Enstrom F28F 280F MM Rev 04 1994 PDF

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ATP Grid Index to Manufacturer’s Publications:
Enstrom Helicopter
F28F and 280F Series
Maintenance Manual
Secti on Topi c
General Information
Title Page
List of Chapters (Table of Contents)
Record of Revisions
Record of Temporary Revisions
´•´•_;Section i-Introduction
Section 2 General Information
Section 3 Periodic Inspections and Airworthiness Limitatio
Section 4 Servicing and General Maintenance
Section 5 Weight and Balance
Section 6 Electrical System
Section 7 Instruments
Section 8 Structure
Section 9 Main Rotor
Section 10 Tail Rotor
Section 11 Drive Belt System
Section 12 Flight Controls
01/28/2008 Copyright Aircraft Technical Publishers Page 1 of 2
(EN 0130 MM)

Section Topic
Section 13 Powerplant and Accociated Systems
Section 14 Utility Systems
Section 15 Supplement Procedures
Section 16 Aircraft Description
Section 17 Airworthiness Limitations
Section 18 Powerplant
Section 19 Main Rotor Transmission
Section 20 Belt Drive System
Section 21 Electrical Systems and Components
Section 22 Structure
Section 23 Flight Controls
Section 24 Instruments
Section 25 Tail Rotor Drive Assembly
End of Index
01/28/2008 Copyright Aircraft Technical Publishers Page 2 of 2
(EN 0130 MM)

IVI FG I
INTRO
ENSTROM-
F28F AND 280F SERIES
MAINTENANCE MANUAL
~1
F28F
i
I ,1
280F
The Airworthiness Limitations Section (Section 3) is FAA approved

and specifies inspections and other maintenance required under
43.16 and 91.163 of the Federal Aviation Regulations unless an
alternative program has been FAA approved.
(I ENSTRONI HELICOPTER CO~RPORATION

;1)
M~NOMINEE MICHIGAN
I RECORD OF REVISIONS
MFG,REVI ISSUE ATP REV

NUMBER SECTION PAGE NUMBER DATE DATE BY
REISSUE ENTIRE BOOK 1985 4-24-86Rl ATP/
8- 8 -16-89 ATP DAT1
3 SM: 4, ~C71 ~I 3/00/C14 2/8/94 ATI?
4 ,P~EISSUE 3/00/94 12/8/94
rOR1~ LRCA,OOS.,1 6-01-84

LOG OF REVISIONS
REV. REV. DATE F.A.A.

PACES AFFECTED DATE
NO. APPROVED
1 1 4-3-86 1 vi, vii, viii and ix

MM-3-1 14-3-8
Added Sections 15 through 25
inclusively.
Section 17 Supplemental
Airworthiness Limitations
4-3-8~JC
2 1 11-18-88 lix
MM-2-10,2-14 2-15
MM-3-13 &3-20,4-1&4-6 111-18~88
MM-6-1,6-2,6-5,6-9,6-21,6-23
6-24,6-26,6-27,6-28,6-29
MM-9-14 9-47
MM-11-32 11-63
MM-12-43
MM-13-19,13-22,13-23,13-94,13-9
13-96
MM-21-3,21-4,21-7,21-10,21-11
21-12,21-13
3 1 3/00/94 1 MP~-4-1
4 1 3/00/94 1 ~EISSUE
NOTES:
i. REVISED TEXT IS INDICATED BY A BLACI( VERTICAL LINE
2. REVISIONS TO SECTION 3 AND II MUST BE F.A.A. APPROVED
82 Rev. 11j18/88 ix
I RECORD OF TEMPORARY REVISIONS
TEMP ISSUE ATP REV DATE REV

REV NO DESCRIPTION DATE DATE BY REMOVED INCOR BY
FORM LRCA_006-1 4-12-88

MAINTENANCE MANUAL
TABLE OF CONTENTS
Page
Section.l- INTRODUCTION
1-1 Manual Arrangement MM-1-1

112 Aircraft Effectivity MM-1-1
1-3 Manual Changes and Revisions MM-1-1
1-4 Application of Notes, Cautions and Warnings MM-1-2
Section 2 GENERAL INFORMATION
2-1 Specifications MM-2-1

2-2 Model Specifications MM-2-10
2-3 Conversion Data MM-2-ll
2-4 Related Publications MM-2-12
2-5 Special Tools MM-2-13
2-6 Torque Data MM-2-14
*Section 3 PERIODIC INSPECTIONS AND AIRWORTHINESS LIMITATIONS
3-0 General MM-3-1

3-1 Daily and/or Preflight Inspection MM-3-1
3-2 Periodic Inspection MM-3-6
3-3 Special Inspections MM-3-24
3-4 Airworthiness Limitations MM-3-29
Mandatory Service Life Limits
3-5 Mandatory Overhaul Cycles MM-3-30
Section 4 SERVICING AND GENERAL MAINTENANCE
4-1 Lubrication MM-4-1

4-2 Servicing MM-4-19
4-3 Ground Handling MM-4-25
4-4 Cleaning MM-4-26
4-5 Helicopter Preservation and Storage MM-4-27
4-6 Preventive Maintenance for Corrosion Control MM-4-31
in the Field
4-7 Maintenance and Repair of Main and MM-4-45
Tail Rotor Blades
*Adherence to theinspection intervals and component retirement lives in

this Section is required by the FAA.
page
MAINTENANCE MANUAL
Page
Section 5 WEIGHT AND BALANCE
5-1 General Information MM-5-1

5-2 Approved Center of Gravity Envelopes MM-5-1
5-3 Weighing the Helicopter MM-5-3
5-4 Loading MM-5-6
i ."_
Section 6 ELECTRICAL SYSTEM
6-1 Electrical System MM-6-1

6-2 Battery MM-6-2
6-3 Alternator MM-6-s
6-4 Voltage Regulator MM-6-8
6-5 Overvoltage Relay MM-6-10
6-6 Starter MM-6-10
6-7 Fuel BoostPump MM-6-13
6-8 Lighting MM-6-14
6-9 Clutch Disengage Warning Light MM-6-16
6-10 Manifold Pressure Overboost Caution Light MM-6-16
6-11 Hourmeter MM-6-17
6-12 Trim Motors MM-6-17
6-13 Ammeter Charging System MM-6-18
6-14 Instrument Cluster Troubleshooting MM-6-19
6-15 Charts MM´•6-25
Section 7 INSTRUMENTS
7-1 Instrument Panel MM-7-1

7-2 Altimeter MM-7-1
7-3 Airspeed Indicator MM-7-4
7-4 Engine and Rotor Tachometer MM-7-5
7-5 Fuel Quantity Indicator MM-7-5
7-6 Engine Oil Pressure GAuge MM-7-6
7-7 Main Rotor Transmission Temperature Indicator MM-7-7
7-8 Engine Oil Temperature Indicator MM-7-7
7-9 Ammeter MM-7-8
7-10 Cylinder Temperature Indicator MM-7-9
7-11 Exhaust Gas Temperature Indicator (EGT) MM-7-9
7-12 Manifold Pressure and Fuel Flow Indicator MM-7-11
7-13 Outside Air Temperature Indicator MM-7-12
7-14 Magnetic Compass (F-28F) MM-7-12
7-15 Magnetic Compass (280F) MM-7-12
7-16 Hourmeter MM-7-12
7-17 Pitot Static System MM-7-13
7-18 Replacement of Instruments MM-7-13
7-19 Inspection of Instruments MM-7-15
page iv
MAINTENANCE MANUAL
Page
Section 8 STRUCTURE
8-1 Cabin MM-8-1

8-2 Windshield (F-28F MM-8-4
8-3 Windshield (280F) MM-8-7
8-4 Cabin Doors (F-28F) MM-8-10
8-5 Cabin Doors (280F) MM-8-13
8-6 Overhead and Lower Windows MM-8-15
8-7 Seat Belts Lap-Type MM-8-16
8-8 Seat Deck MM-8-18
8-9 Landing Gear MM-8-19
8-10 Pylon MM-8-34
8-11 Baggage Compartment MM-8-35
8-12 Tailcone Assembly MM-8-37
8-13 Torque Tube Extension MM-8-40
8-14 Horizontal Stabilizers (F-28F) MM-8-42
8-15 Stabilizers (280F MM-8-46
Section 9 MAIN ROTOR
9-1 Main Rotor Hub Assembly MM-9-1

9-2 Retention Assembly (Disassembly) MM-9-15
9-3 Universal Block Assembly MM-9-2O
9-4 Retention Assembly (Assembly) MM-9-2O
9-5 Dampers MM-9-32
Section 10 TAIL ROTOR
10-1 Tail Rotor Assembly MM-10-1

10-2 Static Balancing MM-1O-19
10-3 Tracking and Dynamic Balancing/Chadwick System MM-10-21
10-4 Pitch Control Assembly MM-10-26
10-5 Tail Rotor Gearbox MM-10-31
10-6 Tail Rotor Driveshaft and Flex Coupling MM-1O-34
10-7 Tail Rotor Cables MM-1O-45
Section 11 DRIVE BELT SYSTEM
11-1 Clutch Control Rigging MM-11-1

11-2 Clutch Cable MM-ll-5
11-3 Clutch Control Lever MM-ll-8
11-4 Jackstrut and Pulley Assembly MM-ll-9
11-5 Drive Belt MM-ll-15
11-6 Main Rotor Gearbox MM-ll-23
11-7 Overrunning Clutch and Pulley Assembly MM-ll-26
11-8 Idler Pulley Troubleshooting MM-ll-36
11-9 Belt Tension Assembly MM-ll-~3
page v
MAINTENANCE MANUAL
Page
Section 12 FLIGHT CONTROLS
12-1 Troubleshooting the Articulated Rotor System MM-12-1

12-2 Main Rotor Blade Tracking Spotlight and Reflectors MM-12-9
12-3 Main Rotor Blade Tracking Chadwick System MM-12-12
12-4 Collective Pitch Control Stick MM-12-18
12-5 Collective Trim System MM-12-21
12-6 Cyclic Pitch Control Stick\ MM-12-26
12-7 Lateral and Longitudinal Trim Actuators MM-12-27
12-8 Flight Control Rigging MM-12-33
12-9 Cyclic Azimuth Check MM-12-41
12-10 Cyclic Trim Springs Rigging Procedure MM-12-43
12-11 Swashplate Assembly MM-12-45
12-12 Flight Test Procedure MM-12-66
Section 13 POWERPLANT AND ASSOCIATED SYSTEMS
13-1 Powerplant (General Information) MM-13-1

13-2 Engine MM-13-3
13-3 Engine Exhaust System MM-13-19
13-4 Fuel Injection System MM-13-23
13-5 Turbocharger MM-13-47
13-6 Turbocharger Static Air Fuel Nozzle MM-13-49
Pressure System
13-7 Primary Airflow System MM-13-52
13-8 Cooling System MM-13-57
13-9 Ignition System MM-13-64
13-10 Fuel System MM-13-72
13-11 Lubricating System MM-13-88
13-12 Correlator MM-13-94
Section 14 UTILITY SYSTEMS
14-1 Cabin Heat MM-14-1
page vi
MAINTENANCE: MANUAL
Page
Section 16 AIRCRAFT DESCRIPTION
16-1 General Description 280FX MM-16-1

16-2 Airframe and Systems Description 280FX MM-16-1
16-3 General Description F-28F MM-16-2
16-4 Airframe and Systems Description F-28F MM-16-2
16-5 Model Specifications F1M-16-5
*Section 17 AIRWORTHINESS LIMITATIONS
17-1 Inspections MM-17-1

17-2 Daily Preflight Inspections MM-17-1
17-3 Special Periodic Inspections MM-17-3
Section 18 POWERPLANT
18-1 General MM-18-1
Section 19 MAIN ROTOR TRANSMISSION

19-2 Main Rotor Gearbox Chip Detector MM-19-1
19-3 Lubricant Change MM-19-2
Section 20 BELT DRIVE SYSTEM
20-1 General Information MM-20-1
Section 21 ELECTRICAL SYSTEMS AND COMPONENTS

21-2 Combined Anticollision and Navigation Lights MM-21-1
21-3 Annunciator Panel FIM-21-1
21-4 Troubleshooting Chart MM-21-9
21-5 Lamp Replacement Guide Chart MM-21-10
21-6 Flight Ampere Loan Conditions MM-21-ll
Section 22 STRUCTURE
e2-1 General MM-22-I

22-2 Airscoop MM-22-1
22-3 TailRotor Driveshaft Cover MM-22-3
22-4 Tubular Tail Rotor Guard MM-22-5
22-5 Horizontal Stabilizers with Vertical Endplates MM-22-7
22-6 Landing Gear Fairings MM-22-1O
22-7 Door Assembly F-28F MM-22-13
fl Rev. 4/3/86 Page vii

MAINTENANCE-MANUAL
Page
Section 23 FLIGHT CONTROLS
23-1 General MM-23-I

23-2 Push-Pull Tubes MM-23-1
Section 24 INSTRUMENTS

24-2 Graphic Engine Monitor MM-24-1
24-3 Engine Trouble Shooting with Graphic Eng. Monitor MM-24-2
24-4 Avionics MM-24-4
Section 25 TAIL ROTOR DRIVE ASSEMBLY

25-2 Tail Rotor Driveshaft Cover MM-25-1
25-3 Tail Rotor Gearbox Chip Detector MM-25-1
"Adherence to the inspection intervals and component retirement lives in

this Section is required by the F.A.A.
~1 Rev. 4/3/86 Page viii

SECTION
INTRODUCTION
MAINTENANCE MANUAL
SECTION 1
INTdODUCTION
1-1 MANUAL ARRANGEMENT
Manual sections the helicopter into

divide major systems and related
subsystems provide
to maintenance procedures required for proper system
function and optimum component service life.
Each section details the following maintenance functions, if applicable,

for associated subsystems and components.
General Information
Troubleshooting
Operational Check
Tracking
Balancing
Removal
Disassembly
Inspections (other than Periodic Inspections)
Reassembly
Installation
Adjustment/Rigging
Repair
Where extensive coverage of a specific maintenance function is necessary,

that function is incorporated as a major subdivision within a section.
1-2 AIRCRAFT EFFECTIVITY
The maintenance data presented is applicable to all F-28F and 280F model
Enstrom helicopters configured with standard equipment. Differences
between models are specified in the text within the affected section or
subsection.
Optional equipment maintenance procedures are defined in Maintenance Manual

Supplements supplied with aircraft which are so equipped, or with retrofit
kits.
1-3 MANUAL CHANGES AND REVISIONS
Subsequent to the publication of the initial issue of the Enstrom

F-28F 280F Maintenance Manual, changes in aircraft equipment, support
concepts and procedures, as well as information developed by experience,
may affect the contents of the Manual. To ensure that coverage in the
Manual continues to reflect such changes, revised information is released
by one of the following methods:
MM-1-1
MAINTENANCE MANUAL
A. Revision
An alteration of portions of the Manual accomplished by the replace-

ment, addition and/or deletion of pages.
NOTE: A revised List of Effective Pages is distributed with each

revision. Current revisions are denoted by an asterisk
adjacent to affected pages.
The revised List of Effective Pages lists all pages replaced, added or
deleted. Remove and destroy all affected pages from the Manual.
Insert new revised and added pages. The new List of Effective Pages
provides a current record of Manual revisions.
B. Reissue
Where of changes are involved,

large numbers a complete reissue of the
Manual is
warranted. Preceding issues of the Manual then become
obsolete and should be discarded.
C. Service Information Letters and Service Directive Bulletins
Service information is to be considered as part of the Manual. Incor-

poration of service information in the Manual will be accomplished at
the next revision date and listed on the Service Informati’on Summary
page.
(1) Service Information Letter Used to transmit information,

recommendations, and general service instructions to the customer.
(2) Service Directive Bulletin Used to direct the customer to make

mandatory changes, improvements or inspections to his aircraft.
1-4 APPLICATION OF WARNINGS, CAUTIONS AND NOTES
Throughout this Manual and the Maintenance Manual Supplements it is neces-

sary to highlight or emphasize important points to avoid injury to
personnel, damage to equipment, or unnecessary confusion while performing
routine maintenance procedures. The terms WARNING, CAUTION, and NOTE are
used to draw attention to instructions or information deserving special
consideration.
A. WARNING Calls attention to use of materials, processes, methods,

procedu~res, or limits which must be followed precisely to avoid injury
to persons.
B. CAUTION Calls attention to methods and procedures which must be

fo~9lowed to avoid damage to equipment.
C. NOTE Calls atten ti on to i n fo rmat i on essential to hi gh1 i ght for

clarification of procedures or to make the ,iob easier.
MM-1-2
SECTION
GENERAL
INFORMATION
MAINTENANCE MANUAL
SECTION 2
GENERAL INFORMATION
DESCRIPTION
The "F" model Enstrom is a two/three place helicopter of conventional configura-

tion powered by a 225 hp turbocharged Lycoming piston engine. It isa modern
helicopter with clean flowing lines, completely cowled engine and rugged,
dependable structure. One of the fastest, smoothest helicopters of its size, it
is also one of the quietest.
The following covers details of the construction of its assemblies, components

and systems.
2-1 SPECIFICATIONS
A. Power Plant
A Lycoming HIO-36O-F1AD four cylinder air cooled horizontally opposed

engine is used in "F" model Enstroms. This engine incorporates
features suitable for turbocharging and is turbocharged by the Enstrom
installation.
NOTE: It is recommended that the appropriate Lycoming Operator’s

Manual be consulted prior to any internal adjustments or
repairs to the engine.
B. Induction System
The air induction consists of a filtered air intake located on

non-ram
the right side of the engine compartment. The air filter container
assembly incorporates a spring-loaded automatic alternate air source.
The filtered intake air passes through the container assembly and into
the fuel servo unit.
C. Primary Airflow System
The primary air system consists of an inlet filter assembly, a fuel

servo, a turbocharger and an induction inlet tube. The filtered
outside air passes into the fuel servo where it is metered. The air
from the servo is drawn into the turbocharger impeller. The inlet air
is compressed and delivered to the engine intake sump.
MM-2-1
WIDTH
TIP TO
TIP2’8~0! Ir
5.3’
29.3~ it
-I
m
18.25
z
o
16.0 m
L----=-.,
z
c
4.7
9.0
1
o
73’----1 1--------------------- 28.6

-1
ENSTROM 280F HELICOPTER

Fig. 2-1
WIDfH
Tig T0 TIP
28, O1 n 9.5’
29.3’
I
i
r~3
18.25’~----------;-1
16.0’ BADIUS
9.0’
~I 9,1’
L i 1 28.1’
ENSTROM F28F HELICOPTER

Fig. 2-2
MAENTENANCE MANUAL
D. Oil System
The Lycoming engine is provided with a wet sump pressure oil system
having a capacity of eight quarts. The total oil system has a
capacity of eleven quarts. This includes oil in the lines, engine,
oil coolers and oil filter. An engine driven gear scavenge pump
returns the oil from the turbocharger back to the engine sump. There
is a check valve rated at 27 psi located in the oil line at the
turbocharger inlet.´• The purpose of the check valve is to prevent oil
flow to the turbocharger after engine shutdown.
An oil dipstick level is part of the oil tank filler unit

to check oil
and is accessible
through the left hand side cowling door. Engine
cooling is accomplished by the use of two reverse flow oil coolers
with thermostatic valves and bypass provisions located in the engine
section. Two gauges are located on the instrument panel to provide
visual engine operating limitations of oil temperature and oil
pressure.
E. Fuel Noizle Vent System
The fuel nozzle vent system provides positive ambient air pressure at
the engine fuel nozz’les for all operating conditions, installed in
the fuel nozzle vent system is a single swing-type low pressure check
valve vented to ambient pressure on the filtered side and to deck
pressure on the other side. During starting, idling, and manifold
pressures up to ambient the valve is open. As turbocharger outlet
pressure exceeds ambient pressure the valve closes, providing pres-
surized air to the fuel nozzles from a line connected to the deck side
of the air induction tube. The engine-driven fuel pump is vented to
the deck side of the air induction tube to obtain system air pressure
for all operating conditions.
F. Turbocharger System
The turbocharger unit has only one moving part, a rotating shaft with
a turbine wheel on one end and a compressor impeller on the other.
The turbine wheel, driven by exhaust gas energy, drives the impeller,
which compresses intake air to a density equivalent to near sea level
and delivers it to the engine intake manifold. This increased volume
of air allows the e n g i ne to b re a the wi th the same vo 1 umetri c
efficiency that it does at 70w 7eve7s, up to 12,000 feet density
altitude.
A turbocharger inlet gas temperature gauge (EGT) is provided on the

instrument panel to aid in leaning and maintaining safe inlet tempera-
tures. The gauge is red-lined at 16500F. The exhaust gas inlet
temperature probe is located on the exhaust stack just before inlet to
the turbocharger.
MM-2-4
MAINTENANCE MANUAL
G. Wastegate System
A wastegate system is installed between the engine exhaust collector

and the turbocharger to control turbocharging output. A mechanical
linkage between the servo throttle lever and wastegate allows exhaust
gases to bypass the turbocharger at low power settings. As throttle
setting increases, the wastegate closes causing increased exhaust gas
flow through the turbocharger impeller, which increases engine
manifold pressure and power output.
H. Engine Controls
i. Mixture Control
A vernier locking mixture control is provided on the instrument

console, incorporating a button-lock push/pull cable. A vernier
screw type is provided to fine tune any preset mixture settings.
2. Throttle Correlator System
A throttle correlator system is located at the pilot’s collective

stick and ensures a constant rpm under collective movements.
Through bellcranks and control rods it is one hundred percent
mechanical, giving turbine engine operation on a piston-powered
engine.
I. Fuel System
The fuel system consists of two interconnected 20 U.S. gallon fuel

tanks which feed simultaneously to the engine fuel system. The tanks
have a total capacity of 40 U.S. gallons, with a total of 2 gallons,
one each tank, unusable. The tanks are located on the right and left
sides of the aircraft, just above the engine.
A fuel shut-off valve is located aft of the backwall with a push/pull

cable on the backwall to ensure positive fuel shut-off from the fuel
tanks to the engine.
A fuel pressure flow indicator is located on the instrument panel.

The indicator is marked for operating ranges from 0 to 160 pounds per
hour and O to 25 psi in 5 psi increments. A calibrated fuel quantity
gage, located on the instrument panel, records fuel quantity in pounds
from 0 to 240.
An electrically operated fuel boost pump is mounted in the engine

compartment to provide positive fuel flow to the engine fuel system.
An engine-driven fuel pump is mounted on the engine to provide
positive fuel flow during engine operation and is interconnected to
the boost pump. A boost pump switch is located on the instrument
console, along with pressure warning lights.
MM-2-5
MAINTENANCE MANUAL
Transmission System
1. Main Transmission
The main gearbox provides an 8.277 reduction ratio

transmission
between engine and main rotor system.
the The transmission
incorporates an over-running clutch in the upper pulley which
allows the main and tail rotors to over-run when the engine is
throttled back for autorotations. The transmission has a sight
gauge which is located on the aft right side and is visible
through a panel in the baggage compartment. Total oil quantity
in the transmission ~s six pints. A magnetic drai?, plug located
on the bottom left aft side of the transmis3ion can be
electrically checked for metal particle contamination.
2. Tail Rotor Transmission
The rotor transmission, mounted at the aft end of the tail

tail
cone the stinger tube, supports and drives the tail rotor
on
assembly. Total oil supply is five ounces, with a sight gauge on

the aft housing to check oil quantity. A magnetic drain plug
located on the bottom of the housing can be electrically checked
for metal particle contamination.
K. Belt Drive System
The belt drive system consists of a jackstrut and pulley assembly,

idler assembly, belt tension assembly and a clutch engagement lever
operated from the cabin. The jackstrut pulley, which is bolted to the
engine crankshaft, drives the main rotor transmission through a drive
belt, which in turn drives the main and tail rotor assemblies. The
belt tension assembly has a positive over-center locking feature and
incorporates a warning light on the instrument to assure proper
engagement of the system.
L. Main Rotor System
The main rotor system is of the fully articulated design, which allows
the blades to lead, lag and flap independently of each other. Three
hydraulic dampers are incorporated to control the lead-lag motions.
Three all-aluminum main rotor blades with a chord of 9.5 inches and an
average weight of 51 pounds each give excellent autorotative
capabilities.
M. Tail Rotor System
The tail rotor system is of the feathering and delta hinge teetering
design. Two blades with a chord of 4.4" and an rpm of 2514 give more
than adequate anti-torque control in all phases of flight.
MM-2-6
MAINTENANCE MANUAL
N. Landing Gear
The landing gear consists of two skids and four air oil oleos that
give the Enstrom
good ground running smoothness and excellent touch-
down capabilities, in the event of hard landings. Two ground handling
wheels are provided for ease of movement along the ground.
O. Electrical System
The electrical system is a 12-volt DC

ground installation.
common A
70-ampere alternator provides enough operate equipment and
current to
recha rge the ba tte ry which is a 12-vol t 35-ampere hour Rebat.
Internal cabin service lights, night instrument lighting, anti-
collision, navigation and two landing lights are provided. Voltage
regulation and over-voltage protection are designed within the system.
P. Airframe
The airframe is comprised of three sections:
1. Tail Cone
The tail cone assembly

is a semi-monocoque type and attaches to
the pylon assembly with
three bolts for easy removal and instal-
lation. The tail cone supports the horizontal stabilizers, tail
rotor gearbox, tail rotor and tail rotor guard.
2. Pylon Assembly
The pylon assembly is fabricated from steel tubing and houses the
engine, supports the landing gear, cabin, main transmission and
tail cone.
3. Cabin
The cabin is fabricated from molded fiberglass and is an integral

unit. It is attached to the pylon by six bolts and contains the
aluminum seat structure, plus the instrument panel, cyclic,
collective and tail rotor controls. The windshield and upper and
lower windows provide excellent visibility. The swing-open style
doors operate for ease of loading or unloading.
Q. Cabin Heating System
Warm air used for heating the cabin is derived from a heat exchanger
mounted on the exhaust stack muffler. A push-pull cable mounted on
the left side of the pilot’s seat structure controls the amount of
heat passing through a valve, which is mounted on the right side
firewall in the engine compartment. A diffuser outlet is located in
the center of the seat structure to give adequate heat for all kinds
of weather.
MM-2-7
MAINTENANCE MANUAL
R. Flight Controls
1. Main Rotor
Dual and collective control systems are provided.

cyclic Control
push rods connect the cyclic and collective controls to a swash-
plate located on the base of the transmission. Three push rods
pass from the swashplate, up through the center of the mast, to
the cyclic walking beams on the main rotor head.
2. Tail Rotor
Anti-torque control assemblies are mounted on the cabin floor,

with cables running back to the tail rotor gearbox yoke assembly,
to control both anti-torque and directional control.
S. Flight Instruments
The standard flight instruments which are installed in the instrument

panel as basic equipment comply with requirements under visual flight
rules for day or night operation. The panel arrangement provides ease
of visual observance and includes space for additional individual
requirements.
1. Airspeed Indicator
The single-scale airspeed indicator is calibrated in mph and

provides an indicated airspeed at any time during forward flight.
2. Altimeter Indicator
The altimeter
is a sensitive type that provides distance-height
readings from 0 to 25,000 feet. The long hand indicates in
100 feet while the short hand indicates in 1000 feet altitudes.
3. Free Air Indicator
The free air indicator, located at the top front of the cabin, is
a direct reading, bi-metallic instrument, which reads ambient
temperature.
4. Magnetic Compass
a. F-28F The vertical

card compass is a dry compass utilizing
eddy dampening.
current It consists of a two-inch vertical
dial and is compared with a fixed miniature
rotatinq to )enil-ria
present magnetic heading of the
aircraft at all times. Heading information is more natural
because the heading is read at the 12 o’clock position and
off the nose of the miniature airplane. The compass card
rotates and presents all quadrants in their true relation to
line of flight. A compass light is furnished for night
flying. A compass correction card and card holder are
attached to the instrument console.
MM-2-8
MAINTENANCE MANUAL
b. 280F The magneticcompass indicates the heading of the

hencopter in relation
to magnetic north. It is a direct
indicating compass and indicates the heading by means of a
floating card element that is against a fixed reference
1 i ne. The liquid used in the compass dampens the card
oscillation. A compass light is furnished for night flying.
A compass correction card and card holder are furnished
adjacent to the instrument.
T. Baggage Compartment
A completely internal, swing-open door with a key lock is located just

forward of the tail cone under the wrap cowl. It has a capacity of
108 pounds with 6.3 cubic feet of space. Measurements of 16"W x 22"H
x 22"n give ample room for baggage.
MM-2-9
MAINTENANCE MANUAL
2-2 MODEL SPECIFICATIONS
POWER PLANT
Type Lycoming
Designation HIO-36O-F1AD
Cylinders 4
Normal power 225 hp

Normal rpm 3050
Specific fuel consumption .69 Ibs hp/hr

Weight 324 lbs
Oil 10 qts or 13.75# Ibs inst.
TURBOCHARGEK
Type Rotomaster
Designation 3BT5EE1OJ2
OPERATING KPM’s
Engine 2900-3050
Tail rotor 2514 (at 3050 engine rpm)

Main rotor 350 (at 3050 engine rpm)
Main rotor autorotation range 332-385
RATIOS
Lower drive pulley to upper pulley 1.226:1
Upper pulley to main rotor shaft 7.154:1
Engine to main rotor 8.7871:1
Tail rotor input shaft to output shaft 1:1
DIMENSIONS (F-28F)
Width (overall 28’2"
Rotor diameter 32’
Height (overall) 9’
Length (overall 29’4"
Cabin width at seat 5’1"
Tread landing gear 7’4"
DIMENSION (280F)
Width (overall 28’2N
Length (overall 28’8"
Cabin width at seat 4’10"
#2 Rev. 11/18/88
MM-2-1O
MAINTENANCE MANUAL
MAIN ROTOR SYSTEM
Number of blades 3
Chord each 9.5"
Diameter 32’
Dise area 804 so ft
RPM 350
TAIL ROTOR SYSTEM
Number of blades 2
Chord 4.4"
Diameter 4.67"
Disc area 17.1 so ft
RPM 2514
2-3 CONVERSION DATA
WEIGHTS DIMENSIONS F-28F
Empty weight 703 Kg Tread landing gear 2.23 m
(basic equipped machine) Rotor diameter 9.75 m

Gross weight 1066 Kg Height (overall) 2.74 m
Useful load 363 Kg Length (overall) 8.94 m
Cabin width at seat 1.55 m

ENGINE (Single) Width (overall) 2.29 m
Lycoming HIO-360-F1AD 225 hp DIMENSIONS 280F

4 cycle engine with
Rotomaster turbocharger Tread landing gear 2,23 m
3BT5EE1OJ2 Rotor diameter 9.75 m
Height (overall) 2.74 m

FUEL Length (overall) 8.93 m
Cabin width at seat 1.47 m
100/130 min. or 100 LL min. Width (overall) 2.29 m
grade aviation gasoline

Fuel capacity 151 It) 108.8 Kg CABIN
Usable fuel (143 It) 103.4 Kg
Volume 2.8 cu m
OIL 2 seats in dual
configuration
MIL-L-6O82B SAE grade OR 3 seats with single
MIL-L-22851 ashless control
dispersant SAE grade
Capacity (9.5 It) 8.5 Kg BAGGAGE
Volume .2 cu m
Capacity 49 Kg
MM-2-l1
MAINTENANCE MANUAL
2-4 RELATED PUBLICATIONS
The following are publications and directives considered helpful when used
in conjunction with this manual:
Unit Number Title Address
Engine 60297-12 Operator’s Manual HIO-360 Avco-Lycoming Division

Williamsport, PA 17101
Fuel Injection 15-3386 Fuel Injection Systems Bendix Corporation

System Aerospace Div.
South Bend, IN
Fuel Pump, Boost 10019 Maintenance Overhaul Weldon Tool Company

of Weldon Pumps 3000 Woodhill Road
Cleveland, OH 44104
Ignition ABC’s of Bendix Shower Bendix Corporation

of Sparks Engine Product Division.
Jacksonville, FL
Magneto 0-3000 Inst’l, Operation Maint. Bendix Corporation

Instr. for 0-3000 Series Engine Product Division
Magnetos Jacksonville, FL
Lamar Voltage 28-19018 Test Specifications Lamar, Inc.

Regulator Burlington Cty. Airport
Medford, NJ 08055
Lamar Overvoltage 28-19019 Test Specifications Lamar, Inc.

Relay Burlington Cty. Airport
Medford, NJ 08055
Alternator ALX-8421 Prestolite

PO Box 931
Toledo, OH 43601
Starter M2-4225 Test Specifications Prestolite

PO Box 931
Toledo, OH 43601
Battery (standard) R35M Prestolite Battery Div.

PO Box 931
Toledo, OH 43601
Turbocharger 38T5EE10J2 Rotomaster, Inc.

7101 Fair Avenue
N. Hollywood, CA 91605
Exhaust Gas Report No. Installation Operating Alcor Aviation, Inc.

Temperature 65-112 Instructions PO Box 28299
San Antonio, TX 78228
MM-2-12
MAINTENANCE MANUAL
2-5 SPECIAL TOOLS
A. General Information
The special tools listed below are manufactured and designed for
to rqu i ng 1
remo v a installation and overhaul of components on the
Enstrom helicopters.
B. Part Number and Nomenclature
1. T-00O3 Tool for removing or torquing the main rotor

lead/lag nut
2 T-0008 Reflectors for tracking main rotor blades
3. T-00O8-901 Spotlight with peep scope for tracking main rotor

blades
4. T-0009 Tool bullet for installing main rotor blade bolts
5. T-O011 Tool sling for removing main rotor head or lifting

aircraft
6. T-O013 Tool for removing or torquing main rotor lamiflex

hearing retention nut
7. T-0016 Tool gimbal for overhaul of lower swashplate
8. T-0017 Tool hoisting eye for lifting transmission
9. T-0022 Tool for removing collective spring capsule
10. T-0O26 Tool for adjusting main rotor blade tabs
11. T-0027 Tool for measuring main rotor blade tab angles
12. T-0029A Tool for overhaul of idler assembly
13. T-OO35 Tool for bonding nylatron strap to main rotor

spindle
14. T-O036 Tool for installing main rotor grip seal
15. T-0044 Tool for aligning upper and lower drive pulleys
16. T-0045 Tool for removing doglegs from push rod
17. T-0048 Tool for removing or torquing main rotor mast nut
18. T-0051 Tool for removing or torquing main rotor flapping

hinge pin nut
19. T-0O53 Tool for removing or torquing main transmission

pinion shaft nut
MM-2-13
MAINTENANCE MANUAL
20. T-0054 Tool for phasing dogleg to push rod
21. T-0056 Tool for removi ng or torquing tai i rotor trans-

mission input nut
22. T-0079 Tool for swagging dogleg bearing
23. T-OO8O Tool for rigging tail rotor transmission controls
24. T-0086 Tool for removing or torquing upper swashplate guide

tube nuts
25. T-O088 Tool for aligning tail rotor driveshaft
26. T-0087-15 Tool mandrel for balancing tail rotor assembly
27. T-0099-1 Tool for overhaul of lower swashplate
28. T-0100-1 Tool for overhaul of lower swashplate
29. T-01O1-1 Tool for overhaul of lower swashplate
30. T-O102-1 Tool for overhaul of upper swashplate
31. T-O103-1 Tool for overhaul of lower swashplate
32. T-O105-1 Tool for overhaul of lower swashplate
33. T-1758 Tool clamps for overhaul of upper swashplate
34. T-1794 Tool for weight and balance datum
2-6 TORQUE DATA
Unless specified below, all hardware should be torqued to standard

torques or as called out in the component manufacturer’s
specifications.
B. Location and Torque Values
1. Main rotor mast nut 410 ft-lbs
2. Main transmission pinion nut 175 ft-lbs
3. Main transmission attachment nuts 190 in-lbs
4. Main rotor blade attachment nuts 50 ft-lbs
5. Main rotor blade drag link nuts 140 in-lbs
6. Main rotor damper pivot nut 190 in-lbs
#2 Rev. 11/18J88 MM-2-14

MAINTENANCE MANUAL
7. Main rotor damper rod end nut 25 ft-lbs
8. Upper swashplate guide tube nuts 20 ft-lbs I
9. Engine lord mount nut 460-500 in-lbs
10. Tail cone attachment bolts 240 in-lbs
Tail rotor transmission input nut 45/50 ft-lbs
12. Tail rotor assembly to output shaft bolt 300 in-lbs
13. Tail rotor blade to grip nuts 75 in-lbs
14. Lower engine pulley to crankshaft bolts 50 ft-lbs
15. Cyclic walkirlg beams
a. At push/pull rods 40 in-lbs
b. At center points 40 in-lbs
c. At pitch links 75 in-lbs
16. Landing gear at pivot points 60 in-lbs
17. Landing gear oleos at pivot points 60 in-lbs
18. Tail rotor driveshaft taper pins 25 in-lbs
19. Oogleg to push/pull rod nut 140 in-lbs
20. Alternator drive belt belt to slip at 12 ft-lbs
#2 Rev. 11/18/88 MM-2-15

SECTION
PERIODIC
INSPECTIONS AND
Al RVVO RT H I N ESS
LIMITATIONS
MAINTENANCE MANUAL
SECTION 3
PERIODIC INSPECTIONS AND AIRWORTHINESS LIMITATIONS
The inspections and airworthiness limitations specified in this

section are FAA approved. This section specifies inspections and
other maintenance required under 43.16 and 91.163 of the Federal
Aviation Regulations.
JUN 88 1985
FAA APPROVED BY I CYL~. DATE
W. F. H
MANAGE
CHICAGO AIRCRAFT CERTIFICATION OFFICE
CENTRAL REGION
FEDERAL AVIATION ADMINISTRATION
MM-3-O
MAINTENANCE MANUAL
SECTION 3
PERIODIC INSPECTIONS ANDAIRWORTHINESS LIMITATIONS
3-0 GENERAL
A, Inspections
Mandatory preflight and periodic inspections are set forth in

paragraphs 3.1 and 3.2, respectively, of this section. These
inspection check lists are intended to be used in conjunction
with more detailed procedures presented in other sections of this
manual. Special inspections are set forth in paragraph 3.3.
These special inspections are required following such occurrences
asa main rotor and/or tail rotor blade strike, a hard landing,
or a rotor overspeed. Mandatory supplement inspections appear in
Section 17.
B. Service Lives
Mandatory component replacement times in flight hours are

specified in paragraph 3.4.
C. Overhauls
Some components are. placed into service in an "on condition"

basis, subject to periodic inspections and overhaul in lieu of a
i ’;i´•:::
’sp~cified’:’ jerS’i~e- life.:’Mandatory com’ljohent~ overhaul intervals
a re ed:. i~n :paragrap:h 3.5.
:.´•:I´• :.1.:;
3-1 DA IL’Y: AFiOO R:’l PRE FL i GH;T.’ I N S P ECT I O N Ref; Figurel3.1 for walk-around
procedure)
Ch~eck hel’i.cbpt~r :ahd lengine log books to determine if helicopter is

ai rwdrthy;
~:ijS
This checklist is designed to~be used~’as a guide by the pilot or

mechaniC: whi?´•~ ii iierfdi~m’? ng the daily or brerl i sF~t i nspecti on.
Thorol;lghly familiariz’e ’yourseif’~with-. the Maintenance Manual before
uti 1 ´•i z i ng‘ ´•th i c~i-iic:k’i i´•s~t.
A. Cabin
Prior to starting theexterior inspection, check the cabin for

t h e ‘f o 1´•1 oQ~i ng -i- tems’:
t
;1 ii.
1. Standard Airworthiness Certificate~,:’1FAA Form 8100-2.
2. Certiiicate of Aircraft~ Registratioh’, AC Form 8050-3.

3. If commu n i c~t i On radi o is i nstal 1 ed Ai rcraft Radio
Stations License FCC Form 556.
FAA Approved: June 28, 1985

#1 Rev. 4/3/86
MM-3-1
MAINTENANCE MANUAL
4. Flight Manual for helicopter to be flown. Check forms

F-165A and F-168A in Section 6 for actual weight and balance
of helicopter to be flown. The serial number of the
helicopter to be flown should appear on these forms.
NOTE: The above items are to be carried in the

helicopter at all times. Owners and operators of
exported helicopters should check with their own
Aviation Officials to determine documents
required.
5. Master switch OFF.
6. Ignition switch OFF.
All other switches OFF.
8. Fuel valve ON.
B. Exterior Inspection
1. Remove covers and tie-downs.
2. Left door check condition, security and latch operation.

3. Windshield check condition.
4. Pitot tube unobstructed.
5. Landing light check condition.
6. Right door check condition, security and latch operation.
7. Right oleo struts check extension and security.
8. Right landing gear check condition and security. Check

ground handling wheel in up position and secured.
9. Right side engine compartment.
a. Electrical wiring condition and terminals tight.
b. Induction system no obstructions filter secure,
induction hose and lines secure and backfire and
alternate air doors free.
c. Fuel filter secure and drain fuel sample into jar.
d. Fuel lines secure and no signs of leakage.
e. Oil lines secure and no signs of leakage.
f. Exhaust no cracks or signs of leakage.
g. Cowl door secure.
1O. Upper inspection door.

a. Fuel tank drain drain sample into jar.
b. Swashplate and control rods check condition and
security.
c. Fuel tank and lines check for leaks and lines and
fitting secure.
d. Fire curtain check condition.

MM-3-2
MAINTENANCE MANUAL
11. Kick-in step door.
a. Belt drive system check security and condition of

idler pulley, main drive belt.
b. Tail rotor drive shaft check condition of flex
coupling.
c. Rotor tach drive check condition.
d. Cooling fan check condition.
12. Right fuel tank.
Check for leaks, fuel quantity and cap secured.
13. From steps.
a. Check main rotor gearbox filler cap closed.

b. Check area between fuel tanks for leaks and obstruction
to air flow.
c. Main rotor shaft check condition.
d. Main rotor blades security and condition of leading
edge blade tape, no bond separations, cracks or
corrosion. Main rotor retention pins secured.
e. Check main rotor hub for security of all fasteners, no
cracks or obvious damage.
f. Main rotor pitch links check for binding or
looseness.
g. Main rotor dampers check for security and no leakage.
14. Baggage box.
a. Check contents secured. Observe weight limitations.
b. Open inspection door check main rotor transmission
sight gauge. No rma 1 level is halfway mark on sight
gauge.
c. Door secured.
15. Right static port check unobstructed.
16. Tail cone check condition.
17. Tail rotor drive shaft condition and security of drive

shaft, hangar bearings and flex couplings.
18. Horizontal stabilizer check condition and security.
19. Position lights check security.
20. Tail rotor
a. Control cables check condition and security.

b. Tail rotor transmission check for oil leakage and
check oil quantity. Check for security of attachment.
c. Tail rotor guard check for security and evidence of
strike damage.
d. Pitch change mechanism check condition and operation.
Check pitch links for binding or looseness.
e. Tail rotor hub check security. Check condition of
teeter stop bumpers.
f. Tail rotor blades check security. Check for cracks
or bond separations. Check strike tabs for evidence of
strike.
FAA Approved: 3une 28, 1985

MM-3-3
MAINTENANCE MANUAL
21. Left static port unobstructed
22. Inspection door

a. Belt dri ve sy s tem engage manual cl utch for full
engagement and check belt tensioning system for proper
rigging. Disengage manual clutch.
b. Cooling fan check condition.
23. Left fuel tank
Check for leaks, fuel quantity and cap secured.
24. Upper inspection door
a. Check engine oil quantity 10 quarts full, 8 quarts

minimum for flight.
b. Fuel tank drain drain sample into jar.
c. Swashplate and control rods check condition and
security.
d. Fuel tank and 1 i nes check for 1 ea ks lines and
fittings secure.
e. Fire curtain check condition.
25. Left engine compartment

a. Turbocharger check condition of mount and security.
Check condition of thermal cover and check area around
turbocharger for evidence of heat damage.
b. Exhaust system and wastegate check for security and
evidence of leakage. Wastegate linkage should be i’n
detent, throttle motion should be free and unrestricted
with associated wastegate motion.
c. Cowl door secure.
26. Left oleo struts check extension and security.

27. Left landing gear check condition and security. Ground
handling wheel in up position and secured.
28. Check operation of all lights for night flight.

MM-3-4
’P
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C3~ -4
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WALK AROUND
PROCEDURE
Fiff. 3-1
MAINTENANCE MANUAL
3-2 PERIODIC INSPECTION
This inspection guide is intended for aircraft operating under normal

conditions. More frequent inspections may be required should adverse
operations be encountered.
For more detailed inspection procedures and tolerances, refer to the

appropriate section in the maintenance manual.
MECHANIC’S
NATURE OF INSPECTION FREQUENCY INITIALS
50 100 200
A. GENERAL INSPECTION
1. Inspect aircraft for evidence of oil and X

fuel leaks
2. Clean aircraft thoroughly X
3. Remove the following cowling and

inspection panels:
a. Wraparound cowl (top and sides) X
b. Engine side panels X
c. Upper side panels X
d. Spark plug covers X
e. Cabin doors X
f. Seat deck X
g. Floor panels X
h. Firewall panels X
i. Fuel, transmitter panel X

right fuel tank
4. Inspect aircraft and record discrepancies X

on Form F-122
B. AIRCRAFT STRUCTURE AND FUSELAGE
i. Inspect structure and fuselage for:

a. Cleanliness and corrosion X
b. Evidence of damage X
c. Cracks, tears or buckling of skins X

MM-3-6
MAINTENANCE MANUAL
MECHANIC’S
50 1100 1200
2. Inspect fuel tanks for:
a. Evidence of loose rivets and bond I X

separation
b. Proper operation of drain valves X
c. Scupper bags for looseness, tears X

and security
d. Evidence of corrosion and security X
of wires on fuel transmitter
e. Condition of gasket and security X

of fuel caps
C. COMPONENTS
1. Inspect components for:
a. Cleanliness and evidence of corrosion X
b. Evidence of damage I x
c. Cracks, nicks or scratches X
D. ENGINE SECTION
1. Lubrication system:
a. Drain oil sump and oil coolers X
b. Remove oil filter and inspect for X

metal particles
c. Replace oil filter security safety X
d. Inspect oil coolers for:
(1) Security of mounting X
(2) Security of oil lines X
(3) Obstruction of air flow X
(4) Security of cleanout panels X
e. All oil lines for security X
NOTE: For proper engine oil grades refer to

Section 4, Servicing.
MM-3-7
MAINTENANCE MANUAL
MECHANIC’S
NATURE OF INSPECTION FRE ENCY INITIALS
50 100 200
2. Fuel system:
a. Inspect auxiliary boost pump for X
leakage and security of mounting
b. Inspect engine driven fuel pump for X
leakage and security
c. Inspect main fuel filter for:
(1) Proper operation of drain valve X
(2) Cleanliness of filter X
(3) Security and safety X
d. Inspect servo finger screen for
(1) Cleanliness of screen X
(2) Security and safety X
e. All fuel lines for chafing and security X
f. Inspect fuel shut-off valve for
(1) Evidence of leakage X
(2) Security and operation of cable X
g. Condition and security of air manifold X

hoses at fuel nozzles
h. Security of fuel nozzle lines X
3. Accessory Section
a. Inspect fuel servo for:

(1) Condition and security of AMC X
blast tube
(3) Proper operation of mixture and

throttle controls
(4) Security and safety of controls X
(5) Condition and security of X

induction hose
(6) Security of metal ducting and X

adapters
b. Inspect scavenge pump for:
(1) Evidence of leaks X
(2) Security of lines and fittings X
MM-3-8
MAINTENANCE MANUAL
MECHANIC’S
NATURE OF INSPECTION FREOUENCY INITIALS
50 100 200
4. Ignition System
a. Inspect magnetos for:
(1) Frayed or damaged leads X
(2) Condition of points X
(3) Proper timing X
b. Inspect ignition harness for:
(1) Frayed, worn or damaged shielding X
(2) Condition of cigarette connectors X
c. Inspect spark plugs for:
(1) Proper torque X
(2) Security of ignition harness X
5. Cylinders Assembly
a. Inspect cylinders for
(1) Damaged or broken fins X
(2) Damage, cracks and security of X

air deflectors
(3) Dents, cracks and security of X

push rod housings
(4) Condition of rocker box covers X
6. Exhaust system
a. Inspect exhaust system for
(1) Evidence of leakage or cracks X
(2) Heat exchanger for leaks and X

deterioration
(3) Proper security of all clamps X
7. Intake System
a. Inspect intake system for:
(1) Dents and cracks X
(2) Evidence of leakage X
!3) Security of all connections and X

clamps
MM-3-9
MAINTENANCE MANUAL
MECHANIC’S
NATURE OF INSPECTION FRE ENCY INITIAL
50 1100 200
8. Turbocharger System
a. Inspect turbocharger system for:
(1) Worn or eroded sections X
(2) Security of clamps and oil X

fittings
(3) Evidence of leakage or coking X

heat blanket
b. Inspect turbocharger support brackets

for:
(1) Breakage X
(2) Sagging X
(3) Corrosion X
(4) Security of attachment points X
c. Inspect wastegate system for:

(1) Freedom of operation X
(2) Security of connections X
9. Cooling System
a. Inspect cowls and baffling for:
(1) Damage, cracks or tears X

fire curtain
(3) Fan shroud for condition and X

alignment
(4) Worn or missing fasteners X
b. Inspect cooling fan for:
(1) Loose rivets X

fan blades
(3) Condition of shroud seal X
(4) Proper fan clearance at shroud X
10. Starter Assembly

a. Inspect starter for:
(1) Condition of Bendix gear X

MM-3-1O
MAINTENANCE MANUAL
MECHANIC’S
50 100 200
ii. Alternator Assembly

a. Inspect alternator for:
(1) Evidence of overheating X
(2) Broken, worn, burned or oily X

brush holder
14) Belt tension (8-12 ft-lbs X

pulley drag)
12. Engine Mounts
a. Inspect engine lord mounts for:
(1) Deterioration of rubber X
(2) Proper security X
13. Electrical System (Engine

a: Inspect electrical system for:
(1) Chafed, fraying and security X

ofwirings
(2) Security of electrical panel X
mounting
(3) Evidence of corrosion and X
of ground strap
14. Pylon Assembly (Engine)
a. Inspect pylon assembly for:
(1) Evidence of cracks or dents X
(2) Corrosion X
(3) Security of attaching hardware X
15. Air Induction System

a. Inspect servo air ducting for:
(1) Cleanliness of air filter X
(2) Proper operation of bypass doors X
(3) Torn or deteriorated hose I I X
(4) Cracks or damage of air box X

and mounts
(5) Proper security of lines X

and clamps
(6) Condition of rubber inlet seal X

MM-3-ll
MAINTENANCE MANUAL
MECHANIC’S
50 1100 1200
16. Compression
a. Inspect engine compression for leakage X
(1) #1 cylinder f2 cylinder

#3 cylinder_ #4 cylinder
17. Engine Panels
a. Inspect engine doors for:
(1) Damage or chafing X
(2) Security of hinges X
(3) Worn or missing fasteners X
NOTE: For all required engine maintenance

and/or inspections, see published
Lycoming requirements.
E. Landing Gear Assembly
1. Inspect landing gear for:

a. Damage and cracks X
b. Condition of wear plates X
c. Security of attachments X
d. Condition of end caps X
e. Condition of non-skid tape X
2. Inspect landing gear oleos for:
a. Evidence of corrosion X
b. Evidence of leakage X
c. Condition of boot X
d. Proper extension X
e. Security of attachments X
3. Inspect ground handling wheels

and brackets for:
a. Damage and cracks X
b. Tires cut, cracked or worn X
c. Condition of bearings X
d. Proper inflation (75 to 80 psi) X
e. Condition and security of X

quick-disconnect pin

MM-3-12
MAINTENANCE MANUAL
MECHANIC’S
50 100 200
F. Main Drive Belt System
i. Inspect belt over-center assembly for:
a. Proper extension of piston with clutch X

engaged (measurement: 1 5/8" to 1 3/4")
b. Worn bushings in side plate slots X
c. Microswitch for proper operation X

at overcenter position
d. Bushing in bellcrank at pylon X
for looseness
e. Security of clutch engagement cable X
f. Security of all attaching hardware X
2. Inspect idler assembly for:

a. Looseness of rod end in idler X
yoke shaft
b. Cracks and security of idler .I x
support bracket and yoke casting
c. Evidence of belt out of track X
d. Worn or loose idler yoke X

support bushings
e. Proper clearance of belt snubber X
roller (clutch engaged)
f. Security of all hardware X
3. Inspect jackstrut and pulley assembly for:

a. Evidence of roughness or looseness X
of upper bearing
b Bond separation of jackstrut X
c. Main rotor drive belt for cracks X

or missing sections
d. Lower pulley for security X
e. Condition of rotor tach drive belts X
f. Looseness of taper pins and condition X

of flex pack
g. Evidence of rough bearings and X

proper operation
h. Cracks or dents in pylon assembly X
(center section)
i. Proper torque on transmission X
pinion nut (175 ft-lbs)
NOTE: Retorque after disassembly
at 25 hours

MM-3-13
#2 Rev. 11/18/88
MAINTENANCE MANUAL
MECHANIC’S
50 1100 1200
G. Tail Cone Assembly
1. Inspect tail cone for:
a. Cracks in tail cone mount fittings X
b. Proper security to pylon X
c. Cracked or damaged bulkhead and doublersl X
d. Legibility of decals and markings X
2. Inspect tail rotor driveshaft for:
a. Rough or worn bearings X
b. Position of rubber inserts X
c. Looseness of taper pins and X

condition of flex pack
d. Security of pillow blocks X
3. Inspect stabilizers for:
a. Damage or cracks X
b. Loose rivets X
c. Security of attachment X
4. Inspect tail rotor guard for:
a. Damage and loose rivets X
b. Security of attachment X
5. Inspect singer tube for:
a. Evidence of loose rivets at X

aft bulkhead
b. Security of mounting X
H. Tail Rotor Gearbox
1. Inspect tail rotor gearbox for:
a. Evidence of leakage at seals X
b. Security and safety of mounting screws X
c. Evidence of cracked or damaged housing X
d. Drain gearbox oil and inspect for:
(1) Presence of metal particles on X

magnetic plug
(2) Security and safety of all plugs X
MM-3-14
MAINTENANCE MANUAL
MECHANIC’S
50 100 200
e. Inspect gearbox controls for:

(1) Worn bushings at pivot points X
(2) Slider assembly for freedom of X

operation and wear
(3) Security and safety of X
control hardware
I. Tail Rotor Assembly
1. Inspect tail rotor assembly for:
a. Cracks, nicks, dents and scratches X
b. Evidence of bond separations X
c. Loose tip rivets X
d. Condition of blade strike tabs X
e. Looseness, roughness or binding X

of teetering bearings
f. Security of teeter bearing end caps X
g. Looseness, roughness or binding X

of pitch change bearing
h. Looseness, binding or wear X
on pitch link rod ends
i. Security and safety of all hardware X
j. Fretting of blade and grip at X

attachment
J. Main Rotor Gearbox
1. Inspect main rotor gearbox for:
a. Presence of metal particles on X

magnetic plug
c. Cleanliness and corrosion X
d. Worn or spalled ring and pinion gears X
e. Cleanliness of sight glass X
f. Security of mounting bolts and plugs X
g. Cracks or dents in pylon assembly X

(gearbox area)
h. Condition of main rotor mast X

MM-3-15
MAINTENANCE MANUAL
MECHANIC’S
50 100 200
K. Main Rotor Assembly
1. Inspect main rotor blades for:
a. Cleanliness and evidence of corrosion X
b. Condition of blade tape, if applicable X
c. Nicks, dents or scratches X
d. Evidence of bondline separations X
e. Condition of trim tabs X
f. Evidence of loose rivets on X

drag link attach fittings
g. Proper security of blades X
2. Inspect main rotor retention and

spindle for:
a. Evidence of ratcheting or binding of X

feathering bearings
b. Proper spring-back of lamiflex~bearings X
c. Evidence of lamiflex bearing X

deterioration
d. Condition of lamiflex nylatron strap X
e. Condition of o-ring leakage X
f. Security of spindle retention nut X
g. Condition of up and down stops X
h. Condition and security of pitch X

change horn
i. Evidence of sheared roll pin at X

hinge pin
j. Evidence of ratcheting or binding of X
flapping bearings
k. Proper preload setting on retention X
assembly in flapping axis
i. Proper security of hinge pin locking X
tang washer
3. Inspect universal block assembly for:
a. Condition of lead/lag stops X
b. Proper security and safety of X

lower nuts

MM-3-16
MAINTENANCE MANUAL
MECHANIC’S
50 100 200
4. Inspect main rotor dampers for:

a. Rod end radial clearance X
.007" maximum allowed
c. Proper fluid level in reservoirs X
d. Condition and security of rod end X

bearings
e. Proper security of attachment points X
f. Proper safety of all hardware X
5. Inspect center hub section for:
a. Evidence of cracks X
b. Fretting at upper and lower X

spline adapters
c. Proper to ue and safety on X
mast nut rs 10 ft-lbs)
6. Inspect cyclic walking beams for:
a. Evidence of cracks in brackets X
b. Proper bearing operation and X

wear at pivot points
c. Condition and security of pitch link X

rod end bearings
d. Security and safety of all hardware X
7. Inspect upper control push rods for:
a. Evidence of loose rivets X
b. Evidence of damage X
L. Swashplate Control System
1. Inspect swashplate assembly for:
a. Looseness of universal pivot points X
b. Looseness of push rod dogleg bearings X
c. Roughness of cyclic bearing 1 x
d. Condition of rod end and fitting on X

push rods at cyclic bearing housing
e. Security and safety of all hardware X
2. Inspect collective guidetube assembly for:

a. Radial wear of DU bushings X
b. Roughness of collective bearing X
~AA Approved: June 28, 1985

MM-3-17
MAINTENANCE MANUAL
MECHANIC’S
NATURE OF INSPECTION FRE ENCY INITIALS
50 1100 1200
c. Evidence of looseness in collective

walking beam at:
(1) Bushings in straps at gearbox X

attachment
(2) Bearings at collective bearing X

housing
d. Security and safety of all hardware X
M. Cabin Section
1. Inspect cabin exterior for:
a. Proper door operation X
b. Cleanliness, cracks or crazing of door X

and cabin plexiglass
c. Obstructedor bent pitot tube X
d: Cracked or broken position light X

lens if applicable
2. Cabin interior
a. Inspect interior of cabin for:
(1) Cleanliness and evidence of X

corrosion
(2) Presence and legibility of decals X
(3) Deterioration of seat cushions, X

carpet, backwall and headliner
(4) Condition and operation of X
safety belts and shoulder harnesses
(5) Fire extinguisher date of last check X
and security
(6) Condition of seat deck and X

collective covers
b. Inspect instrument console for:
(1) Security and damage to all X

instruments
(2) Condition and security of console X

shrouds
(3) Electrical switches for proiper X

operation
(4) Legibility of all placards X

MM-3-18
MAINTENANCE MANUAL
MECHANIC’S
50 1100 1200
3. Inspect cabin flight controls for:

a. Cyclic:
(1) Proper range of travel X
(3) Looseness of rod ends and X

bellcrank bushings
(4) Evidence of loose rivets on X

push rods and bellcranks
(5) Proper security and safety at X
all connections
(6) Lubrication at rod ends and X

bellcrank pivots
b. Collective:
(3) Proper operation of collective X

friction
(4) Evidence of corrosion on X

torque tube
all connections
(6) Lubrication at rod ends and X

bellcrank pivots
c. Throttle Correlator:
!3) Proper operation of throttle X

friction

all connections
(5) Evidence of bent rods X
(6) Lubrication of all pivots X

4. Inspect seat structure for:
a. Cleanliness and evidence of corrosion I X
b. Evidence of loose rivets X
c. Condition of bulkheads X

MM-3-19
MAINTENANCE MANUAL
MECHANIC’S
NATURE OF INSPECTION FKEQUENCY INITIALS
50 1100 200
5. Inspect cabin heating system for:

a. Condition and security of ducting X
b. Obstruction in outlets X
c. Proper operation of valve and cable X
6. Inspect tail rotor controls and cables for:
a. Correct range of travel X
b. Evidence of binding or ratcheting X
Wear at pulleys, fairleads, X

c.
proper alignment, and tension (30/401) 1

d. Looseness of bellcranks at pivot points X
e. Wear of bushings and rod ends on X

push rods
f. Evidence of loose rivets X
g. Security of attachments X
N. Battery Compartment
1. Inspect battery for:
a. Current specific gravity X
b. Proper venting X
c. Evidence of electrolyte spillage X
d. Preservation of surrounding area X
e. Condition of case, cables and hold down X
f. Evidence of corrosion at cable X

connections
O. Electrical
i. Inspect electrical system for:
a. Operation of all exterior lights X
b. Operation of all interior lights X
c. Operation of both trim motors X
d. Operation of console electrical X

instruments
e. Operation of boost pump motor X
f. Operation of all circuit breakers X
FAU Approved: June 28, 1985

MM-3-20
#2Rev. 11/18/88
MAINTENANCE MANUAL
P. LUBRICATION CHECK SHEET
Lubricate the following items as stated. See Section 4 of the

Maintenance Manual for exact service points and approved lubricants.
NO. OF MECHANIC’S
POINTS DESCRIPTION HOURS _
INITIALS
GREASE
Tail Rotor Assembly:

2 Tail rotor feather bearings 50
2 Tail rotor teeter bearings 25
5 Tail rotor driveshaft 50
1 Tail rotor pitch control bearing (hand pack) 100
Main Rotor Drive System:

2 Clutch engagement cable 50
1 Lower jackstrut bearing 50
1 Upper jackstrut bearing (hand pack) 100
2 Idler roller bearings (hand pack) 100
1 Drive belt snubber bearings 50
Main Rotor Assembly:

3 Cyclic walking beam bearings 50
6 Lead/lag bearings 50
9 Flapping bearings 50
6 Feather bearings 50
Swashplate Assembly:
1 Cyclic swashplate bearing 50
Guidetube assembly:
1 Collective guidetube bearing 50
OIL
Engine:
1 Drain and refill add as required (fill can) 50
Overrunning Clutch:
1 Inspect level of oil toil can) 50

MM-3-21
MAINTENANCE MANUAL
NO. OF MECHANIC’S
POINTS DESCRIPTION HOURS INITIALS
Tail Rotor Gearbox:
1 Drain and refill 6 ounces toil can) 100
2 Control yoke pivot points toil can) 50
Main Rotor Gearbox:
1 Drain and refill 51 pints (fill can) 100
Main Rotor Drive System:

3 Cyclic walking beam pivot points toil can) 50
Tail Rotor Pedal Assembly:

4 Pedal pivot bushings toil can) 50
4 Pedal control bellcranks toil can) 100
Cabin Flight Control System:

5 Cyclic control bel7crank pivot points 1 ioo
toil can)
2 Cyclic control stick pivot points toil can) 100
6 Collective control bellcrank pivot points 100

toil can)
MM-3-22
MAINTENANCE MANUAL
Q. Post Inspection Ground Run
i. inspect engine operation for: (1500 rpm idle)

a. Oil pressure
b. Alternator
c. Engine compartment for oil or fuel leakage

d. Magnetos for:
(1) Left
(2) Right
(3) Off
e. Mixture control for idle cut-off operation
2. Inspect rotor engagement for: (1500 rpm idle)

a. Smoothness of operation and positive over-center position
(light)
b. Proper clutch handle stowage
c. Track of belt on idler roller
3. Inspect the following instruments for "green" operation

a. Oil pressure
b. Oil temperature
c. Cylinder head temperature
d. Main gearbox temperature
e. Tach needles married
4. Inspect ground run for: (3050 rpm)

a. Manifold pressure (17.5" to 19")
b. Operation of one way clutch
c. Rotor blades for out of track
d. Magneto check (left right)

e. Proper operation of all instruments
f. Proper operation of "press-to-test" lights

g. Proper operation of 611 avionics

MM-3-23
MAINTENANCE MANUAL
3-3 SPECIAL INSPECTIONS
This section
contains guidelines for performing the requ i red
inspections by qualified maintenance personnel, after experienc-
ing any of the following occurrences: main rotor blade and/or
tail rotor strikes, hard landings, rotor overspeed, engine
overspeed or engine overboost. It should be emphasized that
other parts and/or adjacent componentsnot listed may also be
damaged, dependent on the severity of the incident. Therefore,
this guide should not be considered absolute and should be
expanded as required by the inspecting maintenance personnel, as
the occurrence may require, per appropriate sections of this
manual.
B. All Aluminum and Steel Components
NOTE: All aluminum and steel components must be inspected by

the following processes:
1. All aluminum machined or cast components are to be inspected

by Zyglo.
2. All aluminum sheetmetal components are to be inspected for

deformation.
3. All steel components are to be insected by Magnaflux.
All parts and components that may be affected by the specific

occurrence are to be given a complete inspection for possible
damage.
C. Main Rotor Blade Strike and/or Sudden Stoppage
NOTE: The following inspections are mandatory:
1. Classification of blade strike (Minor)
a. Blade damage does not exceed damage as defined in

Section 4-7, and shows no visible kinks, ripples in the
skin or trailing edge.
Action Required: Repair blade per Section 4-2.

MM-3-24
MAINTENANCE MANUAL
b. Blade damage exceeds limits of Section 4-7, but has not

contacted airframe or other rigid body.
Action Required: Check main rotor shaft TIR per

pa rara ph TElJ f this section. Inspect tail rotor
driveshaft taper pins and flex packs for damage per
Section 10-6.
NOTE: If taper pins flex

packs do not meet
or
inspection criteria,
proceed to paragraph2
and follow all noted requirements. The main
rotor blades must be replaced or returned to
Enstrom Helicopter Corporation for inspection
and/or repair.
2. Classification, main rotor blade strike and/or sudden

stoppage (Major). Obvious blade damage.
a. Main Rotor Gearbox
The main rotor gearbox must be returned to Enstrom

Helicopter Corporation for complete disassembly and
inspection. This shall include the upper pulley,
overrunning clutch and tail rotor driveshaft couplings.
b. Main Rotor Hub
The main rotor hub must be returned to Enstrom

Helicopter Corporation for complete disassembly and
inspection. This shall include the damper assemblies.
c. Flight Control System and Components
1 All flight control system push-pull control rods

must be inspected for sheared rivets in fittings
and/or damaged rod end bearings. Inspect closely
the three main rotor control rods from
push-pull
the swashplate to the hub for sheared rivets or
other damage. Inspect the cyclic and collective
torque tubes, bellcranks and fittings for sheared
rivets or damage.
NOTE: If rivets are suspect they should be

removed from each fitting and replaced.
2 Inspect- the lower swashplate for warped or cracked

casting and for bent or damaged guidetubes in the
upper swashplate. Inspect tie rod and universal
rod for straightness. Inspect bolt holes for
elongation.
3 Replace all tail rotor driveshaft taper pins.

MM-3-25
MAINTENANCE MANUAL
4 Inspect the tail rotor driveshaft at the fore and

aft for complete or partial failure at the
ends
taper pin holes.
NOTE: The aluminum plugs inside the shaft at

either end could be holding the shaft
together, even if a failure has
occurred, and transmi t torque to the
tail rotor briefly.
5 Magnaflux the tail rotor driveshaft.
6 Inspect the pylon structure at the gearbox mount-

ing areas for broken or bent tubes. Check
trueness of the four gearbox attachment points.
7 Inspect all blades for distortion, especially

along the leaning and trailing edge, for dents,
scratches and bond line cracks or separations.
NOTE: Damaged main rotor blades must be

replaced or returned to Enstrom
Helicopter Corporation for inspection
and evaluation.
8 Inspect all components of the dri ve sys tem,

including disassembly of the overcenter belt
tension assembly, for cracks and distortion of
parts.
D. Tail Rotor Strikes
1. Tail rotor strike (minor) defined as strike tab missing

but no physical damage to tail rotor blade.
Action Required: Inspect aft coupling taper pins and flex

packs for distortion per Section 10-6. if no damage is
noted, make log book entry and advise Enstrom. If damage to
taper pins is noted proceed to paragraph 2 of this section
and follow all noted requirements.
2. Tail rotor strike (major) defined as obvious p hy s i ca 1

damage to tail rotor blade.
NOTE: For tail rotor strikes involving the deformation

of the strike tabs, and/or other physical damage,
the following inspections are mandatory
a. The tail rotor gearbox, tail

assembly and
rotor
controls must be returned
Enstromto Helicopter
Corporation for complete disassembly and inspection.
This shall include the tail rotor driveshaft couplings.

MM-3-26
MAINTENANCE MANUAL
b. Replace all tail rotor driveshaft taper pins.
c. Inspect the tail rotor driveshaft at the fore and aft

ends for complete or partial failure at the taper pin
holes. (See "NOTE," Item 4 above.)
d. Inspect hangar bearing housings and attachments.
e. Inspect tail rotor cables and pulley attachments.
f. Inspect tail rotor pedal push-pull rods, tie rod and

bellcranks under the floor panels.
E. Hard Landing
In the event of a hard landing which may or may not be associated

with a main or tail rotor strike, the following inspections must
be conducted.
1. Inspect the
forward and aft cross tubes for a bend or bow.
Bows greaterthan 1/2 inch should be mechanically
straightened or the cross tube replaced. Bows of 1/2 inch
or less may be accommodated by inverting the cross tube with
the bow up.
2. Inspect the landing gear leg assemblies for any distortion

or deformation, all fit~ings and bolt holes for elongation,
all welds and gussets for cracks, especially the shoe
weldment at the lower skid tube attach point.
NO’TE: The landing gear leg assemblies which are not

kinked may be mechanically straightened.
3. Inspect the skid tubes for straightness. Gentle bows or

bends ’may be mechani cally straightened. Inspect all
hardware attachment holes for elongation and/or tears.
4. Inspect the oleo ass emb lies for leakage and freedom of
movement. Visual damage warrants return to Enstrom for
complete inspection and overhaul.
5. Inspect the attach points at pylon, pylon to

landing gear
gearbox, pylon to cabin and pylon to tail cone for any
deformation or hardware failures. The upper cabin mount
fittings should be dye checked for cracks.
6. The main rotor shaft TIR should be checked.
NOTE: This can be done on the ship with the blades

removed. Maximum TIR is .012 inch. TIR in excess
of .012 should be brought to the attention of
Enstrom Customer Service for disposition.

MM-3-27
MAINTENANCE MANUAL
7. The main rotor gearbox mounts should be examined for any

distortion. Check mount bolt torque. Any loss of torque
warrants disassembly of attaching hardware and magnaflux or
replacement of hardware.
8. The transmission lugs should be inspected with dye penetrant

prior to returning to service.
F. Rotor Overspeed
The maximum permissible rotor rpm is 385. Inadvertent maneuvers

at altitude or heavy weights can result in rotor overspeed.
Overspeeds above 385 to 400 rpm require the following inspection.
1. Remove the main rotor blades and inspect the flapping axis
for proper drag, notchiness, and freedom of movement, ref.
Section 5.
2. Inspect the main rotor blade retention for any deformation.
3. Remove the main rotor blade grips, inspect the lamiflex

bearings for deformation, proper thickness, delamination or
extruded brass. Inspect the teflon liner for any damage or
unusual wear, ref. Section 9.
4. Inspect the main rotor spindles for pulled or distorted

threads.
CAUTION: If any mechanical deficiencies are noted from

Items 2, 3 and 4, or rotor rpm exceeded 400 rpm,
the complete rotor head must be returned to the
factory for inspection and overhaul.
G. Engine Overspeed or Overboost
Operators are cautioned that any engine operation which exceeds

the published maximum red line for rpm and/or MAP will require
action as defined by Lycoming Service Bulletin Number 369~ or
later.

MM-3-28
MAINTENANCE MANUAL
3-4 AIRWORTHINESS LIMITATIONS MANDATORY SERVICE LIFE LIMITS
The following items are the retirement lives in hours established

by Enstrom Helicopter Corporation.
B. Part Number, Item and Hours
1. 28-13104-1 Main rotor shaft 76,250 hrs
2. 28-14100 Main rotor blade 95,000 hrs
3. 28-14207-1 Cyclic walking beams 76,500 hrs
4. 28-14282-11 Main rotor spindle 19,000 hrs
5. 28-14283-1 Main rotor drag link 13,750 hrs
6. 28-150002-1 Tail rotor blade 3,100 hrs
7. 28-150044-1 Tail rotor blade grip 6,200 hrs
8. 28-16119-1 Lower swashplate 17,700 hrs

housing
9. 28-13609-1 Tail rotor 1,200 hrs

driveshaft coupling
10. A005-1991 Tail rotor driveshaft 1,200 hrs

flex pack
11. 202577 Idler pulley bearing 600 hrs
12. 5201SBKZZ-ABEC Lower swashplate 1,200 hrs

bearing
13. Z993L13XR3B Upp~r swashplate 1,200 hrs

bearing
*14. 01-691-08 Damper rod end bearing 500 hrs
*15. MXK3R-8R Damper rod end bearing 500 hrs
*16. MSSKR88-2OBAC Damper rod end bearing 500 hrs
*17. ART-8E Damper rod end bearing 500 hrs
18. 103574-00 Turbocharger 2,000 hrs

Model 3BT5EE1032
*500 hours or .007 inch radial clearance, whichever occurs first

MM-3-29
MAINTENANCE MANUAL
3-5 MANDATORY OVERHAUL CYCLES
The following are component overhaul cycles established by their

respective manufacturers:
1. HIO-360-F1AD Engine 1,500 hrs
2. 3BT5EE10J2 Turbocharger 1,000 hrs
3. 28-13170 Main rotor transmission 1,200 hrs
4. 28-13525 Tail rotor transmission 1,200 hrs
5. 28-13401-2 Overrunning Clutch 2,400 hrs
All other components are overhauled "on condition" or as called

out in manufacturer’s publications.

MM-3-3O
SECTION
SERVICINGAN D
GENERAL
MAINTENANCE
MAINTENANCE MANUAL
SECTION 4
SERVICING AND GENERAL BIAINTENANCE
4-1 LUBRICATION
A. GENERAL INFORMATION
This section contains all the items requiring lubrication or
servicing the types of lubricants approved, as well as the

methods, ~requency and number of points requiring service.
NOTE: Refer to the latest revision of TEXTRON Lycoming

Service Instruction Letters for updating of
authorized fuels and lubricants.
B. FUELSAND LUBRICANTS
FUEL TAWKS
i. 100/130 Aviation Grade MIL-G-5572 Phillips 66 Phillips Pet.
2. 100LL Aviation Grade Shell Shell Oil
ENGINE OIL
3. Mineral MIL-L-6082 Aeroshell´• Shell Oil
4. Ashless Dispersant MIL-L-22851 Aeroshell W Shell Oil
Phillips X/C Phillips Pet.
Ffultiviscosity
FLIGHT CONTROL LUBRICANTS

5.´• Grease MIL-G-25537 Aeroshell 14 Shell Oil
6. Grease MIL-G-25760 Aeroshell 16 Shell Oil
7. Grease MIL-G-81322 Aeroshell 22 Shell Oil
8. Grease MII;-Q-8i322 Mobil 28 Mobil Oil
9. Grease MIL-G-18709 ANDOC "B" Exxon
10. Grease Marfac O, Texaco
00, or 1
11. Grease MIL-G-23827 Mobil 22 Mobil Oil
ENCO Beacon ENCO Oil
No. 325
EXXON Exxon
No. 5114EP
LANDING GEAR OLEOS

12. Oil MIL-H-5606 TL 5874 Texaco
XSL 7828 Shell Oil
Aero HFB ~obil Oil
"PO" 4226 American Oil
6r Supply
Revision r~3, 3/94 ~DI-I-1

MAINTENANCE MANUAL
MAIN ROTOR DAMPERS

13. Oil L-45 Silicone Union Carbide
Oil
MAIN ROTOR TRANSMISSION

14. Oil MIL-L-2105 Mobilube Mobil Oil
No. HD 90
Shell Splrex Shell Oil
HD 90
Shell EP 90 Shell Oil
Exxon Gear Exxon
Oil GX 90
Pennzoil Pennzoil
No. 4096
Mobil 1 Mobil Oil
OVERRUNNING CLUTCH
15. Oil MIL-L-7808 Exxon No. 15 Exxon
16. Oil MIL-L-23699 Turbo Oil .Exxon
Aeroshell Shell Oil
Turbine
Oil 500
No. 2",80
No. 520 ATF Mobil Oil
Fluid
No. B-10103 ENCO Oil
TACH DRIVE CABLES

17. Grease No. 2701-109 S.S. White Co~
Piscataway, NJ
TAIL ROTOR GEARBOX

18. Oil HIL-L-6082 SAE 10W Shell Oil
SAE 10W Texaco
19. Oil MILLL-ii851 SAE 20W-50 Phillips Pet.
20. Oil ~IL-L-2105 Mobil 1 Mobil Oil
MISCELLANEOUS
21. Anti-Seize Compound .GO-JO NO-LOK~ GO-30 Indust.
Akron, Ohio
22. Solvent MEK or Acetone
MAINTENANCE MANUAL
LUBRICATION AND SERVICING CHART
FREQUENCY METHOD TYPE LUBE VIEWS

NUMBER REQUIRED
zl I I I OF ITEM NO.
COMPONENT CAPACITY C~ Z U SERVICING
cr rr -I REFER TO REFER TO
O Q W U d POINTS GENERAL
O O I v, u ACCEPTABLE LUBE
-~I I I o LOCATION
OWWJ~Z FUELS AND CHECK
0’0’ h’ "’4
U.S. LITER or~ LUBRICANTS SHEET
Fuel Tanks (Servicing) 40 151.4 X I I I I I I 1 2 places 1,2 A 1

gals
Fuel Tank Sump Drain x I I I I I I I I 1 2 places A 2
tngine Oil Filler I I I I I I I I I I I I I I A 3
Engine Oil Dipstick 8 qts I I I I Ix x 1 place 3,4 or 5 A 4
Main Fuel Screen I I I I Ix I I I I I I I 1 place I I B 5
Engine Fuel Nozzles I I I I I Ix I I I I I 1 4 places 22 N/A N/A
Engine Oil Sump Drain I 1 I I IX I I I I I I 1 place 3,4 or 5 B 6
Engine Oil Filter I i I I Ix I 1 I I I I I 1 place I I C 7
Engine Air Filter I I I Ix I I I I I I 1 place D 8
Main Engine Oil Cooler I I I I (X I I I I I 1 place D 9
Aux. Engine Oil Cooler I I I I IX I I I I I I 1 place D 10
Main Fuel Filter Drain x I I I I I I I I I 1 place ~D 11
Main Rotor Gearbox 5.5 2.6 1 I IX I I I I I I 1 place E 12

Drain Magnetic Plug pts
MM-4-3
MAINTENANCE MANUAL

NUMBER REQUIRED
ZI I I I OF ITEM NO.
COMPONENT CAPACITY O SERVICING
C~ Z
4 z 4 REFER TO REFER TO
4 W U
POINTS GENERAL
O
r v, o
ACCEPTABLE LUBE
O O
Q o LOCATION
_J 11 u
z FUELS AND CHECK
gww
U.S. ~IIER
O O
~UBRICANTS SHEET
acu
Main Rotor Gearbox x I I .I- I I I I I 1 place E 13

Sight Glass Level
Main Rotor Gearbox I I I Ix x 1 place 13 F 14
Main Rotor Gearbox I I I I~ r Ix I I I Ix 1 place 15 G 15

Overrunning Clutch
Upper Jackstrut Bearing I I I I I Ix x´• X 1 place 10 G 16
Lower Jackstrut Bearing I I I I IX X I I I I 1 place 6,7,8& 9 H 17
Drive Belt Idler I I I Ix I I I I Ix 2 places 12 I 18

Roller Bearings
Drive Belt Idler Straps I I I I I Ix I I I Ix 2 places 8 19 I 19
Drive Belt Snubber I I I I Ix X I I I 1 place

Bearings
Drive Belt Clutch i I I I Ix X 2 places 6,7,8 9 K 21
Rotor Tach Drive I I I I IX X I I I 1 place 6,7,8 9 L 22

Bearings
XLater models are fitted with a grease fitting for lubricating
MM-4-4
MAINTENANCE MANUAL
LUBRICATION END SERVICING CHART
METHOD TYPE LUBE VIEWS

FREQUENCY
NUMBER REQUIRED
ZI I I OF ITEM NO.
Y
COMPONENT CAPACITY SERVICING
Z O
4 REFER TO REFER TO
4 Z
POINTS GENERAL
ACCEPTABLE LUBE
O O I V) U
LOCATION
~J IrlI u4J
-1 -I
o
FUELS AND CHECK
o w w
4
LITER
4 L"’O’O aid
LUBRICANTS SHEET
U.S. C3CULD ~n(3LLOI
Tail Rotor Driveshaft I I xl I -I I x I I I 1 5 places 6,7,8 9 M 23
Bearings
Tai 1 Rotor Gearbox I I I I x i I I I I I 1 place N 24

Drain Magnetic Plug
Tail Rotor Gearbox 5 oz .15 1 I I Xt I I X I I 1 place 18 19 N 25

Filler Plug
Tail Rotor Gearbox xl I N 26
Sight Glass
Tail Rotor Control I I i I I xl I I I x 4 places 8 19 N 27

Pivot Points
6,7,8 9 N 28
Tail Rotor Grip I I I I Xt I I X I I I 1 2 places
Feather Bearings
Tail Rotor Teeter I I I xl I I I x I I I 1 2 places 10 N 29
Bearings
Tail Rotor Pitch I I I x\ I I x 1 place 10 N 30

Control Bearing
Col lecti ve Gui detube; I I I I x X I I I I 1 place 6,7,8 9 O 31

Bearing
~MM-4-5
MAINTENANCE MANUAL
METHOD TYPE LUBE VIEWS

FREQUENCY
NUMBER REQUIRED
ZI I I I OF ITEM NO.
3
CAPACITY SERVICING REFER TO
COMPONENT cL~ Z
REFER TO
Z 4
POINTS GENERAL
a w u 4
ACCEPTABLE LUBE
I
4" LOCATION
U -1 a
FUELS AND CI1ECK
a w w I1I-1 Z
4 QO or 4
LUBRI CANT S SI1EET
U.S. LITER a c~ Lnl~lv, c~ LL. a I
X x I I I I 1 place i 6,7,8 9 O 32
Cyclic Swashplate I I I I I
Bearing
place 8 19 O 33
Cyclic Push Rod I I I I I XI I I I I X 1
Oilite Bushing
X X I I I 1 3 places 6,7, 8 9 P 34
Cyclic Walking Beam I I I I I
Pivot Point
3 places 8 .19 P 35
Cyclic Push Rod I I I I I XI I I I IX
Spacer Bushing
Main Rotor Lead/Lag I I I I I x X I 1 3 p~aces 6,7,8 9 P 1 36

Bearings
Main Rotor Grip X X I I I 1 6 places 6 recommended P 37

Feather Bearings alt: 7,8 9
Main Rotor Damper Asl relauilredl I I I X 6 places 16 P 38

Service Plugs
I I I I I x X I I 1 3 places 6,7’,8 9 q 39
Main Rotor Lead/Lag
Bearings
Main Rotor Flapping I I I I I x X I I I I 9;places 6,7,8 9 q 1: 40
if not grease
When lubricating main rotor grip feathering bearinQs be sure purge screw is removed,
may be forced past the spindle end seal and contaminate the Lamiflex bearing.
#2 Rev._11/18/88
MM-4-6
MAINTENANCE MANUAL

NUMBER REQUIRED
zl I I I OF I I ITEM NO.
3’ 1
COMPONENT CAPACITY Cr C~ Z O SERVICING
4 Z REFER TO REFER TO
O W U 4: POINTS GENERAL
O O I (J) U ACCEPTABLE LUBE
LOCATION
OW
O
g -l_lZ
o
FUELS AND CHECK
4~1LO 0’0
U.S. LITER C3~lm V)C3LLOI LUBRICANTS SHEET
Landing Gear Oleos Asl relau ilredl I I X 4 places 17 R 41

Servicing Point
Ground Handl i ng I I I I I x I I r I x 2 places 10 R 42

Wheel Bearings
Battery Servicing I I I Ixl I I I I I All cells S 43
Tail Rotor Control I I I I I I X I I I I X 4 places 8 19 T 44

Cabin I I I I I I I I i I I 1 I I I 45
Cabin Flight Control I I I I x I I I I x 11 places 8 19 U 46

Bell Crank Bushings
MM-4-7
MAINTENANCE MANUAL
Lubrication And Servicing Check List
NOTE: Numbers listed below identify lubricating and servicing points.
VIEW "A" """~i
i. Fuel Tanks
(2 places)
2. Fuel Tank Sump Drain ~3

(2 places)
3. Engine Oil Filler
4. Ehgine Oil Dipstick
ORIGINAL i.
as Received By
ATP
6) (5
´•ii~
VIEW "B"
5. Main Fuel Filter

(P/N G-450-4 or
i uti-~´• s
35-199-908)
6. Engine Oil Sump Drain ~s
MM-4-8
MAINTENANCE MANUAL
7
;T*il
VIEW "C"
7. Engine Oil Filter

(P/N CH48103):Ij!
ii:eis;;le
i. ´•li!
Sfiii:’
´•r.´•,´•
OBIGINAL
As eeceived By
ATP
VIEW "D"
8. Engine Air Filter 10. Aux. Engine Oil Cooler
(P/N 6487923)
9. Engine Main Oil Cooler
11. Main Fuel Filter Drain
9) (8) (~1) (~o
MM-4-9
MAINTENANCE MANUAL
12) (13
VIEW "E"
12. Main Rotor Gearbox Drain and

Magnetic Particle Plug I
13. Main Rotor Gearbox Oil Level
Sight Gauge
Iliil"ii
ORIGINAL
As Received BY
ATP
VIEW "F"
14. Main Rotor Gearbox Filler

and Screen
MM-4-10
MAINTENANCE MANUAL
16) (15
VIEW "G"
15. Main Rotor Gearbox

Overrunning Clutch
Drain and Filler Plugs
Upper Jackstrut Bearing

Grease Fitting
ORIGINAL
As Received By
AT’P
17) (17
VIEW "H"
´•tirlie:: ´•´•"I~´•
17. Lower J~ackstrut Bearing
Grease Fitting and
i;i
Purge Plug ;i
I´• .R
MM-4-ll
MAINTENANCE MANUAL
VIEW "I"
18. Idler Roller Bearings

(2 places)
19. Idler Strap Bushings

(2 places)
ORIGINAL
As Received By
AVP
VIEW "J"
20. Drive Belt Snubber

Roller Bearings
KM-4-12
MAINTENANCE MANUAL
VIEW "K"
21. Drive Belt Clutch

Engagment Cable
Grease Fitting
(2 places)
(Aft
ORIGINAL
as Received By
ATP ~2i
n I;~
(Fouward)
MM-4-~3
MAINTENANCE MANUAL
VIEW "L"
22. Rotor Tach Drive

22
Grease Fitting
ORIGINAL
As Received By
ATP
VIEW "M"
23. Tail Rotor Drive

Shaft Bearings
(5 places) I I
23
MM-4-14
MAINTENANCE MANUAL
29) (30) (25) (27) (26
VIEW "N"
24. Tail Rotor Gearbox Drain

and Magnetic Particle Plug
25. Tail Rotor Gearbox Filler Plug
26. Tail Rotor Gearbox Sight Gauge
27. Tail Rotor Control Yoke Pivot

Points (4 places)
28. Tail Rotor Feathering

Bearings (2 places)
:i´•i 1
29. Tail Rotor Teetering

Bearings (2 places)
30. Tail Rotor Pitch change

Bearing. (28) ~24
OR161NAC
As Received By
a’TP
VIEW "O"
31. Collective Guidetube Bearing

Grease FitfinR
32. Cyclic Swashplate Bearing

Grease Fitting
33. Cyclic Push Rod Oilite

Bushings and Spacer
33) (32
MM-4-15
EIl\INTENANCE MANUAL
VIEW "P"
38) (35) (34) (36) (37
34. Cyclic Walking Beam
Grease Fitting (3 places)
35. Cyclic Walking Beam

Push Rod Bushing
(3 places)
36. Main Rotor Lead/Lag

Bearings 3 places)
37. Main Rotor Feathering

Bearings (6 places)
38. Main Rotor Damper Service
Plugs (2 places)
OWIGINAL
~.ce
~rW 8eceived By
A-TP
i´•:~
VIEW "Q"
39. Main Rotor Lead/Lag

Bearings (3 places)
40. Main Rotor Flapping

Bearings (9 places)
39) (40
MM-4-16
MAINTENANCE MANUAL
VIEW "R"
41. Landing Gear Oleo

Service Point
42. Ground Handling

Wheel Bearing
42
(Z~RIGI MAL
Ae Received B~
ATP
43
VIEW "S"
43. Battery Servicing_

Points (6 points)
MM-4-17
MAINTENANCE MANUAL
44) (45
VIEW "T"
44. Tail Rotor Pedals

Lubricating Points
(4 places)
45. Tail Rotor Control

Bushings (4 places)
$RIGINAL
Rgceived B11
´•AfP
VIEW "U"
46. Cabin Flight Control

Bellcrank Pivot
Bushings (11 places)
MM-4-18
MAINTENANCE MANUAL
4-2 SERVICING
Servicing of the Enstrom helicopter is normally accomplished at

specified hourly intervals. Operators should take into consideration
environmental conditions and determine whether more frequent servicing
intervals-are necessary. See the appropriate charts and diagrams in
Section 4-1 for service intervals, locations, and approved fuels,
oils, and lubricants.
B. Engine Oil System Servicing
NOTE: The quantity is checked by using the dipstick located behind

the panel above the left hand engine door. Oil is added
through the filler located next to the dipstick. Normal
operating oil level is between 6 and 8 quarts; add oil as
required.
(12 Check engine oil level prior to each flight. Oil change
intervals is 50 hours. The oil filter is changed every 50 hours.
Refer to latest revision of Avco Lycoming Service Letter
No. L-157 for requirements of extending intervals between oil
changes.
(a) Drain oil from hot engine.
(b) Disconnect hoses from both oil coolers and allow to drain.
(c) After removal, open and inspect oil filter element.
(2) Filling engine oil system: Refer to Fuel and Oil Index for
approved oils. To fill oil system, add oil at filler until
dipstick indicates operating level, between 6 and 8 quarts.
NOTE: Total oil capacity is 10 quartsincluding lines, filter

and coolers. Consumable oil capacity is 8 quarts as
indicated on dipstick.
(3) Ground engine after servicing.

run Check for leaks, recheck
dipstick level, service as required.
C. Main Rotor Gearbox Servicing
NOTE: The main rotor gearbox has a self-contained oil supply. The
oil level should be checked prior to the first flight of the
day. The oil change interval is 100 hours. The oil level
is visually checked through a sight gauge located at the aft
right side of the gearbox housing and is viewed from a panel
in the baggage box. The normal operating oil level is
6 pints and nill show mid-way in the sight gauge with the
gearbox nearly level (ground handling wheels down). Minimum
operating oil level is 4 pints.
MM-4-19
MAINTENANCE MANUAL
(1) The gearbox is fitted with a magnetic-type

plug located on
drain
mounting O
magnetic plug may be periodically checked for possible metal
contamination using a VOM, unless equipped with chip detectors.
(2) Draining main gearbox: Place a sheet metal trough under gearbox,
remove magnetic drain plug and allow to completely drain. Check
drain plug for metal chips, clean and reinstall. Re-safety.
NOTE: There will be approximately f pint of residual oil left

in gearbox after draining.
(3) Filling main gearbox: Open filler cap, remove and check screen
from filler neck for cleanliness. Replace screen and service
with 5.5 pints of gearbox oil. Refer to Fuels and Lubrication
list for approved oils.
D. Tail Rotor Gearbox Servicing
The self-contained oil supply in the tail rotor gearbox is visually

checked through the sight gauge located on the aft side of the gearbox
housing. The oil level should be checked prior to the first flight of
the day. The proper operating quantity is between 4 and 5 fluid
ounces with normal sight gauge levels full in window, helicopter level
(wheels down). Servicing consists of maintaining proper oil level.
(1) The tail rotor gearbox is fitted with a magnetic drain plug
located on the lower surface of the housing. The magnetic plug
may be periodically checked for possible metal contamination
using a conventional VOM.
(2) Draining tail rotor gearbox: Remove magnetic drain plug and
allow oil to completely drain. Check magnetic plug for metal
chips, clean and reinstall. Re-safety.
(3) Filling tail rotor gearbox: Remove filler plug located directly
above the sight gauge. Using suitable filler can, add a measured
5 fluid ounces of oil or fill level to top of sight gauge.
Reins tall fi lier plug. Re-safety. Refer to Fuels and
Lubrication list for approved oils.
NOTE: Check condition of seals and gas kets, repl ace as
necessary.
E. Dampers Servicing and Bleeding Procedures
NOTE: Dampers may be serviced on or off the aircraft.
(1) Remove top reservoir plugs (2 places).
(2) Fill reservoir ports with L-45 silicone oil.
MM-4-20
MAINTENANCE MANUAL
(3) Replace reservoir plugs.
(4) Cycle damper slowly, end to end, a minimum of four times.
NOTE: (a) Dampers on the aircraft are cycled by slow fore and
aft movement of the rotor blades.
(b) Cycling dampers off the aircraft can be done in the

T-O051 (special tool) damper cycling fixture.
(5) Remove top reservoir plugs and check fluid level.
NOTE: Full fluid level, with no air bubbles, indicates the

damper is serv i ced. If fluid level is 1 ow, or air
bubbles appear, repeat steps 1 through 4.
(6) Install reservoir plugs and safety wire with .032 safety wire.
F. Oleo Struts Servicing
(1) General Information
There three methods of servicing the oleo assemblies.

are Oleo
pressure is 400 psi and it is important that this pressure is
maintained. The use of nitrogen is recommended for servicing, as
it has no moisture content.
(2) Oleo Extension Check
CAUTION: Oleo pressure must be maintained for proper extension to

prevent the oleo struts from bottoming out when the
helicopter is run up on the ground. Lack of proper
extension can cause vibration and possible ground
resonance.
NOTE: Oleo extension check is mandatory on all preflight

inspections.
(a) Rock the helicopter to distribute the weight evenly between

the struts.
(b) Check the chrome piston extension from top of brass retainer
to tape line. Correct extension is 3/4" to 1 3/4"
(3) Oleo Strut Servicing Methods
Method 1
(a) Remove oleo struts from aircraft.
MM-4-21
MAINTENANCE MANUAL
(b) Connect nitrogen pressure line to oleo valve. Set nitrogen

pressure valve to 400 psi and slowly open oleo valve. Allow
oleo to fill for approximately 10 seconds bringing o7eo
pressure to 400 psi. Close oleo valve first, then nitrogen
tank valve, and remove pressure line.
NOTE: Nitrogen will bleed out from line when disconnected.
(c) Reinstall oleo struts on aircraft. See Section 8-7, Landing

Gear, for installation procedures.
Method 2
(a) Sling load the aircraft to remove all weight from the oleo
struts.
NOTE: Proper installation of the sling can be noted in

Section 9-2, Main Rotor Hub Removal.
(b) Without removing the oleos from the aircraft, pressurize

them to 400 psi as described in Method i.
Method 3
NOTE: If removal of the oleos or the use of a sling hoist is

not possible, the oleos can be pressurized with the
weight of the aircraft on them. This method is not as
accurate as the previous methods, and should only be
used if Methods 1 and 2 cannot be completed.
(a) Pressurize the aft oleos first as follows:
1 Set the nitrogen tank valve pressure to 1000 Ibs.

Connect pressure line to oleo valve.
2 Have another person lift up on the tail cone stinger

tube. Slowly open the oleo valve until approximately
1 inch of chrome piston is extended. Repeat on opposite
aft oleo.
3 Rock the aircraft several times and re-check oleo piston

extension. Repeat step 2 until aft oleos have equal
extension falling in the 5j4" to 1 3/4" range.
4 Pressurize the forward oleos until they have an equal

piston extension as the aft o’leos. Rock aircraft and
re-check. Bleed or add pressure as required.
NOTE: The forward oleo struts pressurize more rapidly than

the aft oleos; therefore, open oleo valves slowly to
prevent excessive pressure.
MM-4-22
MAINTENANCE MANUAL
G. Battery Servicing
The battery is located on the right hand side of the seat deck and is
accessible by removing the seat cushion and panel in the fiberglass
seat deck.
(2) Checking electrolyte level
(a) Unscrew filler caps at top of battery.

(b) Visually inspect electrolyte level in all cells. Maintain
electrolyte level above plates at bottom of each cell.
(c) Add distilled water as required, and recheck electrolyte

level.
(d) Install filler caps.
(3) Hydrometer test
(a) Electrolyte level low, below top of plates.

1 Add distilled water to bring electrolyte to the proper
level.
2 Apply charge of approximately 15 amperes for 10 minutes.
3 Hydrometer readings which vary beyond 30 points (from

cell to cell) indicate a failing battery which should be
replaced.
(b) All cells show only a slight variation in gravities (within
30 points).
1 Apply a charge of approximately 10 amperes for
30 minutes.
2 Record hydrometer readings each cell. A slight or no

increase in hydrometer readings indicates a sulfated
battery which may be brought back to serviceable condi-
tion by a slow charge of 3 to 4 amperes for 48 to
72 hours. After this charge period, cells should read
at least 1.250 corrected gravity and have clear
electrolyte; if not, the battery is not serviceable. If
the variation in hydrometer readings is more than
30 points for any cell, the battery is defective
replace the battery.
WARNING: Batteries produce explosive gases; keep

sparks, flames, cigarettes away. Ventilate
when charging or using in enclosed space.
This battery contains SULFURIC ACID which
causes severe burns.
NOTE: Capacity test such as high rate discharge

testers arerecommended
not for aircraft
batteries and should not be performed.
MM-4-23
MAINTENANCE MANUAL
State of Charge Chart
Specific Gravity State of Charge

1.265 100~
1.225 75"/0
1.190 50%
1.155 2541
1.120 discharged
(4) Cleaning battery electrolyte spillage
NOTE: Flight maneuvers within the maximum allowable attitudes

will not electrolyte spillage. If the battery and
cause
helicopter electrical system are properly maintained,

there should be no leakage or electrolyte damage to the
structure.
(a) Mix one part baking soda to three parts water.
CAUTION: Do not allow soda solution to enter battery cells.
(b) Using mixed soda solution, thoroughly flush the affected

areas.
(c) Rinse affected areas with clear water and wipe dry with
clean cloth.
H. Air Induction System Filter Change
The air filter is located on the right hand side of the engine com-
partment. Access is obtained through the right side engine panel.
(1) Rotate the four screws securing air box housing cover and remove
cover.
(2) Remove filter retainer by disconnecting center fastener. Remove

filter.
(3) Using a soft cloth, remove all foreign matter from inside of air
box and cover.
(4) Visually inspect air box, cover, and bypass air doors.
(5) Install new filter in air box and secure in place with filter
retainer.
NOTE: Position the filter retainer with the auxiliary bypass

door in the aft position.
(6) Install air box cover and secure in position.
NOTE: Check condition of the foam rubber around air inlet of

air box cover. Replace if torn or damaged.
MM-4-24
MAINTENANCE MANUAL
I. Overrunning Clutch Servicing
CAUTION: Before servicing, determine the type of oil previously used.

If unable to determine, it is recommended that the clutch be
drained, purged with solvent, and then serviced per
instructions. Clutches leaving the factory have been
serviced with Aeroshell 500 turbine oil. See lubrication
chart for brand names of other approved oil.
(1) Servicing procedure
(a) Rotate clutch until two bolts are in a horizontal position

and third bolt is above.
(b) Remove top bolt and one side bolt. If clutch is properly
serviced, oil will seep from the side hole.
(c) Add oil using a spring type oiler through the top hole until
a positive stream of oil comes from side hole.
NOTE: Because of location of the drilled oil passage, it

is possible for the sprags to partially block the
hole so that the clutch will take oil very slowly.
(d) Rotate hole slightly above horizontal position and refill.

Install bolts in filler holes.
(e) Rotate clutch and re-check level.
4-3 GROUND HANDLING
A. Wheels Servicing
NOTE: Ground handling wheels require hand packing the bearings as

determined by operating conditions.
(1) Remove and disassemble wheel and axle assembly. See procedures
in Section 8-9, Structures.
CAUTION: When raising or lowering the ground handling wheels on

the aircraft, approximately 135 Ibs of force is exerted
through the wheel bar handle. Keep the wheel bar slot
aligned on the flats of the axle and apply a constant
pressure to the handle when releasing the retaining pin
and rotating the wheel bar. Keep feet from under skid
tubes, stay outside of skid, and do not straddle.
(3) Inflate tire pressure to 75 psi.
CAUTION: Secure wheel and tireassembly on axle before inflating

tire to prevent possible separation of wheel halves.
(4) Install wheel assembly on aircraft. See Section 8-9, Structures,

for installation procedures.
MM-4-25
MAINTENANCE MANUAL
B. Tie Down Weather Protection
(1) Install protective hub cover over main rotor hub assembly.
(2) Rotate main rotor hub until main rotor blade is centered
one
directly over tailcone with tail

rotor assembly horizontal.
Install main rotor blade tie down sleeve on tip of blade and
secure blade to stinger tube at aft end of tailcone using a rope
or nylon cord.
NOTE: When securing main rotor blade, do not pull down beyond
the normal droop stop position.
(3) Install protective cover on tail rotor assembly.
NOTE: Protective covers for main rotor hub and tail rotor
assembly must be installed daily if helicopter is not
stored in a hangar.
4-4 CLEANING
A. Washing Waxing Exterior
The exterior of the helicopter is painted with a high quality paint.

Proper maintenance of this finish will provide corrosion protection as
well as an attractive finish.
(1) Wash exterior as follows:
(a) Check security of all doors and access panels before

starting washing operation.
(b) Flush entire helicopter free of dirt.
CAUTIOFI: Avoid direct high pressure spraying of main rotor

head, tail rotor assembly and tail rotor shaft
bearings to prevent loss of lubricant. These
areas should be all purged with grease after
washing to eliminate any moisture.
(c) Using a soap and water solution and a soft cloth pad, wash a
specific area using a circular motion.
(d) Flush the washed area immediately.
(e) Repeat steps (c) and (d) until entire helicopter is clean.
(f) Rinse with clear water and dry with chamois.
MM-4-26
MAINTENANCE MANUAL
(2) Wax exterior as follows:
(a) Clean exterior as described in washing procedure.
(b) Using a soft cloth, apply a good quality paste wax to

painted exterior using a circular motion.
(c) Polish waxed area to a high luster using a clean and dry
soft cloth.
B. Cleaning Interior
(1) The standard interior has upholstered seats and carpeted floor
and should be cleaned as follows:
(a) Clean dust and dirt from upholstery and carpet with a small
brush or broom.
(b) Vacuum interior after brushing to remove any remaining dirt.
(c) Upholstery cleaner should be used to remove imbedded dirt

and grease.
C. Cleaning Plexiglass
(1) Wash plexiglass using a clean soft cloth and mild soap and water.
Rinse with clear water.
CAUTION: Do not use coarse abrasive type soaps as they can cause
fine scratches.
(2) Removal ~of fine scratches from plexiglass is accomplished by

polishing and waxing the glass using Meguiar’s Mirror Glaze
Plastic Cleaner MGH 17.
4-5 HELICOPTER PRESERVATION STORAGE
Aircraft that see low usage or are stored for extended periods exhibit
an accelerated rate of corrosion damage. Special attention should be
given to aircraft inactive in corrosive atmosphere (coastal, high
humidity, air pollution, or sandy areas) to assure components remain
in a serviceable condition.
Lycoming Service Letter No. L18OA states "Engines in aircraft that are
flown only occasionally may not achieve normal service life because of
corrosion; this occurs when moisture from the air and products of
combustion combine to attack cylinder walls and bearing surfaces
during periods when the aircraft is not used.
MM-4-27
MAINTENANCE MANUAL
The procedures for combatting this condition consist of coating the

vulnerable surfaces with rust inhibitor compounds as herein described.
However, the need for doing this must be evaluated by the owner or
operator of the aircraft, based -on environmental conditions and
frequency of aircraft activity.
Essentially, the Lycoming Service Letter discussed two conditions and

their maintenance procedures: (1) Intermittently flown aircraft in
favorable atmospheric conditions can be adequately protected by
turning the engine over five revolutions by means of the cooling fan.
Unless the aircraft is flown, this should be done every 5 days. After
30 days the aircraft should be flown for 30 minutes or a ground run-up
should be made long enough to produce an oil temperature within the
lower green are range. Avoid excessive ground run-up. (2) Aircraft
which will be inactive for a period exceeding 30 days should be
treated with a special corrosion preventive oil mixture and procedure.
Specific instructions for conditions (I) and (2) are contained in
Lycoming Service Letter No. L180A.
Similarly, the maintenance procedures to be followed for the

helicopter airframe and drive system are categorized in terms of
aircraft with low usage, and those scheduled to be inactive for an
extended period. This information is intended to cover both hangared
and outdoor conditions unless otherwise noted, and is subject to
owner/operator judgment regarding the helicopter’s operating environ-
ment, and should be considered in addition to the normal servicing
requirements.
NOTE: Wash and wax the helicopter prior to any type of storage.
B. Low Usage (flown short periods several times per month)
(1) Engine Complete the instructions for contained in Lycoming

Service Letter No. L180A.
(2) Position main rotor blades so that tail rotor assembly is

horizontal to the earth. Tie down main rotor blades with
collective locked hal fway up to re lieve the steady load on
lamiflex bearings.
(3) Install covers on main rotor hub and tail rotor assembly.
(4) Protect the windshields and interior equipment with suitable dust
covers and/or solar shields.
NOTE: If interior temperature of fuselage exceeds 1500F,

ventilate helicopter by opening doors or vents.
(5) Cover the pitot and static air vents.
(6) Wash and wax aircraft monthly to remove contaminants.
MM-4-28
MANUAL
(7) Prior tb the next flight; complete the following:
(a) Remove all covers and tiedowns.
(b) Check all items listed on the Daily Check List and complete
a Preflight Inspection. See Section 3, Inspections and
Routine Checks.
NOTE: When inspecting oil levels, check for evidence of

water contamination.
(c) Check for rust and corrosion on all exposed parts.
(d) Lightly oil the clutch engagement rod end and bellcrank
bearings.
(e) Purge tail rotor grips and rive shaft bearings.
(f) Check all controls for freedom of movement.
(g) Check oleo struts for proper extension.
C. Storage Up to 45 Days
(1) Eng i ne Complete the i n s t ru ct i on s for Znact i ve Ai rcraft"

containedin Lycoming Service Letter No. L18OA.
(2) Complete steps 1 through 6 of paragraph B.
(3) Disconnect battery.
(4) Remove main rotor blades.
NOTE: Store main rotor blades in a horizontal position on wood

racks cut out to the contour of the leading edge of the
blade. Use care in handling to prevent damage to blade
and trim tabs.
(5) Returning to service complete the following:
(a) Remove all covers.
(b) Connect battery.
(c) Install main rotor blades.
(d) Check all items listed on the Daily Check List and complete
a Preflight Inspection. See Section 3, Inspections and
Routine Checks.
NOTE: When inspecting oil levels, check for evidence of

water contamination.
(e) Lubricate all daily and 50-hour items listed on the Lubri-
cation and Servicing Chart of Section 5.
MM-4-29
MAINTENANCE MANUAL
(f) Check for rust and corrosion on all exposed parts.
(g) Check all controls for freedom of movement.
(h) Check oleo struts for proper extension.
D. Storage Up to 6 Months or Longer
(1) Engine Complete the instructions for Inactive Ai rcraft"

contained in Lycoming Service Letter No. L18OA.
(2) Remove main rotor blades.
NOTE: Store main rotor blades in a horizontal position on wood

racks cut out to the contour of the leading edge of the
blade. Use care in handling to prevent damage to blade
and trim tabs.
(3) Remove battery and store in a cool, dry area. Clean battery box
area if necessary.
(4) Cover the pitot and static air vents.
15) Drain fuel tanks and fuel tank sump.
(6) Hangar the aircraft.
NOTE: If hangar is not available, proceed to steps 7

through 9.
(7) Install main rotor hub and tail rotor covers.
(8) Protect the windshields and interior equipment with suitable dust
covers and/or solar shields.
NOTE: If interior temperature of fuselage exceeds 150"F,

ventilate helicopter by opening doors or vents.
(9) Wash aircraft monthly to remove contaminants.
(10) Returning to service, complete the following:
(a) Remove all covers and shields.
(b) Install and connect battery.
(c) Install main rotor blades.
(d) Fill fuel tanks and inspect all connections for leaks.
(e) Perform a complete 100-hour inspection and lubrication per

Section 3 and Section 4, Servicing.
(f) Identify sources of oil leaks and repair as necessary.

Ground run and re-inspect for oil leaks.
MM-4-30
MAINTENANCE MANUAL
4-6 PREVENTIVE MAINTENANCE FOR CORROSION CONTROL IN THE FIELD
Airframe
The helicopter airframe is fabricated of high strength aluminum and

steel alloys and should be inspected regularly for signs of corrosion.
Any areas where the projecting finishes have been scuffed, scratched,
chipped or worn off should be treated temporarily to control the onset
of corrosive action. Then dt the earliest convenience a permanent
refinish of the area should be accomplished. Another very important
step in any corrosion prevention program is regularly scheduled
washing and waxing of the aircraft surfaces.
Main and Tail Rotor Blades
It is extremely important that the blade coatings be maintained and

protected against oxidation, erosion and atmospheric residues which
are continually attacking these components during their service life.
Once this coating is breached and corrosive action is allowed to
propagate unchecked, premature bond line corrosion will occur,
resulting in early retirement of these components.
B. Regularly Scheduled Field Preventive Maintenance Program
NOTE: This procedure is intended for the complete helicopter, with

special attention to the main and tail rotor blades.
The following procedures must be followed for:
(1) Helicopter operations over salt water or coastal regions.
(a) Flush with fresh water thoroughly, daily.
(b) Wash with mild soap and fresh water, flush thoroughly
weekly, and wax every second week.
C. Helicopter operations in tropical or subtropical high humidity

regions.
(1) Wash with mild soap and fresh water, flush thoroughly weekly, and
wax every second week.
D. Helicopter operations in arid, moderate, and cold regions.
(1) Flush with fresh water thoroughly weekly.
MM-4-31
MAINTENANCE MANUAL
(2) Wash with mild soap and fresh water, flush thoroughly monthly,
and wax every second month.
NOTE: Use a good quality paste wax.
NOTE: This procedure may be suspended during cold or winter

months if item (2) was accomplished prior to the cold
season.
NOTE: Aircraft based in or near heavy industrial and/or

nietropol i tan areas wi th heavy atmosphe ri c poi 1 u t i on
should abide by procedure (B).
E. Helicopter operations involving agricultural spraying and dusting must

consider the procedures in paragraph (A) as a mandatory minimum
requirements, and should increase the frequency per their specific
operation.
F. Helicopters which are to be non-operational and not hangared for a

period of one week or more should be washed with mild soap and fresh
water, flushed thoroughly and waxed prior to parking.
NOTE: It should be emphasized that after washing, as indicated in

parts (A) through (E), the tail rotor drive shaft and
teeter bearings should be purged with grease to assure that
any ingested water is evacuated.
G. Field Inspections of Main and Tail Rotor Blade Assembliesi

A constant watch for corrosion damage must be maintained ~n the field.
The following procedures will define specific conditions to inspect
for.
General Daily Inspection:
(1) Examine the condition of paint coverage for blistering, erosion,

cracking, chipping, peeling, or overall oxidation, on:
(a) Exposed areas on the leading edge or spar.
(b) Exposed areas on the blade skins and trailing edge.
Any areas found in (a) or (b) where the paint cover and primer
have broken down be protected by
methods described in part exposinPH, must
(2) Visually examine the main rotor blade spar, especially on blades
not using leading edge tape, and those where the paint cover has
eroded away, for the following:
(a) Slight slivering or flaking of the expoS_ed spar surface.
NOTE: When checking for slivering, do not use hands; use
glove or´• shop cloth.
(b) A light grainy surface, resembling a fine wood grain finish.
MM-4-32
MAINTENANCE MANUAL
If either condition as described in (a) or(b) is found, these

surfaces must be reworked as soon as possible to arrest the
corrosive condition by methods described in part (K),
paragraph (1).
(c) Deep material slivering, heavy or deeply grained surface,

and may be accompanied by a white powdery substance in the
bdttom of the granular crevices. If this condition is
present, the operator should take immediate action to have
blades inspected for possible rework as described in part
(K), paragraph (2), by competent maintenance personnel.
(3) Visual examination of bond lines at:
(a) The main and tail rotor blade trailing edge, for any voids
or openings, dark deposits, bubbly or scaly paint condition.
If an voids or openings are found, procedures as noted ~n

part YI, must be followed for acceptance or rejection. Dark
deposits, bubbly or scaly paint conditions must be treated per
procedures in part (J).
(b) The leading edge bond lines for raised sections or voids.
Dark deposits, bubbly or scaly paint condition along its
length.
If any raised sections or voids are detected, procedures as noted

in part (I), paragraph (1) must be followedfor acceptance or
rejection. Dark deposits or scaly paint must be treated per
procedures in part (J), paragraph (1).
(c) The faired bond lines on doubler edges for paint cracking,
dark deposits, voids in fairing compound, and scaly paint
condition, with special attention to tail rotor blades.
Any of the indications as noted must be treated by procedures

prescribed in part (J), paragraph (1) through paragraph (3) for a
more permanent deterrent.
(4) Main Rotor Blade Leading Edge Tape
The leading edge polyurethane tape should be inspected for:
(a) Security; loose ends should be carefully trimmed equally on

all blades.
(b) Check for punctures or tears.
(c) Bubbles or lumpy surface.
Any blade tape found with questionable security should be

replaced. If
punctures, tears, or bubbles are detected, the tape
should be replaced with new material. Prior to instailation the
spar should be carefully inspected per part (Gj, paragraph (2).
New blade tape should never be installed on spars without proper
preparation and paint cover.
MM-4-33
MAINTENANCE MANUAL
H. Limited Anti-Corrosion Methods for In-Field operation
These are considered as temporary corrosion deterrent until permanent

maintenance procedures can be accomplished at a proper facility.
(1) Any areas detected by inspections in part (G), paragraphs (1)

through (4), should have corrosion inhibitors applied upon
detection and semi-weekly as a minimum, until proper maintenance
can be accomplished. Application by aerosol of corrosion
inhibitors per MIL-C-16173D, MIL-C-23411 or MIL-C-85O54 Type I.
(a) To all exposed areas of the main and tail rotor blades.
(b) Application to be made

on all suspect bond line corrosion
a reas cracks, fin´•ish and small voids.
scaly This al so
includes bond lines on the blade doublers, with special
attention to the tail rotor blades.
NOTE: For helicopters operating (ref. part B) over salt

water or coastal regions, MIL-C-85054 Type I
inhibitor is preferred.
(2) For larger exposed the main rotor spar as defined in

areas of
part (Gr, paragraph (2) (a)(b), the spar should be worked lightly
with aluminum oxide medium grit paper, washed, and degreased with
acetone or perchlorethylene. Application of the inhibitor can be
made and allowed to dry at least 30 minutes. This can be fol-
lowed by a coat of epoxy primer DeSoto 593)(300 for improved
protection. Cover over with flat acrylic aerosol paint.
NOTE: Blades must be worked on in sets equally to assure
continuity of weight between them.
List of materials in order of preference:

PRIMERS
DeSoto #593X300
Primer Aerosol Touch-Up Epoxy
Zinc Chromate per MIL-D-6889C Type I, MIL-P-8585A.
CORROSION INHIBITORS
LPS #1 or P2 Metal Protector

MIL-C-1673D MIL-C-23411
Crown #7540
MIL-C-1673D
WD-40
MIL-C-23411
SALT WATER CORROSION INHIBITORS
Care #1900
Amg ua rd
MIL-C-85O54 (A5) Type I
NOTE: Any product meeti ng the corros i on inhibitor MIL

specification can be used as a deterrent.
MM-4-34
MAINTENANCE MANUAL
I. Inspection and Rejection Criteria for Bond Line Corrosive Delamination
(1) Main Rotor Blade
Inspect edge of all bond lines for separations, visually and coin
tap. If inspection reveals evidence of delamination, depth may
be checked on trailing edge and doublers with plastic shim stock
.001" in thickness. Douse shim stock
not to check spar to
leading edge delamination, COIN TAP ONLY.
CAUTION: Do not use anything other than shim stock to check depth
of lamination.
(a) Coin tap detectable bond separations at the skin-spar joint

in excess of limits in Figure 4-1 and 4-2 are cause for
rejection.
(b) Visual or coin tap detectable bond separations at the blade

trailing edge of more than 3.00 inches in length deeper
or
than .25 inch are cause for rejection. (See Figures 4-3
and 4-4)
(c) Any bond separations on the doubler closer than 2.00 inches
to the tip, or more than 3.00 inches in length, or greater
than .125 inch in depth are cause for rejection.
(2) Tail Rotor Blade
Using the same method as in Part (I) (1), inspect all bond lines.
(a) Bond separations on the trailing edge deeper than .050 inch
or more than 2.00 inches in length are cause for rejection.
(b) Any bond separation on the stainless steel cap more than
2.00inches from the tip or greater in depth than .062 inch
is cause for rejection.
(c) Any bond

separation on the doublers closer than 2.00 inches
to the tip of the doubler under which it appears, or greater
than 1.00 inch in length, or deeper than .062 inch in depth
NOTE: Del amination as noted in (1) and (2) which are

lesser are acceptable, if procedures in paragraph J
are performed.
J. Preliminary Repair Procedures for Acceptable Blade Bond Delamination

to Arrest Corrosive Action Prior to Refinish
(1) Skin to Spar Bond Sealing Procedure (Main Rotor Blade)
Separations smaller than the limits shown in Figures 4-1 and 4-2
may be sealed using the following procedure.
MM-4-35
MAINTENANCE MANUAL
(a) Remove paint and or surface corrosion in separated area by

aluminum oxide abrasive paper.
(b) Degrease by wiping with acetone or MEK.
(c) Warm to 180-200"F to evacuate residual moisture.
NOTE: Do not heat bond line above 250"F.
(d) Apply corrosion inhibitor and allow to dry 30 minutes.
(e) Seal with epoxy, Hysol Type EA 9309.2 sealant.
NOTE: The skin to spar seam should be faired flush with

the blade contour.
(f) Refinish per part (M).
(g) This repair requires a preflight daily inspection anda

close visual and coin tap inspection at 25-hour intervals to
monitor for growth of delamination.
(h) Log book entry must be made at the time of repair

identifying location and S/N of blade; thereafter at 25-hour
intervals for inspections.
(2) Trailing Edge Bond Sealing Procedure (Main and Tail Rotor Blade).
Separations less than the limits in part (I), paragraph (Ib) or

paragraph (2a) may be sealed by procedures in part (J),
paragraphs (la) through (Ih), or asnoted in Figures 4-3 and 4-4.
(3) Doubler Edge Bond Sealing Procedure (Main and Tail Rotor Blade).
Separations less than the limits in Part (I), paragraph (Ib) or

paragraph (2c) may be sealed by procedures in part (J),
paragraphs (la) through (Ih).
NOTE: With application of sealant item (C) the epoxy should

be faired along the exposed edge, completely along its
length.
(4) Stainless steel cap bonding sealing procedures (tail rotor blade)
separations less than the limits in~part (I), paragraph (2b) may
be sealed by procedures in part (J), paragraphs (la)
through (Ih).
NOTE: The skin to stainless steel cap seam should be faired

flush with blade contour, both sides with epoxy sealant,
per paragraph (le), this part.
MM-4-36
MAINTENANCE MANUAL
K. Inspection and Rejection Criteria for Main Rotor Spar
Spar intergranular corrosion illustrates its presence by exfoliation,

flaking or metal slivers on the exposed surface. This condition can
also create a wood grain effect on the metal surface in early and/or
later stages of its progress. This condition, if allowed to progress
untreated, will eventually destroy the spar. Therefore the following
maintenance action is very important.
(1) For spar conditions as noted in part (G), paragraph (2a)

and (2b), the following procedures should be followed.
(a) Blade spars exhibiting slight flaking, less than .032 inch
in depth, slivering or a fine wood grain surface must be
reworked. The surface should be mechanically worked by
hand, removing this corroded surface condition. This rework
must be accomplished uniformly to contour on each blade and
in sets, to insure continuity of weight between them. This
hand work should only be accomplished by abrasive paper or
flap wheel, to insure uniform removal.
NOTE: Care must be taken when working the contaminated

or corroded areas. Contamination can be spread by
hands, tools, or materials to other blades or areas.
(b) After rework is accomplished, wash thoroughly with mild soap

and water, flush thoroughly.
(c) The area then must be etched for 15 minutes with acid paste,
Passa Jell Xt105, or a metal prep, to remove any residual
corrosive residue. Flush thoroughly with fresh water and
allow to dry.
(d) A chemical conversion coat is then applied per´• part (M),

paragraph (4).
(e) The reworked area is now ready for refinish. Ref. part (M).
NOTE: The skin to spar bond line must be inspected in

the repair area to be sure the rework has not
damaged the sealing or fairing compound which fills
the crevice. Reseal if damaged.
(2) For spar conditions inaspart (G), paragraph (2c):

noted
Indicated intergranular
severe corrosion in the advanced stages,
see Figure 4-5. No attempt to rework these areas in the field
should be made prior to contacting your nearest Enstrom Service
Center or Enstrom Customer Service Department for proper action.
During this interim the owner should treat the affected area
daily with a recommended corrosion inhibitor as defined in
part (H), paragraph (1).
NOTE: Spars exceeding the limits in Figure 4-5 must be

rejected as unairworthy.
MM-4-37
MAINTENANCE MANUAL
L. Disposition of main and tail rotor blades rejected under the criteria
as noted in paragraph (G) may still be within repai rabl e 1 imi ts.
Therefore owners and operators with subject rejected blades should
contact their nearest Enstrom Service Center or Enstrom Customer
Service for final disposition.
M. Main Rotor and Tail Rotor Refinishing
(1) Strip assembly with Electro Cold T-416 or alternate. Remove

residue with stiff bristled brush, flush thoroughly with water.
Do not allow stripper to remain on blade assemblies for more than
a 3 hour period. Additional stripper may be used as required,
but must be flushed clean every 3 hours.
(2) Inspect blade thoroughly as defined in this section.
(a) Any areas requiring rework should be accomplished at this

time.
(b) Resealing and fairing of all bond lines on skins and

doublers.
(c) Removal of any surface corrosion or residues with fine grit

aluminum oxide paper.
(3) The total blade assembly must be washed thoroughly and treated
with metal prep. Alum Prep f33 can be brushed on and flushed for
this application.
(4) A chemi ca 1 coating

conve rs i is
on appl i ed by brush, per
MIL-C-5541. Prepa solutionreAl 1 ied-l(el ite, I ri di te #144 for
application. Keep solution wet on blade assembly until a dark
gold color is achieved, then rinse with cold water and allow to
dry.
(5) Primer appl ication preferred, MIL-P-23377C, Primer Epoxy

Polyamide by DeSoto. Alternate Super Koropon II by DeSoto.
(a) Main rotor, application of three coats. Care must be

exercised for thin, even coats. These coats shall be
applied as follows to maintain uniformity of weight on the
blade. Apply two coats to spar. Feather out past leading
edge skin line. Apply two coats to trailing edge straight
on, then finish total blade with the third coat.
(b) The application is the same for the tail rotor blade, except
for three coats all over.
NOTE: It is extremely important that the trailing edge

of both blades have good coverage.
MM-4-38
MAINTENANCE MANUAL
(6) The finish overcoat can be any good quality finish. Urethanes
are preferred, as they will remain intact for a longer period of
time, resulting in more equitable life for the owner, with better
corrosion protection of the blade assemblies.
CAUTION: Refinishing of tail rotor blades requires that the tail

rotor assembly be rebalanced dynamically (i.e., Chadwick
balancer). Refinishing the main rotor blades will
require retracking the rotor system. Dynamic lateral
balance is permissible with the Chadwick balancer.
CAUTION: Tip weight changes must be made to keep 75% of the blade
tip weight in the forward blade pocket to maintain
chordwise balance.
(7) List of materials in order of preference:
PRIMERS
Primer Epoxy Polyamide by DeSoto #(513X3O7(510X386),

MIL-P-23377C
Super Koropon II by DeSoto #(5136329)
Zinc Chromate per MIL-D-6889C, MIL-P-8585A
STRIPPER
Electro Cold Stripper #T-416 by Whittaker Chemical, or any

name brand alternate.
CHEMICAL COATING
Allied Kelite Iridite ~144 per MIL-C-5541
SEALING COMPOUND
Hysol #EA9309.2 Two-Part Epoxy by Dexter

Fairing Compound Epoxy #RP-1257-3 by REN
METAL ETCH
Passa Jell ~105 by Semco
METAL PREP
Aluma Prep ~33 by American Chemical
MM-4-39
MAINTENANCE MANUAL
Figure 4-1 Bond Separation Criteria Skin to Spar Bond
.25 1 I 1 .125
Inboard of Outboard of
Station 156 Station 156
T
T-
G NOTES:
i. Determine extent of separation

by coin tap.
2. Separations greater than 3.0
inches spanwise dimension are
cause for rejection.
3. Separations greater than

indicated chordwise depth are

4. Coin detectable separations
less than these limits must
be sealed using approved

materials, and inspected
daily for growth,
5. Log book entry must be made

when each separation is first
detected and sealed, and for
each daily inspection
thereafter.
MM-4-40
MAINTENANCE MANUAL
Figure 4-2 Skin-Spar Bond Separation Criteria
Sta 192
Chordwise depth exceeding .125 inch

is cause for rejection outboard of
Sta 156.
Spanwise length exceeding 3.0 inches

Sta 164
Sta 156
Chordwise depth exceeding .25 inch

is cause forrejection inboard of
Sta 156.
Spanwise length exceeding 3.0 inches

Sta 109
Sta 039
Sta 020
MM-4-41
MAINTENANCE MANUAL
Figure 4-3 Edge Bond Separation Criteria
G
NO~TES:
i. Determine extent of separation

using .001 inch plastic shim
stock.
2. Separations greater than 3.0

inches spanwise length must
be repaired using approved
j 3.
procedures.
Separations greater than
.25 inch chord\cise depth must
be repaired using approved
procedures
4. Separations less than these
limits must be inspected daily
for growth.
MAXIMUM DEPTH
MM-4-42
MAINTENANCE MANUAL
Figure 4,4 I’~ailing ~dge Bond Sepa~ation Kepair Criteria
Sta 192
Outboard of Sta 01 repaii- using

3l’p’~v"d procedul´•es.
Sta 161
Sta 103
Sta 101
Inboard of Sta 101 repair using

approved procedures and inspect
for cracks every 25 hours
Enter in Zog book at time of

repair and at every 2S-hour
inspection thereafter.
Sta 039
Sta 020
MM-4-43
MAINTENANCE MANUAL
Figure 4-5. Spar Rejection Criteria for

Intergranular Corrosion
(Exfoliation)
Sta 192
j Exfoliation
maximum
at tip to
damage deeper than a
depth varying from .080 inch
.060 inch at Sta 156 is
B
Sta 16-1
Sta 156
Exfoliation damage deeper than a

maximum depth varying from .060 inch
at Sta 156 to .030 inch at Sta 101
Sta 109
Sta 101
Exfoliation damage deeper than a
maximum depth varying from .040 inch
at Sta 101 to zero at Sta 048 is
Exfoliation damage inboard of

Sta 048 is cause for rejection.
NOTES:
i. Any main rotor blades found with

Sta 048
intergranular corrosion exceeding
s.o´• the depths as indicated must be
sta 039
rejected as unairworthy.
2. Any rotor blades found with

intergranular corrosion in excess of
.032" in depth, but not exceeding the
limits as defined in this figure,
should be treated
noted inas
Sta 020
Part (H) paragraph (1).No rework
should be attempted. Advise your
nearest Enstrom Service facility or
Enstrom Customer Service Department
for disposition.
MM-4-44
MAINTENANCE MANUAL
4-7 MAINTENANCE REPAIR OF MAIN TAIL ROTOR BLADES
The main and tail rotor blades of the Enstrom helicopters are highly
stressed and it is vitally important that they be maintained with the
utmost care and vigilance against any mechanical damage. Mechanical
damage, such as nicks and scratches, may seem minimum but can create
stress risers resulting in damaging fatigue cycles during continued
operation of the components. The result of such damage in a critical
location can culminate in a catastrophic failure if prompt maintenance
and repair are not accomplished.
NOTE: Mechanical damage, no matter how minimal, breaks the

protective coating on the blades, allowing corrosive action
to be initiated. Therefore, prompt corrective action is
imperative.
These procedures should be used in conjunction with the regularly

scheduled maintenance program as defined in Section 4-6 for corrosion
control. These combined preventive maintenance programs, if followed
regularly, will assure the owner/operator of long and useful life of
these components.
B. General Daily Inspection
1. Inspect the main rotor blade, spar, skins, trim tabs, retention
plates, drag link fittings, and root doublers for any mechanical
damages such as nicks, scratches, dents and cracks. Inspect the
blade tip rib, trim tab and drag link fittings for loose rivets.
Reference Figure 4-6 for component definition.
C. Main Rotor Blade Spar
i. Rejection Criteria
a. Nicks and scratches greater than the limits on Figures 4-7

and 4-11 are cause for rejection.
b. Leading edge dents with smooth surfaces greater than the

limits shown on Figures 4-8 and 4-9 are cause for rejection.
c. Leading edge dents with sharp width to depth ratios (i.e.,

less than 3:1), or with torn, nicked, scratched or creased
surfaces greater than the limits in Figures 4-9, 4-10 and
4-13 are cause for rejection.
2. Repair Procedures
a. Nicks and scratches within repairable limits should be

polished out and blended smooth as shown in Figure 4-11.
b. Sharp dents wi thi n the pe rmi s s i bl e limits sh own in

Figure 4-10 and 4-13 must be blended as noted in Figure 4-9.
MM-4-45
MAINTENANCE MANUAL
D. Main Rotor Blade Skins
1. Rejection Criteria
a. Punctures in the blade skin.
b. Sharp dents with width to depth

ratios of less than 3:1 and
deeper than .020 inch, in which the metal has either been
creased or the surface scratched or nicked, are cause for
rejection.
c. Dents which have resul ted in perma ne nt skin de fo rma t i on
greater than .060 inch in depth are cause for rejection.
d. Trailing edge chordwise dents or nicks deeper than .20 inch

are cause for rejection.
e. Trailing edge flapwise kinks extending more than .20 inch

chordwise are cause for rejection.
2. Trailing Edge Damage Repair Procedure
a. Blend out nicks and kinks to a chordwise depth not exceeding

.20 inch, on a circular are with not less than a 2.00 inch
radius (see Figure 4-12).
3. Main Rotor Blade Skin Repair
a. Buff out all light scratches.
b. Polish out all nicks, scratches, and sharp dents in the

chordwise direction not greater than .010 inch deep. Blend
out smoothly to approximately .50 inch on each side of the
damaged area. Any nicks, scratches or sharp dents in excess
of those noted are cause for rejection.
c. Polish out all nicks, scratches and sharp dents oriented

within +30" of the span direction (see Figure 4-7) and not
greater than .020 inch deep. Blend out smooth to
approximately .50 inch on each side of the damaged area.
Any nicks, scratches or sharp dents in excess of those noted
d. Smooth dents up to .020 inch deep are acceptable. Deeper

dents are cause for rejection.
e. Cracks in any direction are cause for rejection.
MM-4-46
III
)I I
I
I I I
1
I RlB TIP
,I i
I I
II
I I
III
II I
I
I I
II I I
I I
,I I
III
I
I i
II I
III
I
I I TRIM TAB
III
II I
SPAR, _, SKIN
i
I I
I I
I I
I I
I i
I t
1 I
I ROOT DOUBLER
I I
I I
I I
I I
I I
I t
I I
I I
I I
I I
I
I o
I
RETENTION I I DRAG LINK

O
PLATE :(C~ I flTtlNO
IYI O
I
o
o
FIGURE 4-6
MAIN ROTOR BCADE ASSEMBLY

MM-4-47
MAINTENANCE MANUAL
FIGURE 4-7
Spar Rejection Criteria
Nicks and Scratches
Sta 192
7~30´•1( Nicks or scratches in the spar

deeper than are cause for
.080 inch
rejection. Nicks or scratches in
the spar deeper than .050 inch and
oriented greater than 300 from
the span axis are cause for rejection.
Sta 164
Sta 156
Nicks or scratches in the spar deeper

than .050 are cause for rejection.
Nicks or scratches in the spar
deeper than .020 inch and oriented
greater than 300 from the span axis
Sta 109
Sta 039
Sta 029
NOTE: 1. Nicks and scratches lesr than these limits must be repaired
using approved procedure,
MM-4~48
MAINTENANCE MANUAL
FIGURE 4-8
Spar Rejection Criteria
Smooth Dents at Leading Edge
Sta 192
Leading edge dents with smooth

surfaces greater than .100 inch
j
deep are cause for rejection.
I Sta 164
Sta 156

deep located inboard of Sta 156
Sta 109
Sta 101

deep located inboard of Sta 101
Sta 039
NOTE: For sharp edged dents (i.e.,
bottom radii smaller than
.03inch) reduce permissible
depth dimensions by .020.
Sta 020
NOTE: i. Leading edge is considered to be .5 inch above and below the

nose, measured around the contour,
MM14-49
MAINTENANCE MANUAL
FIGURE q-9
Leading Edge Definition
.bO
´•C
MAIN ROTOR BLADE
MM-4-50
MAINTENANCE MANUAL
FIGURE 4-10
Spar Rejection Criteria -.SK~i;pDents at Leading Edge
O
Sta 192 ..Sharp dents are those which have
width to depth ratios less than 3:1
or which have torn, nicked, scratched,
or creased surfaces.
Sharp dents deeper than .080 inch

Sta 164
Sta 156

Sta 109
Sta 101

Sta 039
Sta 020
NOTE: i. Sharp dents less than these limits must be repaired using
approved procedure.
MM-4-51
MAINTENANCE MANUAL
FIGURE 4-11
Spar Repair Criteria Nicks t; Scratches
Sta 192
Nicks and scratches oriented greater

than 300 from span axis,blend smooth
5~ 11 not more than .060 inch deep over area
not less than 2.0 inches each side of

defect.
Within 300, blend not more than
i .100 inch deep over area nor less than
1.0 inch each side of defect.
Sta 164
Sta 156

than 300 from span axis, blend smooth
not more than .030 inch deep, not less
than 2.0 inches each side of defect.
.060 inch deep not less than 1.0 inch
each side of defect.
Sta 109
Sta 101

t113II 300 from span axis, blend smooth
not niore than .030 inch deep, not less
than 3.0 inches each side of defect.
.060 inch deep not less than 1.5 inch
each side ofdefect.
Sta 039
Sta 020
NOTES: I. Repairs exceeding these depths are cause for rejection.

2. Excessive material removal will affect track and balance.
MM-4~52
MAINTENANCE MANUAt
ii
o i o o o o o
I I
.200 ~AX.
2.0
R. MIN.
FIGURE 4-12
TRAILING EDGE DAMAGE REMOVAL

(MAIN ROTOR BLADE
MM-4-53
MAINTENANCE MANUAL
FIGURE 4-13
Spare Repair Criteria Sharp Dents at Leading Edge
Sta 192
Blend dent smooth not deeper than

.100 inch over area not less than
2.0 inch spanwise dimension.
Sta 164
Sta 156

.080 inch over area not less than
2..0 inches spanwise dimension.
Sta 109
Sta 101

.050 inch deep over area not less
than 2.0 inches spanwise dimension.
Sta 039
Sta 020
NOTES: 1. Material removal beyond these depths is cause for rejection.

2. Excessive disruptionof leading edge contour will affect track.
MM-4-54
MAINTENANCE MANUAL
E. Main Rotor Blade Doublers
i. Polish out all nicks, scratches, and sharp dents in the chordwise
direction not greater than .010 inch deep. Blend out smoothly to
approximately .50 inch on each side of the damaged area. Any
nicks, scratches or sharp dents in excess of those noted are
2. Polish out all nicks, scratches and sharp dents oriented within
+30" of the span direction (see Figure 4-7) and not greater than
.020 inch deep. Blend out smooth to approximately .50 inch on
each side of the damaged area. Any nicks, scratches or sharp
dents in excess of those noted are cause for rejection.
3. Smooth dents up to .020 inch deep are acceptable. Deeper dents

4. Cracks in any direction are cause for rejection.
F. Main Rotor Blade Retention Plates
1. Polish out all nicks, scratches and dents not greater than
.050 inch in depth. Damaged area to be blended smooth over an
approximate 2.00 inch diameter. Any nicks, scratches and dents
in excess of those noted are cause for rejection.
2. Cracks in any direction are cause for rejection.
G. Main Rotor Blade Trim Tabs
i. Flatten dents or kinks and polish out scratches and nicks.
2. Drill out and replace loose rivets.
H. Main Rotor Blade Drag Link Fittings
1. Blend out nicks and scratches not deeper than .010 inch in depth.
Any nicks or scratches in excess of those noted are cause for
rejection.
2. Any cracks are cause for rejection.
3. Loose rivets are cause for rejection.
I. Main Rotor Blade Tip Rib
1. Cracks are cause for rejection.
2. Loose rivets can be replaced.
NOTE: For items A through I, refinish per paragraph K after

rework.
MM-4-55
MAINTENANCE MANUAL
J. Tail Rotor Blades
Inspect the tail rotor blade, skins, abrasion strip, retention plates
and root doublers for nicks, scratches, dents and cracks (see
Figure 4-15). Check the tip rib for loose rivets and strike tab for
damage.
i. Tail rotor blade skin
a. Buff out all scratches not deep enough to penetrate the clad
material.
b. Polish out all deeper scratches to a depth not exceeding

.010 inch. Blend smooth over an area 2.00 inches in diameter.
Scratches deeper than noted are cause for rejection.
c. Blend out nicks in the trailing edge to a depth (chordwise) not

to exceed .100 inch, in a circular are, not less than 1.00 inch
in radius. (See Figure 4-14) Any nicks in the trailing edge in
excess of the noted depth are cause for rejection.
d. Sharp dents exceeding .010 inch are cause for rejection.
e. Smooth dents exceeding .025 inch are cause for rejection.
f. Cracks in any direction are cause for rejection.
2. Tail rotor blade abrasion strip
a. Polish out scratches to a depth not exceeding .005 inch.

Blend smooth over an area 1.00 inch long and .50 inch wide
(length parallel to span). Scratches in excess of depth as
noted are cause for rejection.
b. Dents not deeper than .040 inch are acceptable. Deeper

dents are cause for rejection.
c. Erosion penetration of the stainless steel is cause for

rejection.
d. Cracks in any direction or punctures are cause for

rejection.
3. Tail rotor root doublers
a. Polish out all nicks, scratches, and sharp dents not deeper
than .010 inch. Blend smooth to approximately .50 inch on
either side of the damaged area. Nicks, scratches, and
sharp dents in excess of depth as noted are cause for
rejection.
b. Smooth dents not greater than .020 inch in depth are accept-
able. Deeper dents are cause for rejection.
MM-4-56
MAINTENANCE MANUAL
4. Tail rotor retention plates
a. Polish out all nicks, scratches, and dents not deeper than
.030 inch. Blend smooth over an area approximately
1.00 inch in diameter. Deeper nicks, scratches, or dents
b. Cracks in any direction are cause for rejection.
5. Tail rotor blade tip rib
a. Cracks are cause for rejection.
b. Loose rivets may be replaced.
c. Any damage to the strike tab is cause for removal and

inspection of the entire tail rotor assembly.
K. Limited Refinishing Methods for In-Field Maintenance
These are considered as temporary refinishing procedures to inhibit

the start of corrosion on areas of repair until permanent maintenance
procedures can be accomplished at a proper facility.
1. Any areas of repair where the cover coat of the blade has been
removed must be recoated by one of the following methods:
a. Mi nimum protecti on appl i cati on of aerosol corrosion

inhibitors per MIL-C-16173D, MIL-C-23411, or MIL-C-85O54,
Type I.
b. Maximum protection, should be washed and degreased with

area
acetone or coating of corrosion inhibitor can be
MEK, then a
applied and allowed to dry for 30 minutes. This is then

followed by a coat of epoxy primer (DeSoto 593X300 aerosol)
and covered over with an acrylic aerosol paint.
NOTE: For helicopters operating over salt water or coastal

regions, MIL-C-85054, Type I inhibitor is preferred.
L. For complete refinishing of main and tail rotor blade assemblies see
Section 4-6.
MM-4-57
MAINTENANCE MANUAL
M. List of materials in order of preference for requirements of this

Service Inforniation Letter:
Primers
DeSoto #593X500 aerosol touch-up epoxy

Zinc chromate per MIL-D-6889, Type I, MIL-P-8585A
Corrosion Inhibitors
LPS #1 or #2 metal protector

MIL-C-1673D MIL-C-23411
Crown #7540
MIL-C-1673D
WD-40
MIL-C-23411
Salt Water Corrosion Inhibitors
CARE #1900
AMGUARD MIL-C-85054(AS), Type I
MM-4-58
MAINTENANCE MANUAL
.100 MAX.
1.0
R. MIN.
FIGURE 4-14
TRAILING EDGE DAMAGE REMOVAL

(TAIL ROTOR)
MM-4-59
MAINTENANCE MANUAL
I
I-
o
STRIKE TIE I
I
I
I
I
I
I
I
I
I
I
I II
I
I
I
I
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I
I
I
I
I
I
I
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SKIN
ABRASION
STRIP I I
I
I
I
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I
I
I
t
I
1
I
I
I
I
I
DOUBLERS
I I
I
I
I
I
I
I
r
I
I
I
I
I
RETENTION
I
PLATE
I
I
I
FIOUCIE 4-15
BLADE ASSEMBLY
(TAIL dOfOR)
MM-4-60
SECTION
VVEIGHT AN D
BALANCE
MAINTENANCE MANUAL
SECTION 5
WETGHT AND BALANCE
5-1 GENERAL INFORMATION
This helicopter must be flown within the weight and center of gravity
limits. The helicopter empty weight, empty weight c.g., total basic weight
and basic weight c.g. for this helicopter are found on form F-168A,
Figure 5-9. Removal or installation of approved optional equipment will
change the basic helicopter weight and moment. This change shall be
recorded on Form F-165A, Figure 5-8, Basic Weight and Balance Record. The
pilot will use the figures on Form F-165A when pe’rforming calculations to
insure the helicopter is loaded properly.
5-2 APPROVED CENTER OF GRAVITY ENVELOPES
A. Longitudinal c.g.
(1) Station zero located 100.0 inches forward of centerline of main

rotor hub.
(2) Longitudinal c.g. range varies with gross weight from 92.0 inches
to 100.0 inches. See Figure 5-1.
LONGITUDINAL C.G. ENVELOPES

2600
VELOPE;D
2500 1 1 I/ I ENVELOqE-C
24 00 t~--te
2300
~2200
ENVELDPE-A
~j 2100
w
~2000
1~ 1900
c3
1800
1~00
1600
92 9~3 94 95 96 97 98 99 100
LO N G I TU DI NA L C.G. I NC H ES AFT OF DATU M
Figure 5-1
i~bl-5-1
MAINTENANCE MANUAL
B. Lateral Offset Moment
(1) Centerline of helicopter is O inch lateral moment arm. Moment

arms left of centerline are negative.
(2) Lateral c.g. Locations
a. Two on board
(1) Left seat (pilot) -13.5
(2) Right seat (co-pilot) +13.5
b. Three on board
(1) Left seat (pilot) -13.5
(2) Center passenger 3.0
(3) Right passenger +20.5
(3) Lateral offset moments variable with gross weight from -3250 in-lb
to +3700 in-lb. See Figure 5-2.
LATERAL OFFSET MOMENT ENVELOPE

2600
vj 2400
2200
~2000
1800
-4000 -2000 O 2000 4000

LATERAL OFFSET MOMENT (IN_LBS.)
Figure 5-2
MM-5-2
MAINTENANCE MANUAL
5-3 WEIGHING THE HELICOPTER
A. Tools and Equipment
(1) Tape measure
(2) Two scales 1000 Ib capacity

(3) Scale 100 Ib capacity
(4) Bubble level
(5) Work stand
B. Weighing Procedure
(1) Clean helicopter remove rags, charts, etc.
(2) Drain fuel, check all other operating fluids full.
(3) Move helicopter inside closed building.
(4) Check for proper installation of accessory items.
(5) Close and secure both doors.
(6) Align one main rotor blade over tail cone.
(7) Hoist or jack helicopter to a height to clear scales.
(8) Position a pipe nipple in the center of left and right 1000 Ib
capacity scales. Place scales under landing skids so nipples will
contact skid gear at a point 17.7 inches aft of forward 3 inch
diameter cross tube (Station 93.4).
NOT E See 5-3 for

Figure locating fulcrum by using T-1794.
This tool may be purchased from Enstrom Helicopter
Service Department.
(9) Locate the 100 Ib capacity scale at the center line of the tail
rotor output shaft. See Figure 5-4.
(10) Adjust height of tail to level helicopter. Level checked at left

lower pylon tube. Lateral level checked at lower forward pylon
tube.
(11) When helicopter is level, read the scales and enter weights on
Weight Chart, Figure 5-7.
CAUTION: Weight and measurement readings are critical. Double

check results.
(12) Remove helicopter from scales.
NOTE: DO NOT remove curbing, nipples, blocks, etc. from scales.

Weigh these items and enter weights in ~are column on
Figure 5-7.
MM-5-3
17.7"
T-1794 TOOL I (F
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cln ~c_ II~T L~, 1 W IZb
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p I i II ~I 11 10
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FULCRUM
WEIGHT AND BALANCE
TOOL POSITIONING
Fig. 5-3
100.0
~ROTOR HUB
PUEL tAWK
LCO ’1O lle.Tl
z
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CAblU PWD. bAOOAOE APT
9*" Box
WL Wg IT
WEIGHING STATIONS
Fig. 5-4
MAINTENANCE MANUAL
(13) Subtract tare from scale readings and enter net weights.
(14) Enter arms and multiply by weights to get moments.
(15) Total weights and moments.
(16) Using formula on bottom of Figure 5-7, calculate c.g.
(17) Transfer weight, c.g. or arm and moment to top of form F-168A
(Figure 5-8).
(18) On Form F-168A enter all optional and surplus equipment in the
helicopter at weigh-in. Then enter all standard equipment not
installed on the helicopter at weigh-in.
(19) Total weights and moments.
(20) Find total empty weight and moment of standard helicopter.
(21) Add to this figure optional equipment to obtain total basic weight
and moment.
(22) Transfer these figures to Form F-165A (Figure 5-8), Basic Weight
and Balance Record.
NOTE: Any changes to the helicopter such as structural repairs

or modifications, installation of optional equipment or
removal of optional equipment, will require an entry on
Form F-165A.
5-4 LOADING
It is responsibility of the helicopter pilot to insure that the

the
helicopter is loaded properly. Using the basic weight and moment from
Form F-165A (Figure 5-8) and the loading Chart (Figure 5-5), the pilot
can obtain the total weight and moment for various loading conditions.
The pilot should first calculate the total weight and moment for zero
usable fuel, as this will show the c.g. shift with fuel burn-off. If
the c.g. is within limits, add the planned fuel load and compute the
c.g. If the c.g. is within limits, the last item to check is the
lateral offset moment.
MM-5-6
MAINTENANCE MANUAL
B. Sample Calculation Longitudinal C.G.
SAMPLE HELICOPTER HELICOPTER S/N
Arm Weight Moment Weight Moment

SAMPLE LOADING CALCULATIONS in. Ibs 100 in-lb Ibs 1000 in-lbs
i. Basic empty weight 100.7 1610.0 162.1

from Form F-165A
2. Pilot and passengers 62.0 480.0 29.8(1)

Cabin seats
3. Baggage compartment 135.0 20.0 2.7(1)

load
4. Total and
(2) 194.6
weight 92.2 2110.0
moment with zero
usable fuel to check
c.g. shift with fuel
burn-off (landing
condition)
5. Usable fuel 96.0 240.0 23,0(1)
6. Total
(2) 2350.0
(3) 217.6
weight and 92.6
moment with usable fuel
(takeoff condition)
(1) Moments obtained by multiplying weight times am or from Loading Chart,

F.igure 5-4.
(2) The longitudinal c.g. relative to the datum line may be found by dividing
the moment by the weight.
194 600 in-lbs

c.g. zero fuel 92.2 in.
217 600 in-lbs

c.g. full fuel 92.6 in.
The total weight and moment can also be plotted on Figure 5-5 to determine
if the loading is within longitudinal limits.
(3) Total weight not to exceed 2600 Ibs.
MM-5-7
MAINTENANCE MANUAL
C. Sample Calculations Lateral Offset Moment
Arm Weight Moment

in. Ibs in-lbs
Pilot (left seat) 13.5 170 2295
Passenger (center seat) 3.0 140 420
Passenger (right seat) 20.5 170 3485
1610
Plot 2350 Ibs and +1610 in-lbs on Figure 5-2 to assure moment is in
approved area.
MM-5-8
LOADING CHART
Fig. 5-5
100
000
EAT LOAI)
LBS.MA
608
u,
PD 1 400 ii Il IT 771 1 I I I I I 1 I 1 1J r7 1 I I I Il I I 1 r7 T rTTT TT~ I 1 I I I I 1 I I I I I I T1 I I~1 I I I I 1 I i I 1 1 ilrrI r T T 1 r I
rr
Z
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~1 300
o
~I II L1 I I I I I r TT 1 I~ 1 177 T I i I I I~I I T I rT T T I 1 I I I I IY7 TI I1T7T T IT I I T II I I I 1 I II 1 17 1 1 I I 1 I 1 I I II I I I I
tOO
100 LII III Illlmllrl Ilnllxllrrl I Is~slm

"VV´•iOVB~
It (t tO 3t 3t ~O
YOYENT IN. LBS. X 1000

2600
2400
B
o
B
22001 1 I i I I 1 1 I I 1 I 1 r 1/ Irr r I I I I r 1 1 I 1 I I I~
I I I I I I I I I I I I I I I A~ I VYI I I I I I I I I I I I I I~
(3
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cn
A
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(L 2000
1800
1600
140 160 180 200 220 240 260 280
LONGITUDINAL MOMENT INCH POUN DSi 1000
GROSS WEIGHT VS LONGITUDINAL MOMENT
Fig. 5-6
MAINTENANCE MANUAL
WEIGHT SHEET
MODEL SERIACNO. REG. NO.
WEIGH POINT SCALE LBS. TARE NET WT. ARM MOMENT X

1000
LEi~T GEAR (W,)
I RlOnTOEIR (WR)
TAIL (WT)
TOTAL
WT(320.0)+ (WL+ WR) (93.440)

LCG=
WT’ WL~ WR
DATE WEIGHED BY
Fig. 5-7
MM-5-ll
YOYtWt
WElOnt I ARY 1000
ACTUAL DELIVERED WEIGHT AND BALANCE DATA IW.- LB. O
X
r
ItLw VEIOH’T ADDu)+ WLlOHT REYOVED RUIYWI)IO OARIC TOTAL a
DESCRIPIIOW OCIRTICLE: O
WO. OR Y001PIC1TIOW ROYRRT YOYEW’T YOYellT
tw *EIQnT IRY 1000 WElORT ARY 1000
II~LI. IW-LB.
(n"
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F-IB~A
Fig. 5-8
MAINTENANCE MANUAL
HELICOPTER WEIGHT AND C.G. CALCULATION
MODE L SERIAL NO. REG. NO.
WEIGHT ARM MOMENT

LBS. IN. 10001NILB.
WEIGHT (AS WEIGHED)

PLUS:MISSING STD. EQUIPMENT
LESS:OPTIONAL a SURPLUS WT.
LESS:ENGINE OIL
PLUS: 12 LBS.UNUSABLE FUEL
WEIGHT EMPTV COMPUTED
STD. HELICOPTER ACTUAL
PLUS:ENGINE O1L
PLUS:OPTIONAL EQUIPMENT
TOTAL BASIC WEIGHT
FORM F-168A
Fig. 5-9
IYIY-5-13
MAINTENANCE MANUAL
Fig. 5-10
EKSTROM E4UIPMENT LIST
SERIAL NO.
F.A.A. APPROVED REGISTRATION NO. DATE
NO. ITEM WT.I ARM
INSTRUMENTS-REQUIRED
ALT IMETER 1.2 36
AIRSPEED 36
TACHOMETER 1.3 36
MANIFOLD-FUEL PRESSURE 1.5 36
I NSTRUMENT CLUSTER 2.0 36
OIL TEM PERATUR E
OIL PRESSURE
GEARBOX TEMeERATURE
CYLINDER TEMPERATURE
FUEL OUA)JTITY
AMMETER
COMPASS 1.0 40
OAT GAUGE O.S bl)
BALL BANK INDICATORI
E.G=T. GAUGE O.b 36
NO. OPTIONAL EQUIPMENT WT
,STANDARD EOUIPMENT NOT REOUIRED BY FA.A.

MM-5-14
MAINTENANCE MArlUAL
ENSTROM OPTIONAL EQUIPMENT LIST CONTINUED
SERIAL NO.
F.A.A. APPROVED REGISTRATION NO. DATE
NO. ITEM WT. I ARMIMOM ENT
~1M-5-15
SECTION
ELECTRICAL SYSTEM
MAINTENANCE MANUAL
SECTION 6
ELECTRICAL
6-1 ELECTRICAL SYSTEM
The F28F/280F electrical system is either a 12 volt or a 28 volt D.C.

solid state regulated type. The system consists of one main buss,
one generating source and one power storage source.
Electric current is distributed via buss bar thru individual trip

free circuit breakers. Networks not protected by trip free breakers
contain inline fuses.
The aircraft storage battery is a manifold vented type with suffi-

cient power capacity to start the aircraft under all normal operating
conditions.
Electrical safety devices are provided for buss overcurrent and

overvoltage protection.
Aircraft equipped with avionics systems are supplied with radio

frequency interference filters.
B. General Troubleshooting
(1) Always refer to the Electrical System Schematic for system

interconnections, Figures 4 and 5.
(2) Simple, fast, wire checks can be performed by making continuity

tests with an ohmmeter. The continuity check is a quick
procedure for isolating electrical problems to a specific
circuit.
(3) Check for loose hardware or loose connectors at wire

terminations.
(4) Check all ground connections for evidence of looseness

. noisorrocro I
(5) Check wire insulation, grommets, tie wraps for wearer
deterioration.
(6) In the event of trsuble with A/C lighting, substitute equivalent

bulbs to operate) from a different location on the A/C to
(known
determine whether problem is lamp or system related. Especially
useful for checking strobes and anti-collision lamps.
#2 Rev. 11/18/88 MM-6-1

MAINTENANCE MANUAL
(7) The following devices should be serviced as recommended by

the respective manufactures.
(a) Alternator
(b) Starter motor.
(c) Magneto-vibrator-ignition switch
(d) Fuel boost pump motor
(e) Strobe systems
(8) Continuous wire runs (Ref: Schematic Diagram) are typically

identified by an assigned wire no., i.e. 24-2, from the aircraft
battery positive terminal to the starter relay contacts. In
cases where wire runs are interrupted by splices, disconnects,
fuses etc., the wire number is also assigned a letter i.e., wire
49-1A from buss to F3, and wire number 49-18 from the opposite
end of F3 to wire number 49-10. The A-B designation indicates
wire discontinuities. Typically wire nos. (not letters)
sequence through electrical devices such as lamps motors and
relays etc.
6-2 BATTERY
The aircraft is equipped with a 12 volt or 28 volt battery as

described below. In either case, manifold style
eliminate the need for a battery box.
battery vents
Gases are vented outside the
I,
aircraft by tubes attached to the manifold. Battery connections are
L. Type terminals.
The following specifications apply to the standard aircraft battery:
12 VOLT 28 VOLT
Manufacturer Concorde Gill (Teledyne)

Type CB12-11M 6-243
Voltage 12 24
Amp Hours 35 (5 hours) 10 (1 hour)
Cold Cranking Amperes 330 150
Overall Dimensions
Inches 9.75L x 5.13W x 7.25H 7.39L x 7.31W x 6.75H
Cm 248L x 131W x 185H 188L x 186W x 171H
#2 Rev, MM-6-2
11!18(88
MAINTENANCE MANUAL
ALTERNATOR INSTALLATION REMOVAL
i 1
Fig. 6-1A
FAN SI1ROUD SIDE SHOWING ALTERNATOR MOUNT

PIVOT SLIDE TENSION BAR AND DRIVE BELT
Fig. 6-1B
UNDERSIDE OF ENGINE SNOWING ALTERNATOR

MOUNT POSITION AND PIVOT MOUNT BOLTS
OWIGI NAL
MM-6-3 ks Weceived By
ATP
MAINTENANCE MANUAL
8. Battery-Troubleshooting
Problem Cause Required Action
Battery Loose or Clean connections, tighten

discharged corroded terminal hardware
terminals
Low electrolyte Reference Section 5-2

level in battery Battery Servicing
cells (below top hydrometer test
of cell plates)
Loose belt Reference Section 6-3D

Alternator Installation
C. Battery Master Power Troubleshooting
Master Dead battery Replace or recharge

switch-on, all
electrical Master relay Replace master relay
systems faulty (RLI)
in-operative (coil or
contacts bad)
Overcurrent trip Reset overcurrent breaker

breaker "open" or replace breaker if
or faulty (CB16) faulty
Inline fuse Replace fuse

blown (f18)
Overcurrent Replace breaker

breaker faulty
CB17
MM-6-4
MAINTENANCE MANUAL
D. Buss Faults Breaker System
General Description:
This battery protection system is designed to remotely sense elec-

trical overloads in the aircraft which cause excessive battery
current drain. This system consists of fuse (FIB), overcurrent
breaker (CB17) and the "overcurrent trip" breaker (CB16) on the
instrument panel.
Circuit breaker CB17 (located at the aircraft battery) senses the

overload condition, simultaneously trips the dash mounted overcurrent
breaker CB16 and deactivates the master relay. This action removes
the battery from the aircraft buss.
Battery power cannot be returned to the A/C buss unless the "over-
current trip"
dash mounted breaker is first reset. The "overcurrent
trip" breaker cannot be reset until the overload condition has been
corrected. Repair of this system is limited to replacement of faulty
components, and the removal of the overload condition.
6-3 ALTERNATOR
The aircraft alternator is a belt driven type manufactured by the

Prestolite Co. The alternator output rating is 70 amperes continuous
at approximately 12 volts D.C. or 28 volts D.C., depending on the
electrical system. Principle components of the alternator are the
stater, the rotor, the slip ring end head, the drive end head and the
rectifier diodes.
B. Troubleshooting
The following list suggests areas to be investigated should

alternator performance become suspect:
(1) Rotor-Test for ground or shorted windings
(2) Rectifier Diodes Test for open or shorted diodes
(3) Stater-Test for open.
(4) Bearings-check for roughness or excessive clearance.
(5) Housing cleanliness End housing´•should be kept clean by wiping

with a cloth dampened in solvent.
NOTE: It is recommended that the Prestolite service manual

applicable to your alternator type be consulted for
detailed repair procedures.
#2 Rev. 11J18/88 MM-6-5

MAINTENANCE MANUAL
C. Alternator Removai (see Fig. 6-1)
(1) Disconnect the battery cables.
(2) Remove cowling and baggage box.
(3) Remove the jackstrut and pulley assembly. (see Section 11-4 for
for Jackstrut Removal Procedure).
(4) Remove the fan assembly exposing the alternator.
(5) Remove the four bolts attaching auxiliary oil cooler and lower
the cooler.
NOTE: Allow oil cooler to hang free on attached oil lines.
(6) Remove the lower access panel from fan shroud located above the
auxiliary oil cooler.
(7) Cut safety wire on bolt securing alternator belt tension arm and
remove bolt. Pivot alternator and remove v-belt from alternator
pulley.
(8) Disconnect wires from alternator.
NOTE: Identify wires for re-installation.
(9) Remove the two alternator mount bolts and remove alternator.
D. Alternator Installation (see fig. 6-1)
NOTE: On new or replacement alternators, remove fan and replace

with spacer from removed alternator.
(1) Align alternator with mount bracket and install the two
attachment bolts.
NOTE: Tighten mount bolts finger tight allowing alternator to

pivot.
(2) Place v-belt on alternator pulley and install bolt thru the belt
tension arm.
(3) Connect wires to the alternator as previously marked.
NOTE: Check attachment per wiring schematic.
(4) Pivot alternator and adjust belt tension until pulley just slips
at 12 ft-lbs.
(5) Torque alternator mount bolts 2 places.
(6) Install and secure lower access panel on fan shroud. i)
MM-6-6
MAINTENANCE MANUAL
STARTER INSTALLATION REMOVAL
Fig. 6-2A
UNDERSIDE OF ENGINE SHOWING STARTER MOUNT

POSITION WITH COWL ADAPTER AND SPACERS
E;Fclll
9iEI!:´•
Fig. 6-2B
STARTER MOUNT FROM FAN

SIDE LOOKING FORWARD
~RBGONAb
k~s Woceived BL
MM-6-7
BTe~
MAINTENANCE MANUAL
(7) Position auxiliary oil cooler in place and secure with four
attachment bolts.
(8) Install fan assembly and shims on flywheel.
(9) Install jackstrut and pulley assembly. (See Section 11-4 for
Jackstrut Installation Procedure).
(10) Inspect all items for security.
(11) Install cowling.
(12) Connect the battery cables.
6-4 VOLTAGE REGULATOR
Alternator voltage is controlled by a solid state transistor

regulator. The regulator is factory set for proper voltage control
and shoul~d not normally require field adjustment. Field repair of
the regulator is generally not practical and the unit should be
replace in the event of failure.
B. Troubleshooting
Symptoms of a faulty regulator include:
(1) Continuous discharge on aircraft ammeter.
(2) Large fluctuations in ammeter needle (needle oscillates from

charge to discharge).
(3) Excessive charging indication on ammeter with fully charged or
new battery.
(4) Annneter needle drops to discharge position as additional

electrical loads are switched on such as strobes landing
lights, etc.
(5) Battery frequently requ i res water indicates ove rcha rg i ng

regulator.
NOTE: Solvents engine cleaning fluid should not

and be used
on the regulator. Cover regulator during engine
compartment cleaning.
MM-6-8
MAINTENANCE MANUAL
C. Voltage Regulator Removal
(I) Open right side engine panel and remove the air filter housing
assembly. (See Section 13-7, Primary Airflow System).
(2) Cut the tie wraps from wires running to the voltage regulator.
(3) Cut regulator wires at splices.
(4) Remove screw to disconnect the ground wire. (Black wire).
(5) Remove the two screws securing voltage regulator and remove
regulator.
D. Voltage Regulator Installation
(1) Install voltage regulator on firewall panel and secure with two
screws.
(2) Secure black ground wire with screw.
(3) Connect the remai ning regulator wires with new splices and
secure in position with tie wraps.
(4) Install air filter housing assembly. (see Section 13-7 Primary
Airflow System).
E. Voltage Regulator Adjustment
NOTE: If amme te r shows conti;nuous charge or discharge check

voltage regulator adjustment. A voltmeter will be required
to check the regulator.
(1) Establish an electrical system load of approximately 15 to 20

amperes.
(2) Connect voltmeter positive lead to aircraft battery

terminal. Connect voltmeter negative lead to battery
terminal.
(3) After one minute of engine operation at proper electrical load,

rotate regulator adjustment screw until voltmeter at battery
indicates 14.0+ .2 volts for a 12 volt system, or 28.5+ .2 volts
for a 28 volt system.
NOTE: C1 oc kw i se screw rotati on increases voltage. Do not

force adjustment screw.
(4) Disconnect meter from battery and secure battery compartment for
airworthiness.
#2 Rev. 11/18/88 MM-6-9

MAINTENANCE MANUAL
6-5 OVERVOLTAGE RELAY
This system aids in the protection of auxiliary and standard aircraft

electronics in the event of an excessive overvoltage occurrence.
The overvoltage relay system directs power to the regulator through

the terminal marked "load" until such time when the terminal marked
"battery: senses overvoltage
an condition.
Upon sensing over- an
voltage the regulator power path becomes interrupted, thereby

disabling the alternator charging system. The charging circuit is
held open (Regulator-Al ternator Off) and can be reset only by removal
of battery voltage from the overvoltage relay "battery" terminal.
This is accomplished by manually cycling the alternator switch (dash
switch panel) on and off thereby resetting the overvoltage relay.
The overvoltage relay will not reset until the problem causing the
overvoltage condition has been corrected.
6-6 STARTER
Components which comprise the starter system include the ignition

breaker (CB6), starter switch (S8), starter relay (RL2) and the
starter motor (SM).
The starter motor receives power directly from the aircraft battery
through relay RLZ. A pushbutton switch located at the throttle end
of the collective stick activates the starter relay by drawing power
from the main buss thru ignition breaker CB6. The starter relay is
located near the aircraft battery.
Troubleshooting this system is best accomplished by component

replacement with the exception of the starter motor which can be
serviced. Servicing of the starter motor should be performed to
manufacturers specification.
MM-6-10
MAINTENANCE MANUAL
B. Troubleshooting
Problem cause Required Action
Starter motor Low battery Charge or replace

inoperative voltage battery
Collective start Replace switch

switch 58
defective
Starter breaker Reset breaker

switch open or switch or replace
defective (CB6) if defective
Starter relay Relay coil Check continuity

does not activate "open" of relay coil,
(RL2) replace relay if
defective
Starter relay (RL2) Relay contacts Replace starter

activates, starter defective relay
motor does not run
Starter relay OK, Starter motor Rebuild or replace

sufficient battery defective starter motor
motor does not run.
C. Starter Removal (see fig. 6-2)
(1) Disconnect battery cables.
(2) Remove cowling and baggage box.
(3) Remove jackstrut and pulley assembly. (See Section 11-4 for
jackstrut removal procedure.)
(4) Remove fan assembly.
(5) Remove bolts and strap securing starter housing to alternator

housing.
(6) Remove starter housing bolt from aft side of fan shroud.
(7) Remove fan shroud access panels from inside engine compartment
to aid in starter removal.
(8) Disconnect power cable from starter.
(9) Remove the two outboard nuts from starter housing mount pad.
MM-6-ll
MAINTENANCE MANUAL
(10) Loosen the two inboard nuts from starter housing mount pad and
slide starter assembly outward to remove.
NOTE: The starter mount pad is slotted on the inboard side

for ease of removal. Do not completely remove the
inboard mount nuts. (See fig. 6-2)
(11) Remove starter shim from mount pad area if applicable.
NOTE: Retain shim for re-installation.
D. Starter Installation (See Fig. 6-2)
(1) Align starter housing mount pad slots with inboard studs and
slide starter into position.
NOTE: Be sure shim is installed between mount pad and starter

housing if applicable.
(2) Secure starter with mount hardware.
(3) Install starter housing mount bolt in aft side of fan shroud.
(4) Install and secure strap between starter housing and alternator
housing.
(5) Connect battery cables and power cable to starter.
(6) Check starter bendix gear to ring gear clearance as follows:

(Clearance .010-.030 inch)
CAUTION: The starter and the ring gear must be securely mounted
before this check can be completed. Install ring gear
with two short bolts without fan installed.
(a) Remove the four lower spark plugs.
(b) Engage starter momentarily to bring bendix gear in contact

with ring gear.
(c) Check for backlash clearance between the gears at a minimum

of four locations on the ring gear (90" apart) by rocking
the fan back and forth. If a tight spot is felt or a place
of zero backlash is encountered, reshimming of the starter
is required.
NOTE: It is also possible to check this clearance with gauge

wire or safety wire at the point where the timing holes
in the fan dish align with the starter. The clearance
check will be between the tip of the bendix gear tooth
and the bottom of the ring gear groove.
MM-6-12
MAINTENANCE MANUAL
(7) Safety wire starter mount bolts.
(8) Remove two short bolts from ring gear hub and install fan
assembly.
(9) Install jackstrut and pulley assembly. (See Section 11-4 for
jackstrut installation procedure).
(10) Install fan shroud access panels in the engine compartment.
(11) Install baggage box and cowling.
6-7 FUEL BOOST PUMP
The electric fuel boost system consists of the boost pump motor (BM)
and the boost pump breaker switch (CB12). Fuel boost pressure is
monitored by an independent electric circuit comprised of the fuel
ressure switch, red pressure status indicator and a circuit breaker
Low fuel boost pressure (example: electric boost pump off)
will cause the red indicator to be energized. With sufficient fuel
pressure (electric boost motor on) the red indicator will be
extinguished. The indicator lamp has a press-to-test function for
checking lamp filament continuity.
B. Troubleshooting
Either or both Indicator lamp Replace lamps

indicator lamps filaments failed
out, low fuel (L8 or L9)
pressure
CB7 instrument Reset or replace

breaker failed breaker
or open
Fuel pressure Replace fuel

switch faulty pressure switch
Boost pump breaker Reset or replace

switch (CB12) open breaker
or failed
Boost motor (BM) Replace boost motor

failure
MM-6-13
MAINTENANCE MANUAL
-s
A. Forward Landing Light Troubleshooting

Landing light Lamp filament Replace lamp
inoperative burned out (L14)
Landing light Reset or replace

breaker (CB5) breaker
open or failed
Inline fuse (F2) Replace fuse

open (F28F only)
Landing light relay Replace relay RL4

(RL4) open or
shorted, contacts
worn (F28F only)
Cyclic stick Replace landing

forward landing light switch
light switch
failed (F28F only)
B. Aft Landing Light Troubleshooting
Aft lamp Lamp filament Replace Lamp (L3)

inoperative burned out (L3)
Circuit breaker Replace or reset

switch CB10 open breaker switch
or failed
C. Panel Lights

Lights do not Rheostat (R3) Replace rheostat
dim/lights wiper faulty,
inoperative rheostat windings
open
Rheostat (R3) knob Tighten set screw

loose on rheostat of knob
shaft
Panel light breaker Reset breaker,

switch (CB2) open replace if defective
or faulty
NOIE: Illu.inated legend bar lamps are not easily replaced.

Replacement of bar is recommended if lamp failure occurs.
MM-6-14
MAINTENANCE MANUAL
D. Navigation Lighting
Running lights Lamp filaments Replace lamps

inoperative (F28F) (L5-2) and (L5-1)
burned out
Tail lights Lamp filaments Replace lamp

inoperative (F28F) (L4 or L2) burned
out
All navigation Navigation light Reset or replace

lights inoperative circuit breaker circuit breaker CB3
(F28F) tripped or faulty
Tail light Lamp filament (L1) Replace lamp (L1)

inoperative (280F) burned out. Circuit Reset or replace
breaker CB3 tripped circuit breaker
or faulty CB3
Right or left Burned out lamps Replace lamps

strobe lamps in-
operative (L2-1,
L2-2) 280F
Right or left Strobe power supply Repair or replace

strobe lamps in- (SLPS) faulty strobe power supply
operative (L2-1, NOTE: Lamps have
L2-2) 280F separate power
supplies.
Both left-right Navigation light Reset or replace

navigation lights circuit breaker breaker CB3
and tail light in- open or faulty
operative (280F)
Both right and left Anti-collision Reset or replace

strobe lamps in- light breaker CB4 breaker
operative (280F) (CB4) open or
faulty
Anti-collision lamp Lamp filament Replace lamp

inoperative (F28F)~ burned out L11-l, L12-1
Both anti-collision Circuit breaker CB4 Replace or reset

lamps inoperative open or tripped breaker CB4
(F28F)
Both anti-collision Power supply PSAL Repair or replace
lamps inoperative faulty power supply

(F28F)
MM-6-15
MAINTENANCE MANUAL
6-9 CLUTCH DISENGAGE WARNING LIGHT
The clutch disengage warning system consists of a red indicator lamp

mounted in the instrument panel and a limit switch located on the
clutch actuator mechanism. This circuit is protected with an inline
fuse located in the instrument panel.
The system provides a visual cockpit warning indication of an improp-

erly positioned clutch overcenter mechanism. The red warning cockpit
lamp is illuminated whenever the clutch overcenter mechanism is not
properly positioned tightly against the clutch side plates.
Troubleshooting this system consists mainly of clutch rigging checks

switch replacement and indicator lamp or fuse replacement.
NOTE: Installation and rigging covered in section 11-1 Belt Drive

System.
6-10 MANIFOLD PRESSURE OVERBOOST CAUTION LIGHT
The manifold overboost caution system consist of a pressure activated

snap switch and associated amber indicator. System fault protection
is provided by a single inline fuse (F17) located in the instrument
panel.
Engine manifold pressures near maximum allowable will illuminate the

amber caution lamp drawing the operators attention to the manifold
gauge for possible corrective action. The lamp activating switch
operates from a tap in the aircraft manifold pressure instrument
line. Transient pressures from quick throttle inputs may appear to
illuminate the lamp at low gauge pressure readings. This occurs due
to inherent dampening characteristics of the pressure gauge which
prevent the needle from following transient pressures. Lamp filament
and fuse continuity can be checked via the indicator press to test
feature.
Troubleshooting of this system is generally limited to component

replacement such as fuse, switch, lamp, etc.
MM-6-16
MAINTENANCE MANUAL
6-11 HOURMETER
A. Troubleshooting
Hour meter Inline fuse (FI) Replace fuse (FI)

inoperative open
Oil ressure switch Replace oil pressure

(OPS failed switch (OPS)
Hour meter faulty Replace hour meter

(HM)
6-12 TRIM MOTORS
A. Troubleshooting
Erratic or no trim Lateral limit Replace S11 or S12

motor operation switch S11 or limit switch
S12 failed
Fore-aft limit Replace S9 or S10

switch S9 or limit switch
S10 failed
Shorted motor Replace trim

TM1 or TM2 motor
Four-way cyclic Replace four-way

switch faulty switch
Circuit breaker Reset or replace

switch CB8 open breaker CB8
or failed
MM-6-17
MAINTENANCE MANUAL
6-13 AMMETER CHARGING SYSTEM
A. Troubleshooting
Ammeter shows Regulator failed Adjust regulator per

continuous dis- or out of adjust- recommended specifi-
charge (engine ment cation. Replace if
running) defective.
Alternator breaker Reset or replace

open or defective breaker CB1
(CB1)
Alternator Reset or replace

breaker (CB15) breaker CB15
open or defective
Overvoltage relay Reset overvoltage

tripped or relay. Replace if
defective defective.
Alternator switch Replace switch S6.

(S6) defective
Alternator windings Service alternator

shorting per mfg. spec.
Worn or loosened Replace/tighten

alternator belt belt.
MM-6-18
MAINTENANCE MANUAL
6-14 INSTRUMENT CLUSTER TROUBLESHOOTING
A. Troubleshooting
Fuel quantity Instrument breaker Reset or replace

indicator CB7 faulty or open breaker CB7
inoperative or
erratic Loose, damaged, Inspect sending

broken ground wire unit wiring repair
from sending unit as necessary
Faulty module Perform electrical

electronics check of module
see Figure 6-7
B. Troubleshooting Main Rotor Gearbox Temperature
Erroneous Instrument breaker Replace or reset

indication or CB7 open or faulty breaker CB7
inoperative
temperature meter Loose, damaged or Inspect sending unit
broken ground wire wiring repair as
from sending unit necessary
Damaged Replace thermocouple

thermocouple wire. Use type
approved for
application
Faulty module Perform electrical

electronics check of module
See Figure 6-6
Needle pegged Excessive resist- Check probe wiring

beyond full scale ance in temperature for break and
probe line repair as necessary
Needle pegged Shorted probe wire Inspect probe wire

below zero for improper ground.
Replace wire.
MM-6-19
MAINTENANCE MANUAL
C. Troubleshooting Amperage Meter
Meter not Loose connection Tighten shunt

operating at meter shunt terminals
Faulty indicator Perform electrical

check of module
See Fig. 6-7
D. Oil Temperature Module
Oil temperature Breaker C87 Reset or replace

faulty or open breaker
Faulty indicator Perform electrical

check of module
see Figure 6-5
Needle pegs Faulty sending Repair or replace

unit ground defective wiring
Excessive resist- Check probe wiring

ance in temperature for break and repair
probe wiring as necessary
Defective sending Replace temperature

unit probe
Needle pegs below Open in probe Inspect wiring from

zero wiring probe for improper
ground. Replace
ground wire.
MM-6-2O
MAINTENANCE MANUAL
E. Cylinder Head Temperature Module Troubleshooting
Cylinder head Circuit breaker Reset or replace

temperature module CB7 open or faulty CB7
inoperative
Defective Replace temperature

temperature probe probe
Needle pegged at Excessive resis- Check wiring for

full scale tance in temp break. Repair or
probe wiring replace probe wire.
Needle pegged below Shorted probe wire Inspect wiring from

zero probe for improper
ground. Replace
defective wiring.
F. Instrument Cluster Module Check Procedure
This procedure will assist in determining the operational status of

the individual instrument modules. The steps do not constitute an
instrument calibration procedure. Resistance values given are
approximate.
Equipment Required:
(1) 14 or 28 volt, 2 amp, filtered-regulated power supply.

(2) Variable power resistor or resistance decade box.
(3) Test Leads.
Procedure:
(1) Position rear of module as pictured.
(2) Connect power and variable resistor per individual-diagram.

(3) Adjust desired resistance level.
(4) Set power supply for 14 volts D.C. or 28 volts D.C., as
appropriate.
(5) Do not useresistance values lower than those specified in the
respective charts, instrument damage may result.
(6) Pin having "no connection" is 14 or 28 volt lighting.
(7) All grounds are power supply "negative output" connections.
(8) Proper instrument operation is observed when resistance values
and scale readings correlate. See applicable chart for each
module type.
NOTE: Excessive resistance or open in probe wires may cause

meter needle to "peg" full scale.
A short or very low resistance in probe wires may cause

meter needle to "peg" below zero.
#2 Rev. 11/18/88 MM-6-21

J5
TRIM MOTOR
INTERCOMMIKE KEY SWITCH
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CANNON CONNECTOR
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LIGHT
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STARTER MOTOR
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FUEL PRESSURE SSU

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OVERCURRENT
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WARNING LIGHT
HOURMETER
SWITCH BREAKER ANTI~COLLISION
SI LI 15-2- 11 LIGHTCONNECTOR
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1;-38)17(811: (DUIL)
cLYuc 01001110110 ´•YCL

MAINTENANCE MANUAL
6-15 CHARTS
A. Electrical Loads
The flight ampere load conditions chart describes the typical

amperage required to operate specific standard electrical devices in
the F28F and 280F aircraft. Total electrical loads (amperes) are
shown for various combinations of electrical devices under simul-
taneous operation. The electrical load totals can be used to
estimate the percent reserve power available from the alternator when
additional electrical equipment is installed on the aircraft.
(Maximum continuous alternator output is 70 amperes).
COMPONENT LOCATION CHART
FUSES
LOCATION SCHEMATIC ID DESCRIPTION F28F 280F
Instrument panel Fl Hourmeter fuse X X
Instrument panel F2 Forward landing light fuse X X
Instrument panel F3 Utility light fuse X X
Instrument panel F17 Overboost light X X
Battery box F18 Overcurrent system X X
Instrument panel F20 Clutch disengaged system X X
RELAYS
Aft firewall RL1 Master relay X X

co-pilot side
Battery box RL2 Starter relay X X
Behind seat deck RL4 Landing lamp relay X

pilot side
SPECIAL SWITCHES
Engine compartment FPS Fuel pressure switch X X

cross tube
co-pilot side
Instrument panel OPS Oil pressure switch X X
Instrument panel S13 Turbo boost pressure X
Instrument panel 513 Turbo boost pressure X
MM-6-25
MAINTENANCE MANUAL
280F FLIGHT AMPERE LOAD CONDITIONS 12 VOLT SYSTEM r

DAY MIGHT
ELECTRICAL DEVICE A B C D E F G H I J K L
Boost Pump 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5
Longitudinal Trim" 6.0 6.0 6.0 6.0 6.0
Lateral Trim* 6.0 6.0 6.0 6.0
Radio Transmit* 3.5 3.5 3.5 3.5 3.5
Radio Receive 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
Instrument Cluster 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14
Master Relay 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Stroke Kits (Total) 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4
Position Lights Right Left 4.0 4.0 4.0 4.0 4.0 4.0 4.0
Panel Lights 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Aft Position Light 1.6 1.6 1.6 1.6 1.6 1.6 1.6
Forward Landing Light 4509** 8.23 8.23
Forward Landing Light (4313)f** (20.8) (20.8)

Aft Landing Lights** 3.14 3.14
9.64 19.14 15.64 17.24 26.74 23.24 38.11 28.61
(50.68)(41.18)
NOTE: Flight condition "A" is day normal cruise
Flight condition "F" is night normal cruise

Denotes intermittent use
Denotes short duration use (5 minutes)

*f*
4313 Landing lamp acceptable substitute
The above load conditions include typical electrical appliances for 280F series helicopters.
If other special equipment is added, the loads for conditions A and F in the above table are
to be modified,
#2 Rev. 11/19/88 MM-6-26

MAINTENANCE MANUAL
F-28F FLIGHT AMPERE LOAD CONDITIONS 12 VOLT SYSTEM t

DAY NIGHT
Nav Lights 6.44 6.44 6.44 6.44 6.44 6.44 6.44

4 1.61 amps each
Boost Pump 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5
Longitudinal Trim* 6.0 6.0 6.0 6.0 6.0
Lateral Trim* 6.0 6.0 6.0 6.0
Radio Transmit* 3.5 3.5 3.5 3.5 3.5
Radio Receive 0.6 0.6 0.6 0.6 0.6 0,6 0.6 0.6 0.6 0.6 0.6 0.6
Instrument Cluster 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14
Master Relay 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Anti-Collision 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0
Panel Lights 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Forward Landing Light 4509*f 8.23 8.23
Forward Landing Light (4313)*** (20.8) (20.8)

Aft Landing Light 4509*X 8.23 8.23
Aft Landing Light (4313)*** (20.8) (20.8)

Landing Light Relay 0.21 0.21
14.24 23.74 20.24 22.68 32.18 28.68 48.85 39.35
(73.99)(64.49)
NOTE: Flight condition "A" is day normal cruise

Flight condition "F" is night normal cruise
Denotes intermittent use
Denotes short duration use (5) minutes)
4313 Landing lamp acceptable substitute
The above load conditions include typical electrical appliances for F-28F series helicopters. If other
special equipment is added, the loads for conditions A and F in the above table are to be modified.
#2 Rey, 11!18!e8 MM-6-27

MAINTENANCE MANUAL
F-28F LAMP REPLACEMENT CHART
ASSEMBLY
AMOUNT LOCATION MANUFACTURER ASSEMBLY NO. BULB NO.
12 Volt 28 Volt
1 Aft Landing Light Enstrom 4313 or 4509 4591
1 Forward Landing Light Enstrom 4313 or 4509 4596
1 Forward, Right Position Light Grimes A-1285-6-12 1512 1524

Green
1 Forward, Left Position Light Red Grimes A-1285-R-12 1512 1524
2 Uft Position Lights Grimes A-1285-C-12 1512 1524
2 Anti-Collision Lights Whelen HDA-14 A469A A469A

Flash Tube
1 Map Light Grimes 15-007-5 1816 313
2 Post Lights Grimes A8970 330 327
8 Eyebrow Lights Grimes B4855-B-330 330 327
1 Fuel Boost Light Red Dialight 803-1710-0331-504 1815 1819
2 Switch Panel Placard Enstrom 28-18091-1 Replace

(Master Switch, etc)
Lights 28-18091-3 Assembly

(Alternator, etc)
1 Overboost Caution Light Dialight 1815 1819
1 Clutch Disengage Warning Light Dialight 803-1710-0331-504 1815 1819
#2 Rev. 11/18/88 MM-6-28

MAINTENANCE MANUAL
280F LAMP REPLACEMENT CHART
ASSEMBLY
AMOUNT LOCATION MANUFACTURER ASSEMBLY NO. BULB NO.
12 Volt 24 Volt
1 Aft Landing Light Enstrom 4406 4591
1 Forward Landing Light Enstrom 4313 or 4509 4596
1 Right Side Position Whelen (modified A650PG W1290-14 W1290-28

by Enstrom)
Light and Strobe (Enstrom 28-21048-3) A61O Strobe A61O
1 Left Side Position Whelen (modified A6O5OPR W1290-14 W1290-28

by Enstrom)
Light and Strobe (Enstrom 28-21048-1) A610 Strobe A61O
1 Aft Position Light Whelen A555 A5O8-14 A508-28
1 Map Light Grimes 15-007-5 1816 313
2 Post Lights Grimes A8970 330 327
8 Eyebrow Lights Grimes B-4855-B330 330 327
1 Fuel Boost Light Red Dialight 803-1710-0331-504 1815 1819
1 Fuel Boost Light Green Dialight 804-1710-0332-504 1815 1819
2 Switch Panel Placard Enstrom 28-18091-1 Replace

(Master Switch, etc)
Lights 28-18091-3 Assembly

(Alternator, etc)
1 Overboost Caution Light Dialight 1815 1819
1 Clutch Disengage Warning Light Dialight 803-1710-0331-504 1815 1819
#2 Rev. 11/18/88 MM-6-29

SECTION
INSTRUMENTS
MAINTENANCE MANUAL
SECTION 7
INSTRUMENTS
7-1 INSTRUMENT PANEL (See Figures 7-1 7-2)
The instrumentpanel is centrally located inthe front of the cabin for

optimum visibility by either pilot or cc-pilot. The "F" model instrument
panel is mounted at an 80 angle.
NOTE: Instrument panel angle is required when replacing an attitude

gyro (horizontal horizon) designed to operate at the same angle.
7-2 ALTIMETER
A. Description
The altimeter indicates the height of the helicopter above sea level.
It is operated by static air pressure derived from the airspeed
pitot-static system. The altimeter is of the sensitive type that
provides a height reading from O to 20,000 feet. The long hand reads
in increments of 100 feet, the middle hand in increments of 1,000
feet, and the short hand in increments of 10,000 feet. The control
knob on the face of the altimeter adjusts the barometric pressure
reading to set field altitude.
CAUTION: Never apply positive pressure to static lines with the

instruments connected; this will damage the instrument
mechanism.
B. Altimeter Troubleshooting
Indicating hands Static pressure Disconnect static pressure

fail to respond, line obstructed, line from instruments and
blow with compressed air.
Static pressure Check static pressure

connection lines and connect
improperly made. correctly.
Indications are Leaks in static Replace damaged tubing

obviously pressure line and/or check instruments
incorrect. and/or leaks in for leaks.
cases of
instruments in
same system.
Defective Replace altimeter.

instrument.
MM-7-1
MAINTENANCE MANUAL
COMPASS
COMPASS CALIBRATION CARD

LOCATION MAY VARY)
AIRSPEED INDICATOR
a
LNGIIIE 4ND ROTO~
TACHOMETER
CLUTCH DISENGAGE ALTIMETER

WARNING LIGHT
OVERBOOST WARNING
BALL BANK
LIGHT
INDICATOR
MANIFOLD/
ERUS PLEUF INDICAfORAMMETER
FCIRCUIT BUSS FAULT
BREAKER
I/
HEAD TEMP
1,CYLINDER INDICATOR
EXHAUST GAS
FUEL OUANTITY GAGE -------_ 1 I TEMPERATURE GAGE
FORWARD LANDING
CIRCUIT BREAKER
LIGHT
MAIN ROTOR GEARBOX

TEMPERATURE CAGE
\_ -ALTERNATOR EXCITATION
CIRCUIT BREAKER
ENGINE OIL PRESSURE
I
LOW FUEL BOOST PUMP
INDICATOR PRESS TO TEST
LIGHT
ENGINE OIL TEM_P,.~
INDICP~TOR
MALiNETO
GIG. LIGHTER (OPTIONAL)
(IGNITION) SWITCH’ ,I
MASTER SWITCH
INSTRUMENT CIRCUIT BREAKER
ALTERNATOR SWITCH
ALTERNATOR CIRCUIT BREAKER
FUEL MIXTURE CONTROL~
AFT LANDING LIGHT
PANEL LIGHTS
LIGHTS
Y
NAVIGATION
CIRCUIT
ANTI-COLLISION LIGHTS BREAKER
SWITCHES
a onr CLOCK (OPTIONAL)
(LOCATION M~Y VARY) 1~ FUEL BOOST
TRIM
PUMP
ASHTRnv (oPTloNAL)/
IGNITION
F28F
FIG. 7-1. INSTRUMENTS AND INSTRUMENT PANEL
MM-7-2
MAINTENANCE MANUAL
COMPASS
COMPASS CALIBRATION CARD
AIRSPEED INDICATOR
ENGINE AND
TACHOME TER
CLUTCH DISENGAGE ALTIMETER

WARNING LIGHT
PANEL LIGHTS
DIMMER
OVERBOOST WARNING
LIGHT BALL BANK
INDICATOR
I’’ suss FnuLT

CIRCUIT BREAKER
MANIFOLD/ FUEL )v ´•/AMMETER

PRESSURE INDICATOR
CYLINDER HEAD TEMP
INDICATOR
EXHAUST GAS
TEMPERATURE GAGE
FUEL QUANTITY GAGE J /t; ,INSTRUMENT

CIRCUIT BREAKER
MAIN ROTOR GEARBOX 8\ ALTERNATOR EXCITATION
TEMPERATURE GAGE
CIRCUIT BREAKER
ENGINE OIL PRESSURE
I
LOW FUEL BOOST PUMP
INDICATOR PRESS TO TEST
NORMAL LIGHT
ENGINE OIL TEM~
INDICATOR
MAGNETO
(IGNITION) SWITCH’
ALTERNATOR
CIRCUIT BREAKER
FUEL MIXTURE CONTROL/

AFT LANDING LIGHT
s DAY CLOCK (OPTIONAL~ LANDING LIGHT

FORWP~RO
(LOCATION MAY VARY)
PANEL LIGHTS
GIG. LIGHTER (OPTIONAL VIGATION LIGHTS CIRCUIT

(LOCLITION MAY VARY)
ANTI-COLLISION LIGHTS SWITCHES
FUEL BOOST PUMP
TRIM
IGNITION
ALTERNATOR SWITCH
MASTER SWITCH
280F
FIG. 7-2. INSTRUMENTS AND INSTRUMENT PANEL
MM-7-3
MAINTENANCE MANUAL
B. Altimeter Troubleshooting (continued)
Indicator hands Excessive vibration Anchor tubing with tube

vibrate, of static pressure clamps.
tubing.
7-3 AIRSPEED INDICATOR
A. Description
The single scale airspeed indicator is calibrated in miles per hour

or knots per hour and provides an indicated airspeed reading at any
time during forward flight. The reading is obtained by measuring the
difference between impact air pressure and the static vent. The
pitot tube, which provides the impact air pressure source, is located
on the lower side of the cabin nose section. Static air pressure for
instrument operation is derived from two static vents located on
either side of the tail cone assembly. The openings in the pitot
tube and static vent ports must be maintained obstruction-free and
clean at all times for proper instrumentation operation.
CAUTION: Never apply positive pressure to static lines with the

instruments connected; this will damage the instrument
mechanism.
B. Airspeed Indicator Troubleshooting
Airspeed indicator Incorrect pitot Check tubing connection

needle fails to tube hookup, and make necessary
respond. corrections.
Obstruction in Disconnect pitot line from

pitot lines. pitot head and instruments
and static line from
fuselage and instrument;
clear lines with compressed
air. Check pitot tube
drain hole.
Oscillation of Leak in pitot or Check all connections and

airspeed or static lines. check flexible hoses at
indicator. back of instrument for
leakage.
Moisture in pitot Disconnect pitot line from

or static lines. instrument and static line
from fuselage flanges and
instruments; clear lines
with compressed air.
Check pitot drain hole.
MM-7-4
MAINTENANCE MANUAL
7-4 ENGINE ROTOR TACHOMETER
A. Description
The engine and rotor tachometers are combined on a single indicator

(twin tach) with concentric scales calibrated in engine and rotor
rpm. The needle marked "E" indicates engine rpm, while the needle
marked "R" indicates rotor rpm. The tachometer is mechanically
connected to the rotor assembly and engine assembly through flexible
drive cables.
B. Engine Rotor Tachometer Troubleshooting
Fluctuating Binding cable. Lubricate cable.

needle(s).
Defective Replace instrument.
instrument.
No reading on Twisted or broken Replace cable or drive

indicator, cable or tach belts.
drive belts.
Needles either Defective Replace instrument.

permanent or instrument.
intermittent.
Reverse instal- Install cables in correct
lation of cable. position.
Needles do not Instrument out of Check tolerance,

superimpose, tolerance. 2900 25 rpm,
3050 25 rpm,
spread between needles
1/4 of needle width maximum.
Tech drive belts Replace drive belts.

slipping or
broken.
7-5 FUEL QUANTITY INDICATOR
A. Description
The fuel quantity gauge continuously indicates the total quantity of
fuel. It is electrically actuated by a float type sending unit
located in the right-hand fuel tank.
NOTE: See Section 13-16 for gauge calibration procedure and

adjustments.
MM-7-5
MAINTENANCE MANUAL
B. Fuel Quantity Indicator Troubleshooting
Indicator Poor connections Clean and tighten

registers "Fn, or sender ground. connection.
or consistently
high reading
(battery switch
on).
7-6 ENGINE OIL PRESSURE GAUGE
A. Description
The engine oil pressure gauge indicates the pressure in the engine
oil lines in pounds per square inch.
CAUTION: Low oil pressure can result from improper oil level,
incorrect oil viscosity, faulty oil pump, or bearing
failure.
B. Engine Oil Pressure Gauge Troubleshooting
Low reading on Kinked tubing or Replace or clean tubing.

oil pressure obstruction in
gauge. tubing.
Instrument out of Replace instrument.

tolerance.
Sticking oil Defective gauge. Replace gauge.

pressure indicator.
Sluggish oil Sludge or heavy Bleed line and service with

pressure reading. oil in line, engine oil, or in cold
climates use kerosene.
Safety orifice in Remove engine fitting and

engine fitting blow clear.
partially blocked
by debris.
Fluctuating oil Air in pressure Service oil pressure line

pressure. line. with engine oil.
MM-7-6
MAINTENANCE MANUAL
7-7 MAIN ROTOR TRANSMISSION TEMPERATURE INDICATOR
A. Description
The main rotor transmission temperature indicator is located in the

instrument cluster. It is electrically operated by a temperature
sensitive heat probe connected to the transmission.
B. Main Rotor Transmission Temperature Indicator- Troubleshooting
Open circuit Check continuity. Clean and tighten ground

no reading, connection.
Blown fuse. Replace fuse.
7-8 ENGINE OIL TEMPERATURE INDICATOR
A. Description
The engine oil temperature indicator measures engine oil temperature

electrically by means of a resistance probe installed on the left
side of the engine aft of the oil filter.
B. Engine Oil Temperature Indicator Troubleshooting
No reading on oil Open circuit. Repair or replace leads.

temperature
indicator with Poor ground at Repair ground.
battery switch on, panel.
either constant
or intermittent. Open or short Replace indicator.
circuit in
indicator.
Reading off scale Short circuit in Make continuity check and

at low temperature leads from repair or replace lead.
end or low reading, resistance probe
either constant to indicator.
or intermittent.
Short circuit Replace probe.
in probe.
NOTE: Do not use thread
lube when installing
new probe.
MM-7-7
MAINTENANCE MANUAL
7-9 AMMETER
A. Description
The ampmeter indicates the amount of electric current supplied by the

alternator to the battery and electrical bus.
B. Ammeter Troubleshooting
No reading or Worn brushes, Repair or replace alternator,

erratic reading burned commutator, tighten belt, or replace
with battery belt slippage or belt.
and alternator broken.
switch on and
engine at idle
rpm.
O reading or Overvoltage Reset (see Section 6)

showing discharge, relay kicked out.
Excessive charge Faulty voltage Replace.

or discharge in regulator.
excess of 5-10
minute duration. Looser or Check indicateci,
as
corroded especially the ground

connections in connection.
VR circuit.
NOTE: Normal operating system should show a medium to heavy charge

just after engine is started.
rate If the battery is in good
condition it will accept this charge until the set system
voltage is reached (14 volts) in approximately 8-10 minutes.
At this point the ampmeter should drop to about zero or just
above, depending on system load.
0 reading; Defective meter Check out and/or replace

everything is or connections, meter as required.
functional.
MM-7-8
MAINTENANCE MANUAL
7-10 CYLINDER TEMPERATURE INDICATOR
A. Description
The cylinder temperature indicator measures the cylinder head temper-

ature by means of electric current from a temperature probe located
in the bottom of No. 3 cylinder head.
B. Cylinder Temperature Indicator Troubleshooting
Temperature Poor connections Check continuity of leads.

reading high or partial break Repair or replace faulty
throughout scale. in le~ds. leads.
Defective Remove instrument for

instrument, overhaul.
No reading, Break in lead; Repair or replace lead;

either permanent break in replace thermal switch.
or intermittent. thermocouple.
Faulty indicator. Remove instrument for

overhaul.
Low reading, Poor connection Clean and tighten

either permanent or short circuit. connections. Eliminate
or intermittent. short circuit.
7-11 EXHAUST GAS TEMPERATURE INDICATOR (EGT)
A. Description
One of the most important factors in flying an aircraft is to main-

tain the correct fuel/air mixture. Proper mixture to the engine will
give maximum range, economical operation, and maximum service life.
Improper mixture will prove costly in fuel economy and maintenance
costs, as well as shorten the life of the engine. The most accurate
method for determining the correct fuel/air ratio is a sensitive and
fast responding exhaust gas temperature indicator (EGT). The EGT
indicator operates off a heat sensitive probe located in the exhaust
system just forward of the turbocharger.
B. EGT Readings at Cruise
Exhaust gas temperature, as shown on the Enstrom EGT indicater,

should be used as an aid for fuel mixture leaning in cruising flight
at 75% power or less, i.e. 29 inches manifold pressure and 3050 rpm.
MM-7-9
MAINTENANCE MANUAL
To obtain a best economy mixture, lean to 16500F EGT. To obtain a

best power mixture, lean to 1550"F EGT. Do not exceed 1650"F EGT.
Operation on the lean side of peak EGT is not approved. Also any
change in altitude or power will require a recheck of the EGT
indication.
Fuel Mixture: Engine may be leaned at 29" MP or below to 16000F on

rich side of peak. Never exceed 1650"F EGT. Mixture
must be full rich for landing and takeoff regardless
of power for proper engine cooling.
C. EGT Functional Check
Due to the narrow margin of temperature error allowed while operating

at or near 1650"F EGT, it is recommended that at each 100 hour
inspection, or at any time an error is suspected, the EGT system be
tested for proper calibration.
CAUTION: DO NOT operate above 1600" EGT nor with a fuel flow setting
less than 80 pounds per hour at 75% power (28.0 inches MP)
until a calibration check has been completed after the EGT
system or any part thereof has been replaced.
D. EGT Calibration
Instructions for testing and calibrating of the EGT system may be

found in the Alcal EGT Operating Instruction Manual AR70-155. It is
recommended that a log book entry be made during the next flight of
the fuel flow reading with the power set at 29" manifold pressure,
rpm at 3050, and mixture leaned to 16500 EGT. A normal fuel flow
indication would be 83 pounds per hour plus or minus 3 pounds per
hour. A variation exceeding this range would indicate that the EGT
is reading either high or low respectively.
Example: Mixture normally leaned to 16500 EGT, fuel flow in excess

of 86 pounds per hour actual EGT temperature is lower
than indicated.
This i
forma t i on
n if moni tored wi 1 1 g i ve operators s uf fi c i ent
warning if there is a problem developing in either the engine or the
EGT system. An EGT reading that varies from normal and is engine
related will be apparent by other symptoms.
Example: Partially restricted injector nozzle high fuel flow, low

EGT with rough running engine.
CAUTION: Do not operate above 1600" EGT nor with a fuel flow setting
less than 80 pounds per hour at 75X power (29.0" MP) until
a calibration check has been completed after the EGT system
or any part thereof has been replaced.
After replacement of broken instrument or at 100 hour inspection, it

is recommended that a functional check be made of the system using an
ALCOR A1Cal Mark V Calibrator in accordance with these instructions.
MM-7-10
MAINTENANCE MANUAL
7-12 MANIFOLD PRESSURE FUEL FLOW INDICATOR
A. Description
The manifold pressure indicator is connected to the primary airflow

system at the #3 cylinder and measures power being produced and used.
The fuel flow indicator which is mounted in the same instrument is
connected to the fuel flow system at the flow divider. It indicates
fuel flow in relation to manifold pressure.
B. Manifold Pressure Indicator Troubleshooting
Excessive error Water or Disconnect at instrument

at existing restriction in and blow out line.
barometric line between
pressure. instrument and
eng~ne.
Sluggish Damaged or Remove line and blow out

operation of restricted line. restriction. Replace line
needle. if damaged.
NOTE: Restricted fitting

just aft of instrument
must also be removed
before blowing out
line.
Defective Replace instrument.

instrument.
C. Fuel Flow Indicator Troubleshooting
Low reading on Kinked tubing or Replace or clean tubing.

fuel flow obstruction in
indicator. tubing.
Leak in fuel Repair leak or replace line.

nozzle lines.
Instrument out Replace instrument.

of tolerance.
Sticking fuel Defective Replace instrument.

flow indicator. instrument.
MM-7-ll
MAINTENANCE MANUAL
7-13 OUTSIDE AIR TEMPERATURE INDICATOR
A. Description
The outside air temperature indicator is a direct reading,

bi-metallic instrument with a stainless steel probe. This instrument
provides ambient temperature information which, when utilized, will
aid in determining performance capability of the helicopter at the
existing climatic condition. The indicator is located in the top of
the cabin.
7-14 MAGNETIC COMPASS (F-28F)
A. Description
The vertical card compass is a dry compass utilizing eddy current

dampening. It consists of a 2" vertical rotating dial and is
compared with a fixed miniature airplane (lubber line) to present
magnetic heading of the aircraft at all times. Heading information
is more natural because the heading is read at the 12 o’clock posi-
tion and off the nose of the miniature airplane. The compass card
rotates and presents all quadrants in their true relation to line of
flight. A compass light is furnished for night flying. A compass
correction card and card holder is attached to the instrument
console.
7-15 MAGNETIC COMPASS (280F)
A. Description
The magnetic compass indicates the heading of the helicopter in

relation to magnetic north. It is a direct indicating compass and
indicates the heading by means of a floating card element that is
against a fixed reference line. The liquid used in the compass
dampens the card oscillation. A compass light is furnished for night
flying. A compass correction card and card holder is furnished
adjacent to the instrument.
7-16 HOURMETER
A. Description
The hourmeter is located inside the right side engine compartment

door. It is mounted just forward of the air filter housing. The
meter keeps a running log of the total hours on the aircraft.
MM-7-12
MAINTENANCE MANUAL
7-17 PITOT STATIC SYSTEM (See Figure 7-3)
A. Description
To operate the airspeed indicator and altimeter, it is necessary to

have a static source of air pressure. A pitot-static system has been
installed in the aircraft with two static air pressure ports. One is
on the left-hand side of the tail cone just aft of the baggage
compartment and the other is on the right-hand side of the tail cone.
The static pressure ports are interconnected to a single static
pressure line which runs up the right side of the pylon and through
the seat structure to a tee fitting in the instrument console. It
then runs to the altimeter and to one side of the airspeed indicator.
CAUTION: The two static ports should always be checked prior to

flight and also at any time the helicopter is operated in
dusty or freezing conditions where the small inlet holes
may become clogged, which will cause the instruments to be
inoperative or inaccurate.
B. Pitot Tube Description
The pitot tubeis located on the lower forward side of the cabin
structure. It is a curved aluminum tube secured with mounting plates
to the bottom of the fiberglass cabin wall. A flexible rubber hose
is routed through the instrument console connecting the pitot tube to
the airspeed indicator instrument line.
CAUTION: The pitot tube inlet end should be covered when the
aircraft is to be parked for any prolonged period of time
to prevent ingestion of dirt or ice that will impair the
operation of the airspeed indicator. Use a red cover so it
will be noticeable for removal on preflight inspection.
7-18 REPLACEMENT OF INSTRUMENTS
A. Replacement Procedures
NOTE: The fol 1 owing procedures are typical and apply to all
instruments installed in the instrument panel.
(1) Check that all electrical power is off to avoid the possibility
of electrical shorts while working in the area of the instrument
panel.
(2) Remove covers from instrument console.
(3) Disconnect electrical plug, wiring, or tubing as applicable,

from the back of the instrument. Install suitable covers over
tube fittings, instrument fittings, and loose wire terminals.
Tag all connections for reinstallation.
MM-7-13
MAINTENANCE MnNUAL
AIRSPEED
INDICATOR
ALTIMETER
~JJ
PRESSURE PORT
’uSTATIC
~I
/i
iI .I
i
i I
STATIC PRESSURE LINE

PITOT TUBE LINE
FIG. 7-3 PITOT STATIC SYSTEM
FLEXIBLE HOSE
I‘: _
r..
I 9’s
´•i.
STATIC PRESSURE PORT
cC
PITOT TUBE
ir: j--F-j´•l
~L
Q
PITOT TUBE INSTALLATION
STATIC PRESSURE LINE CONNECTION
VIEW OF TAILCONE BULKHEAD

LOOKING AFT
MM-7-14
MAINTENANCE MANUAL
(4) Remove the screws securing the instrument to face of the panel
and remove instrument from instrument panel.
(5) Place replacement instrument into panel in mounting position and

secure with mounting screws.
(6) Connect tubing, electrical plug or wiring as applicable to the

back of the instrument. Use care to avoid reversing connections
for pitot and static lines.
(7) Reinstall covers on instrument console.
7-19 INSPECTION OF INSTRUMENTS
A. Inspect as Follows
(1) Inspect instrument case for dents and cover glass for slippage
and cracks.
(2) Inspect fitting or electrical connector at back of instrument

for damaged threads that might prevent proper connection of the
tube nut or electrical plug.
(3) Inspect index markings and numerals on dial face for discolor-
ation and legibility. Inspect pointers for cracked or peeling
fluorescent paint,
(4) Inspect for presence of all required range markings and slippage
of any marks, indexes, or scales.
7-20 CALIBRATION OF INSTRUMENTS INDICATORS
Calibration checks of the instruments are to be performed at

qualified instrument calibration facilities.
MM-7-15
SECTION
STRU CTU RE
MAINTENANCE MANUAL
SECTION 8
STRUCTURE
8-1 CABIN
A. General Description
The cabin assembly is constructed of an aluminum sheet metal seat

structure which supports an outer cabin shell of reinforced
fiberglass. The entire cabin section can be removed from the pylon
as a unit.
B. Cabin Removal
(1) Remove cabin doors and fiberglass seat deck.
(2) Remove cowling and disconnect and remove the engine compartment
door hinge bracket from cabin.
(3) Disconnect and remove air filter housing.
(4) Disconnect collective push rod from collective walking beam at

the cabin firewall.
(5) Disconnect the lateral and longitudinal cyclic push-pull rods at

bellcranks on each side of cabin wall.
(6) Disconnect the main battery cable inside the engine compartment.
(7) Drain fuel from both fuel tanks and remove tanks.
NOTE: Install plugs in fuel line fittings.
(8) Disconnect tail rotor control cables at turnbuckle in the engine

compartment. See Section 10-7.
(9) Disconnect all oil lines, fuel lines, and airspeed static tube
at firewall.
(10) Disconnect electrical wiring in the engine compartment.
(11) Disconnect clutch control cable at turnbuckle in seat structure

and at forward clutch cable mount on aft side of firewall. See
Section 11-2.
(12) Disconnect engine and rotor tachometer cables.
(13) Disconnect throttle control cable from injector and pylon mount.
(14) Disconnect mixture control cable from injector and pylon mount.
MM-8-1
MAINTENANCE MANUAL
(15) Remove screws connecting fire curtain to firewall.
NOTE: Sealastic bead will peel from firewall to remove.
(16) Disconnect fuel shut-off control.
(17) Disconnect shoulder harness cables on aft side of cabin back

wall and seat belt cables.
(18) Disconnect flex hose and control cable from cabin heat duct on
aft side of firewall.
(19) Support cabin and remove the six cabin attachment bolts. See
Figure 8-1 for bolt locations. Lift cabin tree of aircraft.
C. Cabin Installation
(1) Lift cabin and align with pylon mounts. Install the six
attachment bolts. Torque bolts. See Figure 8-1.
NOTE: Throttle, mixture and clutch cables must be lined up

and guided through firewall.
NOTE: Safety wire the two outboard lower cabin mount after
torque.
(2) Connect flex hose and cabin heat control cable to duct on aft
side of firewall.
(3) Connect shoulder harness cables on aft side of cabin.
(4) Connect fuel shut-off control cable.
(5) Secure fire curtain to firewall using screws and sealastic.
(6) Connect mixture cable and throttle control cable to

control
pylon mounts and See Section 13-12 for proper rigging
injector.
of the injector and correlator.
(7) Connect clutch cable at forward pylon mount and at turnbuckle in

seat structure. Do a complete clutch cable rigging procedure.
See Section 11-1.
(8) Connect all electrical wiring in the engine compartment.
(9) Connect all oil lines, fuel lines, and air speed static tube at
firewall.
(10) Connect engine and rotor tachometer cables.
(11) Connect tail rotor cables at turnbuckle in engine compartment.

Adjust cable tension. See Section 10-7. Check tail rotor
rigging per Section 10-1.
MM-8-2
NOTE: Some instal~ations may be
shimmed at point (B) bottom
a&s
e~ ~76-n C
FIGURE 8-1
CABIN ASSEMBLY INSTALLATION
MAINTENANCE MANUAL
(12) Install engine compartment door hinge bracket between cabin and
bulkhead.
(13) Install fuel tanks and connect all fuel lines. Check for leaks
after installing fuel.
(14) Connect the main battery cable inside engine compartment.
(15) Connect the lateral and longitudinal cyclic push-pull rods to

bellcranks on each side of cabin wall.
(16) Connect the collective push rod to collective walking bean; at

cabin backwall.
(17! Install air filter housing and connections.
(18) Check all flight controls for proper operation. Check all items
on the Daily Check List and complete a Preflight Inspection.
See Section 3 Inspections and Routine Checks.
(;9) Install cowling and engine compartment doors.
(20) Install fiberglass seat deck and cabin doors.
8-2 WINDSHIELD (F-28F)
A. Wi ndshield -Removal (F-28F) (See Figure 8-2)
(1) Remove doors.
(2) Remove door hinges to provide clearance for windshield

installation.
NOTE: Hinge locations must be marked on hinges for proper

rei nstallation. Hinges will not align for proper fit
if positions are altered.
(3) Remove attachment screws around outer edge of windshield.
(4) Remove compass from windshield.
(5) Cut out and remove center portion of windshield.

NOTE: When cutting center portion, stay approximately
2-3 inches away from cabin frame. Apply two layers of
masking tape to cabin adjacent to windshield edge to
protect paint.
(6) Heat the remaining edge of glass and bonding adhesive using a
portable heat gun and peel glass from cabin frame.
NOTE: When bonding adhesive is warm it can be scraped from

edge of cabin using a suitable size putty knife.
(7) Sand windshield mount area clean and free of old bonding
adhesive with a fine sandpaper.
MM-8-4
NOTE: INSTALL FOAM TAPE
WITH SEAM ON COWER SIDE
OF WINDOW
COMPASS DECAL
Ba
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g
20~’z Ir,
m
z
o
03 1 I I I Im
Ln NOTE: MARK HINGE~ 1 13

POSITION BEFORE ~2
c
REMOVAL ~b
FIGURE 8-2
F-28F WINDSHIELD
SEAM LOCATION
MAINTENANCE MANUAL
B. Windshield Installation (F-28F) (See Figure 8-2)
(1) Clean recessed windshield area of cabin frame with acetone or
equivalent.
NOTE: Be sure this area has been sanded smooth and free of
old bonding adhesive before wiping with acetone.
(2) Position new windshield over cabin and apply tape to temporarily
hold windshield in place.
(3) Apply 1/4" masking tape following contour of windshield and

recessed area of cabin to mark windshield size for cutting.
(4) Remove windshield and cut to size on a fine wavy tooth bandsaw.
(5) Sand edges on belt sander for final fit to cabin.
NOTE: Check fit to cabin and re-sand as required.
(6) Install windshield and match drill the glass to old screw holes
in cabin using a #19 drill or drill new screw holes through
windshield and cabin at midpoints between old holes.
Countersink holes in windshield with an 82" countersink.
NOTE: Drill bits can be

ground to a very sharp point to aid
in drilling through plexiglass. Use care when drilling
to prevent cracking glass.
(7) Drill approximately 6 or 8 holes on upper and lower edge of

windshield with a f41 drill for mechanical fasteners (clecos).
(8) Remove windshield. Clean fiberglass recess of cabin with

acetone. Lightly sand bonding edge of windshield and clean with
acetone.
(9) Apply bonding adhesive EC801 (3M Brand) to recess in cabin frame
using a putty knife. Spread adhesive approximately 1/8" to
3/16" thick.
NOTE: Follow the exact mixing requirements of EC8O1 or it may

set up too fast or not at all.
(10) Install windshield in position and press firmly against

adhesive.
(11) Temporarily install mechanical fasteners (clecos) to hold

windshield in position until EC801 adhesive is set up.
CAUTION: Allow adhesive to dry approximately 24 hours before

installing attachment screws to prevent cracking
the glass.
MM-8-6
MAINTENANCE MANUAL
(12) Run a #19 drill through screw holes to remove bonding adhesive
and install screws into holes. Secure with washers and nuts.
CAUTION: Do not overtorque attachment screws on

installation.
(13) Remove mechanical fasteners.
(14) Install door hinges in position as previously marked in removal

procedure.
(15) Install compass to windshield as follows: (see Figure 8-2)
(a) Install compass to windshield from middle rib of lower door

hinges and mark centerline of windshield with a grease
pencil.
NOTE: Use cloth type measurement tape if possible to

prevent scratching plexiglass.
(b) Measure up 243" from bottom edge of windshield and

mark a line.
(c) Clean contact surface of windshield with acetone.
(d) Apply double back tape (Scotch Brand 4262 Neoprene) to

contact area of compass.
NOTE: Tape is not to extend beyond contact surfaces.
(e) Align top edge of compass to line marked on windshield and

press firmly into position. While holding compass on
inside have another person rub windshield from outside to
remove air bubbles.
(f) Apply the compass decal over contact surface on outside of

windshield.
(16) Prepare windshield edges for paint. Repaint outer mount edge.
(17) Install doors.
8-3 WINDSHIELD (280F)
A. Windshield Removal (280F) (See Figure 8-3)
NOTE: The 280F windshield consists of two pieces of plexiglass.

Windshield halves can be replaced individually.
(1) Drill out rivets holding center strip in position and remove
strip.
MM-8-7
MAINTENANCE MANUAL
(Z) Drill out remaining rivets around outer edge of windshield.
(3) Cut out and remove center portion of windshield.
NOTE: When cutti ng center porti on s tay approx ima tel y

2-3 inches away from cabin frame.
(4) Heat the remaining edge of glass and bonding adhesive using a
portable heat gun and peel glass from cabin frame.
NOTE: When bonding adhesive is warm it can be scraped from

edge of cabin using a suitable size putty knife.
(5) Sand windshield mount area clean and free of old bonding
adhesive with a fine sandpaper.
(6) Remove foam tape from center support brace.
B; Windshield Installation (280F) (See Figure 8-3)
(1) Clean recessed windshield area of cabin frame with acetone or
equivalent.
(2) Position new windshield over cabin and apply tape to temporarily
hold windshield in place.
NOTE: Use care aligning windshield to recess in cabin as

in
the plexiglass is formed with a slight indentation
along outer edge that must be matched to cabin frame.
(3) Apply 1/4" masking tape following contour of windshield and

recessed area of cabin to mark windshield size for cutting.
(4) Remove windshield and cut to size on a fine tooth bandsaw.
NOTE: Check fit to cabin and re-sand as required.
(6) Install windshield and match drill to old rivet holes in cabin
using #30 drill, or drill new holes through windshield and
a
cabin at midpoints between old holes.
CAUTION: Drill bits can be ground to very sharp point to

a
aid in drilling plexiglass. Use care in drilling
to prevent cracking glass. Do not drill through
inner fiberglass interior trim when drilling side
and bottom of windshield.
MM-8-8
,CENTER STRIP
FOAM TnpE
POSITION SEAM AT
LOWEST POINT ON WINDOW
u,
K F
03
m
’r,
z
DRILL CHUCK (REF) c
O
i/ ALUMINUM TUBING
FOR STOP
-1/
FOAM TAPE 1119 DRILL\
NOTE
USE CARE IN ALIGNING WINDSHIELD
AS PLEXIGLASS IS FORMED WITH A
SLIGHT INDENTATION TO FIT THE
POSITION SEAM AT LOWEST
POINT OF WINDOW
ON WINDSCIELD
.loo"
ON OVERH;EAD AND
.080"
LOWER WINDOW)
~L_
f
B
CABIN SHELL.
DRILL PLEXIGLASS WITH STOP
AS SHOWN ABOVE ONLY
FIG. 8-3 280F WINDSHIELD

MAINTENANCE MANUAL
(7) Drill approximately 6 to 8 holes through windshield on top and

bottom for mechanical fasteners (clecos) using a #41 drill bit.
(8) Remove windshield. Clean fiberglass recess of cabin with

acetone. Lightly sand bonding edge of windshield and clean with
acetone.
(9) Apply foam tape to center strip bar of cabin. Use 3M Brand tape
#4016, 1" wide by 1/16" thick.
(10) Apply bonding adhesive EC8O1 (3M Brand) to recess in cabin frame
using a putty knife. Spread adhesive approximately
1/8" to 3/16" thick.
NOTE: Follow the exact mixing requirements of EC801 or it may

set up too fast or not at all.
NOTE: Do not apply EC801 adhesive to center strip area.
(11) Install wi ndshield in position and press firmly against

adhesive.
(12) Temporarily install mechanical fasteners (clecos) to hold

windshield in position until EC801 adhesive is set up.
CAUTION: Allow adhesive to dry approximately 24 hours before

installing rivets to prevent cracking glass.
(13) Run a #30 drill through rivet holes to remove bonding adhesive.
(14) Dri 11 through all existing rivet holes in plexiglass with a
modified #19 drill. See Figure 8-3 for drill modification.
CAUTION: Drill through plexiglass only with #19 drill. Do

not drill through fiberglass cabin frame.
(15) Apply a small bead of silastic on each side of windshield center

seam and install center strip in position. Secure with rivets.
(16) Install and secure rivets in remaining holes.
(17) Remove mechanical fasteners (clecos).
(18) Prepare windshield edges for paint. Repaint outer mount edge.
8-4 CABIN DOORS (F-28F)
A. Door Removal(F-28F) (See Figure 8-4)
(1) Disconnect lower bungee (1) at forward corner of door frame.
(2) Pull hinge pins (2) from upper and lower hinges and carefully
remove door.
MM-8-10
MAINTENANCE MANUAL
B. DoorInstallation (F-28F) (See Figure 8-4)
(1) Align door to hinges and install hinge pins (2).
(2) Connect lower bungee (1) at forward corner of door frame.
C. Door Glass Removal (F-28F) (See Figure 8-4)
(1) Disconnect cables and remove door handle (3).
NOTE: Remove the roll pin from the inboard door handle and
separate and remove external door handle.
(2) Remove cables (4) and lower bungee (1) from door frame.
(3) Mark door hinges (5) as to their position on door frame and
remove hinges.
NOTE: Hinges cannot be alternated for upper and lower

positions.
(4) Remove sliding vent window (6) and snap vents (7).
(5) Remove foam strip from outer edge of door frame.
(6) Remove screws securing T-molding (8) and remove molding.
(I) Remove screws from door glass. Heat bonded area of plexiglass
with a portable heat gun and remove glass from door frame.
NOTE: Use care in glass removal to prevent distortion of

tubular door frame.
(8) Remove excess bonding adhesive from door frame with a putty
knife. Sand frame clean.
NOTE: When ordering a replacement door glass, be sure to

specify if a sliding vent window and/or snap vents are
required so they can be installed at the factory,
D. Door Glass Installation (F-28F) (See Figure 8-4)
NOTE: Check fit of door frame to cabin before locating glass on
frame.
(1) Position new glass on door frame and match drill to screw holes
using a t41 drill. Countersink holes using an 82" countersink.
NOTE: Replacement door glass has been rough cut to size.

Final sanding of plexiglass to door frame is completed
after bonding procedure is done.
MM-8-ll
MAINTENANCE MANUAL
4~((
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FIG. 8-4. F-28F CABIN DOOR
MM-8-12
MAINTENANCE ‘MAN~AL
(2) Remove door glass from frame and clean bonding sd’rfa~Ea: ’F both´•
items using acetone or equivalent.
(3) Apply bonding adhesive EC801 (3M brand):’:tq, bondi.rig surfacei of

door frame. Spreadadhesive approximately -1/8" to 3/16" thidk.
(4) Carefully install door glass on door frame.
NOTE: Install approximately door glass anS~::´•’

frame to hold glass in DO NOT tighten
until bonding adhesive is set up (app roxima,t~y
24 hours).
(5) Install screws to secure door glass to frame.
(6) Final fit plexiglass to door frame by sanding on belt sander.
(7) Install T-molding (8) to door frame and secure with screws.
(8) Install foam strip on outer edge of door frame.
(9) Install and secure hinges (5) to their previously marked posi-
tion on door frame.
(10) Prepare and repaint door frame.
(11) Install and secure door handles (3). cables (4), and latches.
(12) Install lower bungee (1) at forward corner of door frame.
(13) Install door on aircraft and check operation of door handle and
latch.
8-5 CABINDOORS (280F)
A. DoorRemoval (280F) (See Figure 8-5)
(1) Remove screw from door strap (1) on the lower corner of the
door.
(2) Remove bolt (2) and spacer (3) from hinge pivot point at top of
door.
(3) Carefully lift door from cabin frame.
MM-8-13
MAINTENANCE MANUAL
i
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‘------._ I
FIG. 8-5. 280F CABIN DOOR

MM-8-14
MAINTENANCE MANUAL
8. (see Figure 8-5)
(1) Align bottom pivot peg (4) on lower corner of door with hole in
cabin door frame and install door into position.
(2) Install spacer (3) and mount hardware in upper hinge. See
Figure 8-5 for proper hardware installation.
(3) Secure door strap (1) on lower corner of door with screw.
(4) Check door and door latch for proper operation.
C. Door Glass Installation (280F)
NOTE: Installation of door glass on 280 model doors requires the

use of special bonding fixture. Doors should be returned
a
to Enstrom Helicopter Service for glass replacement.
8-6 OVERHEAD AND LOWER WINDOWS (See Figure 8-2)
A. Window Removal
(1) Drill out existing rivets.
(2) Remove plexiglass from double backing tape.
(3) Remove tape from cabin recessed area.
B. Window- Installatj~on (See Figure 8-2)
(1) Clean recess in cabin with acetone or equivalent.
(2) Install double backing foam tape in position. Use 3M Brand tape
#4016, 3/4" wide x 1/16" thick.
NOTE: Install tape with ends meeting at bottom side of window

to prevent possible leakage through seam. Do not
removepaper backing from outboard side of tape until
window has been marked for cutting.
(3) Position new plexiglass window over recessed area of cabin and
apply masking tape to temporarily hold window in place.
(4) Apply 1/4" masking tape following contour of window and recessed
area of cabin to mark window size for cutting.
(5) Remove window and cut to size on a fine tooth bandsaw.
MM-8-15
MAINTENANCE MANUAL
NOTE: Check fit to~cabin and re-sand as required.
(7) Clean outer edge of window with acetone.
(8) Remove paper backing from foam tape and install window in
position. Press firmly against tape.
(9) Match drill to old rivet holes in cabin using a #30 drill or
drill new holes through window and cabin at midpoints between
old holes.
NOTE: Drill bits can be ground to a very sharp point to aid

in drilling plexiglass. Use care in drilling to
prevent cracking glass.
(10) Drill through all rivet holes in plexiglass with a modified #19
drill. See Figure 8-3 for drill modifications.
(11) Secure window in place with rivets.
(12) Prepare window edges for paint. Repaint outer mount edge.
8-7 SEAT BELTS LAP-TYPE
A. Seat Belt Removal
(1) Remove seat cushions.
(2) Disconnect attachment end of belts by applying pressure to the

spring loaded "latch", opening it sufficiently to clear the
structural attach point as it is lifted.
B. Seat Belt_ Installation (See Figure 8-6)
NOTE: a. Seat belts must be connected to the specified

structural attach points to insure belt security.
b. There four structural attach points to accommodate

are
two- three-passenger configurations; (1) left rear
and
cabin wall, (2) right of left center seat beam,
(3) right of right center seat beam, and (4) right rear
cabin wall.
c. Secure belts to the airframe by applying downward

pressure on the structural attach point with the
Mlatch" portion of the belt attachment mechanism until
it locks in place.
MM-8-16
MAINTENANCE MANUAL
I II
POINT C
POINT B"
POiNT"D’’
FIGURE 8-6
SEAT BELT AT TA C H M E N T
MM-8-17
MAINTENANCE MANUAL
(1) Left seat position install as follows:
(a) Attach seat belt half with release mechanism to left rear
cabin wall structural attach point. See Figure 8-6, Point
"A"
(b) Attach seat belt half with flat tab to structural attach
point right of left center seat beam. See Figure 8-6,
Point "B".
(2) Center seat position (if required) attach as follows:
(a) Attach seat belt half with release mechanism to the

structural attach point right of left center seat beam.
See Figure 8-6, Point "B".
NOTE: Install on right side of left seat position belt.
(b) Attach seat belt half with flat tab to structural attach
point right of right center seat beam. See Figure 8-6,
Point "C".
(3) Right seat position attach as follows:
ia) Attach seat belt half with release mechanism to the

structural attach point right of right center seat beam.
See Figure 8-6, Point "C".
NOTE: Install on right side of center seat position belt

(if installedr
(b) Attach seat belt half with flat tab to right rear cabin
wall structural attach point. See Figure 8-6, Point "D".
8-8 SEAT DECK
A. Seat Deck Removal
(1) Remove seat cushions and seat belts.
(2) Disconnect cyclic stick canon plugs and remove cyclic boots.
(3) Remove screws securing fiberglass cover over pilot’s collective

stick and remove cover.
(4) Remove screws securing fiberglass cover over collective

push-pull rod at top of seat deck and remove cover.
MM-8-18
MAINTENANCE MANUAL
(5) Remove handles from clutch engagement lever.
NOTE: Handles are screwed together.
(6) Release and remove expando pin andremove co-pilot’s collective

stick.
(7) Remove screws from battery access cover.
(8) Remove screws securing fiberglass seat deck in place and

carefully lift seat deck from seat structure.
B. Seat Deck Installation
(1) Install fiberglass seat deck over clutch engagement lever and
into position. Secure in place with attachment screws.
(2) Install co-pilot’s collective stick into bellcrank and secure

with expando pin.
NOTE: Flip expando pin lever down and check security.
(3) Install handles in clutch engagement lever and screw together to

secure.
(4) Install fiberglass cover over collective push-pull rod at top of

seat deck and secure with screws.
(5) Install fiberglass cover over pilot’s collective stick and

secure with screws.
(6) Install battery access panel and secure with screws.
(7) Install cyclic stick boots and secure the cyclic canon plugs
into their receptacles.
(8) Install seat belts and seat cushions.
8-9 LANDING GEAR
A. Landing Gear Assembly
(1) Landing Gear Removal
(a) Install sling T-0O11 on main rotor hub and hoist helicopter
to remove weight from landing gear. See Figure 9-3 in
Section 9 for sling installation.
(b) Remove left and right engine doors and bottom cowling.
MM-8-19
MAIi\lTENANCE EIAFIUAL
PYLON
9~-
2
CROSS TUBE
FIGURE 8-7
LANDING GEAR TO PYLON ATTACHMENT
MM-8-20
MAINTENANCE MANUAL
(c) To remove the landing gear assembly as a unit from the

pylon, proceed as follows: (See Figure 8-7)
1 Disconnect engine controls, EGT, heater control and

quarter panels.
2 Remove top bolt from pylon mount clamps on cross tubes

(4 places).
3 Lower and remove landing gear assembly.
(d) Remove individual landing gear items as follows: (See

Figure 8-8)
NOTE: See individual items B, C, and D for removal or

replacement of skid shoes, ground handling wheels,
or oleo struts.
1 Skid tube (1) Remove the six attachment bolts from

landing gear legs (2). Remove skid tube assembly.
Install in reverse order.
2 (2)
Remove oleo. Disconnect
Landin93, Leg
strut
drag
landing gear leg. Remove upper pivot
from
bolt from clamp (8) on cross tube and remove the three
lower bolts securing landing leg to skid tube. Remove
landing gear leg. Install in reverse order.
B. Skid Shoes
(1) Description
Three individual skid shoes are installed on each landing gear

skid tube. It is important that the operator inspect the bottom
of the shoes periodically, depending on the types of operations,
to check for wear.
(2) Skid Shoes Replacement (See Figure 8-8)
(a) Skid shoes may be replaced by one of the following methods:
1 Jack up landing gear.
2 Install sling T-O011 on main rotor hub and hoist

helicopter.
3 With ground handling wheels down, pull down on aft of

tailcone.
4 Repl ace skid shoes (4) or (5) by removal and

replacement of the three attachment bolts securing them
to skid tubes.
MM-8-21
NOTE: LANDING GEAR BOLTS AT PIVOT
POINTS ARE TO BE TOROUED TO
40-601N. LBS. TO ALLOW GEAR
TO FLEX
~i´•a
BPB
1 /s
ia
2 d
10
,e
~o
"2~
I o 5
FIGURE 8-8
LANDING GEAR
ASSEMB LY BREAKDOWN
a,
MAINTENANCE MANUAL
C. Ground Handling Wheels
(1) Operational Description
Eachlanding gear skid tube has provisions for easily installed

landing gear wheel assemblies. Each assembly has a manually
operated over-centering device to lift the skids for
installation of the wheels or retract them for flight. The
ground handling wheels should be retracted and the helicopter
allowed to rest on the skids when the engine run-up is being
performed or when helicopter is parked. To raise or lower
ground handling wheels, proceed as follows: (See Figure 8-9)
WARNING: Approximately 135 Ibs of force is exerted through

the wheel bar when raising or lowering wheels. It
is important that the wheel 6ar does not slip off
the end of the axle or the operator does not lose
his grip on the handle, particularly when removing
or replacing the lock pin, or possible injury could
result.
(a) To lower the wheels, the slot in the end of wheel bar
should be inserted on the axle with the handle facing
forward. Then, keeping the handle aligned on the flats of
the axle, apply a constant pressure to the handle and
release the retaining pin. An upward and aft lifting
motion is applied to the handle until the retaining pin
holes line up for pin insertion. Insert pin and remove
wheel bar. Keep feet from under skid tubes, stay outside of
the skid, and do not straddle during procedure.
(b) To the wheels the same procedure is used with the

raise
exception that the wheel bar is installed with the handle
facing aft, and the operator must restrain the wheel bar
from rotating downward after the retaining pin is removed.
(2) Ground Handling Wheels Removal (See Figure 8-10)
(a) Place wheel assembly in retracted position.
(b) Remove snap ring (7) and washer (6) from outboard end of
axle (4). Pullpin (5) and slide wheel and axle assembly
from mount bracket.
(c) Remove nut (1) and washer (2) from axle and slide wheel
assembly from axle.
(3) Ground Handling Wheels Installation (See Figure 8-10)
(a) Install wheel assembly (3) on axle (4) and secure with
washer (2) and nut (1).
MM-8-23
MAINTENANCE MANUAL
RAISE WHEEL
WHEEL BAR START POSITION
LOWER WHEEL
WHEEL BAR START POSITION
WARNING USE CAUTION WHEN RAISING OR LOWERING WHEELS WITH HANDLE, CARE
SHOULD BE TAKEN TO KEEP HAN DL E ALIGNED WITH AXLE A N D FI RMLY
HELD WHILE ENGAGED FOR ROTATION
FIGURE 8-9
GROUND HANDLING WHEEL OPERATION
MM-8-24
MAINTENANCE MANUAL
CAUTION: WHEEL ASSEMBLY MUST BE SECURED ON AXLE BEFORE

IN FLATI N G T I RE TO PR EVE NT POSS I BLE SEPER ATION OF
RIM.
;Z ~3
FIGURE 8-10
GROUND HnNDLING WHEEL

REMOVAL AND IN STALL AT ION
MM-8-25
MAINTENANCE MANUAL
(b) Inflate tire to 15 psi.
CAUTION: Wheel assembly must be secured on axle before

inflating tire to prevent possible separation of
the rim.
(c) Apply lubriplate to axle and slide axle in mount bracket on
skid tube with wheel in raised position.
(d) Install retaining pin (5) and secure with washer (6) and
snap ring (7).
D. Oleo Struts
(1) Oleo Strut Removal (See Figure 8-11)
NOTE: The weight of the aircraft must be removed from oleo

struts before strut removal can be accomplished.
Install sling T-0011 on main rotor hub and hoist entire
helicopter.
(a) Remove upper and lower attachment hardware from oleo strut
at cross tube and landing gear leg.
(b) Remove oleo assembly.
(c) Remove bolts securing universal links (1) to oleo strut and
remove links.
(2) Oleo Strut Disassemb~y (See Figure 8-12)
(a) Remove cap from valve (1) and slowl~ open valve to relieve
pressure from oleo strut.
(b) Remove valve (1) and pour hydraulic fluid from oleo into a
pan.
(c) Clamp lower of cylinder assembly (14) in a vise and

end
unscrew guide shaft assembly (6) from cylinder by using a
strap wrench. Clamp on universal block, not ears of
cylinder.
NOTE: If strap wrench slips on painted surface of guide

shaft assembly, place a piece of emery cloth
between strap and guide shaft to aid in gripping.
(d) Slowly pull piston assembly out of cylinder assembly.
MM-8-26
NOTES: I. TORQUE PIVOT MOUNT BOLTS TO 40 -60 1 N. LBS.
2. VALVE ORIENTATION FORWARD OLEOS VALVE FACES AFT)

REAR OL EOS VALVE FACES AFT
3. AGRICULTURE A~JD FLOAT SHIP-(REAR OLEO-VAL\IE FACES
FORWARD
V1EWIIAI(
22 IE
VIEW "B"
n
do
VIEW IIAll
FORWARD UPPER OLEO STRUT ATTACHMENT 1YI
VIEW "B"
FIGURE 8-11
OLEO STRUT INS TA LL AT ION
MAINTENANCE MANUAL
(e) Lay piston shaft assembly with edge of piston (13) on a

block of wood, and using a flat punch remove dowel
pin (12).
NOTE: Use care in removing dowel pin to prevent damage to

piston (13).
(f) Remove valve assembly (13) from piston shaft (2).
(g) Remove rebound rings (11) and spacer (10).
(h) Slide guide shaft assembly (6) and boot (3) from piston
shaft.
(i) Disassemble guide shaft assembly (6) as follows:
1 Remove O-ring (7) from O.D. of threaded area.
2 Remove O-ring (9) and back-up ring (8) from I.D. of

guide shaft assembly.
3 Remove felt wiper (4) from brass guide (5).
4 If brass guide is worn or damaged, it can be removed by

tapping out with a nylon drift.
(j) Disassemble valve assembly (13) if required, as follows:

(Figure 8-12, View B)
NOTE: Do not disassemble this unit unless damage or wear

has occurred to valve (19).
1 Remove nuts (15) and washers (16).
2 Remove valve pistons (17) and valve springs (18) from

shaft (20).
3 Carefully press shafts (20) from piston (19).
(3) Oleo Strut I ns pect i on (See Inspection Table Oleo Strut

Assembly)
(4) Oleo Strut Assemble (See Figure 8-12)
(a) Assemble piston assembly (13) if required as follows: (See

Figure 8-12, View B)
1 Carefully press shafts (20) into piston (19).
CAUTION: If excessive pressure is used to press shafts

into piston, damage to valve area of piston
can result.
MM-8-28
MANUAL
vEua 2
20
I
;a~4-
19
2
17
2 VEW~
Is
2
0; 6
P2 17
"2
2 ~2´•
15 2 9
FLOW PASSAGE PORT
12~ NOTE: NOTCHES

IN REBOUND
RINGS MUST BE
2, .d""
--rr
VALVE SETTING DIMENSION
OLEO STRUT ASSEMBLY

FIGURE 8-12
MM-8-29
MAINTENANCE MANUAL
OLEO STRUT INSPECTION
Fig. Serviceable Repair

Part No. Item No. Part Name Inspect Limits Limits Repair or Action
AN 6287-1 Fig 8-12 Valve Check valve o-rings None allowed Not repairable Replace o-rings
Item 1 for cracks or tears
1.2495
28-17146 Fig 8-12 Piston Shaft Shaft diam. -.0005 -.001 Return to factory fo r
TT~
Item 2 re-chrome grind
Check for nicks and None allowed Not repairable Replace piston shaft
Dowel pin hole +.0005 Not repairable Replace piston shaft

.2490
diameter
TZVQ5
Threaded boss no None allowed Not repairable Replace piston shaft

crossed or missing
threads
28-17158 Fig 8-12 Oleo Boot Check for cracks or None allowed Not repairable Replace boot
Item 3 tears
28-17144 Fig 8-12 Guide Shaft Threads no crossed None allowed Not repairable Replace guide shaft
Item 6 Assembly or missing threads
Brass guide bore +.002 Not repairable Replace brass guide

1.256
diameter
(Part #28-17153)
1.258
MM-8-30
MAINTENANCE MANUAL
OLEO STRUT INSPECTION (Continued)
Pig. Serviceable Repair

28-17149 Fig 8-12 Spacer Check for nicks and None allowed .010 deep Polish and blend
Item 10 scratches
28-17151 Fig 8-12 Rebound Rings Check for cracks or None allowed Not repairable Replace rings
Item 11 tears
.2505
28-17147 Fig 8-12 Dowel Pin O.D. diam. -.0002 Not repairable Replace pin
TZV95
Item 12
1.7655
28-17140 Fig 8-12 Cy linder Bore diam. +.001 Not repairable Replace cylinder
Item 14 Assembly
Threads no crossed or None allowed Not repairable Replace cylinder

missing threads
Mount holes in ears +.001 Not repairable Replace cylinder

.312 diameter
1.763
28-17145 Fig 8-12 Piston O.D. --iT;f~diam. -.001 Not repairable Replace piston
Item 19
.2495
Pin hole +.002 Not repairable Replace piston
~V´•Cr
Check for scratches None allowed .002 deep Polish to remove with
in O.D. very fine sandpaper or
emery cloth
NOTE: All O-rings should be replaced when rebuilding oleo strut assembly.
MM-8-31
MAINTENANCE MANUAL
2 I:nstall valve pistons (17) and springs (18) on shafts.
3 Install washers (16) and nuts (15).
4 Adjust valve and spring length to 1.60" .010".

Measurement is taken from inner base of piston (19) to
outboard edge of valve piston (17). See Figure 8-12,
Valve Setting Dimension.
(b) Assemble guide shaft assembly (6) as follows:
1 Press brass guide (5) into position if previously

removed.
2 Install felt wiper (4) into brass guide (5).
3 Install O-ring (7) on O.D. of guide shaft (threaded

end).
4 Install back-up ring (8), then O-ring (9) into groove

in I.D. of guide shaft (threaded end).
NOTE: Convex side of back-up ring (8) must face

toward O-ring (9).
(c) Install oleo boot (3) on piston shaft (2).
(d) Soak both ends of guide shaft assembly in a pan of

hydraulic fluid (MIL-H56O6A) to provide lubrication for
assembly, and install the assembly on piston shaft (2).
(e) Install spacer (10) on piston shaft (2).
NOTE: Flanged end of spacer faces toward threads of guide

shaft assembly (6)
(f) Install rebound rings (11) (5 each) on piston shaft (2).
NOTE: Notches in rebound rings must be staggered.
(g) Align flow passage port on inner edge of piston

assembly (13) to the flow passage hole in piston shaft (2)
and install piston assembly.
(h) Secure valve to piston shaft with dowel pin (12).
NOTE: Ends of dowel pin must be seated below O.D. surface

of piston to preventpossible binding on
installation in cylinder assembly.
(i) Slide guide shaft assembly (6) and rebound rings (11) up
against piston (13). Keep rebound rings staggered.
MM-8-32
MAINTENANCE MANUAL
(j) Clamp cylinder assembly (14) in a vise in an upright

position. Fill cylinder to base of threads with hydraulic
fluid (MIL-H5606A)
NOTE: Clamp on universal block, not ears of cylinder.
(k) Install piston and guide shaft assembly into cylinder

assembly and slowly lower the piston to base of cylinder
assembly (collapsed position).
NOTE: Piston must be collapsed slowly to allow hydraulic

fluid to work through staggered rebound rings and
flow passage in piston assembly.
(1) Tighten guide shaft assembly to cylinder assembly using a
strap wrench. Remove oleo from vise.
(m) With piston in fully depressed (collapsed) position, hold

oleo strut in a horizontal position with oleo valve boss
up. Pour hydraulic fluid into valve hole until strut is
full and no air bubbles appear.
(n) Install and secure oleo valve (1). Safety wire valve to
mount flange of piston shaft with .032 wire.
to) Connect nitrogen pressure line to oleo valve. Set nitrogen

pressure valve to 400 psi and slowly open oleo valve.
Allow oleo to fill until piston shaft is fully extended and
oleo pressure is 400 psi. Close oleo valve first, then
nitrogen tank valve, and remove pressure line.
NOTE: Nitrogen will bleed out from line when

disconnected. The use of nitrogen is recommended
for servicing because of its inert qualities.
(p) Inspect oleo assembly for leaks.
(q) Install groove in oleo boot (3) over brass guide (5).
(5) Oleo Strut Installation (See Figure 8-11)
NOTE: Helicopter must be hoisted with a sling for oleo strut

installation.
(a) Place a light washer (2) on each side of universal link (1)
and install between mount ears on oleo strut (2 places).
Secure in place using bolt (5), heavy washers (3) and
nut (4).
MM-8-33
MAINTENANCE MANUAL
(b) Install oleo strut assembly into landing gear. Place a

light washer (2) on each side of universal link (1) and
install between mount ears on cross tube and landing gear
leg. Secure in place using bolt (5), heavy washers (3) and
nut (4).
NOTE: 1nsta71 o7eo struts with valves facing aft. See

the following exception:
Agriculture and float ships require rear oleo

valves to face forward.
NOTE: Torque pivot mount bolts (4 places on each oleo) to

40-60 in-lbs.
(c) Lower helicopter on skids. Check oleos for proper

extens~on. See Section 4-2, Servicing and General
Maintenance, Item F, Oleos.
(6) Oleo Struts Servicing
(a) General Information
There are three methods of servicing the oleo assemblies.

Oleo pressure is 400 psi and it is important that this
pressure is maintained. For complete instructions for
servicing the oleo struts see Section 4-2, Item F, Oleo
Struts Servicing.
8-10 PYLON
A. _4ylon Removal and Installation
The pylon assembly supports all major structural and drive train
components of the helicopter. The removal and installation of the
pylon is accomplished by completing the removal and installation
procedures for the following items:
(1) Cabin Assembly See Section 8-1

(2) Tailcone Assembly See Section 8-10
(3) Main Rotor Transmission See Section 11-6
(4) Powerplant See Section 13-2
(5) Landing Gear See Section 8-9
B. ~ylon Inspection
Inspection is limited to a field survey of the pylon condition.

Visually inspect all members of the pylon for the following:
(1) Cracks and dents

(2) Integrity of finish
(3) Evidence of corrosion
(4) Security of welded points
(5) Scuffing and abrasion
MM-8-34
MAINTENANCE MANUAL
C. Pylon Repair
Damage to the pylon section tubes can be repaired in accordance with

FAR 43. Special care must be taken during such repairs as not to
distort the structure.
8-11 BAGGAGE COMPARTMENT
A. Baggage Compartment Removal (See Figure 8-13)
(1) Remove baggage compartment door as follows: (See Figure 8-13,

View A)
(a) Remove panel (1) from kick-in steps.
(b) Release fastener screws (2) on upper cowling.
(c) Remove the two bolts (3) from upper hinge pin post at top
right corner of baggage compartment.
(d) Turn key latch and open door.
(e) Lift upper cowling to slide it from pivot pins on door and
remove door assembly.
(2) Remove upper and side cowling.
(3) Remove sheet metal flanges (4) from front edges of baggage
compartment.
(4) Remove the two attachment screws (5) securing baggage

compartment to pylon.
(5) Remove attachment bolt (6) from lower left aft corner of baggage
compartment.
(6) Remove bolt (7) from mount strap on lower left forward corner of
baggage compartment.
(7) Carefully slide baggage compartment out of pylon structure.
B. Baggage Compartment- Installation (See Figure 8-13)
(1) Slide baggage compartment into pylon structure.
(2) Install bolt (6) in lower left aft corner of baggage

compartment. Torque bolt and safety using .032 safety wire.
MM-8-35
UPP~R COWL
VIEW A
BAGGAGE STEP
o COMPARTMENT PANEL
DOOR
FIGURE 8-13
BAGGAGE COMPA RTMENT INSTALLATION
VIEW B
MM-8-36
MAINTENANCE MANUAL
(3) Install bolt (7) through mount strap and baggage compartment at
lower left forward corner. Torque bolt.
(4) Install screws (5) securing front of baggage compartment to

pylon.
(5) Install sheet metal flanges (4)

the to front edges of baggage
compartment and secure with screws.
(6) Install upper and side cowling.
NOTE: Do not fastener screws (2) on right side of

secure
upper cowling until baggage compartment door has been

installed.
(7) Lift upper cowling slightly and install baggage compartment door
into position. Secure fastener screws (2)in upper cowling.
(8) Install bolts (3)

upper hinge post
in at top right corner of
baggage compartment. Torque bolts.
(9) Install kick-in steps panel (1).
(10) Close baggage compartment door and check key latch operation.
8-12 TAILCONE ASSEMBLY
A. Tailcone Removal (See Figure 8-14)
(1) Remove wrap-around cowling.
(2) Disconnect flex coupling at forward end of tail rotor drive

shaft. See Section 10-6, Drive Shaft and Couplings for correct
procedure.
(3) Remove tach drive cover and O-rings.
(4) Disconnect static line from bulkhead fitting (1) on lower right
side of tailcone.
(5) Disconnect strobe wires (2) at forward end of tailcone.
(6) Remove quick disconnect at antenna and rotating beacon if so
equipped.
(7) Disconnect the tail rotor cables (3) at control brackets on tail
rotor transmission. Attach a string to each individual cable
and pull cables through fair leads to forward portion of tail
cone assembly. For later ships with pulley fairleads at aft
bulkhead, remove inspection panel for access and remove cotter
keys from pulleys.
NOTE: Disconnect strings from cables and allow them to remain

routed through tailcone to facilitate installation upon
assembly of tailcone assembly to pylon.
MM-8-37
MAINTENANCE MANUAL
(8) Place two supporting fixtures (4) under fuselage of tailcone to

support it during removal. Remove the three attachment bolts
(5) securing tailcone to pylon and remove tailcone.
NOTE: If any shims are found they must be used at same points
with new tailcone.
NOTE: Use care in removal procedure to prevent possible

damage to tail rotor assembly and/or transmission.
B. Tailcone Installation (See Figure 8-14)
(1) Align tailcone to pylon mount and install bolts (5) and shims if
used (3 places). Torque bolts to 240 in-lbs and safety with
.032 safety wire.
NOTE: Tailcone installation requires a person at each end to

lift and align tailcone to pylon.
(2) Connect previously routed strings to tail rotor cables (3) and
pull cables back through fair leads to aft end of tailcone.
Connect cables to tail rotor control brackets on transmission.
NOTE: Check cable tension and adjust if required. See

Section 10-7, Tail Rotor Cables.
(3) Install quick disconnects at antenna and rotating beacon if so
equipped.
(4) Connect strobe wires (2) at forward end of tailcone.
~5) Connect static line to bulkhead fitting (1) on forward end of

tailcone.
(6) Install O-rings on tach drive assembly and install tach drive
cover.
(7) Connect flex coupling at forward end of tail rotor drive shaft.
See Section 10-6, Drive Shaft and Couplings.
(8) Inspect all wires, cables, and attachment points for security.
(9) Install wrap-around cowling.
NOTE: If any area of tail rotor assembly, tail rotor drive

shaft, or tail rotor transmission was worked on, see
Section 10 for correct installation procedures.
MM-8-38
E
5
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p
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4~ N M ~VI IB
m
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c
2
NOTE: If shims are found between tail
cone and nylon mounts they must
remain in same location if
tail cone is replaced.
FIGURE 8-14
TAILCONE INSTALLATION
MAINTENANCE MANUAL
8-13 SORqUE TUBE EXTENSION
A. Torque Tube Removal (See Figure 8-15)
(1) Disconnect tail rotor cables and remove tail rotor assembly and
gearbox. See Section 10-5, Tail Rotor Gearbox Removal.
NOTE: The tail rotor assembly and gearbox can be removed as a

unit.
(2) Remove tail rotor guard (1) to provide clearance for torque tube
removal.
NOTE: The tail rotor guard on the 280-F helicopter can remain
attached as it does not obstruct torque tube removal.
(3) Remove the left

horizontal stabilizer to provide access to the
inspection plate. See Section 8-14, Stabilizer Removal.
NOTE: Stabilizer on the 280-F helicopter is mounted forward

of the inspection panel and does not require removal.
(4) Remove attachment bolts from aft pillow block (2).
(5) Remove inspection panel (3).
(6) Remove the three attachment bolts (4) from forward end of torque
tube inside tailcone. Access is gained through inspection panel.
(7) Remove bolts from torque-tube clamp (5) (4 places). Remove

torque tube (6) by pulling aft with a slight oscillating action.
B. Torque Tube Extension- Installation
(1) Apply lubrication to the forward end of torque tube (6) and
slide tube into tailcone mount. Install bolts (4) through mount
and into torque tube. Torque bolts.
(2) Install the four attachment bolts into torque tube clamp (5) and
torque bolts.
CAUTION: Excessive torque on these bolts can deform the

torque tube.
(3) Install attachment bolts in aft pillow block (2). Torque bolts
and safety wire with .032 safety wire.
(4j Install and secure inspection panel (3).
(5) Connect and secure tail rotor cables to control bracket. See
Section 10-7, Tail Rotor Cables.
NOTE: Check that cable tension is 35-40 Ibs.
MM-8-40
4 2 6
L_
FIGURE 8-15
TORQUE TUBE EXTENSION
MAINTENANCE MANUAL
(6) Ins ta 11 the left horizontal stabilizer on F-28F model

helicopters. See Section 8-4, Stabilizer Installation.
17) Install and secure tail rotor guard (1) on F-28F model
helicopters.
(8) Install tail rotor gearbox and tail rotor assembly as a unit.
See Section 10-5 for Gearbox Installation.
(9j Check tail rotor rigging. See Section 10-I, Tail Rotor
Assembly.
(10) Inspect all connections for security.
8-14 HORIZONTAL STABILIZERS (F-28F)
A. Stabilizer Removal~ (See Figure 8-16)
(1) Remove screw and washers from tab (1) in aft end of left hand
stabilizer (4).
(2) Remove bolts (2) from left hand stabilizer (5) and spar (3).
(3) Slide stabilizer from spar.
(4) Repeat steps 1 through 3 to remove right hand stabilizer (6).
(5) Remove access panel (7) on left side of tailcone.
(6) Remove bolt (4) which secures spar (3) to left side spar fitting
and slide spar from tailcone.
B. Stabilizer Inspection (F-28F)
NOTE: Inspect per following Inspection Table Horizontal

Stabilizer. If either stabilizer requires it
shall be necessary to install a new spar, as stabb,ilizers
are match-drilled to spar on installation.
C. Stabilizer Installation (F-28F) (See Figure 8-16)
(1) Apply lubriplate or equivalent to spar (3) and slide spar into
tailcone spar mounts.
NOTE: Install spar with mount hole for bolt (4) to left side
of tailcone.
(2) Align bolt hole in spar with hole in spar mount located inside
tailcone inspection panel and install bolt (4). Torque bolt.
(3) Install and secure access panel (7) on left side of tailcone.
MM-8-42
MAINTENANCE MANUAL
HORIZONTAL STABILIZER F-28F INSPECTION

28-20100 Fig 8-16 Horizontal Stabilizer bushings +.001 Not repairable Replace bushing
Items 5 Stabilizer 1.130 diam. .001
&6
Bolt holes +.002 Not repairable Replace stabilizer
.189 diam. .005
Stabilizer skin None allowed Not repairable" Replace stabilizer

check for cracks
NOTE: Structural repairs to be made utilizing

Part FAR 43 (Sheet Metal)
1.125
28-11222 Fig 8-16 Cross Soar O.D. diam. -.0005 Not repairable Replace spar
Bolt holes +.002 Not repairable Replace spar

.189 diam .005
Spar surface check None allowed Not repairable Replace spar

for nicks, scratches,
cracks
"Repair per FAR 43 recommendations
MM-8-43
I
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(NOTE I.)
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NOTES:
I. SHIN WITH WASHERS TO EOUAL
GAP BETWEEN STABILIZER ANC
TA I LCONE.
FIG. 8-16. F-2BF HORIZONTAL STABILIZER INSTALLATION

MAINTENANCE MANUAL
(4) Apply lubriplate or equivalent to O.D. of spar extending from

each side of tailcone.
(5) Slide stabilizers (4) and (5) onto spar (3).
(6) Align bolt holes in stabilizer to holes in spar and install

bolts (2) in each stabilizer. Torque bolts.
NOTE: When installing new stabilizer and spar, proceed as

follows:
(a) Lubricate and install spar in tailcone. Secure

with bolt (4).
(b) Lubricate O.D. of spar and slide stabilizer in

position.
(c) Align pre-drilled pilot holes (#41 drill size) in

stabilizer to pilot holes in spar.
(d) Drill through stabilizer and spar in the pilot hole

positions with a t12 drill (.189 diameter).
(e) Install bolts (2) and torque.
(7) Shim with washers between the tailcone and tab (1) and secure
with screw.
NOTE: Shim thickness (washers) to equal gap between inboard

end of stabilizer and tailcone. This dimension may
vary from side to side.
MM-8-45
MAINTENANCE MANUAL
8-15 STABILIZERS 280F
A. Stabilizer Removal (280F) (See Figure 8-17)
(1) Remove screw and washers from tab (1) in aft end of stabilizer.
(2) Remove bolts (2) securing stabilizer to soar.
(3) Slide stabilizer off of spar to remove.
(4) Separate strobe wires at quick disconnect points to allow

complete removal.
B. Stabilizer Inspection (280F)
See Inspection Table Horizontal Stabilizer 280F
C. Stabilizer Installation (280F) See Figure 8-17
(1) Apply lubriplate or equivalent to spar on each side of tailcone.
(2) Attach strobe wires at quick disconnect points and slide

stabilizer onto spar.
(3) Align bolt holes in stabilizer to holes in spar and install

i bolts (2). Torque bolts.
(4) Shim with washers between the tailcone and tab (1) and secure
with screw.
NOTE: Shim thickness (washers) to equal gap between inboard

end of stabilizer and tailcone. This dimension may
vary from side to side.
MM-8-46
MAINTENANCE MANUAL
HORIZONTAL STABILIZER 280F INSPECTION

Part No. Item No. Part Name Inspect Limi ts Limi ts Repai r or Acti on
280-200003 Fig 8-17 Horizontal Bolt holes +.002 Not repairable Replace stabilizer
Item 3 Stabilizer .189 diam. .005
&4
Stabilizer skin None allowed Not repairable Replace stabilizer
check for cracks
Strobe lights None allowed Not repairable* Replace lense cover

check for cracks
in lense cover
NOTE: Structural repairs to be made using Part FAR 43 (Sheet Metal)
280-200000 Fig 8-17 Spar Bolt holes +.002 Not repairable Replace spar
.189 diam +.005
Inspect for visual None allowed Not repairable Replace spar

cracks
*Repair per FAR 43 reconsnendations
MM-8-47
A y
-a
9 NOTE I)
j
jR i!
4 tNOTE I
1-,
4t
"a
PP
a 3
do p"
Q3 P
r
8%
/ir
NOTES:
k I. SHIM WITH WASHERS TO EOUAL
GAP BETWEEN STABILIZ’ER AND
TAILCONE.
FIG. 8-17. 280F HORIZONTAL STABI1IZER INSTALLAflON

SECTION
MAIN ROTOR
MAINTENANCE MANUAL
SECTION 9
MAIN ROTOR
9-1 F´•1AII~ ROTOR HUB ASSEMBLY
The main rotor hub assembly is of the fully articulated design which
allows the blades to lead-lag and flap. Three dampers of hydraulic
design damp the lead-lag motion of the blades. Th ree u n i ve rsal
blocks and a center spacer make up the center section of the hub.
Three retention assemblies are attached to the universal blocks at a
hinge pin which allows flapping motions. An elastomeric lamiflex
bearing is incorporated into each retention assembly to control the
feathering axis. Three all-aluminum blades attach to the retention
assembly by a retention bolt and drag link. Eighteen roller
bearings, with 24 grease fittings, provide long life and low
maintenance in the hub assembly.
B. Main Rotor Hub Removal (See Figure 9-1)
(1) Remove main rotor as follows:
(a) Disconnect drag link (1) from trailing edge of blade.
(b) Remove blade retention bolt (2) from blade and grip.
(c) Carefully slide blade from grip to remove.
CAUTION: When removing blades, lift blade tip up until

blade is parallel to the ground to prevent
expanding blade grip ears.
(2) Remove bolt (3) from push-pull rods and bolt (4) from center
pivot point of cyclic walking beams.
(3) Lift walking beams from mount brackets and allow them to hang
free onpitch links.
NOTE: Install tie wraps to hold pivot spacers in walking

beams and spacers in push-pull rods.
(4) Cut safety wire and install mast nut tool (T-O048) on nut. See
Figures 9-2A and 9-2B.
(5) Disconnect tail rotor drive flex plate at pinion to prevent

damage.
(6) Remove mast nut (34) and washer (33). See Figure 9-3.
(7) Install hoist sling (T-0011) by wrapping straps around lower

universal block nuts and attaching to hoist hook. Slowly lift
hub assembly from mast.
MM-9-1
3,
NOTE:WALKING BEAM MUST BE INSTALLED

WITH GREASE FITTING TRAILING
THE MAIN ROTOR HUB DIRECTION
OF ROTATION.
O
I~
p
Z
O
m
ru
z
c
2
r
FIG. 9-1 MAIN ROTOR HUB REMOVAL AND INSTALLATION

MANUAL
Figure 9-2A MAST NUT REMOVAL PROCEDURE
Figure 9-2B MAST NUT TOR4UING PROCEDURE
ORIGINAL
MM-9-3
As Received By
ATP
MAINTENANCE MANUAL
b.
P e´•
NOTE 4.
12~3s
138 19
14Y 1 23
, 24
,20
Q 25
(NOTE 3.) 22
,~cf
(NOTE
(NOTE 2.)
0 26
NOTES
I. CHAMFER OUTBOARD TOWARDS HUB

PLATE
8 2. CHAMFER INBOARD TOWARDS U-BLOCK.
3. L~OWER END OF U-BLOCK HAS NOTCHES

9
IN´•THREADS.
10 4 UPPER HUBPLATE BOSSES ARE THREADED

FOR WALKING BEAM BRACKET ATTACHMENT.
18
Figure 9-3 MAIN BOTOR HUB ASSEMBLY

MM-9-4
MAINTENANCE MANUAL
C. Main Rotor Hub Disassembly
NOT E: Al 1parts should be marked for reassembly in the same
respective position.
(1) Remove pitch links (2) and walking beams from pitch horn (1).
See Figure 9-4.
(2) Remove pitch horn (1) from blade grip.
(3) Remove dampers as follows: See Figure 9-5.
(a) Remove cotter pin (14), nut (13) and washer (12).
(b) Remove bolt (11) and washer (12).
(c) Pivot damper to remove spacers on top and bottom of damper

rod end.
(d) Remove nut (10) and washer (9) from inboard damper pivot
bolt (7) and remove bolt.
(e) Remove damper from hub assembly.
NOTE: For damper disassembly, see Section 9-5 Damper

Disassembly.
(4) Remove retention assemblies as follows: See Figure 9-6.
(a) Bend tab up on hinge pin lock washer (4).
(b) Install tool (T-0051) on nut (5) and remove nut.
(c) Lift retention assembly up and slide or tap hinge pin (3)
from assembly and remove assembly from hub.
(d) Remove DU washers from both sides of universal block

recesses.
NOTE: If shims are installed behind DU washers, remove

and save for reassembly.
NOTE: For retention disas semb ly, see Section 9-2,

Retention Disassembly.
SEE FIGURE 9-3 FOR FOLLOWING STEPS
(5) Remove bolts (1) and (2) from walking beam brackets (3) and
remove brackets.
(6) Remove dust cover(4).
(7) Bend tab up on lock washer (6).
MM-9-5
MAINTENANCE MANUAL
SPPICERS
Figure 9-4 PITCH LINK ATTACHMENT

TO PITCH ARM
MM-9-6
FLAPPING PIN ASSEMBLY DAMPER INSTALLATION
´•e
8~ IISI
m
z
h Y/ I
a
2
9
lo~ g~p,,
~R 13
~W 4"
Bp
i4
5
Figure 9-5
NOTE: INSTALL SHIMS (2) BEHIND DU WASHER AS REOUIRED TO OBTAIN
PROPER TENSION OF RETENTION FLAPPING BEARINGS. INSTALL
DU WASHERS WITH CHAMFER INBOARD TOWARDS U-BLOCK
Z-h~\
28-14019-3 Green .003 thick
-4 Clear .0075 thick
-5 Blue .005 thick
-6 Brown .010 thick
/I Flapping Pin Index Roll Pin
i
3
03
FIG. 9-6 RETENTION INSTALLATION

MAINTENANCE MANUAL
(8) Install ´•tool (T-0051)on Inut (5) and remove nut and washer.
(9) Turn hub assembly ov~y and remove screw (27), washer (28) and
lock key (10).
(10) Install tool (T-0003) on nut (9) and remove nut and shims (8).
(11) Remove DU washer (7).
(12) Remove hardware and bolts (11) from center hub adapter.
(13) Remove upper spline adapter (12) and lower spline adapter (18)
by tapping from hub plates with a nylon drift.
(14) Remove dowel pins (13) from hub plates and center spacer (16) by
tapping through with an aluminum drift.
(15) Heat upper hub plate (14) to approximately 250" and lift hub
plate from universal blocks (15). Tap with a plastic mallet if
necessary.
(16) Heat lower hub plate (17) to approximately 250" and tap
universal blocks (15) from hub plate.
(17) Remove grease fittings (19) from hub plates (6 places).
D. inspection see Detailed Inspection Sheets, pages 9-10 through 9-14.
MM-9-9
MAINTENANCE MANUAL
D. MAIN ROTOR HUB ASSEMBLY INSPECTION
Figure Serviceable Repair

28-14202 Fig 9-4 Walking Deformed or None allowed Not repairable Replace bracket
Item 3 beam bracket cracked ears
Security of No play Not repairable Replace bracket

bushings in
bracket
press fit
?8-14227 Fig 9-4 Nut Threads no None allowed Not repairable Replace nut
Item 5 crossed or
missing threads
W-09 Fig 9-4 Lockwasher Tangs no None allowed Not repairable Replace lockwasher
Item 6 deformed or
cracked tangs
28-13236 Fig 9-4 DU washer Flatness .005 Not repairable Replace washer
Item 7
Thickness -.003 Not repairable Replace washer
.093-.090
28-14256 Fig 9-4 Nut Threads no None allowed Not repairable Replace nut
Item 9 crossed or
missing threads
MM-9-10
MAINTENANCE MANUAL
D. MAIN ROTOR HUB ASSEMBLY INSPECTION (continued)
Se i bl e Repa~
Part No. PdrtName Inspect Li:Yt:ea Limit: Repair or Action
28-14223 Fig 9-4 Spacer. 3 holes +.001 Not repairable Replace spacer
Item 16 5/16" diameter
6 holes +.0015 Not repairable Replace spacer

.318
diameter
.313
28-14224 Fig 9-4 Spline Inboard face of +.0005 Not repairable Replace adapter
Items Adapters adapter
12 18 perpendicular to
O.D. within
.002 TIR
Spline P.D. +.0005 Not repairable Replace adapter

concentric to
3.6245
diameter
3.623~E;
within .001
Spline pitting .003 deep Not repairable Replace adapter
Spline corrosion None allowed Surface rust Wire brush to remove
Spline wear .0015 on side Not repairable Replace adapter
28-14280 Fig 9-4 Upper Hub Bores (3 places) +.0008 Not repairable Replace hub plate
Items 14 2.4986
diameter
2.4994
MM-9-ll
MAINTENANCE MANUAL
D. FIAIN ROTOR HUB ASSEMBLY INSPECTION (continued)

28-14280 Fig 9-4 Upper Hub Recesses for hub +.0005 Not repairable Replace hub plate
(continued) Items 14 (continued) adapter parallel
to recesses for
DU washer
within .001
Damper bolt +.0005 Not repairable Replace bushing

bushings
.4995-.5000 dia.
Walking beam 5/16-24 thread Not repairable Replace with

mount bracket 1191-5CN0625
threads in hub Helicoil
_boss
No
crossed or
missing threads
(Helicoil)
28-14281 Fig 9-4 Lower Hub Bores (3 places) Not repairable Replace hub plate
Item 18 2.4986
diameter
2.4994
Recesses for hub +.0005 Not repairable Replace hub plate

adapter parallel
to recesses for
DU washer
within .001
Damper bolt +.0005 Not repairable Replace bushings

bus h i´•ng s
.4995-.5000 dia.
MM-9-12
MAINTENANCE MANUAL
UNIVERSAL BLOCK ASSEMBLY INSPECTION

28-14251 Fig 9-4 Stop Pad Visual damage None allowed Not repairable Replace stop pad
Item 21 no cracks,
chips, etc.
28NBC2040YZP Fig 9-4 Bearing OD 2.4994-2.5000 None allowed Not repairable Replace bearing
Item 22 diameter
ID 1.7493-1.7500 None allowed Not repairable Replace bearing

diameter
Bearing rotation None allowed Not repairable Replace bearing

no ratchety
feeling
28-13236 Fig 9-4 DU washer NOTE: Same as

Item 23 Item 7
28-14117 Fig 9-4 U-Block Bore 2.4996-2.4988 +.0002 Not repairable Replace U-block
Item 24 diameter
Bearing surface -.0002 Not repairable Replace U-block

OD 1.7494-1.7488
diameter
Bearing surface None allowed Not repairable Replace U-block

concentricity
.001 TIR
MM-9-13
MAINTENANCE MANUAL
UNIVERSAL BLOCK ASSEMBLY INSPECTION (continued)

28-14117 Fig 9-4 U-block Threads no None allowed Not repairable Replace U-block
icontinued) Item ?4 (continued) crossed or
missing threads
No scratches None allowed Maximum scratch Polish to remove
permitted in depth repair- scratch

.030 radius at able .003 deep
28-14235 Fig 9-4 Spacer Ends parallel None allowed Not repairable Replace spacer
Item 25 within .0015 TIR
28-14233 Fig 9-5 Flapping No crossed or None allowed Not repairable Replace pin
Fig 9-6 Pin missing threads
Item 3
.5015/.5005 +.0015 Not repairable Replace pin
Dia. bolt holes
O.D. 1.7494 -.0005 Not repairable Replace pin

to 1.7488
Longitudinal No deeper Blend out Return to

scores or than .005/.011" locally service
scratches in depth
Radial scores None allowed Not repairable Replace pin
#2 Rev. 11/18/88
MMY4
MAINTENANCE MANUAL
9-2 RETENTION ASSEMBLY (SeeFigure 9-8)
A. Disassembly
(1) Clamp retention assembly in a vise in vertical position.
CAUTION: Use brass protector plates on vise jaws to prevent

damage to spindle surface.
(2) Remove hardware from dust cover (18) and remove cover.
(3) Remove cotter pin (17) from nut (16).
(4) Install tool T-OO13 on nut (16) and remove nut.
(5) Remove shims (15) and lamiflex bearing (14).
(6) Tap blade grip (13) with a plastic mallet to remove.
(7) Remove nylatron strip (5) from spindle by peeling off.
CAUTION: If bearing wears through the nylatron

lamiflex
strap, a inspection of the spindle is
careful~
required. The maximum depth allowed for a groove
worn in the spindle is .020 inch. Groove must be
blended out before installing a new nylatron strap.
(8) Remove O-ring (12) and DU washer (li) from spindle.
(9) Remove retainer ring (10) from groove in main rotor spindle (3).
(10) Remove the hinge pin alignment roll pin from ear of spindle by
tapping out with a small punch.
(11) Install press tool between seal (6) and bearing (7) on spindle.
(12) Place in hydraulic press and press bearings (7) and (9), and
spacer (8) from spindle.
(13) Remove seal (6) from spindle.
(14) Removal and replacement of retention stops (1) and (4) are
necessary only if stops are damaged or adhesive has loosened.
(15) Remove cap (2) from bore of spindle.
CAUTION: When cleaning parts for inspection do not submerge

lamiflex bearing (14) in any type of cleaning
solvent damage to bearing will
or result. Clean
bearing by hand using alcohol.
B. Retention Inspection See Detailed Inspection Sheets, pages 9-16

through 9-19.
MM-9-15
MAINTENANCE MANUAL
RETENTION ASSEMBLY INSPECTION

Part No Item No Part Name Insnpct Limits Limits ReDair or Action
r-
28-14240 Fig 9-8 Droop Stop Visual general .003 wear Not repairable Replace stop
Item 1 condition
28-14231 Fig 9-8 Up Stop Visual general .003 wear Not repairable Replace stop
Item 4 condition
28-14282 Fig 9-8 Spindle Lamiflex bearing .191 width Not repairable Replace spindle
Item 3 slot width
.189-.187
Small bearing 1.9993 diameter Not repairable Replace spindle

su-rface
2.0003-1.9996
diameter
Large bearing 2.4993 diameter Not repairable Replace spindle

surface
2.5002-2.4996
diameter
Seal. surf ace 2.870 diameter Not repairable Replace spindle

2.878-2.872
Hinge pin bores 1.7505 diameter Not repairable Replace spindle

1.7500-1.7495
diameter
MM-9-16
MAINTENANCE MANUAL
RETENTION ASSEMBLY INSPECTION (continued)

Part No.~ Item No. Part Name Inspect Limits Limits Repair or Action
Item 7
Bore 2.500-2.4993 None allowed Not repairable Replace bearing
General None allowed Not repairable Replace bearing

condition no
ratchety feeling
28-14261 Fig 9-8 Spacer Length 3.060 Not repairable Replace spacer
Item 8 3.062-3.061
Ends parallel .0012 Not repairable Replace spacer

within .001
Item 9 diameter
Bore 2.0000- None allowed Not repairable Replace bearing

1.9993 diameter
General None allowed Not repairable Replace bearing

condition no
ratchety feeling
28-14313 Fig 9-8 DU washer Thickness .087 Not repairable Replace washer
Item 11 .093-.090
MM-9-17
MAINTENANCE MANUAL

28-14279 Fig 9-8 Blade Grip Blade bolt bore .8765 diameter Not repairable Replace grip
Item 13 .876-.875
diameter
Large bearing 3.2540 diameter Not repairable Replace grip

bore 3.2522-
3.2512 diameter
Small bearing 2.7530 diameter Not repairable Replace grip

bore 2.7519
2.7511 diameter
Thru bore 1.5180 diameter Not repairable Replace grip

1.5165-1.5145
diameter
Drag link ear .744 width Not repairable Replace grip

width
.747-.745 width
Threads no None allowed Not repairable Replace grip

crossed or
missing threads
MM-9-18
F-28F 280F
MAINTENANCE MANUAL

28-14320 Fig 9-8 Lamiflex Thickness None allowed Not repairable Replace lamiflex
Item 14 Bearing .770-.790
External to 3" Not repairable Replace lamiflex

internal tab
angle -12"
Column for None allowed Maximum of Return to Enstrom

separations 2 separations for inspection and
possible rebond.
28-14335 Fig 9-8 Nut Thrust face .0015 Not repairable Replace nut
Item 16 flat within .001
Threads no None allowed Not repairable Repl$ce nut

crossed or
missing threads
Mi-9-19
MAINTENANCE MANUAL
9-3 UNIVERSAL BLOCK ASSEMBLY
A. U-Block Disassembly See Figure 9-4
(1) Remove upper and lower bearings (22) and DU washers (23) from
U-block (24).
(2) Press flapping bearings (22) and spacer (25) from bore of
U-block.
(3) Remove screws and stop blocks (21) if visual damage appears on
blocks.
(4) Remove grease fittings (20).
B. U-Block Inspection
NOTE: See detailed inspection sheets in Main Rotor Hub Inspection

of Section 9-2.
C. U-Block Assembly See Figure 9-4
(1) Install stop blocks (21) and secure with screws.
(2) Lubricate bore of U-block and place in arbor press. Install a

DU washer (23) in recessed area of U-block and press flapping
bearing (22) into U-block until it is flush with face of
DU washer.
(3) Rotate U-block in press and install spacer (25). Press another
bearing (22) into bore until flush against spacer.
(4) Lubricate O.D. of upper and lower bearing surfaces. Install

DU washers (23) with DU side of washer facing inboard against
U-block. (Chamfered side toward hub plates).
(5) Press upper and lower bearings (22) onto U-block.
9-4 RETENTION ASSEMBLY
A. Assembly See Figure 9-8
(1) If installing new retention stops (1) and (4) proceed as

follows:
(a) Clean blocks (1) and (4) and spindle (3) with acetone or
equivalent.
(b) Apply Versilok acrylic adhesive accelerator to bonding

surfaces of both st-ops and spindle. Allow to dry until
accelerator turns white.
MM-9-20
gP
FIGURE 9-7
INSTALLATION NYLATROT\I STRAP

TO SPINDLE USING T-0035
MAINTENAN~E MANUAL
(c) Apply Versilok acrylic adhesive k(506 to bonding surface of

stop and install stop into position on spindle (3).
NOTE: When installing droop stop (1), secure stop in position

with adhesive and screws.
(d) Allow adhesive to dry until hard.
(2) Apply zinc chromate to bore of spindle (3) and install plug (2)
in end of bore.
(3) Clamp spindle (3) in vise in vertical position.
(4) Apply lubrication to seal surface of spindle (3) and install

seal (6).
NOTE: Seal is installed with spring s i de of seal fa c i ng

toward ears of spindle.
(5) Apply lubrication to bearing surface and tap bearing (7) onto
spindle using a plastic mallet.
(6) Install spacer (8) on spindle.
(7) Apply lubrication to bearing surface and tap bearing (9) onto
spindle using a plastic mallet.
NOTE: Be sure bearings (7) and (9) are seated firmly against
shoulders of spindle.
(8) Install retainer ring (10) in groove of spindle.
(9) Bond nylatron strip (5) to spindle as follows:
(a) Clean bonding surface of nylatron and spindle with acetone

or equivalent.
(b) Apply a light coating of Swift adhesive #HT3-7864 (contact

cement) to both bbnding surfaces. Allow to dry until
adhesive is tacky.
(c) Install nylatron strip on spindle. See Figure 9-7.
NOTE: Strip should be installed with seam 90" to lamiflex

notches in spindle.
(d) Ins ta 11 tool T-OO35 over nylatron strip and secure in

place.
NOTE: Allow adhesive to dry for approximately 1 2 hours

before removing tool.
MM-9-22
81718
BE
Is
13
f 14
15
12
a m~
io z
N
w z
FIG. 9-8 RETENTION ASSEMBLY BREAKDOWN

MAINTENANCE MANUAL
(e) Remove tool T-0035. Trim nylatron out of lamiflex notches

using a razor knife.
CAUTION: Do not scratch spindle surface when trimming.
(10) Install DU washer (11) on spindle (3).
NOTE: DU washer must be installed with chamfered side of

washer facing inboard toward bearings.
(11) Install O-ring (12) on spindle until seated against DU

washer (11).
(12) Install tool T-O036 behind seal (6) with chamfered side of tool
toward large radius of spindle.
(13! Lubricate bore of blade grip (13) and install on spindle and
bearings. Tap grip down with plastic mallet until seal (6) is
seated in grip.
(14) Remove tool T-0036 and tap blade grip down until fully seated.
(15) Install lamiflex bearing (4) while aligning tabs to slots in

spindle and blade grip.
(16) Determine the thickness of shims (3) required as follows:
(a) Inrtall nut 12) on spindle until cotter pin hole in nut
aligns to hole in spindle.
(b) Temporarily install cotter pin (1).
(c) Check gap between lamiflex bearing and nut using a feeler
gauge to derive approximate shim thickness.
(d) Remove cotter pin and nut.
(e) Install variable thickness shims to equal gap in step "c".
(f) Install nut (2) on sp;indle. Torque to 15-20 in. Ibs. using
tool T-O013.
NOTE: Add or subtract shims (3) until cotter pin hole in

nut aligns wi;th hole in spindle when nut is torqued
to 15-20 inch pounds. DO NOT under torque nut to
align holes.
CAUTION: Shims (3) must be installed with O.D. of shims

concentric to O.D. of. nut and lamiflex bearing.
Improper alignment of these shims can cause wear
to the inner surfaces of main rotor blade grip.
See Figure 9-9.
MM-9i24
MAINTENANCE MANUAL
AREAS OF POSSIBLE
WEAR
NOTE SHIMS MUST BE

CONCENTRIC WITH
NUT FLANGE
Figure 9-9 LAMIFLEX BEARING CHANGE
MM-9-25
MAINTENANCE MANUAL
CAUTION: To prevent damage to the lamiflex bearing during

normal maintenance, note the blade grip placard
cautioning against over-rotation of the grip
when the;pitch link is disconnected.
(g) When shimmed install

pin (1roperly cotter pin
and nut
ends to
torqued,
secure.
cotter
(17) Install dust cover (18) and secure with hardware.
(18) Install grease fittings and purge screws in blade grip.
(19) Attach pitch change horns to blade grips and torque bolts to
75 in-lbs. Safety wire bolts in pairs with .032 safety wire.
See Figure 9-4.
(20) Attach pitch links (2) to pitch change horns and secure with
bolts. Torque nut and install cotter pins. See Figure 9-4.
(21) Attach pitch links (2) to pitch change horns and secure with
bolts. Torque nut and install cotter pins. See Figure 9-4 for
correct hardware attachment.
E. Main Rotor Hub Assembly S~e Figure 9-3
(1) Heat the upper hub pla:te (14) and lower hub plate (17) to
approximately 2500.
NOTE: To distinguish between hub plates, the upper hub plate

has hell-coil threads in outer bosses for walking beam
bracket attachment. Lower hub plate bosses are solid.
(2) Place lower hub plate (17) on 2" x 4" wood blocks and lubricate
bearing bors.
(3) Install U-block assembly (15) into bearing bore of hub plate
with threaded notched end of U-block down (3 places).
NOTE: Be sure the DUi washers (23) have been installed on
U-blocks with chiamfered side facing the hub plates. DU
washers must be seated in recessed area of hub plate.
(4) Place spacer (16) on lower hub plate and align bolt holes.
(5) Lubricate bearing bores of upper hub plate (14) and install it
on U-block assemblies.
NOTE: Be sure DU washers are seated in recessed area of hub

plate.
MM-9-26
MAINTENANCE MANUAL
(6) Lubricate dowel pins (13) and tap pins into the center hole of
the 3-hole bolt pattern (3 places
NOTE: Dowe 1 pins must be installed until slightly recessed

from face of hub plate surface.
(7) Insert bolts in upper spline adapter (12) as guides and install
spline adapter into upper hub plate (14).
CAUTION: When installing spline adapters the phasing marks on

top of the splines must align with one of the walking
beam mount brackets (3). Using a felt marker, mark a
line;on outboard edge of hub plate in line with spline
phasing marks to aid in the alignment when installing
lower spline adapter.
NOTE: To distinguish between spline adapters the upper

spline adapter (12) has the wider flat surface on top
side of splines while the lower spline adapter has a
rib extending from lower end of spline.
(8) Carefully turn hub assembly over and position on wood blocks.
(9) Install lower spline adapter (18) into lower hub plate (17).
(10) Install center hub bolts (11) in holes adjacent to walking beam
bractet mount hales and install uashers End nuts. Torque bolts.
(11) Install walking beam brackets (3) and secure with bolts (1)
and (2). Torque bolts (1) and safety with .032 safety wire.
Torque bolts (2).
(12) To set rotational drag of U-blocks (15) proceed as follows:
(a) Place hub assembly on a stand with lower end of U-blocks

up.
(b) Install DU washer (7) into recess of hub plate with chamfer
in board toward hub plate.
(c) Install approximately .025 shims (8) and lower U-block

nut (9). Tighten nut using tool T-O0O3.
(d) Rotate U-block to one of the stops and install a hinge pin
partially into bearing until it extends 4.75 inches.
(e) Attach a spring scale to head of hinge pin and pull to

check drag of U-block.
NOTE: Drag tolerance with nut torqued is 8 to 16 Ibs.
MM-9-27
MAINTENANCE MANUAL
(f) Add or subtract shiims (8) until propeu drag torque is

obtained.
NOTE: Nut (9) must be torqued before checking drag.
(g) Place locking key (10) into slot of nut (9) aligned with
notch in U-block and secure key with screw.
(h) Adjust drag of all three U-blocks following steps (b)

through (g).
(13) Turn hub assembly over on stand.
(14) Install upper U-block nuts (5) as follows:
(a) Install lockwasher (6) and nut (5) on U-block.
(b) Torque nut (5) to 20 ft-lbs using tool T-0051.
(c) Using a plastic mallet, tap down on top of nut and

re-torque to seat upper bearing.
NOTE: Repeat step (c) until nut (5) will not move when
being torqued to 20 ft-lbs.
(d) Bend tab from lock washer (6) into slot in nut (5) to
secure nut after torque is completed.
(e) Install dust cover (4) on nut and secure with screws and
washers.
(f) Repeat steps (a) through (3) on each U-block.
(15) Install grease fittingis (19) into upper and 1 ower hub
plates (6 places).
F. Retention Assembly Installation See Figure 9-6
(1) Install DU washers (1) in each side of U-block.
NOTE: The chamfered side of DU washers face inboard toward

U-block.
(2) Carefully slide retention assembly into position over DU washers

and U-block.
(3) Lubricate O.D. of hinge pin (3) and install it through spindle
and U-block.
(4) Align roll pin slot in hinge pin with hole in ear of spindle and
tap roll pin into position until it is flush with hinge pin.
(5) Install lock washer (4) and nut (5) on hinge pin.
MM-9-28
MAINTENANCE MANUAL
(6) Torque nut (5) to obtain a flapping preload using tool T-0051.
Torque not to exceed 100 ft. Ibs.
~AUI!ON: Torque nut (5) until retention assemblywill remain in

the up-stop position with no more than~20-25 in. Ibs.
of force to move it to the down stop. Excessive torque
could shear the roll pin installed in head of hinge
pin (3).
NOTE: Shims (2) may be installed required on the inboard

as
side of DU washers (1) to avoid excessive torque in
obtaining flapping preload. All three retention
assemblies should have an equal flapping preload.
(7) Lubricate U-block lead lag end and flapping bearings and
re-check retention assembly to stay in up position. See
Section 9-4 for U-block lubrication procedures.
NOTE: Retorque nut (5) if required to obtain proper flapping

preload.
(8) When proper preload has been obtained secure nut (5) by bending
tab from lockwasher (4) into slot of nut.
(9) Lubricate retention assembly. See lubrication procedure.
G. Retention Assembly Lubrication Procedure See Figure 9-10
NOTE: See Section 4, Lubrication, for approved grease when

lubricating main rotor hub and retention assemblies.
(1) Remove purge screw (2) and pump grease into grease fitting (1)
until grease purges through screwhole. Install screw (2).
(2) Remove purge screw (3) and pump grease into grease fitting (1)
until grease purges through screwhole.
(3) Pump grease into fitting (4) until grease purges through
screwhole. Install screw (3).
(4) Pump grease into grease fitting (4) until grease purges through
seal between end of grip and spindle.
(5) Remove purge screw (3) to relieve any internal pressure against
seals. Replace screw.
NOTE: Purge all three retention assemblies when lubricating

the hub to prevent an out-of-balance condition.
H. Damper Installation
(1) Reniove cotter pin and nut from center walking beam bolt. Slide
bolt back to end of threads.
MM-9-29
MAINTENANCE MANUAL
4 3
Figure 9-10 LUBRICATION PROCEDURE
MMi-9-30
MAINTENANCE MANUAL
(2) Install damper assembly on main rotor hub.
(3) install chamfered washer on in board damper bolt.
NOTE: Chamfered side of washer must go against bolt head.
(4) Install inboard bolt through hub plates and damper. Install
bottom washer and nut but do not secure.
(5) Pivot the damper to align rod end with hole in hinge pin.
NOTE: Slotted style rod ends using the locking key must be
installed with the key on the top side to prevent
interference with the hinge pin. See Figure 9-15.
(6) Install spacers on each side of rod end and slide rod end into
hinge pin while aligning spacers with hole.
(7) Install washer on 1/2 inch bolt and install bolt through hinge
pin and rod end. Install two washers and locknut on bolt.
(8) Torque 1/2 inch bolt to 450 to 500 in-lbs while aligning cotter
pin hole. Install cotter pin.
(9) Torque inboard damper bolt to 190 in-lbs.
(10) Install washer and locknut on center walking beam bolt. Torque
nut and install cotter pin.
I. Main Rotor Hub Installation See Figure 9-1
(1) Locate the spline with phasing mark at top of main rotor shaft
and mark it with a black felt marker for alignment ease. Apply
No-Lok anti-seize compound to the rest of the rotor shaft
splines.
(2) Using sling T-0011 on main rotor hub assembly, carefully lower
hub onto main rotor shaft while aligning the phasing marks on
lower spline adapter to phasing mark of rotor shaft spline.
Remove sling.
CAUTION: When hub installed the rotor shaft spline phasing

is
mark must located between upper spline adapter
be
phasing marks. Check this before installing mast nut
and washer.
(3) Install mast washer with chamfered side down toward splines.
(4) Install mast nut and torque to 400 ft-lbs using tool T-0048.
See Figure 9-2. Safety wire mast nut using .041 safety wire
(3 places).
MM-9-31
MAINTENANCE MANUAL
i5) Install pivot spacer in p~sh-pull rod (3) and center pivot Feint
positonof walkin93 beam

(4).places).
Install hardware to secure walking beam in
NOTE: Torque beam mount hardware to 40 in-lbs at

walking
points and 4 o;f Figure 9-1.
3 Torque outboard walking
beam bolts at pitch link attachment to 70 in-lbs.
~JOTE: Wa Iking beam must be installed with grease fitting

trailing the main rotor hub direction of rotation.
(6) Reconnect tail rotor drive flex plate at pinion.
(7) Install main rotor blade and secure with blade bolt (2). Torque
blade bolt to 600 in-lbs.
NOTE: Install tool T-0009 on threaded end of blade bolt for

installation ease.
(8) Connect drag link to trailing edge of blade and secure with
hardware. Torque bolts to 140 in-lbs.
(9) Inspect all connections for security and proceed to the

Preflight Control System check.
J. Preflight Control System Check
NOTE: Whenever a has had work accomplished to the

helicopter
flight controls, it is
recommended that a flight test be
conducted before returning the helicopter to service.
(1) Perform a complete Flight Test Procedure as described in

Section 12, Flight Controls.
(2) Check blade track. See Section 12-2 and 12-3, T ra c k i ng

Procedures.
9-5 Dampers
The damper assembly consists of a damper housing, a piston and restrictor

assembly and a reservoir with two relief valves. The damper is used to
damp lead-lag movement of the mai’n rotor blades. Proper servicing and
maintenance is required to keep the dampers operating at an equal rate.
MM-9-32
MAINTENANCE MANUAL
B. Damper Troubleshooting
PROBLEM CAUSE ACTION
Erratic lateral bounce Air entrapment Bleed dampers

in a hover with control
inputs
Erratic lateral bounce Airentrapment Bleed dampers

th rou g h ~t ra n s 1 a t i on al
flight
Steady lateral bounce Low fluid level Bleed dampers

in hover flight OR
Faulty relief valve Replace valve
Excessive ground Low fluid level Bleed dampers

bounce OR
Faulty relief valve Replace valve(s)
Excessive fore and Plugged piston Disassemble and

aft rocking of ship restrictor clean assembly
during rotor
engagement
Fluid leakage from Damaged seals Replace seals

seals
Steady bounce in Rod end worn Replace rod end

sharp turns during OR
flight Weak relief valve Replace valve(s)
NOTE: A lateral bounce can be best determined from a vertical

bounce in that a lateral is erratic in nature whereby a
vertical is constant. The hovering flight is the best area
to determine lateral bounces, with power changes and
collective and cyclic input changes.
C. Lead-Lag Check
(1) Raise blade off its droop stop.
(2) Move blade slowly fore and aft to cycle damper.
NOTE: The damper should offer resistance through the complete

cycle no undamped motion.
D. Damper Servicing and Bleeding Procedure
NOTE: These dampers can be serviced on or off the aircraft.
(1) Remove reservoir plugs.
MM-9-33
MAINTENANCE MANUAL
(2) Fill reservoir ports with L-45 silicone oil.
(3) Replace reservoir plugs.
(4) Cycle damper slowly, a minimum of four times.
NOTE: (a) Dampers on the aircraft are cycled by slow fore

and aft movement of the rotor blade.
(b) Cycling dampers off the aircraft can be done in

the T-OO51 damper cycling fixture.
i5) Remove reservoir plugs.
(6) Check fluid level.
(a) Full fluid level indicates damper is serviced; proceed to

step (7).
(7) Install reservoir plugs.
(8) Safety wire.
F. Relief Valve Replacement (see Figures 9-11 through 9-14 for

appropriate style damper)
NOTE: The relief valve pressure has been preset at the factory
and cannot be adjusted in the field. Return faulty valves
to Enstrom Helicopter Service for i ns pect i on and val ve
adjustment.
(1) Remove damper from aircraft.
(2) Remove plugs (16) and O-rings (21).
(3) Drain L-45 damper oil.
(4) Remove plugs (12) and O-rings (11).
(5) Remove relief valves (22) through the open ports with tool
T-OO91.
(6) Install new relief valves (22). Torque 70-90 in-lbs.
(7) Install O-rings (11) and;plugs (12).
(8) Fill reservoir with L-45 damper oil through the top bleeder
ports.
(9) Install O-rings (21) and plugs (16).
MM-9-34
12500750-2508 SEAL 12
I I
16 22
MS28774-1 16
8L\CK-UP RING i;; r
5iJ~ M~28775- i 16
22
23
"O R!NG I I
24
9
C
I 13
10
c
0( 14 1
15
6
1 ~41
2
20
19
O
28-14375-1 DAMPER ASSEMBLY
Figure 9-11
12
I I
12500750-2508 SEAL 16 22
MS28774-116
BACK-UP
RINGb;
5
22
MS 287 75 I 1 6 23
II
"O"RING
24
9 ~1 d
13
H
7
10
18
17 01 14
15
6 z"
4,
Po
O
D
3 20
19
O
Figure 9-12
12
I I
16 22
g
21
12500750 SEAL~-CL
959-5 WIPER
22
23
I
Io~b
24
9
i~--
~v
11II~ 13
io ~r
17 01 14
15
4, 6
o,
O
1 "141
3
20
19
O
Figure 9-13
12
16 22
2500750 SEA~
IZ 21
959-5 WIPER
22
23
I I
12
24
19
13
7_
10
18
17 ol 14
4,
,o
1 ",’41
j,ldUII I U.
20
19
a
Figure 9-14
MAINTENANCE MANUAL
(10) Follow servicing and bleeding procedure to insure all air is

purged from the damper. (See Servicing and Bleeding Procedure.)
(11) Safety wire plugs.
G. Damper Disassembly (See Figures 9-11 through 9-14 for appropriate

style dampers)
(1) Remove damper from the helicopter.
NOTE: Reference Figures 9-11 through 9-14 for the appropriate

style damper configuration.
(2) Disengage locking feature on the rod end (1).
(a) Straighten locking washer tabs (3) oh the -1 and -5

dampers.
(b) Remove safety wire from locking key (3) on the -3 and -7
dampers.
(3) Loosen locknut (2) and remove rod end (1) from piston as
follows:
(a) -1 and -5 dampers Hold piston (7) with tool T-0015 to

break lock nut loose. Remove rod end.
(b) -3 and -7 dampers Place wrench across flats of rod end

next to the uni-ball to hold piston from rotating and break
lock nut loose. Remove rod end.
(4) Remove reservoir plugs (16) and pour fluid from reservoir.
(5) Remove reservoir~-plugs (12) and O-rings (11).
(6) Remove bolts (18) and washers (17). Remove reservoir.
(7) Remove sleeves (15) and O-rings (14).
(8) If troubleshooting indicates malfunctioning relief valves,

remove relief valves (22) using tool T-0091.
CAUTION: Field disassembly of relief valves (22) is not permit-

ted. Relief valve setups and adjustments are critical
and require special equipment. Return valves to
Enstrom Helicopter Service.
i9) Remove bolts (19) and washers (20) from damper housing and
cap (4).
MM-9-39
MAINTENANCE MANUAL
(10) Rotate end cap (4) approximately 450 using a soft mallet, and
remove end cap by tapping outward on its corners.
NOTE: Remove all burrs from piston shaft to prevent damage to

brass sleeve and seals (5) during end cap removal.
(11) Pour fluid from damper housing.
(12) Tap piston (7) out of housing with a nylon dr´•ift and remove
O-ring (9) from piston.
(13) Remove brass sleeve assemblies (5) from end cap (4) and hous-
ing (13) by heating the aluminum housings and pressing the brass
sleeves out using a suitable size drift.
NOTE: Remove brass sleeve assemblies (5) only if seals are
going to be replaced to reduce wear on the cover (4)

and housing (13’) bores.
(14) Discard O-rings and seals.
(15) Install too 1 T-0095 between ears of damper housing and press
bushing (24) out using a suitable size drift.
(16) Inspect of bushings (23) for fretting and wear.

face DO NOT
remove thebushings unless replacement is required. Upon
replacement, bushings must be reamed with a 3" line reamer.
H. Damper Inspection See detailed inspection sheets, pages 9-41

through 9-44.
MM-9i40
MAINTENANCE MANUAL
28-14375 DAMPER ASSEMBLY INSPECTION

28-14370-15 9-12 Piston Surface for nicks None allowed .005 deep max. Polish out
Figs
28-14267-13 14 to and scratches 3" long to remove.
9-11 13 Clear with

Item 7 Restrictor for None allowed compressed air
obstruction
(28-14570-15 preferred)
Sliding .746-.748 diameter Not repairable Replace piston
journal O.D.
Concentricity .001 TIR Not repairable Replace piston
Threads No crossed or Not repairable Replace piston

missing threads
Surface for nicks None allowed .020 deep Polish blend to

28-14265-1 Figs 9-15 Cap
to 9-18 and scratches remove. Brush on
Item 4 iridite
Bore 1.1250-1.1257 diameter Not repairable Replace cap
No obstruction None allowed Clear with

in port compressed air
MM-9-41
MAINTENANCE MANUAL
28-14375 UAMPER ASSEMBLY INSPECTION (continued)

28-14356-5 Figs 9-11 Brass O.D. 1.126-1.1265 diameter Not repairable Replace sleeve
to 9-14 Sleeve
Item 5 I.D. .750-.753 diameter Not repairable Replace sleeve
(Preferred replacement Scratches or .001 deep on one Not repairable Replace sie
for Fig. 9-11 9-12) scoring of I.D. land only
Concentricity .002 TIR Not repairable Replace sleeve

O.D. to I.D.
28-14366-1 Figs 9-11 Reservoir Threaded plug No crossed or missing Not repairable Replace reservoir
to 9-14 holes threads
Item 10
Obstructions in None allowed Clear with
flow ports compressed air
If valves are None allowed Flush with cleaning

removed, inspect solvent and dry
threads ports with compressed air
for contamination
MM-9-42
MAINTENANCE MANUAL
28-14375 DAMPER ASSEMBLY INSPECTION (continued)

28-14357-1 Figs 9-11 Housing Brass sleeve 1.1250-1.1257 diameter Not repairable Replace housing
to 9-14 bore
Item 13
Flanged bushings 1/3 of total f’ace 1/2 of total Polish and
in ears for light fretting face light blend to remove
excessive fretting
frettin~
Flow ports free None allowed Clear with

of obstructions compressed air
Threads No crossed or Not repairable Replace housing

missing threads
Security of No movement allowed Not repairable Replace housing

chrome sleeve
to bore of housing
Surface scratches None allowed .020 deep Polish and blend

to remove.
Brush on iridite
28-14277-1 Figs 9-11 Sleeve O.D. .5005-.4994 Not repairable Replace sleeve
to 9-14
Item 24 Nicks scratches .002 deep .005 deep Polish blend to
remove scratches
I.D. .3757-.3747 diameter Not repairable Replace sleeve
MM-9-43
MAINTENANCE MANUAL
28-14375 DAMPER ASSEMBLY INSPECTION (continued)

28-14369-1 Figs 9-11 Sleeve O.D. I.D. None allowed Not repairable Replace sleeve
to 9-14 for nicks
Item 15
28-14368-1 Figs 9-11 Plug Threads No crossed or Not repairable Replace plug
to 9-14 missing threads
Item 12
AN814-2DL Figs 9-11 Plug Threads No crossed or Not repairable Replace plug
to´• 9-14 missing threads
Item 16
01-691-08 Figs 9-12 Rod End Radial play .005 maximum Not repairable Replace rod end
MXKJR-8R to 9-14
Item 1 Axial play .007 maximum Not repairable Replace rod end
01-691-08 Figs 9-11 Threads No crossed or Not repairable Replace rod end
9-13 missing threads
Item 1
All O-Rings Close visual No defects Not repairable Replace defective

inspection for item
obvious defects
MM-9-44
MAINTENANCE MANUAL
I. Damper Assembly (See figures 9-11 through 9-14 for appropriate

style dampers)
NOTE: Correct illustration must be used to assure proper seal

installation in brass sleeves (5).
(1) Install seals, O-rings, or wipers into brass sleeves (5) as

determined by appropriate illustration.
(2) Install O-rings (6) on O.D. of brass sleeves (5).
(3) Heat damper housing (13) and end cap (4) to approximately 250".
Apply L-45 damper oil to O.D. of brass sleeves as a lubricant
and press sleeves into damper housing and end cap using tool
T-0094. Allow to cool.
(4) If required, install flanged bushings (23) utilizing an arbor

press to seat each bushing.
CAUTION: New bushings must be reamed with a 3" line reamer

after installation.
(5) Lubricate O.D. of bushing (24) and press into place.
CAUTION: Place tool T-0095 between ears of damper housing to

prevent collapsing of ears during press operation.
(6) Clamp damper housing in a vise with bore upright.
CAUTION: Insure components are free of dirt or other

contaminants prior to assembly. Use only L-45 Grade
#20 silicone fluid for assembly of the damper.
(7) Lube the inside of housing bore with L-45 damper oil.
(8) Lube O-ring (8) with damper oil and install on piston (7).
(9) Install piston (7) into damper housing by gently tapping with a
plastic mallet until piston is bottomed out.
NOTE: Threaded end of piston must face end cap (4).
(10) Fill housing with L-45 damper oil and install O-ring (9) into
recess of damper housing (13).
(11) Lube seals in end cap (4) with L-45 oil and gently slide end cap
over end of piston (7). Tap gently to seat end cap into damper
housing.
NOTE: Care must be used not to cut 0-rings and seals on

installation.
MM-9-45
MAINTENANCE MANUAL
(12) Secure end cap to housing with bolts (19) and washers (20).
Torque bolts using cross pattern tightening sequence.
(13) If relief valves (22)

had been removed for cleaning or replace-
ment, re-install valves in the reservoir (1) using socket
the
tool T-0091. Torque valves to 70-90 in-lbs.
(14) Reposition damper to horiiontal position in vise with reservoir

parts up.
(15) Install O-rings (14) onto sleeves (15) and insert sleeves into
ports in damper housing.
(16) Align reservoir (10) with sleeves (18) on damper housing and
position reservoir in place. Secure with bolts (18) and
washers (17) and torque bolts.
(17) Place O-rings (11) on plugs (12) and secure plugs into reser-
voir.
(18) Reposition damper in vise with bleeder ports up. Move damper
piston approximately 3 inch off bottomed out position.
(19) Fill reservoir with L-45 damper oil and install O-rings (21) and
plugs (16).
(20) Install locking hardware on rod end (1) as follows:
(a) Install nut (2) and flat lock washer (3) on the -1 and -5
dampers.
(b) Ins ta 11 nut (2) and locking key (3) on the -3 and -7
dampers.
(c) Apply Vibra-Tite to the threads of the rod end and allow to
dry.
CAUTION: Do not apply Loctite to rod end threads in place

of Vibra-Tite or damage to the damper piston can
result when trying to remove rod ends.
(21) Install rod end (1) into damper piston until correct rod end
dimension is obtained. See Figure 9-15.
(a) Dimension is .975" .025 from centerline of rod end to

outboard edge of jam nut on the -1 and -5 dampers.
(b) Dimension is 1.230" .010 from centerline of rod end to

inboard edge of jam nut on the -3 and -7 dampers.
NOTE: Locking key (3) must be aligned into piston slots

before jam nut will seat against end of piston on
-3 and -7 dampers.
MM-9-46
MAINTENANCE MANUAL
NOTE: THIS
INSTALLATION
FOR -la-5
DAMPERS
PISTON
REF. CENTERLINE OF
.025
.975 -~t ROD END
LOCKING TANG UP
NOTE: THIS
INSTALLATION
FOR S 8r -7
DAMPERS I I I
-t.oos
1.050
PISTON
REF.
f CENTER LINE OF
THIS DIMENSION MUST BE MI\INTI\INED

ROD END
Figure 9-15
DAMPER ROD END INSTALLATION
#2 Rev. 11/18/88 MM-9-47

MAINTENANCE MANUAL
(22) Torque jam nut (2).
NOTE: On -1 and -5 dampers tool T-0015 is used to hold piston

from rotating during torque sequence. An adjustable
wrench held across rod end flats will hold piston
rotation on the´•-3 and -7 dampers.
(23) Secure rod end to piston as follows:
(a) -1 and -5 dampers i

Bend the flat locking washer over the
flats on the damper piston and the flats on the jam nut.
(b) -3 and -7 dampers i

Safety wire the jam nut (2) to locking
key (3).
(24) Bleed damper in damper cycling fixture T-0057. (See

Section 9-5, Servicing a:nd Bleeding Procedure)
(25) Safety damper bolts and plugs with .032 safety wire as follows:
(a) Safety end cap bolts (19) in pairs.
(b) Safety plugs (12) to reservoir bolts (18) in pairs.
(c) Safety bleeder plugs (16) in a pair.
(26) See Section 9-4 (H) Damper Installation.
MMi9-48
SECTION
TAIL ROTOR
MAINTENANCE MANUAL
SECTION 10
TAIL ROTOR
10-1 TAIL ROTOR ASSEMBLY
The tail ~rotor assembly consists of two blade and grip units mounted
on a spindle by the use of a pair of matched DT ball bearings
common
and one needle bearing per grip. This rotating assembly is
teeter-mounted on a center hub by the use of two tapered roller
bearings. The center hub is splined to match the tail rotor ~earbox
output shaft for positive mounting and driving. The control of this
~ssembly is blade to pitch link, to sliding pivot yoke, to cables,
cables to bell crank and bell crank to foot pedals in the cockpit.
B. Troubleshooting
Foot pedal Pivot bolts on Loosen pivot bolts and

controls are tail rotor retorque.
binding. bracket
overtorqued.
Improper Install spacers properly to

assembly of allow for needed clearance on
pitch links to each side of pitch links.
pitch arm.
Tail rotor Remove tail rotor and reinstall

misaligned on using correct alignment. See
output shaft, Figure 10-5.
causing pitch
links to bind.
Not i ceabl e Imp rope r Check rigging procedure and

dead spot in tension on adjust cables to 35-40 Ibs.
tail rotor’ .control pedal control. cables.
Feathering Disconnect pitch links and

bearings worn rotate grips to determine
or rubber problem blade. Replace faulty
bumper shifted or worn parts.
and binding.
MM-10-1
MAINTENANCE MANUAL
Tail rotor Out of Dynamic balance with Chadwick

vibration. balance. system.
Excessive end Remove tail rotor assembly and

play in teeter retighten retainer caps until
bearings, hub rotates firmly by hand with
creating out no end play. Grease and static
of balance balance.
condition. NOTE: If teeter bearings are
bad, they may be replaced

without removing blade and grip
assemblies.
Improper Both grips must be greased each

lubrication. time tail rotor is lubricated
or an out of balance condition
will result.
C. Tail Rotor Assembly Removal (See Figure 10-1)
(1) Disconnect pitch change links from pitch arms.
(2) Remove safety wire from hub retention bolt (1). Remove bolt,
washer (2) and teeter stop (3).
NOTE: Index mark hub an:d shaft splines for installation ease.
(3) Carefully slide tail rotor assembly from transmission output

shaft.
D. Tail Rotor Blade Assembly Disassembly (See Figure 10-1)
Removal of blade grip and feathering bearings.
(1) Clamp tail rotor assembly in vise so the blades can be rotated,
(2) Remove bolts (21), washers (20), and nuts (19) from pitch arm
(6).
(3) Cut safety wire and remove bolts (4).
NOTE: To ease blade grip ass emb ly removal, remove lube

fitting (9) from grip.
MM-1O-2
MAINTENANCE MANUAL
CAUTION: INSTALL BEARINGS (25) IN MATCHED SETS WITH CLOSED

SIDE OF BEARINGS 18
INBOARD TOWARD THE HUB.
FACING
b
THIS SIDE OF THE BEARINGS WILL ALSO HAVE THE WORD
"THRUST" IMPRINTED ON THE FACE OF THE OUTER RACE.
MOST OF THESE BEARING SETS WILL ALSO BE SCRIBED
WITH A "V" ON THE OUTER RACES POINTING TOWARD THE II
CENTER HUB.
’5 P
14
13
28
27 4 21
20
26 3
2
25
13
14
15
Q
16
7
17
9
d
TORQUE PAINT STRIPE
BALANCING SCREWS
FIGURE 10-1
TYPICAL VIEW OF
RETAINER CAP
MM-10-3
MAINTENANCE MANUAL
~4) Apply heat to grip (7) using a heat gun. Heat to approximately
250"F. Blade can be removed by pulling blade with one hand
on
and using a nylon hammer to tap on blade bolt nuts.
CAUTION: DO NOT TAP ON ROOT OF BLADE. Do not separate blade

from grip as these are match-drilled on assembly.
(5) Remove bumpers (22) from end of spindle and inspect for wear
damage.
(6) Remove lockwasher (23) by prying up on tabs with a screw drive.
(7) Remove lock nut (24) from spindle (8) using tool T-OO54.
(8) Remove thrust bearings (25).
NOTE: These are matched sets. Keep together.
(9) Remove bearing retainer (27) and bearing (28).
(10) Remove bearing sleeve (26).
(11) Remove pitch arm (6).
Removal of teeter bearings and hub.
NOTE: The teeter bearings niay be removed from tail rotor without
removal of the blade and grip assembly. Cut safety wire
and remove two bolts (4) from pitch arm. This will allow
clearance for bearing removal. Proceed with steps (12)
through (17). Reass~mble following steps (1) through (7)
of assembly procedure (see Figure 10-1). Reinstall bolts
in pitch arm, torque, and safety wire. Grease and static
balance.
(12) Cut safety wire from retention cap (17).
(13) Remove caps (17) from spindle (8).
(14) Remove screws (16) and washers (15).
(15) Remove bearing race (14) and bearing cone (13).
(16) Remove shields (12) and washers (11).
(17) Remove hub (10) from spindle (8).
(18) Tail rotor assembly is now ready to be cleaned and inspected.
MM-1O-4
MAINTENANCE MANUAL
E. Cleaning
Care should be used in cleaning the tail rotor to prevent scratching

or damaging parts. Wash parts in cleaning solvent.
NOTE: Bearings should be washed in clean solvent to prevent

contamination.
F. Tail Rotor Assembly Inspection
See Inspection Tables.
G. Tail Rotor Assembly Assemble (See Figure 10-1)
(1) Place hub (10) into tail rotor spindle (8).
(2) Install washers (11) on hub with chamfers toward the radius.
(3) Install shields (12) (with cup side toward the bearing) and
cones (13) on hub,
(4) Secure bearing assembly to hub with retainer washers (15) and
screws (16).
(5) Install cups (14) over bearing cones (13).
(6) Press Grease fittings (18) into retainer caps (17) if fitting
was not previously installed.
(7) Install retainer caps (17) into spindle to secure bearing cups.
NOTE: Tighten caps until hub rotates firmly by hand with no

end play. To visually center the hub in the spindle
check that an equal number of threads are visible on
outboard edge of bearing retainer caps.
NOTE: A torque paint strip and safety wire of the retaining

caps (17) is required; however, this step cannot be
accomplished until the static balance procedure is
completed.
(8) Place pitch arm (6) on spindle with the machined clearance
surface of pitch am facing outboard toward bearing (28).
(9) Install bearing sleeve (26) on spindle.
(10) Press bearings (28) into bearing retainers (27) and install on
bearing sleeve (26).
NOTE: Closed end of retainer faces outboard toward bearings

(25).
MM-10-5
MAINTENANCE MANUAL
F. TAIL ROTOR ASSEMBLY INSPECTION

28-150001-5 Fig 10-1 Blade Grip Bearing bore in 2.0468-2.0454 diameter Not repairable If grip is attached
Item 7 Assembly grip with 1/4" bolts, a
new grip can be
installed at Enstrom’s
factory with 5/16"
bolts. DO NOT attempt
this in the field.
note: Both blades of
a tail rotor assembly
require the same size

bolts. DO NOT
intermix blades with
1/4" and 5/16" bolts.
Scratches in None all’owed Not to exceed Fine abrasive polish

grip (bearing .020 deep to blend out scratch.
housing area) Brush area with
iridite finish.
Scratches in None allowed Not to exceed Fine abrasive polish

grip (near .010 deep to blend out scratch.
blade retention Brush area with
area) iridite finish.
Cracks None allowed None allowed Replace blade and

grip assembly.
SLG1W-P Fig 10-1 Lock washer Locking tabs None allowed Nicks not to Fine abrasive polish
for nicks or exceed .005 to remove nicks to
bent tabs. deep smooth radius.
CONTINUED
MM-1O-6
MAINTENANCE MANUAL

SL61W-5P CONTINUED Tabs to be Tabs not to be Apply enough side

parallel to bore distorted by pressure to return
more than 10" tabs parallel.
to bore
Serrated spline No smooth or Not repairable Replace lockwasher
bore rolled splines
28-15001-5 Fig 10-1 Blade Blade-leading None allowed Not repairable Replace blade
Item 9 edge bond
separations
See Section 4 for complete
inspection and service limits Blade-trailing None allowed Not repairable Replace blade
edge bond
separations
Blade skin None allowed .010 deep Polish out area and
sharp dents and blend smooth, not
scratches exceeding 2" diameter
area. Brush touchup
paint.
Blade skin .020 deep, not Not required None

smooth dents exceeding 1.0"
in diameter
Distortion or None allowed Not repairable Replace blade

rippled blade
Doubler None allowed Not repairable Replace blade

separation
Leading edge Not exceeding Not required None

smooth dents .020" deep
MM-10-7
MAINTENANCE MANUAL
F. TAIL ROTOR INSPECTION ASSEMBLY

Leading edge None allowed .025" deep Polish out area and
sharp dents blend smooth. Brush
scratches. touchup paint.
28-150066 Fig 10-1 Retaining Threads No crossed or missing Not repairable Replace cap.
Item 17 threads.
Wrench flats for Maximum rounded edge Deburr Using very fine
a
rounded corners not to exceed 1/16" file, square off
corners.
28-15033 Fig 10-1 Rubber Check both sides Surfaces to be Not repairable Replace bumper.
Item 22 bumper for friction smooth
wear
MS20002-C6 Fig 10-1 Washer Check for nicks None allowed Not repairable Replace washer.
Item 11
28-150062 Fig 10-1 Shield Visual check for None allowed Not repairable Replace shield.
item 12 deformities
A-2126 Fig 10-1 Bearing I.D.

.3750
+.0005 Not repairable Replace cone
Item 13 -.OOO0
Cage rollers None allowed Not repairable Replace cone

for nicks or pits
Rotate for No ratchety Not repairable Replace cone

smoothness check feeling
MM-1O-8
MAINTENANCE MANUAL
F. TAIL ROTOR INSPECTION ASSEMBLY

Item No. Part Flame Inspect Limits Limits Repair or Action
Part No. _
A-2037 Pig 10-1 Cup O.D. +.001 Not repairable Replace cup
1.2595
Item 4 (bearing race) -.000
Fitted race No pits allowed Not repairable Replace cup
28-150053-1 Fig 10-1 Retaining Check for No distortion Not repairable Replace washer
Item 15 Washer flatness
58-150063 Fig 10-1 Bearing Sleeve I.D. .7882 .7878 diameter Not repairable Replace sleeve
Item 26 Sleeve
Sleeve O.D. 1.1250 1.1243 dia. Not repairable Replace sleeve
Ends perpen- t.0005 Repairable if Grind to

dicular to bore notexceeding serviceable limits.
.001
MR-18 Fig 10-1 Bearing Bearing O.D. +.0000 Not repairable Replace bearing
1.6250
Item 28 -.0005
Needles in I.D. No visible wear Not repairable Replace bearing
28-150055 Fig 10-1 Bearing Retainer OD 2.044-2.043 diameter Not repairable Replace retainer.
Item 27 Retainer
Retainer ID 1.626-1.6250 diameter Not repairable Replace retainer.
Concentricity .001 TIR Not repairable Replace retainer.

OD or ID
MM-10-9
MAINTENANCE MANUAL

7304DT Fig 10-1 Bearing Bearing OD 2.0472-2.0467 diameter Not repairable Replace bearing.
Item 25
Bearing bore .7874-.7870 diameter Not repairable Replace bearing.
Hold bearing to No ratchety feeling Not repairable Replace bearing.

preload side
rotate to check
3L51N-5P Fig 10-1 Nut Threads No crossed or missing Not repairable Replace nut.
Item 24 threads.
Nicks burrs None allowed Deburr Remove burrs with

on OD po-l; i´•;s-h debu´•r´•r- too;l. Fine
abrasive polish
smooth.
Check for Maximum of 2 Remove nicks Remove burrs with

rounded or slightly rounded tabs to accept deburring tool.
burred locking locknut wrench
tabs
28-150064-11 Fig 10-1 Tail Rotor Surface scratches No scratches allowed Minor abrasive Polish with Scotch
Item 8 Spindle not exceeding Brite pads or
.001 equivalent.
Threads No crossed or missing Not repairable Replace spindle.

threads.
Feathering .7868-.7862 diameter Not repairable Replace spindle.

bearing shaft
CONTINUED
MM-1O-1O
MAINTENANCE MANUAL

~art No. Item No. Part Name Inspect Limits Limits Repair or Action
28-150064-11 CONTINUED Teetering bearing 1.2627-1.2615 diameter Not repairable Replace spindle.
bore
Concentricity .001 TIR Not repairable Replace spindle.
Cracks None allowed Not repairable Replace spindle.
28-150051-1 Fig 10-1 Hub Splines Not pitted or wicked Not repairable Replace hub.
Item 10
Teetering .3748-.3741 diameter Not repairable Replace hub.
bearing shaft
Cracks None allowed Not repairable -Replace hub.
Teetering No stripped or Not repairable Replace hub.

bearing shaft missing threads
threads
28-150060-11 Fig 10-1 Pitch Arm Nicks in edge No nicks allowed Nicks not Polish blend
Item 6 of arm exceeding locally to exceed
.005 deep .008 deep.
Pitch link bolt .250-.251 diameter Not repairable Replace pitch arm.
hole
Corrosion or No corrosion Return to factory for

rust inspection
replating, or replace
pitch am.
Cracks None allowed Not repairable Replace pitch am.
MM-10-11
MAINTENANCE MANUAL
(11) Instal 1 bea ri ng s (25) in matched sets with closed s i de of

bearing facing inboard toward hub. This side of the bearing
will also have the word "’thrust" imprinted on the face of the
outer race. Most of these bearing sets will be scribed with a
"V" in the outer races pointing toward the center hub.
(12) Install retaining nuts (24) and torque 45 to 50 ft. Ibs.
(13) Align and install lockwashers (23).
(14) Clean surface of bumper (22) and end of spindle with acetone or
equivalent. Apply a small amount of Eastman 910 adhesive or
equivalent to bumper and attach it to end of spindle. Be-sure
bumper is centered and secure.
(15) Apply lubrication (STP and oil) to O.D. of bearings and a small
mount of lubriplate to end of bumper (22).
(16) Heat blade grip with heat gun to approximately 250"
(17) Apply lubrication (STP and oil) to I.D. of blade grip and
quickly slide grip over spindle assembly. Align pitch link hole
in pitch arm to leading edge of blade. Align dowel pins (5) to
center holes in pitch arm.. (Holes located in sets of three.)
(18) Start bolts (4) into grip and tighten to pull grip down to pitch
arm.
NOTE: To pull grip on straight, tighten bolts 2 or 3 turns

each on alternate sides until grip is completely down
to pitch arm.
(19) Torque pitch arm bolts and safety in pairs using .032 safety
wire.
(20) Re-heat grip and top outboard to assure maximum CF position.
(21) Install grease fittings (9) into blade grips.
(22) Lubricate blade grips (feathering bearings) per Lubrication

Chart in Section 5. Grip is fully lubricated when grease begins
to come through center hole around pitch arm.
NOTE: Be sure to purge both grips each time you lubricate the
tail rotor assembly to prevent an out of balance
condition.
(23) Lubricate hub (teetering bearings) using tool T-0014. See

Lubrication Chart in Section 5 for approved lubricants.
(24) Static balance tail rotor.
MM-1O-12
MAINTENANCE MANUAL
H. Static Balance Procedure See Section 10-2.
NOTE: Complete the static balance procedure before installing the

tail rotor on helicopter.
I. Pitch Link Assembly and Installation
NOTE: Pitch link length

been has
preset and locked at the
factory. DO NOT
disassemble, unless rod ends need
replacing. If replacement is necessary, follow steps
below. (Total length 4.260.) (See Figure 10-4)
II) Install lock nuts on rod ends.
(2) Apply VC-3 Loctite to threads of rod ends.
(3) Turn right hand rod end into barrel until threads completely
cover the sight hole in barrel.
!4) Turn left hand rod end into barrel until overall length of pitch
link measured 4.260 inches.
NOTE: Steps (5) through (8) to be completed after

installation of tail rotor on transmission.
(5) Lock control pedals with blades in neutral position.
(6) Install pitch links on tail rotor assembly and attach to pitch
arm and pitch link retainer. (See Figure 10-2 and 10-3.)
(7) Adjust length of assembly by rotating barrel until pitch link

assembly measures 4.260. Holding barrel with wrench, tighten
lock nuts in place. Recheck length of assembly to be sure it is
still 4.2~0.
CAUTION: Using a piece of .025 safety wire, insert wire in sight

hole of barrel to be sure right hand rod end is still
turned in past the hole.
(8) Dynamic track with Strobex to be sure blades are in track.

Adjustment of pitch links may be required to do this.
J. Tail Rotor Assembly Installation
(1) To install tail rotor on output shaft, visually align the grease
fitting of teeter‘bearing to line up with inside ear of pitch
link retainer, lagging the direction of rotation. Tail rotor
hub should be lagging by 8" to allow clearance for pitch links.
(See Figure 10-5)
NOTE: See Figure 10-1 for steps (2) and (3).
MM-10-13
MAINTENANCE MANUAL
37 35 33 3r 29
NOTE: WASHER STACK UP MAY VARY

WHEN ASSEMBLY IS DYNAMICALLY
BALANCED
45 39
38
FIGURE 10-2 FIGURE 10-3
1
,_"
a B
G
xX FIGURE 10-4
300
MM-10-14
MAINTENANCE MANUAL
!1) Start .041 wrap of safety wire around the hub and feed
through the teetering stop (3). Install teeter stop so rubber
bumpers align with flats of spindle (8).
(3) Install retention bolt (1) and washer (2) into teeter stop.
Torque to 300 in. Ibs. and complete safety wire.
(4) Rotate blade so the pitch arm is opposite the pitch link
retainer.
(5) For assembly

of pitch links to pi tch arm see Fi gure 10-3.
Install washer (30), (31), right hand rod end (32),
spacer (33) and washer onto bolt"P34) reca.)92(
Insert bolt (29)
through pitch arm (6) with the head of the bolt and pitch link
on the inboard side of pitch arm.
(6) Install washers (35), nut (36) and cotter pin (37).
NOTE: During dynamic balancing, it is recommended that not

more than
five washers be used in stack-up (35). If
more than five are required to balance, remove tail
rotor and recheck static balance.
(7) For assembly of pitch links to pitch link retainer see Figure
10-2. Install washer (40) on bolt (39). Insert bolt into pitch
link retainer (38). Guide spacer (41), left hand rod end (42),
spacer (41) on bolt as shown. Install two washers (43), nut
(44). Torque nut and install cotter pin (45).
NOTE: Bolt (39) should be inserted with head of bolt located

in the direction of rotation.
K. Tail Rotor Rigging
(1) Insert neutral position of rigging tool T-0080 between bearing

retainer and output shaft seal retainer. Wedge in this position
with small block of wood placed between yoke and gearbox on side
away from tail rotor assembly. See Figure 10-6.
NOTE: If special tool is not available, neutral measurement

is .590.
(2) Clamp pedals in line (neutral position).
(3) Remove rigging tool and wedge. Remove clamps from pedals.
(4) Insert rigging tool, "right pedal" end between bearing retainer
and output shaft seal retainer.
MM-10-15
MAINTENANCE MANUAL
(5) Depress right pedal to check adjustment.
(a) If spacing is incorrect, adjust left bolt stop on forward

bellcrank assembly under left side of cabin floor. (See
Figure 10-7).
(6) Depress left pedal and check adjustment. Left pedal adjustment
is made with right bolt stop. (See Figures 10-6 and 10-7).
NOTE: If rigging tool is not available, angular measurements

can be taken to check proper bladetravel. Proceed as
follows:
Left blade travel is +32" .5"

Right blade travel is -5" t .5"
(7) Insert rigging tool "left pedal" end between bearing retainer
and output shaft seal retainer.
(8) Rotate tail rotor into a horizontal position. Use a level on
leading edge of blade to check final position.
(9) Center tail rotor spindle with hub. Using two pieces of wood,
shim between hub and spindle to hold teeter beari’ngs rigid.
(10) Depress right pedal.
(11) Using a prop protractor indicating off flat section of blade

grip, check angle of blade. (See Figure 10-8) Adjustments made
at pedal bolt stops. (See Figure 10-7)
(12) Depress left pedal andrepeat above procedure.
NOTE: Control brackets should not stop against tail rotor

gearbox. Pedals must stop against stop bolts on
forward bellcrank.
(13) Check pitch links for overall dimension. Length 4.260 inches.
(14) Check pedals for security and freedom of operation.
(15) Inspect control cable barrels to be sure locking clips are

installed.
NOTE: No more than three threads to be exposed at inboard end

of turn buckle.
(16) Inspect entire system for security.
(17) Check blade track and dynamic balance with Chadwick System.
(See Section 10-3)
MM-1O-16
MAINTENANCE MANUAL
PITCH LINK RETAINER

JREF.
I I
I
I I DIRECTION OF
ROTATION
FIGURE 10-5
TOOL NO. T-OO8O INSTALLED IN

RIGHT PEDAL RIGGING POSITION
TOOL SHOWN IN NEUTRAL

PEDAL RIGGING POSITION
TOOL SHOWN IN LEFT PEDAL

FIGURE 10-6
RIGGING POSITION
MM-10-17
MAINTENANCE MANUAL
RIGHT PEDAL LEFT PEDAL
ADJUSTMENT STOP ADJUSTMENT STOP
AN4- 1 5 BO LT PILOT SIDE (AN4-7 BOLT CO- PILOT

F12NE4753-04B NUT(TYP. BOTH
AN381-2-8 PIN(TYP. BOTH SIDES)
AN38O 4-8 PIN TYP ICAL O N P ILOT BELLCR AN K(28-16338- 1

AN D GO-PILOT BE L LC RA N K( 28- 1 6338 2
NOTE- I. AT ALL DOUBLE LOCKING LOCATIONS NO MORE THAN ONE

THREAD OF BOLT TO BE BELOW SUR IACE OF JOINT.
2. UP TO 3 WASHERS TdTAL MAY BE USED UNDER BOLT HEAD
AND NUT TO INSURE PROPER ENGAGEMENT OF COTTER
PIN IN NUT CASTELLATION.
3. BOLTS OF NEXT DASH NO. IN LENGTH MAY BE SUBSTITUTED
AS LONG AS REQUIREMENTS OF NOTE 2 ARE MET.
4. ALL CHECK NUTS TO BE TR EATED WITH VIBRA-TITE( VC-3)
VISCOUS COATING.
5. BELLCRANK HARDWARE TYPICAL2 PLACES.
FIGURE 10-7
MM-10-18
MAINTENANCE MANUAL
10-2 STATIC BALANCE
A. Balance Procedure (See Figure 10-1 for items listed by number)
(1) Install balance mandrel T-00(37 through hub (10). Align plates
of mandrel with flats of spindle with recess in toward hub.
(2) Rotate blade so that the leading edge of blade aligns with the
teeter bearing in spindle (8).
(3) Align pitch arm plates (6) with hole in mandrel and install bolt
and nuts. Keep bolt centered and tighten nuts finger tight.
(4) Tighten plates againstspindle finger tight.
i5) Install assembly onto balancing fixture in vertical position.

Chordwise balance. (See Figure 10-9)
(6) Determine which direction blade tends to rotate.
NOTE: If trailing edge of blade rises, this is the light

blade. If leading edge rises it signifies the heavy
blade.
i7) Rotate assembly 180" and repeat.
(8) Install’a short plug screw in root end of heavy blade.
NOTE: Use AN515-10 screws of variable length for balancing.
(9) Install screw and AN96O-10 or 10L washers in root of light blade
until assembly will remain stationary in vertical position.
NOTE: Maximum length of AN screw should not exceed 3 inches.

Maximum number of AN washers should not exceed 3 inch
in stack-up.
(10) If tail rotor will not balance using the maximum weight noted in
step 9, the position of the hub (10J must be changed as follows:
While leaving the balancing mandrel on balance stand,

retaining cap (17) on light blade side of
’P indle.10)
loosen
Tighten retaining cap on opposite side to shift hub in
direction of light blade. Hub may be shifted until
chordwise balance can be completed.
(11) Rebalance, rotate 180" and recheck.
MM-1O-19
MAINTENANCE MANUAL
TAIL ROTOR RIGGING
WITH PROP PROTRACTOR
el~iiriln,c´•;
FIGURE 10-8
ORIGINAL
Received By
ATP
MM-10-20
MAINTENANCE MANUAL
(12j Place tail rotor assembly in horizontal pos i ti on Spanwi se

balance. (See Figure 10-10).
(13) Install short plug screw into heavy blade.
(14) Install screw and washers into light blade until assembly will
remain stationary in horizontal position.
(15) Rotate 180" and recheck.
(16! Recheck vertical position, and at 450 to vertical both sides.
(17) Install ~strike tabs and tighten all screws.
(18) Remove balance mandrel.
(19) Install bolt (19),’washers (20), and nut (21) into pitch arm
plate (6). Head of bolt is on inboard side of plate.
(20) Safety wire the teetering bearing retainer caps (17j and apply a
torque paint strip across cap and spindle. See Figure 10-1,
Torque Strip Application.
NOTE: The torque paint strip is a painted line applied across

a of the retainer cap and continued onto the
portion
adjacent surface of the spindle to provide a visual
check for loss of torque on the retainer cap. Use
"Torque Seal" by Organic Products Company of Irving,
Texas, or equivalent to apply the stripe.
(21) Assembly is ready for installation on aircraft.
NOTE: It recommended that all

is tail rotor assemblies be
dynamically balanced on the helicopter.
10-3 TRACKING AND DYNAMIC BALANCE/CHADWICK SYSTEM
A. Installation of Chadwick
(1) Install accelerometer and bracket to right side of stinger tube

at gearbox mounting screw (280’s). On F-28 models install at
loop guard mounting bolt at gearbox.
NOTE: Accelerometer must be installed in a vertical position,

with connector pointing down.
(2) Run wire from accelerometer, wrap around right side stabilizer,
under tailcone to left aft oleo. Secure to oleo. Position
balancer and strobex so rotor disc can be observed from left
side.
(3) Connect wire to channel "B", removing slack from cable.
MM-10-21
MAINTENANCE MANUAL
(I) INSTALL SHORT SCREW IN ROOT

END OF HEAVY BLADE.
(2) BALANCE CHORDWISE WITH SCREWS

AND WASHERS IN ROOT END OF
LIGHT BLADE.
BALANCING
STAND
NOTE:
IF TRAILING EDGE OF BOTTOM BLADE

RISES THIS IS LIGHT BLADE. IF LEADING
EDGE RISES IT IS HEAVY BLADE.
FIG 10-9 CHORDWISB BALANCE
BALANCING STAND
(I) INSTALL SHORT SCREW IN flP OF

HEAVY BLADE.
(2) BALANCE WITH SCREW AND WASHERS

IN TIP OF LIGHT BLADE.
FIG.IO-IO SPANWLSE BALANCE
MM-10-22
C1AINTENANCE MANUAL
(4) Run balancer power wire under cabin to right side door. Remove
seat deck battery access cover and connect power cables to
terminals.
B. Setting Balancer Box Controls
(1) Single/doubler switch to "single."
(2) Common/independent switch to "common."
(3) rpm tune to 250. rpm range to X10.
(4) Switch to "track."
C. Installation of reflective tape
(1) Install tape chordwise on tip of one blade.
j2) Install tape crosswise on tip of other blade.
NOTE: Locate tape in same approximate area of blade tips.
(3) Install a strip, approximately 1" long on one blade grip,

running lengthwise with grip.
D. Tracking Tail Rotor Blades
(Ij Ground run aircraft, faced into wind, pedals neutral.
NOTE: It is important for pilot to give a signal that he has

attained a stabilized 3050 rpm before tracking, or
balancing.
(2) Strobex switch to "ON."
(3) Observe rotor disc from the side, adjusting strobex oscillator
until the single target becomes a stopped image of four targets.
(4) Move to location near left side door and observe targets on tip
of blades.
NOTE: An out-of-track condition should be corrected by use of

the pitch change links.
MM-10-23
MAINTENANCE MANUAL
E. Balancing the Tail Rotor Assembly
If assembly has been torn down for overhaul, or blade and grips
replaced, it should be balanced statically before reinstallation on
the aircraft. (See Section 10-2)
(1) Strobex to "OFF."
(2) Switch to Channel "A".
(3) Observe tail rotor from side of aircraft.
(4) Note clock angle of target, then press "verify tune" button,
adjusting "RPM tune" to return target to original position.
(5) Release "verify tune" button. Observe new target location.
(6) Repeat step (4), adjusting "RPM tune" to new clock angle.
NOTE: Repeat this procedure until target remains at same

clock angle, whether "verify tune" button is depressed
on released.
(7) With button released, record clock angle on Chadwick chart.
18) With strobex NOT flashing, record IFS, depress "Scale Two" and
record "Scale Two" reading if IFS needle pegs.
(9) Using the Chadwick chart, plot which move to make. Make only
one correction, to check line of move.
(10) Repeat steps (7) and (8), recording this as second run.
NOTE: If "line of move" is correct, proceed to balance to

.2 IFS or less.
If "line of move" is incorrect, using "clock angle corrector,"

correct clock angles on chart. This should need to be done only
once.
(11) Proceed to balance to .2 IFS or less.
NOTE: Do not exceed more than 5 washers in a stack-up to

balance. If more than 5 are required to balance,
remove tail rotor and recheck static balance. Addition
or subtraction of Harper .250" stainless steel washers
at "A" or "C" dloes not have much effect, but the
addition or subtraction of tip weights responds a great
deal. Making a small move is better, as it allows you
to nsneak" up on a .2 IFS. Be sure you understand the
Chadwick Chart and make the correct move.
MM-1O-24
MAfNTENANCE MANUAL
Dale
Ho
Ist Run 2Fd Run Jrd Run 4th Run 5lh Run
clock Angle
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~4C’91uBIc 10-11
MM-10-25
MAINTENANCE MANUAL
10-4
A. Pitch Control Removal (See Figure 10-12)
(1) Disconnect pitch links from pitch link retainer (13).
(2) Remove tail rotor assembly. (See Section 10-1)
(3) Remove cotter pin, nut, and pivot bolts from pitch control and
control brackets. (See Figure 10-13)
NOTE: The stainless steel washers located between control

brackets and oilite bushings of pitch control assembly
must be saved for reinstallation.
(4) Slide pitch control assembly off of chrome sleeve (2).
NOTE: Seal retainer (3) and seal (4) are damaged on keys each
time the pitch control assembly is removed. Install
new seal and retainer on reassembly.
(5) Remove keys (1).
B. Pitch Control Disassembly (See Figure 10-12)
(1) Remove seal retainer (3) and seal (4).
(2) Remove cotter pins (14) from retainer (13).
(3) Place pitch link retainer (13) in small arbor press and press
dowel pin (12) through reta:iner and pitch control bearing (5).
(4) Rotate retainer and repeat on opposite pin.
(5) Gently press pitch cont~ol bearing (5) through pitch link
retainer (13), wave spring washers (11~, and bearing (9).
(6) Remove snap ring (10).
(7) Heat bearing housing (8) and gently tap bearing (9) to remove.
(8) Clean parts for inspection.
(9) See pages MM-10-28 and MM-10-29 for inspection requirements.
MM-10-26
MAINTENANCE MANUAL
TAIL ROTOR SLIDER
ASSEMBLY
I)
6
2 3 4 5 4 9 10
i"8 0 ~O
1 1
13
FIGURE 10-12
PIVOT BOLT
STAIN LESS STEEL

WASHER
AN WASHERS
CONTROL BRACKET
FILLER PLUG
SIGHT GUAGE
MAGNETIC PLUG
PITCH CONTROL ASSEMBLY
FIGURE 10-13
MM-10-27
MAINTENANCE MANUAL
C. PITCH CONTROL ASSEMBLY INSPECTION

28-16392 Pitch Link Bore 1.3787-1.3782 diameter Not repairable Replace retainer.
Retainer
Dowel pin holes .2490-.2495 diameter Not repairable Replace retainer.
Bolt holes .250-.251 diameter Not repairable Replace retainer.
Surface nicks None allowed Not exceeding Polish to blend

scratches .010 deep smooth. Brush on
iridite finish.
28-16394 Pitch Bronze OD 1.3781-1.3777 diameter Not repairable Replace bearing

Control
Bearing Bore 1.079-1.081 diameter Not repairable Replace bearing.
Keyway width .1875-.1895 Not repairable Replace bearing.
Dowel pin holes .2450-.2480 Not repairable Replace bearing.
Distortion of None allowed Not repairable Replace bearing.

bore
T-533-023 Seal Visual for cuts None allowed Not repairable Replace seal.
or tears
28-16397 Dowel Pin OD .2500 .0005 Not repairable Replace pin.
MM-10-28
MAINTENANCE MANUAL
C. PITCH CONTROL ASSEMBLY INSPECTION

Part No. Item No. Part Name Inspect Limi ts L imi ts Repa i r or Acti on
28-16331 Bearing Bearing bore 2.6774-2.6779 diameter Not repairable Replace housing.
Housing
Oilite bushings .3765-.3755 diameter Not repairable Replace bushing in
housing.
Surface nicks No scratches allowed Not exceeding Polish and blend

scratches .020 deep to remove.
107-KSZZ6 Bearing Bearing OD +.0000 Not repairable Replace bearing.

2.6772
-.0005
Bore +.0000 Not repairable Replace bearing.

1.3780
-.0005
Axial movement .002 Not repairable Replace bearing.

of inner bearing
to outer race
Rotate to check No ratchety feeling Not repairable Replace bearing.

bearing
smoothness
5002-268-PP Retaining Check for No distortion Not repairable Replace ring.

Ring flatness
W1819-020 Wave Visual check No flat spots Not repairable Replace washer.
Spring for wave
Wsher contour
MM-10-29
MAINTENANCE MANUAL
D. Pitch Control Assembly (See Figure 10-12)
(1) Heat bearing housing (7~) and install bearing (8).
NOTE: Bearing (8) is installed with slots for removal of

inner bearing section facing outboard toward pitch link
retainer. These Slots are located 90" to pivot arms of
bearing housing (7) on installation.
(2) Install snap ring (9) with opening of snap ring in line with
pivot arm of bearing housing (7).
(3) Press pitch control bearing (5) through bearing (8) in outboard
direction.
(4) Install two wave spring washers (10) on pitch control

bearing (5).
(5) While visually aligning dowe 1 pin holes in pitch link

retainer (12) with pin holes in pitch control bearing (5), press
retainer onto bearing.
NOTE: If pin holes do not completely line up, gently tap ear
of pitch link retainer with plastic mallet until holes
do line up.
(6) Press .dowel pin (11) into pitch link retainer (12). Rotate
retainer and repeat.
NOTE: Seat dowel pins to 0.10 inch below surface of pitch

link retainer. Pins must not extend through pitch
control bearing (5).
~7) Install cotter pins (13) into pitch link retainer (12).
(8) Install seal (4) into outboard groove of pitch control

bearing (5).
E. Pitch Control Installation (See Figures 10-12 and 10-13)
(1) Slide seal retainer (3) onto chrome sleeve (2).
(2) Slide seal (4) onto sleeve.
(3) Install keys (1) in slots of sleeve (2).
(4) Align keyway in pitch control bearing (5) with keys (1), and
slide pitch control assembly onto chrome sleeve.
(5) Install stainless steel washers between bushings and control

brackets. (See Figure 10-13)
MM-10;30
MAINTENANCE MANUAL
(6) Install pivot bolts through bushings.
(7) Install three washers for cotter pin clearance and locknut on
each pivot bolt, and torque. (See Figure 10-13)
(8) Align locknut to cotter pin hole and install cotter pin in each
pivot bolt.
(9) Cycle control brackets to be sure pitch control assembly pivots

and slides freely.
NOTE: The heads of the pivot bolts must rotate when control
brackets are moving. If they do not rotate, check for
binding in bushings.
(10) Install seal (4) into seal retainer (3).
(11) Apply asmall amount of Loctite superbonder 495 or Eastman 910

to O.D. of seal retainer and install retainer into recessed area
of pitch control bearing (5).
10-5 Tail Rotor Gearbox
The tail rotor gearbox consists of an aluminum cast housing for a

90 degree miter gear drive, with integral cast mount and control
pivot bosses. The gearbox mechanical input is an independently
mounted shaft and gear assembly that is retained by a matched pair of
duplex ball bearings. The gearbox output to the tail rotor assembly
is an internally mounted shaft and gear assembly that is retained by
another pair of matched duplex ball bearings.
B. Trouble Shooting
Gearbox Low on oil. Add oil,

check sight plug for
running hot. proper level.
Bad internal Return to factory or overhaul

bearing, facility for inspection.
Oil leakage. Worn input or Replace seal.

output shaft
seal.
Roughness in Worn pitted

or Return to factory or overhaul
bearing bearings, facility for inspection.
operation.
MM-10-31
MAINTENANCE MANUAL
Excessive TIR Gearbox Return for gearbox

check on sudden overhaul.
output shaft stoppage or
(.005 max). tail rotor

Tool T-0068 strike.
installed.
Improper Rotate chrome sleeve at 900

spline intervals until runout falls in
alignment of tolerance.
chrome sleeve
to output
shaft.
Excessive Large pieces Return to factory or overhaul

metal or slivers of facility for overhaul
particles on metal flaking inspection.
mag plug. from gears or
bearings.
Fine powdery Drain oil from gearbox.

type metal can Flush with kerosene or’
be caused from equivalent cleaner. Clean mag
normal gear plug and reinstall. Fill
break-in. gearbox with oil and
recheck mag plug after 10 hours
of flight.
NOTE: If excessive metal
appears at this point, return
gearbox for overhaul
inspection.
B. Gearbox Removal
(1) Remove tail rotor assembly (see Section 10-1).
(2) Disconnect tail rotor pitch change cables at the gearbox.
(3) Remove four bolts securing the coupling halves (Zurn coupling).
NOTE: On flex coupling, remove two bolts from aft coupling

half only.
(4) Disconnect or remove tailguard.
(5) Remove safety wire and six screws securing gearbox to the
extension tube.
(6) Remove gearbox by pulling the unit aft with a slight rotational
motion.
MM-10-32
MAINTENANCE MANUAL
C. Inspection
(1) Rotate output shaft and note if there is ariy roughness in

bearing operation.
(2) Check runout of the output shaft as fo Ilows: !.005" Total

Indicated Runout (TIR) maximum.)
INDICATE RUNOUT HERE
I 1
T-0068
FIGURE 10-14
(a) Secure gearbox in a vise.
(b) Install sleeve T-0068 on output shaft. Install spacer T-0068

and torque bolt to 300 in-lbs.
(c) Position height gauge and dial indicator with indicator arm on
outboard diameter of T-OO68.
(d) Zero dial indicator and rotate the input shaft. Mote output
shaft TIR.
(e) If runout exceeds .005 TIR, remove bolt and tool. Remove output
seal. Reposition sleeve on output shaft in 900 intervals until
runout falls within tolerance.
NOTE: If chrome sleeve is removed and repositioned, the

output shaft seal must be replaced.
MM-10-33
MAINTENANCE MANUAL
10-6 TAIL ROTOR DRIVESHAFT AND FLEX COUPLING
The alignment of the tail rotor flex couplings is a very important

factor in achieving the full service life of the flex pack. Large
offsets on the tension side of the pack usually indicate improper
spacing of the coupling sections, and will promote premature
distortion or degradation of the flex pack. A nominal device life
for the flex pack has been established to insure component integrity.
The flex packs must be replacedl after 1200 hours of service with new
flex packs.
B. Flex Coupling Removal (See Figure 10-15)
NOTE: Washers are located against the spacers (2) for the purpose
of centering and aligning the flex elements (3) between
flanges (1 4). Note their location before disassembly.
(1) Remove the bolts, washers and spacers (2) which connect
flanges (1 4) to flex elements (3).
(2) Remove flex elements (3).
(3) Remove taper pins and remove flanges from gearbox and
driveshaft.
C. Flex Coupling Inspection (See Figures 10-17 through 10-20)
NOTE: Figure 10-17 shows a tail rotor driveshaft coupling

i nstal 1 at i on with the tens i on and c omp re s s i on s i des
labeled. There are two types of flex pack distortion which
are typically encountered and which are allowable IF THEY
ARE WITHIN THE LIMITS listed in this section.
(1) The first type of flex element distortion typically encountered

is a simple bow of the el~ments as shown in Figure 10-18. This
distortion is allowable ~LY as long as the coupling meets the
following requirements:
(a) The bend is smooth and gradual, no kinks, etc.
(b) The elements are all deformed evenly, with no separation or

voids between the elements.
(c) The bow, as measured in Figure 10-18, is less than

.080 inch deep on the compression side and less than
.060 inchdeep on the tension side.
MM-1O-34
MAINTENANCE MANUAL
TAIL ROTOR GEARBOX (REF.)
RUBBER SLINGER
-~cs
-´•-L~u i/
1 ’r ii 8 i
RY C7
-1´•
´•´•i
´•i´•
FIGURE 10-16
O FIGURE 10-15
QP
MM-10-35
MAINTENANCE MANUAL
Flex Pack
4~be/ Pear
Flange
L?O~
~eC´•
f~otation
r~J´• /4~be
F~..rd Fl.n~
Looking Aft Bolt Spacers
FIGURE 10-17 Toil Rotor Drive Shaft Coupling

Roar coupling shown; forward coupling similar.
NOTE: Tie-wraps eliminated for clarity.
Death of bow.
Must be less then .080" on compression
side and lees then .060" on tenelon side,
Plates may be bb*ed in either direction.
FIGURE 10-18 Acceptable Liniits of Bowed Flex Pocks~

NOfEI Tie-wraps eliminated for clarity,
MM-10i36
MAINTENANCE MANUAL
Shims may be added here.

J
Offset must be less than .060"

When the flex pack is replaced
added at the bolt spacers as i
the new flex
on both sides.
shims may be
icated to align
pack. Note: Tie-wraps eliminated
I-i Shims may be added here,
for clarity.
CAUTION:~DO NOT ADD SHIMS OR WASHERS BETWEEN THE FLEX PACK AND BEVELED WASHERS.
FIGURE 10-19 ACCEPTABLE LIMITS FOR FLEX PACKS

WITH OFFSET BENDS
Bent Fbnges
--I
Must be less than
olo’:
FIGURE 10-20 ACCEPTABLE LIMITS FOF~ BENT FLANGES
MM-10-37
MAINTENANCE MANUAL
(2) The second type of flex element distortion typically encountered

is an offset bend as shown in Figure 10-19. This type! of
distortion usually occurs because the coupling halves are not
running parallel with each other. This type of distortion is
allowable ONLY as long as the flex elements meet the following
requirements.
(a) The bend is smooth and fair, with no kinks, etc.
(b~ The elements are all deformed evenly, with no separation or

voids between the elements.
(c) The offset is less than .060 inch as shown in Figure 10-19.
(3) The flanges which hold the flex elements must be flat within
.010 inch as shown in Figure 10-20. Any flanges defored beyond
this limit MUST be replaced before further flight.
(4) Whether distortions described

the in the preceding inspections
are present not, the couplings
or are UNSERVICEABLE at any time
the following conditions e~ist:
(a) Elements have kinks or sharp bends.
(b) Separations or voids occur between any of the elements.
(c) Non-uniform or non-fair bends.
(d) Cracked or broken elements.
(e) Elongated bolt holes.
(f) Kinks or deformation adjacent to the bolt spacers.
D. Flex Coupling Installation (See Figure 10-15)
NOTE: Proper during installation and alignment must be

attention
taken permit couplings to operate to full capacity and
to
provide good service life.
(1) Install rain slinger on tail rotor gearbox (see Figure 10-16).
(2) Install flange (1) on gearbox and flange (4) on driveshaft.
(3) Install taper pins, washers and nuts, and torque.
(4) Install a washer and spacer (2) on each bolt.
(5) Install flex elements (3), spacer (2), washer and not on each
bolt. Torque nut.
CAUTION: Heavy or light washers can be used with

spacers (2) to equally space flex elements
between flanges. The curved side of the spacers
must face against the flex elements.
MM-10;38
MAINTENANCE MANUAL
(6) Place washers on bolts and insert through coupling (4).
(7) Install heavy or light washers as required with spacer (2) to

equally space flex elements from flange.
(8) Install spacer, washer, and nut on each bolt. Torque nut.
NOTE: With all bolts torqued, the flex elements (3) should be
straight and equally spaced between flanges.
E. Driveshaft Removal
(1) Remove the upper cowling and the side cowling from one side.
12) Remove tach drive cover and O-rings.
(3) Disconnect the forward and aft couplings.
a. Flex coupling see Flex Coupling Removal.
(4) Remove the anti-collision light from top of tailcone if

required.
(5) Remove the top vertical stabilizer from aft end of tailcone.
This stabilizer is on 280-F models only.
(6) Remove bolts and washers attaching pillow blocks to tailcone

(see Figure 10-24).
NOTE: Save shims for reinstallation.
(7) Remove driveshaft assembly froni tailcone.
F. Driveshaft Disassembly
(1) Remove taper pin and coupling from forward end of driveshaft.
(2) Slide tach drive cover and O-rings from shaft.
(3) Separate and remove tach drive pulley.
(4) Apply lubricant (a detergent soap) to the driveshaft and slide

pillow blocks from shaft.
G. Pillow Block Disassembly
(1) Remove rubber insert.
(2) Remove snap ring.
(3) Heat the housing to approximately 250" and gently tap bearing to
remove.
MM-10-39
MAINTENANCE MANUAL
H. Oriveshaft Inspect for:
(1) Straightness. Sharp kinks or bends in excess of .030 inch per

foot are cause for rejection.
(2) Nicks and scratches. Not deeper than .020 inch may be blended
out; those in excess of .030 inch are cause for rejection.
(3) Taper pin holes for elongation, excessive diameter, and cracks.
Any are cause for rejection.
(4) Corrosion or rust, especially under rubber inserts. Pits in

excess of .030 inch in depth are cause for rejection..
I. Pillow Block Inspect for:
(1) Bearing condition no ratchety feeling.
(2) Bearing housing no cracks, nicks, corrosion.
(3) Rubber insert no tears or rubber deterioration.
J. Pillow Block Assemble
(1) Heat bearing housing to approximately 250".
(2) Lubricate bore of housing and install bearing into position.
NOTE: Open side of bearing is installed inboard toward grease

fitting. On new bearings one shield must be removed.
(3) Install snap ring and allow to cool.
(4) Install rubber insert.
K. Driveshaft Installation.(See iigures 10-21 10-22)
NOTE: When installing a tail rotor driueshaft, both the main

rotor and tail rotor gearbox must be installed on aircraft.
Install a coupling half secured with taper pin in each
gearbox.
(1) Ream bore on one end of driveshaft with a .640 straight reamer
to remove paint. Ream 2" into bore and deburr end of shaft.
(2) Clean bore of driveshaft and O.D. of aluminum plug with Loctite
Primer T.
(3) Apply type "A" Loctite to O.D. of aluminum plug and tap plug
into driveshaft until it is flush with end of shaft.
MM-10-40
MAINTENANCE MANUAL
io
DRIVESHAFT &II I-- -s\ ´•´•INPUT SHAFT
DRIVESHAFT INSTALLATION BLOCK
FLGURE 10-22
COUPLING
V-BLOCK
f
MARK DRIVESHAFT i~ IIPOINT I I 1 .8~8
.875 FROM END
.875
SLIDE COUPLING
TO MARK
500
i´•j:´•a ´•;´•E3IGURE iP’Oi21
i:lli~ i i´•! ´•i
(I.)PLACE COUPLINGI‘OFJ’ AND INS~CL IN V-BLOCK
(2.) MARKAND CENTERPUNCH POINT"A"
.~(3.) DRILL .WITH !’D" SIZE DRILL IN DRILL PRESS
(4,) TAPER:REAh~:.WOLE TO FIT AN38~-2-7A TAPER PIN

i:i-
(s~) INSTALL TAPERIIP.IN,´•

MAINTENANCE MANUAL~
i4) Drill aft coupling as follows (see Figure 10-21).
(a) Mark a line on driveslhaft 7/8" from end of shaft.
(b) Slide coupling on shaft until even with 7/8" line.
(c) Mark and center-punch Point "A" of Figure 10-21 using

dimensions given.
(d) Drill through coupling and driveshaft with a "D" size drill
(.2460 diameter).
NOTE: Drilling must be done in a drill press to assure
that drilled hole is perpendicular to driveshaft.
(e) Ream hole with a #2 tapered reamer to fit an AN386-2-t)A

taper pin very carefully so as not to over ream.
NOTE: If over-reaming of a tapered hole occurs

substitution of AN975-3 cup washer and 28-13600-3,
-4, or -5 taper pins may be required.
(f) Install taper pin through coupling. Install washer and

nut, and torque.
(5) Tempo ra ri 1 y
slide fo rwa rd coupling half on fo rwa rd end of
driveshaft and place driveshaft on tailcone.
(6) Secure driveshaft couplings to gearbox couplings using an

aluminum block .235 inch thick between couplings (see Figure
10-22).
(7) Mark location of forward coupling on driveshaft using a felt

marker. Mark location of eillow blocks on driveshaft.
(8) Remove driveshaft from tailcone.
(9) Remove forward coupling fr6m driveshaft.
(10) Add 7/8" from mark on driveshaft and mark a new line for end of
driveshaft. Cut shaft to length.
NOTE: Do not cut driv~shaft at initial coupling position

mark.
(11) Ream forward end of driveshaft with .640 reamer to remove paint.
(12) Loctite aluminum plug in bore of driveshaft.
(13) Drill forward coupling to driveshaft following procedure in step

(4) (see Figure 10-21).
(14) Install driveshaft on tailcone and connect both couplings to

transmissions using aluminum blocks (see Figure 10-22).
NOTE: Taper pins on both main rotor and tail rotor gearbox
sides of coupling are AN-386-2-7A.
MM-1O-42
MAINTENANCE MANUAL
(15) Mark driveshaft for pillow block alignment to mount holes in

tailcone.
NOTE: Place a 3/4" block of wood under driveshaft to remove

bow in shaft while marking pillow block areas.
(16) Remove driveshaft and forward coupling.
(17) Wipe driveshaft with liquid detergent and slide pillow blocks
into marked positions. See Figure 10-22 for direction of pillow
blocks on driveshaft.
(18) Place driveshaft back on tailcone and connect couplings to

transmissions.
!19) Align pillow blocks with mount holes in tailcone.
L. Driveshaft Alignment (see Figure 10-24)
(1) Clamp piano wire attachment tools T-0O88 to each end of

driveshaft. Attach piano wire between tools and center it
vertically down the centerline of the driveshaft.
(2) Sta rt i ng at the fo rwa rd p i 1 1 ow bl ock pi a ce alignment tool

T-2656 between the driveshaft and the piano wire. Using
variable thickness shims, install shims under pillow block until
step in tool T-OO88 slides snugly between driveshaft and wire.
Intall mount hardware and tighten.
NOTE: Continue step 2 at each pillow block. Recheck

alignment with tool T-OO88 after tightening mount
hardware. Various length mount hardware should be used
as required.
(3) Rotate the wire 90" along centerline of driveshaft to check

lateral alignment. Loosen pillow block mount hardware to shift
driveshaft position until the step of tool T-O088 fits snugly
between driveshaft and wire. Torque mount bolts.
NOTE: Continue step (3) at each pillow block location. after

pillow block mount bolts are torqued re-check
alignment.
M. Final Assembly
(I) Install tach drive pulley on driveshaft.
(2) Disconnect forward coupling and install tach drive O-rings and
cover. Connect coupling.
(3) Install vertical stabilizer on 280-F models only.
(4) Install anti-collision light on top of tailcone.
MM-1O-43
MAINTENANCE MANUAL
F-28F (SHOWN)
NO~ E: AFT PILLOWBLOCK IS

REVERSED ON 280F MODELS
~--CLOSED
CLOSED
AFT END UCLOSED
LOSED
OPEN
FORWARD END
PILLOW BLOCK PILLOW BLOCK

OPEN SIDE CLOSED SIDE
FIGURE 10-23
ALIGNMENT GUAGE
WIRE SUPPORT PIANO WIRE WIRE SUPPORT
NOTE: ALIGNMENT KIT T-O088 INCLUDES Wl~iE SUPPORTS AND ALIGNMENT GUAGE
FIGURE 10-24
MM-10-44
MAINTENANCE MANUAL
10-7 TAIL ROTOR CABLES
A. Tail Rotor Cable Inspection
!1) Remove wraparound cowling and baggage box.
(2) Remove seat cushions and fiberglass seat deck.
(3) Inspect cables for wear, strand separations and fraying.
(4) Visually inspect cable pulleys for wear and security.
(5) Inspect turnbuckles for security.
(6) Cable tension 35 to 40 Ibs with cable tensiometer.
B. rail Rotor Cable Replacement (See Figure 10-25)
(1) Replace aft section of tail rotor cable as follows:
(a) Remove wraparound cowl and baggage box.
(b) Remove left side horizontal stabilizer and remove
inspection panel on tailcone.
NOTE: Stabilizer removal is not required on 280F models.
(c) Remove cotter pins from aft cable guide pulley.
(d) Remove pivot hardware from cable links at aft control

brackets. See item A of Figure 10-25.
(e) Cut tail rotor cable aft of the turnbuckle in engine

compartment.
(f) Attach a string to the forward end of the cable and Full
the cable out through the aft end of tailcone.
NOTE: String will follow routing through pulleys and

eyelets to aid in installation of new cable.
(g) Attach new tail rotor cable to string and pull it back
through tailcone eyelets and cable pulleys.
NOTE: Check that cable is properly routed and riding on
pulleys. See items C D of Figure 10-25.
(h) Clamp tail rotor pedals in neutral position using two wood
blocks and "C" clamps.
MM-10-45
MAINTENANCE MANUAL
!ij Insert tail tool T-0080 in neutral position between

rotor
brass bushing seal housing of tail rotor gearbox.
and
Wedge the tail rotor control brackets in this positidn with
a wood block between gearbox and bracket.
NOTE: If rigging tool is not available, install a spacer

measuring .590 between brass bushing and seal
housing.
(j) Connect aft end of tail rotor cable to cable links and tail
rotor control brackets. Torque pivot bolts and install
cotter pins.
CAUTIPN:Cable links must pivot freely on control brackets

and at cable connections.
(k) Adjust turnbuckle in engine compartment so only one thread

of rod ends is showing at each end of turnbuckle.
(1) Position new cable through cable eye on turnbuckle rod end.
(m) Pull cable taut and swedge in this position. Allow a" to
f" of cable extending from swedge and cut excess cable.
(n) Using cable tensiometer, adjust turnbuckles

a until cables
read 35 to 40 Ibs.
NOTE: The two cables must have equal tension. Adjust

inboard cable first.
CAUTION:Turnbuckles may not have more than three threads

showing at each end.
to) Install safety clips to secure turnbuckles.
(p) Remove clamps from tail rotor pedals and wedge from control
brackets on gearbox.
(q) Install cotter pins in aft cable guide pulley.
(r) Install inspection panel on tailcone.
(s) Install horizontal stabilizer if removed.
(t) Install baggage box and wraparound cowl.
(u) Check complete rigging of tail rotor. See Section 10-I,

Rigging Procedure.
(v) Cycle to tail rotor pedals to check for binding.
MM-10-46
MAINTENANCE MANUAL
(2) Replace forward section of’ tail rotor cable as follows:
(a) Remove cushions and fiberglass seat deck.
(b) Remove floor panels on left side of cabin.
(c) Disconnect cable from forward tail rotor pedal bellcrank.

See item F of Figure 10-25.
(d) Cut cable forward of the turnbuckle in engine compartment.

See item B of Figure 10-25.
(e) Attach a string to aft end of cable and pull it out forward
through firewal7 and seat assembly.
(f) Attach new cable to string and pull it back through

firewall.
NOTE: Check that cable is properly routed and riding on
pulley on forward side of firewall. See item E of

Figure 10-25.
(g)~ Install spacers on each side of cable and insert into

forward bellcrank. Secure with h a rdwa re See item F,
attachment view of Figure 10-25.
(h) Clamp tail ´•rotor pedals in neutral position using two wood
blocks and "C" clamps.
(i) Insert tail tool T-O080 in neutral position between

rotor
brass bushing seal
and housing of tail rotor gearbox.
Wedge the tail rotor control brackets in this position with
a wood block between gearbox and bracket.
NOTE: If rigging tool is not available, install a spacer

measuring .590" between brass bushing and seal
housing.
(j) Adjust turnbuckle in engine compartment so only one‘thread

of rod ends is showing at each end of turnbuckle.
(k) Position new cable through cable eye on turnbuckle rod end.
(1) Pull cable taut and swedge in this position. Allow if" to
3" of cable extending from swedge and cut excess cable.
MM-1O-47
MAINTENANCE MANUAL
(m) Using a cable tensiolneter, adjust turnbuckles until cables

read 35 to 40 Ibs.
NOTE: The two cables must. have equal tension. Adjust

inboard cable first.
CAUTION:Turnbuckles may not have more than three threads

showing at each end.
(n) Install safety clips to secure turnbuckles.
to) Replace floor panels and seat deck in cabin.
(p) Check complete rigging of tail rotor. See Section 10-1,

Rigging Procedure.
(q) Cycle tail rotor pedals to check for binding.
MM-10-48
O
PULLEY
a~
~d,
NOTE: CABLE: TENSION 35-40 LBS.
~a´• 1 I
TAIL ROTOR CABLES

FIGURE 10-25
SECTION
DRIVE BELT SYSTEM

MAINTENANCE MANUAL
SECTION 11
BELT DRIVE SYSTEM
General Information
The belt system consists of a jackstrut and pulley assembly, idler

drive
pulley assembly, belt tension assembly, and a clutch engagement lever which
is controlled from the cabin. The jackstrut pulley which is bolted to the
engine drives the main rotor gearbox through a main drive poly "V" belt.
By engaging the clutch lever, the belt tension assembly pulls the idler
pulley into the drive belt. Belt tension is maintained by properly rigging
the system. Correct rigging and maintenance are very important to keep
this system working properly and extends component service life.
11-1 CLUTCH CONTROL RIGGING
NOTE: The clutch is rigged in the following steps. Rigging is to

be completed in the sequence listed, with the engine off.
A. Preliminary Belt Tension Mechanism Check
Check the following items before proceeding with clutch rigging.

(See Figure 11-3)
(1) is to have thread less exposed above jam

~::ti:1Sable one or
(2) Engage clutch lever and check that belt tension assembly is
locked over center with stops (8) contacting the side
plates ~9), and the clutch engage warning light out.
B. Clutch Lever Adjustment
(1) Place clutch lever in engaged position. (See Figure 11-2A)

With clutch engaged, lift and release lever to stowed
position. Adjust turnbuckle (3). Clutch lever must lie
flat on floor in stowed position.
(2) Disengage clutch. (See Figure 11-2B)
C. Spring Capsule Clearance Adjustment (See Figure 11-1)
(1) Lift clutch handle and bring down to a normal di sengage

position.
NOTE: Clearance between threaded shaft and lower pivot

spacer of bellcrank (2) must be 1/16 to 1/8 inch.
MM-11-1
MAINTENANCE MANUAL
CLUTCH RIGGING
CLUTCH LEVER
ENGAGED
)I
CLUTCH ENGAGED
2 LEVER IN STOWED
POSITION
1/16"TO 1/8"
GAP
4
FIGURE ll-2A
CLUTCH DISENGAGED
LEVER IN STOW ED
CLUTCH LEVER
POSITION
DISENGAGED
FIGURE II-I
FIGURE 11-28
MM-ll-2
MAINTENANCE MANUAL
(2) Loosen jam nut (5) and turnpiston (4) in or out of spring
capsule to obtain proper measurement, lifting and lowering
clutch handle frequently.
(3) Once clearance is obtained, secure jam nut (5) against

piston (4).
D. Belt Tension Adjustment (See Figure 11-3)
(1) Engage clutch assembly.
(2) Measure the exposed length of spring capsule piston (6) from
bottom of piston nut to top of the spring capsule (7).
NOTE:: The exposed length of piston should measure from

1 5/8 to 1 3/4 inches.
(3) Loosen jam nut (5), holding shaft (3) with a wrench.
(4) Disengage clutch assembly.
(5) Disconnect rod end (1) from bellcrank (2).
(6) Adjust shaft (3) in or out of yoke (4) to obtain the proper
measurement.
NOTE: One 360 degree turn of shaft will result in

1/8 inch travel on capsule piston. "IN" will
increase measurement "OUT" will decrease
measurement.
(7) Connect rod end (1) to bellcrank (2) after adjusting and
engage clutch assembly to re-check measurement.
(8) After proper measurement is obtained, secure rod end (1) to

bellcrank (2) with hardware and spacers.
(9) Holding shaft (3) with a wrench, secure jam nut (5).
NOTE: Bellcrank (2) will be horizontal to slightly below

horizontal with clutch engaged.
(10) Disengage clutch assembly.
E. Final Clutch Lever Adjustment
(1) Place clutch lever in engaged position. (See Figure 1l-2A)

Lift and lever to stowed position and recheck that
release
lever will lie flat on floor. Further adjust turnbuckle (3)
to obtain this position.
MM-ll-3
MAINTENANCE MANUAL
2 3/4 APPROX. THREAD
TOP EDGE OF BELLCRANK

3´
1 5 IN!TIALLY
TO BE HORIZONTAL TO
3" BELOW HORIZONTAL
5" 3"
3
STOP MUST CONTACT SIDE

I O WITH CLUTCH ENGAGED
AND DEACTIVATE CLUTCH
WARNING LIGHT SWITCH
FIGURE 11-3
BELT TENSIDN ASSEMBLY ADJUSTMENT
MM-ll-4
MAINTENANCE MANUAL
(2) Secure jam nuts on turnbuckle.

NOTE: With clutch engaged, recheck that belt tension
mechanism is locked in overcenter position (see
Figure 11-3). Stops (8) must contact side
plates (9) and the clutch engage warning light
must be out.
WARNING: Keep hands away from belt tension mechanism when

engaging or disengaging clutch, or personal injury
could occur.
11-2 CLUTCH CABLE
A. Clutch Cable Removal
(1) Disconnect clutch cable at the belt tension assembly arms.

(See Figure 11-3)
(2) Loosen jam nut and remove rod end and spacer from end of
cable.
(3) Remove rubber dust covers from cable.
(4) Remove upper jam nut from belt tension mount block.
(5) Remove two bolts from mount block (11) in belt tension
assembly. (See Figure 11-3)
(6) Slide mount block over end of cable.
(7) Disconnect 3 clamps holding cable to pylon.
(8) Remove forward jam nut from pylon mount. (See Figure 11-4)
(9) Remove fiberglass seat deck.
(10) Loosen jam nuts from adjustment barrel (3). (See

Figure 11-2A)
(11) Turn barrel to disconnect the clutch cable.
(12) Remove jam nut and rubber dust cover from end of cable.
(13) Slide clutch cable aft through pylon mount and remove.
B. Clutch Cable Installation
(1) Remove rubber dust cover and jam nut from forward end of
clutch cable.
(2) Slide cable through pylon mount. (See Figure 11-4)

Position forward as far as possible.
(3) Install large jam nut, rubber dust cover, and small jam nut
on cable.
MM-1l-5
MAINTENANCE MANUAL
FIGURE 11-4. Forward End of Clutch Cable
~d
a ;1
r´•~
FIGURE 11-5. Aft End of Clutch Cable
ai Gs NA&
MM-ll-6
‘ATP
MAINTENANCE MANUAL
(4) Connect clutch lever linkage and cable with turnbuckle

barrel. (See Figure 11-5)
(5) Torque pylon mount jam nuts. Approximately two threads

should extend between aft check and grease fitting.
(6) Remove rubber dust cover and upper jam nut from aft end of
clutch cable.
(7) Slide belt tension assembly mount block down over end of
cable.
(8) Install the two mount block bolts and washers.
(9) Install nuts and torque.
(10) Install mount block jam nut and rubber dust cover.
(11) Install rod end jam nut and rod end on cable.
NOTE: Turn rod end on cable until it bottoms out, then

back it off one-half turn.
(12) Slide spacer into rod end and place aheavy washer on each
side of rod end. Install between bellcrank arms of belt
tension assembly.
(13) Install washer on bolt and slide belt through bellcrank arms
and rod end.
(14) Install washer and nut on bolt and torque.
(15) Torque jam nut against rod end.
(16) Torque the mount block jam nuts with approximately two
threads located above upper jam nut.
(17) Install the three clamps mounting the clutch cable to pylon.
NOTE: Before tightening turnbuckle jam nuts, complete

the rigging procedure. See Item 1, Clutch Control
Rigging Procedure.
(18) With jam nuts torqued and rigging complete, lubricate the
clutch cable. See lube chart for proper grease. Grease
fittings are located on aft side of pylon mount and below
belt tension assembly mount block.
(19) Engage and release the clutch to check for freedom of move-
ment in the system.
MM-ll-7
MAINTENANCE MANUAL
11-3
A. Control Lever Removal
(1) Remove fiberglass seat assembly.
(2) Loosen jam nuts on turnbuckle (3) and rotate to disconnect

clutch lever linkage from cable. (See Figure 11-2A)
(3) Reniove AN hardware that attaches bellcrank to seat section.
(4) Remove clevis pin on bottom of bellcrank to remove linkage.
(5) Remove lever and bellcrank assembly.
(6) Remove spacer from oilite bushings.
B. Control Lever Inspection
(1) Inspect bellcrank bushings for excessive wear.
(2) Inspect roll pins in bellcrank for security and wear.
C. Control Lever Installation
(1) Attach linkage to bottom of bellcrank and install clevis pin

and cotter pin.
(2) Install spacer in oilite bushings of bellcrank.
(3) Install light washer on mount bolt and, with head of bolt
a
inboard, slide bolt through one side of seat section.
(4) Install 3Harper washers, bellcrank and spacer assembly, and

then 2 Harper washers on bolt.
(5) Slide bolt through secon.d side of seat section and install a
light w~sher and nut. Torque nut.
(6) Attach clutch lever linkage to clutch cable with turnbuckle.
NOTE: See paragraph MM-11-1-B, Clutch Control Rigging,

and adjust rigging per instructions.
(7) Tighten turnbuckle jam nuts.
(8) Inspect installation and engage and di sengage clutch to

check freedom of operation.
(9) Reinstall fiberglass seat deck.
MM-11;8
MAINTENANCE MANUAL
11-4 JACKSTRUT PULLEY ASSEMBLY
A. Jackstrut Pulley Removal (See Figure 11-6)
(1) Remove wraparound cowl and baggage compartment.
(2) Remove the four bolts connecting upper end of jackstrut (11)
to bearing housing adapter (15),
NOTE: Keep shims (14) together. Temporarily install a

screwdriver through bearing housing and jackstrut
to keep the strut from falling and cocking the
bearing in lower drive pulley.
(3) Cut safety wire and remove the six bolts (10) from the lower
drive pulley (2).
(4) Carefully pull drive pulley (2) and strut assembly (11) from
the mount flange end and lift free of the belt.
NOTE: Keep shims (1) together. Shims (1) and (14) must
be kept for reinstallation as they are required to
properly align the drive pulley to the driven
pulley.
CAUTION: Exercise care not to cock the self-aligning

bearing (5) in the pulley (2) b3r letting the
jackstrut (11) deflect. If bearing should get
cocked, don’t force it straight. Just slowly
rotate the pulley until it aligns itself.
B. Jackstrut Pulley Disassembly (See Figure 11-6)
(1) Remove grease fitting and purge plug from pulley (2).
(2) Place pulley (2) face down on work bench with jackstrut (11)
extended horizontally. Place blocks beneath strut to keep
it from cocking the self-aligning bearing.
(3) Heat pulley to approximately 250" and using a soft mallet

gently tap the jackstrut on lower side to remove strut and
bearing assembly from pulley.
(4) Remove nut (3) and washer (4) from strut.
(5) Remove washer (12) and belt (13) from bore.
(6) Place seal retainer (8) in and press strut through

bearing (5), seal (6) and (6A Press
and retainer.
(7) Press inner race of seal (6A) from retainer (8) and remove
O-ring (7).
MM-ll-9
MAINTENANCE MANUAL
C. Cleaning
(1) The pulley, washers, seal retainer and jackstrut should be

washed in a cleaning solvent before inspection.
(2) The seal (6) and (6A) should be cleaned with a damp
lint-free cloth.
(3) Bearing (5) must be washed in clean solvent to prevent

contamination.
D. Jackstrut Pulley Inspection
See detailed inspection sheets following.
E. Jackstrut Pulley Assemble (See Figure 11-6)
(1) Apply STP or equivalent to O.D. of seal (6A) and press seal
into retainer (8) with conical side of seal.facing forward.
(2) Install O-ring (7) on seal retainer (8).
(3) Install seal retainer (8) on jackstrut (11).
(4) Apply STP or equivalent to I.D. of male half of seal (6) and
with conical side facing aft, install seal on
jackstrut (11).
(5) Apply lubricant to I.D. of bearing (5) and press on
jackstrut (11).
(6) Install washer (12) on bolt (13) and position in bore of

jackstrut with belt extending through bearing (5).
(7) Install washer (4) on bearing (5) with undercut side of

washer mounted in bearing bore.
(8) Install nut (3) and torqu.e to 300 inch-pounds.
(9) Heat driver pulley (2) to approximately 250".
(10) Lubricate bore of pulley and O.D. of bearing (5) with STP or
equivalent.
(11) While holding jackstrut, visually align bearing (5) with

pulley bore and drop into place.
CAIITION: Do not hammer or force bearing into pulley as

serious damage could result to pulley and bearing.
If bearing stops while only partially into bore,
remove by gently tapping up on bottom side of
jacltstrut and repeat steps 9. 10 and 11.
MM-11-10
MAINTENANCE MANUAL
JACKSTRUT AND PULLEY ASSEMBLY INSPECTION

28-13227-5 Fig 11-6 Jackstrut Bearing surface .0003 Not repairable Replace strut
Item 11 1.7721 1.7715
diameter
Inspect bond for If bond appears In excess of Return to Enstrom

security around loose, insert .032 3/4" looseness Customer Service for
strut safety wire into rebond.
loose Maxi-
area.
mum depth wire can
be inserted is 3/4"
Dents in strut f" diameter, 1/16" Not repairable Replace strut

tubing deep maximum of one
dent
28-13212 Fig 11-6 Washer Corrosion None allowed Not exceeding Remove corrosion and
Item 12 15% of surface touch up with brush on
cad plate
28-13319 Fig 11-6 Seal Outer race on None allowed Not repairable Replace seal
Item 6&6A O.D. for galling
Condition of None allowed Not repairable Replace seal

teflon, race and
"O" ring (no cuts
or scratches)
Spherical steel None allowed Not repairable Replace seal

ion of seal
MM-11-11
MAINTENANCE MANUAL
JACKSTRUT AND PULLEY ASSEMBLY INSPECTION

28-13273 Fig 11-6 Driver Bearing bore .0008 Not repairable Replace pulley
Item 2 Pulley 3.3447
dia.
Nicks and dents None allowed 1/2" long, Polish blend smooth
in belt grooves .025 deep
Depth of groove .176 or less Not repairable Replace pulley

wear
Concentricity .001 TIR Not repairable Replace pulley
Threaded holes No crossed or missing Not repairable Replace pulley

threads
28-13210 Fig 11-6 Washer Visual check for Replace if required

Item 4 defects
22209 VAE Fig 11-6 Bearing O.D. 3.3465 3.3459 dia. Not repairable Replace bearing
Item 5
I.D. 1.7717 1.7712 dia. Not repairable Replace bearing
Axial play None allowed Not repairable Replace bearing
28-13305 Fig 11-6 Seal Seal bore .005 Not repairable Replace retainer
Item 8 Retainer 3.065 3.069
Check for cracks None allowed Not repairable Replace retainer
MM-ll-12
FIG. 11-6 JACKSTRUT ASSEMBLY
6
o~o
5
4
O
pPIO q
aB
2
13
12
og‘
II
6A
10
o~
89
MAINTENANCE MANUAL
(12) Install bolts (10) into washers (9) and lubricate bolt
shanks with Lubriplate.
(13) Align holes in seal retainer (8) with bolt holes in pulley
and install bolts (10).

bearing during handling.
(14) Install grease fitting and purge plug in pulley (2).
NOTE: Grease fitting hole has small diameter hole at

base extending to bottom of bearing bore. Purge
plug hole has an equal diameter hole extending to
one-half depth of bearing bore.

bearing during handling.
F. Jackstrut Pulley Installation (See Figure 11-6)
NOTE: To prevent pulley misalignment the original shims (1)

and (14) must be used on reinstallation.
(1) Install shims (1) on mount flange.
(2) Carefully install jackstrut pulley on mount flange: while

aligning belt and secure with bolts (10).
NOTE: Temporarily install screwdriver through jackstrut

support i15) and jackstrut to keep bearing from
cocking.
(3) Torque drive pulley bolts (10) while alternating sides.
(4) Safety wire bolts in pairs using .041 wire.
NOTE: Do not safety across purge plug.
(5) Install shims (14) between jackstrut and jackstrut upper

bearing adapter (15).
(6) Install four bolts and washers through jackstrut and bearing
adapter.
(7) Install nuts and torque.
(8) Remove purge plug and lubricate drive pulley bearing until
grease appears through plug hole. See lubrication section
for proper lube.
(9) install purge plug in puiley.
MM-ll-14
MAINTENANCE MANUAL
G. Pulley Alignment Procedure
NOTE: If main rotor gearbox, engines, pulleys, or shims

have been changed, it is required to check upper
and lower pulley alignment using tool T-0044.
Adjustments are made with engine off.
(1) Engage clutch place tool T-0044 against aft

and face of
upper or lower pulley. Pulleys should be parallel with a
maximum gap of .010" or less between tool and second pulley.
(2) If pulleys are parallel but have a gap exceeding .020, the
shims (1) between fan and lower pulley must be changed. Add
shims to bring lowerpulley aft and remove shims to move
pulley forward. Repeat this step until parallel gap is in
tolerance.
(3) If pulleys are not

jackstrut support and jackstrut (11). :h,ac","P,,;:’";,l’,’f) bAedtdWien~n
Adding shims
brings lower face of pulley towards engine and subtracting
shims brings face aft.
11-5 DRIVE BELT (See Figure 11-7)
A. Drive Belt Condition
Problem cause Required Action

Cuts, damage or Possible Remove belt and inspect.
blisters in back separation of Replace if plies are
of belt fabric plies. peeling or separating.
Fraying on edge Belt out of Track belt.

of belt. track rubbing
idler straps.
Interference Check upper and lower

problem in belt pulley alignment, idler
alignment. straps and belt track.
Pieces of rib Rib cracking. See Belt Inspection

section missing. (ref. Figure 11-7)
Belt vibration. Large pieces of Replace belt.

belt missing
causing dynamic
unbalance
(Figure 11-7 E).
Belt roller Adjust roller to belt.

improperly
adjusted.
NOTE: With engine off, engage clutch and check for

proper rigging. Adjust belt roller to
1/4 inch to 3/8 inch clearance between
roller and belt before tracking belt.
MM-ll-15
MA~NTENANCE MANUAL
A D
B E
C F~
DRIVE BELT VISUAL INSPECTION CRITERA

FIGURE 11-7
.aa~siNAL
P10~-ll-16 ns Receive6a ev
ATP
MAINTENANCE MANUAL
B. Tracking
(1) Remove upper cowling.
NOTE: See Figure 11-8 for 1 ocation and sequence of

locking points used during belt tracking.
Point #1 Belt mounting support shaft strap to

pylon.
Point #2 Nut on forward end of idler shaft.
Point #3 Nut on aft end of idler shaft.
(2) Loosen bolt at point tl.
(3) Loosen nuts at point #2 and #3. Do not remove.
(4! Start engine and slowly engage rotor system while observing
idler pulley track on belt.
(5) When clutch is fully engaged at idle, use 7/8" wrench and
turn idler support shaft until pulley is tracked on belt.
NOTE: When pulley is tracked it will be centered on
belt.
(6) When pulley is centered tighten bolt at pylon strap

(point #1).
(7) Holding idler support shaft with wrench, tighten forward

idler shaft nut (point #2).
(8) While holding idler shaft, tighten aft nut (point ~3).
(9) Increase engine to 2000 RPM and check track.
(10) If belt track is good at 2000 RPM, gradually increase to

3050 RPM while constantly watching belt track under
increased power.
(11) Inspect assembly for security before installing cowling.
MM-ll-17
MAINTENANCE MANUAL
42~-1 C~ eol N T N O. S
ROTATE SHAFT HERE TO TRACK
POINT NO. 2
POINT NO. I
IDLER STABILIZER AND EEL T

TRAC KING ADJUSTMENT POINTS
FIGURE 11-8
MM-ll-18
MAINTENANCE MANUAL
C. Drive Belt Removal
(1) Remove cowling.
(2) Remove jackstrut and pulley assembly. See Section 11-5

(Jackstrut Removal).
(3) Flex coupling is separated as follows (see Figure 11-9):

Remove the bolts, washers, spacers, and nuts connecting aft
hub of coupling to flex element (3).
(4) Loosen aft nut on belt roller.
(5) Remove AN hardware attaching rear actuator arm to idler

support bracket and idler yoke. Let actuator arm hang in
vertical position on belt roller.
(6) Ease belt off the top pulley and, with drive shaft. to one
side, slide belt between coupling halves to remove.
D. Drive Belt Inspection (See Figure 11-7)
(1) Back of Belt
The back of the belt should be examined for cuts or damage

and blisters which may indicate separation of the fabric
plies. The belt should be removed if there is any damage
which appears to penetrate the fabric cover and if any
blisters are present.
A small crack in the back of the belt at the fabric splice

is not significant. The belt should be removed, however, if
there is any loosening or peeling of the fabric in the
splice area.
(2) Edges of Belt
The edge of the belt should be examined for signs of wear.

This does not affect the belt directly but would indicate
that there is a tracking or interference problem. There may
be some fraying of the edge cord and this is not
significant. The belt should be removed, however, if an
entire cord is beginning to emerge from the belt.
The belt should

edge also be examined for signs of
separation. The belt should be removed if there is any sign
of separation or rubber from the cord.
MM-ll-19
MAINTENANCE MANUAL
1n111111117 1’ O
THESE AREAS REQUIRE SHIMMIPJG TO EQC~ALLY SPACE

FLEX ELEMENTS
FIG. 11-9 FLEX COUPLING
MM-ll-20
MAINTENANCE MANUAL
(3) Belt Rib Surface
Rib cracking is a normal occurrence on this belt and is

caused primarily by the reverse bend idler. The cracks
normally extend to the base of the rib and go no further.
Numerous cracks of this type are not significant. The belt
should be examined for cracks which have extended below the
base of the ribs and, if this has occurred, the belt should
be removed. This is very important if the cracks extend to
the cord line and the cord.is exposed when the crack is
opened.
Loss small pieces of rib section may accompany the rib

of
cracking. This is normally a random occurrence. The belt
should be replaced if there is a loss of three or more
adjacent ribs for a length of two inches or more. The belt
should be replaced if there is any piece of rib missing
which is of sufficient depth to leave the cord exposed.
NOTE: Do not reverse belt to perform this inspection.

Unnecessary damage may result.
(4) The belt should be replaced:
(a) Whenever it has been determined that cord failure

exists.
(b) Whenever edge damage goes beyond the first "V" groove.
(c) When missing pieces of the "V" area become large enough
to cause vibration in the drive system.
(d) When time since installation has reached 48 months.
(5) Reference: Photographs A, B and C are examples of

serviceable belts (see Figure 11-7).
Reference: Photographs D, E and F are examples of

unserviceable belts which should be replaced
(see Figure 11-7).
E. Drive Belt Installation
(1) Slide the belt between the drive shaft and forward coupling
half and ease belt on top of the upper pulley.
(2) Pivot rear actuator arm back into position and install
mounting hardware.
(3) Install nut and cotter pin on inboard bolt of actuator arm.
(4) Torque and safety wire outboard bolts to yoke.
MM-ll-21
2
a,
10
FIG. 11-10 UPPER CLUTCH AND
PULLEY ASSEMBLY
MAINTENANCE MANUAL
(5) Flex Coupling Proceed as follows (see Figure 11-9):
(a) Align aft coupling hub with flex element. With curved
side of spacers (2) against flex element, install
mounting hardware.
NOTE: Washers may be used between spacers (2) and

coupling hubs to align and center the flex
elements.
(b) Torque coupling hub bolts.
(6) Install jackstrut and pulley assembly. See Section 11-5

(Jackstrut Installation).
(7) Engage clutch and check rigging. See Section 11-1 (Clutch
Control Rigging).
(8) Adjust belt roller to 1/4 inch to 3/8 inch clearance between
belt surface and roller.
(9) Track idler pulley to drive belt. See Section 11-6 6

(Tracking Procedure).
(10) Inspect entire belt drive system and install cowling.
11-6 MAIN ROTOR GEARBOX
A. ‘General Description
The main rotor gearbox is a 90" drive unit powered from the
engine by a belt drive system. The internal ring gear and pinion
are ma c h i ned to precision tol erances heat treated and
shotpeened to provide maximum life. Because of the high contact
ratio which can be obtained by the spiral angle gear, the overlap
of contact contributes to smooth and quiet operation. A wet sump
splash system is utilized to provide adequate lubrication to the
ring and pinion gears. This eliminates the need for a
gear-driven oil pump. A magnetic chip detector is located in the

sump, and can be removed to inspect for metallic particles. An
oil temperature sensor is also mounted in the bottom of the
gearbox, and is connected to a gearbox temperature gauge on the
instrument panel. A sight gauge is located on the lower right
hand side of the gearbox to check the oil level. The gearbox
incorporates an overrunning clutch in the upper pulley assembly
which is mounted on the pinion shaft. The overrunning clutch
unit provides a disconnect from the engine in the event of a
power failure and permits the main and tail rotors to rotate in
order to accomplish safe autorotative landings.
MM-ll-23
MAINTENANCE MANUAL
B. Gearbox Removal
(1) Remove the main rotor blades.
(2) Drain fuel and remove fuel tanks.
(3) Remove wraparound cowling.
(4) Remove bulkhead that crosses over gearbox pinion area.
(5) Remove baggage box. See Section 8, Structure, for baggage

box removal.
(6) Disconnect lateral and longitudinal push-pull rods from

lower swashplate.
(7) Remove fiberglass cover inside cabin and disconnect

collective push-pull rod (3) from collective walking beam.
(8) Disconnect temperature probe adapter (4) from fitting on
bottom of gearbox.
(9) Remove jackstrut and pulley, idler assembly, and drive belt
from gearbox.
(10) Remove main rotor hub assembly. See Section 9-1-B for hub
removal procedures.
NOTE: If gearbox hoist tool T-O017 is not available, the

gearbox can be removed by leaving mast nut secured
and lifting hub and gearbox as a unit using sling
T-OO11. Complete the following steps before
removal.
(11) Remove mount bolts from gearbox (4 places).
NOTE: A 7/16" wrench (12 point) will have to be ground

thinner for installation on the aft left gearbox
mount bolt.
(12) Install tool T-O017 on upper end of mast.
(13) Using a hoist, carefully lift gearbox from pylon mount.
NOTE For swas hpl a;te removal see Secti on 12, Fl i ght
Controls.
NOTE: Gearboxes being returned for overhaul should

include the pinion half of the driveshaft
coupling.
MM-ll-24
MAINTENANCE MANUAL
C. Gearbox Installation
(1) Install main rotor hub on gearbox. See Section 9-1-B for
hub installation procedure.
CAUTION: Hub must be installed with index marks on Spline

adapters aligned to properly phased spine on rotor
shaft, or serious flight control problems will
result.
(2) Install push-pull rods and swashplates if required. See

Section 12, Flight Controls, for swashplate installation
procedures.
(3) Secure collective walking beam to swashplate and center

pivot point on gearbox. Torque bolts.
NOTE: Pivot bolts at walking beam-swashplate connection

are safety wired with .032 wire.
(4) Using sling T-O011, lift gearbox into position on pylon.
(5) Install gearbox mount hardware (4 places). Torque bolts.
NOTE: Gearbox mount bolt torque is 190-200 in-lbs.

Torque seal should be applied to the installed
hardware for slippage indication.
NOTE: NEW hardware must be used when re-installing a

main rotor gearbox, as the self-locking feature of
the recommended nuts precludes re-use.
(6) Install jackstrut and pulley assembly, idler assembly, and

drive belt.
(7) Connect temperature probe adapter to fitting on bottom of

gearbox.
(8) Connect collective push-pull rod to collective walking beam.

Install fiberglass cover.
(9) Connect lateral and longitudinal push-pull rods (1 2) to

lower swashplate. See Figure 12-20 of Section 12 for
correct hardware installation.
(10) Install baggage box. See Section 8, Structure, for baggage

box installation.
(11) Install bulkhead over gearbox pinion area.
(12) Install fuel tanks and connect fuel lines.
MM-ll-25
MAINTENANCE MANUAL
(13) Se rv i ce gearbox with oil. See Section 5, Servicing and

General Maintenance, fo~ approved oil and quantity required.
(14) Check all connections for security.
(15) Install main rotor blades.
(16) Track dri ve belt. See Sections 11-5-8 and 11-6-8, Belt
Drive System, for installation and tracking procedure.
(17) Install wraparound cowling.
(18) Complete the "Preflight Control System Check" in

Section 12, Flight Controls.
(19) Track main rotor blades. See Section 12, Flight Controls,
for tracking procedure.
11-7 OVERRUNNING CLUTCH PULLEY ASSEMBLY
A. Clutch and Pulley Troubleshooting
Rotor engine Overrunning Replace clutch.

rpm needles do clutch lockup.
not split when
power is cut
back.
Erratic needle Clutch slipping. Replace clutch.

movement Internal clutch
engine tach malfunction.
seems to climb.
Worn pulley Replace clutch.
grooves.
Clutch end play Internal wear Replace clutch.

exceeding of clutch.
.050 inch.
Excessive noise Internal wear. Replace clutch.

on run-down.
Upper pulley Clutch faces Replace clutch.

TIR exceeding worn from loss
.009 inch. of pinion nut
Check while torque.
holding pulley
stationary and NOTE: If excessive TIR still exists after
rotating replacing clutch, the problem could
gearbox be internal wear in main rotor
with clutch Searbox. Gearbox should be
disengaged. returned to factory or authorized
overhaul facility for inspection.
MM-ll-26
MAINTENANCE MANUAL
B. Clutch Servicing Inspection
CAUTION: Before servicing, determine the type of oil previously

used. If unable to determine, it is recommended that
the clutch be drained, purged with kerosene and then
se rv i ced per instructions. Clutches leaving the
factory have been serviced with Aeroshell 500 Turbine
Oil. See lubrication chart for brand names of other
approved oil.
(1) Servicing Procedure
(a) Rotate clutch until two bolts are in horizontal

position and third bolt is above.
(b) Remove top bolt and one side bolt. If clutch is

properly serviced oil will seep from the side hole.
(c) Add oil using a spring type oiler through the top hole
until a positive stream of oil comes from side hole.
NOTE: Because of location of the drilled oil

passage it is possible for the sprags to
partially block the hole so that the clutch
will take oil very slowly.
(d) Rotate hole slightly above horizontal position and

refill. Install bolts in filler holes.
(2) Overrunning Clutch Inspection
NOTE: The total fluid amount in this unit is less than

one ounce, a´• significant portion of which can be
lost very quickly through a leaking seal. The
clutch area should be looked at frequently to
determine if any leaks exist.
(a) Monitor oil level (servicing).
(b) If clutch has been subjected to rapid or instantaneous

rotor engagements or loss of oil is suspected, follow
steps below:
1 Rotate the upper pulley in reverse direction by

hand to check for roughness or noise. If
abnormality is detected, unit should be replaced.
2 Maximum clutch axial play is .050 inch.
3 If clutch serviceable but has a

is leaking seal,
replacement seals can be ordered from Enstrom
Customer Service.
MM-ll-27
MAINTENANCE MANUAL
4 Service clutch.
5 Ground run helicopter until normal operating

temperatures ~re reached.
6 Increase power until helicopter is light.on skids.

Split needles and allow rotor RPM to drop to 200.
Re-engage normally and repeat a minimum of three
times, observing clutch response.
7 If all functions are normal, inspect for leakage

and proper oil level before returning helicopter
to service.
C. Clutch Pulley Removal
(1) Remove cowling.
(2) Remove jackstrut and pulley assembly. See Section 11-5

(Jackstrut Removal).
(3) Separate coupling halves on forward end of drive shaft.
(a) Flex Coupling Remove the two bolts connecting forward

coupling hub to flex element. See Figure 11-9. Remove
forward taper pin from coupling hub and pinion. Remove
coupling hub.
(4) Remove tach drive cover and O-rings.
(5) Remove bolts from forward pillow block. Push drive shaft to
one side so right side hole in pillow block aligns with left
side mount hole in the tail cone and install a bolt to hold
drive shaft to one side.
NOTE: The F-28F models are equipped with a strobe

mounted over the drive shaft. When pushing the
drive shaft to one side, protect it from rubbing
side of strobe mount.
(6) Remove drive belt.
See Figure 11-10 for Steps 7 through 15.
(7) Gently tap a drift between lock washer (1) and lock nut (2)
while alternating sides to remove washer.
CAUTION: Use extreme caution when tapping drift so it does

not hit the pinion threads. Severe unrepairable
damage can occur to pinion if threads are rolled
over or missing.
MM-ll-28
MAINTENANCE MANUAL
UPPER JACKSTRUT BEARING REMOVAL
FIGURE 11-11
CLUTCH AND UPPER PULLEY REMOVAL
FIGURE 11-12
ORIGI NAL.
MM-ll-29 89 Receiwed By
ATP
MAINTENANCE MANUAL
(8) Install special tool T-0053 on the pinion lock nut (2).
With tool attached to a 3/4" drive extension, hold flush
against nut.
(9) Using a steel drift and hammer, tap against side of tool
turning lock nut (2).
(10) Remove nut.
(11) Install tool 1-0114 in end of pinion.
(12) Install a two-jaw puller with jaws attaching behind face of

bearing housing (6) and adjustable shaft located in end of
tool T-O114. See Figure 11-11. Hold jaws together with "C"
clamp.
(13) Pull bearing housing to remove from pinion.
(14) Slide clutch and pulley assembly off of pinion.
NOTE: If clutch will not slide off, install tool T-O114

back in end of pinion. Place jaws of puller in
groove of clutch. See Figure 11-12. Clamp in
place and pull clutch and pulley assembly from
pinion.
(15) Remove key (12) from pinion. If key was shimmed on
assembly, save shim.
D. Disassembly (See Figure 11-10)
(1) Clutch Pulley Disassembly (See Figure 11-10)
(a) Remove nuts (11) from bolts (7).
(b) Remove bolts and washers (8).
(C) (10) approximately 250" and

C1UtChHeat plllgley to remove
(2) Jackstrut Bearing Housing Assembly Disassembly

(See Figure 11-10)
(a) Remove snap ring (3).
(b) Heat bearing housing (6) to 2500 and gently tap bearing
(5) from housing.
(c) Press bearing adapter (4) from bearing (5).
MM-ll-3O
MAINTENANCE MANUAL
E. Cleaning
(1) Clutch If clutch is determined serviceable, wash O.D. with

kerosene toluol or equ i valent clean i ng sol vent. Avoid
using excessive solvent in seal area. DO NOT VAPOR degrease
clutch as damage could result to seal.
(2) Upper Jackstrut Bearing Carefully remove seals from both

sides of bearing. Wash and flush old grease from bearing
using fresh cleaning solvent, kerosene, toluol or vapor
degrease. Apply a light oil (1O-W) to bearing and spin
bearing by hand to determine if it is serviceable. Bearing
should rotate smooth wi th no ratchety feel i ng. See
lubrication section for required intervals and grease to
repack bearing. Install seals. As sembl i es w i th g r´•ea se
fittings require that shields be replaced.
(3) All other parts may be cleaned with kerosene, toluol or
equivalent solvent, or vapor degreased before inspection.
F. Inspection
See detailed sheets.
G. Assembly (See Figure 11-10)
(1) Clutch Pulley Assembly
(a) Heat pulley (10) to approximately 250".
(b) Apply STP or equivalent lubricant to bore of

Using two bolts (7) for alignment, drop clutchinto
pulley.
NOTE: Remove one of the servicing bolts in the

clutch to allow clutch oil to seep from hole.
Heat expansion causing internal pressure
could cause damage to seal if bolt is not
removed. Allow clutch and pulley to cool
before servicing.
(c) Install servicing bolt back into clutch.
(d) Install bolts (7) thru washers (8) and through clutch
and pulley.
(e) Install washers (8) and nuts (11) on bolts.
(f) Torque nuts, alternating sides during torque process.
(g) Service clutch. See Clutch Servicing.
MM-ll-31
MAINTENANCE MANUAL
(2) JatkStTUt Bearing Housing Assembly
(a) Press bearing adapter (4) into bearing (5).
(bj Heat bearing housing ~6) to approximately 250".
(c) Lubricate O.D. of bearing (5) and drop into housing

(6). The adapter (4) should be facing aft toward
housing mount area.
(d) Install snap ring (3) into housing.
H. Installation clutch and pulley assy. (See Figure 11-10)
(1) Before installing key (12) into pinion, check to see that
key slides freely through the keyway in the clutch. If it
does not slide through, the key must be filed slightly on
one side to allow proper fit. A clearance of .0005 to .001
inch between key and clutch keyway is required. If key is
loose in pinion keyway, proceed to (a) thru (e) below.
(a) Install key in pinion and using a feeler gauge, measure

the gap between side of key and pinion key way.
(b) Divide measurement in half to get the thickness of

stainless steel shim stock required.
(c) Cut shim 2" long and la" wide.
(d) Wrap shim around key and, with chamfered side of key
down, tap key and shim into pinion keyway.
(e) Using a razor knife, trim shim stock along sides of key
flush with pinion. Key must be secure in pinion.
(2) Apply anti-seize compound to the bore of the clutch (9) and
slide clutch and pulley assembly on the pinion.
(3) Heat the inner race of upper jackstrut bearing adapter and
slide the bearing housing assembly on the pinion until it is
flush against clutch.
(4) Install tool T-1575. The long arm on this tool slides into
forward end of pulley and the short arm hooks under the
idler arm mount to hold.pinion from rotating when applying
torque to pinion nut (2).
(5) Install nut (2) on pinion and torque nut to 175 ft. lbs.
using tool T-0O53.
NOTE: Nut should be rechecked after 25 hours of service

and at 100 hour intervals thereafter.
#2 Rev. 11/18/88 MM-ll-32

MAINTENANCE MANUAL
UPPER CLUTCH PULLEY ASSEMBLY

28-13271 Fig 11-10 Driven Bore 4.2490 .0003 Not repairable Replace pulley
Item 10 Pulley 4.2495 diameter
Concentricity .001 TIR Not repairable Replace pulley

Nicks and gouges None allowed 1/4" long, Polish and blend
in belt grooves .025 deep smooth
Depth of groove .176 or less Not repairable Replace pulley

Cracks None allowed Not repairable Replace pulley
28-13401-2 Fig 11-10 Clutch O.D. 4.2500 .0002 Not repairable Replace clutch
Item 9 4.2490 diameter
Inner race axial .050 inch Not repairable Replace clutch

play tend play)
Inner race faces .0005 TIR Not repairable Replace clutch
perpendicular to
bore
Bore 1.564 .0003 Not repairable Replace clutch

1.563 dia.
Seal leakage None allowed None allowed Replace seal

Oil level Service per Item 7-B
Inner race None allowed Can be rebuilt Return to Enstrom

rotation to be factory for
smooth with no evaluation
noise or roughness
SLN 3045 Fig 11-10 Nut Threads (no None allowed Not repairable Replace nut
Item 2 rolled or missing
threads)
Tightening tabs None allowed Not repairable Replace nut
(not rounded or
bent)
MM-ll-33
MAINTENANCE MANUAL
UPPER CLUTCH AND PULLEY ASSEMBLY Cont’d.

SLW 3045 Fig 11-10 Washer Locking tabs not None allowed Not repairable Replace washer
Item 1 bent or broken
28-13142 Fig 11-10 Key Width .3105 .001 Not repairable Replace key
Item 12 .3125
No visible wear None allowed Not repairable Replace key

on side of key
99608X3B Fig 11-10 Bearing Roughness, None allowed Not repairable Replace bearing
Item 6 spalling, pits
or corrosion
28-13125 Fig 11-10 Bearing Cracks No cracks Not repairable Replace bearing
Item 6 Adaptor
Nicks scratches .025 .030 depth Blend out smooth
3.5434
Bore I.D.
~28
’001 Not repairable Replace adaptor
28-13129 Fig 11-10 Bushing Fretting wear None allowed Not repairable Replace bushing
Item 4 on end surfaces
1.3125
Bore I.D.
-~gTm
.0005 Not repairable Replace bushing
1.5745
o.o.
-~YW
.0005 Not repairable Replace bushing
MM-ll-34
MAINTENANCE MANUAL
(6) Use a of aluminum tubing with 1-1/4" to 1-3/8" I.D. to

piece
align lock washer (1) on pinion and tap the lock washer into
place with tabs locking over nut.
(7) Install drive belt over upper pulley.
(8) Return forward pillow block to original position and install

bolts. Use the same shims as originally installed under
block.
(9) Install O-rings and tach drive cover.
(10) Connect coupling halves:
(a) Flex Coupling
1 Install coupling hub into pinion and install taper

pin. Install washer, nut and torque.
2 Align forward coupling hub with flex element. See

Figure 11-9. With curved side of spacers (2)
against flex element, install mounting hardware.
NOTE: Washers may be used between spacers (2)

and coupling hubs to align and center
the flex elements.
S Torque coupling hub bolts.
(11) Install jackstrut assembly. See Section 11-6 (Jackstrut

Installation).
(12) Check clutch control rigging. See Section 11-1 (Rigging

Procedure).
(13) Track idler pulley on drive belt. See Section 11-5-B

(Tracking Procedure).
(14) Inspect entire drive system and replace cowling.
MM-1l-35
MAINTENANCE MANUAL
11-8 IDLER PULLEY ASSEMBLY
A. Idler Assembly Troubleshooting
End play in Wornbearings, Replace bearings.

roller assembly.
Excessive belt Improperly Adjust roller to a 3/8 inch

vibration at ad3usted ~elt gap between belt and
low power roller. roller with clutch e?gaged.
settings.
Play in idler Worn dilite Replace bushings.

actuator arm. bushings.
Play in Worn oilite Replace bushings.

over-center bushings in
bellcrank. bellcrank.
Worn rod end. Replace rod end.
Idler pulley Ratchety idler Replace bearings.

rotates by bearings.
hand.
Over-center Improper Check rigging.

bellcrank not rigging.
parallel to
shaft with
clutch engaged.
MM-ll-36
MAINTENANCE MANUAL
(7
)5
13
d
(3
r 12
12
13
14
FIGURE 11-13
BE LT TET\ISIOT\J STRAPS
10 ROLLER ASSEMB LY
8 9
MM-ll-37
MAINTENANCE: MANUAL
B. Idler Pulley Removal
(1) Remove cowling.
(2) Remove jackstrut assembly. See Section 11-5 (Jackstrut

Removal).
(3) Disconnect actuator arm (10) from aft side of idler pulley
assembly. See Figure 11-13.
(4) Disconnect coupling and remove drive belt. See

Section 11-5-0 (Drive Belt Removal).
(5) Disconnect idler assembly rod end (21) from over-center

bellcrank. See Figure 11-16).
(6) Remove support strap between pylon mount and idler support
arm. See Figure 11-8.
(7) Remove idler assembly.
C. Disassembly (See Figure 11-13)
(1) Remove shaft (18), nut (17) and washer (16) from yoke (15).
(2) If rod end needs replacing, cut safety wire and break torque
on nut (17).
(3) Remove bolts attaching actuator arm (10) to pulley yoke (8).
(4) Remo~e spacers (9) from actuator arms (10).
(5) Remove nuts (14) and washers (13) from roller assembly (11).
(6) Remove bolts attaching actuator arms (10) to yoke (15).
(7) Slide actuator arms frdm roller assembly (11) and remove
washers (13) and spacers (12).
NOTE: Steps 8 through 14 disassemble idler pulley and

yoke assembly. See Figure 11-14.
(8) Remove cotter pin and nut (6) from shaft (1).
(9) Remove spacer (5) from shaft.
(10) Remove snap rings (2) from yoke (8).
(11) Install tool T-0029B against bearing (3) with head of

shaft (1) inside tool.
MM-ll-38
MAINTENANCE MANUAL
8 2
FIG. 11-14 IDLER PULLEY AND YOKE ASSEMBLY
MM-ll-39
MAINTENANCE MANUAL
26
24
27
25
26
~I
FIG. 1 1-15
BE LT ROLLER ASSEMBLY
MM-ll-40
MAINTENANCE MANUAL
(12) Place pulley assembly in arbor press and using tool T-0029A
against threaded end of shaft (1) press shaft through
bearings and pulley. Remove shaft.
NOTE: Hold tool T-0029A in bearings and pulley to keep

pulley from falling out of yoke.
(13) Place assembly on bench and remove tool T-O029A. Remove

pulley (7) and spacers (4).
(14) Heat pulley yoke (8) to approximately 250" and gently tap
bearings (3) out.
NOTE: Steps 15 through 18 disassemble roller assembly.

See Figure 11-15.
(15) Using a plastic mallet, tap end of shaft (28) to remove

bearing housing (25) and bearing (26) from one end of
roller.
(16) Reinstall shaft (28) in opposite bearing and tap to remove.
(17) Remove shaft (28) and spacer (27). Save shims (29) located
behind bearing for reassembly.
(18) Press bearings (26) from bearing housings (25).
D. Cleaning
(1) Idler Pulley Bearings Carefully remove seals from both

sides of bearing. Wash and flush old grease from bearing
using fresh cleaning solvent, kerosene, toluol or vapor
degrea se Apply a light oil (10-W) to bearing and spin
bearing by hand to determine if it is serviceable. Bearing
should rotate smooth with no ratchety feeling. See
lubrication section for required intervals and grease to
repack bearing. Install seals.
(2) Roller Assembly Do not ke ros ene roller assembly into

cleaning solvent as a unit. Clean outer surfaces of roller
with cleaning brush and solvent. If unit is disassembled,
clean bearings in fresh cleaning solvent and repeat step
(1).
(3) All other parts of idler assembly may be cleaned in

kerosene tol uol or vapor deg rea sed B1 ow dry wi th
compressed air.
MM-ll-41
MAINTENANCE MANUAL
IDLER PULLEY AND YOKE ASSEMBLY

28-13230 Fig 11-14 Shaft Bearing surface .0002 Not repairable Replace shaft
Item 1 .5908 .5903
diameter
Concentricity .001 TIR Not repairable Replace shaft
Threads No crossed Not repairable Replace shaft

or rolled threads
N5000-137-M Fig 11-14 Snap Spring Visual flatness None allowed Not repairable Replace snap ring
Item 2 check
.0000
202-SZZ Fig 11-14 Beari´•´•ng Beari;ng 0.0. 1.3780
_
.0005
Not repairable Replace bearing
Item 3
.0000
Bearing I.D. .5906
-.0003
Not repairable Replace bearing
Rotate (no None allowed Mot repairable Replace bearing

ratchety feeling)
Hours Limited None allowed Replace bearing

life bearing 600
hours
=8-13233 Fig 11-14 Spacer Width .250 .003 Not repairable Replace spacer
Item 4
28-13234 Fig 11-14 Spacer Width .125 .005 Not repairable Replace spacer
MM-ll-42
MAINTENANCE MANUAL
IDLER PULLEY AND YOKE ASSEMBLY Cont’d.

28-13229 Fig 11-14 Idler Shaft bore .0002 Not repairable Replace pulley
Item 7 Pullev .5908 .5898
diameter
Shaft bore .001 TIR Not repairable Replace pulley

to O.D.
concentricity
Belt wear in .020 deep Maximum .040 Return to Enstrom

O.D. deep Customer Service for
possible repair
Cracks None allowed Not repairable Replace pulley
28-13292 Fig 11-14 Pulley Yoke Bearing bore .0002 Not repairable Replace yoke
Item 8 1.3781 1.3786
diameter
Nicks scratches None allowed Maximum .008 Polish to remove. Area

deep to be finished with
#180 emery cloth.
Brass bus´•hing .0005 Not repairable Replace bushings and

bore .627 .628 line ream to size
diameter
Actuator arm None allowed Not repairable Replace yoke

mount hole
.250 .251 dia.
Cracks None allowed Not repairable Replace yoke
MM-li-43
MAINTENANCE MANUAL
IDLER ACTUATOR STRAPS AND ROLLER ASSEMBLY

28-132008-11 Fig 11-13 Spacer Length .350-.353 .0005 Not repairable Replace spacer
Item 9
Bore .250-.254 .0005 Not repairable Replace spacer
diameter
Ends perpendicu- None allowed Not repairable Replace spacer

lar to bore
within .001
28-13318-3 Fig 11-13 Actuator Inspect for belt None allowed Not repairable Replace arm
Item 10 Arm wear on side of
arm
Slot width .003 Not repairable Replace arm

.380+ .010
Notch worn in .015 deep Not repairable Replace arm

roller slot
Brass bushing .001 Not repairable Replace bushing

bore .3755-.3765
Cracks None allowed Not repairable Replace arm
28-13245 Fig 11-13 Roller Bearings Rotate None allowed Not repairable Replace bearings
Item 11 Assembly free with no
ratchety feeling
Shaft No end None allowed .030 end play Disassemble and shim
play to preload bearings
MM-ll-44
MAINTENANCE MANUAL
IDLER ACTUATOR STRAPS AND ROLLER ASSEMBLY Cont’d.

28-13245 Fig 11-15 Roller Shaft threads None allowed Not repairable Replace shaft
(continued) Item II Assembly (no crossed or
SEE DETAILS FIGURE 11-15 missing threads)
.000
28-13278 Fig 11-13 Spacer Lgth..260 NO"e allowed Not repairable Replace spacer
_
.005
Item 12
O.D. .62 .015 None allowed Not repairable Replace spacer

’005
I.D. .472 None allowed Not repairable Replace spacer
-.000
28-13299 Fig 11-13 Yoke Shaft threads None allowed Not repairable Replace yoke
Item 15 (no crossed or
missing threads)
Bolt holes .191 .005 Not repairable Replace yoke

diameter
Cracks None allowed Not repairable Replace yoke
28-132005-11 Fig 11-13 Shaft Threads I.D. None allowed Not repairable Replace shaft
Item 18 O.D. No crossed
or missing
threads
MM-ll-45
MAINTENANCE MANUAL
UPPER BELLCRANK ASSEMBLY

Part Name Limits Limits Repair or Action
Part No. Item No. Inspect
MXJKR-8R or Fig 11-16 Rod End Threads None allowed Not repairable Replace rod end
01-691-08 Item 21 (no crossed or
missing threads)
MXJKR-8R or Fig 11-16 Rod end Axial play of .007 clearance Not repairable Replace rod end
01-691-08 Item 21 swivel ball
28-132009-11 Fig 11-16 Spacer Bore .500 .505 None allowed Not repairable Replace spacer
Item 22
Width .090 .005 Not repairable Replace spacer
28-132006-11 Fig ii-16 Spacer Lgth. .765-. T85 None allowed Not repa-i--rab~e :Replace spacer
Item 23
O.D. .4990-.4995 .0003 Not repairable Replace spacer
MM-ll-46
MAINTENANCE MANUAL
IDLER ROLLER ASSEFIBLY

_~
28-13297 Fig 11-15 Roller End cap bore None allowed Not repairable Replace roller
Item 24 1.8115-1.8120 dia.
Nicks scratches None allowed .005 deep Polish to remove

in O.D.
28-13296 Fig 11-15 End Cap O.D. 1.8120 None allowed Not repairable Replace end cap
Bearing bore None allowed Not repairable Replace end cap

1.2591 1.2586
diameter
Tube bore 1.004 .0005 Not repairable Replace end cap

1.006 diameter
.0000
201P Fig 11-15 Bearing Bore.4724 None allowed Not repairable Replace bearing
_
.0003
Item 26
+.0000
O.D. 1.2598 None allowed Not repairable Replace bearing
-.0005
Check bearing for None allowed Not repairable Replace bearing

smooth rotation
(no ratchety
feeling)
28-13248 Fig 11-15 Sleeve Length 5.525 t .005 Not repairable Replace bearing
Item 27
MM-ll-47
MAINTENANCE MANUAL
IDLER ROLLER ASSEMBLY Cont’d.

28-13246 Fig 11-15 Shaft Bearing surface .0003 Not repairable Replace shaft
Item 28 .469 .471
Threads (no None allowed Not repairable Replace shaft

crossed or miss-
ing threads)
All radii to be None allowed Not repairable Replace shaft

free of nicks
and scratches
MM-ll-48
MAINTENANCE MANUAL
F. Roller Assembly Assemble (See Figure 11-15)
(1) Press bearings (26) into end caps (25).
(2) Press one end cap (25) into roller (24).
(3) Install tube (27) into I.D. of roller and align into end cap
(25).
(4) Install shaft (28) into roller and bearing (26).
(5) Press opposite end cap into roller.
(6) While holding roller (24) stationary in vertical position,

install dial indicator on end of shaft (28) and move shaft
up and down to check end play.
NOTE: Shimming is required to remove end play and

preload bearings. Shaft end play measurement plus
.002 equals shims required.
Example: End play .022 .002 .024 (shims

required).
(7) Using a plastic mallet, tap end of shaft (28) to remove
bearing (26).
(8) Reinstall shims (29) on bearing surface of shaft (28).
(9) Press bearing (26) into end cap (25).
(10) Rotate shaft (28). The inner race of bearings (26) should
rotate with shaft and no end play should exist.
NOTE: If inner race of bearing does not turn with shaft

or if end play still exists, there is not enough
preload on bearings. Install additional shims as
required. Recheck assembly.
G. Idler Pulley Assembly Assemble (See Figure 11-14)
(1) Spray bearing bores of yoke (8) and O.D. of bearings (3)
with Loctite primer.
(2) Heat bearing area of yoke (8) to approximately 250". Apply

a small amount of Type A Loctite to O.D. of bearing (3) and
install into yoke (8). Repeat on opposite bearing.
~3) Place spacers (4) and pulley (7) in yoke.
NOTE: Small end of spacer faces against bearings (3).
14) Install tool T-OO29A through bearings (3), spacers (4) and
pulley (7).
MM-ll-49
MAINTENANCE MANUAL
~kd
22
23
22
FIG. 11-16
21
NOTE: Alternate rod end without
locking key uses (19)
flat lock plate bent over

flats of nut and rod. ~IP 19
IDLER BELL CRANK ASSEMBLY
MM-lli50
MAINTENANCE MANUAL
(5) Place tool T-0029A-1 against aft bearing (3) and install in
press while holding tool T-0O29A and pulley in place.
NOTE: Tool T-0O29A is used for alignment and will be

pressed out while pressing shaft (1) in.
(6) Apply lubricant, STP or equivalent to bearing surface of

shaft (1) and carefully press through bearings and pulley.
NOTE: Shaft (1) should be installed with threaded end

facing aft when installed on helicopter.
(7) Remove from press and install retaining rings (2) in bearing
bores.
(8) Install spacer (5) on threaded end of shaft (1) with chamfer
facing inboard.
(9) Install nut (6). Torque nut 290-410 inch Ibs.
(10) Install cotter pin through nut. See Figure 11-14.
(11) Install spacers (12) and Harper washers (13) on roller

assembly (11). See Figure 11-13.
(12) Install actuator arms (10) on roller assembly (11) against

inboard Harper washers (13).
NOTE: Actuator arms are flange of

to be installed with
oilite bushing outboard.
facing The roller
assembly (11) is installed with grease fitting end
of roller facing aft as installed on helicopter.
(13) Install outboard Harper washers (13) and nuts (14) on
roller. Tighten nuts finger tight.
(14) Place yoke (15) between actuator arms (10) and install mount
bolts in each end. Tighten finger tight.
(15) Install bushings (9) into oilite bushings of actuator arms.
(16) Connect actuator arms to pulley yoke (8) with pivot mount
bolt and Harper washer.
NOTE: Head of AN bolt and Harper washer are installed

from inboard side of actuator arms. Place
AN washer and nut on outboard end of bolt.
(17) Torque hardware mounting forward actuator arm (10) to

yoke (15).
NOTE: Do not tighten hardware mounting the aft actuator

am as it must be removed to install drive belt.
MM-ll-51
MAINTENANGE MANUAL
(18) Install cotter pin in forward actuator arm pivot bolt.
(19) Sa~fety wire two of the three mount bolts attaching forward
actuator arm to yoke (15) with .032 wire.
(20) Install locking key (19) into nut (20) and into slot on rod
end (21). See Figure 11-16.
(21) Turn rod end (21) into shaft until measurement from end of
shaft to centerline of rod end ball is 6.75 inches.
(22) Torque jam nut and safety wire locking key to jam nut. See
Figure 11-13.
(23) Install nut (17) and washer (16) on shaft (18).
(24) Apply Lubriplate to threads of shaft (18) and turn into

yoke (15) until approximately 1/2" of threads extend beyond
jam nut.
H. Installation of Idler Yoke and Ter;sion Assemblies
(1) Install spacer with chamfer forward on idler support shaft.
(2) Slide idler pulley assembly on idler support shaft.
(3) Install idler support strap (8) between idler shaft and
pylon. Install mounting hardware at points #1 and At3 and
partially tighten. See Figure 11-8.
(4) Install spacer (22) in rod end (21) and place spacers (22)
on each side of rod end. See Figure 11-16.
(5) Insert rod end with spacers into over-center bellcrank and
install mount hardware, partially tighten, torque after belt
tension is rigged.
(6) Remove aft actuator arm and install drive belt on upper
pulley. See Item 6-E(Drive Belt Installation).
(7) Place actuator arm back in position on idler pulley assembly

and roller. Install mounting hardware. Torque pivot bolt
and install cotter pin.
(8) Torque bolts which attach actuator arm to yoke and safety
wire with .032 wire.
(9) Install jackstrut and pulley assembly. See Section 11-4

(Jackstrut Installation),
(10) Install and connect tach drive, O-rings, and cover.
MM-ll-52
MAINTENANCE MANUAL
(11) Install aft taper pin and connect coupling halves with four
Alien screws and nuts.
NOTE: If flex coupling is used, see Section 11-5 (Belt

Installation) for installation instructions.
(12) Engage clutch.
(13) Adjust belt tension. See Section 11-1 (Clutch Control

Rigging Procedure).
(14) With clutch engaged, adjust belt roller to 3/8 inch

clearance between belt surface and roller. Lubricate roller
assembly. (See Lubri-cation section for approved lubricants)
(15) Track idler pulley on drive belt. See Section l1-6-B (Belt
Tracking).
(16) Inspect complete drive system for security of hardware.
11-9 BELT TENSION ASSEMBLY
A. Belt Tension Troubleshooting
Clutch lever Notches worn in Notches which do not

sticks when lower end of exceed .050" deep may be
releasing in brackets polished and blended until
from engaged causing nylon clutch releases smoothly.
position. bushings to Replace brackets if notch
stick in slots, exceeds .050" deep.
Excessive play Nylon\bushings Replace bushings.

in slider bolt work. (Check by
area (bottom holding each end
bolt through of bolt and
spring capsule). pulling in and
Maximum out.)
play .025.
Excessive side Worn DU bushing Remove belt tension

play spring
in in capsule end assembly and remove
capsule piston. cap, spring capsule.
Replace bushing.
Excessive play Worn oilite Replace rod end.

in over-center pivot bushings
bellcrank. in bellcrank.
MM-ll-53
MAINTENANCE MANUAL
U. Belt Tension Assembly Removal (See Figure 11-3)
(1) Remove cowling.
(2) Disconnect idler pulley rod end from over-center bellcrank.

Remove spacers.
(3) Remove bolt connecting over-center bellcrank to pylon mount

bracket.
(4) Break torque on jam nut against clutch cable rod end.
(5) Break torque on upper jam nut against clutch cable mount
block.
(6) Remove bolt connecting clutch cable rod end to pivot mount
of belt tension assembly.
(7) Remove rod end and jam nut from end of clutch cable.
(8) Remove rubber dust protectors from clutch cable and remove
mount block jam nut over end of cable.
(9) Remove two bolts mounting belt tension assembly to pylon.
(10) Slide belt tension assembly over end of clutch cable to

remove.
C. Belt Tension Assembly Disassembly (See Figure 11-17)
(1) Remove spacer (29) from bellcrank (28).
(2) Remove hardware attaching bellcrank (28) to spring capsule

(6). Remove spacers (24).
(3) Remove bolt (20) from brackets (9) and remove spacers (21),
(22) and (23).
(4) Remove bolts (16) and spacers (19) from pivot straps (3).
(5) Remove bellcranks (18) and spacers (17).
(6) Remove bolt (1) from spring capsule (6) and remove pivot
straps (3), spacers (4) and spacer (5).
(7) Remove nuts (7), washers (11) and nylon washers (10) from
spring capsule slider bolt.
(8) Remove bolts (12) from brackets (9) and clutch cable mount
block (14). Remove block (14).
(9) Remove brackets (9) from spring capsule (6).
MM-lil-54
9
~27 O
2826
21
24
2o
19
26
23 18\ ~a 15
13
17 ~8
3 6~3 IIE
7
4 J~iY14
3
zz
m
--1
16 z
r,
r
m
r 18
cn
Ln
Iff\ 17 z
c
2
21
9 3 r
Jg
;Q
I9 3\\\ 4
FIG. 11-17 BELT TENSION ASSEMBLY
13
12
MAINTENANCE MlANUAL
FIG. 11-18
5 SPRING CAPSULE ASSEMBLY
~9 c~s
12
MM-~1-56
MAINTENANCE MANUAL
D. Spring Capsule Disassemble (See Figure 11-18)
(1) Break torque on jam nuts (2) against rod end (1) and
piston (3).
(2) Remove cotter pin from rod end and remove rod end.
j3) Remove jam nuts (2) from threaded shaft (7).
(4) Remove safety wire and screws (12) from end cap (4).
(5) Slide shaft and spring assembly from spring housing (13).
(6) Hold lower nut (10) stationary and turn piston (3) from
shaft (7).
(7) Remove end cap (4) and spring (6).
(8) If bushing (5) is worn, press from end cap.
(9) Remove end cap (8) from shaft.
(10) Remove cotter pin in nut (10) and remove nut.
(11) Press shaft (15) through anchor (14).
(12) Remove anchor (14) and spring retainer (16).
NOTE: Anchor (14), shaft (15) and spring retainer (16)

do not require removal unless wear is noted which
requires part replacement.
E. Cleaning
(1) Parts should be washed in toluene, kerosene, or an
equivalent solvent. They may also be vapor degreased before

inspection.
NOTE: The nylon bushings and washers may be deformed

from the heat of a vapor degreaser and should be
cleaned separately.
F. Inspection
See detailed inspection sheets.
MM-ll-57
MAINTENANCE MANUAL
BELT TENSION ASSEMBLY
Fig Serviceable Repair

28-13268 Fig 11-17 Strap Bolt holes .257 .005 Not repairable Replace strap
Item 3 diameter
Nicks scratches None allowed Max. .010 deep Polish and blend to
remove
28-13277 Fig 11-17 Spacer Width .125 .130 None allowed Not repairable Replace spacer
Item 4
I.D. .257 dia. .005 Not repairable Replace spacer
28-15285-6 Fig 11-17 Spacer Lgth. .434 .440 None allowed Not repairable Replace ~spacer
Item 5
O´•.D-. .3745 .335;5´•None a´•llowed´• Mot repairable Replace s,pacer
28-13264 Fig 11-17 Nylon I.D. .250 .251 None allowed Not repairable Replace bushing
Item 8 Guide
O.D. (sliding .0005 Not repairable Replace bushing
surface) .3730
.3740 diameter
Wear on .3730 No flat areas Not repairable Replace bushing

allowed
28-13283 Fig 11-17 Bracket Slot width .376 None allowed Not repairable Replace bushing
Item 9 .378
Notch in
wear None allowed Notch .050 deep Polish and blend to
bottom end of maximum remove deep radius
slot into notch.
MM-ll-58
MAINTENANCE MANUAL
BELT TENSION ASSEMBLY Cont’d.

28-13283 Fig 11-17 Bracket Bolt holes rt .005 Not repairable Replace bracket
Item 4 .191 dia.
Bolt hole None allowed Not repairable Replace bracket

.249 .251 dia.
Nicks scratches None allowed .005 deep max. Polish blend to

in bracket remove
28-13265 Fig 11-17 Nylon Width .058 .063 None allowed Not repairable Replace washer
Item 10 Washer
I.D. .374 .376 .001 Not repairable Replace washer
28-13269 Fig 11-17 Mount Bore .72 dia. .010 Not repairable Replace block
Item 14 Block
Bolt holes .005 Not repairable Replace block
28-13285-7 Fig 11-17 Spacer Lgth. .130 .135 None allowed Not repairable Replace spacer
Item 17
Bore .3745 None allowed Not repairable Replace spacer
.3755 diameter
28-13274 Fig 11-17 Bellcrank Spacer holes .0005 Not repairable Replace bellcrank
Item 18 .376 .378 dia.
Bolt hole .257 .0005 Not repairable Replace bellcrank

diameter
MM-ll-59
MAINTENANCE MANUAL

Part No, Item No. Part Name Inspect Limits Limits Repair or Action
28-13267 Fig 11-17 Spacer Length .40 .010 Not repairable Replace spacer
Item 19
I.D. .250 .001 Not repairable Replace spacer
.252 diameter
28-13280-3 Fig. 11-17 Spacers -3 length None allowed Not repairable Replace spacer
Item 21 .365 .370
28-13280-4 Item 22 -4 length None allowed Not repairable Replace spacer

.750 -.755
Both spacers .001 Not repairable Replace spacer

.3-76;- .380
I.D. diameter
28-13285-5 Fig 11-17 Spacer Length 1.750 None allowed Not repairable Replace spacer
Item 23
I.D. .257 dia. .005 Not repairable Replace spacer
28-16520 Fig 11-17 Spacer Lgth. .192 .195 None allowed Not repairable Replace spacer
Item 24
I.D. .249 .250 .001 Not repairable Replace spacer
diameter
MM-ll-60
MAINTENANCE MANUAL

Part No. Item No. ~Part Name Inspect Limits~ Limits Repair or Action
28-13260-3 Fig 11-17 Bellcrank Brass bushings None allowed Not repairable Replace bushings and
Item 28 .3755 .3770 line ream to size
diameter
Security of bell- No looseness Remove loose side and

crank sides to allowed apply Type A Loctite
center spacer to spacer. Replace
side. Note: Place
1" bolts thru holes
~or proper alignment.
28-13284 Fig 11-17 Spacer Length 1.243 None allowed Not repairable Replace spacer
Item 29 1.248
O.D. .3745 None allowed Not repairable Replace spacer

.3755
MM-1l-61
MAINTENANCE MANUAL
SPRING CAPSULE ASSEMBLY
Fiy. Serviceable Repair

02-691-04 Fig 11-18 Rod End Axial clearance .007 Not repairable Replace rod end
Item 1
Threads No None allowed Not repairable Replace rod end
crossed or
missing threads
28-13263 Fig 11-18 Piston O.D. .4360 None allowed Not repairable RPplace piston
Item 3 .4370 diameter
Threads No None allowed Not repairable Replace piston

crossed or
missing threads
Concentricity .002 TIR Not repairable Replace piston
28-13255 Fig 11-18 End Cap O.D. 1.318 .0005 Not repairable Replace cap
Threads No None allowed Mot repairable Replace cap

crossed or
missing threads
Bushing wear
See Item 5 below
07-DU-08 Fig 11-18 Bushing Bore .437 .002 Not repairable Replace bushing
Item 5
O.D. .530 .005 Not repairable Replace bushing
MM-ll-62
MAINTENANCE MANUAL
SPKING CAPSULE ASSEMBLY Cont’d.

28-13279 Fig 11-18 Spring Free length None allowed Not repairable Replace spring
Item 6 1?.4" 12.6"
Visual inspect .010 Not repairable Replace spring

side of spring
for wear caused
by rubbing.
28-13256 Fig 11-18 Shaft Threads No None allowed Not repairable Replace shaft
Item 7 rolled or
missing threads
Straightness None allowed Not repairable Replace shaft

Check with
straight edge
28-13252 Fig 11-18 Retainer O.D. 1.280 .005 Not repairable Replace retainer
Item 8
Note: This Maximum .005 Not repairable Replace retainer
dimension wears out of round
oval shaped from
rubbing against
housing walls.
28-13253 Fig 11-18 Housing Ends of housing .0002 Not repairable Replace housing
Item 13 bored for end
cap 1.319 1.320
diameter
#2 ~ev. 11/18/88 MM-ll-63

MAINTENANCE MANUAL
SPRING CAPSULE ASSEMBLY Cont’d.
Fly. Serviceable Repair

28-13253 Fig 11-18 Housing Housing wall Max. 005 wear Not repairable Replace housing
Item 13 thickness .035 allowed
t .005. Inspect
for wear in I.D.
Shaft hole .0005 Not repairable Replace housing

.249 .251 dia.
28-13250 Fig 11-18 Anchor Bushing hole .0003 Not repairable Replace anchor
Item 14 .376 .378 dia.
Shaft hole .0005 Not repairable Replace anchor
Bore 1.376 None allowed Not repairable Replace anchor

1.380 dia.
28-13254 Fig 11-18 Shaft Shaft O.D. .250 .0005 Not repairable Replace shaft
Item 15
Threads No None allowed Not repairable Replace shaft
crossed or
missing threads
28-13257 Fig 11-18 Retainer O.D. 1.315 None allowed Not repairable Replace retainer
Shaft hole .0005 Not repairable Replace retainer

.249 .250 dia.
MM-ll-64
MAINTENANCE MANUAL
G. Spring Capsule Assemble (See Figure 11-18)
(1) Press anchor (14) on spring housing (13) while aligning

holes for shaft (15).
NOTE: Anchor (14) will be installed with ear of anchor

in line with center end cap screw (12). If anchor
is installed 180" to this position, the end cap
screw (12) will rub against pylon on installation.
(2) Press retainer (16) into spring housing (13) while aligning
holes for shaft.
(3) Press shaft (15) through anchor, housing, and retainer until
threads of shaft are equally spaced in housing.
(4) Install lock nut (10) on shaft (7) until slot in lock nut
aligns with cotter pin hole in shaft. Install cotter pin.
(5) Install washer (9) and retainer (8) on shaft (7) with recess
in retainer covering nut (10);
(6) Install spring (6) over shaft (7) and seat on retainer (8).
(7) Press bushing (15) into end cap (4).
(8) Install piston (3) through end cap and bushing.
(9) Turn piston onto shaft (7) and compress spring until unit
will slide into housing (13) without bottoming against
retainer (16).
(10) Apply grease to spring and to wall of housing (13) and

insert spring assembly into housing assembly. Use Texaco
Marfax #1 grease.
(11) Insert screws (12) through washers (11). Turn into end cap.
Torque screws.
(12) Safety wire screws in set of three with .032 wire.
NOTE: Safety wire must be installed on same side of

housing as ear of anchor (14) for clearance from
pylon.
(13) Install both jam nuts (2) on shaft (7).
(14) Install rod end (1) on shaft (7) until hole in rod end
aligns with hole in shaft.
(15) Install cotter pin through rod end.
(16/ Lock upper jam nut (2) against rod end.
MM-ll-65
MAINTENANCE MANUAL
H. Belt Tension Assembiy Assemble (5ee Figure 11-17)
(1) Install spacer (5) into ear of spring capsule assembly (6).
(2) Install bolt (1) through washer (2), strap (3), spacer (4),
strap (3) and washer (2).
(3) Insert bolt through spacer (5) in spring capsule assembly

with head of bolt facing forward as installed in helicopter.
(4) Ins ta 11 another washer (2), strap (3), spacer (4), strap
(3), washer (2) and nut (7). Tighten nut to remove side
play but do not torque at this point.
(5) Install nylon guide (8) on threaded shaft of spring capsule.

Repeat on opposite side.
(6) Install brackets (9) an spring capsule with nylon guide (8)
extending through slots in bracket.
(7) Install nylon washer (10) on nylon guide (8) flush against
bracket (9).
(8) Install washer (II) and nut (7) on threaded shaft against
nylon washer. Partially tighten nuts until approximately
two threads extend beyond nut.
(9) Place mount block (14) between brackets (9) and install
bolts (12) with washers (13) and nuts (15). Tighten bolts
but do not torque at this time.
(10) Install spacer (17) in center hole of bellcrank (18).
(11) Place bellcrank betwee~ straps (3) and insert bolt (16)
through straps and bel!crank with head of bolt inboard.
(12) Install washer (2), sp8cer (19), another washer (2) and nut
(7) on bolt (16). Torque bolt.
(13) Repeat steps 10 through 12 on opposite bellcrank (18).
NOTE: Straps (3) and bellcrank (18) should pivot freely

at this point.
(14) Place spacer (22) between bellcranks (18) and insert spacer
(23) through both bellcranks and spacer (22).
(15) Install spacers (21) on outboard ends of spacer (23).
(16) Place spacer stack-upbetween brackets (9) and insert bolt

(20) through brackets and spacers using washers (2) and nut
(7). Head of bolt should be forward as installed in
helicopter. Partially tighten nut.
MM-11-66
MAINTENANCE MANUAL
(17) Place unit on a flat surface´•so brackets (9) are standing

flat and parallel to each other. Torque all bolts at pivot
points and at mount block (14).
NOTE: Do not overtorque nutsagainst nylon washer and

guide as capsule will not slide freely.
spring
You should be able to rotate the Harper washer
(11) by hand after torque of nut. No side play
should exist between nut and washer.
(18) Holding brackets (9) by hand, slide spring capsule assembly

back and forth. Unit should slide free with no binding in
pivot points or slider.
(19) Place spacers (24) on each side of rod end and install
bellcrank (28).
(20) Insert belt (25) through bellcrank, spacers and rod end
using washers (26) and nuts (27).
(21) Install spacer (29) into bellcrank oilite bushings.
Belt Tension Assembly Installation (See Figure 11-3)
(1) Slide belt tension assembly mount block over clutch cable
and align assembly with pylon mounts.
(2) Install heavy washers between pylon mounts and belt tension
brackets. Insert bolt with washers through bracket and
mount (2 places).
(3) Install washers and nuts and torque bolts.
(4) Install large ~jam nut over clutch cable and against mount
block. Tighten jam nut finger tight.
(5) Install rubber dust protectors into position on clutch

cable.
(6) Install rod end jam nut on cable and install rod end.
NOTE: Turn rod end on cable until it bottoms out; then

back it off 3 turn.
(7) Slide spacer into rod end and, with a heavy washer on each
side of rod end, install between bellcrank arms of belt
tension assembly.
(8) Install washer on bolt and slide bolt through bellcrank arms
and rod end.
(9) Install washer and nut on bolt and torque nut.
MM-1l-67
MAINTENANCE MANUAL
(10; Tighten jam nut again,t rod end.
(11) Torque mount block jam nut with about two threads extended
above upper jam nut. See Figure 11-3.
(12) With spacer installed in oilite bushings of over-center

bellcrank, place two heavy washers on each side of bellcrank
on installation into pylon mount bracket.
(13) Place washer on bolt,and insert bolt through mount bracket

and bellcrank with h~ad of bolt facing forward.
(14) Install washers and nut on bolt and torque nut. Install
cotter pin.
(15) Install spacer in idler rod end.
(16) Install spacers on each side of idler rod end and place into
over-center bellcrank:.
(17). Place washer on bolt and insert through bellcrank, spacers,

and rod end.
(18) Install washers and nut on bolt. Torque nut and install
cotter pin.
(19) Adjust clutch control’ rigging. See Section 11-1 (Clutch

Control Rigging Proce´•dure)
(20) Inspect all connections for security and check that all
cotter pins are installed in double-locking hardware.
NOTE: The heads o;f all bolts in belt tension assembly

and bellcrank connections should be facing forward
with nuts on aft side.
(21) Replace cowling.
MM-ll-68
SECTION
FLIGHT CONTROLS
MAINTENANCE MANUAL
SECTION 12
FLIGHT CONTROLS
12-1 TROUBLESHOOTING THE ARTICULATED ROTOR SYSTEM
Helicopter vibration and cyclic feedback are often attributed to an

out-of-track main rotor system when the actual cause can be traced to
components within the system that are worn, damaged or out of
adjustment.
The following troubleshooting guide is provided to direct maintenance

personnel to possible problem areas within the rotor system that can
cause vibration or roughness.
This guide covers some of the problems and related causes that can be
checked prior to attempting to track the blades. Performing the
suggested checks and attention to routine maintenance schedules will
help reduce time unnecessarily spent in attempting to track blades
that may not be the cause of the problem.
B. Problems, Checks and Solutions
Problem 1. Aircraft develops a sudden roughness during flight.
Cause Check Solution
(a! Lamiflex Disconnect the rotor pitch Replace

bearing links at the upper walking lamiflex
failure. beams (see Figure 1, Item A) bearing.
and flex the blade grip in no
more than a 30" (i.e., +15")
are. Failure of the blade grip
to spring back indicates a
failed lamiflex bearing.
(b) Main Cycle blades fore and aft to Disassemble

rotor damper move damper piston in and out. and clean
seized. Failure of damper to cycle damper and
indicates a restrictor is restrictor.
plugged.
(c) Leading Inspect tape for separation Replace

edge tape from blades, leading edge
loosening (if tape.
blade tape is
used).
MM-12-1
MAINTENANCE MANUAL
(d) Main Inspect blades for evidence of Replace or

rotor blade separation, repair blade.
leading/
trailing edge
separation
occurring.
NOTE: Replacement blades must be matched by Enstrom Helicopter

Service. Provide serial numbers of good blades and
helicopter serial number. Blade repairs must be performed
by an authorized blade repair facility.
(e) Main Inspect blades for evidence of Extent of

rotor blade strike damage. damage will
suffered determine if
strike. blade
requires
replacement.
Problem 2. Aircraft’s first flight is rough (Frevious day it was smooth).
(a) Main Check tab anglles. inspect tabs Reset tab

rotor blade for damage or deformation. angles as
tab recorded on
inadvertently the "Blade
bent. Information
Sheet," or
replace tabs
if damaged.
NOTE: If tab angles are not available, contact Enstrom Helicopter

Service for orignal angles. Provide aircraft serial number.
ib) Lamiflex Disconnect rotor pitch links at Replace

bearing the upper walking beams and lamiflex
failure. flex the blade, grip in no more bearing.
than a 30" (i.e. t15") are.
Failure of the blade to spring
back indicates a failed
lamiflex bearing.
MM-12-2
MAINTENANCE MANUAL
(c) Main Inspect blades for evidence of Extent of

rotor blades damage. damage will
suffered determine if
"hangar rash" blade
damage. replacement
is required.
Problem 3. Aircraft gradually develops in increasing roughness

over a period of days.
(a) If it’s Check track. Track blades.

a new
aircraft,
touching up
blade track
may be
required due
to wear in
and seating
of system
components.
(b) Upper Inspect for looseness. Replace

push rod bushings and
bushing and spacers as
spacers worn required.

excessively
(see Figure NOTE: Ream bushings with a
12-1, 3/8" adjustable reamer,
Item B). to avoid looseness or
binding.
(c) Lower Rotate main rotor hub to Retorque nuts

swashplate position each axis of the lower to take up
axes worn swashplate over the play, or
(see Figure longitudinal push rod and move overhaul the
12-3, cyclic stick fore and aft. swashplate if
Item A). Note any play at the axes. necessary.
NOTE: Preload on each axis should be equal (check after

disconnecting both upper and lower controls). If unable
to obtain equal preload, overhaul as necessary.
MM-12-3
MAINTENANCE MANUAL
(d) Upper Move bell housing from side to Play in

swashplate DU side to check for looseness. excess of
bushings worn .010" may
excessively require
(see Figure overhaul of
12-4, the assembly.
Item A).
(e) Dog leg Note looseness of the bearing Reswage or

uniball and insure the bearing is replace
bearings worn secure in the dog leg, bearings as
excessively required.
(see Figure NOTE: Bearinos must be swaged
12-2, into the dog legs with
Item A). equal preload on each.
(f) Move collect:ive walking beam, Replace

Excessive noting amount of play at the bearing if
play in the~ bearing, excessive
upper play is
collective evident.
bearing (see
Figure 12-4,
Item B).
(g) Lamiflex a. Inspect for evidence of Replace

bearing grease in bearing area. lamiflex
swelled or b. Inspect bearing for bearing if it
deteriorated. evidence of deterioration shows
(i.e., e’xcessive extruded evidence of
rubber o~ rtial swelling or
separation deterior-
c. Check folr proper torque on ation.
retaining nut (12-15
in-lbs).
Inspect Nylatron strips for Replace

evidence of looseness or Nylatron
grooves. strips if
loose or
damaged.
MM-I 2:-4
MAINTENANCE MANUAL
(h) Flapping Remove main rotor blades. Lift Shim or
bearings retention assembly from down replace DU

exhibit stop approximately one inch at washers or
roughness, a time and check for excessive bearings as
notchiness, in-plane (lead-lag) looseness. required

or excessive and/or
play in NOTE: Retorquing requires retorque
lead-lag removal of the main hinge pin
plane. rotor dampers. If more nuts.
than 100 ft-lbs of
torque is required to
meet the above
condition, it indicates
reshimming or
replacement of the DU
spacers is necessary.
All three retention
assemblies should be
equally preloaded.
Lift retention assembly to the Retorque

"up" stop. Assembly should hinge pin
remain up with only hand nuts using
pressure to bring it down. Enstrom tool
#0051.
(i) Overall Inspect control system for Replace worn

control excessive play. components as
system rod required.

end bearings
or bellcrank
spacers/bush-
ings are
wi~rn.
Problem 4. Aircraft has cyclic stick feedback.
(a) Outboard Inspecttabs for proper angle Track blades

tabs are not as noted on "Blade Information if necessary
properly set. Sheet.n after
resetting tab
NOTE: If angles are not angles.
available, contact
Enstrom Helicopter
Service for original tab
angles. Provide
aircraft serial number.
MM-12-5
MA~NTENANCE MANUAL
(bj Lamiflex Disconnect the rotor pitch Replace

bearing links at the upper walking 1 am~i flex
fa~led. beams and flex the blade grips bearing.
in no more than a 30" (i.e.,
+15") are. Failure ´•of the
blade to spring back indicates
a failed lamiflex bearing.
(c) One axis Disconnect lateral and Reshim

of lower longitudinal push rods at the swashplate
swashplate swashplate. Disconnect push for equal
binding, rods at the upper walking preload on
beams. Pivot swashplate on each axis.
axes, noting any binding.
NOTE: Binding exhibits a

cyclic stick whirl
during rotor enga~ement.
(d) Upper a. Disconnect pitch link at Repair as

walking beam walking beam and walking required.
binding, beam at pivot point.
Rotate walking beam on push NOTE:
rod, noting any binding or beams
roughness. must pivot
freely.
b. Check torque on 1/4"
walking beam bolts. Torque
to 40 in-jbs.
NOTE: Binding exhibits a

cyclic stick whirl
during rotor engagement.
NOTE: While this is not a complete listing of possible problems that could
produce system vibration, it illustrates the fact that proper
maintenance and ins pecti on of system components can reduce
maintenance time involved in trying to track blades that are reacting
to problems elsewhere in the system.
When tracking is necessary re fe r to the t ra c k i ng
procedures in Section 12-2.
MM-12-6
MAINTENANCE MANUAL
BEAM
CYCLIC WALKING
VO~
Fig. 12-1 v~
~BB P
A
"1 I "1
o H O
Lec ASSMBLY ~p
Fig. i2-2
BEARING UP -R
LOWER SWASHPLATE ASSEMBLY
Fig. 12-3
MM-12-7
MAINTENANCE MANUAL
ie~
o
o
o o
86b
OPEN SIDE OF
BEARING UP
e\ /a
O
O C~’
COLLECTIVE GUIDETUBE ASSE~IBLY
pig. 12-4
MM-12-8
MAINTENANCE MANUAL
12-2 MAIN ROTOR BLADE TRACKING SPOTLIGHT REFLECTOR SYSTEM
A. Tracking Procedure Chart
STEP "A" STEP "B" STEP "C" STEP "D" STEP "E"
FLAT PITCH I I FLAT PITCH I FLAT PITCH I I HO\IERING I I FORWARD FLIGHT
2000 Engine RPM 1 100% Engine RPM 1 100% Engine RPM I 1 100% Engine RPM I 100X Engine RPM
PITCH LINK I I "WITH" A CYCLIC I I "WITHOUT" I I PITCH LINK I INBOARD"
ADJUSTMENTS I FEEDBAGK I I ACYCLIC FEEDBACK I I ADJUSTMENTS I TAB
"ONLY" I I "OUTBOARD TAB" I PITCH LINK I I "ONLY" ´•I I "’ONLY"
ADJUSTMENT I I ADJUSTMENTS
Continue until I I Use no more than I I Continue until I I Use no more than
all three blades 1 2 degrees I all three blades I 1 2 degrees

are I I per adjustment. I I are I per adjustment.
"In Track" I I Eliminate I I "In Track" I I DO NOT tab
Visually I I "A!1 Feedback" I and hover is I opposite of
"Smooth" I I outboard tab
NOTE 1: Tabs are set at zero degrees using special tools T-O026 T-OO27.
NOTE 2: If "Steps" cannot be followed, refer to "Rotor Troubleshooting" in this manual.
MM-12-9
MAINTENANCE MANUAL
B. General Information
The purpose in tracking the main rotor blades is to obtain a smooth

ride. This is accomplished by adjusting the blade track so as to
have all three blades flying in the same plane. An out-of-track
condition will produce a vibration, usually a one-per-rev which is
felt as a vertical vibration. Main rotor blades do not suddenly
produce a vibration unless a trim tab has.been inadvertently altered
or a blade has suffered other damage. Trim tab settings should be
recorded in the aircraft’s Log Book and referred to if an altered tab
is suspected. Before attempting to remove a vibration by adjusting
the track, refer to the troubleshooting guide for other possible
causes.
The fo 1 1 owl ng t ra c k i ng procedures were es t a bl-i s hed using the

"Spotlight/Reflector" system.
C. Installation of Equipment
(1) Connect spotl ight to DC power. (Battery located under

right-hand seat deck panel.)
(2) Install reflector with str’ip painted across the reflector into
threaded hole on bottom side of blade tip. Reflector facing
inboard and aligned with end of blade.
(3) Install clear reflector on next blade, reflector facing inboard.
(4) Install clear reflector on last blade, reflector facing

outboard.
NOTE: When tracking with the "Spotlight/Reflector" system you

are only observing two blades at a time. The "master"
and one of the tw’o "clears."
D. Tracking Procedure
(1) Grease main rotor head.
(2) Bleed main rotor dampers.
(3) Zero tab all main rotor blade tabs, or set tabs at recorded
angles on the "Blade Information Sheet."
(4) Ground run aircraft (rotor engaged).
2000 engine rpm.
(6) Observe track with spotlight.
MM-12;1O
MAINTENANCE MANUAL
(7) Record track and reverse clear reflectors.
(8) Observe track and record condition.
(9) Adjust track using pitch links.
E. Ground Track 3050 rpm (enginerpm)
(1) Observe cyclic stick for any feedback.
NOTE: If no feedback is evident, adjust track using pitch

links. If feedback exists, proceed to item (2).
(2) Observe track with spotlight and adjust conditions using

"outboard" tab.
NOTE: (a) Adjust only one tab, no more than 2 degrees per
adjustment.
(b) If feedback gets worse or has no effect, zero the

tab and adjust the next blade’s outboard tab.
(c) Continue until all feedback is gone.
(d) If more than 3 degrees of tab is requ~red, use

both the inboard and outboard tab (i.e., +3
degrees outboard, 3 degrees inboard).
(3) Once all feedback is gone, adjust track using pitch links.
F. Hover Tracking
(1) Hover aircraft into the wind (3050 rpm).
(2) Observe track and adjust using pitch links ONLY.
NOTE: Reverse reflectors frequently and adjust track until

aircraft is smooth.
G. Forward Flight Tracking
(1) Level flight, 80 to 100 mph, rpm stable.
(2) Observe track with spotlight.
(3) Reverse reflectors and observe condition of other clear blade.
MM-12-11
MAINTENANCE MANUAL
(41 Adjust out-of-trac~ condition using ’inboard" tabs.
NOTE: (a) Adjust tabs using no more than 2 degrees per

adjustment.
(b) Reverse reflectors frequently.
(c) Do not tab an inboard tab in the opposite

direction of outboard tab. If such a move is
called for, subtract a degree from the outboard
tab and observe cyclic for feedback.
(d) Any move made on an outboard tab will require a
pitch link move to regain smooth hover.
12-3 Main Rotor~Blade Tracking Chadwick System
A. Tracking Procedure Chart See Section 12-2 A.
B. Chadwick Mount Brackets Installation
(1! Install magnetic pickup mounting bracket and block, P/N 4385,
under main rotor transmission filler cap assembly.
(2) Rotate main rotor blades to place a blade directly forward or
just to the right of forward.
(3) Install interrupter, P/N 4393, around mast. Rotate interrupter

until the straight leg of the doubler interrupter is in line
with the magnetic pickup ~L-shaped interrupter tab should trail
in direction of rotation).
(4) Snug the three interrupter mounting bolts, securing the

interrupter to the mast.
(5) Install safety clamp below interrupter and secure.
C. Magnetic Pickup Installation
(1) Install magnetic pickup in mounting bracket. Adjust until there

is a .040" clearance between magnetic pickup and interrupter
leg.
(2) Rotate blades, checking gap of other two legs.
D. Accelerometer Installation
(1) Secure lateral (ba~ance) accelerometer to magnetic pickup

bracket with connector pointing to the left.
(2) Secure vertical (track) accelerometer to instrument panel

console using any convenient screw. Connector pointing down.
MM-12-12
MAINTENANCE MANUAL
E. Cable Installation
(1) Connect magnetic pickup cable, P/N 3319, to magnetic pickup.
(2) Connect accelerometer cable, P/N 3284, to lateral accelerometer

on magnetic pickup bracket.
(3) Route magnetic pickup and accelerometer cables into cabin.

Secure cables to airframe to allow for forward flights.
(4) Connect other cable, P/N 3284, to vertical accelerometer on
console.
(5) Place balancer box in cabin and plug magnetic pickup cable into
channel "A" magnetic pickup receptacle of the balancer box.
(6) Plug lateral accelerometer cable into channel "A" accelerometer

receptacle.
(7) Plug vertical accelerometer cable into channel "B" accelerometer

receptacle.
NOTE: Insure all cable connections are plugged into the

proper receptacles.
(8) Connect Strobex to balancer box.
(9) Connect balancer box to aircraft’s DC power. (Battery located

under right-hand seat deck panel.)
F. Balancer Box Control Settings
(1) "Magnetic pickup" to "Common."
(2) "Interrupter logic" to Double."
(3) "Function" switch to "Track."
(4) "RPM Range" to "X 1."
(5) "RPM Tune" to "350"
NOTE: The and M-6 do not have "magnetic pickup" and

177M-5
"interrupter" switches. The Strobex must be plugged in to
real ize the double interrupter logic. Set switches as
shown in 3, 4 and 5.
G. Strobex Setting (135M-10A, B, or C)
(1) Set "oscillator" switch to the "off" position.
NOTE: The internal oscillator of the Strobex is used for tail

rotor balancing ONLY.
MM-12-13
MAINTENANCE MANUAL
H. Tip Target Installation
(1! Install tip targets, P/N 4479, one to each blade. Secure with a
#10 round head screw. (Ref~ective numbers inboard.)
NOTE: Rotate blades until "double interrupter" is over

magnetic pickup. Main rotor blade in front of ship is
designated "targef blade." Blade following "target
blade" is designated "A" blade, and the last blade
designated "B" blade.
I. Tracking Procedure Chadwick System
Once the Chadwick system is set up as per the preceding instructions,

the aircraft is ready for tracking or balancing the rotor blades.
(1) Grease main rotor hub.
(2) Bleed main rotor dampers.
(3) Zero tab all main rotor b;lade tabs, or set tabs at recorded
angles on the "Blade Information Sheet."
(a) 2000 rpm (engine rpm).
(b) Observe track with St~obex.
(c) Adjust using main rotor pitch links.
(a) 3050 rpm
(b) Observe cyclic stick for any feedback.
NOTE: If no feedback is evident, adjust track using pitch

links. If feedback exists, go to Item 6.
(6) Observe track with the Strobex and adjust condition using the
outboard tab.
NOTE: (a) Adjust only one tab no more than 2 degrees per
adjustment.
(b) If feedback gets worse or has no effect, zero the

tab and adjust the next blade’s outboard tab.
MM-12-14
MAINTENANCE MANUAL
(c) Continue until all feedback is gone.
(d) If more than 3 degrees of tab is required, use both

the inboard and outboard tab +3 degrees
outboard, +3 degrees inboard).
J. Hover Tracking (for vertical vibration)
(1) Observe track with Strobex.
(2) Switch balancer selector to vertical channel "B."
(3) Record "clock angle" and "ips" reading.
NOTE: It is important for the pilot to hold a steady hover,

and stabilize rpm before recording conditions.
(4) Refer to channel "B" tracking chart and plot move. It should be
the same as you observed with the Strobex. It is important to
be able to correctly read the track with the Strobex.
NOTE: Adjust conditions until ips is reading less than .2

ips, and if aircraft is not smooth, follow the ngalan-
cing Steps" listed next.
K. Lateral Balancing
CAUTION: Balancing the main rotor blades should only be necessary if

work has been done to the blades that may have created an
out of balance condition. An out of balance exists ONLY if
the Lateral IFS reading is higher than the Vertic~i;rIPS
reading.
Reading the Lateral channel is recommended as a
troubleshooting procedure to isolate a faulty component

that is creating an out of balance condition.
If work has been done to the blades as per paragraph 1,

follow the procedures listed below.
(1) Hover aircraft into the wind.
(2) Switch balancer selector to channel "A."
(3) Record "clock angle and ips" reading.
(4) Refer to channel "A" balance chart and plot move.
NOTE: Balancing is done using the pockets located on the

outboard end of the blade.
MM-12-15
MAINTENANCE MANUAL
ADJUSTMENT OF PITCH-LINK TO
DESIGNATED BLADE SHOULD RESULT 3~L
IN A MOVE IN THE DIRECTION
OF ARROW
;J
o"
I I
12 ~Q
J to
i
91 r 1 1 r r I I -f-~´•’ t11’’11’’3
7a
~PS
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a, s Y4
8
.\o
.6 I
7 5
O~ a
J
"TPRGET"BLnDE
I ~c´•A UP
TARGET BLADE IS FORWARD

VIEWED FROM TOP WHEN DOUBLi INTERRUPTER
IS OVER YAG~ETIC PICKUP
SET BALANCER TO
"n" sLnDE 360 R.PM. FO~ FPBC,O80C,F28 F,2BOF
332 R.PM. FOR P28A~280
’’B" BL ADE I READ VERTICAL(´•IPS´•AND CLOCK ANGLE)AND
OBSLRVE,T~PCK AT MOVER AND CRUISE PLOT
CHANNEL B VERTICAL READING
REA´•D CHAN~EL"B"
WERTICAL ACCELEROMETER
FIGURE 12-5
MM-12-16
MAINTENANCE MANUAL
WEIGHT TO DESIGNATED BLADE

SHOULD RESULT IN A MOVE
OIRECTIOI O~ ARROW IN07JHE
.4 k ~P
to po
2
.9
P, 8 4
t EQ
f
7 5
0 6
O "TnRcE~’eLnoE
i
SET BALAICER tO
360 R.P.Y.ICOCI
332 R.PI.POI PSIA,20O
TARGET BLADE IS FORWARD WHEN
SHIP fO IL 11 9000 TRACK
DOUBLE INTERRUPTER LS OVER
A1JD BAUWCED IW MOVER
MAGWETIC PICKUP
ONLV
ADD OR SUBTRACT NO MORE
THAN 20 GRAMS PER MOVE
"e"eLnoE I"n"eLAoE
READ CHANNEL"A’
LATERAL ACCELEROMETER
FIGURE 12-6
MM-12-17
MAINTENANCE MANUAL
(5) Add or subtract "tip weights" until ips is below .2 ips and
aircraft is smooth.
NOTE: The addition or suibtraction of tip weights will some-

times affect the "vertical." If so, revert back to
Item J for corrections.
L. Forward Flight Tracking
(1) Level flight in cruise, rpm stable (305G rpm)
(2) Observe track with Strobex and record conditions.
(3) Switch balancer to channel "B" and record "clock angle" and
"IPS."
(4) Plot move on vertical chart "B."
(5) Adjust condition using inboard tab.
NOTE: (a) Use no more than 2 degrees per move.
(b) Do not bend inboard tab in opposite direction of an

outboard tab on the same blade. If this move is
required, subtract a degree of tab from the
outboard.
(c) Observe cyclic feedback.
(d) Any time a mov;eis made on an outboard tab it will

rebuire a pitch link adjustment to make hover
smooth.
12-4 Collective Pitch Control Stick
1. Description
The collective pitch control stick controls rate of climb when pulled
upward by increasing the pitch df all three main rotor blades simul-
taneously and to the same degree. Downward movement of the collec-
tive stick decreases the pitch of the blades which decreases lift on
the rotor and allows for a controlled descent. The collective pitch
control stick is incorporated into the throttle correlator system.
This mechanism combines the throttle motion with the collective stick
movement such that the proper power inputs are automatically estab-
lished asthe collective stick is moved. The correlator is designed
to keep the rotor/engine rpm within the desired green band for the
majority of all flight regimes. Friction control is provided on the
throttle grip of the collective.stick. See Figure 12-7 for locations
of the friction control points. The engine starter button is located
on the end of the pilot’s collective stick.
MM-12-18
MAINTENANCE MANUAL
2. Pilot’s Collective Control Stick
A. Pilot’s Collective Removal (See Figure 12-7)
(1) Remove fiberglass cowl over collective stick.
(2) Disconnect starter button wires at the quick disconnect

terminals.
(3) Remove bolt (1) connecting throttle bellcrank to collective

stick.
NOTE: Do not disconnect the co-pilot collective linkage

or the correlator linkage attached to the throttle
bellcrank.
(4) Cut safety wire and remove bolt (2) from top of collective
bellcrank.
(5) Remove collective stick from collective and throttle

bellcranks. Keep DU washer (3) for reinsta~lation.
B. Pilot’s Collective Installation (See Figure 12-7)
(1) Install collective stick into collective bellcrank and

align holes.
[21 Install washer and bolt (2). Torque bolt and safety wire
with .032 wire.
(3j Install DU washer (3) on stick with DU side of washer

facing forward toward grip.
(4) Install throttle bellcrank and align holes.
(5) Install bolt (1), washers, nut and torque.
(6) Connect wire terminals for starter button.
(7) Cycle collective stick up and down and rotate throttle to

check freedom of movement.
(8) Install fiberglass cowl and screws.
NOTE: Grease or oil build-up on torque tube may cause

collective friction to slip. To remedy this
problem spray Locquic Primer T into slotted area of
collective clamp on torque tube until oil is
removed.
MM-12-19
o
6 o
SIDE VIEW OF COLLECTIVE TRIM

MECHANISM INSTALLATION
z
--I
m
5 z
4 K
m
r
1;3 I I I~
N I I II l~z
o I I I! I Ic
STARTER BUTTON I I THROTTLE FRICTION 1 1~2
CONTROL
COLLECTIVE FRICTION CONTROL B UZIII~U’ 3
FIG. 12-7 COLLECTIVE CONTROL SYSTEM

MAINTENANCE MANUAL
3. Go-Pilot’s Collective Control Stick (See Figure 12-7)
A. Go-Pilot’s Collective Removal
(1) Lift tab of the expando pin (4) to a vertical position and
pull to remove.
(2) Remove co-pilot’s stick from collective bellcrank.
B. Go-Pilot’s Collective Installation
(1) Align slot in end of collective stick with bolt in

collective bellcrank and slide into place.
(2) Align expando pin holes and install pin.
(3) Flip eccentric tab of expando pin to secure.
NOTE: To adjust tightness of expando pin, loosen set

screw on side and rotate pin to required tension.
Tighten set screw. The expanding segments must be
contained for tight fit.
12-5 Collective Trim System (See Figure 12-9)
A. Collective Trim Removal
(1) Remove fiberglass seat deck.
(2) With collective stick down and spring capsule in compressed

position, install special tool T-0029 between bottom of hex nut
and top of spring housing.
(3) Secure tool T-0029 in position by wrapping upper end with .032
safety wire. See Figure 12-8.
WARNING: With the spring capsule in compressed position

there is approximately 180 Ibs of force exerted by
the springs. Handle with extreme care.
(4) Remove nuts (1) and washers (2) from spring capsule pivot (3).
(5) Remove bolts (5), washers (6), and nuts (7) from brackets (4).
Remove brackets.
(6) Remove bolt (9), washers (10) and nut (11) from pivot retainer
straps (8). Remove spacer (12).
(7) Slide pivot retainer straps (8) outboard on torque tube to

detach from capsule pivot (3).
(8) Remove bolt (13), nut (15), and washers (14) from upper end of
spring capsule.
MM-12-21
MAINTENANCE MANUAL
Fig. 12-8
COLLECTIVE SPRING CAPSULE
IN HOLDING TOOL T-0022
8RIGI NA&
As
ATP
MM-12-22
MAINTENANCE MANUAL
18
16
I I
10
~t ’~oV
17
Is ~t
15
14
14 8
13
24
12
w~ 4
10
67
i3
23
,69~
15
14
16
2
6
21
5 25
~8’ 29
20
16
26 14
19
27
FIG. 12-9 COLLECTIVE TRIM,SPRING CAPSULE
MM-12-23
MAINTENANCE MANUAL
(S) Carefully remove rpring capsule assembly.
(10) To remove tie rod assembly from seat, remove bolt (19),
washers (14j and (16), spacer ~20) and nut (15).
B. Collective Trim Disassembly (See Figure 12-9)
(1) Carefully place spring capsule assembly horizontally between

jaws of bench vise.
(2) Cut safety wire from special tool T-0029.
!3) Slowly rotate vise handle to release spring pressure until all
tension is relieved.
(4) Remove spring housing (24), springs (25) and (20j, washer (27),
and spring retainer (28).
NOTE: "F" models with corrlators may not have the inner
spring (26) installed.
(5) Remove spring capsule pivot (3) from spring retainer (28).
(6) Tie rod assembly break torque on checknuts (21) and turn tie
rods to remove from threaded shaft (22).
C. Collective Trim Assembly (See Figure 12-9)
(1) Apply grease to springs (25) and (26). See lubrication section
for proper grease.
(2) Install spring capsule pivot (3) on spring retainer (28) with 3
to 4 threads extended above spring capsule pivot.
(3) Install washer (27) in spring retainer (28).
(4) Install springs into spring retainer (28).
(5) Install spring housing (24).
(6) Place tool T-0029 on spring capsule and carefully compress

capsule in vise until lip of tool locks between ears of spring
housing (24), ref. Figure 12-8.
WARNING: With the spring capsule in compressed position, there

is approximately 180 Ibs of force exerted by the
springs. HANDLE WITH EXTREME CARE.
(7) With spring capsule still in vise, wrap tool T-0029 with .032
safety wire to secure in position.
(8) Install checknuts (21) on shaft (22).
(9) Install tie rods (23) and (29) on shaft (22), leaving check nuts
loose for adjustment.
MM-12:-24
MAINTENANCE MANUAL
D. Collective Trim Installation (See Figure 12-9)
(1) Install bushing (20) into tie rod (29).
(2) Place washers (16) on each side of tie rod and install assembly
into seat mount.
(3) Install bolt (19), washers (14) and nut (15). Torque bolt.
(4) Install spacer (17) into bellcrank (18).
(5) Place washers (16) on each side of bellcrank (18) and carefully
slide spring capsule assembly into position.
(6) Attach spring capsule to bellcrank (18) with bolt (13),

washers (14), and nut (15). Torque bolt.
(7) Slide pivot retainer straps (8) inboard and onto spring capsule
pivot (3).
(8) Place spacer (12) between upper end of pivot retainer straps (8)
and secure in place with bolt (9), washers (10), and nut (11).
NOTE: Do not over torque bolt (9), as this will cause binding
in the system. You must be able to rotate spacer (12j
by hand after tightening.
(9) Installstraps (4) onto spring capsule pivot (3).
(10) Install washers (2) and nuts (1). Torque nuts.
(11) Install bolts (5) with washers (6) through brackets (4) and tie
rod (23). Adjustment of rod (22) may be required to align bolt
holes for brackets. Install nuts (7) and torque.
(12) Cut safety wire and remove tool T-0O29.
E. Collective Trim Rigging (See Figure 12-7)
NOTE: Rigging adjustments to be made with collective stick in

down position.
(1) Adjust rod (6) so the upper end of the spring capsule
assembly (8) is slightly aft of the forward edge of the pivot
retainer straps (9).
(2) Adjust the lower end of the spring capsule assembly (8) to
balance out pilot’s collective force load in flight.
NOTE: When correct adjustment is complete, the collective

stick should stay in full down position with collective
friction released. Collective should also have equal
pressure in both directions of travel in flight.
MM-12-25
MAINTENANCE MANUAL
(a) To correct for an out of balance condition, a light collec-

tive (easier up than down), release tension on spring in
trim capsule.
(b) For a heavy collective, increase spring tension.
iSf Secure checknuts (7) against tie rods.
CAUTION: When properly adjusted for collective trim in flight

the collective may have a tendency to pop up during
ground operation. USE EXTREME CARE.
12-6 Cyclic Pitch Control Stick
A. Description
The cyclic stick controls the movement of the helicopter forward,

aft left and right whi le in´• flight. Longitudinal control is
obtained by the forward or aft motion of the cyclic stick, which
causes the swashplate to tilt forward or aft at a 450 angle to the
ship centerline, resulting in a variable pitch change of each rotor
blade per revolution. With the swashplate in a forward angle, the
rotor blades assume a higher pitch angle in the retreating sector of
the plane of rotation, and a lower pitch angle to the advancing
sector. This causes the blades to fly low in front and high in back,
thus inducing a forward thrust component in the rotor system. This
will cause forward flight at the desired speed when coordinated
the proper application of collective pitch and throttle. or
withRearw d
lateral flight is similarly accomplished by moving the cyclic stick
in the appropriate direction. The cyclic control stick has a grip
that contains a cyclic trim switch, to reduce stick loads during
flight.
B. Cyclic Stick Removal
(1) Disconnect snap fasteners and remove boots.
(2) Disconnect cannon plug from receptacle.
(3) Remove the two bolts connecting cyclic stick to bellcrank.
(4) Remove stick assembly.
C. Cyclic Stick Installation
(1) Install cyclic stick on bellcrank.
(2) Install bolts, washers and nuts and torque.
(3) Connect cannon plug to seat receptacle.
(4) Install boot and snap fasteners.
MM-12-26
MAINTENANCE MANUAL
12-7 Lateral and Longitudinal Trim Actuators
A. Troubleshooting
Problem Cause Requi red Action
Trim Actuator (1) Faulty motor Remove Actuator Assembly.

inoperative Troubleshoot in the follow-
(2) Faulty ing order to determine
microswitch which area is causing
problem.
(3) Spring capsule
binding on (1) Disconnect wires and
acme shaft remove motor. Test
motor with 12V
(4) Binding of battery for operation.
internal gears
(2) Remove microswitch
assembly and inspect
switches.
(3) Rotate spring capsule

on shaft and
acme
check for freedom of
movement for full
travel.
(4) Remove rubber coupling

and rotate internal
gears with screw-
driver to check for
freedom of rotation.
B. Lateral Trim Actuator Removal (See Figure 12-10)
(1) Identify wires and their location before dis connecting from
microswitches.
(2) Disconnect w i res from m i c roswi tch es and from the qu i ck

disconnect attached to ground wire.
(3) Remove bolt (3), light washers (4), and nut (6) from spring
capsule (2).
(4) Remove bolt (7), washers (4), and nut (6) from housing (1).
(5) Remove lateral trim actuator from seat structure.
(6) Remove spacers (8) from housing (1).
(7) Remove spacer (5) from spring capsule (2).
MM-12-27
I 4
10--Uj ----i~--Lc4
i ii 9-~1 1 cr~t- 12
10
13
t I L.ONO1TTUDINAL TRIM I
I
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PII--c’ ACTUATOR
I Z
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ct´• F’G. 12-10 TRIM MOTOR r=Ls~c- s o
I
INSTaLLATION r m
ANO RE:MOVAL ~c-- a
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ORIGINAL
As Received B3y
AT’P
I-~ci i
i 5
LRTERAL TRIM
AC~UATOR
6
6
MAINTENANCE MANUAL
C. Longitudinal Trim Actuator Removal (See Figure 12-10)
(1) Identify wires and their location before disconnecting from

microswitches.
(2) Di scb;nnect wi res from mi croswi tches and from the quick
disconnect attached to ground wire.
(3) Remove bolt (11), light washers (4), heavy washers (12), and
nut (6) from spring capsule (10).
(4) Remove bolt (14), harper washers (15), spacers (16), and nut (6)
from housing (9).
(5) Remove longitudinal trim actuator from seat structure.
(6) Remove spacer (17) from housing (9).
(7) Remove spacer (13) from spring capsule (10).
D. Trim Actuators Disassembly (See Figure 12-11)
(1) Separate wire leads to microswitch and disconnect.
(2) Remove screws (1) and washers (2) attaching switch assembly.
Remove switch assembly.
(3) Rotate spring capsule assembly (5) to remove from acme shaft.
(4) Remove nuts (13), lockwashers (12) and washers (11) from
motor (7). Remove motor.
(5) Remove coupling (8) and snap ring (9).
(6) Remove the remaining screws (1) and washers (2) from cover
assembly (6).
(7) Gently tap cover to one side and pull acme shaft to remove cover
assembly (6).
(8) Top face of housing (4) against work bench to remove worm gear
assembly (10).
E. Trim Actuator Part Replacement
NOTE: After de termi n i ng which pa rt of the trim actuator is

causing a malfunction, that item should be replaced as
follows.
(1) Microswitch remove the two screws and washers holding switch
in place and remove switch. Install new switch and replace
screws.
MM-12-29
MAINTENANCE MANUAL
O) i
~2---
i
1_1 a
i
I
8 9 10
12 13
FIG. 12-11 TRIM MOTOR ASSEMBLY
AND DISASSEMBLY
MM-12-30
MAINTENANCE MANUAL
(2) Spring capsule assembly Acme nut replacement is accomplished

by removing the three screws at base of capsule. Remove and
replace nut. Reinstall switch activator and screws to base of
capsule.
The rubber bumper at base of capsule is attached by applying

contact cement adhesive to both the bumper and acme nut. Press
bumper firmly into place.
(3) Cover and acme shaft assembly, worm gear assembly, and motor
assembly are replaced as assembly units.
F. Trim Actuator Assemble (See Figure 12-11)
(1) Install worm gear assembly (1) into housing (4) until aft
bearing is aligned with bearing seat in housing. Do notinstall
into bearing seat at this time.
(2) Apply grease into housing (4), packing against outer walls and
to worm gear. See lubrication section for grease.
(3) Install cover and acme shaft assembly (6) into housing (4) with
cover turned to side exposing worm gear (10).
(4) With cover seated in housing, push worm gear assembly (10) into
place, seating bearings in place, and install snap ring (9).
(5) Rotate cover into position and install two screws (1) and
washers (2) in cover holes located opposite worm gear.
(6) Rotate worm gear with screwdriver to check for binding in gears.
(7) Install coupling i8) onto slotted end of worm gear.
(8) Align slots in motor with coupling and install motor into
position on housing (4).
(9) Install washer (11), lockwasher (12) and nut (13) on motor studs
and torque.
(10) Apply lubriplate or equivalent to threads of acme shaft and turn

spring capsule (5) onto acme shaft until rubber bumper at base
of spring capsule is approximately one inch from cover.
(11) Turn switch activator of spring capsule to.align with slot in

microswitch assembly (3) and attach to housing (4) using
screws (1) and washers (2).
(12) Torque screws and safety wire.
(13) Connect wires to switch.
MM-12-31
MAINTENANCE MANUAL
G. Lateral Trim Actuator Installation (See Figure 12-10)
(1) Install spacer (8) into housing (1).
(2) Install spacer (5) into spring capsule (2).
(3) Install actuator assembly into seat structure and align with
mounts.
(4) Install bolt (7) through light washer (4), seat structure mount
and spacer (8).
(5) Install light washer (4) a.nd nut (6).
(6) Install bolt (3) through washer (4), seat structure mount and
spacer (5).
(7) Install ´•light washer (4) and nut (6). Torque nuts (6) in two
places.
(8) Connect wires at ground and microswitches.
(9) Test trim actuator for freedom of movement and full travel in
both directions.
H. Longitudinal Trim Actuator Installation (See Figure 12-10)
(1) Install spacer (17) into housing (9).
(2) Install spacer (13) into spring capsule (10).
(3) Install actuator assembly into seat structure and align with
mounts.
(4) Install spacers (16) on each side of housing (9) with chamfered
side of spacer facing outboard.
(5) Install bolt (14) through harper washer (15), seat structure,
and spacers (16) and (17r
(6) Install harper washer (15) and nut (6).
(7) Install heavy washer (12)

a and light washer (4) on each side of
spring capsule (10).
(8) Install bolt (11) through washers (4), seat structure,

washers (12), and spacer (13).
(9) Install washer (4) and nut (6). Torque nuts (6) in two places.
(10) Connect wires at ground and microswitches.
(11) Test trim actuator for freedom of movement and full travel in
both directions.
MM-12-32
MAINTENANCE MANUAL
12-8 FLIGHT CONTROL RIGGING
NOTE: Cyclic and collective rigging must be done in sequence starting

with the cyclic pitch controls. A rigging check must be accom-
plished any time components of the control system have been
removed and exact dimensions such as rod lengths or bellcrank
angles are not available prior to re-installation of that
component.
NOTE: Install connecting rod ends during rigging as follows:
(1) HMVV-5 right hand rod end to the right, top, and aft.
(2) HMLVV-5 left hand rod end to the left, bottom, and fovward.
A. Preliminary Rigging (See Figure 12-12)
(1) Level helicopter with reference to lower left hand and forward
pylon bay tubes.
(2) Remove fiberglass seat deck and flooring panels.
(3) Remove side cowling panels above engine compartment.
(4) Disconnect control rods (13) and (14) from bellcranks (9)
and (11).
B. Cyclic Rigging Seat Deck Area (See Figure 12-12)
(1) Adj ust rod (1) connecting eye 1 i c stick bellcranks until
bellcranks (17) and (18) are centered laterally in the stop ring
hole. Secure check nuts.
Adjustment check move cyclic stick full left and full right to
assureboth bellcranks (17) and (18) hit stops.
CAUTION: Check inspection holes in control rods for minimum

thread engagement of rod ends. Rod end bearings must
be centered between bellcrank ears to allow full pivot
after check nuts have been tightened.
(2) Adjust rod (5) until outboard edge of bellcrank (2) and inboard
edge of bellcrank (4) are pa ral 1 el to each other and
perpendicular to the firewall. Secure jam nuts.
NOTE: When adjusting rod (5), the left

hand rod end HMLVV-5
must be adjusted one past witness hole and
turn
secured. All adjustments must be made by rotating the
right hand rod end only.
(3) Move cyclic stick full forward and adjust rods (3) and (6) until
both bellcranks (17) and (18) hit stop ring.
Adjustment check Pull cyclic stick aft to assure bellcranks

are hitting stops. Adjust if necessary.
MM-12-33
14
13
S
10
II I~
12
II
15
5) (16
FIG 12-12 CYCLIC RIGGING CHART

MAINTENANCE MANUAL
(4) Secure jam nuts and move cyclic stick laterally to assure rod
ends do not bind.
Adjustment check Rotate pilot’s cyclic stick around cyclic

stop ring. Check that both left and right bellcranks maintain
contact with the stop ring through 360 degrees of travel.
NOTE: If binding or interference exists, make slight adjust-

ments to rod lengths or reposition rod end bearings to
correct condition.
(5) Install cyclic centering tool T-1775 in stop ring. See

Figure 12-13.
(6) Position bellcrank (7) so the forward edge is in vertical

position. Adjust length of rod (8) to hold this’ position.
Secure check nuts.
Adjustment check Remove centering tool T-1775 and move cyclic

stick fore and aft to check rod end and check nut clearance to
bellcrank.
(7) Place p~lot’s cyclic stick in the full forward position

(bellcrank aft against stop) and centered laterally. Position
bellcrank (9) so the lower edge is parallel to its cabin mount.
Adjust length of rod (1) to maintain in this position. See
Figure 12-14. Secure check nuts.
Adjustment check Cycle to check for interference.
(8) Connect longitudinal trim actuator to bellcrank (7) if discon-

nected. See Section 12-7, Trim Actuator Installation.
(9) Place pilot’s cyclic stick in the full left position and
centered longitudinally. Position bellcrank (11) so the lower
edge is parallel to its cabin mount. Adjust length of rod (12)
to maintain this position. See Figure 12-14. Secure check
nuts.
Adjustment check Cycle to check for interference.
NOTE: Recheck security of all check nuts and rod end

clearances.
C. Collective Rigging Seat Deck Area (See Figure 12-7)
(1) Place collective control stick in full down position and tighten
friction.
(2) Adjust rod (5) to obtain 1/8" to 3/16" clearance between collec-
tive bearing housing spacer and swashplate mount flange. See
Figure 12-15. Secure check nuts.
MM-12-35
MAINTENANCE MANUAL
ii::: ::i´•
Fig. 12-13
CYCLIC STICK RIGGING
TOOL T-1775 INSTALLED
ORIGINAL
As Receiked By
AT~
MM-12-36
MAINTENANCE MANUAL
BELLCRANK TO BE
PARALLEL TO MOUNT
II I I I I II~
II I I II
81 1~11 I I II~ i ~8
LONGITUDINAL LATERAL
FIG. 12-14 CYCLIC BELLCRANKS

PARALLEL TO MOUNT
01
d ~8" TO 3/1~ CLEARANCE
FIG. 12-15 COLLECTIVE HOUSING TO

SEAL HOUSING CLEARANCE
MM-12-37
MAINTENANCE MANUAL
O. Cyclic Rigging To Swashplate (See Figure 12-12)
(1) Install rigging tool T-1775 in eye lic stop ring. (See
Figure 12-13)
NOTE: Run trim motors to slightly preload cyclic stick

against tool.
(2) Install swashplate centering tools T-1575 to hold swashplate

perpendicular to main rotor shaft. See Figure 12-16.
(3) Connect rod (13) to swashplate. Adjust the length of rod 13)
until the attachment bolt slides freely into bellcrank (11).
Install spacers and mount hardware. Secure check nuts and
hardware. See Section 12-11 for hardware attachment to
swashplate.
(4) Connect rod (14) to swashplate. Adjust the left hand rod end
HMLVV-5 at bellcrank (9) until attachment bolt slides freely
into bellcrank. Install spacers and mount hardware. Secure
check nuts and hardware. See Section 12-11 for hardware attach-
ment to swashplate.
E. Main Rotor Hub Cyclic and Collective Rigging
(1) Level aircraft along pylon bay tube inside the left engine door.
Install tripod stand under tail rotor guard to hold ship level.
NOTE: Avoid standing on or sitting in aircraft after

leveling.
(2) Phase main rotor blades 120 degrees apart. This is accomplished
by moving each blade grip until one inch of the damper piston
shaft is exposed on each damper.
(3) Rotate main rotor hub until #1 grip is at the 97 degree azimuth
position. See Figure 12-17.
NOTE: The 90 degree position is to the right side of the

helicopter. The 97 degree position may be checked by
observing that the dog leg rod end bearing controlling
the #1 blade is directly over and in line with rod (14)
of Figure 12-12, Cyclic Rigging.
(4) Place bubble type protractor on top flat area of main rotor
blade grip. Adjust pitch change link to obtain 6.5 degrees +.5
degree. Center rod end bearings for full pivot and secure check
nuts.
NOTE: Protractor will be positioned pe rpe nd i cu 1 a r to the

leading edge of the blade.
(5) Repeat the sequence for blades 2 and 3. Recheck #1 blade.
MM-12-38
MAINTENANCE MANUAL
´•5:t’i’a’i*’
Fig. 12-16
INSTALLATION OF SWASHPLATE
RI´•GGI~G TOOL T-1575
ORIGENBF
Received B~-
ATP
MM-12-39
MAINTENANCE MANUAL
FIGURE 12-17 MAIN ROTOR AZIMUTH POSITIONS
1800
Cj O
MM-12-40
o"
MAINTENANCE MANUAL
(6) Remove tool T-1575.
(7) Place collective control stick in full up position.
(8) Rotate #1 blade to the 97 degree azimuth position. (See

Figure 12-17)
(9) Set protractor at +19 degrees and position it on top flat area
of blade grip. Adjust collective up stop at seat deck until
bubble is centered, giving +19 degrees .5 degree. Secure
collective up-stop check nut.
(10) Remove tool T-1775.
12-9 CYCLIC AZIMUTH CHECK
A. Verification of Rigging
(1) Rotate #1 blade to the 97 degree azimuth position. See

Figure 12-17.
NOTE: ~The 90 degree position is to the right side of the

helicopter. The 97 degree position may be checked by
observing that the dogleg rod end bearing controlling
the #1 blade is directly over and in line with rod (14)
of Figure 12-12.
(2) Lower collective stick to full down position and tighten

friction. Recheck 6.5 degrees +.5 degree measurement of main
rotor blade grip.
(3) Move cyclic stick to full aft position. Measure blade grip
angle. Measurement to be 14.5 degrees t.5 degree.
NOTE: If adjustments are required, adjust the left hand rod

end HMLVV-5 on rod (14). See Figure 12-12.
(4) Move cyclic stick to full forward position. Measure blade grip
angle. Measurement to be -2.5 degrees +.5 degree.
NOTE: Total travel must be 17 degrees +.5 degree.
NOTE: Because push-pull rod adjustments in the cyclic rigging

affect all three main rotor blades equally, it is only
necessary to do an azimuth angel check on one blade.
(5) Rotate main rotor hub until the dog leg rod end bearing control-
ling the #1 blade is directly over and in line with rod 13) of
Figure 12-12, Cyclic Rigging.
MM-12-41
MAINTENANCE MANUAL
(6) Move cyclic stick to full’ right position. Measure blade grip
angle. Measurement to be 14.5 degrees .5 degree.
NOTE: If adjustments are required, adjust rod (13). See

Figure 12-12.
(7) Move cyclic stick to full left position. Measure blade grip
angle. Measurement to be -2.5 degrees +.5 degree. Total travel
must be 17 degrees +.5 degree.
(8) Rotate cyclic stick 360 degrees around stop ring to check for
evidence of binding.
CAUTION: Upon completion of any adjustments to control system

check to see if autorotative rpm is in a safe range
during first ground run-up.
Range: 18.5 to 19.5 inches manifold pressure at
3050 rpm.
NOTE: A high manifold pressure indicates a low autorotation

rpm. A
low manifold pressure indicates a high
autorotation rpm. See Item B for autorotative rpm
adjustment.
B. Autorotative RPM Adjustment
(1) Load helicopter with full fuel and two people (2350 Ibs gross
weight approximate).
(2) Enter autorotation at altitude adequate for stabilized

autorotation at 58 mph.
(3) Acceptable rotor rpm is 350 to 360 (standard day sea level).
NOTE: For other than standard conditions the following

corrections can be made:
(a) 1,000 ft increase in density altitude will increase

autorotative rpm by 5.
(b) 1,000 ft decrease in density altitude will decrease

the autorotative rpm by 5.
(c) 100 Ibs increase in gross weight will increase

autorotative rpm by 10.
(d) 100 Ibs dec rea se in gross weight will decrease

autorotative rpm by 1O.
MM-12-42
MAINTENANCE MANUAL
(4) Adjust rotor rpm.
(a) Disconnect pitch linkrod ends at the walking beams on all

three blades.
(b) Rotate only the disconnected rod ends one full- turn
(360 degrees).
NOTE: One 360degree turn of the rod ends, shortening the

pitch links, will decrease autorotative rpm by 10.
One turn of the barrel 20 RPM.
(c) Connect pitch links to walking beams and safety.
(d) Secure jam nuts.
(5) Flight check for performance (steps 1 through 4 as necessary).
12-10 CYCLIC TRIM SPRINGS RIGGING PROCEDURE
A. Lateral Bias Spring Installation (See Figure 12-18)
NOTE: The lateral bias spring is located on the left side of the
seat structure.
(1) Attach spring (1) to bracket (2) and to the third hole from
forward end of bracket (3).
(2) Flight check helicopter to see if desired lateral trim forces

can be obtained.
B. Lateral Adjustment (See Figure 12-18)
(1) Maximum left lateral trim is obtained by moving spring outboard

on bracket (3).
(2) Maximum right lateral trim is obtained by moving spring inboard

on bracket (3).
C. Spring Installation (See Figure 12-19)
NOTE: The longitudinal bias spring is located on the right side

of seat structure.
(1) Attach spring (1) to bracket (2) and to the fourth hole from top
of bracket (3).
(2) Flight check helicopter to see if desired 1 ongi tudi nal trim
forces can be obtained.
o. Longitudinal RdJurtment (See Figure 12-19)
(1) Moving spring down on bracket (3) will provide maximum forward
trim force.
#2 Rev. 11/18/88 MM-12-43

MAINTENANCE MANUAL
Fig. 12-18 LATERAL BIAS SPRING

INSTALLATION
\----_ (O
Fig. 12-19 LONGITUDINAL BIAS

SPRING INSTALLATION
MM-12-44
MAINTENANCE ~MANUAL
(2) Moving spring upward on bracket (3) will provide maximum aft
trim force.
NOTE: Should locating the spring in the top hole of

bracket (3) provide insufficient aft spring force, the
bracket may be moved aft to the second notch and the
choice of hole location repeated.
12-11 SWASHPLATE ASSEMBLY
A. Troubleshooting Lower Swashplate Assembly
(1) To check for possible wear in the lower swashplate, proceed as

follows:
(a) Rotate a main rotor blade to the 97 degree position. See

Figure 12-17.
(b) Move the cyclic stick fore and aft, just working the free
play of the system.
(c) Observe the axis of the swashplate from the right side of
the aircraft. Any free play or movement will indicate the
swashplate needs rebuilding.
(d) Rotate the rotor to the next97 degree position, to check

the other swashplate axis.
NOTE: If either axis shows any play, the swashplate

should be removed and rebuilt.
(2) To check for possible binding in lower swashplate, proceed as

follows:
(a) Disconnect the upper walking beams at the push-rods and

center pivot point.
(b) Disconnect both cyclic push-rods from the firewall at the

lower swashplate.
(c) By hand, cycle the swashplate, one axis then the other,
noting any binding.
NOTE: Swashplate should have equal preload in both axes

with end play.
no If one axis is tighter than the
other, the swashplate should be removed and
re-shimmed to equal preload.
NOTE: See Section 12-1, Troubleshooting the Articulated

Rotor System, for other problems in this area.
MM-12-45
MAINTENANCE MANUAL
B. Troubleshooting Upper Swashplate Assembly
NOTE: If a lower swashplate has been operating in a worn condi-

tion, it may have caused the upper swashplate to wear also.
(1) Upon removal of the lower swashplate, check the upper swashplate
as follows:
(a) Check unibail in dogl~egs for looseness or binding.
NOTE: Uniball preload should be equal in all three

doglegs.
(b) Check security of doglegs to push-pull rods.
(c) Exert fore and aft force on lower bell housing of upper
swashplate to check for DU bushing wear.
NOTE: Upper swashplate should be removed and rebuilt if

DU bushings have excess of .010 play.
(d) Check upper collective bearing by disconnecting yoke and

rotating bearing to check for roughness.
C. Lower Swashplate Removal (See Figure 12-20)
(1) Remove both side panel cowls.
(2) Drain fuel tanks.
(3) Disconnect fuel lines and remove left side fuel tank.
(4) Disconnect the longitudinal cyclic rod (2) from lower bearing
housing (1) by removing bolt (3), washers (4) and (5),
spacer (6) and nut (7).
(5) Disconnect the lateral cy~lic rod (11) from bearing housing (1)
by removing bolt (8), washers (9), and nut (10).
(6) Disconnect rod ends (15) in three places from the lower
swashplate housing (17) by removing bolts (16), spacers (14),
washers (13) and nuts (12).
(7) Cut safety wire and remove screws (18) and washers (19) in six
places.
(8) Pull downwa rd on lower bearing housing (1) to remove 1 ower

swashplate assembly.
D. Upper Swashplate Removal (See Figure 12-21)
(1) Remove the screws and fiberglass cover over the collective
push-pull rod located above the seat deck in the cabin.
MM-12-46
19
18
12
14 16
15
B~B 17
~iiel
LATERAC
i I
I ROD b
H
N
7,
a: 8
9 z
b
z
c
U‘ e‘
6
Fig. 12-20 LOWER SWASHPLATE

REMOVAL AND INSTALLATION
MAINTENAN~E MANUAL
14
15
O
\9
R 2 17
15 10
13
16
Fig. 12-21A
CYCLIC W~LKING BEAi´•I A´•SSEMBLY
6
4
-I
19
5
18
-a;s8
Fig. 12-21B UPPER SWASHPLATE REMOVAL
AND INSTALLATION
MM-12-48
MAINTENANCE MANUAL
(2) bolt (1) connecting push-pull (2) and walking

beam (5).Remov rod
(3) Remove bolts (3) from pivot straps (4) and pull straps off
studs.
(4) Cut safety wire and remove bolts (6) from upper bearing housing.
Pull walking beam (5) outward to remove frombearing housing.
(5) Remove the cotter pins from lower end of push-pull rods (9).
NOTE: Index mark each dogleg (8) to its respective push-pull

rod (9) before disassembly. Doglegs have tapered bores
which are matched to push-pull rods.
(6) Remove castle nuts (7) from push-pull rods (9).
(7) Install puller tool T-0045 over dogleg (8) with center of
tool aligned with push-pull rod (9), and remove doglegs
(8) Disconnect upper end of push-pull rods (9) at the main rotor hub
by removingbolt (11), washer (12) and nut (13) from walking
beam (10).
(9)_ Remove bolt (14), washers (15) and nut (16) from walking beam
bracket (17). Lift walking beam out of bracket and separate
from push-pull rod.
NOTE: Secure spacers in push-pull rod and walking beam with a
piece of safety wire on disassembly and removal.
(10) Remove push-pull rods (9) through upper end of mast.
(11) Remove bolts (18) and washers (19) connecting swashplate to

gearbox (3 places).
(12) Slide bell of upper swashplate up and down to tap swashplate

assembly from lower end of mast.
E. Lower Swashplate Disassembly (See Figure 12-22)
(1) Install tool T-O016 inend of tie rod (19). Place wrench on end
of tool to hold tie rod from rotating and remove cotter pin,
nut (1), spacer (12), DU washer (13), and shims (20).
(2) Using an aluminum drift, top tie rod (19) out of bushings,
separating housing (18) from housing (8).
(3) Remove shims (20) and DU washer (13) from tie rod (19).
(4) Temporarily install tie rod (19) in shaft (16) to keep it from
rotating. Remove cotter pins, nuts (11), spacers (12), DU
washers (13) and shims (20) from both ends of shaft (16).
MM-12-49
MAINTENANCE MANUAL
14
Is
s~t,,
IO~b
12
14\13
20
O 15
8
~j5
~o
3\20
~s
OPEN SIDE OF
BEARING UP
e~2
g
Fig. 12-22 LOWER SWASHPLATE DISASSEMBLY
AND ASSEMBLY
~lM-12-50
MAINTENANCE MANUAL
(5) Using an aluminum drift, tap end of shaft (16) to remove shaft
and sleeve (15) from housing (8).
(6) Tap opposite sleeve (15) to remove from housing (8).
(7) With aluminum drift, tap sleeves (15) to remove from

housing (18).
(8) Holding shaft (1) with a wrench, remove cotter pin, nut (1) and
washer (9). Pull shaft and bearing assembly from housing (8).
(9) Press shaft (1) from bearing (3) and remove slinger (7) and
spacer (6).
(10) Remove snap ring (2) and grease fitting (5) from housing (4).
(11) Heat housing (4) to approximately 250" and press bearing (3)
from housing (4).
(12) Press 00 bushings (14) from sleeves (15).

F. Lower Swashplate Inspection
See Inspection Tables on following pages.
G. Lower Swashplate Assemble (See Figure 12-22)
(1) Remove seal from one side of bearing (3).
(2) Heat bearing housing (4) to approximately 250" and install

bearing (3) with open side of bearing up as installed in
helicopter.
(3) Install snap ring (2) and grease fitting (5) in housing (4).
(4) Support inner race of bearing (3) and press shaft (1) into
bearing with head of shaft on snap ring side.
(5) Install spacer (6) with narrow side of spacer against inner race
of bearing.
(6) Install slinger (7) on shaft (1).
(7) Apply lubrication to shaft (1) and insert in housing (8).

Install washer (9) and nut (10. Torque nut and install cotter
pin.
(8) Press DU bushings (14) in sleeves (15) using tool T-0105 (4

places).
(9) Apply lubrication to O.D. of sleeves (15) and bores of ears on
housing (8).
MM-12-51
MAINTENANCE MANUAL
INSPECTION TABLE LOWER SWASHPLATE ASSEMBLY

28-16123-1 Fig 12-22 Shaft Bearing diameter -.0002 Not repairable Replace shaft
Item 1 .4726
diam
.47’23
Threads no None allowed Not repairable Replace shaft

crossed or
missing threads.
1.2598
SZO1SBKZZ Fig12-22 Bearing 00 diam None allowed Non repairable Replace bearing
r~
Item 3
.4724
ID diam None allowed Not repairable Replace bearing
~KZ
No ratchety Replace bearing

feeling
28-16361-1 Fig 12-22 Housing Bearing bore +.0002 Not repairable Replace bearing
Item 4 1.2604
diam
1.-~598
Bolt holes in None allowed Not repairable Replace housing

pivot ears
check for
elongation
Cracks None allowed Not repairable Replace housing
28-16228-1 Fig 12-22 Spacer Check for nicks None allowed .003 deep Polish to remove
Item 6 or galling on ID
MM-12-52
MAINTENANCE MANUAL

28-16387-1 Fig 12-22 Slinger Check for bends .005 Not repairable Replace slinger
Item 7 in outer edge
28-16119-1 Fig 12-22 Housing Bushing bores +.0002 Not repairable Replace housing
Item 8 .7500
diam
.75(75
Center bolt bore +.0003 Not repairable Replace housing

.4375 diam (no
galling in this
bore)
Bolt holes in
pivot ears
.375
diam on one +.0005 Not repairable Replace housing
.3f6
side
.250
diam
.251
opposite side
Cracks in None allowed Not repairable Replace housing

casting
28-16227-1 Fig 12-22 Spacer Nicks gouges None allowed Not repairable Replace spacer
Item 12
MM-12-53
MAINTENANCE MANUAL

28-16263-1 Fig 12-22 DU washer Replace when

Item 13 Teflon DU surface
is through to
bare metal
28-16102-4 Fig 12-22 DU bushing Replace when

Item 14 Teflon DU surface
wears through to
bare metal
.7508
28-16226-1 FI912-22 Sleeve 00 diam -.0001 Not repairable Replace sleeve
Item 16
.5937
ID
T591fT
diam +.0002 Not repairable Replace sleeve
.5000
28-16223-1 Fig12-22 Shaft 00 d’am -.0002 Not repairable Replace shaft
Item 16
Concentricity None allowed Not repairable Repace shaft

.0015 TIR
Threads no None allowed Not repairable Replace shaft

crossed or
missing threads
.5000
28-16225-1 Fig 12-22 Spacer 00
TV4V~
diam -.0002 Not repairable Replace spacer
Item 17
MM-12-54
MAINTENANCE MANUAL

28-16116-1 Fig 12-22 Housing Bushing bores +.0002 Not repairable Replace housing
Item 18 .7500
diam
.7505
Cracks in casting None allowed Not repairable Replace housing
.3750
28-16224-1 Fig 12-22 Tie Rod OD diam +.0002 Not repairable Replace housing
Item 19
Threads no None allowed Not repairable Replace tie rod

crossed or
missing threads
Concentricity None allowed Not repairable Replace tie rod

.0015 TIR
MM-12-55
MAINTENANCE MANUAL
(10) Using tool T-0100, tap one sleeve (15) into housing (8).
(11) Install shaft (16) into sleeve through open ear of housing (8).
Place opposite sleeve (15) on shaft (16) and tap into housing
with tool T-0101. Shaft should rotate freely at this point.
(12) To shim shaft (16), proceed as follows:
NOTE: Ideal shimming of the assembly is to have equal amount

of shims on each end of shafts; however, a .005 maximum
difference in shims is allowed from end to end to
obtain proper prelioad.
(a) Place a mark on one ear of housing (8) and install a .020
shim (20) on same end of shaft (16). Mark indicates
.020 shim end.
(b) Install teflon side of DU washer (13) inboard against

shim (20).
(c) Install spacer (12) with chamfer outboard.
(d) Insert tie rod (19) in shaft (16) to hold shaft from
rotating and install nut (11). Torque nut to align with
cotter pin hole.
(e) Ins ta 11 .020 shim (20), DU washer (13), spacer (12), and
nut (11) on opposite end of shaft.
(f) Torque nut (11) aligning cotter pin hole.
(g) Tap each end of shaft (16) to seat stack up with an

aluminum drift.
NOTE: Shaft should rotate by hand with a slight drag. If

end play is noticed in shaft, remove shims. If
shaft is excessively tight, add shims. It is very
important to keep shims within .005 difference end
to end.
(13) When shimming is correct, install cotter pins in nuts 11).
(14) Apply lubrication to O.D. of sleeves (15) and I.D. of

housing (18). Install sleeves in housing using tool T-01OO.
(15) Install spacers (17) into sleeves (15).
(16) Ins ta 11 DU washer (13) on tie rod (19) with teflon side of
washer facing inboard.
(17) Install a .020 shim (20) on tie rod (19).
(18) Insert tie rod (19) partially into spacer (17) with head of tie
rod located through clearance hole of housing (18).
MM-12-56
MAINTENANCE MANUAL
(19) Place upper housing (18) over lower housing (8), aligning
clearance holes in upper housing to outer ears of lower housing.
(20) Push tie rod (19) through shaft (16) and opposite spacer (17).
(21) Install a .020 shim (20), DU washer (13), spacer (12) and
nut (11).
(22) Hold end of tie rod (19) with tool T-0O16, torque nut and align
cotter pin hole.
(23) Tap each end of tie rod (19) with an aluminum drift to seat
stack up.
(24) Rotate housings in both directions to check end play and drag.
NOTE: Equal pressure is required to move lower housing in

either direction. Add or subtract shims from tie
rod (19) to equalize movement of shaft (16). It is
important to keep shims within .005 difference end to
end. Tapping both ends of shaft with an aluminum drift
is required each time shims are changed.
(25) Upon comp letion of equal movement, install cotter pins in

nut (11).
H. Upper Swashplate Disassembly (Figure 12-23)
(1) Install aluminum blocks (tool T-1758) on each side of bearing

housing (15) and clamp blocks in a vise with nuts (1) facing up
for removal.
(2) Bend locking tab (2) back to a flat position and remove nuts (1)
with special socket tool T-0086. Remove locking tab.
(3) Place swashplate assembly in arbor press using blocks T-1758 for
support and positioned with housing (3) up.
(4) Position plug tools T-01O2 three places in threaded end of

retainer and guide tube assembly (16) and press swashplate
assembly apart.
(5) If DU bearings (14) are worn, press to remove from bearing

housing (15).
(6) Press spacer (13) from bearing housing assembly and remove rain
slinger (12).
(7) Cut safety wire and remove screws (4), washers (5), bearing
retainer (6), spacer (7) and shims (8).
(8) Heat bearing housing (10) to approximately 2500 and press

bearing (9) from housing.
MM-12-57
MAINTENANCE MANUAL
8 1´•
15
13
12
6~ 1 I
10
OPEN SIDE OF 9
BEARING UP
8\ /d
a ~A6
0 ~4
O CS
Fig. 12-23 UPPER SWASHPLATE o

ASSEMBLY AND
DISASSEMBLY
MM-12;58
MAINTENANCE MANUAL
I. Inspection (Upper Swashplate)
See detailed forms on following pages.
J. Upper Swashplate Assembly (See Figure 12-23)
(1) If installing a new bearing, remove seal from one side of

bearing (9).
(2) Heat bearing housing (10) to approximately 2500.
(3) Apply a lubricant (STP or equivalent) to 0.0. of bearing and

I.D. of
housing. INstall bearing in housing with open side of
bearing facing up as installed in helicopter. Allow to cool.
NOTE: Bearing must be seated against inboard fiange.
(4) To calculate the shims (8) required to preload bearing into

housing, proceed as follows:
(a) Use depth micrometer to

a measure distance from face of
bearing to face of housing.
(b) Subtract .003 inch from measurement in step (a) to equal

the shims required.
NOTE: available in thicknesses of .002, .003 and

Shims.005 inch.are
(5) Place shims (8) and shield retainer (7) on face of housing (10).
(6) Install bearing retainer (6) in place and secure with

washers (5) and screws (4). Torque screws in alternating
sequence and safety wire in pairs with .025 safety wire.
(7) Install tool T-17O9 on inner race of bearing (9) (sealed side).
Place slinger (12) over open face of bearing and press
spacer (13) into position, securing slinger in place.
(8) Clean gu~de tube bores of bearing housing (15) and O.D. of DU
bushings (14) with loctite primer.
(9) Apply type A loctite to O.D. of DU bushings and press bushings

into bearing housing (15).
NOTE: Press DU bushings in housing until they are flush with

face of bearing housing. Rotate assembly and repeat on
opposite end.
(10) Install bearing housing (15) on retainer and guide assembly (16)
with large flange of housing facing toward threaded end of guide
tube.
MM-12-59
MAINTENANCE MANUAL
INSPECTION TABLE UPPER SWASHPLATE ASSEMBLY

28-16113-1 Fig 12-23 Nut Threads no None allowed Not repairable Replace nut
Item 1 crossed or
missing threads
Hex corners no None allowed Not repairable Replace nut

rounded or
smashed corners
28-16126-1 Fig 12-23 Locking Replace on

Item 2 Plate re-assembly
28-16112-1 Fi-g12-23 Mou´•sing Threads no None allowed Not repairable Replace housing
Item 3 crossed or
missing threads
Nicks gouges .005 deep .025 deep Polish blend to

remove. Brush on
iridite finish
Guide tube holes +.0003 Not repairable Replace housing

.9062-.9069 diam
28-16110-1 Fig 12-23 Bearing Nicks scratches .005 deep .010 deep Polish blend to
Item 6 Retainer remove
+.0000
Z993L13X38 Fig 12-23 Bearing 00 3.9370 None allowed Not repairable Replace bearing
-.0004
Item 9
+.0000
ID 2.5591 NO"e allowed Not repairable Replace bearing
-.0004
MM-12-60
MAINTENANCE MANUAL

Z993L13X3B CONTINUED Bearing Condition of No pits or flat Not repairable Replace bearing
balls cage spots allowed
check after
c~eaning
28-16108-2 Fig 12-23 Bearing Pivot bolt holes None allowed Not repairable Replace housing
Item 10 Housing for galling or
wear
Threads no Noneallowed Not repairable Replace housing

crossed or
missing threads
Bore 3.9371 None allowed Not repairable Replace housing

3.9365 diam
28-16386-1 Fig 12-23 Rain Check for None allowed Not repairable Replace slinger
Item 12 Slinger deformation
28-16106-1 Fig 12-23 Spacer Check guide tube .002 deep .008 deep Polish blend to
Item 13 holes for galling remove
16-DU-12 Fig 12-23 Bushing OD 1.125 -.0005 Not repairable Replace bushing
Item 14
ID 1.00 diam +.0005 Not repairable Replace bushing
MM-12-61
MAINTENANCE MANUAL

1.1250
28-16103-1 Fig 12-23 Bearing Hole diam +.0004 Not repairable Replace housing
Item 15 Housing
OD 2.6470 -.0003 Not repairable Replace housing

2.6465 diam
Galling OD .001 deep .005 deep Polish to remove
Cracks None allowed Not repairable Replace housing
28-16260-1 Fig 12-23 Retainer Check for worn None allowed If rivet is Replace rivet
Item 16 Guide or sheared sheared with no
Shafts ri vets o-the;r damage to
Assembly assembly
Threads no None allowed Damaged Replace guide shaft

crossed or threads in retainer
missing threads
Check for loose- None allowed Not repairable Replace assembly

ness of guide
shaft in retainer
Galling of guide .001 deep .005 deep Polish blend to

shafts not exceeding remove
1" in length
Cracks in None allowed Not repairable Replace assembly

retainer
MM-12-62
MAINTENANCE MANUAL
(11) Place retainer and guide assembl in arbor press with threaded
end up. Lubricate guide tubes 16) and holes in spacer (13)
with STP or equivalent lubrication.
(12) Press bearing housing assembly (10) on guide tubes with

slinger (12) facing housing (15).
(13) Lubricate holes in bell housing (3) and press onto guide tubes.
Be sure housing is seated into bearing (9).
NOTE: Slide housing (15) up and down on guide tubes. If

housing is excessively tight or binding, mark the
positions of bell housing (3), spacer (13) and
housing (15) to guide tubes (16). Press assembly
apart, rotate items (3), (13), and (15) 120 degrees on
guide tubes and re-assemble. Re-check to be sure
housing (15) slides with no interference.
(14) Clean threads of guide tubes and threads of nuts (1) with
loctite primer.
(15) Install aluminum blocks (Tool T-1758) on bearing housing (15)

and clamp in vise with bell housing (3) up.
(16) Install lock tab (2) on guide tubes.
(17) Apply Vibr-Tite to threads of nuts (1) and install on guide

tubes. Torque nuts to 20 ft Ibs (3 places).
K. Upper Swashplate and Guidetube Installation (See Figure 12-21)
(1) Apply lubriplate to bottom bore of main rotor mast.
(2) Align slot in upper swashplate housing with locking pin in lower
end of mast and install swashplate into position.
NOTE: By sliding upper swashplate on guide tubes, gently tap

the assembly into place.
(3) Install washers (19) and bolts (18) in three places. Torque
bolts and safety with .025 safety wire.
NOTE: Rotate upper collective bearing housing with unit in

full up position to check for clearance to safety wire.
(4) Install walking beam (5) into ears of upper collective bearing
housing.
(5) Install bolts (6) through walking beam, torque and safety wire
with .032 wire.
(6) Install pivot straps (4) on gearbox and walking beam studs.
MM-12-63
MAINTENANCE MANUAL
(7) Install hardware (3), torque nuts and install cotter pins.
(8) Install push-pull rod (2) into walking beam (5) and connect with
hardware (1).
(9) Insert stainless steel spacers in push-pull rods (9) and center
pivot of walking beam (10).
(10) rods (9) into mast and connect to walking

beams (1Instal di""w"-pul~
with bolts (11), washers (12) and nuts (13). Torque
nut to 40 in Ibs. Install cotter pin.
(11) Connect walking beams (10) to mount brackets (17) with

bolts (14), washers (15), and nuts (16). Torque nuts to
40 in Ibs. Install cotter pin.
(12) To install doglegs (8), proceed as follows: (See Figures 12-21

and 12-24)
(a) Position dogleg (8) on push-pull rod (9) and install

nut (7) finger-tight.
NOTE: Doglegs must be re-installed to the respective

push-pull rods they were removed from.
(b) Position special tool T-0O54 on bell housing of upper

swashplate assembly while aligning dogleg parallel to its
respective walking beam on main rotor hub. Install screws
to hold tool in place. Place spacer on each side of swivel
ball in dogleg and install bolt to position dogleg on tool.
See Figure 12-24.
(c) Torque nut (7) to 140 in Ibs and install cotter pin.
(d) Repeat steps (1) through (c) on each dogleg.
L. Lower Swashplate Installation (See Figure 12-20)
(1) Install lower swashplate with attachment ears aligned to

doglegs (15).
(2) Secure in place with washers (19) and screws (18). Torque and
safety screws in pairs with .032 safety wire.
(3) swashplate housing using bolts (16)

q14).(15)
Secure to lower
dnaelgod
spacers
s
NOTE: Spacers (14) are installed with chamfer inboard toward

bearing in dogleg.
(4) Install washers (13) and nuts (12) on bolts (16). Torque nuts
and install cotter pins (3;places).
(5) Installspacer (6) in long:itudinal push-pull rod (2).
MM-12;64
MAINTENANCE MANUAL
"*-:’lt
Fig. 12-24
TOOL T-0054
FOR COG LM; INSTF~TION
ORIGINAL
As Received Bbr
ATP
MAINTENANCE MANUAL
(6) With washers (5) on each side of spacer (6), insert push-pull
rod into lower bearing housing (1).
i7j Install bolt (3), washers (4) and nut (7) to secure rod in
place. Torque nut and install cotter pin.
(8) Connect lateral push-pull rod(11) to housing (1) using

bolt (8), washers (9) add nut (10). Torque nut and install
cotter pin.
(9! Rotate cyclic stick to check for binding in the system. Check
all connections for security.
(10) Install fuel tank and connect fuel lines. Install fuel and
check for leaks.
(11) Replace side panel cowls.
12-12 FLIGHT TEST PROCEDURE
A. Preliminary Checks
NOTE: Whenever a helicopter has had work accomplished to the

flight controls, it is recommended that a flight test be
conducted before returning the helicopter to service.
(1) Perform a preflight inspection. See Section 3-2, Inspections.
(2) Perform a Verification of Rigging, see Section 12-8.
(3) Perform normal start and runup checks to 2300 rpm.
B. Flat Pitch Test (low rpm checks)
NOTE: The following test is used to check rigging of the flight

controls.
(1) Adjust engine rpm to 2300 with rotor engaged.
WARN ING: Clear all persons from tip path plane area as blades may
dip as low as 5 feet during this test.
(2) Displace cyclic fore, aft, and laterally while visually inspect-
ing for proper tip path plane reactions. Center cyclic stick
after test.
(3) Displace cyclic laterally to the left until a slight mast

bumping is felt through the airframe. Look down at the static
cyclic stop ring in the floor on pilot’s side and note the
distance between the ring and the cyclic stick. Repeat this
procedure for right lateral, fore, and aft. All four positions
should have approximately the same distance from stop ring,
indicating proper rigging of push-pull tubes. Center cyclic
after this procedure.
MM-12-66
MAINTENANCE MANUAL
(4) Trim cyclic stick to neutral position and release cyclic grip.
Visually watch cyclic stick for motion. Cyclic should remain
centered and still. Move cyclic fore and aft without trimming
and check smoothness. No hard vibrations should be present.
NOTE: If hard vibrations are present or the cyclic wanders,

either the aircraft will have to be tracked or a
problem exists in the main rotor control system.
(5) Displace the left tail rotor pedal approximately 2 inches.

Observe engine tach for a drop in rpm indicating proper rigging.
Return pedals to neutral position after performing this
procedure.
CAUTION: If aircraft is on a slippery surface it may turn during

this test.
(6) Retard throttle to idle position and check for disengagement of

sprag clutch by observing tachometer needle split.
(7) Smoothly rejoin tach needles and set engine rpm at 3050.
Perform normal runup procedures.
(8) Check throttle for false limit at 3050 rpm. No stop should be
contacted prior to 3050 rpm.
(9) Check that engine has 19 inches of manifold pressure at

3050 rpm.
NOTE: 19 inches of manifold pressure indicates that adequate

autorotational rpm will be available in later tests.
C. Hover Test
(1) With engaged and engine at 3050 rpm, release the collec-
rotor
tive friction and slowly increase collective pitch. While
making minor adjustments to controls, watch for proper response
as aircraft becomes light on the skids.
NOTE: If rocking or bouncing occurs at this point the

aircraft may need tracking, oleo, or damper work
performed.
(2) Bring aircraft to a hover with cyclic stick centered laterally

and slightly forward of center in static stop ring.
NOTE: This test should be performed in low wind conditions.

If winds arein excess of 10 mph the cyclic will be
displaced in that direction. If aircraft has rough
ride see tracking procedures for hover track
(Section 12-2 or 12-3).
MM-12-67
MAINTENANCE MANUAL
(3) Pedal position in a hover should be d" to 1" right pedai.
NOTE: Improper pedal position requ i re s ta i 1 rotor rigging

check at this point. Collective should be in normal
position and throttle must not be against false stop or
into override.
(4) Stabilize aircraft at a hover and check the following:
(a) Change collective setting up and down approximately one

inch and note collect,ive spring loadings. If collective has
equal forces in both directions, release throttle to check
for override contact.
NOTE: Throttle and collective should remain in position

without friction.
(b) Adjust cyclic trim to full left and full aft. The cyclic
should have slight right force (approximately 2 Ibs) with
pilot and passenger and "0" forces fore and aft. Record
discrepancies in control forces and make adjustments for
throttle, cyclic position, and collective position.
NOTE: Do notadjust for minor trim conditions until

necessary adjustments for autorotation, V and
cruise procedures have been completed are
discussed later in this test procedure.
(5) For left pedal and collective rigging low rpm check, proceed as
follows:
(a) Stabilize aircraft at 1 foot hover and normal operating

range with heading into the wind.
(b) Slowly reduce engine rpm while maintaining one foot hover.
As aircraft reaches 220 rotor rpm, sufficient left pedal
should be available to maintain heading into the wind.
(c) Continue to decrease engine rpm until aircraft contacts the

ground. The collective up stop should not be contacted
until touchdown. This indicates proper collective rigging
to upper control armf.
(6) For right pedal rigging check proceed as follows:
(a) Hover aircraft at on~ foot heading into wind.
(b) Perform hovering autorotation while maintaining one foot

altitude.
(c) As the rotor passes through 220 rpm, the aircraft will
settle to the ground,
NOTE: Collective should not contact the up stop prior to

ground contact.
MM-12;68
MAINTENANCE MANUAL
(d) Sufficient right pedal ‘should be available until firmly on

the ground.
NOTE: If above conditions cannot be met, check rigging of

appropriate items.
(7) 20 mph hover checks proceed as follows:
(a) Position aircraft over a flat smooth area.
(b) Hover aircraft at 20 mph airspeed and normal operating rpm

(3050 rpm). Check in both directions l~aterally, forward
and rea rwa rd. No stops should be contacted during this
phase.
(c) If no stops are contacted, repeat procedure at minimum rpm

(2900 rpm).
D. Cruise Flight Test 75% Power
(1) Perform normal takeoff and level off at 1000’ AGL and set
altimeter to 29.92. Record pressure altitude, temperature and
gross weight information.
(2) Set engine rpm at 3050 and 29" manifold pressure with steady
heading approximately 90-95 mph.
NOTE: Allow two minutes for aircraft to stabilize.
(3) Visually check static ring for cyclic position on pilot’s side.
Cyclic stick should be centered and slightly aft in the ring.
(4) Trim aircraft to neutral forces. Release cyclic to ensure
adequate trim is available.
(5) -Change collective setting to check spring forcesof collective

bungee. Record if other than "0" forces.
(6) Release collective to check that throttle holds position.
E. Autorotation Checks at 58 MPH
(1) Climb to 1500 ft AGL. Set up autorotational landing to suitable

area.
CAUTION: Enter autorotation by lowering collective while main-

taining engine rpm. DO NOT exceed maximum rotor rpm.
Split tach needles to ensure adequate rotor rpm for
autorotation.
(2) Enter straight into autorotation and adjust airspeed to 58 mph.
MM-12-69
MAINTENANCE MANUAL
(3) At 58 mph in stabilize autorotation depress right pedal

smoothly to pedal stop. Sufficient pedal should be available to
yaw the aircraft to a minimum of 25" to the right of course.
(4) Re-establish autorotational glide at 58 mph and full down

collective.
CAUTION: DO NOT exceed maximum rotor RPM.
(5) Record temperature, pressure altitude, gross weight information,

and autorotation rpm.
(6) As aircraft approaches 100ftAGL, power recover by bri_nging

engine rpm to low green. Rejoin tach needles by pulling
collective pitch and adjust throttle as necessary while
establishing climb.
CAUTION: Land aircraft and make adjustments to unsafe conditions

before continuing tests.
F. and Checks
Vh Vn,
(1) Fly aircraft to 1000 feet AGL. Record pressure altitude,
temperature, and gross weight information.
(2) Adjust engine rpm to 30510 with 39" manifold pressure in level
flight.
(3) Allow two minutes for aircraft to stabilize. Record airspeed.
CAUTION: Do exceed Speed envelope

not
Vne or maximum manifold
pressure during this test.
(4) Visually inspect cyclic position in static stop ring. Cyclic

should be centered later~lly with a minimum of clearance to
aft portion of static stop ring.
(5) Trim aircraft and check for zero forces fore and aft. Check for
zero lateral forces at 110 mph by momentarily releasing grip
after trimming. Aircraft should maintain level flight.
(6) Adjust engine rpm and repeat step (4) above.
(7) Record discrepancies, land and make corrections.
G. Flight Check Lateral Trim
NOTE: Flight check with a pilot and passenger, approximately

360 Ibs.
(1) Hover Cyclic should have approximately 2 Ibs left

force (pressure to the right) with full lateral trim.
MM-12-70
MAINTENANCE MANUAL
NOTE: If aircraft is adjusted to obtain full lateral trim in

a hover, it will not be able to obtain full lateral
trim in forward flight.
(2) Forward Flight Flying to 110 mph and trimmed laterally, the
aircraft should fly straight and level with full trim (no yaw to
left or right).
Lateral Cyclic Positions:
(3) Hover (no wind) Cyclic stick bellcrank should be centered in

cyclic stop ring in floor.
(4) Forward
centered
flight
(same
at
as
75%
hover d~’;l
po~:t ushould
bellcrank bbe~ 9
slightly aft in
stop ring.
(5) Forward Flight at V Sea level conditions (112 mph), low

rotor rpm 332. Cleciic stick bellcrank should be centered
laterally and have approximately clearance from aft portion
of stop ring.
MM-12-71
SECTION
POVVER AND
AS S O C IAT E D
SYSTEMS
MAINTENANCE MANUAL
SECTION 13
POWERPLANT AND ASSOCIATED SYSTEMS
13-1 POWERPLANT
The "F" model helicopter utilizes a Lycoming air-cooled

Enstrom
horizontally opposed four-cylinder direct drive engine, model
HIO-360-F1AD. The engine is turbocharged by Enstrom giving it
the power capability of maintaining 225 HP up to a 12,000 foot
density altitude.
The is mounted in the center airframe pylon by a dynafocal

engine
mount system attached to the rear engine case facing forward in
the helicopter. The turbocharger is mounted to a tubular frame
that is attached to the rear engine crankcase and accessory
housing and is easily removable. Easy access to the engine is
provided by two large hinged panels, one.on either side of the
helicopter and another removable panel, located in the cabin
firewall, for access to the rear engine accessory section.
B. Operating Specifications
Powerplant Limitatianz
Engine Lycoming model HI0-360-F1AD

with Rajay model #BT5EE10J2
turbocharger
~uel 100/130 minimum grade
Oil viscosity 50 hour break-in period

MIL-L-6082B
Averaae ambient temDerature SAE Grade

ovegD"F 60
Above 60"F 50
30"F to 900F 40
O" to 700F 30
Below 100~ 20
After break-in period

MIL-L-22851 Ashless Dispersant
Averaee ambient temDerature SAE Grade

temperatures. 15W50 or 211~50
Above 80" 60
Above 60"F 40 or 50
30"F´•to 90"F 40
O"F to 700F 40, 30 or
20W40
Below 100F 30 or 20W30
MM-13-1
MAINTENANCE MANUAL
Horsepower 225 HP at 3050 rpm,

39.0 in. Hg manifold pressure
Operating rpm 3050 maximum

2900 minimum
Idle rpm 1500 minimum (clutch disengaged)
Manifold pressure 39.0 in. Hg,

sea level to 12,000 ft density altitude
EGT 1650"F maximum
Oil temperature 245"F maximum
Oil pressure Normal 50 to 95 psi

Idling 25 psi minimum
Starting warmup 115 psi
Main rotor gearbox 225"F maximum
Cylinder head temp. 500"F maximum
Fuel mixture Engine may be leaned at 75% power or
below to 1600"F on rich side of peak.

NEVER exceed 1650"F EGT. Mixture must
be full rich for landing and takeoff
regardless of power for proper engine
cooling
Rotor Flight Limitations (Power Off)
Maximum 385 rpm
Minimum 332 rpm
Instrument Markings
Rotor tachometer red line 385 rpm

red line 332 rpm
green are 332-385 rpm
Engine tachometer red line 3050 rpm

red line 2900 rpm
green are 2900-3050 rpm
Airspeed indicator red line 112 mph (F-28F)

117 mph (280F)
117 mph (280FX)
Manifold pressure red line 39.0 in. Hg
Engine oil temp. red line 245"F

green are 120-245"F
yellow are 60-1200F
MM-13-2
MAINTENANCE MANUAL
Oil pressure red line 100 psi

red line 25 psi
green are 60-100 psi
yellow are 25-60 psi
EGT red line 1650"F
Cylinder head temp. red line 500"F’

green are 200-500"F
Transmission oil temp. red line 225"F

green are 0-225"F
13-2 ENGINE
A. Engine Turbocharger Troubleshooting
Experience has proven that the best method of troubleshooting is

to analyze all symptoms of the problem and carefully eliminate
any systems that are not contributing to it. The following
troubleshooting chart has been prepared to help the maintenance
personnel pinpoint the problem areas by focusing on specific
engine operating symptoms. In the following charts these are
depicted by the major headings followed by the most probable
cause and remedy.
NOTE: The remedies and/or actions in the following charts are

in an abbreviated form. For full description of any of
the problems turn to the specific paragraph in the
following sections of the Powerplant Section.
Problem Cause Action
Failure of engine Dead battery, starter Self explanatory.

to crank over, relay defective,
defective starter or
corroded terminals on
ground or battery leads.
Failure of engine Lack of fuel to engine. Check main fuel valve

to start. "ON", fuel level,
boost pump pressure,
filters and mixture
setting.
Static air nozzle Clean valveor replace.

vent valve stuck
closed. May be
accompanied by induc-
tion tube sump valve
´•backfire.
MM-13-3
MAINTENANCE MANUAL
Probl em Cause Action
Failure of engine Shower of sparks Check for low voltage to

to start, inoperative, no buzz circuit during
(CONTINUED) from vibrator, cranking (9.5V min),
defective vibrator relay,
or corroded connections.
Sump valves stuck Clean all three sump

open accompanied valves.
by backfire or popping.
Magneto inoperative Check ignition lead for

or "P" lead grounded. spark, or breakage.
Check retard action,
and "P" lead
connections.
Engine kicks back. Check shower of sparks

vibrator relay
operation, check retard
timing and breaker
action, magneto timing,
damaged distributor cap
or shorting internally.
Failure of engine Severe flooding. Review starting

to start, accom- procedure.
panied by puffing
black smoke from Excessive priming. Review starting
exhaust stack, fuel procedure.
dripping from sump
valves. Servo center body Replace servo.
seal leak.
Servo mixture valve Remove and repair

plates leaking. mixture valve plates.
Excessive fuel boost Reduce duration of

pressure. priming check fuel
boost pressure.
Failure of engine Incorrect idle mixture Correct idle mixture

to idle properly, setting, setting.
Leak in induction Check induction system

system, sump drain for leaks, check opera-
valves stuck open. tion of sump drain valves.
Incorrect idle air Adjust throttle stop to

adjustment. obtain correct idle
speed.
MM-13i4
MAINTENANCE MANUAL
Failure of nirt in air side of Carefully clean

engine to fuel nozzle. nozzles.
idle properly.
(CONTINUED) Bad or fouled spark Replace or clean as
plugs. required.
Shorting of ignition Check ignition leads.

lead.
Unable to pull full Mixture tod rich, Check fuel servo for
rated power, indicated by sluggish proper fuel output
missing, or engine operation, red exhaust metering.
twitching in mounts. flame, black soot
residue in exhaust
stack and smoky black
exhaust.
Partially clogged or Clean as required.

clogged fuel injection
nozzle or nozzles on
either fuel or air side.
Air leaks in the air Check induction system

induction system, for leaks, clean sump
sump drain valves drain valves.
stuck open.
Inadequate fuel supply, Check fuel flow,

servo mis-rigged, filters and rigging of
restricted static air controls.
nozzle in fuel system,
usually accompanied by
high temperatures,
vent valve stuck open.
Restriction in air Check ducting,

intake. condition of filter
and intake scoop.
Turbocharger waste- Check wastegate for

gate and throttle proper operation,
override not r~gging and over-
functioning properly. ride actuator ride,

internal heat
erosion.
Leak in engine exhaust Check exhaust flange

system, reducing gaskets, turbo gaskets
exhaust pressure to and couplings or
turbo system. system tube failures.
MM-13-5
MAINTENANCE MANUAL
p~ c~S´•
Unable to pull Turbo rotating Check freedom of assembly.

full rate power, assembly rubbing on Allowable shaft radial
missing, or housing, distorted play is .017 to
engine twitching housing, dirt accumu- .028 inch on bearings,
in mounts. lation on impeller, allowable shaft axial
(CONTINUED) carbon build-up, or play is .004 to .009 inch.
foreign object damage,
bearing seizure.
Engine timing is Check timing to

slightly off. required specifications.
NOTE: During magneto check if EGT has a

variance of more than 100" from R to L
magneto check timing.
High speed ignition, Check wiring harness

high tension leak or and plugs.
faulty spark plugs.
Engine will not Idle mixture´• set too Check idle mixture,
accelerate from lean, fuel pressure fuel pressure, supply
idle, too low, fuel supply and air intake
restricted, or air obstruction.
supply restricted.
Engine accelerates Idle mixture on lean Check mixture or

from idle but is side, servo too rich replace servo.
rough and erratic. or bo:dy pin

center
hang-up caus:ed by
internal mis,alignment.
Rough engine Engine mounts Check mounts, belts

operation at high deteriorated, or and torque.
power settings, improper torque.
Plugged or partially Clean fuel nozzles

plugged fuel nozzle thoroughly.
air or fuel side).
This is indicated by
higher than normal fuel
flow and slight
increase in MAP.
Misfiring of ignition Check ignition high

system, high tension tension system and
leak, fouling spark plugs.
plug.
Misfiring due to Check fuel octane

detonation, due to rating, reduce power,
excessive cylinder and increase mixture
head temperatures, setting.
MM-13-6
MAINTENANCE MANUAL
Cause Action
Low oil pressure Insufficient oil Check oil level, grade

at operating rpm, supply, improper grade of oil, increase mixture
of oil, excessive setting for high ambient
operating temperatures. temperatures.
Oil pressure relief Check oil p~´•essure

valve hung up, relief valve setting and
defective or loose, operation.
Oil leakage from Check all lines and

lines or fittings. and fittings.
Oil pump failing or Check oil pump output

sump suction screen and suction screen.
partially blocked.
High oil and Insufficient cooling Check cooling air inlet

cylinder head air to engine and for obstruction, check
temperatures. oil coolers, cylinder fins for
excessive dirt accumu-
lation, check oil cooler
inlets for dirt and debris.
Insufficient quantity Check oil level and grade.

of oil or improper
grade.
Operating at Reduce power, increase

excessively high power mixture settings.
settings exceeding
EGT limitations.
E:xcessive oil Improper grade of oil, Check grade of oil. If

consumption, turbo seals failed, turbo seals are bad, oil
engine ring and/or seepage f~om induction
valve clearance .out sump valves may occur
of limits, after parking, and this
oil may be found in
turbo assembly. This
condition is usually
indicated by excessive
exhaust smoke on start-
up and at idle.
NOTE: Oil input line check valve hang to the

turbo housing will indicate the same
problem.
MF?-13-7
MAINTENANCE MANUAL
Excessive oil On new engines or Continue to break in

consumption, rebuilt engines ring engine with recommended
(CONTINUED) may not be properly oil until oil
seated. consumption stabilizes.
NOTE: Avoid continuous operation at maximum

power settings and EGT’s during this
break-in period.
Glazed cylinder walls, Cylinders must be

caused by improper removed and reworked
engine operation during by honing.
break-in period.
Clogged engine crank- Clean vent of sludge,

case breather vent be sure small side vent
line. In cold weather in tube inside of cowl
frost can restrict line is clear and open.
this vent and cause This will allow engine
nose seal to fail to breathe properly if
or pump oil. the exposed portion
below frosts closed.
Loss of, reduction Malfunction o~ MAP Clear line and recheck.

of, fluctuation
or indicator may be the
of manifold result of debris in
pressure when the MAP reference
turbocharging. 1 i ne to engine.
Air intake restriction, Check condition of

duct collapsing or air ducting.
filter blocked or icing.
Turbo output leakage Check complete induction

through induction system for leaks or
system, loose duct, failures.

adapter or collar,
failure of intake pipe.
Partial fuel vapor Reduce power

locking due to hot
fuel altitude, or
combination of both
with high power set-
tings, may be accom-
panied by detonation.
Malfunctioning fuel Reduce power. If engine

pump or
pressure begins to detonate,
regulator, blown seal terminate operation.
or leaking primp deck
pressure line.
MM-13-8
MAINTENANCE MANUAL
Engine runs hot Ambient temperatures Reduce power to safe

during too hot. EGT levels.
turbocharging.
Over-boosting or Reduce power to proper
mixture too lean. MAP and EGT limitations.
Increase mixture setting.
Ignition timing off. Check timing to required

specification.
B. Preparation for Engine Removal for Replacement or Overhaul (See

Figure 13-1)
The engine is removed as a unit with components of engine

associated systems and engi ne accessory (alternator,
items
Starter, magnetos, wiring harness, etc.) attached to the engine.
(1) Disconnect battery.
(2) Remove segmented cowl, baggage box, side panels, 1 ower
cowling and engine compartment doors.
(3) Remove fuel tanks and drain fuel lines.
NOTE: Upon removal all line, fittings and/or openings to

engine, tanks or coolers should be plugged with
dust caps or covers to protect from contamination.
(4) Drain oil from engine, oil coolers and oil lines.
(5) Remove jack strut and fan assembly.
(6) Remove main rotor transmission.
NOTE: Utilizing some type of overhead lifting device is

recommended the easiest and safest method of
as
engine removal. If overhead lifting capability is

not available, it will not be necessary to remove
the transmission (step 6) or install lifting ring
(step 10).
(7) Disconnect fuel line from the fuel shutoff valve and detach
the doubler encircling the fuel line at the fire curtain.
(8) Remove upper engine baffling.
(9) Remove or detach fire curtain as required.
(10) Remove primary oil cooler (right side).
(11) Remove induction air box and ducting.
MM-13-9
MAINTENANCE MANUAL
(12) Disconnect exhaust gas temperature probe and remove exhaust

system and associated flexible ducting.
(13) Detach fan shroud from engine and remove mount brackets from
top and bottom of engine.
(14) Pull fan shroud and secondary oil cooler away from engine.
(15) Detach clutch cable clamps from bay tube.
(16) Disconnect fuel lines from main fuel strainer.
(17) Remove bay tubes.
(18) Remove sump drain lines and valves.
(19) Disconnect fuel inlet line to fuel pump, scavenge pump inlet
line and remove fuel pump drain line.
(20) Disconnect engine ground strap starter and alternator lines.
(21) Remove turbocharger, wastegate and injector adapter.
(22) Remove injector, inlet air adapter and flexible duct.
(23) Disconnect static pressure lines from induction tube and

remove induction tube.
(24) Disconnect static pressure line from fuel pump.
(25) Disconnect tach drive, oil cooler oil lines and crankcase
breather tube from engine.
(26) Disconnect oil temperature, pressure, and cylinder head

temperature probes.
(27) Remove fuel pressure lines from flow divider.
(28) Disconnect magneto primary leads.
(29) Remove static pressure manifolds from engine baffling.
(30) Remove top ignition wires from engine baffling.
(31) Remove remaining engine baffling.
(32) Remove oil filler tube.
(33) Remove turbocharger and injector mount brackets.
(34) Install caps or plugs on all disconnected lines, fittings

and engine openings to prevent contamination.
(35) Position all lines, wires, etc. to prevent interference with

engine removal.
MM-13-10
MAINTENANCE MANUAL
2) (4
1. Restricted engine oil

pressure fitting
2. Restricted turbo oil

outlet fitting
3. Engine oil temperature

probe fitting location
4. Chamfered case plug

location
5. Check blankstud holes

for break-through of case,
to prevent oil leakage
6. Oil outlet
CAUTION: Do not overtorque
fitting case
may crack
7. Turbo mount hole must

be threaded to receive
mount bolt
8. Scavenge pump and

piggy-back fuel pump
installation
9. Check engine sump for

a machined flat and
tapped hole to receive
turbo mount.
:~RlelNBb.
As dewivecl By
ATP
8) (9
FIGURE 13-1. ENGINE ACCESSORY SECTION
MM-13-ll
MAINTENANCE MANUAL
C. Engine Removal
(1) Install lifting ring; attach at third case half bolt from
the accessory case.
(2) Support the weight of the engine with the lifting device.
(3) Remove the four mount bolts and Lord mount assemblies.
(4) Lower engine to a suitable support on the floor, tilting it

as necessary to allow accessories to clear pylon.
(5) Remove any remaining lines, fittings, brackets, probes and

accessories as required preparing the engine for overhaul or
replacement.
D. Inspection Prior to Engine Reinstallation
(1) Engine Compartment
(a) Check engine mount rings and tubes for cracks or

distortion.
(b) Check pylon for worn spots, distorted tubes, cracks at

welded joints and corrosion.
(c) Check firewall for loose fittings, cracks and holes.
(d) Inspect fire curtai~n for general condition. Repair or

replace as necessary (see page MM-13-62, paragraph D).
(e) Inspect Lord mounts for checks, cracks, deformity and

age hardening. Replace as required.
(f) Check electrical panel for security and condition of

wiring, and clean ground connections.
(g) Clean main fuel sump screen and replace filter as
required.
(h) Check oil

coolers for cracks, damaged fins, seal
deterioration, and restrictions to airflow.
CAUTION: If engine removal was necessary due to internal

engine failure, it will be necessary to flush oil lines
and coolers with mineral spirits, kerosene, etc. to
insure removal of all possible contaminants. Inspect
turbocharger and oil lines for damage or contamination.
MM-13i12
MAINTENANCE MANUAL
(2) Associated Engine Components
(6) ;~heck all lines, hoses, fittings and seals for evidence
of deterioration, damage or contamination.
(b) Check exhaustsystem for cracks and distortion of

mounting flanges.
(c) Check wastegate for evidence of internal heat erosion,

freedom of movement, cracks and distortion.
(d) Check exhaust tube matting flanges and V clamps for

distortion and cracks.
(e) Check heater muff and heat exchanger for evidence: of

cracks or deterioration.
(f) Check turbocharger for freedom of rotation, cracks,

indications of leakage, condition of heat shroud and
security of fittings.
(g) Check turbo mount tubing and fittings for cracks,

distortion and excessive corrosion.
(h) Check intake induction tube for cracks or distortion of

mounting flange, and matting duct adaptor for
deterioration.
(i) Check static air fuel nozzle vent check valve for dirt
contamination and freedom of movement at low pressures.
(j) Check three sump drain valves, two in bottom engine

sump and one low point in intake induction tube, for
sticking or clogging.
NOTE: These valves are open in a neutral pressure

position; a slight positive or negative
pressure will close them.
(k) Check engine baffling, fan shroud and fan for cracks,
galling or other damage.
NOTE: For full inspection requirements see specific

section identified.
(3) Engine Preparation Prior to Installation
(a) Check mounting points on rear and case of new or

rebuilt engine; hole on right upper rear case flange
must be dr´•i lied and tapped for turbo mount bolt
(Ref. 7, Fig. 13-.1). Check bottom aft lokier right sump
for flatness and turbo mount clearance to drain boss
radi us.
MM-13-13
MAINTENANCE MANUAL
(b) Transfer restricted oil pressure fitting (Ref. i,

Fig. 13-1).
(c) Transfer restricted oil feed fitting to turbo (Ref. 2,

Fig. 13-1).
(d) Transfer oil return line fitting from scavenge pump

(Ref. 8, Fig. 13-1).
(e) Transfer oil inlet and outlet fittings (Ref. 6,

Fig. 13-i).
(f) Check four cast holes (Ref. 5, Fig. 13-1) in accessory

housing for break-through. If they show evidence of
breaking through case the holes will have to be drilled
and tapped to seal them or the accessory housing will
have to be replaced.
(g) Transfer case plug (Ref. 3, Fig. 13-1) to upper port

and install oil temperature pick-up in lower port.
NOTE: If a new plug is being used it will have to

be machined down to clear the engine mount.
NOTE: Items (1), (3), (5), (6) and (7) must be

accomplished prior to engine installation. If
not, engine may have to be removed to perform.
(h) Remove fuel pump, transfer scavenge pump and bolts and
install fuel and scavenge pump.
(i) Check security of oil filter.
(j) Check condition and security of magneto. Be sure fuel

pressure line clamp support is attached under upper
bolt. Verify timing per page 13-68.
(k) Check security of alternator if new and remove fan to

install spacer. If transferring alternator, inspect
for cracks, check brushes and bearings and reinstall.
(1) Check starter for security, condition of electrical

connections and brushes, and lubricate Bendix assembly.
Check for proper ring gear clearance to Bendix.
(m) Install lifting ring, attach at third top engine case

bolt from the accessory end.
MM-13-P4
MAINTENANCE MANUAL
LEFT
SIDE
81i
RIGHT
SIDE
:-*0i
BRIGINAL
As Rectlivech By
BTP
FIGURE 13-2. ENGINE COMPARTMENT VIEWS
MM-13-15
MAINTENANCE MANUAL
E. Engine Installation
(1) Place engine in position under the pylon and attach lifting
device.
(2) Raise engine into py ion, tilting as necessary to insure

accessories are not damaged.
(3) Install serviceable Lord mounts and bolts with one to three
AN 960-716 washers under the nuts.
CAUTION: Check number of washers requi red on each

installation so nut will not bottom out at
torquing.
(4) Torque upper bolts to 460-500 in. Ibs. before releasing the
weight of the engine.
(5) Install cotter pins on top bolts.
(6) Disconnect and remove lifting device.
(7) Torque lower mount bolts to 460-500 in. Ibs. and install
cotter pins.
(8) Remove lifting ring.
(9) Install baffling around sides of engine.
(10) Install ignition wires to engine through baffling.
(11) Install static air manifolds on baffling and safety wire

screws in pairs.
(12) Connect static air lines to nozzles.
(13) Install oil filler tube.
(14) Loosely install fan shroud and mount brackets.
(15) Replace fan shroud foam rubber air seal if required.
(16) Temporarily install fan to align shroud.
(17) Secure fan shroud, baffling and brackets, insuring the

shroud stays centered during the process.
(18) Remove the fan.
(19) Install fuel lines to engine driven fuel pump, oil lines to
engine crankcase breather tube and fuel pump drain.
(20) Install induction tube to engine sump.
MM-13-16
MAINTENANCE MANUAL
(21) Install sump drain valves, three places.
(22) Install bay tubes and fuel filter.
(23) Connect fuel lines to filter.
(24) Install induction tube to engine.
(25) Install induction air line from fuel pump to inductiontube.
(26) Install primary oil cooler and ducting.
(27) Install oil lines to both oil coolers.
(28) Install induction air box, hoses, and fuel nozzle static air
check valve.
(29) Install engine ground strap, starter wire and alternator

leads.
(30) Install injector and turbocharger mount brackets.
(31! Install injector, inlet adapter and AMC assembly.
(32) Connect fuel and air lines to injector.
(33) Inrtall inlet adapter to injector and safety wire.
(34) Install turbocharger and connect induction tube, oil lines

and controls.
!35) Connect manifold pressure line.
(36) Install cylinder head, oil tempe ra tu re and oil pressure

probes and connections.
(37) Install exhaust system and exhaust gas temperature probe.
(38) Connect flexible duct to heater muff, heater control and fan
shroud.
(39) Connect fuel and pressure lines to the fuel flow divider.
(40) Install fire curtain and seal with Dow Coming Silicone
Sealant.
(41) Install fuel line to fuel shutoff valve and seal doubler
around line to the fire curtain with Dow Coming Silicone
Sealant.
(42) Install top engine baffling.
(n3) install main rotor transmission.
MM-13-17
MAINTENANCE MANUAL
(44) Install fan and JacL strut assembl*.
(45) Install baggage box.
(46) Install fuel tanks.
(47) Connect battery.
(48) Service engine according to HZO-360- Operators Manual.
(49) Run engine to check control operation, fuel pressure and for
evidence of system leaks.
(50) Install all cowling.
F. Cylinder Removal in Helicopter
(1) Remove upper side cowling to gain access to cylinder.
(2) Remove engine baffling above affected cylinder.
(3) Disconnect fuel and airlines from nozzle.
(4) Remove any clamps attached to cylinder tubes.
(5) Remove static air manifold.
(6) Remove ignition wires as necessary and remove side baffling.
(7) Disconnect exhaust system.
(8) Remove induction tube to cylinder.
(9) Disconnect oil return line from cylinder.
(10) Remove probes if there are any in the affected cylinder.
(11) Remove or relocate any other hoses or lines obstructing

cylinder removal.
(12) Refer to Avco Lycoming HtO-36O Operators Manual for detailed

procedure on cylinder renioval, inspection and assembly.
G. Cylinder Installation
(1) Install cylinder per instructions in Avco Lycoming HIO-360

Operators Manual.
(2) Install any probes removed for disassembly.
(3) Connect oil return lines to the cylinder.
(4) Check condition of induction tube.
MM-13-18
MAINTENANCE MANUAL
(5j Check exhaust system flanges and gaskets and install exhaust
sys tenl.
iGj Install engine side baffling.
(7) Install ignition wires.
(8j Install static air manifold, safety wire screws in pairs.
(9) Install flow divider fuel line clamp.
(1U) Install nozzle and connect fuel and static air lines.
(11) Service engine oil and fuel systems.
Run engine to check for system leaks.
i13) Install remaining baffling and cowling.
13-3 ENGINE EXHAUST SYSTEM
The exhaust system on the engine consists of two manifolds which

route exhaust gases through the heater-muffler and out through
the wastegate and/or turbocharger, depending on engine power
requirements.
Exhaust Manifold Removal iSee Fig. 13-2)
ii) Disconnect exhaust gas temperature (EGT) probe (1) from

exhaust manifold.
i2) Remove ducting from the heater muff (2).
(3) Loosen turbocharger exhaust inlet clamp (3) and slide it

down on the exhaust tube.
(Y) Remove exhaust inlet gasket.
(5) Disconnect linkage (4) at the wastegate.
(6) Remove clamp from turbocharger outlet (5),
i7) Remove exhaust outlet and gasket.
(8) Remove safety wire and retention pin (8) then remove
I
wastegate (6).
(9) Remove two nuts (7) on exhaust flange on each cylinder.
(10) Break loose the sleevejoint at the heater muff. This will
allow the exhaust system to be removed in two pieces.
#2 Rev. 11/18/88 MM-13-19

MAINTENANCE MANUAL
C. Exhaust Manifold Inspection
Upon removal of the complete exhaust system, check the flange

mounting of each exhaust stack for cracks, distortion of the
flange and proper gaskets.
WARNING: At the 100-hour inspection it will be necessary to

remove the cabin heat exchanger cover to inspect for
any cracks internally which could allow carbon monoxide
to enter the cabin through the heating system.
D. Exhaust Manifold Installation (See Fig. 13-2)
(1) Assemble the muffler cuff.
(2) Install the right side manifold section with new gaskets and
hardware. DO NOT TORQUE.
(3) Insert heater muff sleeve on left half of manifold, over
right side manifold.
(4) Install left s i de manifold sec ti on to en g i ne with new
gaskets and hardware. DO NOT TORQUE.
(5) Connect exhaust manifold to turbocharger inlet (3).
(a) Install new gasket.
(b) Slide collar up and rotate for proper alignment.
(c) Install turbocharger inlet clamp.
(6) Install wastegate assembly (6).
(7) Install exhaust outlet, shims, and clamp (5).
(8) Check all attachment points for alignment.
(9) Torque turbocharger clamps and manifold nuts to 80-90

in. Ibs.
(10) Safety wire turbocharger clamps.
(11) Install EGT probe (1).
(12) Install heater muff ducting (2).
(13) Connect wastegate linkage (4).
(14) Run engine and check for possible exhaust leaks.
MM-13-20
MAINTENANCE MANUAL
E. Wastegate Operational Check
NOTE: This check is done with the engine shut down.
(1) Check freedom of operation of injector to wastegate rod

"breakaway" function by holding the wastegate arm
stationary, partially opened, and rotating the throttle in

both directions causing rod to break away and move
approximately two inches in each direction.
(2) Insure breakaway mechanism is engaged after conipletion of

operational check.
F. Wastegate Rigging (See Fig. 13-3)
NOTE: Insure throttle am is properly rigged to the injector.
(1) Set injector to full throttle position.
(2) Check wastegste butterfly to insure it is fully closed.
(3) Adjust butterfly position by adjusting the inboard rod end.
(4) Adjust wastegate closed stop to provide a .015-.020 gap

between stop and arm.
(5) Lock closed stop with jam nut.
(6) Set injector to position throttle arm on the idle stop.
(7) Check wastegate butterfly to insure it is open past center.
(8) Adjust wastegate open stop to provide a .015-.020 gap

between stop and arm.
(9) Lock stop with jam nut.
G. Wastegate Removal (See Fig. 13-3)
(1) Disconnect wastegate linkage.
(2) Disconnect clamp from turbocharger outlet.
!3) Remove exhaust outlet and gasket.
(4) Reniove wastegate assembly.
H. Wastegate Inspection
Check wastegate for internal heat erosion, freedom of movement,

excessive clearance, cracks and distortion.
MM-13-21
’ct-~
J5
lbt/
g~8
rlr
4 F
i 1’3
FIGW\E 13-3
ENGINEEXHAUST SYSTEM
CLAMP
AND WASTEGATE
MAINTENANCE MANUAL
i. Wastegate Installation (See Fig. 13-3)
jl) Place wastegate in position on exhaust nianifold.
i2) Install exhaust outlet, gasket and clamp on turbocharger and

wastegate.
i3) Torque clamp to 20 in-lbs and safety wire.
NOTE: Later versions of wastegate installations no longer use

the stainless band clamp. In its place is a stainless
retention pin that is safetied with .032 ss ms wire.
i4) Connect wastegate actuating rod.
(5) Check assembly for security of attachment and freedom of

mov ernent
13-4 FUEL INJECTIGN SYSTEM
All KSU type fuel injectior~ systems are based on the principle of
measuring engine air consumption by use of a Venturi tube and
using the airflow forces to control fuel flow to the engine.
Fuel distribution to the individual cylinders is obtained by the
use of a fuel flow divider and fuel injection nozzles.
It suggested that all adjustments to the RSA-5 fuel injection

is
system be performed with the use of the Operation and Service
Manual, Form 15-3380, published by the Bendix Corporation.
B. Fuel Injector System Troubleshooting
NOTE: a. Internal field maintenance of KSU type injector is

limited lapping the main metering jet
to and
rotating plates, and replacing the "0" ring.
b. Repairs to and calibration of the regulator

section must be done by an authorized Bendix
Service Center or Overhaul Facility, for the
specific parts list number indicated on the servo
dataplate.
~2 Rev. 11/18/88 MM-13-23

MAINIEMANCE MANUAL
Hard starting Flooding because of Clear engine by cranking

accompanied by the excessive prime with with throttle in the
discharge of black boost pressure or wide open position, boost
puffs of smoke and improper mixtirre pump off and mixture in
popping from exhaust setting. idle cut-off position.
stack while cranking
and possible fuel Flooding because of See paragraph (C),
leakage from the fuel servo leaky page MM-13-29
engine sump drains. mixture control plate,
usually indicated
previously by failure
to have a crisp shut-off
when mixture control
was placed at idle
cut-off position.
Flooding because of See paragraph (B),

center body seal leak page MM-13-29
in servo.
Hard starting insufficient fuel Reference normal engine

accompanied by prime, improper starting procedures
possible backfiring mixture control page MM-13-37
and fuel leakage setting, no boost
from induction pressure or
tube sump drain. obstructed fuel flow.
Insufficient fuel to Clean fuel static air

fuel nozzles because vent valve. Ref.
fuel static air vent paragraph (2)(i)
valve on air filter page MM-13-13
box stuck, resulting
in fuel being drawn
into induction sump
tube and seeping from
drain.
Rough idle. Mixture too rich or Confirm with mixture

too lean, control. A too rich
mixture will be
corrected and roughness
decreased during lean-out,
while a too lean mixture
will be aggravated and
roughness increased.
Adjust idle to give a
25-50 rpm rise at
1400-1500 rpm.
MM-13-24
MAINTENANCE MANUAL
Rough idle. Plugged nozzle(s), Clean nozzles.

(CONTINUED) usually accompanied
by high takeoff fuel
flow readings and
slightly higher MAP’s.
Slight air leak into Confirm by temporarily

induction system plugging sump drain
through manifold drain lines. Replace or clean
check valve. Usually check valves as
able to adjust initial necessary.
idle, but rough in
1000-1500 rpm range,
and will have a slightly
higher MAP.
Internal leak in Replace injector.

injector (usually
unable to lean out
idle range).
NOTE: If engine does not stop crisply at
mixture idle cut-off sition, check
paragraphs (b) and (ePY page MM-13-29
and paragraph (9), page MM-13-35.
Fuel vaporizing in Increase engine rpm,

fuel line or distri- turn into the wind or
butor. Encountered terminate ground
only under high operation. See
ambient temperature paragraph C, page
conditions or MM-13-27.
following prolonged
operation at low idle
rpm’s.)
Low takeoff Fuel filter or Remove and clean in a
fuel flow, finger screen suitable solvent.
partially plugged.
Injector out of Replace injector with

adjustment, properly calibrated
unit.
Faulty gauge. Replace as necessary.
Low fuel pressure. Readjust to correct

setting.
MM-13-25
MAINTENANCE MANUAL
Poor cut-off. Improper rigging of Adjust.

mixture control.
Mixture control valve Eliminate cause of

scored or not scoring (usually a burr
seating properly. or dirt) and lap mixture

control valve and plug
on surface plate.
Boost on. Turn off.
Rough engine and Fuel injection Clean or replace nozzles.

poor cut-off. nozzle air bleed
hole(s) clogged.
Erroneous fuel Faulty gauge. Replace as necessary.

flow.
AMC blast tube Repair as necessary.
disconnected.
TYPICAL FUEL FLOW PERFORMANCE FOR "F" MODELS
3050 RPM
SEA LEVEL DENSITY ALTITUDE
MANIFOLD PERCENT FUEL FLOW ENDURANCE

PRESSURE HORSE OF HORSE (PPH) (HOURS)
INCHES POWER POWER LEAN RICH LEAN RICH
20" 120 53~ 62 76 3.8 3.1
22" 130 58% 68 82 3.4 2.8
24" 142 63% 74 89 3.2 2.6
26" 153 68% 80 97 2.9 2.4
28" 165 73% 87 107 2.7 2.2
30" 176 78% NA 119 NA 2.0
32" 186 83% NA 131 NA 1.8
34" 198 88X NA 142 NA 1.6
36" 208 92% NA 153 NA 1.5
38" 220 982 NA 163 NA 1.4
39" 225 100~ NA 168 NA 1.4
NOTE: This performance is typical for Enstrom "F" models. There will
be some variation between individual helicopters.
NOTE: "LEAN" limits denote EGT at 1550 degrees.

NOTE: "NA" denotes not approved mixture setting.
MM-13-26
MAINTENANCE MANUAL
C. General Operating Information
Several phases of ground operation adversely affected by fuel

are
vaporization in the lines. Fuel vaporization is experienced

under extreme conditions of ambient and/or nacelle temperatures.
Starting idle operating and engine shutdown procedures must all
be modified to obtain optimum results under these conditions.
(1) Starting
In cold weather the engine compartment (nacelle) temperature

drops off rapidly following engine shutdown and the nozzle
lines remain nearly full of fuel. Cold weather starting
procedures are therefore simple with highly predictable
results. However, in extremely hot weather, nacelle
temperatures increase rapidly following engine shutdown and
fuel in the lines vaporizes and escapes out into the
manifold. Hot weather starting procedures therefore depend
on how soon the next start is attempted. Within the first
20-30 minutes wait; the vaporized fuel in the manifold will
have nearly disappeared and some slight "priming" could be
required to refill the nozzle lines and keep the engine
running after first firing.
(2) Idling
During ground operation every precaution should be taken to

keep nacelle temperatures from increasing to the extent that
fuel will vaporize in the fuel lines. The following
suggestions are aimed at minimizing this problem.
(a) Keep nacelle temperatures as low as possible by:
1 Avoiding excessive ground operation.
Keeping cooling airflow up by keeping engine RPM’s

as high as possible.
3 Upon restarting of a hot engine, operate engine at

1200-1500 rpm for several minutes to reduce the
residual heat in the engine compartment.
(b) Keep fuel temperatures as low as possible. Higher

RPM’s with the accompanying higher line pressure and
flow will help to dissipate some of the heat within the
lines.
(c) Make an idle

speed and mixture adjustment that is a
compromise between the engine’s requirement during the
cool of the morning and the heat of the day. The
higher than normal temperature encountered during the
heat of the day results in the engine requiring a
considerably leaner idle mixture. However, with fuel
injection, this richer setting at the heat of the day
will help dissipate more engine heat.
MM-13-27
MAINTENANCE MANUAL
(3) Shutdown (Cut-Off)
The idling procedure practiced just prior to engine shutdown

has considerable bearing on the "cleanliness" or smoothness
with which the engine stops. If the idling procedures
suggested above are not followed and fuel is vaporizing in
the lines, the engine will continue to idle very rough for
several seconds. This, despite a 100X cut-off of fuel
supply by the mixture control.
D. Injector
(1) General
Since the air differential pressure is function of the

a
airflow, and the fuel dif~erential pressure a function of

is
the fuel fl ow, the correct fuel-to-air ratio is always
maintained with this system regardless of the quantity of
air being consumed by the engine.
Provisions been made to compensate for the low air

have
forces experienced in the idle range by the incorporation of
the constant head idle spring. This spring provides a
constant fuel differentia3 pressure that will allow adequate
fuel supply for the idle range. As the air forces increase,
the spring compresses until the spring retainer touches the
air diaphragm and acts as a solid member.
NOTE: The Bendix Model RSA5AB1 fuel injector which is

supplied with the HI0-360-F1AD Lycoming engine is
internally adjusted specifically for the Enstrom
turbocharged installation. ALL replacement
injectors must be acquired from your nearest
Lycoming or Bendix distributor by parts list
number.
(2) Operational Checks
(a) Idle Mixture and rpm Check
1 Engine Normal operating temperature.
2 Check magneto.
3 rpm 1450 to 1500
4 Rotor Disengaged
5 Boost pump On
MM-13-a8
MAINTENANCE MANUAL
6 Slowly lean the engine, observing rpm change.
NOTE: Mixture to full rich before engine cuts

out.
rpm rise during leaning--idle mixture is

rich.
Immediate rpm drop--idle mixture is

lean.
7 Perform idle mixture and rpm adjustment if

necessary.
(b) Center Body Seal Leakage Check
1 Remove intake flex hose from injector inlet.
2 Disconnect injector fuel outlet line.
3 Cap injector fuel outlet fitting.
4 Magneto Switch Off
5 Throttle Full On
6 Mixture Full Rich
7 Master Switch On
8 Boost Pump On
9 Observe injector impact tubes for fuel leakage.
NOTE: Leakage indicates a damaged center body

seal. This repair is done ONLY by an
authorized Bendix Service Center or
Overhaul Facility.
10 Replace injector if necessary.
(c) Mixture Control Plates Leakage Check
5 Magneto Switch Off
2 Disconnect injector fuel outlet line from

injector.
3 Mixture Control Full Lean
4 Throttle All the way out (off).
MM-13-29
MAINTENANCE MANUAL
AUTOMATIC MIXTURE
CONTROL
FUEL INLET AND

STRAINER
WASTEGATE ARM
NO. 10-24 THREADS
IDLE MIXTURE I(o FUEL OUTLET

ADJUSTMENT
NO.IO-32 THREADS
IDLE VALVE
IMPACT AIR
FIGURE 13-4 FUEL SERVO
MM-13-30
MAINTENANCE MANUAL
5 Master Switch On
6 Boost Pump On
7 Observe open fitting for evidence of fuel leakage.
NOTE: Fuel leakage indicates scored (a)

mixture control jet, (b) rotating plates
or a damaged "O" ring on the jet.
8 Lap plates as necessary. See paragraph (9), page

MM-13-35.
(3) Normal Operating Characteristics
(a) Mixture full rich, engine at 3050 rpm.
1 29" MAP fuel flow 110/120 Ibs/hr.
2 39" MAP fuel flow 150/155 Ibs/hr.
(b) Cold engine may not idle with boost pump off.
(c) At normal operating temperature engine should idle with

boost pump on or off.
(d) Engine idle rpm will not decrease, boost off to boost
on.
(e) When throttle is rapidlyreduced to idle (chopped) from

3050 rpm, engine idle will not drop below normal idle
setting.
(4) Rigging Throttle and Wastegate Actuating Arm to Injector
(a) Position centerline

of throttle arm two serrations
(approximately 30") counterclockwise from an imaginary
line drawn between the throttle shaft end and the
center of the idle valve arm pivot point.
(5) Injector Removal (See Fig. 13-5)
NOTE: Injector removal, through the firewall access, can

beaccomplished without removing the turbocharger
or the turbocharger can be removed to improve
accessibility.
(a) Disconnect hose from blast tube assembly (1).
(b) Disconnect mixture control cable (2).
(c) Disconnect and plug fuel inlet (3) and outlet

lines (4).
MM-13-31
MAINTENANCE MANUAL
(d) Disconnect throttle (5) and wastegate (6) controls.
(e) Remove four attachment bolts (7).
(f) Disconnect air inlet hose (8) from injector adapter.
(g) Disconnect injector and air inlet adapter (9) by

removing the four connecting bolts, two of which attach
these components to the mounting bracket.
(h) Remove the injector, inlet adapter and outlet gasket.
(6) Injector Inspection
(a) Check air inlet hose and blast tube hose for evidence
of wear that could cause leakage.
(b) Check condition of gasket between injector and

turbocharger.
(7) Injector Installation (See Pig. 13-5)
NOTE: On new injectors and those that have had throttle

arm removed, it will be necessary to check rigging
of throttle arm to injector and adjust idle stop
screw prior to installation. (See Fig. 13-5)
(a) Place injector and air inlet adapter (9) in position in

the engine compartment.
(b) Attach air inlet adapter to injector with the two

forward bolts.
(c) Assemble shock mounts on mounting bracket.
1 Place one large diameter shock mount on each side

of bracket, aligned with the hole.
2 Insert small diameter shock mount into two large

diameter shock mounts and mounting bracket.
3 Insert metal spacer into small diameter shock

mount.
(d) Install injector and air inlet adapter on mounting

bracket with one washer on each side of the shock
mounts.
(e) Connect air inlet hose (8) to adapter (9).
(f) Insert gasket (10) between injector and turbocharger

adapter and secure the components with the four
bolts (7).
MM-13-32
MAINTENANCE MANUAL
a i
ie
~i?
o
.Q O
TURBOCHARGER (REF)
a P~
:mi i
MOUNT BRACKET(REF.)
´•~_\
9
k io
.I
INJECTOR
ril
d~i
~98 e n
i´•
’Bp’ BLAST TUBE ASSIY/
\~6*
NOTES:
SECURE FASTENER WITH LOCKWIRE.
FTGL’RE 13-5 FUEL SERVO INSTIV;LATION
MM-13-33
MAINTENANCE MANUAL
(g) Safety wire injector inlet adapter bolts (7).
(h) Connect throttle cable (5) and wastegate actuating

rod (6).
(i) Connect fuel line (3) and outlet (4) lines.
(j) Connect mixture con~trol (2).
(k) Connect hose to blast tube (1).
CAUTION: On new servos, when transferring blast tube

assembly by removing AMC screws and replacing
them, be sure the gasket is not rotated to
block vent hole.
(1) Check security of all connections.
Lm) Install turbocharger if it has been removed.
(n) Test run engine to insure freedom of control movement

and proper function.
to) Shut engine down and inspect for leaks.
(8) Injector Adjustments (See Fig. 13-4)
~a) Idle Mixture and rpm
1 Engine At normal operating temperature.
2 Check magneto.
3 Rotor Disengaged
4 Boost Pump On
5 Mixture Full Rich
6 Adjust idle stop to provide 1450-1500 rpm idle.
7 Loosen jam nut on throttle lever to idle valve

lever linkage.
NOTE: Rotation to shorten the linkage leans

the mixture (turning the coarse thread
into the throttle lever block).
MM-13c34
MAINTENANCE MANUAL
8 Lean engine until it runs smooth but will not

accelerate from idle (maintain idle rpm at
1450-1500),
NOTE: If the linkage rod bottoms out or
disengages at either end during

adjustments, it will be necessary to
remove, adjust and reassemble linkage
rod, threaded pin and block as follows:
Remove cotter pins and washers holding

throttle lever block and idle valve
lever pin to their respective levers.
Remove and measure the overall length of

the block, linkage rod and pin assembly.
Disassemble block, rod and pin.
Rea ss emb I e to the same length as

measured previously allowing enough
thread at each end for further
adjustment.
Reassemble linkage to the injector

levers.
9 Increase idle mixture in small increments until

the engine will accelerate from idle, yet no rpm
increase is noted during mixture leaning with the
cockpit mixture control.
NOTE: After each adjustment clear engine

(2000 rpm).
10 Perform injector operational check.
11 Lock linkage jam nut.
12 Engine Normal cooling and shutdown procedure.
NOTE: Optional idle mixture adjustments:

Required equipment: 100 cc flask and spare
28-12463-1 fuel outlet line.
Method: Engine off, mixture full rich, main fuel
valve on, throttle at idle, attach spare fuel
line to servo outlet, turn boost pump on and
measure flow in cc. For one minute flow
should be 90-100 cc. If not, readjust idle
mixture to required flow.
MM-13-35
MAINTENANCE MANUAL
(9) Injector Repairs
(a) Lapping idle valve and mixture control valve.
1 Disconnect mixture control cable from the in~ector

mixture control lever.
2 Remove the following:
Two screws ho~ding the mixture control lever

assembly in injector body.
Mixture control lever assembly.
Packing.
Idle valve.
NOTE: A hook fabricated from 1/8" brass rod

can be used to hook the orifice of the
idle valve and gently work it out.
3 Visually inspect non-tapered end of valves and

control plates for scoring.
4 Remove scores by lapping components in a

figure 8 pattern with crocus cloth and clean oil
on a surface plate.
5 Wash components with clean gasoline or solvent.
6 Reinspect components to insure they are free of

scores.
7 Reinstall the components as follows:
Idle valve, flat side first.
NOTE: Idle valve has a full length keyed slot.
New packing and "0" ring on mixture

control valve.
Mixture control valve, flat side out.
Mixture control lever assembly.
8 Connect mixture control cable.
9 Perform leakage check.
MM-13-36
MAINTENANCE MANUAL
E. Mixture Control
The mixture control cable is manually operated by depressing

the knob in end of control handle and pushing inward to lean
mixture and pulling out to enrich mixture. The mixture
control handle also has a vernier adjustment to complete
fine mixture adjustments. Vernier adjustments are made by
turning the large diameter portion of the control handle.
CAUTION: It is important to keep friction on the mixture

control shaft to prevent vibration from turning
the vernier control during flight. If unobserved,
cyl inder head temperatures and exhaust gas
temperature could exceed limits, causing engine
and/or turbocharger damage.
Mixture control friction should be adjusted to provide

sufficient "drag" to prevent rotation due to vibration, yet
allow normal mixture adjustment without binding. Friction
adjustments can be made by varying the torque on the large
hex nut (11) by finger pressure without disturbing the
mounting position of the control. See Fig. 13-6.
(2) Mixture Cable Removal (See Fig. 13-6)
(a) Remove f i be rgl ass seat deck and fi rewa 11 i nspecti on

panels.
(b) Remove covers from instrument console.
(c) Disconnect mixture cable rod end (5) from mixture

control lever (3) on injector.
(d) Break check nut (6) loose from rod end (5) and remove
both items from cable (9).
(e) Remove check nuts (7) securing mixture cable to pylon

mount which is aft of firewall. Remove nuts from
cable.
(f) Cut tie wraps securing cable in seat structure.
(g) Remove check nut (10) from mixture cable inside

instrument console.
(h) Carefully pull mixture cable (9) through seat structure

and out through instrument console.
MM-13-37
MAINTENANCE MANUAL
/STOP (I)
3
2
~z
.BLAST TUBE STOP (I) 1
´•a i~-
CLEARANCE
:´•YC~´•
g
i~
MIXTURE CONTROL ARM POSITION MIXTURE CONTROL ARM POSITION
WITH MIXTURE CABLE PUSHED IN WITH MIXTURE CABLE PULLED OUT
(FULL RICH (FULL LEAN)
7 12
II
7----e
11
3
e
FIGL;RE 13-6 MIXTURE CONTROL RIGGING
MM-13-38
MAINTENANCE MANUAL
(3) Mixture Cable Installation (See Fig. 13-6)
(a) Install mixture cable (9) through instrument panel and

route it through seat structure and firewall.
NOTE: Install check nut (10) on cable before

routing through seat structure.
(b) Secure mixture control to instrument console with check

nuts (10).
NOTE: Mixture control is to be located in panel

with a .120" gap between friction nut (11)
and check nut (1O). See Fig. 13-6.
(c) Route mixture cable through pylon mount (8) on aft side
of firewall and temporarily secure with check nuts (7).
NOTE: The final steps of cable installation are
completed in the following Rigging Procedure.
(4) Mixture Control Rigging (See Fig. 13-6)
(a) Locate mixture control lever (3) on injector as

follows:
1 Rotate the mixture control arm (2) until it hits

stop (1) in the full rich position.
See Fig. 13-5.
2 Locate mixture control(3) in a down

lever
position, leaving a slight gap between lever and
blast tube cover (5) while aligning notches to
mesh with mixture control arm (2),
3 Install nut to secure mixture control lever (3) in

this position.
NOTE: Recheck arm and lever positions after

tightening nut. Control arm will
sometimes rotate with nut during torque
procedure.
(b) Install check nut (6) and rod end (5) on mixture cable.
Rotate rod end until it bottoms out on cable.
(c) Attach mixture cable rod end to mixture control lever

(3) and secure with hardware. Torque nut and install
cotter pin.
MM-13-39
MAINTENANCE MANUAL
(d) Tighten check nut (6) against rod end (5).
(e) Position mixture co:ntrol knob allowing a 3/8 inch gap

between check nut (12) and friction nut (11!
(f) With mixture control this position, loosen check

in
nuts (7) at pylon mountand adjust cable sheath at
mount bracket(8) until mixture control arm (2) hits
the stop(l). Secure check nuts (7).
NOTE: Mixture c0ntrol arm (2) must be in full lean

position as shown in Pig. 13-6.
(g) Pull mixture control knob out to full rich position and
check that control arm (2) hits the stop (1).
(h) Inspect all hardware for security.
(i) Install covers on instrument console.
(j) Install firewall inspection panels and fiberglass seat

deck.
F. Automatic Mixture Control (AMC)
This unit provides a variable orifice between impact

pressure. It is responsive to both changes in air
temperature and pressure (density) and will keep the
d i ffe re nt i a 1 air pressure between the two air chambe rs
constant for any airflow, regardless of changes in the air
inlet density.
The automatic mixture control incorporates a contoured

needle that is moved in or out of an orifice by a bellows
assembly. The sealed bellows, which reacts to changes in
air density, is filled with helium gas and a small quantity
of inert oil to help cjamp vibration. Under high density
conditions, the bellows is contracted and positions the
needle in the orifice so that the effect of impact pressure
on venturi throat pressure in the airflow section is at a
minimum. As density decreases, due to either a decrease in
pressure or an increase in temperature, the bellows
elongates and repositions the needle in the orifice to
increase the effect of impact pressure on venturi pressure
which decreases the air metering forces to maintain a
constant fuel-air ratio.
Attached to the aluminu~ housing, enclosing the temperature

sensitive AMC unit, is a blast tube assembly which provides
the necessary cooling airflow.
MM-13;40
MAINTENANCE MANUAL
(2) AMC Removal (See Fig. 13-4)
(a) Disconnect blast tube hose.
(b) Remove safety wire and two screws attaching blast tube
assembly and AMC unit.
NOTE: Observe position of gaskets and spacer to

insure correct reassembly and operation.
(3) AMC Cleaning
(a) Remove the 9/16-24 plug and immerse unit in clean

naptha.
(b) Invert the unit to fill with fluid.
(c) Exercise the AMC needle with a hardwood or plastic rod

to facilitate cleaning.
(d) Shake the unit vigorously while allowing fluid to

drain.
(e) Repeat steps 2 through 4 several times.
(f) Allow naptha to evaporate thoroughly. DO NOT dry with

pressurized air.
(g) Install 9/16-24 plug and gasket.
(h) Torque plug to 55-60 in. Ibs. and install safety wire.
(4) AMC Installation (See Fig. 13-4)
(a) Install screws with washers through blast tube assembly

and AMC.
(b) Position gaskets and spacer on the screws and install

assembly on injector.
(c) Safety wire.
(d) Connect air hose to blast tube.
G. Fuel Servo Screen
(1) Servo Screen Removal (See Fig. 13-4)
(a) Remove automatic mi xture control and blast tube

assembly.
(b) Disconnect and cap fuel inlet line.
MM-13-41
MAINTENANCE MANUAL
(c) Remove fuel inlet elbow.
(d) Remove fuel screen carefully to avoid depositing

residue from screen in the injector.
(2) Servo Screen Cleaning
Refer to Bendix Overhaul Manual for RSA-AB1 Fuel Injectors,

Form 15-419.
(3) Servo Screen Installation (See Fig. 13-4)
(a) Insertscreen into injector body.
(b) Install new "0" ring and fuel inlet elbow.
(c) Connect fuel inlet line.
(d) Run engine and check for fuel leakage around the inlet
elbow.
H. Fuel Flow Divider
(1) Flow Divider Removal (See Fig. 13-7)
(a) Remove top right and left engine baffles.
(b) Disconnect fuel lines (1) and (2) from flow divider.
(c) Disconnect fuel nozzle lines (5).
(d) Remove bolt (3) attaching center of flow divider mount

bracket.
(e) Remove two bolts (4) attaching inboard side of mount

bracket to engine case.
(f) Remove flow divider and mount bracket from engine

compartment.
(2) Flow Divider Disassembly
Refer to Bendix Form 15i540A Flow Divider Overhaul Manual.
(3) Flow Divider Installation (See Fig. 13-7)
(a) Place flow divide.r and mount bracket in position on the

top right side of the engine.
(b) Install bolt (3) attaching center of mount bracket to

engine case.
(c) Install two bolts (4), washers and nuts attaching top
side of mount bracket to engine case.
MM-13i42
MAINTENANCE MANUAL
(d) Connect fuel lines (1) and (2).
(e) Connect fuel nozzle lines (5).
(f) Briefly run engine and check connections for fuel

leaks.
(g) Install baffling.
I. Air Bleed Nozzles
(1) Nozzles Troubleshooting
Engines operating with a plugged nozzle may exhibit some of

the following characteristics:
(a) Rough idle (with severe obstruction, a popping exhaust

noise).
(b) Roughness during high power settings.
(c) Engine may quit with power reduction with severe

obstruction.
(d) Fuel nozzle pressure will indicate slightly higher fuel

flows than normal.
(e) Slightly higher MAP setting than normal for conditions.
(2j Nozzles Operational Check (See Fig. 13-7, View A)
(a) Disconnect the fuel and air lines at the nozzles. See
Removal Procedure.
(b) Remove nozzles.
(c) Reattach nozzles to fuel lines.
(d) Direct nozzles into bottles of equal size.
(e) Move throttle and mixture controls full forward.
(f) Turn on boost pump.
(g) Fill bottles about half full of fuel.
NOTE: Observe fuel flow from the nozzles. Fuel

should flow in a stream, approximately the
size of the lead in a mechanical pencil, from
the discharge end of the nozzle. Leakage
from the air bleed hole indicates an
obstructed nozzle.
MM-13-43
MAINTENANCE MANUAL
(h) Remove the bottles and place them on a table or some

other flat, level surface.
(i) Compare fluid levels in the bottles to identify which

nozzles, if any, are obstructed.
(3) Nozzles Removal (See Fig. 13-7, View A)
(a) Remove right and left panels from top of engine.
(b) Disconnect air line hoses (2) from nozzles.
(c) Disconnect fuel line fittings (1) from nozzles.
(d) Remove air line fitting (3) and spring to provide

access for socket installation on nozzle, and remove
nozzles.
NOTE: Use care in retaining the two "0" rings

located inside airline fitting for
reinstallation.
(4) Nozzles Cleaning (See Pig. 13-7, View A and Fig. 13-8)
(a) Remove fuel restricltor from nozzle body and clean in

MEK or acetone. Fuel restrictors should be cleaned
annually. More frequent cleaning may be required, not
to exceed 100 hours operational time.
(b) Use air pressure to clean the nozzle body. The nozzle
body should be removed annually to reduce possibility
of seizure in the cSllinder. Do not clean any internal
passages with sharp instruments such as drills, pins,
needles, etc.
NOTE: Keep each restrictor with its respective body.
(5) Nozzles Installation (See Fig. 13-7, View A)
(a) Install nozzles in cylinders. Torque to 60 in. Ibs.
(b) Install air line fitting (3) and nozzle springs.
NOTE: Be sure to install both "O" rings under air line

fitting.
(c) Connect fuel line fittings (1) to nozzles. Torque

25-50 in-lbs maximum.
(d) Connect air line hoses (2) to nozzle fittings (3) and
secure with clamp.
(e) Install right and left top engine panels.
MM-13-44
MAINTENANCE MANUAL
I’’
3;
i’i
i /Y
j)
r-
t Y:~
ip´•
’i
1,
j.~
´•´•´•4 -s
5 4
2\
FLOW DIVIDER
INLET SHOWN
(I)GAUGE LINE 3
ROTP~TED FOR
CLEARITY
(2) FUEL INLET
FLOW DIVIDER INSTALLATION TYPICAL AIR BLEED

NOZZLE INSTALLATION
LOOKING AFT
FIGURE 13-7 FLOW DIVIDER- AND AIR BLEED NOZZLES

MM-13-45
MAINTENANCE MANUAL
LA-8249A AIRBLEED NOZZLE ASSEMBLY SAME AS LW-18267

EXCEPT DEVIATIONS AS NOTED FOR ITEM NUMBER 3 AN D
NOTCHED RESTRICTOR.
i" NOTE: ONE NOTCH ON RESTRICTOR
IIII.LCLD NOL2LE rlSBEMBC( Ln82494
2. SPRING
4. PRE FORMED PACKING
~U a.
7.
PREFORMED PACKING
BODY ASSEMBLY
AIRBLEED NOZZLE ASSEMBLY LW 182 67
FIGURE 13-8
MM-13-46
MAINTENANCE MANUAL
13-5 TURBOCHARGER
The turbo units primary moving parts are a rotating shaft with a
turbine wheel on one end and a compressor impeller on the other,
all precision balanced and each impeller contained in its own
housing. The turbine wheel, driven by exhaust gas energy, drives
the impeller which compresses intake air to a density equivalent
of near sea level and delivers it to the engine intake. This
increased volume of air allows the engine to "breath" with the
same volumetric efficiency, and produce equivalent power, at all
altitudes up to 12,000 feet density altitude.
When turbocha rged the eng i ne s enti re intake system is

pressurized. The fuel/air mixture is literally forced into the
cylinder the instant the intake valve starts to open; completely
filling the entire chamber prior to the start of the compression
stroke. This assures a full charge of the fuel/air mixture,
resulting in more power during each combustion stroke. It also
assures a more evenly balanced air/fuel/power ratio between
cylinders.
B. Turbocharger Removal (See Fig. 13-9)
(1) Remove seat cushions and back access panel in fiberglass

seat deck.
(2) Remove firewall access panels from cabin firewall.
(3) Open left side engine panel.
(4) Remove clamp from exhaust outlet and gasket.
(5) Disconnect and remove turbo heat shield.
(6) Remove exhaust inlet clamp and slide adapter collar down on
the exhaust tube. Remove gasket.
(7) Loosen induction tube clamps and slide adapter collar down
on the induction inlet tube.
(8) Disconnect inlet and outlet lines.
NOTE: Leave the lower elbow and flexible line attached

to the turbocharger.
(9) Remove the four bolts from the turbo inlet adapter at the
injector. Leave inlet adapter mounted on the turbocharger.
(10) Detach turbocharger from the turbo mount brackets.
NOTE: Identify washers (shims) for proper reassembly.
MM-13-47
MAINTENANCE MANUAL
(11! Slide turbocharger up and off the mount brackets to remove

turbo and adapter gasket from the aircraft.
(12) Cover openings at injedtor, induction tube and exhaust

system to prevent contamination.
(13) Remove injector inlet adapter and gasket from turbocharger.
NOTE: Identify orientation of adapter to turbocharger

forreassembly.
C. Turbocharger Inspection
Check turbocharger unit for the following:
(1) Rotating unit rubbing housing.
(2) Cracked or distorted housing.
(3) Dirt accumulation on impeller.
(4) Carbon buildup on turbine wheel.
(5) Foreign object damage.
(6) Evidence of looseness between compressor and turbine

sections.
D. Turbocharger Installation (See Fig. 13-9)
(1) Install a new gasket between the turbo inlet adapter and the
turbocharger andsecure adapter, properly oriented, to the
turbocharger. Safety wire screws.
(2) Install the lower outlet oil elbow and flexible outlet line
to the turbocharger on the bench. Torque and safety wire.
(3) Install inlet oil elbow, if removed.
(4) Install turbocharger an mount brackets with washers (shims)

located properly. DO NOT torque bolts.
(5) Install turbocharger heat shield. Safety wire from a cap on

one side of each mount bracket, behind the bracket, to the
next cap.
(6) Install a new gasket and the bolts connecting the injector
to turbo inlet adapter. DO NOT torque bolts.
MM- 1,3-48
MAINTENANCE MANUAL
(7) Connect exhaust collar and steel gasket to the turbocharger

exhaust inlet. Rotate the collar for correct alignment.
Install exhaust inlet clamp, torque to 70-80 in-lbs and
safety.
NOTE: Slip clamp over end of tube to assemble. Do not

spread.
NOTE: If required, loosen turbo mount brackets on the

engine to achieve proper turbo alignment.
(8) Install the flexible sleeve and clamps between the induction
inlet tube and the turbocharger compressor. Torque and
safety.
NOTE: The turbocharger center divider clamp may be

released to rotate the compressor section for
adjustment. DO NOT break the seal.
(9) Install gasket, exhaust outlet and clamp. Torque clamp to

70-80 in. Ibs.
(10) Torque the two turbocharger mount bolts.
NOTE: If required, torque and resafety the lower engine

turbocharger mount bracket bolts.
(111 Torque injector outlet attaching bolts. If required, torque

turbo center divider clamps and safety.
(12) Connect oil inlet and outlet lines.
NOTE: Be sure that check valve located in the oil inlet

line has arrow pointing toward turbocharger.
(13) Inspect all areas prior to closure of the engine compartment

and flight check.
E. Turbocharger Repair
Consult Roto-Master, Inc., North Hollywood, Ca 1 i fo rn i a or an
authorized Roto-Master turbocharger repair facility for

information on turbocharger repair or overhaul. The overhaul
life of the turbocharger is 1,000 hours.
13-6 TURBOCHARGER STATIC AIR FUEL NOZZLE PRESSURE SYSTEM
In order to attain positive pressure at the air bleed nozzles for

starting, idle, and all other operating environments, a static
air system is required.
MM-13-49
MAINTENANCE MANUAL
GASKET INLET HOSE TURBOCHARGER

FROM OIL FILTER BRACKET
jMOUNTrNG
;6B:
NIPPLE
URBO INLET WASHERS

PTOR u
(NOTE I)
-L,
i II s
-i
i II
---I TURBOCHARGER
I-iC-’
INJECTOR (REF.)
!@P~ HEAT SHIELD
i (NOTE 3)
i
(NOTE
METAL GASKET
GASKET;I
"’B
EXHAUST
~TURBOCHARGER CENTER
I
OUTLET\
~DIVIDER COUPLING
TORQUE CLAMP (~NOTE 4)
I‘
FLEXIBLE
SLEEYE
d
HOSE CLAMP
ELBOW
FITTING
PLING
(NOTE 5)
Q (NOTE
TORQUE
4)
CLAMP
(f:i´•~,
OT~ sOdhTv~cTE HpOtSIEp
INDUCTION TUBE COLLAR j
~I I-------7
1_
NOTES:
I, SHIM WITH WASHERS TO AID ALIGNMENT

OF TURBOCHARGER WITH MATING COMPO-
(TYP)
NENTS.
2. SAFETY SCREWS WITH LOCKWIRE.
EXHAUST INLET
3. SECURE HEAT SHIELD WITH LOCKWIRE
(LOOP WIRE BEHIND TURBOCHARGER
MOUNTING EAR),
4. TORQUE CLAMP TO 20 IN.LB. \LOCKWIRE

5. ELBOW MUST BE ORIENTATED TO CLEAR
TURBOCHARGER MOUNTING BRACKET
UPON INSTALLATION.
FIGURE 13-9 TURBOCHARGER INSTALLATION

MM-13-50
MAINTENANCE MANUAL
Installed in the static air system is a single, swing type, check

valve which is vented to ambient air pressure on the filtered
side of the inlet container. During starting, idling and
manifold pressure up to ambient, this valve is open. The valve
closes automatically when turbocharger compressor inlet pressure
exceeds the existing ambient pressure. Pressurized air is now
being furnished to the air bleed nozzle from a line connected to
the induction inlet tube. Static pressure lines run to manifold
pipes located above the rocker covers on each side of the engine.
Flexible lines run from these manifolds to each cylinder nozzle
to provide positive system pressure in all operating
environments.
8. Turbocharger Static Air Pressure System Troubleshooting
Hard starting or Ambient air check Clean or replace valve.

will not start, valve stuck closed
or sticky.
Dirt in nozzle. Clean lines and nozzles.
Dirt in air manifolds. Disconnect lines and

blow out static air
manifolds.
Engine rough at Ambient air check Clean or replace valve.

idle and low valve partially
power, closed or sticky.
Excessive smoking Ambient air check Clean or replace valve.

at idle. valve stuck closed
or sticky.
Excessive EGT at Ambient air check Clean or replace valve.

high power. valve stuck open.
Engine quits Ambient air check Clean or replace valve.

with power valve stuck closed
reductions at or sticky.
high density
altitude.
MM-13-51
MAINTENANCE MANUAL
C. Ambient Air Check Valve
(1) Ambient Air Check Valve Removal (See Fig. 13-10)
Disconnect inlet and outlet lines at the ends of the valve.

Observe airflow marking on valve case for correct
installation.
(2) Ambient Air Check Valve Disassembly
Remove "hinge" end of valve (marked on hex flat) by locking

opposite end in vise and loosening hinge end with a wrench.
(3) Ambient Air Check Valve Cleaning
Carefully clean inside surfaces and components with a clean,

lint-free cloth and air.
(4) Ambient Air Check Valve Installation (See Fig. 13-10)
Connect to inlet and outlet lines to allow "free flow" from

the air inlet container to the static pressure lines.
13-7 PRIMARY AIRFLOW SYSTEM
A. General Information (See Fig. 13-11)
Intake air is drawn in through the non-ram air scoop mounted on

the right side of the aircraft. The intake air then passes
through the air filter on its way to the injector. At the
injector the air volume is metered in proper proportion to the
fuel mixture that the engine requires. The metered air is drawn
into the compressor impeller section of the turbocharger where it
is compressed. This compressed ai´•r is forced into the intake
manifolds where it is delivered to the various cylinders. After
combustion, the exhaust gases are expelled out the exhaust ports
and through the exhaust manifolds back to the turbocharger. The
engine exhaust gases drive the turbocharger exhaust turbine wheel
which drives the compressor impeller through a common rotating
shaft. Exhaust gases are then dumped overboard through the
exhaust outlet. A bypass, just before the turbocharger exhaust
inlet, incorporates a waste.gate which is mechanically linked to
the throttle lever to regulate exhaust flow through the
turbocharger for varying engine power requirements.
MM-13-52
MAINTENANCE MANUAL
TURBOCHARGER STATIC PRESSURE SYSTEM
MANIFOLD
AIR BLEED
NOZZLES
ENGINE DRIVEN
FUEL PUMP
ENGINE
TO FILTERED
AMBIENT
PRESSURE
INDUCTION INLET
TURBOCHARGER AIR BLEED

NOZZLES
MANIFOLD
FUEL
P~MBIENTPRESSURE PRESSURE Il FUEL PRESSURE FROM
CH ECK VALVE GAUGE FLOW DIVIDER
FIGURE 13-10
MM-13-53
MAINTENANCE MANUAL
PRIMARY AIR FLOW SCHEMATIC
AIR FILTER INTAKE
EXHAUST
INDUCTION INLET
INJECTOR ´•3j
ENGINE
TURBO
COMPRESSOR
TURBO
EXHAUST
WASTEGATE
COMPRESSED AIR
EXHAUST
a AMBIENT AIR
U(HIUST~IR
FIGURE 13-11
MM-13-54
MAINTENANCE MANUAL
B. Air Filter and Housing
A polyurethane filter is utilized to remove all foreign

material from the air before it enters the induction system.
The filter is installed in a housing which also incorporates
an alternate air door and auxiliary bypass door. In the
event of a filter blockage, due to ingested dirt or ice
buildup, the spring loaded alternate air door will open,
allowing engine compartment air to be drawn into the
injector. The auxiliary bypass door prevents damage to the
filter assembly and flexible intake hose by allowing back
pressure, due to engine backfire, to escape with minimal
restriction.
(2) Filter Removal (See Fig. 13-12)
Filter change
is recommended every 100 hours. More frequent
changes will be necessary for aircraft used for agricultural
spraying, dusting or operation in dusty areas.
(a) Remove air box cover (1).
(b) Remove filter retainer (2).
(c) Remove and discard filter (3).
(3) Filter Installation (See Fig. 13-12)
NOTE: Clean air box and check for freedom of operation

of the alternate air door (4) and auxiliary bypass
door (5) before installing filter.
(a) Install filter in air box (6).
(b) Install filter retainer with auxiliary bypass door (5)

oriented to align with aft side of inlet hole in air
box cover(l).
(c) Install air box cover.
(4) Housing Removal (See Fig. 13-12)
(a) Disconnect flexible intake hose (7) from air box.
(b) Disconnect static air line (8) above hose.
(c) Disconnect unit from pylon mount bracket (9).
(d) Support air box and disconnect it from the firewall

mount bracket (10).
(e) Lift unit fro, aircrair, allowing drain line (11) to

pull through cowling.
MM-13-55
MAINTENANCE MANUAL
AIR SCOOP
AIR
BOXCOVER J.
AIR FLOW
AIR BOX
FI Lf ER
RETAINER --)1~ 1) (1F- BACK- FIRE
DOOR
~/INfAKE FLEX
FILTER
HOSE
I~ REF. TOP VIEW

i---
COVER
ASSEYBLV ALTERN ATE
AIR DOOR DZUS FASTENERS
MOUNT BRACKET n’ _
FUEL NOZZLE
VENT LINE
AIR BOX
REF. SEAT STRUCTURE
DRAIN LINE
´•p
REF. AS VIEWED FROM LEFT
O 31DC
FILTER- PRIMARY AIRFLOW SYSTEM
FIGURE 13-12
MM-13-56
MAINTENANCE MANUAL
(5) Housing Installation (See Fig. 13-12)
(a) Position unit in aircraft with drain line (11) going

out through the lower side cowling.
(b) Secure unit to firewall mount bracket (10).
(c) Secure to pylon mount bracket (9).
(d) Connect static air line (8).
(e) Connect flexible intake hose (7).
13-8 COOLING SYSTEM
The cooling system consists of the fan assembly, shroud assembly,

oil coolers and ducting. Outside air is drawn in by the fan and
forced through the shroud assembly to provide cooling air flow to
the engine and other components.
B. Fan Assembly
(1) Fan Removal
(a) Remove aft cowling and baggage box.
(b) Remove idler pulley assembly.
(c) Remove jack strut and drive pulley.
(d) Remove fan.
NOTE: The fan, like the starter ring gear support,

is designed to fit on the output flange of
the engine in only one position. Marking a
fan mount hole and its associated stud is
suggested to ease installation.
(2) Fan Disassembly
NOTE: Disassembly of the fan to replace blades requires

that the fan be statically rebalanced prior to
installation. Repair and balancing can be
accomplished by Enstrom Helicopter Corporation or
a maintenance facility equipped with tools
specified in the Balancing Procedure.
(a) Mark blade ring and fan disc to show proper relation-
ship for reassembly.
MM-13-57
MAINTENANCE MANUAL
(b) Remove all nuts, bolts and washers attaching blade ring
to fan disc.
NOTE: Check for elongation of bolt holes. Fan

should be replaced if evidence of hole
elongation exists.
(c) Discard used locknuts.
(d) Drill out rivets securing damaged blade(s).
(3) Fan Reassembly
(a) Attach new fan blade(s) to blade ring with AN427M4-7

rivets.
(b) Align and attach blade ring to fan disc.
NOTE: Attach With AN3-6A bolts, one AN960-10L

washer under each nut, and new AN364-1032
nuts.
(c) Balance fan.
(4) Fan Balancing (See Fig. 13-13)
(a) Install balancing arbor (T-1900) to fan assembly.
(b) Place assembly on balancing stand and allow heavy side

to settle to th;e bottom. Identify blade that is
closest to the bottom.
(c) Remove nuts and washers from heavy side and

bolts,
replace with AN3-5A bolt, (2) AN960-10L washers, and a
AN364-1032 nut ahd/or remove AN960-10L washers from
light side and replace with AN96O-1O washers as
required for balaricing.
NOTE: Not more than (3) AN960-10 washers may be

used per bolt for balancing.
Fan blade should balance in any position with

blade drift not exceeding one inch in five
seconds from any check position.
(d) Torque all nuts.
(5) Fan Installation
(a) Align and install fan on engine output flange.
NOTE: Insure shim is installed on output flange

before installing fan.
(b) Install jack strut and lower drive pulley.
MM-13-58
MAINTENANCE MANUAL
FAN
6/ \o
\il i T-19O0 BALANCING ARBOR

O
O
O 0,
0\ ‘1 I IV;´•´•lO~
INSTALL WASHERS FOR BALANCING

UNDER NUT.(SEE NOTE)
BALANCING STAND
NOTE:
NOT MORE THAN (3) AN960-IO WASHERS

MAY BE USED PER BOLT FOR BALANCING.
FAN BLADE SHOULD BALANCE IN ANY

POSITION WITH BLADE DRIFT NOf
EXCEEDING ONE INCH IN FIVE SECONDS
FROM ANY CHECK POSITION.
FIGUIIE 13-13 FAN BALANCING
MM-13-59
MAINTENANCE MANUAL
(c) Install idler pulley assembly.
(d) Slowly rotate fan to check for proper fan to shroud

clearance. Adjust shroud as necessary.
(e) Run engine to check belt tracking and fan operation.
(f) Install baggage box and cowling.
C. Fan Shroud
(1) Fan Shroud Removal
(a) Remove aft cowling and cowling from both sides.
(b) Remove baggage compartment.
(c) Remove idler pulley assembly.
(d) Remove jack strut and drive pulley.
(e) Remove fan assembly.
(f) Remove shim, starter ring gear and alternator drive

belt.
(g) Disconnect lines and drain oil from auxiliary oil

cooler.
NOTE: Raise lines as they are disconnected to

prevent drainage of oil from lines and
primary oil cooler.
(h) Remove auxiliary oil cooler.
(i) Disconnect shroud from bracket attaching it to the

bottom of the engine.
(j) Disconnect flexible duct to heater muff.
(k) Remove two lower panels from the front of the shroud
assembly.
(1) Disconnect alternator from belt tension adjustment

bracket and remove bracket.
(m) Remove fasteners attaching fan shroud to fire curtain

and top and side engine baffling.
(n) Disconnect air deflection vanes.
to) Remove air deflection vanes.
(p) Remove fan shroud assembly by pulling it aft and

tipping it as necessary to clear pylon.
MM-13’-60
MAINTENANCE MANUAL
(2) Fan Shroud Installation
(a) Position fan shroud in engine compartment and loosely

attach it to the top engine bracket and side baffling.
(b) Temporarily install the fan to align shroud and tighten

fasteners.
(c) Install air deflection vanes.
(dJ Install twolower panels on front of shroud assembly

and attach lower engine shroud bracket.
(e) Attach fire curtain.
(f) Install belt tensioning bracket.
(g) Install auxiliary oil cooler.
(h) Sea 1 holes where leakage may occur with Dow Coming
Silicone Sealant or equivalent.
(i) Connect flexible duct to heater muff.
Connect lines to primary oil cooler.
(k) Install alternator drive belt and starter ring gear.
(1) Check shroud foam tape and replace if necessary.
(m) Install shim and fan assembly.
(n) Install drive pulley and jack strut.
to) Install idler pulley assembly.
(p) Check engine oil level and replace oil removed with oil
cooler.
(q) Run engine to check fan clearance and belt tracking.
(3) Foam Tape Installation
(a) Remove all tape from the fan shroud and check fan blade
to shroud clearance. Adjust if necessary.
NOTE: If significant amounts of tape were missing,

check oil coolers for partial obstruction by
tape fragments.
(b) Remove all grease, oil and contaminants from area to be

tapped by cleaning with solvent. Avoid finger prints
on cleaned area.
(c) Cut end of foam tape at approximately 45" angle.
MM-13-61
MAINTENANCE MANUAL
(d) Install tape and cut finishing end to match.
CAUTION: Upon initial running of the engine it is

necessary to clean oil cooler air passages of
foam tape particles sheared off by the fan.
D. Firewall Repairs (See Fig. 13;14)
NOTE: All openings in the firewall in excess of 1/32 inch are

to repaired.
be Small openings, such as around pylon
tubes, may be caulked with 3M CP-25 or silicone
sealant. Fire curtains requiring extensive repairs
should be replaced.
(1) Clean area of repair with acetone.
(2) Holes up to 4 inch in stainless steel cabin firewall:
(a) Caulk with sealant.
(3) Holes up to 1 inch in fabric (see Fig. 13-14 A):
(a) Form (2) round patches of .015 thickness stainless

steel, allowing 3 inch overlap on all sides of existing
hole.
(b) Drill .015 inch diameter hole in center of both

patches.
(c) Coat one side of each patch with sealant.
(d) Place one patch on each side of fabric hole with

sealant against the fabric.
~e) Fasten patches over the hole with (1) AN525-6R6 screw,
(1) AN960-6L washer, and (1) AN364-632 nut.
(4) Areas of worn fabric around pylon tubes or cables (see

Fig. 13-14 8):
(a) Cut a patch of similar material (firewall curtain,

RL-638-3N as purchased from Raybestos-Manhattan, Inc.)
to cover 1/2 to 3/4 inch beyond the damaged area.
(b) Coat one side of patch with sealant.
(c) Apply patch, sealant side against fabric.
(d) Attach patch with AN525-6R6 screws, AN96O-6L washers,

and AN364-632 nuts at 3/4 to 1 inch spacing.
(e) Seal nonessential gaps (around pylon tubes, etc.) with

sealant.
MM-13;62
MAINTENANCE MANUAL
Q"
~n´•8
B
Y
/~kS,
FIGURE 13-14
STANDARD FIRE CURTAIN REPAIR PROCEDURE
MM-13-63
MAINTENANCE MANUAL
(5) Tears in fabric material which are less than 3" in length
(Fig. 13-14 C):
(a) Lace damaged area together with .020 inch stainless

steel safety wire.
(b) Apply sealant to repaired area on the side away from

the engine compartment.
(6) Tears in fabric material in excess of 3 inches in length:
(a) Cut two i-inch wide strips of .015 inch stainless steel
to a length allowing for 1/2 inch overlap at each end
of the repair (Fig. 13-14 D).
(b) Dri 11 .150 inch (approximate) diameter holes, space

1 inch apart diagonally.
(c) Apply patch, sealant side against fabric.
(d) Attach patch, sealant sides against fabric, with

AN525-6R6 screws, AN960-6L washers, and AN364-632 nuts.
13-9 IGNITION SYSTEM
The D-32OO ignition system consists of a dual magneto which

features two electrically independent ignition circuits in one
housing, a harness assembly, starting vibrator (for shower of
sparks starting system), and the magneto switch.
At low cranking speed of the engine the vibrator provides the

high voltage spark necessary to fire the plug. The vibrator
provides interrupted battery current to the primary coil of the
magneto where it is stepped up by transformer action, producing a
shower of sparks which is directed to the spark plugs through the
retard points located in the left magneto. Detailed operation,
installation and service instruction may be found in Bendix
Operational Manual No. L-928 and Overhaul Manual No. L-945.
B. Ignition System Troubleshooting

NOTE: Refe rence i nformati on found in Bendix I n stal 1 ati on
Operating and Maintenance Instructions Manual L-928.
MM-13-64
MAINTENANCE MANUAL
Hard starting. Low voltage at Check and change or

vibrator input replace battery as
(9.5 volts minimum required. Use of an
on 12 volt systems, auxiliary power unit
measured between is recommended for
vibrator "IN’’ and cold weather starts.
ground terminal with
starter engaged). Check all electrical
grounds and connections
for corrosion or
looseness.
Inoperative vibrator Check ground and

(no buzzing audible power in.
when starter is Replace vibrator.
engaged).
Incorrect vibrator .025" .005" gap.

point gap.
Retard points Check timing of retard

opening too late. points according to
paragraph E (2), page
MM-13-68.
tngine kicks Open retard circuit. Check continuity (10 ohms

back during Engine fires only in or less) between LR
starting. its normal advance terminal of the vibrator
position, to nearest paint-free
ground. If circuit is
open, retard contact
spring in magneto may
not be making contact.
Retard points not Check and adjust retard

closing due to points as necessary.
incorrect adjustment.
Poor electr´•ical Check connections at

connection. vibrator and magneto.
Internal relay in Replace vibrator

vibrator unit not assembly.
functioning.
Magneto incorrectly Check magneto to engine

timed to the engine, timing (see Magneto
Installation and Timing
to Engine).
Magneto internal Check magneto timing

timing incorrect, per paragraph E (2),
page MM-13-68.
MM-13-65
MAINTENANCE MANUAL
Engine roughness. Fouled or defective Clean or replace

spark plugs. spark plugs.
Defective spark Check plug leads for

plug leads. continuity and break-
down.
Arcing in distributor. Check distributor block

for moisture and
carbon tracking.
Eroded or compressed Check contact springs in

distributor block distributor block.
contact spring(s).
Burned magn;eto Check magneto contact
contacts. assemblies for burring
or dirt.
Excessive magneto Magneto to engine Adjust timing.

drop on rpm check. timing incorrect.
Incorrect contact Inspect contact

adjustment. assemblies for proper
opening.
One or more Check plugs and leads.

cylinders misfiring.
C. Vibrator-Magneto Check
(1) Disconnect starter input wire to prevent engine from turning

during this check.
(2) Turn engine in direction of normal rotation to bring number

one cylinder to top dead center on its compression stroke.
(3) Check to insure retard points have opened.
(4) Hold No. 1 cylinder top plug wire 3/16 inch from ground.
(5) Turn magneto switch to BOTH.
(6) Depress starter button,
NOTE: A steady spark should be visible between the plug

wire and giround. A weak or mi ss i ng spark
indicates possible faulty vibrator, electrical
connection or magneto internal timing.
MM-13-66
MAINTENANCE MANUAL
(7) Release starter button.
(8) Turn magneto switch to OFF.
(9) Check system, replace or adjust components as necessary.
(10) Repeat checking procedurebefore reconnecting starter.
D. Magneto Operational Check
(1) Start engine and engage rotor.
NOTE:
Maintain rotor in flat pitch during the following procedure.
(2) Advance throttle to 1800 rpm and allow cyl inder head
temperature to reach 200" F.
(3) S1 owly advance th rottl e to 2300 rpm and a 1 1 ow oil

temperatures to reach 80" F.
(4) Advance throttle to 3050 rpm.
(5) Check manifold pressure; 17-19 inches.
(6) Check fuel flow; 60-80 Ibs./hr.
(7) Turn magnetoswitch from BOTH to L (left magneto) position.

Note rpm drop (125 rpm max.) and EGT rise (100" F. max.) in
5 seconds.
(8) Return switch to BOTH position and allow rpm to stabilize.
(9) Turn magneto switch from BOTH to R (right ma

Note rpm drop (125 rpm max.) and EGT rise 100" qneto) F
position.
maximum)
in 5 seconds.
NOTE: Maximum pemissible rpm differential between left

and right magnetos is 50 rpm without engine
roughness. A differential of greater than 50 rpm
or a drop in rpm greater than 125 rpm may indicate
spark plug, spark plug lead wire, or magneto

problems.
An EGT rise in excess of100" F. while operating

in either L or R position of the magneto switch
indicates a magneto timing problem.
(10) Return switch to BOTH position and allow rpm and EGT to
stabilize prior to engine shutdown.
MM-13-67
MAINTENANCE MANUAL
E. Magneto
(1) Magneto Removal
(a) Remove magneto cover.
(b) Remove nuts and washers from magneto mounting clamp

studs.
(c) Pull flow divider fuel line bracket forward to clear

stud and rotate bracket and clamp upwards to allow
clearance for magneto clamp removal.
(d) Remove magneto and clamps.
(2) Magneto Installation and Timing to the Engine
(a) Remove timing hole plug from one side of magneto and
plug from rotor viewing location at center of housing.
(b) Turn the magneto d:rive shaft in the direction of normal

rotation until painted tooth on the distributor gear is
centered in the timing hole.
NOTE: Observe that at this time the pointer in

rotor viewing window aligns with the "L"
marked on the rotor. If internal timing of
the magneto is required, refer to Bendix
Operation and Maintenance Manual No. L-928.
(c) Set engine No. 1 cylinder at 200 BTDC (align mark on
starter ring gear with mark on starter housing) on its

compression stroke. (See Fig. 13-15)
(d) Maintain magneto No. 1 firing position (tooth in center

of hole and pointer aligned with "L" on rotor).
Install magneto to the engine and loosely clamp in
position.
NOTE: Insure flow divider fuel line bracket is

placed on magneto mount stud before nut and
washer are installed.
(e) Attach red leads from magneto timing light to each "P"
lead, black lead to ground.
(f) Turn the entire mbgneto in direction of rotor rotation

until the timing l.ight comes on.
(g) Rotate the magneto in the opposite direction until the

light for the left magneto just goes off, indicating
the left main breakers have opened.
MM-13-68
MAINTENANCE MANUAL
TIMING MARKS
NOTE: T I M ING MAR KS VI SI BLE

THRU HOLES IN FAN
ASSEMBLY
FLYWHEEL TIMING MARKS
~V/3( ~X STARTER HOUSING

TIMING MARK
I
i /i
FIGURE 13-15
MM-13-69
MAINTENANCE MANUAL
(h) Tighten magneto clamps and install plugs in timing and

rotor viewing holes.
(i) Back the engine up approximately 200 to 300 and then

carefully bump the engine forward while observing
timing light.
(j) At the No. 1 firing position (20" BTDC) the light for
the left magneto should be off, indicating the left
breaker has opened. The light for the right magneto
should go out within 2" of left magneto.
NOTE: Each tooth of the starter ring gear is

approximately 2".
(k) Disconnect timing light leads from "P" leads and

reconnect one to the retard breaker terminal.
(1) Rotate the crankshaft to bring No. 1 cylinder to top

dead center (aligni TDC mark on starter ring gear with
index mark on starter housing).
NOTE: Timing light should go out at TDC

(plus 2", minus O") indicating retard points
have opened.
(m) Loosen retard cam securing screw and adjust cam, as
necessary, to achieve correct timing.
(n) Retorque cam securing screw to 16-20 in. Ibs.
to) Back engine off 20" to 300 and bump it forward again
until timing light goes out. Check timing mark on
starter ring gear to insure cylinder is at TDC. Adjust
retard cam as necessary.
(p) Remove timing light leads.
(q) Install magneto cover and "P" leads.
(r) Insure retard contact spring is in position by checking

continuity (10 ohms or less) fromthe LR terminal of
the starting vibrator to the nearest paint-free system
ground.
F. Harness Assembly (See Fig. 13-16)
Ignition wires are routed from the left magneto to all cylinder
top spark plugs and those from the right magneto go to all
cylinder bottom spark plugs.
MM-13-70
MAINTENANCE MANUAL
IGN I T ION WI RE INSTALLAT ION
I-
’---CYL.#I
FIRING ORDER :IB:
CYL.#2 C.CIWISE ROTATION (li
i FLYW~EEL
I
I ~CYL.# 3
ri
,I
CYL.#4
L:R
TOP SPARKPLUGS
BOTTOM SPARKPLUGS
j
ie
0-3200 SERIES
MAGNETO
FIGURE 13-16
MM-13-71
MAINTENANCE MANUAL
13-10 FUEL SYSTEM
The fuel system consists of the fuel tanks, fuel boost pump,
valve, fi 1 ter, fuel lines, engine driven fuel pump and fuel
pressure switch. Fuel is gravity fed from the tanks through the
shut-off valve, boost pump, filter and fuel lines to the inlet
side of the engine driven fuel pump. This fuel pump functions
whenever the engine is operating and delivers a constant flow of
fuel under a regulated pressure to the fuel metering section of
the injector. The fuel metering section operates by measuring
the airflow through the throttle body of the injector and uses
this measurement to operate a servo valve within the section.
The accurately regulated fuel pressure established by the servo
valve is used to control the flow divider, which then schedules
fuel flow to the cylinders in proportion to airflow.
B. Fuel Tanks
(1) Tank Removal (See ~ig. 13-17)
~a) Drain fuel into suitable containers, siphon fuel from

tanks, then drain remaining fuel by opening the tank
drain valves (1) at the bottom of each tank.
(b) Olsconnect vent lines (2) at top of tanks.
(c) Disconnect fuel level sending unit wires at the

"wristlock" connections located between the tops of the
tanks.
(d) Disconnect fuel outlet lines (3), tank drain lines (1),
and scupper drain lines (4) at bottom of tank.
(e) Remove screws (5) attaching tanks to bulkhead and

cabin.
(f) Remove fuel tanks.
NOTE: Shims dislodged during tank removal should be

resecured in position with 3M brand Trim
Adhesive, P/N 08021, or equivalent.
(2) Tank Installation (See Fig. 13-17)
(a) Position tanks on bulkheads and install attachment

screws (5), at.cabin and bulkhead.
(b) Connect vent lines (2) at top of tanks.
(c) Connect fuel level sending unit wires at the

"wristlock" connections.
MML13-72
MAINTENANCE MANUAL
LEFT SIDE k~Pn’ ~a RIGHT SIDE

(FRONT VIEW) ~n III (FRONT VIEW)
5 ~I 5
FUEL CONTROL
HANDLE
FUEL SHUT-OFF
(CABIN AREA)
VALVE 4
5 (I FUEL SHUT-OFF
B~I I O
PUSH-OPEN
PULL- CLOSED
MAIN
FUEL LINE
FUEL SUMP DRAIN
GASCOLATOR DRAIN CONTROL 0´•

OPEN
CLOSED.
NOTE: Late "F" models will have
push type sump drain.
FUEL TANK INSTALLATION
FIGURE 13-17
MM-13-73
MAINTENANCE MANUAL
(d) Secure plastic covlers over "wristlock" connections with

tie-wrap.
(e) Secure wires to main rotor transmission vent pipe with

tie-wrap.
(f) Connect fuel outlet lines (3), tank drain lines (1),
and scupper drain lines (4) at bottom of tank.
(g) Fill fuel tanks to check gauge calibration. (See

Markings and Gauge Calibration.)
(3) Markings and Gauge Calibration (See Fig. 13-18)
NOTE: Fuel markers on fuel tank sight windows

quantity
are installed
with aircraft in ground attitude,
ground handling wheels up, aircraft setting on
landing gear. Cabin fuel gauge calibration is
done wi th ai rcraft in fl ight atti tude ground
handling wheels down.
(a) Position aircraft in flight attitude, ground handling

wheels down.
(b) Add one gallon of fuel to each tank.
NOTE: Allow fuel level to stabilize between tanks

after each addition of fuel.
(c) Adjust float arm (1) to get cabin fuel gauge reading of
"zero" at this level to include unusable fuel, (See
Fig. 13-19)
NOTE: Cabin fuel gauge adjustments are made by

bending float am on fuel quantity sending
unit.
(d) Position aircraft with ground handling wheels

retracted.
(e) Add five gallons of fuel to each tank.
(f) Install 60 Ib. markers (1) adjacent to this fuel level

on the fuel tank Sight window.
NOTE: Some F-models will not be equipped with the

fuel tank sight window.
(g) Place aircraft in flight attitude, ground handling

wheel´•s down.
MM-13-74
MAINTENANCE MANUAL
FIGURE 13-18
FUEL TANK SIGHT GAUGE USED ON SOME
EARLY F MODE´•L FUEL TANKS
ORIGINAL
As Received BY
ATP
MM-13-75
MAINTENANCE MANUAL
~ce
FUEL LEVEL
SENDING UNIT
FIGURE 13-19
MM-13-76
MAINTE~JANCE MANUAL-:Tic i
(h) cabin fuel gauge reading is 60 1 bs one

indicator needle width).
NOTE: Excessive deviation between fluid level and

gauge reading is cause for replacement of the
sending unit.
(i) Place aircraft in ground attitude, ground handling

wheel retracted.
(j) Add five gallons of fuel to each tank.
(k) Install 120 Ib. markers (2) adjacent to this fuel level
on the fuel tank sight window.
(1) Measure up approximately 10-7/8 inches from bottom edge

of tank along forward side of sight window and install
1801b. markers (3) at this point.
(m) Ins tall 240 Ib. decal (4) at top forward corner of
sight window decal.
USABLE FUEL QUANTITY
1/4 60 Ibs or 10 gallons

Full 240 Ibs or 40 gallons
NOTE: Each tank contains one gallon of unusable

fuel.
(4) Fuel Level Sending Unit
(a) Sending Unit Removal (See Fig. 13-19)
1 Remove three screws (2) attaching sending unit

cover to top of right fuel tank.
2 Remove cover (3) and spacers (4).
3 Clean sealant from cover and its mounting

location.
4 Disconnect ground wire (5) and transmitter output

wire (6).
5 Remove remaining screw attaching unit to fuel

tank, note location for reassembly.
6 Lift sending unit assembly out of fuel tank.
NOTE: Due to the shape of the float it is

necessary to tilt the unit to get float
out of fuel tank opening.
MM-13-77
MAINTENANCE MANUAL
(b] Sending Unit Installation (See Fl,. 13-19)
I Replace seal (7) around fuel tank opening, if

damaged.
NOTE: Seal is secured in place with 3M brand

Trim Adhesive, P/N 08021, or equivalent.
2 Install sending unit (1; into fuel tank.
3 Install screws, attaching ground wire (5) to

sending unit and sending unit directly to the
tank.
4 Connect transmitter output wire (6).
5 Place a bead of Dow Coming Silicone Rubber

Sealant or equivalent around the recess to act as
a seal when cover is installed.
6 Install cover (3), spacers (4), and screws (2).

Secure screws.
(5) Fuel Tank Repairs
(a) Drain fuel from tanks.
(b) Remove leaking tank(s) from aircraft.
(c) Repair seepage of fuel through fiberglass tank.
1 Remove fuel level sending unit (right tank) and

all fittings.
CAUTI~N: Carefully remove fittings that are

bonded in to prevent damage to scupper
bag.
1 Plug all openings except the fuel cap opening.
3 Pour one gallon of slushing compound into the

tank.
NOTE: Slushing compound used is 3M Scotch-Clad

brand Fuel Resistant Coating 776.
4 Plug fuel cap opening.
5 Slowly roll tank to assure that all surfaces have

been completely covered with compound.
6 Place tank with bottom parallel to floor and drain

excess compound through the main fuel outlet.
MM-13-78
MAINTENANCE MANUAL
Open all openings and force ventilate tank to cure
slushing compound.
NOTE: Allow a minimum of eight hours cure

time. (Slushing compound is tack-free
when cured.)
8 Install main fuel outlet and strainer, adding a
new bond of 3M brand EC801.
NOTE: Allow EC801 to cure tack-free before

fueling tank.
9 Install remaining hardware.
10 Check sump drain to assure it is not blocked.
11 Cap all fuel outlets.
12 Place approximately five gallons of fuel in the

tank to check for leaks before installation on the
aircraft.
13 Drain fuel and reinstall tank on aircraft.
(d) Repair leak(s) around tank cover seam.
1 Drill out rivets in area of leak.
2 Remove EC801 from between tank and cover by

scraping.
3 Install a new coating of EC801
4 Drill out rivet holes and install next size larger

diameter rivets.
5 Allow EC801 to cure tack-free.
6 Coat interior of tank in area of repair with

slushing compound.
CAUTION: Care must be taken to prevent slushing

compound from coating fuel fittings.
Remove fittings and plug holes if
necessary.
7 Drain excess slushing compound.
8 Allow compound to cure tack-free.
9 Place approximately five gallons of fuel in tank

to check for leaks.
10 Drain tank and reinstall on aircraft.
MM-13-79
MAINTENANCE MANUAL
C. Fuel Boost Pump
The fuel system boost pump is factory set at a pressure of

27 psi. A pressure switch monitors the fuel system pressure
and activates the indicator panel lights. The green light
will come on when the fuel system pressure increases to
20 psi and above. The red wa~ning light will come on when
the fuel system pressure falls to 15 psi or below.
NOTE: Newer F-models will not have the green normal fuel
pressure indicator.
(2) Boost Pump Adjustment
NOTE: Adjustments are to be made with a fully charged

battery.
(a) Master switch OFF
(b) Boost pump switch OFF
(c) Fuel shutoff valve CLOSED
(d) Remove 7/16 inch plug from RSA fuel injector.
(e) Instail 0-50 psi pressure gauge.
(f) Fuel shutoff valve OPEN
(g) Mixture control to idle cutoff.
(h) Master switch ON
(i) Magneto switch OFF
(j) Boost pump switch ON
NOTE: Fuel pressure should read 27 psi.
(k) Loosen jam nut on boost pump relief valve adjustment

screw.
(1) Adjust boost pump pressure.
NOTE: Clockwise rotation of the adjustment screw

decreases pressure.
(m) Lock adjustment screw with jam nut.
(n) Recheck pressure.
(0) Boost pump switch OFF
MM-13-8O
MAINTENANCE MANUAL
(p) Master switch OFF
(q) Fuel shutoff valve CLOSED
(r) Adjust engine-driven fuelpump.
D. Engine-Driven Fuel Pump
(1) Engine-Driven Fuel Pump Removal (See Fig. 13-21)
WARNING: Insure fuel shutoff valve is closed.
(a) Remove firewall access panels.
(b! Disconnect fuel inlet line (1) and outlet line (2).
(c) Disconnect static pressure line (3) and drain line (4).
(d) Cut safety wire and remove bolts (5) which secure fuel
pump to scavenge pump and engine accessory case
mounting pad.
(e) Remove fuel pump and fiber spacer (7).
CAUTION: Withdraw fuel pump straight away from engine.

Scavenge pump will remain in position with
oil lines intact.
(2) Engine-Drive Fuel Pump Inspection
Perform an inspection and operational check on the

engine-driven fuel pump in accordance with manufacturer’s
overhaul instructions.
(3) Engine-Driven Fuel Pump Installation (See Fig. 13-21)
NOTE: On new fuel pumps, install elbows in correct

locations prior to installation on engine.
(a) Install bolts (5) with washers through the fuel pump.
(b) Install fiber spacer (7) on bolts.
(c) Align splined shaft and bolts to scavenge pump and

slide fuel pump into position, lubricate spline.
NOTE: Be sure gasket between scavenge pump and

engine is properly aligned before securing
bolts.
(d) Secure scavenge pump and fuel pump to engine accessory

case. Torque bolts and safety wire in pairs with .032
wire.
MM-13-81
ENGINE FUEL PUMP
LEFT RIGHT
FUEL rl T1 FUEL
TANK I II 1 TANK
FUEL SHUT-OFF VALVE

FUEL STRAI
BOOST PUMP
ENGINE FUEL
FLOW DIVIDER
ENGINE z
m
z
H z
T VENTED TURBO
o
m
r
u DECK PRESSURE
dO Z
ru C
BOOST PRESSURE SWITCH
ALTITUDE r
COMPENSATING
INJECTOR
FUEL NOZZLE GAUGE
FUEL FLOW SCHEMATIC

METERED FUEL PRESSURE
FIGW~ 13-20
[m7 UNMETEREO FUEL PRESSURE
MAINTENANCE MANUAL
10
n
p~
7
B
8
2
Q
o‘;ts~P
O
ENGINE DRIVEN FUEL PUMP

AND SCAVENGE PUMP 5
FIGURE 13-21
MM-13-83
MAINTENANCE MANUAL
(e) Connect drain line (4) and static line (3).
(f) Connect fuel inlet line (1) and outlet line (2).
NOTE: Following the removal and overhaul of any

fuel system-related engine components, turn
fuel onand check operation of fuel system.
Every 25 hours a visual check of the pump
drain should be made with the engine running.
If the engine-driven pump fails there is a
possibility that it will pump fuel overboard
through the drain line.
(4) Engine-Driven Fuel Pump Adjustment
NOTE: Fuel boost pump pressure should be adjusted prior

to adjustment of engine-driven fuel pump.
(a) Remove safety wire from engine-driven fuel pump

adjustment screw (6).
(b) Follow normal engine starting and rotor engagement

procedures.
(c) Engine rpm 3050
(d) Boost pump OFF
(e) Adjust engine driven fuel pump to 24 1 psi.
NOTE: Clockwise rotation of the adjustment screw

increases pressure.
(f) Follow normal engine cooling and shutdown procedure.
(g) Safety wire adjustment screw (6).
(h) Remove 0-50 psi pressure gauge.
(i) Reinstall and safety wire 7/16 inch plug.
(j) Run engine and check for fuel system leaks.
(k) Perform idle mixture and rpm check.
E. Fuel Filter
(1) Fuel Filter Removal
(a) Shut off fuel with fuel shutoff valve.
(b) Drain fuel from filter by opening sump drain.
(c) Disconnect sump drain valve extension shaft from

assembly.
MM-13-84
MAINTENANCE MANUAL
(d) Disconnect fuel inlet and outlet line.
(e) Cap lines and fittings.
(f) Remove safety wire from pipe plug at top of assembly.
(g) Remove bolts securing strainer assembly to pylon mount

bracket.
(2) Fuel Filter Disassembly
NOTE: The assembly does not have to be removed from

aircraft for filter inspection.
(a) Remove safety wire from bolt at bottom of filter

retaining bracket.
(b) Loosen filter retaining bracket bolt.
(c) Swing retaining bracket forward to release bottom

cover, outer body a and gaskets.
(d) Remove retaining pin at bottom of filter to release end

cap.
(3) Fuel Filter Inspection
(a) Check fuel filter assembly for:
1 Cracks and evidence of corrosion.
2 Loose or damaged fittings.
3 Worn or damaged gaskets.
4 Security of filter retaining pin.
(b) Check filter for:
1 Rips, dents or deformation.
2 Contamination.
(4) Fuel Filter Assembly Cleaning
(a) Clean all housing parts with a suitable solvent.
NOTE: Payparticular attention to fittings and

passageways within housing body.
(b) Clean interior and exterior surfaces of housing with

solvent and fine bristle brush.
CAUTION: Damage to filter can occur if excessive force

is used during cleaning.
MM-13-85
MAINTENANCE MANUAL
(5) Fuei Fflter Housing Assembly
(a) Install upper gasket, filter top ring, filter and end
cap.
(b) Secure filter with Pin.
(c) Install gasket in bottom cover.
(d) Install outer body and end cap on assembly.
NOTE: Align drain port on end cap with fuel outlet

port on top of assembly.
(e) Swing retaining bracket under assembly and align bolt

with recess in end cap.
(f) Secure assembly by tightening retaining bracket bolt

and safety wiring bolt to bracket.
(g) Install drain valve and tube in bottom of assembly.
~6) Fuel Filter Assembly Installation
(a) Attach filter assembly to pylon with drain valve

positioned aft.
(b) Safety wire plug on top of assembly.
(c) Attach fuel inlet line to the forward top port.
(d) Attach fuel outlet line to the aft top port.
(e) Attach drain valve extension.
(f) Close drain valve.
(g) Open fuel shutoff valve.
(h) Turn boost pump ON.
(i) Mixture control to idle cutoff.
(j) Check for fuel leakage.
(k) Turn off boost pump and close fuel shutoff valve.
F. Fuel Pressure Switch
(1) Fuel Pressure Switch Removal
(a) Close fuel shutoff valve.
(b) Drain fuel sump.
MM-13-86
MAINTENANCE MANUAL
(c) Remove safety wire from electrical connection.
(d) Disconnect electrical connection.
(e) Disconnect switch assembly from pylon attachment.
(f) Loosen jam nut on fuel line attachment fitting.
(g) Remove switch assembly from fuel line fitting.
(2) Fuel Pressure Switch Installation
(a) Install switch assembly on fuel line fitting.
(b) Secure with jam nut.
(c) Attach switch assembly to pylon clamp.
(d) Install electrical connector.
(e) Safety wire connector to switch assembly.
(f) Open fuel shutoff valve.
(g) Turn boost pump on.
(h) Mixture control to idle cutoff.
(i) Check for fuel leakage.
(j) Turn off boost pump and close fuel shutoff valve.
G. Fuel Shutoff Valve
(1) Fuel Shutoff Valve Removal
(a) Remove left fuel tank to gain access to shutoff valve.
(b) Disconnect fuel line from aft side of valve.
(c) Disconnect fuel lines from left and right sides of

valve.
(d) Disconnect cable from valve actuating arm; loosen jam

nut, loosen screw, and unhook wire.
(e) Remove bolts securing valve to pylon.
(2) Fuel Shutoff Valve Installation
(a) Secure valve to pylon mount with two nuts and bolts.
(b) Install and check rigging of control cable.
MM-13-87
MAINTENANCE MANUAL
(c) Connect fuel inlet and outlet lines.
(d) Install fuel tank.
(e) Place fuel in tanks and check for leaks prior to

flight.
(3) Fuel Shutoff Valve Rigging
(a) Position top of shutoff valve actuating arm full

forward to insure valve is open.
(b) Position cockpit shutoff valve control knob pushed in

to within a inch of nut securing it to firewall.
NOTE: This a inch "cushion" is used to insure the

valve is completely open when the control
knob is pushed in.
(c) Insert wire from control cable through hole in valve

actuating arm attachment swivel.
(d) Secure cable sheath to pylon.
(e) Secure wire in swivel by tightening the screw on the

swivel end and locking it with the
jam nut.
(f) Form a hook in the wire end by bending it upward and

aft.
(g) Check control operation by pulling the knob out, to

close valve, and push it back in to open the valve.
With valve fully open the knob should not bottom out at
the firewall.
13-11 LUBRICATION SYSTEM
A. Description (See Fig. 13-22)
Engine oil flows to the turbocharger from the engine through a

restricted elbow fitting. On this same line, a valve is located
just before the oil inlet to the turbocharger. This check valve
prevents an oil buildup in the turbocharger after the engine is
shut down. An engine-driven scavenge pump is utilized to return
the turbocharger oil back to the engine sump. The scavenge pump
parts are stamped "in" or "out" and the correct rotation is
marked.
Two reverse flow coolers are used to cool the oil for the
oil
entire system. Cooling
air from the fan is directed through the
cores of the coolers andi exhausted into the atmosphere.
Regulation of oil flow through the cooler is accomplished by a
temperature and pressure sensitive valve located in the engine
accessory case.
The cockpit oil pressure gauge line runs from under the
instrument console back to thie engine accessory case.
MM-13-88
MAINTENANCE MANUAL
TURBOCHARGER
AUXILIARV OIL COOLER
SCAVENGE PUMP
PRIMARY
OIL COOLER
ENGINE
SUMP
CHECK VALVE RESTRICTED PRESSURE
OIL PRESSU RE GAUGE
OIL SYSTEM DIAGRAM
13-22
MM-13-89
MAINTENANCE MANUAL
B. Oil Coolers
(1) Oil Cooler Removal
The primary oil cooler is mounted on the right-hand side of

the engine compartment. The auxiliary oil cooler is mounted
to a duct located on the lower left side of the cooling fan
shroud.
(a) Primary Oil Cooler
1 Open right side cowl.
NOTE: Place magneto switch in OFF position.
2 Drain oil out of the lower inlet oil line fitting.
NOTE: Place container beneath the radiator

when disconnecting lines to collect any
drain oil from the cooler and lines.
3 Disconnect and cap the inlet lines.
4 Remove four bdlts holding the oil cooler boot to

the inboard side of the oil cooler.
5 Remove four bolts holding the oil cooler air exit

duct to the outboard side of the oil cooler.
NOTE: Upon removal of cooler, visually inspect

rubber flex boot for rips. Replace the
boot assembly if necessary.
(b) Auxiliary Oil Cooler
1 All switches OFF
2 Drain oil from engine sump.
3 Open left cowl.
4 Place oil catch pan beneath oil cooler.
Disconnect and plug inlet and outlet lines.
6 Remove two screws and washers from bottom of oil

cooler heat shield.
Z~ Remove two screws and -washers from top of oil

cooler heat shield.
8 Remove heat shield.
MM-13-9O
MAINTENANCE MANUAL
9 Remove two screws and washers attaching aft side

of oil cooler to oil cooler duct.
10 Remove oil cooler.
(2) Oil Cooler Inspection
(a) Inspect oil coolers for:
1 Bent, broken or dirty core fins.
2 Nicked, burred, or deformed plumbing fittings.
3 Deformed screw holes.
4 Loose boot attachment to radiator inlet.
(b) Inspect oil cooler air ducts for:
1 Cleanliness.
2 Cracks, checking, tears or dents.
3 Integrity of mounting flanges.
(c) Inspect oil’ inlet and return lines for:
1 Cleanliness and freedom from obstructions.
2 Cracks, checking, swelling, and kinks.
3 Integrity of wire shields.
4 Plumbing fittings for nicks, burrs, and deformity.
i3) Oi7 Cooler Leakage Check
(a) Perform a hydrostatic test on the radiator. Operate

test set in accordance with manufacturer’s
instructions, or take radiator to certified radiator
shop and have it pressure tested for leakage.
(b) Install pressure cap on one oil cooler fitting.
(c) Connect test set to remaining oil cooler fitting.
(d) Regulate test set pressure to 150 psi.
(e) Check for leakage.
NOTE: Leakage is indicated by escaping fluid and a
drop in regulator pressure.
MM-13-91
MAINTENANCE MANUAL
(f) Locate and mark source of leak, if any.
NOTE: Use standard procedure to repair leaks. If

required repairs are inaccessible or
extensive, replace oil cooler with a new

unit. After repairs are completed, repeat
steps (a) through (e).
(g) Remove oil cooler from test set.
(4) Oil Cooler Installation
(a) Primary oil cooler.
1 Secure radiator to the oil cooler boot and lower

mount with four bolts.
2 Secure oil cooler inlet and return lines.
3 Secure air inlet duct to oil cooler and lower

mount with four bolts.
4 Thoroughly inspect the oil cooler assembly

installation, torque on fittings, routing of
lines, and ducting.
5 Perform preflight inspections; service engine as
required.
6 Perform operational check of engine prior to

flight.
7 After the
engine has been run up to operating
temperature, inSpect assembly for oil leaks.
NOTE: Oil circulates through the entire system

only when engine is at operating
temperature.
8 Secure right side cowl.
(b) Auxiliary Oil Cooler
1 Position oil cooler in place on the duct from the

cooling fan shroud with inlet and outlet fittings
aft.
2 Install two screws and washers in aft side of oil

cooler mount.
3 Place heat shield in position.
MM-13-92
MAINTENANCE MANUAL
4 Install two screws and washers in top of heat

shield.
NOTE: It may be necessary to bend the heat

shield slightly to facilitate
installation of the top two screws.
5 Install two screws and washers in the bottom of

the heat shield.
6 Remove inlet and outlet line plugs and connect

lines to oil cooler.
7 Check routing of lines.
8 Check fittings and attachment hardware for

security.
9 Service oil system to proper level.
10 Runengine to bring oil to.normal operating

temperature.
11 Shut down engine and inspect for leaks.
C. Scavenge Pump
(1) Scavenge Pump Removal (See Fig. 13-21)
The scavenge pump is removed with the sameprocedure listed

under Engine-Driven Fuel Pump Removal -Section 13-l0,with
the following additions:
(a) Disconnect oil inlet line (8).
(b) Disconnect oil outlet line (9).
(c) Pull engine-driven fuel pump and scavenge pump out as a

unit.
(d) Remove gasket (10).
(2) Scavenge Pump Installation (See Fig. 13-21)
Complete Engine-Driven Fuel Pump Installation Procedure,

Section 13-10, with the following additions:
(a) Install scavenge pump and gasket (10) on bolts (5) with
spacer (7) and engine-driven fuel pump.
(b) Install both pumps as a unit into engine case.
MM-13-93
MAINTENANCE MANUAL
ic] connect oi 1 inlet line (8, and out~rt line (9,.
(d) Check for both oil and fuel leaks.
13-12 COKRELATOR
A. Introduction
This specification presents the method to most accurately and

safely rig the throttle correlator system used on the F-28F and
280F aircraft. The correlator rigging is a repetitive process
and, by necessity, some of the steps are repeated. Although this
procedure is written to incorporate the minimum number of steps,
the more repetitions used to rig the correlator, the better the
correlator will perform.
NOTE: The rigging procedure is written for two

considerations:
1. When installing a new throttle cable or replacing

any part of the correlator or throttle system
start with Item B Correlator Preflight Rigging.
2. For service adj:ustments to cover idle adjustment,

injector servicing or replacement, start with
Item C Correlator Post-Flight Rigging.
3. Correlator Preflight Rigging
(1) Injector Rigging
(a) The injector shall be rigged as shown in Figure 13-26 1

The injector is at idle position. The lever may be
repositioned in 15" increments by loosening the
butterfly shaft nut.
(b) The injector used for the "F" model shall be one of two
types
1 Part No. 2524858-A. This injector has been

modified to obtain 85" butterfly travel with the
idle screw fullly backed out. Preflight idle is to
be set such that the butterfly is closed to .020
inch gap in the sidewall.
2 Part No. 2524858-1 and higher has the idle

position preset at 97" and no further check is
required.
(2) Connect the throttle cable by:
(a) Disconnecting both ends of throttle cable.
#2 Rev. 11/18/88 MM-13-94

MAINTENANCE MANUAL
(b) Set forward cable attach position at 1.13 .13 inches.

(See Fig. 13-23)
(c) Set af’t cable attach position at 6.88 plus .13/-.25

inches. (See Fig. 13-24)
(d) Pre-adjust point "B" override stop to 0.60 .02

inches. (See Fig. 13-25)
(e) Disconnect wastegate link from injector.
(f) Set collectiv~ stick on down stop and lock.
(g) Set injector at idle stop. (See Fig. 13-26)
ih) Set summing lever (1) on idle stop, point "A."

(See Fig. 13-25)
(ij Adjust cable rod ends to fit. Attach at injector.
(j) Slip fit bolt (don’t secure) through forward cable rod
end and output lever (2). (See Fig. 13-25)
NOTE: If and when thread engagement is out of

safety, refer to tolerance of step 2-b above
and adjust accordingly.
(3, Adjust override stop, paint "B" (Fig. 13-27,. 1

(a) Position collective stick on down stop.
(b) Kotate throttle twist grip open enough to insert a

0.14 .01 inch thick shim or tool No. T-0113 between
idle stop screw and stop pin on injector.
(See Fig. 13-28) Rotate twist grip against shim and
maintain pressure during step 3-c.
(c) Check for 5.0" .06 dimension between offset shaft and
summing lever output arm (points "D" and "E"
respectively, Fig. 13-27) by:
1 Use tool gauge T-0111 or similar device and slip

over offset shaft (point "D") adjacent to offset
fitting (1).
2 Attempt to slip other end of tool over cone washer

on summing lever, point "E."
3 Adjust override stop, point "B", until gauge tool

slips over cone was:her on summing lever.
(d) Lock jam nut on stop bolt, point "B."
#2 Rev. 11/18/88 MM-13-95

MAINTENANCE MANUAL
(e) Remove 0.14-inch shim from injector stop.
(f) Remove bolt from forward rod end of cable (see

Fig. 13-25).
ig) Set injector idle stop arm against stop pin

(see Fig. 13-26).
(h) Set correlator summing lever at idle stop, point "A"

(see Fig. 13-25).
(i) Adjust forward cable rod end for a slip fit on the bolt
between the roa end and the correlator output lever
(2). (See Fig. 13-25)
NOTE: If there is insufficient thread engagemerit in

rod end, then aft cable housing attachment on
pylon (Fig.’13-24) can be moved 6.88 plus
.13/-.25 inches.
(4) Check wide open rigging:
(a) Raise collective stick 2 inches at handle or .25 inch

at stop (see Fig. 13-29) from down stop position and
lock.
(b) Rotate twist grip to wide open position.
(c) Check for .05 to .25 inch clearance between cable rod
end and injector arm (Fig. 13-30). If improper
clearance check i nstal lati on of i nj ector arm onto
butterfly plate shaft (Fig. 13-26). If injector arm
must be repositioned on the shaft, repeat correlator
rigging starting from step 2-e.
(d) Check if injector wide open stop arm is against stop

pin for (A) only (Fig. 13-30). On -1 or -2 servos,
stop arm may not contact stop pin; adjust to within
.125" of stop pin.
NOTE: If adjustment
is required, make adjustments
at cable rod ends and aft cable attach point
dimension 6.88 plus .13/-.25 inches
(Fig. 13-243.
(e) Check if output lever (1)

is within 0.06 inch of stop
point "C" (Fig. 13-29).
If out of tolerance, adjust
aft cable attach point dimension 6.88 plus .13/-.25
(Fig. 13-24) and repeat steps 4-d and 4-e.
NOTE: Primary Open stop should be at the injector
and the Stop at point "C" is secondary.
(f) Secure all hardware on cable rod ends.
#2 Rev. 11/18/88 MM-13-96

MAINTENANCE MANUAL
(5) Recheck idle adjustments by:
(a) Set collective stick on down stop and lock.
(b) Rotate throttle twist grip to idle stop.
(c) Check at the injector that the idle adjustment screw is

against the stop pin (Fig. 13-26).
NOTE: The throttle twist grip must have enough

authority to force all backlash out of the
system and cable. A piece of paper placed
between the idle adjustment screw and the
stop pin should be clamped. However, only
10" rotation (20" maximum) of the twist grip
should release the paper enough to be able to
pull it free. Any more rotation than this
causes a large dead band which uses up too
much correlator motion, thus causing improper
collective/throttle correlation. To adjust,
move the aft cable attach point (Fig. 13-24).
Usually no more than one rotation of the jam
nuts is required. For insufficient clamping
of the paper, move the cable down. For
excessive clamping move the cable up.
(6) Adjust wastegate by:
(a) Raise collective stick 2 inches from down stop and

lock.
(b) Rotate throttle twist grip to wide open.
(c) Check that injector open stop arm is against stop pin
(Fig. 13-30).
(d) Adjust wastegate link length for 0.015 inch gap at

wastegate stop. (DO NOT adjust stop. Stop was
previously set for gap with the butterfly

in the fully closed position.)
(e) Rotate throttle twist grip to idle stop.
(f) Adjust wastegate open stop for .09/.06 inch clearance.
NOTE: Preflight rigging is now completed.

Correlator will perform satisfactory until
idle screw/mixture linkage adjustment has
been made. Readjustment of correlator is
then required for satisfactory and safe
correlator function.
MM-13-97
MAINTENANCE MANUAL
C. Correlator Post-Flight Rigging
(1) Readjust override stop, point "B" (Fig. 13-27).
(a) Position collective stick on down stop.
(b) Rotate throttle twist grip open enough to insert a

0.14 .01 inch thick shim or tool No. T-O133 between
idle stop screw and stop pin on injector (Fig. 13-28).
Rotate twist grip against shim.
(c) Check for 5.0" t .06 dimension between offset shaft and
summing lever output arm (points "D" and "E"
respectively, Fig. 13-27) by:
1 Use tool gauge T-0111 or similar device and slip

over offset shaft (point "D") adjacent to offset
fitting (I).
2 Attempt to slip other end of tool over cone washer

on summing lever, point "E."
3 Adjust override stop, point "B", until gauge tool

slips over cone washer on summing lever.
(d) Lock jam nut on stop bolt, point "B."
(e) Remove 0.14 inch shim from injector stop.
(2) Check idle stop position.
(a) Set collective stick on down stop and lock.
(b) Rotate throttle twist grip to idle stop.
(c) Check at the injector that the idle adjustment screw is

against theistop pin (Fig. 13-26).
NOTE: The throttle twist grip must have enough

authority to force all backlash out of the
system and cable. A piece of paper placed
between the idle adjustment screw and the
stop pin should be clamped. However, only
10" rotation (20" maximum) of the twist grip
should release the paper enough to be able to
pull it free. Any more rotation than this
causes a large dead band which uses up too
much corr~lator motion, thus causing improper
collective/throttle correlation. To adjust,
move the dft cable attach point (Fig. 13-24).
Usually no,more than one rotation of the jam
nut is required. For insufficient clamping
of the paper, move the cable down. For
excessive clamping move the cable up.
MM-13-98
MAINTENANCE MANUAL
(d) Readjust stop on wastegate, if necessary, to provide

.06/.09 inch clearance.
(3) Check wide open injector position by:
(a) Raise collective stick 2" from down stop position and
lock or .25 inch from stop (see Fig. 13-29).
(b) Rotate twist grip to wide open position.
(c) Check if injector wide open stop arm is against stop

pin.
(d) Readjust wastegate link length, if necessary, for 0.015

inch gap at wastegate stop. (DO NOT adjust stop. This
stop was previously set for a 0.015 inch gap with the
butterfly in fully closed position.)
MM-13-99
MAINTENANCE MANUAL
CABIN SHELL
FIREWA L L
+.13
1.13
CABLE SUPPORT
FIGURE 13-23
FORWARD CABLE ATTACH POINT
MM-13-100
MAINTENANCE MANUAL
FIGURE 13-24
AFT CABLE ATTACH POINT
VIEW LOOKING FORWARD
wasrEcnTE
i3\j~
WITNESS HOLE
_I~LIC1N ROD END
INJECTOF)
6.88-.25
TURBO MOUNT
BRACKET ASSEMBLY
MM-13-101
FIGURE 13-25
~:,ai;X
CORRELATOR IDLE STOP POSITION
THROTTLE IDLE STOP~’

POINT "A" -c~l
PRELIMINARY 1\ i
ADJUSTMENT
o ~WITNESS HOLE
IN ROD END
i ai
FORWARD CABLE
OD EN i´•I I
SUMMING LEVER(I)
OVERRIDE
STOP B" SLIP FIT THIS
BOLT DURING RIGGING‘´•,
STOP "C"
OUTPUT LEVER(2)
MAINTENANCE MANUAL
´•ro
yLg I
L~J BUTTER FLY PLATE SHAFT
W.L
12.50
~DLE STOP SCREW E
STOP PIN
5 TO9
:‘4
IDLE STOP ARM/ LINJECTOR ARM
THROTTLE CABLE
FIGURE 13-26
rmEL’ SERVO THRDTIZE BI~W, CF~ANK
MM-13-103
FIGURE 13-27
OVERRIDE SrOP
n
TPOL NO,T-OIII
OFFSET
POINT
"D"jC os
OFFSET FITTING~I)
‘´•t~
ADJUSTMENT SCREW POINT "E" z
3 a~ \I I lo
h Ir
JAM NUT
CONE WASHER
OVERRIDE
STOP "8"
SUMMING LEVER
MAINTENANCE MANUAL
TO WASTEGATE
I
IDLE STOP SCREW
INJECTDR
STOP PIN
.14 CABLE ROD END

ro:
TOOL NO. T-O113
FIGURE 13-28
FUEL SERVO WI’IH TOOL NO. T-0113 LNST~V;LED
MM-13-105
COLLECTIVE UP STOP
FZGUP\E 13-29
CORRELATOR FUI~L SrOP POSITION
.25
COLLECTIVE DOWN STOP 3
--I -I
z
p
g I iZo
,I´•S-‘s‘\
~f
b I~
j
I’
.1 ´•----j, C~=
,e
OPEN THROTTLE A/
STOP "C"
O TO 0.0~
OUTPUT LEVER(I)
MAINTENANCE MANUAL
INJECTOR ARM
TO WAST EGATE
iC~i
A´•´•
CABLE ROD END
-~I IhlJECTOR
CLEA RANGE .05/.25
STOP PIN
OPEN STOP ARM
RGORE 13-30
FUEL SERVO mTL~ THRMTLE POSITION
MM-13-107
SECTION
UTILITY SYSTEMS
MAINTENANCE MANUAL
SECTION 14
UTILITY SYSTEMS
14-1 CABIN HEAT
A. Description
Warm air used for heating the cabin is derived from a heat exchanger
mounted on the exhaust muffler. The air enters this system from the
engine cooling shroud and is ducted by a flexible hose to the heat
exchanger. Air flows to the heater control valve which is mounted on
the aft side of the firewall and regulates the air flow into the
cabin area. The control is located on the left hand side of the
pilot’s seat for easy access to vary the temperature by pushing in to
the OFF position or out to the ON position. There are three heat
delivery ducts inside the cabin. The main duct is located in the
center of the seat structure, with two smaller ducts located just
forward of the tail rotor control pedals on either side of the cabin
floor.
B. Cabin Heating System Troubleshooting
Exhaust fumes Crack in exhaust Replace stack, heat

enter cabin when stack or heat exchanger, or repair
cabin heat is exe hange r. by wel d i ng
applied.
Insufficient Flexible hoses Connect hoses and secure

heat, forward of with clamps.
firewall off or
loose.
Control linkage Connect linkage properly.

disconnected or
loose.
Defective heater Replace or repair heater

shroud. shroud.
Defective valve Replace or repair valve

assembly. assembly.
C. Heater Valve Assembly
(1) Heater Valve Removal (See Figure 14-1, View A)
(a) Remove fiberglass seat deck from cabin.
(b) Disconnect the heater control cable (1) from heater

valve (2).
MM-14-1
MAINTENANCE MANUAL
(c) Disconnect and remove hose (3) from aft side heater valve.
id) Remove the attachment screws securing heater valve to hose

divider (4) and firewali. Remove valve.
(2) Heater Valve Installation (See Figure 14-1, View A)
(a) Install heater valve (2) with valve control lever on top
and align to hose divider (4) on firewall.
(b) Install attachment screws to secure valve to firewall, and

torque screws.
(c) Connect heater control cable (1) to heater valve and

adjust. See heater control cable installation.
(d) Connect hose (3) to aft side of heater valve and secure.
(e) Install fiberglass seat deck.
D. Heater Control Cable
(1) Heater Control Cable Removal (See Figure 14-1, View A)
(a) Remove fiberglass seat deck.
(b) Disconnect control cable (1) at the heater valve (2).
(c) Disconnect cable clamp (6) from forward landing gear cross
tube.
(d) Remove cable nut securing control knob to seat structure

and pull cable out through front of seat structure.
(2) Heater Control Cable Installation (See Figure 14-1, View A)
(a) Slide cable (1) through seat structure and install nut and
lock washer on inboard side. Secure nut to mount cable
control knob in place.
(b) Connect cable (1) to heater valve (2) and secure with
clamp (5).
NOTE: Remove hose from aft end of heater valve (2) so

valve damper is visible for cable adjustment.
(c) Adjust cable until valve is in closed position with 1/4" to

3/8" gap between seat structure and cable control knob with
control knob pushed in.
NOTE: Adjustment is
made by sliding cable sheath in or
out at the cabie clamp (5) on top side of heater
control valve. Check that valve fully opens and
closes after
MM-14-2
MAINTENANCE MANUAL
(d) Install hose and secure to aft side of control valve.

O
(e) Connect cable clamp (6) at landing gear cross tube.
(f) Install fiberglass seat deck and cushions.
E. Heater Shroud
(1) Heater Shroud Removal (See Figure 14-1, View B)
(a) Remove hoses (7) and (9) from heater shroud (8).
(b) Remove screws along top of heater shroud.
(c) Separate shroud and remove from heat exchanger.
(2) Heater Shroud Installation (See Figure 14-1, View B)
(a) Install heater shroud (8) around heat exchanger with shroud
seam on top.
(b) Install screws to secure shroud to heat exchanger.
(c) Connect hoses (7) and (9) to heater shroud and secure with
hose clamps.
MM-14-3
t/3
VIEW A
VIEW B
VIEW a
b VIEW C
VIEW C VIEW B
9 94
FIGURE 14-1
CABIN HE ATING SYSTEI~1
SECTION
Supplement
P roced u res
ENSTROM
F28F 19ss 280FX SERIES
MAINTENANCE MANUAL
SUPPLEMENT
F28F 19ss
280 FX
The Airworthiness Limitations Section (Sectionl7j is FAA approved

and specifies inspections and other maintenancerequired under
43.16 and 91.163 of the Federal Aviation Regulations unless an
alternative program has heen FAA approved.
~ENSTROM HELICOPTER CORPORATION

M~NOMINEE, MICHIGAN
MM-15A
MAINTENANCE MANUAL SUPPLEMENT
SECTION 15
SUPPLEMENT PROCEDURES
15-1 INTRODUCTION
This Maintenance Manual Supplement sets forth the recommendations and

procedures for maintaining and servicing the Model 280FX and 1986 F-28F
helicopter, manufactured by The Enstrom Helicopter Corporation. This
Supplement must be used in conjunction with the Model F28F and 280F
Maintenance Manual. The procedures in this manual supercede any
conflicting procedures listed in the earlier manuals andior supplements.
15-2 TABLE OF CONTENTS
See Table of Contents at the beginning of the revised model F-28F 280FX
Maintenance Manual.
15-3 MANUAL CHANCES AND REVISIONS
Reference Section I Par. 1-3 and 1-4.
MM-15-1
SECTION
AIRCRAFT
DESCRIPTION
SECTION 16
AIRCRAFT DESCRIPTION
:6-1 GENERAL DESCRIPTION 280FX
Except for the changes and the systems listed below, the primary
structure of the 280FX is essentially identical to the 280F. The 280FX
is a three-place, piston engine, single rotor helicopter as shown on
Figure 16-1. The helicopter is powered by a Lycoming HIO-360-F1AD engine
equipped with a Rotomaster turbocharger. The engine can be boosted to
39 in-Hg manifold pressure, providing 225 horsepower. The main rotor is
a three-blade fully articulated system whi le the tail rotor is a
two-blade teetering type.
16-2 AIRFRAME AND SYSTEMS DESCRIPTION
The items described below comprise the major changes from the 280F. More
detailed information on these components can be found under the specific
headings in this maintenance manual supplement..
A. Airframe The 280FX incorporates the following improvenients in

the airframe:
Three-piece airscoop
Tail rotor driveshaft cover/fairing
Tubular tail rotor guard
Horizontal and vertical stabilizers
Landing gear fairings
B. Systems The following systems are incorporated into the 280FX:
Combined position and anticollision lights

Annunciator panel with the following indications:
Clutch disengagement
Low fuel pressure
Low rotor rpm
Overboost
Main rotor gearbox chip(s)
Tail rotor gearbox chip(s)
C. Avionics The 280FX is equipped with the following avionics as

standard equipment:
Apollo II Loran-C (II-Morrow)

Graphic Engine Monitor (Insight Instruments)
King KY97 Communications Radio
King KT76 Transponder
MM-16-1
(4) Control and Drive Systems The 280FX also incorporates some
minor changes in the control and drive systems. These are
listed below:
Upper jackstrut bearing assembly with lubrication -fitting

Teflon bearings in push-pull rod/walking beam attachment
1C-3 ENERAL DESCRIPTION F-28F (1986)
Except for a few minor changes to the structure and systems the new F-28F
is similar to the standard F-28F as described in Section 2 of the F-28F
and 280F Maintenance Manual. Ref. Figure 16-2.
16-4 AIRFRAME AND SYSTEMS DESCRIPTION
The items described below comprise tl~ie major changes to the F-28F. More
detailed information on these specific components can be found under the
specific headings in this Maintenance Manual Supplement. All other
system specifications are ref. in Se;ction 2.
A. Airframe F-28F incorporates the follbwing improvements
New cabin door assembly

Horizontal and vertical stabilizers
B. Systems F28F
Low rotor R.P.M. warning system and indication light horn
MM-16-2
63"
m
z
z
o
336:’(280’) z1e"(1sZ5’) m
ol z
RADIUS
G; i cr
Cn
c
o
20" DROOP
4e7" Il(r MAX. FWD. C.G. mr
t
STP;TIC
s~iDIA gj:
m
Z~
I os:’(9.0’)
i 1 ‘U.~":
12" (6.d’)MIN. DROOP
4.0"
78.63’~6.55’) 344"(28.666’)
"(2333’) 351.6’~29.3’)
ENSTROM 280FX HELICOPTER

fig. Is-1
~C11 ss"
G=´•-V-LL; _)
336" 128.0’)
ct
219" (18.25’) m
z
RADIUS z
192" (16.0’)
a~
I!
f
48.7"
-r=
7
MAX. FVU). C. G.
20" STATIC DROOP j
3.0’~
m
z
c
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c
23" STATIC
(9.0’)jr~P
1 56" (4.7’)DIA. o
2.0" r
108"
t- s.o.. II e
m
´•-I-~ z
l.o´•´•
i
135" 16125’1 93.75" (7.813’)
72" (6.0’) MIN. DROOP
´•’~Y
1111~ MAX. AFT C. G.
L 1_1
~!C4a I
78.63" (6.55’)---~ 337"
88" 351.6" (29.3’)
-1
/7.333’)
ENSTROM F28F HELICOPTER

fig. 16-2
MODEL SPECIFICATIONS
16-5
POWER PLANT
Ty pe Lycomi ny
Designation HIO-360-F1AD
Cylinders 4
Normal power 225 hp

Normal rpm 3050
Specific fuel consumption .69 Ibs hp/hr

Weight 324 Ibs
Oil 10 qts or 19 Ibs
PURBOCHARGER
Type Rotomaster
Designation 3BT5EE10J2
Performance Refer to Flight Manual
OPERATING KPM’s
Engine 2900-3050
Tail rotor 2514 (at 3050 engine rpm)

Main rotor 351 (at 3050 engine rpm)
Main rotor autorotation range 334-385
RATIOS
Lower drive pulley to upper pulley 1.213:1
Upper pulley to main rotor shaft 7.154:1
Engine to main rotor 8.6781:1
Tail rotor input shaft to output shaft 1:1
DIMENSIONS
Width (overall) 28’0"
Length (overall) 29’3"
Cabin width at seat ’58"
MM-16-5
MODEL SPECZFICATIONS (continued)
MAIN ROTOR SYSTEM
Number of blades 3
Chord each 9.5"
Diameter 32’
Uise area 804 sq ft
Main rotor rpm 351
TAIL ROTOR SYSTEM
Number of blades 2
Chord 4.4"
Diameter 4.67’
Oise area 17.1 sq ft
RPM 2514
REFERENCE SECTION 2 FOR OTHER GENERAL INFORMATION
MM-1~-6
SECTION
Al RVVO RT H I N ESS
LIMITATIONS
MAINTENA~CE MANUAL SUPPLEMENT
SECTION 17
PERIODIC INSPECTIONS AIRWORTHINESS LIMITATIONS
This Supplemental Airworthiness Limitations Section is FAA approved and

specifies inspections and other maintenance required under FAK 43.16 and
FAR 91.163 unless an alternate program has been approved.
1;-1 GENERAL
A. Inspections
Additional mandatory preflight and periodic inspections are set forth

in Par. 17-2 and 17-3 of this section. These inspection instructions
are intended to be used in conjunction with the F28F and the 280F
Maintenance Manual Section 3. The inspections stated herein
supplement those listed in Section 3, Paragraphs 3.1, 3.2 and 3.3.
B. Service Lives (Ref. Paragraph 3.4)
C. Overhauls (Ref. Paragraph 3.5)
17-2 DAILY AND/OR PREFLIGHT INSPECTION
O jRef. Figure 3-1 for Walk Around Procedure)
This checklist is to be used in addition to the preflight

designed
inspection, Section
listed in 3-1 of the F28F 280F Maintenance Manual.
Thoroughly familiarize yourself with this Manual Supplement before
utilizing this checklist.
A. Exterior Check the following items in addition to Section 3-1

requirements.
(1) Right Landing Gear with Fairings Only (280FX)
a. Landing gear fairings check condition and security.
b. Oleo struts Strut extension may be checked with back side

of fuel dipstick.
NOTE: To check for proper strut extension the helicopter should

be sitting on level ground. The struts should then be
leveled by rocking the helicopter by pushing up and down
slightly on the tail cone. For proper inflation see
Section 4-2Item F.
FAA Approved: April 3, 1986

MM-17-1
NOTE: Align fuel dipstick withcenterline on fairing bump.

I Sight across top of crosstube normal operating levels
are indicated on the stick.
TOP OF CROSS TUBE
BACK SIDE OF FUEL DIP STICK
CENTERLINE FAIRING BUMP
c. Landing gear check condition and security. Check ground

handling wheel removed or in up position and secured.
(2) Left Landing Gear 280FX
Landing fairings chec~ condition security.

a. gear
O
b. Oleo struts check extension and security (see Item Ib).
c. Landing gear check con:dition and security. Ground

handling wheel removed or in up position and secured.
(3) Tail Rotor Driveshaft 280FX
a. Open forward three sections of driveshaft cover.
b. Check security and condition of driveshaft, hangar

bearings, flex couplings and driveshaft cover.
c. Close dri.veshaft cover and check security.
(4) Right Left Horizontal and Vertical Stabilizers Check

Condition and security 280FX F-28F
(5) Right Left Position and Anti-collision Lights Check

Security 280FX F-28F

MM-17-2
i7-3 Special Periodic Inspections (280FX F-28F)
A. Horizontal Stabilizer
Enstrom requires complete dis-assembly and removal for inspection of

the horizontal stabilizers and spar. This is to be accompolished at
the first 1200 hours of service and at every 1200 hours of service
thereafter.
NOTE: For complete dis-assembly and assembly criteria, including

other inspection criteria, see Section 22, pages MM 22-6
thru MM 22-9 of this supplement.
(1) A complete visual inspection of all components.
(2) A zyglo or close visual inspection with a 10 power glass of the

spar fitting, attachment rivets, bulkhead and vertical endplate
attachments,
(3) A magnaflux inspection of the horizontal stabilizer steel spar.
(4) A log book entry is required after these inspections to

reinstate the airworthiness of the helicopter.

Mlvi-17-3
SECTION
POVVER PLANT
SECTION 18
POWERPLANT ANU ASSOCIATED SYSTEMS
18-1 PU~ERPLANT REFERENCE SECTION 13
For all power plant requirements see Section 13 of F-28F and 280F
Maintenance Manual. The only exception is a new door seal on the dir
induction intake scoop. This seal consists of a tubular rubber extrusion
attached to the cover of the air filter box. This forms a seal with the
engine door, preventing hot engine compartment air from entering the
induction system. This seal should be inspected and kept in good repair,
as leaks in this seal will reduce engine performance.
MM-18-1
SECTION
MAIN ROTOR
TRANSMISSION
SECTION 19
MAIN ROTOR TRANSMISSION
19-1 GENERAL REFERENCE SECTION 11-6
Except for the location of the oil temperature probe, the low rotor rpm
sensor, and the magnetic chip detector, the main rotor transmission is
essentially identical to the transmission on the F-28F ?sOF. The oil
temperature probe has been moved from the bottom of the pinion case to
the bottom cover approximately 30" left
at of front center. This does
not affect the operation of the helicopter.
The low rotor rpm sensor is
installed in the forward side of the top cover. This unit is described
in Section 33 under "Low Rotor Warning." NOTE: The chip detector is not
standard in F-28F models.
19-2 MAIN ROTOR GEUKBOX CHIP DETECTOR
The 280FX is equipped with a main rotor transmission chip detection

system. Thischip detection system consists of a magnetic chip detector
in the transmission which is wired to a caution light in the annunciator
panel on the instrument console (ref. Section 21). The magnetic chip
detector is located on the transmission bottom cover approximately 30"
left of rear center. This unit comprises a magnetic plug which locks
into a self-sealing base. If the main rotor gearbox chip light il~umi-
nates, inspect the chip detector as described below:
A. Remove access panel below left fuel tank.
B. Remove magnetic plug as follows:
(1) [jo not disconnect wire.
(2) Grasp plug and push upward.

(3) While holding upward pressure, begin turning plug counter-
clockwise.
(4) Turn plug counter-clockwise one-quarter turn.
(5) Pull plug out of socket in base fitting. See Figure 19-1.
C. Inspect plug.
NOTE: New recently overhauled gearboxes will often

or
make a magnetic "fuzz" which will collect on the magnetic
plug as a gray sludge. This is normal and may be cleaned

off the plug. The plug may then be reinstalled and the
helicopter returned to service. If any chips are found
whichare larger thanl/l6 inch in cross-section, con%act
the nearest Enstrom Service Center or the Enstrom
factory.
MM-19-1
MAINTENANCE MANUAL SIJPPLEMENT
IJ. After determining that the transmission is airworthy, clebn the

magnetic plug. This may be accomplished with a soft cloth or with a
strong magnet attached to a polinted object such as a knife or a small
screwdriver. Use caution to avoid scratching the niagnetic plug.
E. Reinstall magnetic plug as follows:
(I) Insert plug into socket in base fitting.

i2) Align lugs in plug wiith slots in base fitting.
(3) Push plug upward while turning plug clockwise
(approximately one-quarter turn).
!4) When plug stops turning, pull downward.
(5) Check plug to insure that it is locked in base.
F. Reinstall access panel.
19-3 LUBRICANT CHANGE
The main rotor transmission lubricant should be changed Per Section 4

and proceed as described below.
(1) Remove and inspect magnetic chip detector plug as described

above.
(2) Remove safety wire from chip detector base fitting.
(3) Place a trough under the base fitting to carry the oil out the
left side of the helicopter, and place a container under the
trough.
(4) Remove base fitting.
(5) Allow all oil to drain from transmission.
(6) Replace crush washer on base fitting.
(7) Replace base fitting.
(8) Safety base fitting with .032 lock wire.
NOTE: The base fitting may be safetied to the pylon tube after
wrapping the tube with suitable tape to provide
protection.
(9) Reinstall magnetic plug as described above.
(10) Service transmission with 53 pints of Enstrom approved

lubricant.
(11) i,,,,,, transmission for ieats.
MM-19-2
NOTE: To remove press inward and rotate

outer hex assembly counter clockwise. To
reinstall push inward and rotate clockwise
until dedent engages and locks over center,
check for leakage and security.
WARNING: Do not operate helicopter with

chip detector probes removed as severe
lubrication loss may occur.
TYPICAL CHIP DETECTOR INSTALLATTO~
FOR MAIN ROTOR AND TAIL ROTOR TRANSMISSIONS
FIGURE 19-1
MC1-19-3
SECTION
BELT DRIVE SYSTEM

MAINTENANCE FikNUAL SUPPLEMENT
SECTION 20
BELT DRIVE SYSTEM
20-1 GE~EKAL REFERENCE SECTION 11 FOR COMPLETE INFORMATION
Except for the installation of the upper jackstrut bearing lubrication,

the belt drive system is identical to that of the F-28F i~ 280F. The
upper j8ckst´•rut bearing is installed such that it can be serviced
without removing the bearing from the housing. A grease fitting is
located in the seal on the rear side of the bearing. After servicing,
any excess grease should be wiped off the forward side of the bearing
housing. The bearing may be replaced as follows:
A. Servicing and Bearing Removal
(1) Remove bearing and bearing housing as described ill Section 11-4
and 11-7, Par. C of the F-28F 280F Maintenance Manual.
i2) Remove rear seal retainer and bracket by pulling assembly out of
bearing housing. Ref. Figure 20-1.
(3) Remove retaining ring.
NOTE: In some installations the seal retainer is held in

position by the retaining ring. Ref. Figure 20-2.
(4) Heat bearing housing to 200-250"F.
(5) Remove bearing and forward shield.
(6) Clean and inspect bearing housing, shield, and seal.
(7) Put a light coat of grease on the rear side (side with lip) of
the forward shield.
(8) Install shield in housing, with lip facing aft (toward bearing).
(9) Remove any shields or seals from replacement bearing and pack
bearing with grease. Do not reinstall the shields or seals
which were removed in this step.
(10) Install bearing in housing. Per Section 11-7 Par G.
(11) Keinstall grease seal and bracket.
(12) Reinstall bearing housing assembly inaircraftas described in

Section 11-7 Par G of the F-28F 280F Maintenan~e Manual.
MM-20-1
JACK STRUT UPPER BEARING
GREASE FITTING AND SEAL WITH BRACKET
FIGURE 20-1
JACK STRUT UPPER BEARING
GREASE FITTING AND SEAL WITHOUT BRACKET
FIGURE 20-2 ORIGINAL

As Received By
MM-2O-2 ATP
SECTION
ELECTRICAL
SYSTEMS AND
COMPONIENTS
SECTION 21
ELECTRICAL SYSTEMS AND COMPONENTS
21-1 GENERAL REFERENCE SECTION 6 FOR OTHER INFORMATION
The electrical system of the 280FX F-28F is essentially the same as the
system used on the 280F except for the changes listed below:
Combined anticollision and navigation lights F-28F 280FX

Annunciator panel 280FX
Graphic engine monitor 280FX, opt. F-28F
NOTE: The F-28F does not have the annunciator panel but does have press
to test lights for required items in Par. 21-3.
The graphic engine monitor will be discussed in Section 24. The 21;OFX
schematic is shown in Figure 21-2. The F-28F schematic is shown in
Figure 21-3 and is the same except in lieu of an annunciator panel it has
press to test lights.
21-2 COMBINED ANTICOLLISION AND NAVIGATION LIGHTS
The 280FX is equipped with Whelen A6OO-series combined anticollision-

navigation lights. These light assemblies are mounted on the outside
of each vertical stabilizer, and the anticollision light power
supplies are located under the floor on either side of the cabin, as
shown in Figure 21-1.
21-3 ANNUNCIATOR PANEL 280FX PRESS TO TEST LIGHTS FOR F-28F
The 280FX equipped with an annunciator panel which provides

is the
following warning and precautionary information:
Clutch disengagement
Low fuel pressure
Low rotor rpm
Overboost
Main rotor gearbox chip detector
Tail rotor gearbox chip detector
Denotes press to test lights on panel for F-28F models.
The annunciator panel is located at the top of the instrument console

and consists of six indicator lights with a "press-to-test" switch at
the extreme left of the panel. Pressing this switch will illuminate
all of the indicator lights.
The annunciator panel is wired in parallel with the panel light

dimmer switch so that the indicator lights will dim along with the
panel lights. Any time the panel light rocker switch is in the off
position, the annunciator panel indicator lights will be at full
bright when they illuminate.
MM-21-1
1WHI-TE TAIL
NAVI’GATION LIGHT
j ANTI-COLLISION LIGHT
L:NTI-COLLISIONLIGHT
POWER SUPPLY, UNDER
RED OR GREEN FORWARD
NAVIGATION LIGHT (RED SHOWN)
FLOOR ON EACH SIDE

OF CABIN
ANTI-COLLISION AND NAVIGATION LIGHT SYSTEM
FIG. 21-1
MM-21-2
OIL PRESS. SW
‘St~ 47-28 I\LTERN*TOR~OIZ.
NIV LIGHTS i(Op4 I~
N Iri\l Itnl
ELECT T ~T-lel I I
GUCIRDIAN CONTROL GRIP
MOVNT HOURMETER SEP~TSTRUCTURE PEDESTAL TERMINAL STRIP(TZ)
00 0.3a517~e7a)(PILor) BLUE
PANEL Compals ydimnrll gmund
´•´•´•IcRN.srRnP
7511 29168
I
(SLPS) (FI) 2 5 520
R
B
36- IPc.
L
B POWERSUPPLY 2751\ 9 J15
C Pb
u-lia 41-1
Pi Y?----r\~l‘rU --nlr~-. (51,i .a
W PUMP In sao~; o u 28
RUMENT SPARE
r 32-l~n POWER 754 pp~NEL
R
Co L
R 36-28 8b O
L
2 29-17 42
C~SEGND ROTOR
TAILCONE
03 5P~. OVER-
32-178 32-17b, BOOST
Co I.ILLI_I.1 I ITAILCONE
35- 43-1* CLUTCH
BUSS ENG.
PIUDIOJT-I BRN 2 m
P TR.G.B.
e7C BU(
Zso
RED
Z
15-51~ BUSS
.LTS.
(BL n
TSTRUCT GND
CHIP
M.R.GB
3~ 41-2/\
42-
AUDIO
ENGINE IIIIII yol. u’~TI
42-26( BLOCK (F-21) LIO- B
42-28 LTS. ALT EXC Q CHIP PRESS.
TRIM MOTOR(LATERAL) ~oa. 1 1111 1 I I 11 --2 33-12F
35-llC d SPARE
IRED) (GRN) 53- 21 TRGB
.LDG.LT 75A. 33- CHIP
42-40 IGRN1 P
a NOTES
ro r
49~bt Z5" 41-6 PARALLEL
RHEOSTP;T
33- b
~SDENOTES CIRCUIT BREAKER(TRIPFREE Z
PI
I) STRVCT. (83)
37-l6n a4- AFTLDGLT 33-13 TYPE) MIL-C-5BO9 --I
JI TERM:STRIP
-loe,, o
5 PANEL LIGHTS FOUR EYEBROW LIGHTS SHOWN EACH
COM (L6) Z
I REPRESEN~TWoeuLsslNPnRnLLEL
u
UTILITY
ii~jj 29-3
N~
2 LT49-18 TWD POST TYPE LIGHTS
Z
o 49-18 49-IC 2
PI I I 1 49- IA TWO LIGHTS SHOWN EACH REPRESENT O
WHT
SEAT
i FIVE LIGHTS IN pnR~LLEL m
111111 "F7’_ NO NC L$ NIGHT LIGHTING INTERNA L CLUSTE R
33-16
7
(5-24) 62-14 J3 P3 TWO BULBS PER GUAGE IN PARALLEL b
RED
N 1II1II1.II1 29-4 FROM P3-E Z
r 6~L9DENOTES CIRCUITBREAKERS~YITC C
-74 62-58 "rl: to PANEL LTS
(L131 (SI)
W r
7
(SB) IGNITION
27-9 COLLECTIVE
SWITCHI ,III Cn
,2
EP, ~lssl
’S2)MasrERs.u ttmp STARTER SW.
11~ 31-58 C
m N()o NC Al L R 73
BA
P2
4P~ 37-17P.
LDW
"Bldoe2JP1LT CASE
GND
E3~18
23-28
31-1
-O
r
:48 NO 37-178(YEU ROTOR I 1 1111
STRUCT I I I I 1 25-3 1 I I I I 1 m
7P~(GRN)
tilAr
BLK. -I FUEL PRESS
Nc 40- m
N 30-2 30-18 FUELOTY. SWI~CH
32- 198 Z
24-23 AZ PI
P
(RED) AT STRUCT.
rs-sn 29-58 nlRFAnwE
LOWROTOR LEFT MAGNETO RIGHT GND. 20 --I
TRIMMOTOR
MAG PICK-UP (F0RE-AFTI 25-9 X2 (RLI) 2 (814) (PYLON)
PUMP
XI 25-2 CYLHD.TEMP 21-3 P
br~t.onpllon
22-1STP~RTER
ELECT~ 29-7
OVER MWNT~ CI)
r- ,b,,
oH~H´•I-I 1 24-17 CURRENT PANEL I (,,R,
BREAKER 40-4
ELECT.2
REG
OVER 40-5 J5P5
BLKRDBL CASE VIBRATOR STRAP
MOUNT
24- AGE GND. OILTEMP LR IN 3Ge~ BRAID
RELII 4
(TC3) 20- 20-
29-228 L 8127: MOUNT
(F16) r: 29-108 23-2P.
1-15 RI
3
PANEL EN~FINE
~L-U 24-22C(LINE) 24 J4W BLOCK
REMOTE OVER 27-2 MR.G.B. TEMP
CURPENT ~1E/II(ERZL 27-:6
n F (Tt2) CISE 280FX
cnQoND. ALTERNATE
a
WIRES PPIIREDTO
BLOCK
;tilter 29-12
VOLTAGE REG
GRN.
ELECTRICAL SYSTEM
CONTROL BLKRDeL
SCHEMATIC
LL~ _
~]_I RELAY 2 ENGINE
ELECMOUNTI I 27-
12 VOLTS
GUARDIAN CONTROL GRIP 24- 1 t 24- PANEL
SM ENGINE CASE GND COMP/LRTYENT
G.YlSI7(BTA)(DUALl I t7.2
27-16
C BATTERY FZ
PYLONCABIN IZVDC
MOUNT ENGINE BLOCK
___J
CASE GNO ELECT MOUNT PANEL
ELECTRICAL SYSTEM SCHEMATIC 280FX
FIGURE i~l-2 ORIGrMAL

As Received
By
ATP
(FIT)
29-224
IA.
OILPRESS SW
*.VLIC´•~TS ’P28 *LTERNATOR70~.
I (0P5)
47- 24 18
4 OVERBOOSTLT
WZJ(DICN CONTROL GRIP
ELECTT ~7-
MOUNT HOURMETER SEAT STRUCTURE PEDESTAL TERMINAL STRIP(TZ)
c~
PI\ML
´•´•-IcRN.sTRnP
75A crmpouyd(mmll gand
29-1
32- Pi
(SLPS) rFI) 2
Z 5
MOTORS B
L
R
B POWERSUPPLI
36-2
275A. IZGPIBRY9~15
Is LOW ROTOR
-IA. (513) 9a R.PM. LT
w PUMP SHOCK
r
)2-134 8-I POWER WPPUI~UII I 17 11 zsn PANEL
CO R
L 36-
(aSEtND 2 I Irs-ie II I I HII I II ~I IIII I 1 42-11 1 162-12
T
Co II L~hlllll"ll TAILCONE
54.
Co _I I I I I I I I I I "1,.,,,,,,1 ~u/ 1 Inn I 32-178 32-174
33-16 31-
BUSS
AUW~7-I
888 2 m t; CLUTCH DISENGLGE
LT
p- BU(
Z,,
LTS.
STRUCT.GND. II I IL3
RED 2
42- 42-24 31. 41-2
H 31-7 28
ENGINE E
42-2E BLOCK (F-91)
42‘28 ALT E*C II II 1 11111 11 lllllr~o 1 I
sr-2n m
TRIM MOO(LATERAU I A I i 1! --Z

33-110
33-12F Z
(RED) (GRN) 13521 (FZ0) Z
7.54. 33-
42-40 IGRN)
,J-lx I LOTES
NO .1
(5 D
PARALLEL 33- ~1
pt RHEOSTAT DENOTES CIRCUIT BREAKER(TRIP FREE
I)
37-16A
~STRVCT
(R3)
Z
-106 NO D
24- TIPE) lllL~C-5809
JI I rn75‘l"r.7’P1Y=fl"I NC
TER 5 PANEL LIGHTS FOUR EYEBROW LIGHTS SHOWN EACH
COM SIZ (L6)
I (F3)
REPRESENT TWOBULBS IN PARALLEL Z
N
Z I UTILITY LT 2 29-3
;u N TWO POST TYPE LIGHTS O
o 43-ID 49-16 2 m
WHT IA TWO LIGHTS SHOWN EACH REPRESENT
klET
)1-138 SEAT FIVE LIGHTS In PARALLEL
STRUCT NO NC
33-16
L~ NIGHT LIGHTING INTERNAL CLUSTE R
N f~
(5-24) IPI TWO BULBS PER GUACE IN PARALLEL
JaP3
3515 29-4
REO
FROM P3"E Z
7.131
P C
~t3DENOTES CIRCVITBREAltERMIITCH
r>
L13) (SI) r
I
~ssi
IGNITION
27-9 COLiir~drlvE
SYITCI(I ~II V)
STARTER 591.
152) MASTER S.W 31-56 C
Jr
u nOo
Al U(S6) nl
I-Lz
L R
a
37~17A -3 ALT CASE 23-28 73
PZ
-4P. BldoBz GNO.
23-18
73
~SEPT
:4e NO 3T-178(~EUIRSTOR STRUCT
o
7PI(GRN)
25-3 1 I I I I r
til*r m
MASTER BLIL FUEL PRESS
NC
;V ~2-RB
RELAY 30.2
FUELPTY SWITCH
ATSTRVCI. 4- 3 AZ u
(RED) 29-54 29-58 IIRFA~ME m
LOWROTOR TRIMMOTOR LEFT UAGNETO RIGHT GND. 2C
LIAE P(tK~UP (FORE‘AFT) 25-4 X2 (RLI) 2 1821
RIMP 1814) (PILON)
XI 25-2 CYLHDTEMP 21-3 P --I
b~t.snrra 22-1
29-7
TCI)
24-17
ELECT
BRED~KER 40-~r- REG
(,,R,
STIIRTER 2
OVER 40~5
MOUNT BLK RDIL CASE VIBRATOR .STRAP
JSPJ
TAGE GND.
PANEL OILTEMP IN 3~.8AAID
-I RELAY
ELECT.
24 L BAT. LTC~) 20’
(F18) 24-228 i MOUNT
29-108 23-2*
N PANEL ENGINE
rl I 1 1-1,-111 1 II 24-22C(LINE) J4P4 8LOCK
REMOTE OVER 25-2
CURRENT BREAKER ZA ZT-16 YR.G.B. TEMP
RFI
A F 1762, r’ Tnsp F28F
BU~el( ALT) lil)~r 29-12 ALTERNATE
WIRES PAIREDTO GRN.
REG
R VOLTAGE ELECTRICAL SYSTEM
C Rar,
CONTROL BLKRDBL
SCHEMATIC
12 YOLT
GUARDIAN CONTROL GRIP
C- ~.11(871) 1 Our LI OPT
24-1
’’’’’I
t24-2
SU
2
E CASE GND.
IW611(e
COYPIRTYENT
IELK~PINEL 2M
PILONCABIN 84ITVSRCY
MOUNT ENGINE BLOCK CnS’EGND.
I_ _I
FIGURE 21-3
__
CASE GNn ELECT. MOUNT PANEL
ORrGINAL
As Received
By
ATP
MUINTENANCE ~AKUAL SljPPLEMENT
R. Lamp Replacement Fur Annunciator Panel
Each indicator light contains two (;E t330 lamps. These lamps can be
replaced as follows:
(I) Press inward on the right edge of the indicator until

indicator opens.
12) Swing indicator fully open.
i3j C;rasp base of lamp firmly and pull lamp out of’ socket.
j4) Insert replacement lamp and push into place.

(5) Swing indicator closed.
(6) Push on left side of indicator to close.
B. Clutch Disengagement Warning Circuit
The clutch disengagement warning circuit consists of a microswitch on

the clutch plate which operates a red warning light in the
annunciator panel. This switch is normally closed and completes a
circuit to ground when the clutch is disengaged. When the clutch
snaps overcenter into the engaged position, an arm on the actuating
mechanism opens the switch, which turns out the light. The "normally
open" side of this switch arms the low rotor rpm circuit.
If the clutch disengagement light does not go out when the clutch is
engaged, or if the light comes on in flight, this indicates that the
clutch is misrigged or the clutch actuator cable needs servicing.
The problem must be found and corrected before the a i re raf t is
returned to service. Press to test warning indicator on F-28F.
C. Low Fuel Pressure Warning Circuit
The low fuel pressure warning circuit comprises a pressure switch in

the fuel line between the electric boost pump and the engine-driven
fuel pump which activates a red light in the annunciator panel. If
the pressure in this fuel line drops below 15 psi, the switch will
turn on the red light. This circuit provides the pilot with a
warning if the electric boost pump should fail. This light does not
indicate the condition of the engine-driven fuel pump. Press to test
warning indicator on F-28F.
D. Low Rotor RPM Circuit
The low rotor rpm comprises a magnetic sensor in the main

circuit
rotor transmission,signal conditioning unit behind the passenger’s
a
seat, an amber light in the annunciator panel, and a warning horn.

The magnetic sensor is located in the forward portion of the main
rotor transmission housing. It is positioned to sense the passage of
the ring gear teeth. The signal is sent to a small unit located in
the backrest of the passenger’s seat. The unit reads the signal from
the magnetic sensor and activates the light and the warning horn.
MM-2i-5
The system is armed by the same switch which activates the clutch
disengagement light. Thus, the low rotor rpm light will be or, only
when the clutch disengaged light is out, and the main rotor rpm is
below 334. In addition, the warning horn is wired through a position
switch on the collective torque tube such that the horn will not
operate with the collective fully down. The horn has a pulsing tone
of 2900 Hz at 80-95 decibels.
After the engine is started, the following sequence should occur in

the annunciator panel. The red clutch disengagement light will be on
until the clutch is engaged. When the clutch snaps into the engaged
position, the red clutch dis~ngagement light will go out and the
amber low rotor rpm light will turn on. The low rotor rpm light will
remain on until the rotor rpm exceeds 334. The horn will sound if
the rotor rpm is below 334 and the collective is raised off the lower
stop.
This system is set to trigger the light and horn at 334 rpm 1 rpm.
The system can be adjusted with a potentiometer on the top of the
signal conditioning unit. The position of the magnetic sensor was
set at the and will need no readjustment.
factory Any service of the
magnetic sensor should be conducted by the Enstrom Helicopter factory
or by an Enstrom-approved overhaul center. For electrical schematic
see Figure 21-4, for RPM adjustment on low rotor indicator see Figure
21-5. Press to test warning indicator on F-28F.
E. Overboost Circuit
The overboost circuit consists of a pressure switch in the intake

manifold which activates an amber warning light in the annunciator
panel. The light will turn on between 36 and 40 in-Hg manifold
pressure. The light may be triggered by short pressure pulses which
will not appear on the manifold pressure gauge. The manifold
pressure gauge is the primary manifold pressure indicator, while the
annunciator panel is a secondary indicator. The manifold pressure
gauge should be used to dete~mine the severity of any overboost.
Press to test warning indicator on F-28F.
F. Main and Tail Rotor Gearbox Chip Detectors
The main and tail rotor gearboxes are equipped with magnetic chip
detectors which operate amber lights in the annunciator panel. There
is a separate circuit and light for each gearbox. When a chip
attaches to the chip detector, it completes a circuit to ground,
turning on the light. Further information on the chip detectors is
included in Sections 19 and 25, which describe the main and tail
rotor transmissions, respectively,
MM-21-6
ANNUNCIATOR PANEL SCHEMATIC
TEST
925 L29 L23 L24 L25 L26 L27 L28 L30
OPT LO ROTOR OVER CLUTCH T.R.G.B. M.R.G.B. LO FUEL OPT.

STARTER LOW
ENGAGED R.P.M. BOOST ENG. CHIP CHIP PRESS. TAGE
I.D
I.D.
P15
12345678910
3 4 5 6 J5
i 2 7 8 9 Ip
J15
31-1, C
T2 ri31 41-1 31-5C _

31-58" 1 re
AU 3n I
41-
41-2AT "I (’UL~ I I I FUEL PRESSURE SWITCH

S21
_5,
41-
24-2´• 26-11
T2
23-3´•
7A
-J 29-16 Ri2’
RL6 IN LINE´•
4)-4 za-zi IAMP.
TOPINS
29 Vor Izv 1NJ15
82 83 53- 53-108
BUSS
t 33-2 53-
B RED
DIMMERCIRCVIT l4Y)T2 I I I 1 ~53-70’ 1Z
53-11 L41_J BLK.
8U<. RL6
42-78
6’ 1 I II I OPT. STARTER ENGAGED WARNING SYSTEM
42-88
5´•
54-i1A TO PIN 10
´•9 4 GREEN 54-118
LOW V.SENSOR
3´• 54-12A RED~ 54-128 IN J 15
II WARNING INDICATOR
42-48 TVRN ON P~T IVV.or
’12 5dila 24.5 Y.
9
4~ T2E13~
NONC 42- /12V. or 24Y.
62-5A 62-lA_62-18 42-5C
OPT. LOW BUSS VOLTAGE INDICATOR SYSTEM
726621 ~e S24 42-4C
38 AUDIO TONE
RBBP-I
62-3P. 48 BLK.
SC6I6NJ
29-17 29-168 GRN.
8LUE2 IBWE NOTE: ASTERISK (r) DENOTES EXISTING
42-28 WIRE AND HARDWARE
+142-2FRED
513 OVERBOOST 42-2(3 42-2E
el~l 1(6~ T2
J7-I
42-28
F21 IN LINE L
1P~MP ~I=I PHONE
42-2Ai 1 I I I JACKS
12 V.or 24 Y.
BUSS counuoio
#2 Rev. 11/18/88 MM-21-7

F~UINTENANCE MANUAL SUPPLEMENT
I~OWROTOR]
kARNIIUG LIGHT
TO ADJUST LO ROTOR
KPM WARNING LIGHT:
20 Turn clockwise to in-

15 25 II II crease trip point or
RPM
2 ’j
RPM Turn counter clockwise
10 ~P
H to reduce trip point or
kPM
5 F~ \Y 35\
ROTOR
’P "p\
ENGINE
Lo rotor RPM control

unit
Set rotor KPM needle at 334 1~LL’
I"
w~rning light should come on at
decreasing RPM at 334 and lower
a
and I at
off at an increasing F(PM above
334 RPM
a
1~
locations
j
j’ 21-5Typical
L0 rotor RPM indicator adjustment
FIGURE
MM-21´•8
MAINTENANCE MUNUAL SUPPLEMENT
rl-4 kNTICOLLISION AND NAVIGATION LIGHT AND ANNUNCIATOR PANEL TROUBLESHOOTING

CHART
PROBABLE CAUSE KEQU1RED ACTION
Anticollison lights both out with master on and anticollision light

switch on:
Circuit breaker tripped Reset circuit breaker. Check for

wire shorted to ground.
Open circuit Check all connections and continuity

of wiring harness.
One anticollision light out:

of wiring harness.
Failed power supply Check for audible tone from power

supply. If no tone, replace power
supply.
Lamp burned out Replace lamp.
Navigation lights all out with master on and navigation light switch
on:
Circuit breaker tripped Reset circuit breaker, check for wire

shorted to ground.

of wiring harness.
One navigation light out:
Lamp burned out Replace lamp.

of wiring harness.
Annunciator panel does not illuminate when "press-to-test" is

pressed and "panel light" switch is off:
Master off Turn master on.
Circuit breaker tripped Reset "Inst." circuit breaker.
Open circuit Check wiring harness connector inside

console. Also check wiring harness
connections.
NOTE: For F-28F models test each press to test indicator

individually anld-’-tJke indicated -required action.
MM-21-9
Annunciator panel will not illuminate when "press-to-test" is

pressed and panel light switch is on:
Master off Turn master on.
Dimmer switch fully dimmed Brighten lights.

Circuit breaker tripped Reset panel lights circuit breaker.
One indicator will not illuminate when "press-to-test" is pressed:
Both lamps burned out Replace both lamps.

Open circuit in Check connections and wiring in
warning circuit circuit
One indicator is dim when "press-toitest" is pressed:
One lamp burned out Replace lamp. If no change,

reinstall first lamp and replace
second lamp.
Low rotor rpm circuit, including horn, doesn’t work:
Blown fuse Replace 1 amp fuse, in line between

low rotor signal conditioning unit
and 12-volt Buss.

of wiring harness.
21-5 LAMP REPLACEMENT GUIDE CHART
Lamp Location Quantity Manufacturer Number

12 volt 28 volt
Anticollision strobe 2 Whelen A61O A61O
Left and right navigation 2 Whelen W1290-14 W1290-28
Tail navigation 2 Whelen A508-14 A5O8-28
Annunciator panel 12* G.E. 330 327

(MS 25237-330)
*2 lamps per indicator
#2 Rev. 11/18/88 MM-21-10

280FX FLIGHT AMPERE LOAD CONDITIONS 12 VOLT
21-6
ELECTRICAL DEVICE DAY NIGHT

co
1 2
~o
A B C D E F G H I J K L
Boost Pump 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5
Longitudinal Trim’ 6.0 6.0 6.0 6.0 6.0
Lateral Trim’ 6.0 6.0 6.0 6.0
Radio, Transmit" 6.0 6.0 6.0 6.0 6.0
Radio, Receive .8 .8 .8 .8 .8 .8 .8 .8 .8 .8 .8 .8
,I, ´•Transponder 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8
Loran-C 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3
Instrument Cluster4 .64 .64 .64 .64 .64 .64 .64 .64 .64 .64 .64 .64
Master Relay 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Anticollision Lights 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4
Navigation Lights 8.2 8.2 8.2 8.2 8.2 8.2 8.2
Panel Lights 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Forward Landing Light’ 20.8 20.8
Aft Landing Light" 3.14 3.14
Total 15.44 27.44 21.44 25.64 37.64 31.64 61.58 49.53
NOTES: 1 Flight condition ’A’ is normal day cruise

2 Flight condition ’F’ is normal night cruise
3 Device subject to intermittent use
4 Including graphic engine monitor and low rotor rpm circuit
5 Device subject to short duration (5 minutes)
The above load conditions include all standard electrical equipment for the 280FX helicopter.
If other equipment is added, the load conditions above must be modified. F-28F loads same as
indicated in Section 6-15 Page MM 6-27.
;tt
F-28F/280FX FLIGHT AMPERE LOAD CONDITIONS 28 VOLT SYSTEM
DAY NIGHT
NAV LIGHTS
co
4 0.805 amps ea 3.22 3.22 3.22 3.22 3.22 3.22 3.22
BOOST PUMP 2.75 2.75 2.75 2.75 2.75 2.75 2.75 2.75 2.75 2.75 2.75 2.75
LONG. TRIM 2.0 2.0 2.0 2.0 2.0
LAT. TRIM 2.0 2.0 2.0 2.0
RADIO TRANSMIT 1.75 1.75 1.75 1.75 1.75
tE RADIO RECEIVE 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
INSTRUMENT CLUSTER 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07
MASTER RELAY 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
ANTI COLLISION 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5
PANEL LIGHTS 1.0 1.0 1.0 1.0 1.0 1.0 1.0
FOR~ARD LANDING LIGHT 8.93 8.93
AFT LANDING LIGHT 8.93 8.93
LANDING LIGHT RELAY O.11 O.11
7.12 11.87 11.34 15.09 13.34 33.06 29.31
NOTE: Flight condition A is day normal cruise

Flight condition F in night normal cruise
denotes intermittent use
denotes short duration use (5 min.)
red wht.
LEFT
STROBE
32-IOD(bl)
2 HOURMETER 47-28 OIL PRESS SW ALTERNATOR 70A.
36-13E 47-3 (088) I-
32-12C(b)
32 -IOC(r 2A
32-128 ’47-3A 47-18r 1 I SEAT STRUCTURE PEDESTAL TERMINAL STRIP (T2)
BLUE
compassrdimmerll
~I
75A 29-168 gn~urlu
~-SEAT STRUCT GRN. STRAP A

32-128 -130 (FI) 2 5 820
32-IOA 36-138 2
MOTORS IA. 12GA. BRAID B
GUARDIAN 32-108 ~-1111 POWER 2t5A. 33-15 J15
13A Q; .cL’
CONTROL GRlP 32-11LL II SUPPLY .Q
36-1 -IPI.
41-1
PIL~M_3-118 -14C~ (813) o 00
~36-148 U
1 II POWER PUM
7
N’sAiRuMENTS SHOCK
PANEL
o a, a,
c´•
41~28
2 SPARE
SUPPLY Irr~sl
~g
0
o
L -14 2 29-17 42-1

32-1 bl) ROTOR
OSEAT STRUCT. o
F
A 32-13D(bl) 5A. 1-4 OVER-
32-178 32-17A BOOST
RIGHT
prn. STROBE LT. CLUTCH
35-16 43-IA
32-130 2 BUSS 7trtm +t ENG.
L 32-1 IC(r) BRN 27.5 m
PARE pi 1 III Ip T R.G. 8.
GREEN 2-58 35-5A BUSS SEAT STRUCT. GND.
CHIP
P~BU( RED
2 .LTS.
(8L n
41-21
M.R.GB-
´•Ir- 4E- Z~A. -IPH CHIP
ENGINE 1A. PARE COM 33-11
LAR LIO- note
42-2E BLOCK (F-21) .B.
42-28 PANEL LTS. ALT ~XC 33-11 L~ CHIP PRESS.
220A. 1_2 33-12F
7- 37- 78 33-llC d SPARE
ncl 21
7 37- 33-12 TR.GB.
53-1 note CHIP
7 .LIXi.Lf. 7.5A. c
42-4C b) NOTES
S3-12C
CS
3~TDe 25A. 41-6 PARALLEL =133-1 b
DENOTES CIRCUIT BREAKER (TRIP FREE
5 RHEOSTAT
i
´•r
no 37-268 (83) rr,
fYPE)MlL-C-5809
24- AFTLDG.LT. 33-13
JI TER 7-270 S PIINEL LIGHTS
ITERaL ,86 38- 1 L~ FOUR EYEBROW LIGHTS SHOWN EACH
(L6) REPRESENT TWO BULBS IN PARALLEL
RL-9 lo RL- (F3)
111
.I’ 2 i UTILITY LT-qg-lB 29-3
TWO POST TYPE LIGHTS
49-ID 49-10 2
WHT IA TWO LIGHTS SHOWN EACH REPRESENT
no
METER FIVE LIGHTS IN PARALLEL
f.M. MTTIT.M.LI JI
SEAT
NI Ill I I I IN
SW.R.H. SW.L.H. NO NC
33-16
IL~ NIGHT LIGHTING INTERNILCLUSTER-
7 62-5A 62-1A TWO BULBS PER GAUGE IN PARALLEL
(S-24) J3 P3 note
.~UITCH RED B
35-15 29-4 FROM P3-E
ENG. note8b
37-1
B DENOTES CIRCUIT BREAKER SWITCH
62-58 "n"PIP~ I-O´•PPL~:t
L13) (511 280FX
f pmps Pt-21893851700 ured
7 6.I_LOW (88) TYPE 8-7-A
on
280FX w/wrgo hook
~q;m I 1 1_ _113111 IQt37-22n 42-8 IGNITION F28 F w/o
27-9 COLLECTIVE
LONGITUDINAL 01 SWITCH (reqs. mod. for J313M sw.)
STARTER SW.
LS2)U~STERB.W. temp used on F28F v/cor~o hook
4e-6 u a2 1-L2
ItRtdNin; BA
24-23
;g
-3
(ss)
ALTSW
at
23-28
L R
2 CASE 23-18 USED ON 280 FX MODEL ONLY
P2 82 GND
25-4 37-228 FSEAT
ncl STRUCT 25-3
7 4 filter
37-22F MASTER BLK 21’ FUEL PRESS
8 ~3D 8_ ~9"C RELAY 30-2 30-18 FUEL QTY. 20-1 SWITCH
0"0 -220 A2 Al
"C BM 29-5A 29-58 AIRFFiAME
3 LEFT MAGNETO RIGHT 20
289 20 GND
,no X2 (RL1) 29-6 29-68 2 (82) (DM) (PYLON)
PUMP 31-1
O XI 25-2 CYL.HD. TEMP 21-3 P P
RL-7 RL-8 7’228
LOW onpylon 22-1
~4014A 29-7 TCI) 31-58
__ covR, 29-8 2 (V)
MAG. 40-2 A
no REG STARTER
OVER 40-5 55 P5
TM. ilMIT T.M.LIICi[T BLK RD BL CASE VIBRATOR GRN.STRAP
up VOCTPIOE GND.
FWD. PIFT OILTEMP LR L IN
24-17
ELECT
(CS175 OVER
CURRENT 40-4~
RELPIY q
29-9E (TC3) tO- 20-3
ELECT.
LI BREAKER ELECT 8AT MOUNT
MOUNT ELECT -I ~t 29-108 23-2A
24- MOUNT MOUM
2 I-L5 N PANEL EN~GINE
PANEL 23-3
PANELEL
rlll ~-lcYI I I~ ~llOA2
J4W BLOCK
24-18 4-228 27-2 MR.G.B. TEMP
(F18) 27-16
(LOA D) 24-1611 RFI 29-11 (TC2)
a -F 29~22C(UNb 24 VOLT
WIRES PAIREDTO
IENGINEBLOCK CAS~EGNO. aLT) jtilter 29-12
R
TE OVER
RRENT BEAKER QR ELECTRICAL SYSTEM
SC H EM AT I C
LL~ J s RELAY
2 ENGINE
GUARDIAN CONTROL GRIP CO-RLOT 48-2 (RL2) ~r,26-1 SM
F28F and 280FX
ENGINE CASE GND. C OMPA RTMENT
A- 218-938517-00’MPE 8-7-A 48-3
n.plNu~ ORIGIMAL
40-12 21-13
As Received
CASE GNa ELECT. MOUNT PANEL
By
#2 nEv. 11/18/88 ATP
(11111111~11111111 ~24V. BATTERY
SECTION
STRUCTURE
MAINTEFIANCE MANUAL SUPPLEMENT
SECTION 22
STRUCTURE
122-1 GENERAL Reference Section 8 for Other Information
There are several changes in the fuselage structure of the 280FX and
F-28F which are noted in the following paragraphs:
3 piece airscoop
Tail rotor driveshaft cover
Tubular tail rotor guard
Horizontal stabilizers with vertical endplat2s
Landing gear fairings
These components should be maintained using the procedures described in

Section 8 of the F-28F 280F Maintenance Manual.
22-2 AIRSCOOP 280FX
The airscoop comprises three separate pieces which are fiberglass con-
struction. These include a nose piece which is attached to the cabin
roof, a center duct which is mounted to the top of the fuel tanks, and a
large airscoop which is mounted on the wraparound cowl behind the trans-
mission. This airscoop funnels the cooling air around the transmission
and into the cooling fan. The large airscoop blends into the tail rotor
driveshaft cover. (Ref. Figure 22-1)
k. Airscoop removal for access to the upper drive system or for main
rotor gearbox removal.
ii) Remove side cowl (9) and opposite side panel (10) then remove 5
each screws (4) on the forward section of airscoop (6) and lift
airscoop off.
(2) Remove screws (2) 4 places from center duct (7) and nose
piece (8).
(3) Remove screws (3) from either side of the center duct and
remove.
NOTE: The piece (8) need not be removed, the assembly should
nose be
inspected for damage and/or missing fasteners.
B. For reinstallation, assemble in reverse order (3) through (1).
MM-22-3
a 4
3 ~Lt
C ~3
´•r
7
THREE PIECE AIR SCOOP
FIGURE 22-1
MM-22;2
MAINTENANCE FIANUAL SUPPLEIViENT
22-3 TAIL ROTOR DRIVESHAFT COVER 280 FX
The tail rotor driveshaft cover consists of four pieces of formed

aluminum which is attached to the tailcone. This cover helps protect the
driveshaft and the bearings from the weather, and also helps streamline
the tailcone. The aftmost section of the cover is held in place with two
screws and two quarter-turn fasteners. The three forward sections are
held iri place by hinges on the right side and quarter-turn fasteners on
the left side. This provides easy, fast removal of the driveshaft cover
for inspection and servicing the driveshaft and bearings. (Ref. Figure
22-2)
A. Cover-opening for access to tail rotor drive shaft.
(1) Unfasten the a turn fasteners (1) thru (4).
(2) Lift Section (7) up from left side and over.
(3) Repeat same procedure for Section (8) (9).
NOTE: This will allow the required access to lubricate the tail
drive bearing pillow blocks, the aft two pillow blocks are
accessible without removing section (10).
(4) Removal of the aft section (10) for complete tail rotor drive
shaft exposure can be accomplished by unfastening item (5) both
side and by removing screw (6) both sides.
NOTE: With covers in the condition as noted in (1) through (4) will
allow for complete tail rotor drive removal if required.
B. Inspection cover assembly only for other requirements see
sections 3, 4 10-6.
(1) Check for cracks and missing or damaged fasteners, repair and or
replace as required.
C. Cover Closing
(1) Reverse procedures as noted items (4) through (1) Par. A.
(2) Check final security after closing.
Mlvi-22-3
screw
io
7 \3
TAIL ROTOR CRIVE SHAFT COVER
FIGURE 22-2
MM-22;4
22-4 TUBULUR TAIL ROTOR GUARD 280FX F-28F
The 28(jFX is equipped with a tubular tail rotor guard, similar to the
guard used on the F-28F series helicopters. This tail rotor guard
increases the protection of the tail rotor and makes the helicopter
easier to handle on the ground. (Ref. Figure 22-3)
A. Tail Rotor Guard Removal
(1) Remove bolt (13) and associated hardware (14) (15), remove
clamp (12).
(2) Remove bolts (16) and (23) with associated hardware (17) (18).
(3) Remove the tail rotor guard assembly (11).
B. Inspection
(1) Inspect tail rotor guard for cracks or other damage.
(2) Inspect end fittings for loose or sheared rivets.
(3) Inspect end fittings for elongated holes or other damage.
(4) Check retention bolts for excessive wear and or thread damage.
(5) Inspect security of chafe pads (24) (25) for tail guard
protection.
NOTE: Some isolated cases of water have been found inside of the
tail rotor guard assembly, if this condition is present, a 1/8
inch diameter hole may be drilled in the lowest point of tube
for drainage.
C. Tail Rotor Guard Installation
(1) Position tail rotor guard in forward upper fitting and install
bolt (23) and hardware.
i2) Install clamp (12) and bolt (13) with associated hardware.
(3) Position aft tail rotor guard fitting into tail rotor gear box
and install bolt (16) with required hardware, torque all three
bolts (13), (16) and (23).
MM-22-5
F-28F 280FX
B. HORIZONTAL STABILIZER 280FX F-28F INSPECTION

28-20119-1 Fig 34-3 Horizontal Stabilizer bushings +.001 Not repairable Replace bushing
-2 Item 3 Stabilizer 1.130 diam. .001
(3) Bolt
Mount Bolt holes +.002 Not repairable Replace stabilizer
.189 diam. .005
28-20119-3 (1) Bolt Stabilizer skin None allowed Repairable* Replace stabilizer
-4 Mount check for cracks
(2) Clamps
Fitting cracks None allowed Not repairable As required replace
(sheet metal) fittings
~u NOT E: Structural repairs to be made utilizing

Part FAR 43 (Sheet Metal)
End Plate Damage None allowed Not repairable Replace Endplate
1.125
28-11222-15 Fig 8-16 Cross Spar O.0. diam. -.0005 Not repairable Replace spar
1.129
Bolt holes +.002 Not repairable Replace spar

.189 diam. .005
Spar surface check None allowed Not repairable Replace spar

for nicks, scratches,
cracks
Corrosion Pits -.005 in depth Blend out and

protect
*Repair per FAR 43 recommendations
O
22-5 HORIZONTAL STABILIZERS WITH VERTICAL ENDPLATES 280FX F-28F
The horizontal stabilizers are aluminum semi-monoque construction. The

vertical endplates are constructed from fiberglass over foam cores, with
the anticollision and navigation lights mounted on the outboard side of
each end plate. (Kef. Figure 22-3)
A. Stabilizer Removal
(1) Remove trailing edge tab screw (6) and washer (7).
(2) Remove 3 retention bolts (8) and associated washers i9) and nuts
(10).
NOTE: Later model stabilizers are retained by one through bolt (8)
at the outer most end of the spar (3) and two internal
wrenching bolts (20) inboard located on the underside of the
stabilizer under the removable skin plugs (21). The inboard
bolts (20) need only be loosened to allow stabilizer removal.
(3) Slide stabilizer (-4) or (-5) about 3 to 4 inches for clearance

to disconnect strobe (19) and navigation light wiring.
(4) Remove stabilizer.
(5) Repeat steps (1) through (4) for removal of opposite assembly.
(6) Spar removal (3) open access panel on right side of tail cone
aft of spar.
(7) Loosen spar clamp bolts (1) at 2 locations.
(8) Slide spar (3) outward to remove, note spar should be marked to
indicate relative location for correct reinstallation and
matching to stabilizer mount holes. Mark with ink brush pen
only do not scribe.
B. Stabilizer Inspection
NOTE: Inspect assemblies per following table on horizontal

stabilizers. If stabilizers with (3) mount holes require
replacement, it shall be necessary to install a new spar, as
stabilizers are match-drilled to spar on installation,
C. Stabilizer Installation
(1) Apply lubricate or equivalent to spar (3) and slide spar into
tail cone spar mounts in the same original mount position and
snug bolts (1) lightly.
(2) Install the left hand stabilizer (4) by sliding on spar (3)
close to the tail cone and connect navigation strobe light
connector.
MM-22-7
(3) Slide stabilizer on spar completely and align holes to install

through bolts (8) through stabilizer and spar with required O
hardware. Torque two bolts (20) and washer (26) on underside if
applicable assembly.
(4) Position stabilizer and spar so trailing edge tab fitting is in

alignment with the retainer nut plate in the tail cone.
NOTE: In some cases an additional washer (7) shim may be required

under fitting to reduce bending.
(5) Install screw (6) and washer (7).
(6) Torque spar clamp mount bolts (Ij at two places and safety wire.
(7) Install access panel on tail cone.
(8) Install right hand stabilizer assembly by repeating steps (I),

(2), (3) and (4).
(9) Check bolts and screws for proper torque and security.
D. Endplate Assembly
NOTE: If endplate is damaged and removal is required it can be

accomplished as follows:
(1) Remove Nav-Strob light assembiy, disconnect Hiring.
(2) Remove (10) number 10 screws and remove endplate assembly.
(3) Reinstall by reversing steps (2) (1).
MM-22-8
17 1~
23
S
I‘\\
NOTE: On latei veisians of -a
i and -5 asse:iib7 ies the tl;´•s
inboard bolts !9) are
repiaccd 5´• (20) internai
w~´•enching belts, wasnei-;,
and plug on e~i,,
surf are
assembly thr-ouqh the

~9
bottom The outhonl~
´•´•´•´•´•1.1´•
‘c\lo
TUBULAR TAIL ROTOR GUARD AND VERTICAL STABILIZERS
FIGURE 22-3
MM-22-~
22-6 LANDING GEAR FAIRINGS 280 FX
The 280FX is equipped with landing gear fairings on the oleo struts and
landing gear legs. These fairings are made of aluminum and fiberglass
and clamped on to the landing gear assembly. To check for proper strut
extension the helicopter should be sitting on level ground. The struts
should then be leveled by rocking the helicopter by pushing up and down
slightly on the tail cone. method see Section 17-2, for proper
inflation see Section 4-1 ITem F. Checki"1"R
ef. Figure 22-4)
A. Access to Service Oleo Strut
(1) Remove 3 screws (9) from upper flex boot (6) lower end.
(2) Lift flex boot (6) upward to expose oleo valve for required
servicing see Section 4-2 Item F.
B. Access for Oleo Strut Removal
(1) Proceed with items l.-(a) (b).
(2) Remove 2 screws (10) front and back, top and bottom of oleo
fairing (2).
(3) Slip rubber boot (4) at bottom of fairing (2) downward to clear
attaching screws.
(4) Rerove rcrews (5) from trailisg edge of fairing (2j.
(5) Spread fairing (2) carefully to clear oleo and remove from
forward side.
(6) Remove 4 screws (7) and bolt (8) from lower fairing (1) or (3).
(7) To remove forward fairing (1) carefully spread to clear gear and
oleo remove from forward side.
(8) To aft lower fairing

remove (3) carefully spread to clear gear
and oleo and slip forward on drag strut.
(9) Remove oleo as describes in Section 8-9 Par. D.
NOTE: For float installation the complete fairing assemblies must be

removed. Prior to mount clamp removal, their position should
be marked for ease of reinstallation.
C. Reassembly After Oleo Replacement
(1) Reverse procedures in step 3 (8) (1) thru A (2) (1).
(2) Check for proper security.
MM-22-10
U, .Inspection
IZ) Check for cracked or damaged components and replace as required.
(2) Check for missing nut plates and screws replace as required.
MM-22-ll
´•o
10’
~i
DESIGNATES INBOARD SCREWS
LANDING GEAR FAIRINGS 280FX
FIGURE 22-4
MM-22-12
22-7 DOOR ASSEMBLIES F-28F
The cabin door assemblies have been changed to all plastic and fiberglass
construction resulting in a more uniform and resilent component. (Ref.
Figure 22-5)
A. Door Removal
(1) Remove screw (9) from restraint cable (1) on lower corner of
inside door frame.
(2) Remove pins (2) from upper and lower hinge (5).
(3) Carefully lift door from cabin frame.
NOTE: Inspect door for cracks, delamination to frame and plexiglass.

Check vent and sliding window for security or other damage.
Check door latching for proper operation and security.
Inspect hinges for deformity or other damage.
B. Door Installation
(1) Carefully lift door assembly and position into matching hinges.
(2) Holding door in position insert hinge pins (2) into position.
j3) Position restraint cable (1) and attach with screw (9) to cabin
frame (8).
(4) Check operation of door latch and upper and lower retaining
lugs.
NOTE: Installation of new door glass on these new F-28F doors

requires the use of a special bonding fixture to hold and
align the assembly. Doors should be returned to Enstrom
Helicopter for glass replacement.
MM-22-13
ij iI-‘
,I´•
3
j´•:I
YALir71
I
C=-,
9
i
.9
Ij 13´•~.
I i
I r
’c´•
5
111
U
\6. 7
II
’´•\U
,II
I
I
\1
fi;
4 I::
4
I); f
I I I
;,I
i
1
i
i
I\\
s
9 (t i
I~
I’
9
I
g
,I
F-28F CABINi D~OR
FIGURE 2’2-5
MM-22-14
SECTION
FLIGHT CONTROLS
SECTION 23
FLIGHT CONTROLS
23-1 GENERAL
The F28F and 280FX have incorporated a new bearing configuration for the
upper push rod to walking beam attachment.
23-2~ PUSH PULL TUBES
The incorporation of teflon and steel journal bushings in the upper ends
of the main rotor push-pull tubes. Disassembly and inspection of the
upper end of the push-pull tubes is described below.
A. Upper Push-Pull Tube Bearing Inspection (Ref. Figure 23-1)
(1) Remove push-pull tubes as described in Section 12- 11 Par. D of

the Maintenance Manual.
(2) Remove bellcranks as described on page 12-11 Par.’ D of the

Mai ntenance Manual. Mark bellcranks and remove them from the
pitch links.
(3) Inspect for excessive looseness between steel journal

bushing (3) and teflon bearing insert (2).
(4) Remove and inspect steel journal bushing (3) for galling or
roughness.
(5) Inspect teflon bearing insert (2) for liner damage or wear.
(6) If necessary, remove and replace teflon insert.
(7) Reinstall steel journal bushing (3).
(8) Inspect bolt (5) for wear or damage and replace as necessary.
(9) Insert bolt (5) into inboard end of bellcrank (8) and check for
looseness.
(10) Inspect steel bushings (9) and (10) for roughness, galling and
wear.
(11) If necessary press flanged bushings (9) and (10) out of

bellcrank (8) and replace.
(12) Repeat for the other two bellcrank/push-pull rod assemblies.
(13) Reinstall the components on the aircraft per sections 12-11

Par.J of the maintenance manual.
WARNING: Care should be taken not to drop components down rotor

shaft.
MM-23-1
10
PUSH PULL TUBE UPPER BEARING ASSEMBLY
FIGURE 23-1
MM-23-2
SECTION
INSTRUMENTS
SECTION 24
INSTRUMENTS
24-1 GENERAL REFERENCE SECTION 7 FOR OTHER INFORMATION
In addition to the instruments which are standard in the 280F, the 280FX
includes a graphic engine monitor (Insight Instruments) and a new
avionics package. All of the following items are optional on the F-28F
model.
24-2 GRAPHIC ENGINE MONITOR
The 280FX is equipped with a graphic engine monitor, manufactured by

Insight Instruments. This instrument displays both E6T and CHT in bar
graphs, one for each cylinder. The unit also displays turbocharger inlet
temperature (TIT) digitally. The TIT is displayed as a three-digit
number, which is equal to the actual TIT in "F divided by 10. For
example, a display reading 147 means that the temperature is 1470"F. The
temperature limit at the turbocharger inlet is 1650"F as it was for the
280F. Other operating limits and procedures have not changed froin those
defined in Powerplant Section 13 of the Maintenance Manual. See
Fig. 36-1. For complete panel configuration of the 280FX see Fig. 24-2.
GEMdO 3 For Turbochevged engines
EGTAnnunciator Turbine Inlet reading
GRAPH:C
TIT ~nnuncistor
hSONNCI:d CHTAnnunciator
EGT enr
Average rir
:C OF
Peak E G T \L25~ F per bar
SocCf
4000
CHTreading’ 1 2 3 4
aoo"
Insight
Cylinder Number
Reset Button
GRAPHIC ENGINE MONITOR
FIGURE 24-1
MM-24-1
24-3 ENGINE TROUBLESHOOTING AND DIAGNOSIS WITH THE GRAPHIC ENGINE MONITOR
Gradual or sudden Partially plugged Remove and clean

rise in EGT of one fuel nozzle, iridicated cylinder nozzle.
cylinder. Display inaicated by no
will blink when variation in EGT
this occurs, duri ng magneto check
for that cylinder.
EGT CHT~ FouR~ed or defective Perform a magneto check.

spark plug or Cylinder that has a faulty
5 ignition lead. spark plug or ignition
lead will drop on the bar
1234 graph and other cylillders
IN8GHT
will rise, indicating the
top, bottom plug or lead,
with the problem.
Replace spark plug or lead
as required on indicated
cylinder.
Rising E6T
readings Magneto uut of Periorm a magneto check.
on all
cylinders and time, or faulty. RPM drop on both magnetos
all cylinders on should be excessive.
display blink; TIT
digital display Check timing. If correct,
blinks, overhaul or replace
magnetos.
EGT CHT~ Restriction in fuel Check fuel filters and

systemor servo not clean.
s flowing correctly.
s
Perform fuel flow check
12 3 4 at nozzles.
INSIGHT
Check lines for damage or

WARNING;: 7‘his is a serious flex lines for twist.
indication and can cause
abrupt engine failure, if Return servo to authorized

proper steps are not taken. Bendix overhaul center.
MM-24-2
Above normal Cracked, missing or Repair or replace baffles,

temperatures in open baffles or remove obstructions, and
one or more doors. Obstruction close panel doors.
cylinders iCHT). or debris in
cylinder fins.
~GT Cowl panel doors
not secure.
1234
INSIGHT
Low EGT reading Defective or blown Inspect exhaust system

in cylinder,
one exhaust gasket. and correct as required.
continually. Cracked or loose
exhaust system.
EGT CHT~ Intake valve not Perform a compression

opening completely check.
5 causing low
i lI compression.
1234
Plugged fuel Clean nozzle.

nozzle.
Decline in EGT Fuel system Clean fuel nozzles. Do

uniformity, most restriction or flow check for uniformity,
visible at cruise dirty injection and if problem persists
power settings, nozzles. check fuel system for

proper pressure and flow.
EGT
1234
INSIGHT
MM-24-3
MAGNETO CHECK: EGT is often a better indicator of ignition problems that

have been traditionally diagnosed: by observing rpm drop during run-up.
If one spark plug or ignition wire on each mag is defective the single
Q
mag check would indicate an equal rpm drop on each. Such a double
failure would go undetected. The: graphic engine monitor will not only
identify the problem but pinpoint the affected cylinders.
MIXTUKE CHECK: GEM displays a uniform EGT rise of all cylinders during
mixture control check. An abnormally large exhaust gas temperature
differential in one or more cylinders in fuel injected engines may warn
of a fuel injector constriction.
NOTE: For further engine troubleshooting, refer to Section 13.
24-4 AVIONICS
The standard 280FX is equipped with the following avionics; these

items are optional in the F-28F Models.
King KY-97 communications radio

King KT-76 transponder
II Merrow, Inc. Apollo II Loran-C
For further information about these units, refer to the appropriate

manuals published by the specific manufacturers.
MM-24-4
ANNUNCIATOR PANEL CONTENTS:

CoMPAss, OVERBOOST
’LOW ROTOR R.PM
T. R.G.B. CHIP
COMPASS CALIBRATION CARD~
.M.R.G.B CHIP
’LOW FUEL PRESSURE

AIRSPEED INDICATOR
’CLUTCH ENGAGE
ENGINE AND RO LOW VOLTAGE [OPTIONAL)
TACHOMETER PRESS TO TEST FOR ANNUNCIATOR
’STARTER RELAY (OPTIONAL)
PAN E L
ALTIMETER
PANEL LIGHTS
DIMMER
BALL BANK
INDICATOR
r’ suss F*ULT
CIRCUIT BREAKER
MANIFOLD/ FUEL A I~ It /AMMETER

PRESSURE INDICATOR
CYLINDER HEAD TEMP
INDICATOR
,ENGINE MONITOR
FUEL QUANTITY WGE
MAIN ROTOR
CIRCUIT BREAKERINSTRUMENT
GEARBOX
TEMPERATURE CAGE ALTERNATOR EXCITATION
CIRCUIT BREAKER
ENGINE OIL PRESSURE
ENGINE
OILNDICATOR TE
INDICATOR
MAGN ETO
(IGNITION) SWITCH
ALTERNATOR
CIRCUIT BREAKER
FUEL MIXTURE CONTROL

~AFT LANDING LIGHT
8 DAY CLOCK (OPTIONAL! FORWARD LANDING LIGHT
(LOtATION MAY VARY)
PANEL LIGHTS
CIC LIGHTER (OPTION*I NAVIG*TION LIGHTS CIRCVIT

(LOCATION MAY VARY) i AKER
ANTI-COLLISION LIGHTS SWITCHES
t’iO~ FUEL BOOST PUUP
TRIM
IGNITION
ALTERNATOR SWITCH
MASTER SWITCH
280FX
INSTRUMENTS AND INSTRUMENT PANEL
FIGURE 24-2
MM-24-5
SECTION
TAIL ROTOR DRIVE

ASSEMBLY
MAINTENANCE ~ANUUL SUPPLEMENT
SECTION 25
TAIL ROTOR DRIVE ASSEMBLY
25-1 GENERAL REFERENCE SECTION 10 FOK OTHER INFORMATION
Except as described below, the tail rotor drive assembly of the 280FX is
essentially the same as that used on the 280F. This system should be
maintained as described in the F28F 280F Maintenance Manual
25-2 TAIL ROTOR DRIVESHAFT COVER
The installation of the tail rotor driveshaft cover has resulted in two
minor changes to the driveshaft installation. First, in order to
Simplify servicing the pillow blocks, the frontmost and rearmost pillow
blocks are installed with the grease fittings on the aft side of the
pillow blocks. The other pillow blocks are installed with the grease
fittings on the forward side of the pillow blocks. This allows the
operator to grease all five pillow blocks by opening the forward three
hinged sections of the driveshaft cover. Second, the rearmost driveshaft
cover bracket is installed under the aft p~lfow block. This bracket must
be in position before the tail rotor driveshaft can be aligned.
Except as described above, the tail rotor driveshaft should be maintained

in accordance with Section 10 of the MaintenanceManual and Section 22 of
this supplement.
25-3 TAIL ROTOR GEARBOX CHIP DETECTOR
The tail rotor gearbox is equipped with a magnetic chip detector similar
to the one installed in the main rotor gearbox (ref. Figure 19-1, Section
19). This chip detector system consists of a magnetic chip detector in
the gearbox which is wired to a caution light in the annunciator panel on
the instrument console (ref. Section 21). The magnetic chip detector is
located in the rear of the bottom of the gearbox. This unit comprises a
magnetic plug which locks into a self-sealing base. If the tail rotor
gearbox chip light illuminates, inspect the chip detector as described
below:
A. Remove magnetic plug as follows:
(1) Do not disconnect wire.
(2) Grasp plug and push upward.

(3) While holding upward pressure, begin turning plug
counter-clockwise.
(4) Turn plug counter-clockwise one-quarter turn.
(5) Pull plug out of socket in base fitting.
MCI-25-1
Inspect plull.
NOTE: New or overhauled gearboxes will often make a

recently
magnetic "fuzz" which will collect on the magnetic plug as
a gray sludge. This is normal and may be cleaned off the
plug. The plug may then be reinstalled and the helicopter
returned to service. If any chips are found which are
larger than 1/16 inch in cross-section, contact the nearest
Enstrom Service Center or the Enstrom factory.
C. After determining that the transmission is airworthy, clean the

magnetic plug. This may be accomplished with a soft cloth or
with a strong magnet attached to a pointed object such as a
knife or a small screwdriver. Use caution to avoid scratching
the magnetic plug.
D. Keinstall magnetic plug as follows:
(1) Insert plug into socket in base fitting.

(2) Align lugs in plug with slots in base fitting.
(3) Push plug upward while turning plug clockwise
(approximately one-quarter turn).
(4) lJhen plug stops turning, pull downward.
(5) Check plug to insure that it is locked in base.
E. Tail Rotor Gearbox Lubricant Change
The tail rotor gearbox lubricant should be changed every

100 hours as described below.
(1) Remove and inspect magnetic chip detector plug as described

above.
(2) Remove safety wire from chip detector base fitting and the
filler plug.
(3) Remove the filler plug.
(4) Place a trough or contdiner under the base fitting and

remove the base fittin~.
(5) Allow all oil to drain from gearbox.
(6) Replace crush washer on base fitting.
(7) Keinstall base fitting and safety.
(8) Reinstall magnetic plug as described above.
MM-25-2
(g) Inspect O-ring on filler plug and replace if necessary.
(10) Service transmission with 5 ounces of 15W-50 or 20W-50

aviation oil.
(11) Reinstall fil~er plug and safety.
(12) Inspect gearbox for leaks.
MM-25-3

Enstrom F28F 280F MM Rev 04 1994 PDF

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ATP

INDEX COPYRIGHT 2008

COPYRIGHT IS NOT CLAIMED AS TO ANY PART OF AN ORIGINAL WORK

"ATP" is a registered trademark of Aircraft Technical Publishers. All original

ALL RIGHTS RESERVED. NO PART OF THIS PUBLICATION MAY BE

ATP Grid Index to Manufacturer’s Publications:

Section 2 General Information

Section 3 Periodic Inspections and Airworthiness Limitatio

Section 4 Servicing and General Maintenance

Section 5 Weight and Balance

Section 6 Electrical System

Section 9 Main Rotor

Section 10 Tail Rotor

Section 11 Drive Belt System

Section 12 Flight Controls

01/28/2008 Copyright Aircraft Technical Publishers Page 1 of 2

(EN 0130 MM)

Section 13 Powerplant and Accociated Systems

Section 14 Utility Systems

Section 15 Supplement Procedures

Section 16 Aircraft Description

Section 17 Airworthiness Limitations

Section 19 Main Rotor Transmission

Section 20 Belt Drive System

Section 21 Electrical Systems and Components

Section 23 Flight Controls

Section 25 Tail Rotor Drive Assembly

01/28/2008 Copyright Aircraft Technical Publishers Page 2 of 2

(EN 0130 MM)

The Airworthiness Limitations Section (Section 3) is FAA approved

alternative program has been FAA approved.

(I ENSTRONI HELICOPTER CO~RPORATION

MFG,REVI ISSUE ATP REV

REISSUE ENTIRE BOOK 1985 4-24-86Rl ATP/

8- 8 -16-89 ATP DAT1

3 SM: 4, ~C71 ~I 3/00/C14 2/8/94 ATI?

4 ,P~EISSUE 3/00/94 12/8/94

rOR1~ LRCA,OOS.,1 6-01-84

REV. REV. DATE F.A.A.

1 1 4-3-86 1 vi, vii, viii and ix

2. REVISIONS TO SECTION 3 AND II MUST BE F.A.A. APPROVED

TEMP ISSUE ATP REV DATE REV

FORM LRCA_006-1 4-12-88

1-1 Manual Arrangement MM-1-1

Section 2 GENERAL INFORMATION

2-1 Specifications MM-2-1

*Section 3 PERIODIC INSPECTIONS AND AIRWORTHINESS LIMITATIONS

3-0 General MM-3-1

Section 4 SERVICING AND GENERAL MAINTENANCE

4-1 Lubrication MM-4-1

*Adherence to theinspection intervals and component retirement lives in

5-1 General Information MM-5-1

Section 6 ELECTRICAL SYSTEM

6-1 Electrical System MM-6-1

7-1 Instrument Panel MM-7-1

8-1 Cabin MM-8-1

Section 9 MAIN ROTOR

9-1 Main Rotor Hub Assembly MM-9-1

Section 10 TAIL ROTOR

10-1 Tail Rotor Assembly MM-10-1

Section 11 DRIVE BELT SYSTEM

11-1 Clutch Control Rigging MM-11-1

12-1 Troubleshooting the Articulated Rotor System MM-12-1