housing drain
holes may be caused by engine lubricant
leaking past engine shaft seals. Check en
gine shaft seals for leakage prior to disas
sembly of the overhauled overrunning
clutch.

OUTER CLUTCH RACE

WAVE WASHER
(51 CONFIGURATION ONLY)
LOCKWASHER

(NOTE 1)

NOTES:
1. USE WAXED CORD TO COMPRESS SPRAGS. INNER CLUTCH RACE
2. ROTATE COUNTERCLOCKWISE WHILE INSERTING (NOTE 2)
INTO OUTER CLUTCH RACE. H631025A

Figure 701. Clutch - Reassembly of Races


5. Shipping 6. Packing and Storage
If clutch is to be stored or shipped, remove If overhauled clutch is not to be used immedi
from helicopter (Ref. CSPHMI2). Drain ately, package and store the clutch as follows:
lubricant and flush clutch with corrosion
preventive oil (7, Table 903). Install packing (1). Apply a light layer of corrosion preven
(20, Figure 1) and cap plug (21) on end of tative (18, Table 903) and package or
shaft. cover to keep dust off.

Page 703/(704 blank)


631010 Revision 5
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
OVERRUNNING CLUTCH
SPECIAL TOOLS, FIXTURES & EQUIPMENT
1. Reference Data tion, regarding special tools and equipment,
and expendable items and materials required
Table 901 and Table 903 provide specifications, for overhaul/repair. Torque values are con
and when appropriate, procurement informa tained in Table 902.

Table 901. Overrunning Clutch Assembly Overhaul - Special Tools


Item
No. Nomenclature Part No. Manufacturer
1 Bearing Puller 950 Owatonna Tool Company
2 Socket and Anchor Assembly SWE12046 B.K. Sweeney Mfg. Co.,
Denver, Colo.
3 Sprag window wear inspection tool RBT18612 Red Barn Machine Inc.
4681 Isabelle St.
Eugene, OR 97402
Phone: (541) 344-9953
FAX: (541) 344-3863

Table 902. Overrunning Clutch Assembly Special Torques


Torque
Item Figure 1, Index No. In.-Lb. Nm
Bearing Retaining Nut 10 100150 11.30 16.95

Table 903. Repair Materials


Item
No. Material Specification No. Name/No. Manufacturer
1 Paint remover TT-R-248 Turco 5351 Turco Products, Inc.,
Westminster, CA
92684-3600
No. A202 Cee-Bee Chemical Co.
2 Solvent, dry-cleaning P-D-680 (3)
3 India stone (fine) (3)
4 Cloth, abrasive, crocus grade P-C-458 (3)
5 Cloth, abrasive, aluminum P-C-451 (3)
oxide (grade No. 320 or 400)
6 Potting compound SAE-AMS-S-8802 (3)
7 Corrosion preventive oil MIL-C-8188 (3)
8 Grease MIL-G-81322 Mobile 28 Mobile Oil Co.

Page 901
631010 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Table 903. Repair Materials (Cont.)
Item
No. Material Specification No. Name/No. Manufacturer
9 Primer, catalyzed epoxy MIL-P-23377B Material Description: Andrew Brown Co.,
(yellow) HMS 15-1082 Los Angeles, CA
W.P. Fuller & Co.
Los Angeles, CA
Sherwin-Williams,
Los Angeles, CA
10 Paint, acrylic lacquer MIL-L-81352 Material Description: Andrew Brown Co.
(AML-P95) (color 27038) HMS 15-1083 Los Angeles, CA
DeSoto Chemical
Coatings
Berkely, CA
W.P. Fuller & Co.
Los Angeles, CA
Sherwin-Williams,
Los Angeles, CA
11 Adhesive MIL-A-8623 A-1 177-B B.F. Goodrich
12 Lubricating oil MIL-L-23699 (3)
13 Chemical film and chemical film MIL-C-5541 Iridite 14-2 Richardson Co.
materials for aluminum and (Class 2, unless Al-coat Allied-Kelite
aluminum alloys noted. Grade and Products Div.
type optional) 2400 E. Devon Ave.
Des Plaines, IL
14 Masking tape MIL-T-23397 (3)
15 Methyl-ethyl-ketone (MEK) TT-M-261 (3)
16 Anti-seize compound MIL-L-25681 (3)
17 Plastic bead, spherical Poly Plus 20/30 Polyrock Company
20-30 mesh 4763 Murrita Ave
Chino, CA 91710
Abrasive Cleaning
20122 State Rd.
Cerritos, CA 92701
Abrasive Unlimited
4653 S. 33 RD. St.
Suite #1
Phoenix, AZ 85040

Page 902
Revision 12 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Table 903. Repair Materials (Cont.)
Item
No. Material Specification No. Name/No. Manufacturer
18 Corrosion Preventative MIL-C-81309 Corrosion X Corrosion Technologies
Type II Corp.
Fluid Film Eureka Chemical Co.
NOTES:
(1) Numbers are U. S. A. Specifications and Standards. The prefix symbols are defined as follows:
AMS - American Material Standard; MS - Military Standard; MIL - Military Specification; single, double or
triple alpha prefix of the same letter - Federal Specification; AN - Air Force-NavyAeronautical Standard;
NAS - National Aerospace Standard.
(2) Primary selection. Any equivalent material may be used as an alternate selection.
(3) Use the best equivalent commercial grade material when the conformity of available materials of the
same type with the listed U. S. A. Specification No. cannot be determined.

Page 903/(904 blank)


631010 Revision 12
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
OVERRUNNING CLUTCH
ILLUSTRATED PARTS LIST
1. General Explanations of codes and abbreviations used
in this illustrated parts list can be found by
This section contains an illustrated parts list referring to the Introduction section of
to be used in conjunction with the 369A5350 CSPIPC4.
Overrunning Clutch overhaul manual. Correct
part numbers and nomenclature can be
identified for specific configurations and 2. Indenture Level
effectivities.
Item numbers in this parts list refer to the The indenture level to a higher assembly is
figure preceding the parts list table. An item indicated by the amount of bullets in front of
number may be the same or different from the each item in the description column. An item
same part shown in a different illustration that has one more bullet than the part above it
elsewhere in the overhaul manual. is a sub part of that assembly.

Page 1001
631010 Revision 14
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350

21

22

19
23
20
3
1

2
12
13

11
10
14

15

16

9
17

4
18

7
8
9

10

11

H631038B

Figure 1001. Overrunning Clutch Assembly

Page 1002
Revision 16 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Qty.
Fig. &
Part Number Description per
Index
Assy.
1001 369A5350603 Clutch Assy, Overrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
Replaced By 369A5350605 Over Running Clutch Assy
369A5350605 Clutch Assy, Overrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
1 369A53515 Housing, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 369A5369 Plate, Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 369A5350603 Clutch Assy
2 369A53693 Plate, Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369A53695 Indent Plate. Use On 369A5350605
Clutch Assy
2 369A53695 Plate, Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369A53693 Indent Plate. Use On 369A5350605
Clutch Assy
3 369A53703 Plate, Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369A53705 Ident Plate
3 369A53705 Plate, Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369A53503 Ident Plate
4 N5002315 Ring, Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 369A535011 Clutch SubAssy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaced By 369A535021. Not Illustrated
5 369A535021 Clutch SubAssy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaced By 369A535031. Not Illustrated
5 369A535031 Clutch SubAssy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaced By 369A535041. Not Illustrated
5 369A535041 Clutch SubAssy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369A535051. Not Illustrated
369A535051 Is Preferred Part
5 369A535051 Clutch SubAssy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369A535041. Not Illustrated
Used On 369A5350605 Clutch Assy
6 369A5366 Retainer, Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 M83248/1035 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 369A53683 Seal, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369A535021 / 31 / 41 / 51 Clutch SubAssy
(W/O Lip Spring)
9 369A5368 Seal, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369A535011 (With Lip Spring)
10 369A5367 Sleeve, Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
11 M83248/1026 ORing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12 369A5361 Bearing, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 369A5355 Carrier, Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 369A53653 Nut, Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 369A5358 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
16 M83248/1141 ORing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 369A5362 Bearing, Fwd, Sprag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18 369A5353 Race, Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 369A535011 / 21 / 31 Clutch SubAssy

Page 1003
631010 Revision 16
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369A5350
Qty.
Fig. &
Part Number Description per
Index
Assy.
18 369A53533 Race, Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 369A535041 / 51 Clutch SubAssy
19 369A5360 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20 369D25351 Sprag Assy, Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21 369A5363 Bearing, Aft Sprag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22 W1593018 Wave Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use With 369A535051 Clutch SubAssy
23 369A5352 Race, Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use With 369D535011 / 21 / 31 / 41 Clutch SubAssy
23 369A53525 Race, Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use With 369A535051 Clutch SubAssy

Page 1004
Revision 15 631010
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL

Section

63-10-15
Overrunning Clutch
Part Number
369F5450-501, -503, -505

H631027

Page a
Revision 13
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL

This Page Intentionally Left Blank

Page b
Revision 13
MD Helicopters, Inc. CSP-COM-5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
TABLE OF CONTENTS
Para/Figure/Table Title Page

631015 Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Overrunning Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. General Disassembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 301. Clutch Assembly Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Cleaning/Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Component Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Preparation and Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Table 401. Painting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. Ball Bearing Grease Repack (300 Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
3. Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Table 501. Detailed Inspection After Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Table 502. Process Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Figure 501. Service Limits Clutch Outer Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Figure 502. Service Limits Clutch Inner Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Figure 503. Service Limits Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Figure 504. Service Limits Clutch Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Table 503. Detailed Inspection After Cleaning (369F5456 Sprag Assembly) . . 506
Figure 505. Inspection Requirements of 369F5456 Sprag Assembly . . . . . . . . . . 509
Repair/Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Repair and Modification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Clutch Coupling Wear Sleeve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Table 601. Overrunning Clutch Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Table 602. Overrunning Clutch Configuration Conversions . . . . . . . . . . . . . . . 602
Table 603. Overrunning Clutch Modification Criteria . . . . . . . . . . . . . . . . . . . . . 602
Assembly/Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
1. Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

631015 Page i
Contents Revision 13
CSP-COM-5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page
Figure 701. Clutch Coupling Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
2. Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
3. RunIn Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
A. Torque Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Figure 702. Clutch Inner and Outer Race Reassembly . . . . . . . . . . . . . . . . . . . . . . 703
4. Packing and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
5. Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
Special Tools, Fixtures & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
1. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Table 901. Overrunning Clutch Overhaul Special Tools . . . . . . . . . . . . . . . . . . . 901
Table 902. Overrunning Clutch Assembly Special Torques . . . . . . . . . . . . . . . . . . 901
Table 903. Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Indenture Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Figure 1001. Overrunning Clutch Assembly 369F5450 . . . . . . . . . . . . . . . . . . . . 1002

Page ii 631015
Revision 13 Contents
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
OVERRUNNING CLUTCH
DESCRIPTION AND OPERATION
NOTE: Before attempting any repair or over rized modifications for the overrunning
haul of this component, ensure the required clutch.
special tools and processes are available to
assure completion of the work. (6). Reassembly/Shipping . . . . . . . . . . . . . 701
provides overrunning clutch reassembly
1. General and procedures for runin of the
overhauled overrunning clutch.
This section of the Overhaul Manual describes
overhaul procedures for the 369F5450 Over (7). Special Tools, Fixtures
running Clutch Assembly. Procedures given & Equipment . . . . . . . . . . . . . . . . . . . . 901
are the approved methods to be used for provides procedures for fabricating
specific repair or complete overhaul of the special tools required for overhaul of
component. the overrunning clutch.

A. Organization (8). Illustrated Parts List . . . . . . . . . . . . 1001


provides a parts list supplement to
The Overrunning Clutch section of the identify part numbers and configura
Component Overhaul Manual is made up of tion differences for the overrunning
seven parts, listed below. These sections clutch.
contain complete instructions for disassembly,
cleaning, inspection, repair, reassembly and B. Reference Data
testing of the component. The following (1). Reference is made throughout this Part
describes the topic and content of each part of the Overhaul Manual to CSP
with appropriate page numbers: HMI2. This manual should be used as
(1). Description and Operation . . . . . . . . . . 1 noted throughout the overhaul/repair.
describes procedures for complete use of Use the Illustrated Parts Catalog
the overrunning clutch section. (CSPIPC4) when ordering any
replacement parts for 369F5450
(2). Disassembly . . . . . . . . . . . . . . . . . . . . . 301 overrunning clutch assembly.
gives procedures for complete disassem
(2). Table 901 and Table 903 provide
bly of the overrunning clutch.
specifications, and when appropriate,
(3). Cleaning/Painting . . . . . . . . . . . . . . . . 401 procurement information, regarding
contains cleaning and painting require special tools and equipment, and
ments for the overrunning clutch expendable items and materials
components and parts. required for overhaul/repair. Torque
values are contained in Table 902.
(4). Inspection/Check . . . . . . . . . . . . . . . . . 501
provides visual and dimensional (3). Figure 1 shows an exploded view of the
inspection requirements. overrunning clutch, with all parts
indexed. The index numbers are used
(5). Repair/Modification . . . . . . . . . . . . . . 601 throughout the text with the part
provides allowable repairs and parts nomenclature to make part identifica
replacement information and autho tion easier.

Page 1
631015 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450
8

18 6

17 5

16 4
3
15 2
14

13 1
25
24
12
11
23
27
22 10
26
21 9

369F5450501 CLUTCH ASSEMBLY


20

19

8
18
17 7
16
15 6

14 5

13 4
25 12 3
2 30
24 29
9

11 1
10
23

27 28
22
21
26
20
369F5450503, 505 CLUTCH ASSEMBLY
19
NOTE:
ITEM 22 NOT USED AT REASSEMBLY. H631028C

Figure 1. Overrunning Clutch Assembly

Page 2
Revision 13 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Legend (Ref. Figure 1)
1. CLUTCH HOUSING 16. BALL BEARING
2. CLUTCH OUTER RACE 17. PACKING
3. WAVESPRING 18. SEAL
4. BALL BEARING 19. CLUTCH RETAINER
5. SPRAG ASSEMBLY 20. RETAINER RING
6. CLUTCH INNER RACE 21. SHIM
7. WASHER
22. PACKING (NOT USED AT REASSEMBLY)
8. BALL BEARING
23. COUPLING
9. SEAL
24. PACKING
10. LOCK SPACER
11. PACKING 25. BOLT
12. RETAINING NUT 26. IDENTIFICATION PLATE
13. PACKING 27. SCREWS
14. SLEEVE SPACER 28. TEE BOLT (369F5450-503, -505)
15. BEARING CARRIER (369F5450-501 ONLY) 29. WASHER (369F5450-503, -505)
RETAINING RING (369F5450-503, -505 ONLY) 30. NUT (369F5450-503, -505)

Page 3
631015 Revision 13
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450

This Page Intentionally Left Blank

Page 4
Revision 13 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
OVERRUNNING CLUTCH
DISASSEMBLY
1. General Disassembly Information (a). Remove retainer ring (15) from
retainer (19).
Information given in this section provides
procedures for complete disassembly of the (b). Press bearing (16) from clutch
369F5450 Overrunning Clutch Assembly. retainer.
Many specific repairs require only partial
(c). Remove packing (17) from retainer.
disassembly, follow procedures to the point
required. Use care when prying seal (18)
CAUTION from clutch retainer (19), re
2. Disassembly tainer must be replaced if seal groove is
damaged.
(1). Using snap ring pliers, remove retain
ing ring (20, Figure 1) from housing (1); (9). Carefully pry seal (18), which is bonded
remove clutch from housing. in groove, from retainer (19).

(2). On 503 clutches only, remove nut (30), (10). Remove crimps (5 places) in lock spacer
washer (29) and TBolt (28) from (10).
housing.
(11). Using strap wrench, remove retaining
(3). Secure input shaft or clutch outer race nut (12), packing (11) and lock spacer
in aluminum jawed vise or equivalent from clutch outer race (2); discard lock
spline holding fixture. spacer.
Use care when prying seal (9)
(4). Remove bolt (25) with packing (24), CAUTION from retaining nut (12). Nut
coupling (23), packing (22) (if installed)
must be replaced if seal groove is damaged.
and Shim (21).
(12). Remove packing (11) and carefully pry
(5). Remove clutch from vise or holding seal (9), which is bonded in groove, from
fixture and drain oil. nut (12).
(6). Using arbor press and plate support (13). Rotate output shaft of clutch inner race
tool, which picks up lip on sleeve spacer (6) counterclockwise and remove from
(14), remove the sleeve and clutch outer race (2); remove outer race from
retainer assembly. vise.
(7). Disassemble clutch retainer for 501 If any sprags fall out of retainer
clutch assembly as follows: CAUTION when sprag assembly is re
moved, sprag assembly must be replaced.
(a). Press bearing carrier (15) from
bearing (16). (14). Remove washer (7), sprag assembly (5)
and wavespring (3) from clutch outer
(b). Press bearing from clutch retainer. race (2).
(c). Remove packing (17) from retainer. (15). Using suitable bearing puller, remove
bearings (4) and (8) from clutch inner
(8). Disassemble clutch retainer for 503 race (6). Do not press across rolling
and 505 clutch assembly as follows: elements.

Page 301
631015 Revision 13
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450

CLUTCH INNER RACE

CLUTCH OUTER RACE

NOTE

INPUT SHAFT
(ENGINE SIDE)
OUTPUT SHAFT
(XMSN SIDE)

369F5450501 CLUTCH ASSEMBLY

CLUTCH INNER RACE

CLUTCH OUTER RACE

NOTE

NOTE INPUT SHAFT


(ENGINE SIDE)
OUTPUT SHAFT
(XMSN SIDE)

369F5450503, 505 CLUTCH ASSEMBLY

NOTE:
PACKING NOT USED AT REASSEMBLY. H631029C

Figure 301. Clutch Assembly - Cutaway View

Page 302
Revision 13 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
OVERRUNNING CLUTCH
CLEANING/PAINTING
1. Cleaning (1). Housing (1, Figure 1)

Clean all parts except those to be replaced (a). Remove all oil sludge and any other
prior to inspection as follows: foreign materials from exposed parts.

A. General Cleaning (b). Remove paint as required using


plastic bead blast (17, Table 902) or
The following cleaning information applies to paint remover (1).
all reuseable parts and components of the
overrunning clutch assembly. (c). Rinse thoroughly in clean water after
paint removal.
Most cleaning solvents are
WARNING flammable and must be kept (2). Clutch Retainer (19, Figure 1)
away from heat or open flame. Avoid (a). Clean seal groove using cotton swab
inhalation of fumes and extended con and MEK (15, Table 902).
tact with skin.
(3). Retaining Nut (12, Figure 1)
(1). Use agitated immersion, pressure spray
or vapor degreasing to clean all compo (a). Clean seal groove using cotton swab
nents. and MEK.

(2). Dry all parts with compressed air after (b). Clean nut using ultrasonic method
cleaning. and cleaning solvent (2).

(3). Wrap all cleaned parts in suitable paper (4). All Metal Parts
or store in a safe place while not in use.
(a). Rinse in dry cleaning solvent (2).
B. Component Cleaning
2. Preparation and Painting
Cleaning requirements for specific parts of the
Prepare and paint the overhauled overrunning
overrunning clutch are described in the
clutch as follows:
following paragraphs.
(1). Clean external housing (1, Figure 1)
Do not use over 50 psig (345
CAUTION kPa) air pressure for abrasive surface (Ref. Cleaning).
cleaning method. Mask or shield threaded (2). Using masking tape (14, Table 902),
areas or critical surfaces where damage may mask off input drive, output drive, seal
result from abrasive blasting. areas and flange mating surfaces at
each end of housing.
NOTE: Complete removal of epoxybased prim
er is unnecessary. Stripping is necessary on (3). Paint according to Table 401. For
nonferrous parts that are to be fluorescent corrosion control and painting proce
penetrant inspected. dures, refer to CSPHMI2.
Table 401. Painting Requirements
Method of No. of
Item Name Paint Type and Specification Application Coats

Housing Primer (9, Table 902) Spray 1


(1, Figure 1)

Non-specular black acrylic lacquer (10, Table 902) Spray 2

Page 401/(402 blank)


631015 Revision 6
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
OVERRUNNING CLUTCH
INSPECTION/CHECK
1. Inspection (9). Inspect seal (18, Figure 1) in retainer.
Replace if cracked, broken, worn or
Inspect all overrunning clutch components and shows evidence of excessive heat.
parts that are not to be replaced according to
the following instructions. (10). Measure out 18 1 cc of grease (8,
Table 903).
2. Ball Bearing Grease Repack (300 Hour)
(11). Repack bearing 50 percent of capacity
(1). Remove clutch subassembly per with grease by packing open side of
CSPHMI2. bearing level without forcing grease
(2). Using solvent (2, Table 903) and brush, through bearing seal.
thoroughly remove existing grease from (12). Fill seal cavity and void in clutch
clutch outer race splines. retainer with remaining quantity of
(3). Press clutch retainer (19, Figure 1), grease.
with ball bearing (16), from clutch inner (13). Install packing (17, Figure 1) in
race (6). retainer groove.
(4). Temporarily install coupling bolt with (14). Install ball bearing into retainer, open
packing to maintain internal fluid. end toward retainer seal.
(5). For 501 clutch, remove ball bearing
(a). For 503 and 505 clutch, install
(16) from carrier (15) and retainer (19).
retaining ring (15) into retainer (19)
(6). For 503 and 505 clutch, remove to secure ball bearing.
retaining ring (15) and then remove
ball bearing (16) from retainer (19). (b). For 501 clutch, install bearing
carrier (15)into clutch housing.
(7). Check ball bearing for excessive loss of
grease. (15). Remove coupling bolt.

NOTE: If excessive loss of grease is noted in (16). Press clutch retainer, with ball bearing,
ball bearing, perform enginetotransmis onto clutch inner race.
sion alignment check per Structural Repair (17). Reinstall clutch subassembly per
Manual. Remedy cause of misalignment CSPHMI2.
where noted.
(8). If ball bearing is dry or grease is caked, 3. Inspection Requirements
inspect bearing as follows: Table 501 and Table 503 contains visual and
(a). Using solvent (2, Table 903) and dimensional inspection requirements for
brush, thoroughly remove existing overrunning clutch parts. Serviceable dimen
grease from both bearing and retain sions for parts and components, and service
er. (Do not use compressed air to ability criteria for clutch inner and outer races
remove grease from ball bearing). are shown in Figure 501 thru Figure 504 when
using Table 501, and Figure 505 when using
(b). Inspect ball bearing for roughness, Table 503. Parts requiring magnetic particle
pitting, scoring or discoloration (Ref. inspection (MPI) or fluorescent penetrant
Table 501). inspection (FPI) are listed in Table 502.

Page 501
631015 Revision 13
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Table 501. Detailed Inspection After Cleaning
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
NOTE: All inspections are visual inspections unless otherwise specified.
Retaining ring (20, Figure 1) for:
Cracks No defects Not repairable Replace ring.
Nicks or burrs Minor surface defects Minor surface repair Polishing.
Clutch retainer (19, Figure 1) for:
Seal groove damage Not repairable Replace Retainer.

Nicks, burrs, or corrosion Minor surface repair Polishing.

Sleeve spacer (14, Figure 1) for:


Cracks No defects Not repairable Replace sleeve.

Seal surface damage Not repairable Replace sleeve.

Nicks, scratches or burrs Minor surface repair Polishing.

Ball bearings (16, 4, 8, Figure 1) for:


Pitting or scoring Not repairable Replace bearing.

Discoloration from Not repairable Replace bearing.


overheating

Bearing carrier (15, Figure 1) (-501 clutch only) for:


Damage to bearing mating Only bearing removal Not repairable Replace carrier.
surfaces marks allowed

Nicks, pitting or gouges Minor surface repair Polishing.

Cracks (FPI) No defects Not repairable Replace carrier.

Retaining nut (12, Figure 1) for:


Cross-threading or No defects Not repairable Replace nut.
damaged threads

Seal groove damage Burnishing allowed Not repairable Replace nut.

Nicks, burrs or minor Minor surface repair Polishing.


scoring

Clutch outer race (2, Figure 1) for:


Worn splines, bearing If wear is evident, see Minor nicks, scratches or Dress with stone.
bores and clutch race Figure 501 burrs

Cracks (MPI) No defects Not repairable Replace clutch outer race.

Damage to large end No defects Not repairable Replace clutch outer race.
sealing face

Wear on functional If wear is evident see Not repairable Replace clutch outer race.
surfaces Figure 501

Page 502
Revision 13 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Table 501. Detailed Inspection After Cleaning (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Brinelling, scoring or No defects Not repairable Replace clutch outer race.
pitting
Coupling (23, Figure 1) for:
Worn splines If wear is evident, see Minor nicks, scratches or Dress with stone.
Figure 504 burrs
Seal surface damage If wear is evident, see Not repairable Replace sleeve.
Figure 504
Nicks, scratches or burrs Minor surface repair Polishing.
Flaking of coating in spline Solid film lubricant
area touch-up (22, Table 903).
Bolt (25, Figure 1) for:
Cross-threading or No defects Not repairable Replace bolt.
damaged threads
Integrity of self-locking Minimum break-away Replace bolt.
element torque, 92 inch-pounds
(10.40 Nm)
Nicks scratches or burrs Minor surface repair Polishing.
Ring spacer (7, Figure 1) for:
Scoring, nicks, cracks, No defects Minor nicks, scratches or Dress with stone.
scratches or burrs on burrs
mating surfaces

Clutch inner race (6, Figure 1) for:


Worn splines, bearing If wear is evident, see Minor nicks scratches or Dress with stone.
journals and clutch race Figure 502 burrs
Cross-threading or No defects Not repairable Replace clutch inner race.
damaged threads
Wear or functional If wear is evident, see Not repairable Replace clutch inner race.
surfaces Figure 502
Clogged oil holes Not required Not required Cleaning.

On inner race, pay particular attention to area around oil drain holes for cracks.
CAUTION
Cracks (MPI) No defects Not repairable Replace clutch inner race.

Brinelling, scoring or No defects Not repairable Replace clutch inner race.


pitting
Housing (1, Figure 1) for:
NOTE: Engine must be removed to inspect housing.
Cracks (FPI) No defects Not repairable Replace housing.

Paint damaged No defects Not required Repaint.

Page 503
631015 Revision 13
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Table 501. Detailed Inspection After Cleaning (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Identification plate (26) No defects Not repairable Replace plate.
damage or illegible
condition
Mating surfaces damaged If defects are evident, see Not repairable Replace housing.
Figure 503
Minor nicks, scratches or No defects Minor repair Polishing.
gouges

Table 502. Process Inspection Requirements


*Magnetic Particle (ASTM E1444) *Fluorescent Penetrant (ASTM E1417)
Item Index and Figure No. Item Index and Figure No.
Clutch outer race 2, Figure 1 Clutch housing 1, Figure 1
Clutch inner race 6, Figure 1 Bearing carrier 15, Figure 1
(-501 clutch only)

Coupling 23, Figure 1

NOTES:
* Paint removal is not required for magnetic particle inspection, but is necessary on nonferrous parts for
fluorescent penetrant inspection. Complete removal of epoxy primer is not required on normal overhaul.
When inspecting for or after crash damage, all areas should be visually inspected using minimum of
5-power magnifying glass and all suspected areas should have epoxy primer removed locally with plastic
bead blast (17, Table 902) or paint remover (1) for added inspection.

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Revision 13 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
2.6779 IN (6.8018 CM)
2.6772 IN (6.8000 CM)
1.6540 IN (4.2011 CM)
3.462 IN (8.7934 CM)
1.6535 IN (4.1998 CM) 3.460 IN (8.7884 CM)
2.501 IN (6.3525 CM)
2.500 IN (6.3500 CM)

PIN

2.6145 IN (6.6408 CM) PIN = 0.096 IN (2.4384 MM)


0.653 IN (16.586 MM)
2.6130 IN (6.6370 CM)
0.633 IN (16.078 MM)
3.625 IN (9.2075 CM)

1.3376 IN
(3.3975 CM) MIN
MEASUREMENT 369F54511 HOUSING
OVER PINS

H631030
3.639 IN (9.2431 CM)

Figure 501. Service Limits - Clutch Outer 3.641 IN (9.2481 CM)
Race

1.9575 IN (4.9720 CM)


1.9565 IN (4.9695 CM)
1.5753 IN (4.0012 CM)
1.5749 IN (4.0002 CM) 3.462 IN (8.7934 CM)

3.460 IN (8.7884 CM)
2.501 IN (6.3525 CM)
2.500 IN (6.3500 CM)

TBOLT HOLE
0.9848 IN (25.0139 MM)
0.9844 IN (25.0037 MM)

1.5900 IN
(4.0386 CM) MIN 0.653 IN (16.586 MM)
MEASUREMENT 0.633 IN (16.078 MM)
OVER PINS

PIN = 0.096 IN (2.4384 MM)


369F54513 HOUSING
H631031 H631032A

Figure 502. Service Limits - Clutch Inner


Race Figure 503. Service Limits - Clutch Housing

Page 505
631015 Revision 13
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450

1.870 IN (4.7498 CM)


1.880 IN (4.7752 CM)

PIN = 0.0864 IN (2.19456 MM)

1.3313 IN
(3.3815 CM) MIN
MEASUREMENT
OVER PINS

H631033
Figure 504. Service Limits - Clutch Coupling

Table 503. Detailed Inspection After Cleaning (369F5456 Sprag Assembly)


Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action

NOTE: This table is for inspection of the 369F5456 sprag assembly only. For inspection requirements of complete
clutch assembly, refer to Table 501.

Sprag assembly (Figure 505) for:

Cross bar straightness No defects Not repairable Replace sprag assembly.


and uniformity

Retainer assembly for Must slip into outer race Not repairable Replace sprag assembly.
roundness without forcing

Retainer flanges for Minor surface repair Polishing.


excessive gouging or
steps from adjacent
contact surfaces

Outside diameter of Not repairable Replace sprag assembly.


retainer contact surface
with outer race sprag
diameter for excessive
wear

Sprags for freedom of No binding allowed Not repairable Replace sprag assembly.
movement in slots

Page 506
Revision 13 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Table 503. Detailed Inspection After Cleaning (369F5456 Sprag Assembly) (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Sprag retainer spring No defects Not repairable Replace sprag assembly.
(installed) for separation
of coils, kinking, and
corrosion

NOTE: Lightly polished areas are acceptable. Do not reinstall sprag assembly if one sprag is not acceptable.
Window surfaces on 0.004 inch (1.016 mm) Not repairable Replace sprag assembly.
flange and bar surfaces max from original flat
on retainer for wear surface and/or sharp
corner wear at interface of
bars to flanges

Sprags for:
NOTE: It is common to see some flaking or spalling of Formchrome on sprag surfaces after some service hours
at the higher area of load cam. Formchrome is a very thin diffusion layer and this flaking condition does not
alter the sprag geometry as long as the change to surface contour is not over 0.0002 inch (0.0051 MM). Bare
surfaces altered by scoring, scrubbing, or other severe clutch conditions is cause for sprag rejection.
Chips or surface break up None None Replace sprag retainer
(resulting from scuffing or assembly.
scoring) that do not
conform to original cam
profile

Flat wear bands at 0.020 inch (0.508 mm) Not repairable Replace sprag retainer
overrunning cam portion max assembly.
of sprag

Sprags and retainer for None Not repairable Replace sprag retainer
corrosion assembly.

Sprag retainer spring None Not repairable Replace sprag retainer


(removed) for kinks or assembly.
circular arcs

Spring coil sprag contact Wear must not exceed 30 Not repairable Replace sprag retainer
surface for wear percent of wire section assembly.

Sprags for chips or loss of 0.002 inch (0.0508 mm) Not repairable Replace sprag retainer
material on profile max from original surface assembly.
on front flat and back
bumper

Inner race sprag cam for 0.030 inch (0.762 mm) Not repairable Replace sprag retainer
working or loading of high max at high load corner assembly.
loading corner

Sprag inner race and/or None Not repairable Replace sprag retainer
other supporting surfaces assembly.
for wear and loss of clutch
concentricity

Page 507
631015 Revision 13
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Table 503. Detailed Inspection After Cleaning (369F5456 Sprag Assembly) (Cont.)
Maximum Maximum
Inspect Index No. Serviceable Limits Repairable Limits Corrective Action
Retainer and clutch races for:
NOTE: Lightly polished areas are acceptable. Do not reinstall assembly if one sprag is not acceptable.
Slot surfaces on flange 0.004 inch (0.102 mm) Not repairable Replace sprag retainer
and bar surfaces on max from original flat assembly.
retainer for wear surface and/or sharp
corner wear at interface or
bars-to-flanges
Brinnelling 0.0005 inch (0.0127 mm) Not repairable Replace inner and outer
max deformation race.
Evidence of overheating None Not repairable Replace inner and outer
(straw color-to-blueing) race.
Inner and outer wear 0.0004 inch (0.0101 mm) Not repairable Replace inner and outer
max beyond race race.
diameter
Race diameter taper 0.001 inch (0.025 mm) Not repairable Replace inner and outer
max race.

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Revision 13 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450

SPRING

CHECK FOR CHIPPED


CORNERS OR LOSS
OF MATERIAL
SEE ITEM C
FOR DETAIL

ITEM A ITEM B

0.004 IN (0.102 MM) MAX.


WEAR FROM ORIGINAL
FLAT SURFACE AND/OR
0.004 IN (0.102 MM)
SHARP CORNERS. (NOTE)
(NOTE)

INNER RACE OF
INDIVIDUAL SPRAG

STEP CAUSED
BY WEAR
(NOTE)

0.030 IN (0.762 MM)


MINIMUM

ITEM C ITEM D

NOTE: USE TOOL (4, TABLE 901) FOR


INSPECTING OF SPRAG WINDOW WEAR.
H631034B

Figure 505. Inspection Requirements of 369F5456 Sprag Assembly

Page 509
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This Page Intentionally Left Blank

Page 510
Revision 13 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
OVERRUNNING CLUTCH
REPAIR/MODIFICATION
1. Repair and Modification Information 3. Parts Replacement

This section provides allowable repairs and Replace the following parts with new parts at
part replacement requirements and modifica reassembly of the overrunning clutch:
tion upgrades for overhaul of the overrunning
(1). Replace all packings and seals.
clutch.
(2). Replace lock spacer (10, Figure 1).
2. Repair
(3). Replace all parts not within tolerances
The only repairs authorized for overrunning specified in Table 501 and Figure 501
clutch components are as follows: thru Figure 504.

NOTE: All parts must meet the tolerances spe NOTE: If a large number of clutch parts are be
cified in Table 501 and Figure 501 thru yond tolerance, consider replacement of the
Figure 504 after repair. All parts are to be complete clutch subassembly.
recleaned and spot painted as required prior A. Clutch Coupling Wear Sleeve
to reassembly. Replacement
(1). Splines (Ref. Figure 504) When coupling wear sleeve is
worn beyond tolerance, replace as follows.
(a). Dress minor nicks, scratches and
burrs with fine India stone (3, (1). Wear Sleeve Removal
Table 902).
(a). Remove coupling from clutch assem
(2). Nonsealing Ferrous Parts bly.

(a). Polish out minor scoring with crocus (b). Using arbor press and plate support
cloth (4). tool, which picks up lip on sleeve,
remove sleeve from coupling.
(3). Aluminum Parts
(2). Wear Sleeve Installation
(a). Polish out minor scoring with abra (a). Clean sleeve and coupling with
sive cloth (5). Apply chemical film solvent (2, Table 903).
(13) to polish surface (Ref. CSP
HMI2). (b). Center sleeve on coupling and press
until sleeve seats on coupling flange.
(4). Decals
(c). After installation, ensure sleeve is
(a). Seal loose edges of decals with 0.025 0.030 inch (0.635 0.762
adhesive (21, Table 903) mm) past end of coupling.
Table 601. Overrunning Clutch Capacity
Fluid Capacity

Mobil SHC 626 Oil 3.64 U.S. Oz (110 cc)

MIL-G-81322 Grease 18 1 cc

Page 601
631015 Revision 6
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Table 602. Overrunning Clutch - Configuration Conversions
369F5450-( ) Configuration Modification Required
From To (Item No. Table 603)
501 505 1, 2, 3, 4, 5, 6, 7, 8
503 505 8
NOTES:
(1) Configuration upgrades are not mandatory.

Table 603. Overrunning Clutch - Modification Criteria


Item Parts to be Parts to be
No. Quantity Removed Installed Nomenclature
1 1 369F5451-1 369F5451-3 Housing
2 1 369F5460-1 369F5474-1 Retainer
3 1 369F5461-1 RR-267 Retainer Ring
4 1 369F5155-1 369F5155-3 Shim
5 1 MS9432-05 Tee Bolt
6 1 AN960C10L Washer
7 1 MS21042-3 Nut
8 1 369F5457-1 369F5457-3 Bearing
NOTES:
When modifying clutch, reidentify clutch housing and retainer.

Page 602
Revision 13 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
OVERRUNNING CLUTCH
ASSEMBLY/SHIPPING
1. Reassembly (a). Press bearing (16) into clutch retain
er (19) with ball exposed facing down
(1). Apply sealing compound (18, Table 902) toward retainer seal.
to outside diameter of seal (9, Figure 1)
and install in retaining nut (12). (b). Install retainer ring (15) into retainer
groove.
(2). Apply sealing compound to outside
diameter of seal (18) and install in (c). Press bearing and retainer assembly
retainer (19). onto inner race as one unit and seat
against sleeve spacer (14).
(3). On 503 and 505 clutches, install nut
(30), washer (29) and TBolt (28) in NOTE: When installing Sprag assembly onto
housing. Torque nut to 35 45 inch inner race, ensure arrow on sprag assembly
pounds (3.95 5.08 Nm) plus drag is on the spline side of the inner race.
torque.
(12). Place washer (7) and sprag assembly (5)
(4). Press Bearing (4) onto inner race (6) over inner race (washer to be placed
and seat against inner race shoulder. between bearing (8) and sprag assem
bly).
(5). Press Bearing (8), over splines and seat
against inner race shoulder. (13). Lubricate inside diameter of outer race
with oil (12, Table 902).
(6). Install retaining nut (12) onto inner
race against bearing (8). (14). Install wavespring (3, Figure 1) into
outer race (2).
(7). Apply petrolatum (19, Table 902) to
packing (13, Figure 1) and install in (15). Install lock spacer (10, Figure 1) over
groove in sleeve spacer (14). threads of outer race.
(8). With flange of sleeve spacer (14) (16). Apply petrolatum to packing (11) and
towards inner race splines, press into install into retaining nut (12).
retaining nut and seat against bearing
(8). (17). Install inner race, with sprag assembly,
into outer race (Ref. Figure 702).
(9). Apply petrolatum to packing (17) and
install in retainer (19). (18). Using antiseize compound (16,
Table 902), install retaining nut (12,
(10). Assemble clutch retainer for 501 Figure 1) finger tight.
clutch assembly as follows:
(19). Using wrench assembly (3, Table 901),
(a). Press bearing (16) into clutch retain torque retaining nut to 325 375
er (19) with ball exposed facing down inchpounds (36.72 42.37 Nm).
toward retainer seal, ensure hole in
bearing outer race is aligned with pin NOTE: Do not crimp lock spacer (10) until after
in clutch retainer. leak check.
(b). Press bearing carrier (15) onto (20). Verify sprag rotation and dynamic drag
bearing (16). torque (Ref. Torque Test).
(c). Press bearing and retainer assembly (21). Fill clutch assembly with 3.64 U.S. Oz.
onto inner race as one unit. (110 cc) of oil (12, Table 902).
(11). Assemble clutch retainer for 503 and (22). Install coupling (23, Figure 1) as
505 clutch assembly as follows: follows:

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631015 Revision 6
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450
(a). Coat coupling splines and output (c). Reinstall clutch in test stand and run
shaft splines with grease (8, for 30 minutes at 6000 100 rpm to
Table 902) and install shim (21, check for grease and oil leakage.
Figure 1) and coupling onto output
shaft. (d). Remove clutch from test stand.

(b). Coat bolt threads with antiseize NOTE: If no test stand is available, refer to
compound (16, Table 902). RunIn Procedure.

(c). Install bolt and tighten. (28). Crimp lock spacer (10) into notches
(five places) and inspect with 10X
(d). Adjust shims to achieve a magnifying glass; replace lock spacer if
0.0100.030 inch (0.2540.762 mm) cracked.
step above clutch output shaft (Ref.
Figure 701). (29). Install clutch subassembly into clutch
housing (1).
(e). Torque bolt to 315 365 inch
pounds (35.59 41.24 Nm). NOTE: Flat side of retaining ring (20, Figure 1)
faces unit; bevel side is out.
(23). Fill a suitable syringe with 18 1 cc of
grease (8, Table 902) and inject into one (30). Using snap ring pliers, install retaining
of retainers open screw holes. ring (20) into housing groove.
(24). Wipe off any excess grease that pro (31). Install packing (17, Figure 1) in clutch
trudes from screw holes. retainer (19).
(25). Install two screws (27, Figure 1) into
retainer and torque to 5 7 inch
pounds (0.56 0.79 Nm).
(26). Perform the following torque test:
(a). Check clutch assembly dynamic drag,
torque not to exceed a maximum of
5.62 inchpounds (0.635 Nm). 0.0100.030 INCH
(0.2540.762 MM)
(b). Lock output shaft, and using socket COUPLING SHIMMING
and anchor assembly (2, Table 901),
apply 529 79 footpounds (717.3 H631036A
107.1 Nm) torque to input shaft.
There must be no clutch slippage. Figure 701. Clutch Coupling Shimming

(27). If test stand is available: 2. Final Inspection


(a). Install clutch in test stand and run at After reassembly, perform a final inspection as
6000 100 rpm for five minutes to follows. Repair any damage as required (Ref.
expel any residual buildup oil and Repair).
excess grease.
(1). Visually inspect clutch assembly
(b). Remove clutch from test stand and exterior for damage.
wipe off excess grease and oil.
(2). Check attachment of identification
NOTE: Any evidence of oil leakage, other than plate.
residual oil, is unacceptable.
Any evidence of grease leakage, other than (3). Check splines on inner and outer races
"burping" from the seal, is unacceptable. for chips or burrs.

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Revision 14 631015
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COMPONENT OVERHAUL MANUAL
P/N 369F5450
3. Run-In Procedures Helicopter must be operated
WARNING in accordance with ap
proved Rotorcraft Flight Manual.
Runin and test the overhauled overrunning
clutch according to the following procedures.
(4). Run helicopter at 100 percent N2 for 5
minutes. Shut down helicopter and
A. Torque Test examine clutch for leakage. If oil
leakage is evident at seals, assembly
joint lines, or housing drain holes,
The following torque test is the only runin
remove and disassemble clutch for
and test required for the overrunning clutch.
inspection and rework as required.

(1). Check clutch assembly dynamic drag, NOTE: Grease Burping" past the 369F5457
torque not to exceed a maximum of 5.62 bearing seal is acceptable provided that the
inchpounds (0.635 Nm). bearing seal remains securely installed in
the bearing outer race. Any evidence of a
damaged or unsecured bearing seal is unac
(2). Lock output shaft, and using socket and
ceptable.
anchor assembly (2, Table 901), apply
529 79 footpounds (717.3 107.1
NOTE: Leakage from clutch housing drain
Nm) torque to input shaft. There must
holes may be caused by engine lubricant
be no clutch slippage.
leaking past engine shaft seals. Check en
gine shaft seals for leakage prior to disas
(3). Install clutch in helicopter (Ref. sembly of the overhauled overrunning
CSPHMI2). clutch.

OUTER CLUTCH RACE

WAVESPRING

LOCK SPACER

SPRAG ASSEMBLY
(NOTE 1)

NOTES:
1. USE WAXED CORD TO COMPRESS SPRAGS. INNER CLUTCH RACE
(NOTE 2)
2. ROTATE COUNTERCLOCKWISE WHILE INSERTING
INTO OUTER CLUTCH RACE.
H631035

Figure 702. Clutch Inner and Outer Race Reassembly

Page 703
631015 Revision 14
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450
4. Packing and Storage from helicopter (Ref. CSPHMI2). Drain
lubricant and flush clutch with corrosion
If overhauled clutch is not to be used immedi preventive oil (7, Table 902). Install packing
ately, package and store the clutch as follows: (24, Figure 1) and bolt (25) on end of shaft.

5. Shipping (1). Apply a light layer of corrosion preven


tative (20, Table 903) and package or
If clutch is to be stored or shipped, remove cover to keep dust off.

Page 704
Revision 14 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
OVERRUNNING CLUTCH
SPECIAL TOOLS, FIXTURES & EQUIPMENT
1. Reference Data tion, regarding special tools and equipment,
and expendable items and materials required
Table 901 and Table 902 provide specifications, for overhaul/repair. Torque values are con
and when appropriate, procurement informa tained in Table 902.

Table 901. Overrunning Clutch Overhaul - Special Tools


Item
No. Nomenclature Part No. Manufacturer
1 Bearing Puller 950 Owatonna Tool Company
2 Socket and Anchor Assembly SWE12046 B.K. Sweeney Mfg. Co.,
Denver, Colo.
3 Wrench Assembly, Overrunning Clutch 369F9501 MDHS
4 Sprag window wear inspection tool RBT18612 Red Barn Machine Inc.
4681 Isabelle St.
Eugene, OR 97402
Phone: (541) 344-9953
FAX: (541) 344-3863

Table 902. Overrunning Clutch Assembly Special Torques


Torque
Item Figure 1, Index No. (In.-Lb.) Nm
Retaining nut 12 225 - 275 25.42 - 31.07
Bolt 25 315 - 365 35.59 - 41.24
Screws 27 5-7 0.56 - 0.79

Table 903. Repair Materials


Item Specification
No. Material No.(1) Name/No. Manufacturer
1 Paint remover TT-R-248 Turco 5351 Turco Products, Inc.,
Westminster, CA
92684-3600
No. A202 Cee-Bee Chemical Co.
2 Solvent, dry-cleaning P-D-680 (3)
3 India stone (fine) (3)
4 Cloth, abrasive, crocus grade P-C-458 (3)
5 Cloth, abrasive, aluminum P-C-451 (3)
oxide (grade No. 320 or 400)
6 Potting compound SAE-AMS-S-8802 (3)
7 Corrosion preventive oil MIL-C-8188 (3)
8 Grease MIL-G-81322 Mobile 28 Mobile Oil Co.

Page 901
631015 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Table 903. Repair Materials (Cont.)
Item Specification
No. Material No.(1) Name/No. Manufacturer
9 Primer, catalyzed epoxy MIL-P-23377B Material Description: Andrew Brown Co.,
(yellow))
(y HMS 15-1082 Los Angeles, CA
W.P. Fuller & Co.
Los Angeles, CA
Sherwin-Williams,
Los Angeles, CA
10 Paint, acrylic lacquer MIL-L-81352 Material Description: Andrew Brown Co.
((AML-P95)) (color
( 27038)) HMS 15-1083 Los Angeles, CA
DeSoto Chemical
Coatings
Berkely, CA
W.P. Fuller & Co.
Los Angeles, CA
Sherwin-Williams,
Los Angeles, CA
11 Adhesive MIL-A-8623 A-1 177-B B.F. Goodrich
12 Lubricating oil Mobile SHC 626 Mobil Oil Co.
150 E. 42Nd St.
New York, NY
13 Chemical film and chemical film MIL-C-5541 Iridite 14-2 Richardson Co.
materials for aluminum and (Class 2, unless Al-coat Allied-Kelite
aluminum alloys noted. Grade and Products Div.
type optional) 2400 E. Devon Ave.
Des Plaines, IL
14 Masking tape MIL-T-23397
15 Methyl-ethyl-ketone (MEK) TT-M-261 (3)
16 Anti-seize compound MIL-A-907 (3)
17 Plastic bead, spherical Poly Plus 20/30 Polyrock Company
20-30 mesh 4763 Murrita Ave
Chino, CA 91710
Abrasive Cleaning
20122 State Rd.
Cerritos, CA 92701
Abrasive Unlimited
4653 S. 33 RD. St.
Suite #1
Phoenix, AZ 85040
18 Sealing Compound HMS 16-1149 Pro-Seal 890 Product Research and
MIL-S-8802 Chemical Co.
5426 San Fernando Rd.
Glendale, CA 91209
19 Petrolatum (petrolatum jelly) MIL-G-6032 (3)
VV-P-236

Page 902
Revision 12 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Table 903. Repair Materials (Cont.)
Item Specification
No. Material No.(1) Name/No. Manufacturer
20 Corrosion Preventative MIL-C-81309 Corrosion X Corrosion Technologies
Type
yp II Corp.
Fluid Film Eureka Chemical Co.
21 Adhesive, cyanoacrylic / MIL-A-46050 3CI-1000 / Dexter Adhesives
Accelerator Super Drop Accelera- 2850 Willow Path Road
tor Pittsburg, CA 94565
(800) 424-9300
22 Solid film lubricant MIL-L-23398 Molyspray Type Product Techniques Inc.
PT-101
511 East 8th Pl.
Los Angeles, CA
NOTES:
(1) Numbers are U. S. A. Specifications and Standards. The prefix symbols are defined as follows:
AMS - American Material Standard;
MS - Military Standard;
MIL - Military Specification; single, double or triple alpha prefix of the same letter - Federal Specification;
AN - Air Force-NavyAeronautical Standard;
NAS - National Aerospace Standard.
(2) Primary selection. Any equivalent material may be used as an alternate selection.
(3) Use the best equivalent commercial grade material when the conformity of available materials of the
same type with the listed U. S. A. Specification No. cannot be determined.

Page 903/(904 blank)


631015 Revision 12
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
OVERRUNNING CLUTCH
ILLUSTRATED PARTS LIST
1. General Explanations of codes and abbreviations used
in this illustrated parts list can be found by
This section contains an illustrated parts list referring to the Introduction section of
to be used in conjunction with the 369F5450 CSPIPC4.
overrunning clutch overhaul manual. Correct
part numbers and nomenclature can be
identified for specific configuration and 2. Indenture Level
effectivities.
Item numbers in this parts list refer to the The indenture level to a higher assembly is
figure preceding the parts list table. An item indicated by the amount of bullets in front of
number may be the same or different from the each item in the description column. An item
same part shown in a different illustration that has one more bullet than the part above it
elsewhere in the overhaul manual. is a sub part of that assembly.

Page 1001
631015 Revision 13
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450

20

21

22

23
10

24
11
25
12
26
29
13 30

31
1 14 27

2
28
15
3
16

17
4

5 18

6
19

P631002C

Figure 1001. Overrunning Clutch Assembly - 369F5450

Page 1002
Revision 13 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Qty.
Fig. &
Part Number Description per
Index
Assy.
1001- 369F5450-505 Clutch Assy, Overrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
369F5450-503 Clutch Assy, Overrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
Replaced By 369F5450-505 Clutch
369F5450-501 Clutch Assy, Overrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REF
Replaced By 369F5450-503 Clutch
369F5450-5 Clutch Sub-Assy, Overrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369F5450-505 Clutch Assembly
369F5450-3 Clutch Sub-Assy, Overrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369F5450-503 Clutch Assembly
369F5450-1 Clutch Sub-Assy, Overrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369F5450-501 Clutch Assembly
1 369F5160-1 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 M83248/1-1 18 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 369F5133-1 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 369F5155-1 Shim (Aluminum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replaced By 369F5155-3 Shim
4 369F5155-3 Shim (Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 N5002-362 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 NAS600-3P Screw, Machine-Aircraft, Pan Head, Phillips Recess . . . . . . . . . . . . 2
7 369F5460-1 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369F5450-1 Clutch Sub-Assy. Use On
369F5450-501 Clutch Assy
7 369F5474-1 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369F5450-3/-5 Clutch Sub-Assy. Use On
369F5450-503 / -505 Clutch Assy
8 369F5473-1 Plate, I.D. - Contoured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369F5473-3
8 369F5473-3 Plate, I.D. - Contoured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With With 369F5473-1
9 369F5464-3 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 M83248/1-038 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 369F5457-1 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369F5450-1 / -3 Clutch Sub-Assembly. Use On
369F5450-501 / -503 Clutch Assy
11 369F5457-3 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369F5450-5 Clutch Sub-Assembly. Use On
369F5450-505 Clutch Assy
12 RR-267 Spiral Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Compopnent Of 369F5450-3 / -5 Clutch Sub-Assy. Use On
369F5450-503 / -505 Clutch Assy
13 369F5461-1 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Of 369F5450-1 Clutch Sub-Assy. Use On
369F5450-501 Clutch Assy
14 369F5463-1 Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 M8248/1-030 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
16 369F5462-1 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 369F5464-1 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Page 1003
631015 Revision 13
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369F5450
Qty.
Fig. &
Part Number Description per
Index
Assy.
18 M83248/1-147 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
19 369F5465-1 Spacer, Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20 369F5458-1 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21 369F5466-1 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22 369F5455-1 Race, Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23 369F5456-1 Sprag Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
24 369F5459-1 Bearing, Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
25 SSR-0162 Wavespring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
26 369F5453-1 Race, Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
27 369F5451-1 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 369F5450-501 Clutch Assy
27 369F5451-3 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use On 369F5450-503 / -505 Clutch Assy
28 369F5472-1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369F5472-3
28 369F5472-3 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intrch With 369F5472-1
29 MS21042-3 Nut, Self Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
30 AN960C10L Washer, Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
31 MS9432-05 Tee Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Page 1004
Revision 15 631015
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL

Section

63-20-00
Main Transmission
Part Number
369D25100-BSC, -501, -503, -505, -507, -901

Page a/(b blank)


Revision 4
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D25100
TABLE OF CONTENTS
Para/Figure/Table Title Page

632000 Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Overhaul Check Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Main Transmission Major Components . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2. Main Transmission Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 3. Tail Rotor Drive Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 4. Tail Rotor Drive Cover and Accessory Drive Assembly . . . . . . . . . . . . . 5
Figure 5. Input Drive Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 6. Main Rotor Drive Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . 7
Table 1. Main Transmission Overhaul Check Sheet . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. Important Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. Initial Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
A. Tail Rotor Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
B. Input Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
C. Main Rotor Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3. Component Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
A. Main Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
B. Tail Rotor Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
C. Tail Rotor Drive Cover and Accessory Drive Disassembly . . . . . . . . . . . . . . . . . . . 303
D. Input Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Figure 301. Removal and Installation Output Gearshaft Locknut . . . . . . . . . . 304
Figure 302. Removing Output Gearshaft from
Tail Rotor Drive Assembly Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
E. Main Rotor Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Figure 303. Removal Input Bearing Retainer from Input Gearshaft . . . . . . . . 305
Cleaning/Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Refinishing Interior Areas of Main Housing and Covers . . . . . . . . . . . . . . . . . . . . . . . 401
Table 401. Cleaning Main Transmission Parts and Components . . . . . . . . . . . . . 401
3. Painting and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Exterior Painting Spot TouchUp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Complete Exterior Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

632000 Page i

Contents Revision 17
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D25100
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page
D. Liquid Level Plug Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 401. Liquid Level Plug Markings Application . . . . . . . . . . . . . . . . . . . . . . 403
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
A. Output Drive Shaft Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
B. Housing and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Periodic Inspection of Transmission Output Shaft
P/N 369D25100BSC, 501 or 503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Table 501. Detailed Inspection Housing and Related Parts . . . . . . . . . . . . . . . . 503
C. Magnetic Particle and Fluorescent Penetrant Inspections . . . . . . . . . . . . . . . . . . . 509
Table 502. Magnetic Particle and Fluorescent Penetrant Inspections . . . . . . . . 509
Table 503. Inspection After Repair and Replacement . . . . . . . . . . . . . . . . . . . . . . . 511
Figure 502. Accessory Drive Gear Serviceable Dimensions . . . . . . . . . . . . . . . . . 512
Figure 503. Accessory Drive Pinion Gear Serviceable Dimensions . . . . . . . . . . 513
Figure 504. Output Drive Shaft Assembly Serviceable Dimensions . . . . . . . . . 513
Figure 505. Output Drive Pinion Gearshaft Serviceable Dimensions . . . . . . . . 514
Figure 506. Input Drive Pinion Gearshaft Serviceable Dimensions . . . . . . . . . 515
Figure 507. Bearing Retainers in Main Housing Serviceable Dimensions . . . 516
Figure 508. Bearing Retainers in Main Rotor Drive Cover
Serviceable Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
Figure 509. Bearing Retainers in Tail Rotor Drive Cover
Serviceable Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
Figure 510. Mast Mount Attach Lug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Figure 511. Input Drive Pinion Gearshaft Serviceability Criteria . . . . . . . . . . . 518
Figure 512. Input Drive Gear Serviceability Criteria . . . . . . . . . . . . . . . . . . . . . . 519
Figure 513. Output Drive Pinion Gearshaft Serviceability Criteria . . . . . . . . . 520
Figure 514. Output Drive Gear Serviceability Criteria . . . . . . . . . . . . . . . . . . . . 521
Repair/Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. General Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Repair of Minor Corrosion, Nicks and Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Bearing Retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Damaged Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Damaged Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 601. Insert and Stud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Table 601. Insert and Stud Replacement Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 602. Output Bevel Gear Mounting Face Repair Details . . . . . . . . . . . . . . . 604

Page ii 632000
Revision 17
Contents
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D25100
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page
Figure 603. Output Drive Shaft Repair Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Figure 604. Output Drive Pinion Repair Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Figure 605. Input Drive PinionRepair Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
D. Bushings and Pins in Main Transmission Housing and
Main Rotor Drive Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
E. Gears and Gearshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
3. Specific Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
A. Output Drive Shaft Undersized Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
B. Output Drive Pinion Undersized Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . 606
C. Input Drive Pinion Undersized Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
D. Fretting on Mounting Face of Output Bevel Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Figure 606. Output Pinion Nozzle Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
E. Fretting on Mounting Face of Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
4. Inspection After Repair and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
5. Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
A. Transmission Upgrade (Basic to 501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
B. Transmission Upgrade (501 or 503 to 505) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
C. Transmission Upgrade (Bsc, 501, 503, 505 to 507) . . . . . . . . . . . . . . . . . . . . 609
D. Transmission Upgrade (505 to 901) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
Table 602. Main Transmission Configuration Conversions . . . . . . . . . . . . . . . . . . 610
Table 603. Main Transmission Modification Criteria . . . . . . . . . . . . . . . . . . . . . . 611
Figure 607. Input Gear Nozzle Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
Figure 608. Upgrade of 369D25100 Transmission to 507 Configuration . . . . . 612
Assembly/Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
1. Reassembly Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
2. Major Component Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
A. Main Rotor Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
Figure 701. Oil Scavenge Return Tube Installation . . . . . . . . . . . . . . . . . . . . . . . 702
Figure 702. Main Rotor Drive Assembly Shim and Spacer Locations . . . . . . . . 703
B. Tail Rotor Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
C. Tail Rotor Drive Cover and Accessory Drive Assembly . . . . . . . . . . . . . . . . . . . . . . 705
Figure 703. Shim and Spacer Location Output Drive Pinion . . . . . . . . . . . . . . . 706
D. Input Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
3. Initial Reassembly of Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
A. Initial Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
Figure 704. Input Drive Assembly Preliminary Reassembly . . . . . . . . . . . . . . . 709
B. Gearset Backlash and Wipe Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710

632000 Page iii

Contents Revision 17
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D25100
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page
Figure 705. Tooth Contact Pattern and Backlash Correction
Input Pinion and Input Pinion Gear (Sheet 1 of 2) . . . . . . . . . . . . . . . . 711
Figure 706. Tooth Contact Pattern and Backlash Correction Output Drive
Gear and Tail Rotor Output Pinion (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 713
Figure 707. Output Drive Pinion and Gear Inspection Areas
After Dynamic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
4. Final Reassembly of Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
A. Input Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
B. Scavenge Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
C. Main Rotor Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
D. Tail Rotor Drive and Accessory Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
E. Lubrication Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717
F. Main Transmission Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717
5. RunIn and Test Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718
Figure 708. Blower Spacer Thickness Calculation . . . . . . . . . . . . . . . . . . . . . . . . . 718
Figure 709. Input Gear Nozzle Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719
Figure 710. Breather Cap and Filler Orientation . . . . . . . . . . . . . . . . . . . . . . . . . 719
6. RunIn on Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720
A. Preparation for RunIn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720
B. RunIn on Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720
7. RunIn on Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
A. Preparation for RunIn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
B. RunIn on Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
8. Final Inspection and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
9. Transmission Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722
Special Tools, Fixtures & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
1. Special Tool Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
2. Holding Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Tail Rotor Gear Shaft Output Pinion Holding Fixture . . . . . . . . . . . . . . . . . . . . . . . 901
B. Input Drive Gear Shaft Holding Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
3. TBolt Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Table 901. Main Transmission Assembly Overhaul Special Tools . . . . . . . . . . 902
Table 902. Main Transmission Assembly Special Torques . . . . . . . . . . . . . . . . . . . 903
Table 903. Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Figure 901. Holding Fixture Tail Rotor Output Pinion . . . . . . . . . . . . . . . . . . . . 907
Figure 902. Barrel Wrench Tail Rotor Output Pinion Nut . . . . . . . . . . . . . . . . . . 908
Figure 903. Extension Oil Nozzle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

Page iv 632000
Revision 17
Contents
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D25100
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page
2. Indenture Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Figure 1001. Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
Figure 1002. Main Transmission Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006
Figure 1003. Main Transmission T/R Output Drive . . . . . . . . . . . . . . . . . . . . . . . . . 1010
Figure 1004. Main Transmission Input Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014
Figure 1005. Main Transmission Output Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016

632000 Page v

Contents Revision 17
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D25100
TABLE OF CONTENTS (Cont.)
Para/Figure/Table Title Page

This Page Intentionally Left Blank

Page vi 632000
Revision 17
Contents
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D25100
MAIN TRANSMISSION
DESCRIPTION AND OPERATION
NOTE: Before attempting any repair or over- ter, the runin test and a final backlash
haul of this component, ensure the required and contact pattern check, and shipping
special tools and processes are available to instructions for the main transmission.
assure completion of the work.
(7). Special Tools, Fixtures
1. General & Equipment . . . . . . . . . . . . . . . . . . . . 901
provides procedures for fabricating
This section of the Overhaul Manual provides special tools required for overhaul of
overhaul procedures for the 369D25100 Main the main transmission.
Rotor Transmission. Procedures given are the
approved methods to be used for specific repair (8). Illustrated Parts List . . . . . . . . . . . . 1001
or complete overhaul of the component. provides a parts list supplement to
identify part numbers and configura-
A. Organization tion differences for the main transmis-
sion.
The Main Rotor Transmission section of the
Component Overhaul Manual is made up of B. Reference Data
seven parts, listed below. These sections
contain complete instructions for disassembly, (1). Reference is made throughout this part
cleaning, inspection, repair, reassembly and of the Overhaul Manual to CSP
testing of the component. The following HMI2. This manual should be used as
describes the topic and content of each part noted throughout the overhaul/repair.
with appropriate page numbers: The Illustrated Parts Catalog (CSP
IPC4) should be used for ordering any
(1). Description and Operation . . . . . . . . . . 1 replacement parts required.
describes procedures for complete use of
the main transmission section and (2). Table 901 and Table 903 provide
provides Transmission Overhaul Check specifications, and when appropriate,
Sheets. procurement information, regarding
special tools and equipment, and
(2). Disassembly . . . . . . . . . . . . . . . . . . . . . 301
expendable items and materials
gives procedures for complete disassem-
required for overhaul and repair.
bly of the main transmission.
Torque values are contained in
(3). Cleaning/Painting . . . . . . . . . . . . . . . . 401 Table 902.
contains cleaning and painting require-
ments for main transmission compo- (3). Figure 1 thru Figure 6 show exploded
nents and parts. views of the main rotor transmission
and its subassemblies, with all parts
(4). Inspection/Check . . . . . . . . . . . . . . . . . 501 indexed. The index numbers are used
provides visual and dimensional throughout the text with the part
inspection requirements. nomenclature to make part identifica-
tion easier.
(5). Repair/Modification . . . . . . . . . . . . . . 601
provides allowable repairs and parts C. Overhaul Check Sheet
replacement information and autho-
rized modifications for the main The items indicated in the Main Transmission
transmission. Overhaul Check Sheet must have all blanks
filled and initialed. Upon completion of the
(6). Assembly/Shipping . . . . . . . . . . . . . . . 701 overhaul, this sheet must be signed off by the
provides main transmission reassembly, person performing the work and the sheet
runin inspection procedures, including retained as a permanent part of the helicopter
installation in the test stand or helicop- file.

Page 1
632000 Revision 15
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D25100
* CAUTION:
12 OUTPUT PINION NOZZLE ASSEMBLIES (14 AND 15)
13 MUST BE REMOVED BEFORE REMOVING MAIN
1
ROTOR DRIVE ASSEMBLY (18). 5 2
* 15
18

12
4
13
* 14
16
8
17
4

20

6
7

NOTE
19
11

10
NOTE: 9
ELIMINATED ON LATER HOUSINGS.
H632055B

Figure 1. Main Transmission Major Components

1. 6POINT NUT (2) 12. MACHINE SCREW (2)


2. FLAT WASHER (2) 13. WASHER (2)
3. LUBRICATION PUMP ASSEMBLY 14. OUTPUT PINION NOZZLE ASSEMBLY (SMALL HOLES)
4. PACKING (2) 15. OUTPUT PINION NOZZLE ASSEMBLY (LARGE
5. PACKING HOLES)
6. 6POINT NUT (12) 16. BOLT
7. WASHER 17. WASHER (16)
8. TAIL ROTOR DRIVE ASSEMBLY 18. MAIN ROTOR DRIVE ASSEMBLY
9. BOLT (4) 19. MAIN HOUSING ASSEMBLY
10. FLAT WASHER (4) 20. PACKING (2)
11. INPUT DRIVE ASSEMBLY

Page 2
Revision 17 632000
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D25100

21

22
12 16

34 17
13 19
36
14 19

15 32 17 20
18
33
32
30
3

4 8
7
26
6
31
27 38
28 33 29 31
40 35
25
31 24
23
5
2 36
41 1
47
2 42 37
46
43
1 10

45 9
11
10 11
NOTE: 44
ITEMS 28 THRU 39 ARE NOT AT OVERHAUL.
ITEM 5 ELIMINATED ON LATER HOUSINGS. 11
H63-2056
Figure 2. Main Transmission Case Assembly
Legend (Ref. Figure 2)
1. DRAIN VALVE & CHIP DETECTOR (2) 25. ROLLER BEARING
2. PACKING (2) 26. DRIVE SCREW (4)
3. LIQUID LEVEL PLUG 27. IDENTIFICATION PLATE
4. PACKING 28. HOUSING BUSHING (4)
5. PIPE PLUG 29. DOWEL PIN (2)
6. STRAIGHT THREAD PLUG 30. DOWEL BUSHING (2)
7. PACKING 31. OIL PASSAGE PLUG (4)
8. INPUT GEAR NOZZLE 32. WASHER SEAT (6)
9. RETAINING RING 33. INSERT (32)
10. SPRAY NOZZLE
34. BEARING RETAINER
11. PACKING (2)
35. BEARING RETAINER
12. MACHINE SCREW (4)
36. BEARING RETAINER PIN
13. WASHER (4)
37. SPRAY NOZZLE SLEEVE
14. SCAVENGE PUMP ASSEMBLY
38. INSERT (4)
15. SCAVENGE PUMP GASKET
16. MACHINE SCREW (2) 39. STUD (12)
17. WASHER (2) 40. MAIN TRANSMISSION HOUSING
18. NUT (2) 41. NUT
19. SUPPORT CLAMP (2) 42. WASHER
20. INPUT GEAR NOZZLE TUBE 43. WASHER (2)
21. BEARING RETAINING RING 44. PACKING
22. ROLLER BEARING 45. NOZZLE COVER
23. PACKING (3) 46. DRAIN PLUG
24. BEARING RETAINING RING 47. PACKING

Page 3
632000 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D25100
4
9
6
3
8
5
10

7 11
12

24

13 1
14

18

16

15
(NOTE) 18
17 (NOTE) 29

30

16
31
28 2
23
19 22 27

26
20
NOTE: FOR 507 CONFIGURATION TRANS
25
MISSION (REF. TABLE 603).
21

H632057

Figure 3. Tail Rotor Drive Assembly - Exploded View

Legend (Ref. Figure 3)


1. PACKING 17. ROLLER BEARING WITH OUTER RACE
2. PACKING (2) 18. OUTPUT PINION DRIVE
3. 6-POINT NUT (2) 19. INPUT DRIVE GEAR
4. WASHER (2) 20. OUTPUT PINION SPACER
5. SEAL RETAINER ASSEMBLY 21. ACCESSORY DRIVE GEAR
6. PACKING 22. DRIVE PIN
7. DRAIN TUBE 23. BACKLASH SPACER
8. OIL SEAL 24. TAIL ROTOR GEAR ASSEMBLY
9. SEAL RETAINER 25. NUT (3)
10. SPEEDI-SLEEVE 26. BEARING RETAINING PLATE
11. LOCKWASHER 27. TAIL ROTOR OUTPUT BEARING SHIM
12. LOCKNUT 28. DUPLEX BALL BEARING
13. SELF LOCKING NUT 29. TAIL ROTOR DRIVE COVER AND ACCESSORY DRIVE
14. SPHERICAL WASHER ASSEMBLY
15. INNER RACE RETAINING BOLT 30. SPACER
16. ROLLER BEARING INNER RACE 31. RETAINING RING

Page 4
Revision 3 632000
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D25100
10
12 28
10 29
14 13

6
2

23
18
3
9

7
29

4 5
27 15

17
16
28
2 6
29

3 8 26

5 31 22
4
10 20
11 25

26 21
10
30
1
30
24
NOTES:
19 26
1. ITEMS 18 THRU 30 ARE NOT REMOVED AT OVERHAUL.
2. TACHOMETER DRIVE SHAFT (ITEM 11) IS LONGER THAN
OIL PUMP DRIVE SHAFT (ITEM 12).
ROTATED H632058

Figure 4. Tail Rotor Drive Cover and Accessory Drive Assembly

Legend (Ref. Figure 4)


1. OIL PRESSURE SENDER 17. SEAL RETAINER
2. COTTER PIN (2) 18. STUD (3)
3. CASTELLATED NUT (2) 19. STUD (4)
4. WASHER (2) 20. STUD (2)
5. ACCESSORY DRIVEN PINION GEAR (2) 21. STUD (1)
6. WOODRUFF KEY (2) 22. INSERT (2)
7. RETAINER RING (2)
23. INSERT (3)
8. TACHOMETER DRIVE SHAFT ASSEMBLY
24. INSERT (4)
9. OIL PUMP DRIVE SHAFT ASSEMBLY
25. INSERT (1)
10. BALL BEARING (4)
11. TACHOMETER DRIVE SHAFT 26. INSERT (3)
12. OIL PUMP DRIVE SHAFT 27. BEARING RETAINER
13. RETAINER RING 28. BEARING RETAINER (2)
14. SEAL RETAINER ASSEMBLY 29. BEARING RETAINER PIN (3)
15. PACKING 30. OIL PASSAGE PLUG (2)
16. OIL SEAL 31. TAIL ROTOR DRIVE COVER

Page 5
632000 Revision 3
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D25100
6
(NOTE)
7
(NOTE)

8
20

19 4

19A
3
18
1
10
9
11
13
(NOTE)

12
16 (NOTE)

14

17

15

NOTE: NOT TO BE REMOVED AT OVERHAUL UNLESS REPLACEMENT IS REQUIRED. H632059

Figure 5. Input Drive Assembly - Exploded View

Legend (Ref. Figure 5)


1. BLOWER SPACER 12. BEARING PLATE
2. INPUT PATTERN SPACER 13. BEARING PLATE PIN (2)
3. LOCKWASHER 14. CLAMP-UP SHIM
4. LOCKNUT 15. OIL SEAL
5. INPUT DRIVE PINION 16. OIL SEAL
6. ADAPTER PLUG 17. BLOWER MOUNT ASSEMBLY
7. CORK PLUG 18. DUPLEX BALL BEARING
8. INPUT DRIVE BEARING ASSEMBLY 19. ROLLER BEARING INNER RACE
9. INNER INPUT SHAFT SLEEVE 20. ROLLER BEARING WITH OUTER RACE
10. PACKING 21. INPUT PINION BEARING SLEEVE
11. PACKING (2)

Page 6
Revision 3 632000
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D25100
35
6

27 12
26
13 29 28
25 14 38
33 34
36

39

2 32
36
4 1 36

40
5
7
30
41
31
39 37
42

15

16

22
20

23

9 24

17

21
18

8
11
19 (NOTE 2)
10

NOTES:
1. ITEMS 30 THRU 39 ARE NOT REMOVED AT OVERHAUL.
2. AS REQUIRED TO MAINTAIN BOLT PROTRUSION.
H632060A

Figure 6. Main Rotor Drive Assembly Exploded View

Page 7
632000 Revision 17
CSPCOM5 MD Helicopters, Inc.
COMPONENT OVERHAUL MANUAL
P/N 369D25100
Legend (Ref. Figure 6)
1. FILLER CAP AND BREATHER ASSEMBLY 22. BALL BEARING
2. FILLER CAP AND BREATHER 23. ROLLER BEARING
3. FILLER SCREEN 24. OUTPUT SHAFT SPACER
4. FILLER CAP AND BREATHER SHIM 25. CAP SCREW (5)
5. PACKING 26. SUPPORT CLAMP (5)
6. PACKING 27. OIL SCAVENGE RETURN TUBE
7. PACKING 28. BEARING RETAINING RING
8. OIL RETAINER 29. ROLLER BEARING
9. OUTPUT DRIVE SHAFT AND GEAR ASSEMBLY 30. COVER BUSHING (4)
10. 6POINT NUT (4) 31. DOWEL BUSHING (2)
11. WASHER (AS REQUIRED) 32. PLUG (2)
12. 12POINT NUT (4) 33. ORIFICE PLUG (2)
13. FLAT WASHER (4) 34. INSERT (2)
14. DEBRIS COVER 35. INSERT (5)
15. LOCKWASHER 36. INSERT (3)
16. LOCKNUT 37. BEARING RETAINER
17. OUTPUT BEARING SHIM 38. BEARING RETAINER
18. BEARING RETAINING PLATE 39. BEARING RETAINER PIN (2)
19. RING GEAR BOLT (32) 40. MAIN ROTOR DRIVE COVER
20. OUTPUT DRIVE GEAR 41. FILLER CAP EXTENSION
21. OUTPUT DRIVE SHAFT ASSEMBLY 42. PACKING

Page 8
Revision 3 632000
MD Helicopters, Inc. CSPCOM5
COMPONENT OVERHAUL MANUAL
P/N 369D25100

Table 1. Main Transmission Overhaul Check Sheet

Data Plate Information Before Overhaul

Manufacturer: Prime Contractor Name

Address

Sub-Contractor Name
Address
Assemblyy Part Number: Prime Contractor

Sub-Contractor

Assembly Serial No.

Assembly Rubber Cure Date

Removed From Aircraft: Model Serial No.

Registration or N No. Date

Prior to Disassembly: Backlash of Input Gearset Backlash of Output Gearset


0.0060-0.0100 in. 0.0070-0.0120 in.
(0.1520-0.2540 mm) (0.1780-0.3048 mm)

Runout for Input Gearshaft 0.002 in. (0.051 mm) Max.

Runout for Output Gearshaft 0.002 in. (0.051 mm) Max.

Disassembly: Thickness of Shims Measured and Disassembly


Recorded at Removal Completed
Output Backlash Tail Rotor Output Bearing
Spacer in. (mm) Clamp-up Shim in. (mm)
Output Pattern Input Drive Pattern
Shim in. (mm) Shim in. (mm)
Output Bearing Clamp-up Input Bearing Clamp-up
Shim in. (mm) Shim in. (mm)
Input Drive Backlash
Spacer in. (mm) Blower Spacer in. (mm)

Cleaning: Cleaning Completed

Inspection: Inspection Completed

Modifications: Check for Required Required Modifications


Modifications Completed

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COMPONENT OVERHAUL MANUAL
P/N 369D25100

Table 1. Main Transmission Overhaul Check Sheet (Cont.)

Reassembly Shim and Spacer


Dimensions and Thickness (actual)
Tolerances
Output Tail Rotor Output Bearing
Backlash Spacer in. (mm) Clamp-up Shim in. (mm)

Output Input Drive


Pattern Shim in. (mm) Pattern Shim in. (mm)

Output Bearing Input Bearing


Clamp-up Shim in. (mm) Clamp-up Shim in. (mm)

Input Drive
Backlash Spacer in. (mm) Blower Spacer in. (mm)

Reassembly Tests and Checks: Backlash Correct: Wipe Test Satisfactory:

Input Gearset Tail Rotor


0.0060-0.0100 in. Drive Assembly
(0.152-0.2540 mm)

Output Gearset Input


0.0070-0.0120 in. Drive Assembly
(0.1780-0.3048 mm)

(Perform After Run-In)


Axial End Play Gear Contact Patterns Correct:

Input Gearshaft Input Gear Set


0.009-0.015 in.
(0.229-0.3810 mm)

Output Gearshaft Output Gear Set


0.006-0.013 in.
(0.152-0.330 mm)

Final Reassembly Dimensions Shim and Spacer Measurements Completed


and Tolerances:

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Table 1. Main Transmission Overhaul Check Sheet (Cont.)

Run-In and Test: Run-In Completed Final Inspection


Backlash Check (actual):,
Input Gearset Runout (actual):,
0.0060-0.0100 in. Input Gearshaft
(0.1520-0.2540 mm) 0.002-in. (0.051 mm) Max.

Output Gear Set


0.0700-0.0120 in. Output Gearshaft
(0.1780-0.3048 mm) 0.002-in. (0.051 mm) Max.

Axial End Play Check (actual):,


Input Gearshaft
0.009-0.015 in.
(0.229-0.381 mm)

Output Gearshaft
0.006-0.013 in.
(0.152-0.330 mm)

Gaskets Installed Sealant Installed Shims Installed

Torquing Correct
and Complete Lockwire Installed Servicing Complete

Data Plate Information After Overhaul

Final Inspection
Assembly Rubber Cure Date
Installed on Aircraft Model Serial No.
Registration of N No. Date

Partial Overhaul Complete Overhaul Overhaul Completed

This is to certify that to the best of my knowledge the information contained on this check sheet is accurate and
that FAA and manufacturer approved procedures and parts have been utilized.
Signed Date
Address
Title
License No.
Organization
Address
License No.

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COMPONENT OVERHAUL MANUAL
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MAIN TRANSMISSION
DISASSEMBLY
1. Important Reminders NOTE: Prior to disassembly of the main rotor
transmission, measure backlash, shaft run-
The following information applies throughout out, and shaft axial and radial play accord-
the main transmission disassembly procedure. ing to Gearset Backlash and Wipe Test. Re-
When specific repair of the transmission cord findings on the overhaul check sheet
requires only partial disassembly, follow the provided (Ref. Description and Operation).
procedures to the point required.
A. Tail Rotor Drive Removal
(1). A complete disassembly and inspection Remove the tail rotor drive assembly (8,
are required if the transmission is Figure 1) as follows:
removed from service because of
Conditional Inspections (Ref. CSP Do not pry on cover of tail rotor
HMI2, Sec, 055000) such as: CAUTION drive assembly. Serious damage
may result to cover or main housing. Use
(a). After Main Rotor Blade/Drive System three Tbolts (8, Table 901) as pullers.
Sudden Stoppage Level 2.
(1). Remove attaching hardware (6, 7,
(b). After Lightning Strike Level 2. Figure 1).
(2). Screw three Tbolts (8, Table 901) into
(c). A part is thought to have impact insert holes (26, Figure 4) in tail rotor
damage from a crash or shows any drive cover (31).
indication of impact damage.
(3). Tighten Tbolts alternately to provide
(2). Tag and identify all parts with reason even pull on tail rotor drive cover, until
for removal. tail rotor drive assembly (8, Figure 1) is
approximately 0.50 inch (1.270 mm)
(3). Tag all shims and spacers at removal. from main housing (19).
Measure and record thickness to ensure
(4). Grasp tail rotor drive assembly and
duplication at reassembly.
carefully pull it out of main housing
assembly.
(4). Discard packings, seals and gaskets at
removal. New parts are required at (5). Remove Tbolts from tail rotor drive
reassembly. cover.

(5). Place all parts of each subassembly in B. Input Drive Removal


separate containers for easy reference.
Remove the input drive assembly (11,
Figure 1) as follows:
(6). Wrap gearshafts, gears, covers and
housings in protective cloth to prevent NOTE: It may be necessary to heat main hous-
damage. ing to 285F (140C) maximum to remove
input drive assembly.
2. Initial Disassembly
(1). Remove attaching hardware (9, 10) and
pull input drive assembly (11) straight
Initially, the lubrication pump (Ref. Lubrica-
out of main housing.
tion Pump Overhaul, 632001), tail rotor
drive, input drive and main rotor drive C. Main Rotor Drive Removal
assemblies should be removed from the
transmission housing, as described in the Remove the main rotor drive assembly (18,
following paragraphs. Figure 1) as follows:

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Output pinion nozzle assem- (4). Remove drain plug (46) and packing
CAUTION blies (14, 15) must be removed (47). (Not present on early transmis-
before removing main rotor drive assembly sions.)
(18) from main housing assembly (19).
(5). Remove straight thread plug (6) and
(1). Remove attaching hardware (12, 13) packing (7).
and pinion nozzles (14, 15) using oil
nozzle wrench extension (11,
NOTE:
Table 901). Identify nozzle assemblies D Input gear nozzle (8) is bonded in place.
so at reassembly they can be installed D Only remove input gear nozzle (8), if dam-
in same location. age or clogging is suspected, by blowing
air thru nozzle.
(2). Press dowel pins (29, Figure 2) out of
main transmission housing (40). D To remove nozzle, use a long 832 bolt
threaded into nozzle end as puller.
(3). Remove hardware (16, 17, Figure 1)
securing main rotor drive assembly to (6). Remove input gear nozzle (8), if
main housing assembly (19). damage/clogging is suspected.
(7). Remove spray nozzle (10) according to
(4). Screw three Tbolts (8, Table 901) into
(a). or (b). as follows:
holes shown by inserts (36, Figure 6) in
main rotor drive cover (40). Procedure (a). applies to transmission Serial
Nos. 0005 and subsequent, Procedure (b).
(5). Tighten Tbolts to provide even pull on applies to transmission Serial Nos. 0001
main rotor drive cover. through 0004).
(6). When Tbolts reach their limit, lift (a). Using wrench extension (10,
main rotor drive assembly (18, Table 901) or a suitable crowfoot
Figure 1) out of main housing assembly wrench, remove nut (41, Figure 2);
(19). remove washers (42, 43), nozzle cover
(45), and carefully remove spray
(7). Remove Tbolts from main rotor drive
nozzle (10). Remove packing (11)
cover.
from nozzle cover, and packings (11,
(8). Remove two packings (20) from main 44) from spray nozzle.
housing assembly (19). (b). Remove retaining ring (9); carefully
push spray nozzle out of main
3. Component Disassembly transmission housing (40). Remove
Disassemble major components of the main two packings from spray nozzle.
transmission assembly according to procedures (8). Cut safety wire and remove attaching
in the following paragraphs. hardware (12, 13), scavenge pump
assembly (14) and gasket (15).
A. Main Housing Disassembly
(9). Remove attaching hardware (16, 17,
Disassemble main housing assembly (19, 18), support clamps (19) and input gear
Figure 1) as follows: nozzle tube (20).
(1). Remove two drain valve and chip (10). Remove bearing retaining ring (21).
detector assemblies (1, Figure 2) and
packings (2). When pulling roller bearings
CAUTION (22, 25) use care to avoid damag-
(2). Remove liquid level plug (3) and ing retainers (34, 35). Retainers are pinned
packing (4). and line bored in main transmission hous-
ing.
(3). Remove plug (5). (Not present on
transmissions not having threaded (11). Using bearing puller (6, Table 901),
boss.) remove roller bearing (22, Figure 2).

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(12). Remove three packings (23) from input using 1/2 inch, 6 point deep socket with
bore. extension, from retaining bolt (15). Coat
interior of pinion shaft with oil to
(13). Remove bearing retaining ring (24). remove moisture which could cause
corrosion. (On 369D2512513 pinion of
(14). Using bearing puller (7, Table 901),
507 configuration transmission
remove roller bearing (25, Figure 2).
remove retaining ring (31).
(15). Remove drive screws (26) and identifi-
(6). Using suitable puller, remove roller
cation plate (27).
bearing inner race (16) from output
B. Tail Rotor Drive Disassembly drive pinion (18). (On 369D2512513
pinion of 507 configuration transmis-
Disassemble the tail rotor drive assembly (8, sion remove roller bearing inner race
Figure 1) as follows: (16) and spacer (30).
(1). Remove packing (1, Figure 3); remove (7). Remove input bevel gear (19), output
packings (2) if they adhere to tail rotor pinion spacer (20), accessory drive gear
drive cover and accessory drive assem- (21), pin (22) and backlash spacer (23)
bly (29). from tail rotor gear assembly (24).
(2). Remove attaching hardware (3, 4) and (8). Remove cotter pins (2, Figure 4) nuts
seal retainer assembly (5); remove (3), washers (4) and accessory drive
packing (6), drain tube (7) and oil seal gears (5) from accessory drive shafts.
(8) from seal retainer (9).
(9). Remove three nuts (25, Figure 3),
NOTE: Remove speedisleeve installation bearing retaining plate (26) and tail
shoulder to allow removal of self locking nut rotor output bearing shim (27).
(13). Do not remove complete speedisleeve
(10) at disassembly. (10). Remove duplex ball bearing (28) from
tail rotor drive cover and accessory
(3). Install gearshaft assembly in holding drive assembly (29) by applying heat
fixture (9, Table 901), remove lockwash- 285F (140C) maximum to housing and
er (11, Figure 3); using barrel wrench push out bearings by hand. If neces-
(2, Table 901) remove locknut (12, sary, use suitable puller.
Figure 3) from output drive pinion
assembly (8, Figure 1). (Ref. C. Tail Rotor Drive Cover and Accessory
Figure 301). Remove gearshaft assem- Drive Disassembly
bly from holding fixture.
Disassemble the tail rotor drive cover and
Input drive gear (19, Figure 3) accessory drive assembly (29, Figure 3) as
CAUTION and output drive pinion (18) can follows:
be seriously damaged if an adapter similar
(1). Remove oil pressure sender (1,
to that shown in Figure 302 is not used. En-
Figure 4).
sure that output drive pinion does not drop
against arbor press base plate. (2). Remove accessory drive pinion gears
(5).
(4). While heating the gear and bearing
assembly to 285F (140C) maximum (3). Remove woodruff keys (6) and retainer
and cooling the inside of pinion shaft, rings (7).
using an arbor press and suitable
adapter (Figure 302), press output drive (4). Remove tachometer drive shaft assem-
pinion assembly (Figure 3) out of input bly (8) and oil pump drive shaft assem-
drive gear (19) and duplex ball bearing bly (9) from tail rotor drive cover (31).
(28).
(5). Using suitable puller, remove ball
(5). Remove self locking nut (13) and bearings (10) from tachometer drive
spherical washer (14) inside shaft (18) shaft (11) and oil pump drive shaft (12).

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(6). Remove retainer ring (13) and seal the inside of pinion shaft, using arbor
retainer assembly (14); remove packing press and bearing puller (1, Table 901)
(15) and oil seal (16) from seal retainer or suitable adapters, press input drive
(17). pinion (5, Figure 5) out of input drive
bearing assembly (8). Coat interior of
D. Input Drive Disassembly pinion shaft with oil to remove moisture
Disassemble the input drive assembly (11, which could cause corrosion.
Figure 1) as follows: NOTE: Unless necessary, adapter plug (6), cork
plug (7) and bearing plate with pins (12, 13)
(1). Using standard 3leg bearing puller, need not be removed at overhaul. Coat ex-
remove blower spacer (1, Figure 5) from posed end of cork plug (7) with sealant (5,
input drive pinion (5). Table 903) prior to reassembly to prevent oil
(2). Remove input pattern shim (2). Mea- seepage.
sure and record shim thickness on (6). Remove inner input shaft sleeve (9,
Overhaul Check Sheet. Figure 5), packings (10, 11), bearing
clampup shim (14) and oil seals (15,
(3). Remove lockwasher (3). 16) from blower mount assembly (17).
(4). Place pinion end of input drive pinion
(5) in holding fixture (14, Table 901).
Using barrel wrench (4), remove
locknut (4, Figure 5). Remove input
drive pinion from holding fixture.
ARBOR
TORQUE PRESS
WRENCH

COVER
OUTPUT
GEARSHAFT

BARREL
WRENCH
LOCKNUT INPUT
GEAR

ADAPTER

BENCH H632066
HOLDER Figure 302. Removing Output Gearshaft from
Tail Rotor Drive Assembly Cover
(7). Remove duplex ball bearing (18).
Remove roller bearing (20) from input
pinion bearing sleeve (21).
H632065
E. Main Rotor Drive Disassembly
Figure 301. Removal and Installation Disassemble the main rotor drive assembly
Output Gearshaft Locknut (18, Figure 1) as follows:
(5). While heating the bearing assembly to (1). Remove filler cap and breather assem-
285F (140C) maximum and cooling bly (1, Figure 6). Remove filler screen

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P/N 369D25100
(3), filler cap extension (41) (if in- (4). Remove 6point nuts (10), 12point
stalled), filler cap and breather shim bolts (12), washers (13), washers (11)
(4), and packings (5) from filler cap and (retain as required to maintain bolt
breather (2). protrusion) and debris cover (14); lift
main rotor drive cover assembly (40)
(2). Remove packings (6, 7) and oil retainer away from output drive shaft assembly.
(8).
(5). Remove lockwasher (15). Using barrel
(3). Place spline adapter (5, Table 901) in
wrench (3, Table 901), remove locknut
output drive shaft and gear assembly
(16, Figure 6).
(9, Figure 6). Install spline adapter and
main rotor drive assembly in suitable Avoid contact with output shaft
vise. CAUTION spacer when removing bearings
from output drive shaft.

ARBOR
NOTE: It may be necessary to heat bearings to
PRESS 285F (140C) maximum to ease removal
from shaft.

(6). Using arbor press with suitable split


plate puller, press ball bearing (22) and
roller bearing (23) off output drive shaft
assembly (21). Remove backlash spacer
(24).

(7). Remove output bearing shim (17) and


bearing retaining plate (18).
BEARING INPUT
PULLER PINION (8). Remove ring gear bolts (19) and output
BEARING
SLEEVE drive gear (20).

(9). Remove output drive shaft assembly


(21) and spline adapter from vise;
remove spline adapter from output
drive shaft assembly.

(10). Remove cap screws (25), support clamps


(26) and oil scavenge return tube (27)
from main rotor drive cover (40).
H632067

Figure 303. Removal Input Bearing (11). It may be necessary to heat cover to
Retainer from Input Gearshaft 285F (140C) maximum to ease
removal of bearings. Remove bearing
NOTE: It may be necessary to heat output cov- retaining ring (28) and roller bearing
er to 285F (140C) maximum before remov- outer race (29) using retractor tool (13,
al. Table 901).

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MAIN TRANSMISSION
CLEANING/PAINTING
1. Cleaning rotor drive cover, tail rotor drive cover and
other magnesium parts as follows:
Clean individual parts and components of the
main transmission as described in Table 401. (1). Wipe affected area with clean cloth
Most cleaning solvents are moistened with trichlorethylene (9,
WARNING flammable and must be kept Table 903) to remove corrosion or
away from heat or open flame. Avoid chemical build up.
inhalation of fumes and extended con
tact with skin. (2). Apply light coat of chrome pickle
solution (23) to affected area; rinse with
2. Refinishing Interior Areas of Main clean water.
Housing and Covers
(3). Dry thoroughly with compressed air
Refinish interior areas of main housing, main and clean with lintfree cloth.

Table 401. Cleaning Main Transmission Parts and Components


Nomenclature Cleaning Method (Table 903) Remarks
Main transmission Housing (19, Figure 1) Vapor degrease (9) or immerse Dry with compressed air; make
Tail rotor drive cover (31, Figure 4) in cleaning solvent (1) and wash sure oil passages are clear.
Main rotor drive cover (40, Figure 6) with stiff bristle brush.
Nozzle assemblies (14, 15, Figure 1) Agitate in cleaning solvent (1). Dry with compressed air; blow
Input gear nozzle (8, Figure 2) Use soft bristle brush to remove air through nozzles and tubes to
Spray nozzle (10) particles of adhesive. dry interior. Make sure passages
Input gear nozzle tube (20) are clear.
Scavenge return tube (27, Figure 6)
Drain valve and chip detector (1, Agitate in cleaning solvent (1). Dry with compressed air.
Figure 2)
Liquid level plug (3)
Bearing retaining ring (24)
Seal retainer (9, Figure 3)
Oil pressure sender (1, Figure 4)
Seal retainer (17)
Mount assembly (17, Figure 5)
Bearing sleeve (20)
Filler cap and breather (1, Figure 6)
Screen (3)
Oil retainer (8)
Debris cover (14)
Retaining plate (18)
Filler cap extension (41)
Output drive pinion (18, Figure 3) Immerse in cleaning solvent (1) Dry with compressed air. Blow
Input drive gear (19) and wash with soft brush. air inside shafts to dry interior.
Accessory drive gear (21)
Pinion gear (5, Figure 4)
Drive shaft (11, 12)
Input drive pinion (5, Figure 5)
Output drive gear (20, Figure 6)
Output drive shaft (21)

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Table 401. Cleaning Main Transmission Parts and Components (Cont.)
Nomenclature Cleaning Method (Table 903) Remarks
Do not spin bearings while drying with compressed air.
CAUTION
Bearing (22, 25, Figure 2) Degrease using ultrasonic or Dry thoroughly with
Roller bearing (16, Figure 3) activated solvent method to moisture-free compressed air.
Ball bearing (28) dislodge contamination. Use
Ball bearing (10, Figure 4) filtered solvent spray to remove
Duplex ball bearing (18, Figure 5) contamination.
Roller bearing (19)
Roller bearing (23, Figure 6)
Roller bearing (29)
Identification plate (27, Figure 2) Agitate in cleaning solvent (1). Dry with compressed air. Use
Shim (27, Figure 3) care when drying shims to
Shims (2, 14, Figure 5) prevent damage.
Shim (17, Figure 6)
Spacer (24)
All nuts, bolts, washers, screws, clamps, Place parts in wire mesh basket; Dry parts thoroughly while in
retaining rings, spacers, pins and keys. agitate in cleaning solvent (1). basket. Place parts in clean
container after cleaning.

3. Painting and Markings Do not paint mounting surfaces,


CAUTION holes, accessory pads, studs or
The following paragraphs provide painting and shaft extensions. Do not paint drain tube in
marking requirements and procedures for the seal retainer assembly (9, Figure 3), drain
main transmission. valves and chip detectors (1, 46, Figure 2),
identification plate (27), electrical terminals
A. Surface Preparation on oil pressure sender (1, Figure 4) and
packing (6, Figure 6).
Before painting main transmission assembly,
prepare all surfaces as follows: (1). Prepare surface to be spotpainted as
described in Painting and Markings)
NOTE: For additional painting information, re
fer to CSPHMI2. (2). Apply one coat of wash primer (10,
Table 903) to bare metal surface with
(1). Mask all exposed gearshafts, mounting suitable brush. Allow surface to dry
surfaces, holes and accessories with thoroughly.
masking tape (8, Table 903). Mask
identification plate (27, Figure 2) and (3). Apply one coat of epoxy primer (11)
main rotor output shaft. with converter (14), to primed surface.
Allow epoxy primer to dry thoroughly.
(2). Featheredge any chipped or peeling
paint with crocus cloth (2, Table 903). (4). Apply two coats of epoxy paint (12),
Clean all surfaces thoroughly with with catalyst (13), to primed surface.
trichlorethylene (9). Dry surfaces
thoroughly with clean lintfree cloth or NOTE: Allow first coat of paint to dry 4 hours
compressed air. before applying second coat.

B. Exterior Painting - Spot Touch-Up C. Complete Exterior Painting

Touch up bare metal spots on main transmis When necessary, paint complete transmission
sion housing (40, Figure 2) as follows: exterior as follows:

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Do not paint mounting surfaces, (1). Using soft cloth moistened with thinner
CAUTION holes, accessory pads, studs or (25, Table 903), thoroughly rub glass
shaft extensions. Do not paint drain tube in unti