2297

ATP
INDEX COPYRIGHT 2004
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Aircraft Technical Publishers Customer Service
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ATP Grid Index to Manufacturers Publications:
McDonnell Douglas Hel.

3690 Series
SERVICE INFORMATION
Issue Type Eye-Readable Code
SERVICE BULLETIN SE
SERVICE INFO LETTERS SIL
SERVICE INFO NOTICE SIN

SERVICE LETTER SL
TECHNICAL BULLETIN TB
ADS ADs
End of Index
10/18/2001 Copyright Aircraft Technical Publishers Page 1 of 1
i HU 0203 SI)
SB
101 South Hill Drive 6AM-5PM PST M-F
Brisbane, CA 94005 (800)227-4610
MD Helicopters Inc.
3691) Series
SERVICE BULLETIN
1) Applicable AD
2) Part Kit (1)
Issue Number 3) Part Kit (2)
1Issue Date Issue Description 4) Compliance Time
DN-51.8 Inspection of main rotor blade 1)

01/03/2000 root fitting assemblies; 2)See Issue
inspection of main rotor hub 3)
lead-lag link assemblies 4) Mandatory
SB369D-191 MAIN ROTOR TRANSMISSION 1)

09/26/1997 ACCESSORY DRIVE INSPECTION 2)SEE ISSUE
3)
4) MANDATORY
SB369D-192 INPUT SHAFT COUPLING ASSEMBLY 1)99-04-12

09/26/1997 INSPECTION 2) 369F5133-1
4)SEE ISSUE
SB369D-193 R1 TAIL ROTOR BLADE, LEADING EDGE 1)

05/03/1999 INSPECTION FOR CRACKS 2)SEE ISSUE
3)
4) Mandatory
~B369D-195 R3 MAIN ROTOR BLADE ROOT END 1) 98-15-26

07/13/1998 INSPECTION AND TERMINATION 2)SEE ISSUE
ACTION FOR SUSPECT MAIN ROTOR 3)
BLADES 4) MANDATORY
SB369D-196 OIL COOLER BRACKET REPLACEMENT 1)

04/28/1998 2) 369F5194-1
3)
4)SEE ISSUE
1)2/24/2004 Copyright Aircraft Technical Publishers Page 1 of 2
HU 0203 SI SE
1) Applicable AD
2) Part Kit (1)
Issue Date Issue Description 4) Compliance Time
SB369D-197 Engine fuel filter pressure 1)

1- 02/23/1999 switch replacement 2)369[)281443
4) Mandatory
SB369D- 198 Tail rotor fork inspection, 1) 99-13-09

05/10/1999 four- bl aded 2)See Issue
4) Mandatory
SB369D- 199 Turbine outlet temperature 1) 2000-08-22

01/11/2000 (TOT) indicating system, one 2) See Issue
time inspection 3)
4) Mandatory
SB369D-200 Landing gear strut inspection 1)

04/07/2000 and fairing modification 2) See Issue
4) Mandatory
SB369D-201 R2 Main rotor blade assembly 1)

02/04/2004 torque event inspection 2)See Issue
4) Mandatory
SB369D-202 Main transmission bonding 1)

08/14/2002 jumper inspection and rework 2)See Issue
4) Mandatory
End of Index
HU 0203 SI SE
HN-2 11.6*
DN-51.8*
EN-42.6*
FN-31.6*
SERVICE BULLETIN DATE:

PAGE 1 OF 7
3 JANUARY 2000
/I MANoAToRvl/ll/ll/ll/II/ MANDATORYIII//III//I111 MANDATORYIJ
INSPECTION OF MAIN ROTOR BLADE ROOT FITTING

ASSEMBLIES; INSPECTION OF MAIN ROTOR HUB LEAD-LAG
LINK ASSEMBLIES.
and FN-31.5, dated 8
Supercedes Service Information Notices HN-211.5, DN-51.7, EN-42.5
September 1999 and the mandatory blade removal and inspection I
DN-183.1, EN-75.1 and FN-62.1, dated 26 August 1992. This Notice also cancels Service
Information Letters HL-114.1, DL-89.1, EL-40.1 and FL-33.1, dated 01 March 1991.
Compliance with the requirements of this Notice allows cancelling the requirements of PART I
DN-183.1, EN-75.1 and FN-62.1 (removal of 369D21100-515 and 369D21102-501 main rotor
blades every 25 hour to perform a visual inspection of those blades). Operators are still
required to rework their 369D21100-515 and 369D21102-501 blades per the requirements of
PART II of DN-183.1, EN-75.1 and FN-62.1.
1. PLANNING INFORMATION
A. Aircraft Affected:
All 369 Series helicopters, including the 369A (OH-6A) Series helicopter, equipped with any
of the following.
B. Assemblv/ComPonents Affected By This Bulletin:

All 369A1100-BSC thru -505, -601 and -603, 369D21100-BSC thru -515 and
369D21102-BSC and -501 main rotor blades.
All 369A1234, 369A1203-BSC, -3,-11, and 369H1203-BSC,-21 and -3llead-lag link 1
assemblies.
NOTE: All 369D21100 main rotor blades, including those blades with an "I~f after the serial
number, and lead-lag link assemblies listed above must be inspected.
C. Reason:
Operators of 369 Series helicopters have experienced cracks in the lug area of the main
rotor blade root fittings and lead-lag links.
Failure to follow this Service Bulletin could result in loss of main rotor blade. Movement of I
the bushings within the lug could lead to cracking of the root fitting. Therefore, all of the
above listed main rotor blades shall be inspected for cracks in the area of the root fittings
and lead-lag links and for movement of the bushings in the root fitting.
Cracked main rotor blade root fittings or lead-laglinks may produce a sudden change
Z;AUTION_~ i,,,,,,, in helicopter vibration. if operators experience a sudden onset of unusual
or excessive vibration, a precautionary landing must
be made. No further flights shall
be attempted until the cau~se of the vibration has been identified and corrected.
D. Descri~tiont
This revision reduces the time of compliance for PART II from 25 hours to 15 hours for the
369A1234, 369A1203-BSC, -3 and -7,
I
mark to
greater than 500 hours. The previous revision added procedures to apply a slippage
root fitting bushings and lug surfaces and to periodically inspect those slippage marks to
aid operatorsin accurately detecting bushing movement. Movement of the bushings may
cause or be caused by root fitting cracking.
Copyright 1999-2000 by MD Helicoptars Inc. This document may be reproduced and distributed provided no fee is charged,
the text is not moditied, andthis copyright notice is included.
MANDATORY II
/I MANDATORY 11111111111/II MANDATORY IIIII11111111/
HN-2 11.6*
DN-51.8*
EN-42.6*
FN-31.6*
PAGE 2 OF
SERVICE BULLETIN
II MANDAToRvlllllllllll111 MANDATORYIIIIIIIIII/II/ MANDATORYII
PART I of this notice lists a procedure for the removal of the main rotor blades to
inspect for
cracks in the root f~tting attach lugs or the main rotor hub lead-lag link attach
lugs, and/or
bushing movement. In addition, a procedure is also provided to apply a protective coating to
seal the junctions between the stainless steel bushings and attach lugs. Finally. if a
slippage mark has not already been applied, this notice provides a procedure for applying a
slippage mark across all four bushings and root fitting lugs. DO NOT remove bushings.
PART II of this Notice provides instructions for periodic visual inspections of the root
fitting
attach lugs and lead-laglink attach lugs to check for cracked or broken lugs and for
movement of the bushings. It also emphasizes the importance of corrosion
prevention in the
area of the main rotor hub.
E. FAA ADDroval:
The design engineering aspects of this notice have been shown to comply with the
applicable Federal Aviation Regulations, and are FAA approved.
F. Manaower:
N/A
G. Time of Comaliance:
PART I Shall be accomplished within the next 25 hours of helicopter operation and/or
prior to installation of main rotor blades and main rotor hub assemblies in
spares
inventories and every 100 hours thereafter.
PART II Shall be accomplished at each 25 hour interval of operation for aircraft equipped
with 369A1100-BSC thru -505, -601 and -603, 369D21100-BSC thru -515 and
369D21102-BSC and -501 main rotor blades and/or 369111203-31. lead-lag link
assemblies.
For aircraft equipped with 369A1234, 369A1203-BSC, -3 and -7, and 369H1203-BSC and
-21 lead-lag links, accomplished at each 25 hour interval of operation
up to 500 hours and
every 15 hours thereafter until retirement of lead-lag links.
(I) Denotes portion of text added or revised.
Copyright 1999-2000 by MD Helicopters Inc. This document maybe reproduced and distributed provided no fee is charged,
the text is not modified,and this COWll~ht notice is included.
I/ MANDAToRvlllllllllll/II MANDATORY 11//III1111/11 MANDATORYII
HN-211.6*
DN-51.8*
EN-42.6*
FN-31.6*
SERVICE BULLETIN DATE: 3 JANUARY 2000

PAGE 3 OF 7
II MANDAToRvlllllll;/ll1111 MANDATORVIIIIIIIIIIIl/l MANDATORYII
H. MateriaYPart Availability:
Contact MDHI Warranty and Repair Dept.
PARTS
Nomenclature Part No. Qty. Source
369H 1203-51 A/R MDHI

Link, lead-lag
Main Rotor Blade 369A1100-511 AIR MDHI
Main Rotor 81ade 369021100-523 A/R MDHI
Main Rotor Blade 369021102-523 A/R MDHI
MATERIAL
Nomenclature Source
Epoxy paint (white, florescent yellow or orange) Commercial

DO NOT use torque seal.
Sealer, corrosion inhibiting I Product Research

(MIL-S-81733, Type 11-2) 2919 Empire Avenue
(RM007361) P/N PR1436-G Burbank, CA 91504
Coast ProSeal
19451 Susan Rd.
Compton, CA 90221
Primer (MIL-P-8585) (RM009222) or Commercial
(Alternate) Sealer, (MiL-P-23377, Type 2, Class 2) ICommercial
I. Tools andEauiDment:
TOOLS AND EQUIPMENT
Nomenclature Source
Magnifying glass 5X Commercial
Kit, dye penetrant (MIL-I-25135) Commercial
J. Wei~ht and Balance Data:
Weight and balance not affected.
K. Refere~
369H Basic HMI (CSP-H-2) Revised 23 August 1996, or latest revision

500/600N HMI (CSP-HMI-8) Revised 1 June 1999, or latest revision
369D/E~F
1999-2000 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged,
Copyrigh~
the text is not modiFed, and this copyright notice is included.
/I MANDATORY IIIIIIIIIIIII/ MANDATORY 11/1111111/II1 MANDATORY JI

HN-211.6*
DN-51.8*
EN-42.6*
FN-31.6*
DATE:
PAGE 4 OF 7
3 JANUARY 2000
SERVICE BULLETIN
II MANDAToRvlllll/ll/llII/ MANDATORY Illlllrlllllll/ MANDATORY I/
2. ACCOMPLISHMENT INSTRUCTIONS
A. PART I 100-HOUR BLADE REMOVAL/INSPECTION
(1). Remove affected main rotor blades per applicable HMI.
(2). Using a bright light and 5X magnifying glass, visually inspect the attach lugs of all
affected main rotor blade upper and lower root fittings and main rotor lead-lag links for
broken or cracked lugs, corrosion or other damage to the lug areas (Ref Figure 1). Pay
particular attention to area around attach pin hole bushings in the lugs. Pay particular
attention to the cross-hatch areas shown in Figure 2. If slippage marks have already
been applied, inspect the root fitting for any indication of movement of the bushings. No
movement is allowed. Return main rotor blades that have root fitting bushing move-
ment to MDHI for possible rework. If slippage mark is degraded, reapply per steps (5).
and (6)1 (Ref. Figure 2).
NOTE: Do not remove bushings or corrosion inhibiting sealer.
CAUTION
If a cracked or broken
lug is noted in main rotor blade upper or lower root fittings,
replace main rotor blade
before furt~ter fligitt.
If a cracked or broken lug is noted in main rotor lead-lag links, replace or repair main
rotor hub per the applicable HMI before furt~ter fElig~Ttt (see note below).
If a crack is suspected in either the main rotor blade or lead-lag link attach lug,
perform dye penetrant inspection per MIL-I-25135 of the lug. If a crack is noted,
replace main rotor blade or replace or repair main rotor hub per applicable HMI
before f~rther fligitt (see note below).
(3). Inspect lead-lag link blade attach pin hole bushings for any indications of movement of
the bushings in the links. If any of the bushings have movement, replace the link.
NOTE: Lead-lag link assemblies may only be replaced by MDHI authorized personnel or under
MDHI supervision. Contact your local MDHI Field Service Representative for further
information.
If required,
apply a light but thorough coat of sealer or zinc-chromate primer around
the bushings. Note that excessive amounts of sealant or zinc-chromate primer around
the bushings are not desirable and can unbalance the main rotor system.
(4). If corrosion inhibiting sealer Cper MIL-S-81733, Type II-2) has become loose, clean and
then seal alljunctions between all the steel bushings and the main rotor blade root
fitting attach lug; with a frlm of corrosion inhibiting sealer or zinc-chromate primer
without removing the bushings.
(5). For the main rotor blade root fitting attach lugs, carefully remove sufficient amount of
sealant and paint from only the bushing in the area where the slippage mark is to be
applied, if not already done, (Ref. Figufe 2). Using isopropyl alcohol, clean the area
where the slippage mark is going to be applied to allow adequate adherence of epoxy
paint.
NOTE:
Locate slippage mark in a position that can be viewed at subsequent inspections with main
rotor blade installed in the hub.
Ensure that slippage mark is applied to bushing and upper and lower root fitting inside
surfaces as shown in Figure 2.
Copyright 2999-2000 by MD Helicopters Inc. This docccment may be reproduced and distributed provided no fee is chcrrged
the text is not modif~d, and this copyright notice is included.
II MANDATORY IIIIIIIIIIIIII MANDATORY IIIIIIIIIIIIII MANDATORY II

HN-2 11.6*
DN-51.8*
EN-42.6*
FN-31.6*
SERVICE BULLETIN
II MANDAToRv/llllllllll/II MANDATORYIII//III/III/I MANDATORYII
to four locations shown in Figure 2.

(6). Apply epoxy paint slippage maths as
NOTE:
DO NOT use torque seal.
Ensure that slippage mark can be observed for when the blades are installed.
inspection
Slippage marks should not be applied to cross-hatch areas shown in Figure 2 to preclude
masking possible cracks.
(7). Install main rotor blades per applicable HMI.
(8). Record compliance with PART I of this Notice in the Compliance Record section of the
helicopter Log Book.
B. PartII- 15/25-Hour Inspection:
NOTE: Main rotor blades and hub assemblies installed on helicopters operating in a salt water or
corrosive environment should be cleaned and washed on a casilv basis as a preventative
measure to arrest corrosion. Refer to applicable HMI (Tri-Flow wash procedure) or
HN-214, DN-154, EN-44 or FN-33, Service Information Notices.

(1). VisusUv inspect exposed portion of all installed main rotor blade upper and lower root
fitting attach lugs, and main rotor hub lead-lag link attach lugs, for broken or cracked
lugs, corrosion or other damage to the lug areas, Using a bright light, inspect slippage
marks on the root fitting bushings to ensure there has been no movement of the
bushings. If bushings have moved, replace main rotor blade before further flight (Ref.
Figure 2). Return those main rotor blades where bushing movement has occurred to
MDHC for possible rework.
NOTE: If movement is suspected but cannot be verified with the blades installed, remove those
blades and inspect bushings for movement.
CAUTION
If cracked or broken l~ig is noted in main rotor blade upper

a or lower root fitting,
replace main rotor blade before further Fight.
If a cracked or broken lug is noted in main rotor lead-lag links, replace or repair main
rotor hub per the applicable HMI before flight (see note below).
fi~rther
If a crack is suspected in either the rotor blade or lead-lag link attach lug, perform dye
penetrant inspection per MIL-I-25135 of the lug. If cracking is noted, replace main
rotor blade or replace or repair the main rotor hub per the applicable HMI before
further flight (see note below).
NOTE: Lead-lag link assemblies may only be replaced by MDIII Authorized personnel or under
MDHI supervision. Refer to your local MDBI Field Service Representative for further
information.
(2). Record compliance with PART II of this Notice in the Compliance Record Section of the
3. POINTS OF CONTACT
For further information, contact your local MDHI Field Service Representative (refer to the
latest revision of the Product Support handbook for address and telephone numbers) or contact
the Field Service Department atMDHI, Mesa, Arizona. Telephone: 1-800-388-6342 or (480)
891-6342.
CoWright 1999-2000 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is ch~rged,
II MANDATORY IIII/111111111 MANDATORY 1111111111/111 MANDATORY II
HN-2llb*
DN-51.8*
EN-42.6*
FN-31.6*
DATE:
PAGE 6 OF 7
3 JANUARY 2000
SERVICE BULLETIN
/I MANDATORY 11111111111111 MANDATORVI/IIIIIII/IIII MANDATORY/I
(NOTES 1, 2, (NOTES 2
AND 3) 3 AND 4)
O O
UPPER ROOT FITTING

ATTACH LUG
CPIP 2 PLACES)
(NOTE 1)
LEAD-LAG LINK ATTACH LU~
MAIN ROTOR BLADE ~YoPrr2qLACEs)1)
LOWER ROOT FITTING

ATTACH LUG
CPIP 2 PLACES)
(NOTE 1)
1. VISUAUYINSPECTAREAS OFAUROOTFT~TINGS
AND LEAD-LAG ATTACH LUGS FOR CRACKS OR BREAKS.
INSPECT BLADE ATTACH BUSHINGS FOR LOOSENESS.
IF LOOSE, REPLACE LEAD-LAG UNKS (REFER TO TEXT).
2. PAY PARTICULAR ATTENTION TO AREA AROUND ATTACH
PIN HOLES IN LUGS.
3. SEALAUJUNCTIONS BETWEEN BUSHINGSANDATTACH
LUGS WITH SEALER OR PRIMER (REFER TO MATERIALS
TABLE).
4. LEAD-LAG LINKASSEMBLIES ARE SUBASSEMBUES OF
THE MAIN ROTOR HUB ASSEMBLY.
88-3470
Figwre 1. Inspection of Main Rotor Blade Root Fitting Attach Lugs and Main Rotor Hub
Lead-Lag Link Assemblies
Copyright L999-2000 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged,
the tert is not modifed, and this copyrt~ht notice is included.
II MnNDAToRYIIIIIIIIIII/II MANDATORY/IIIIIIIIII111 MANDATORYII

HN-211.6*
DN-51.8*
EN-42.6*
FN-31.6*

PACE 7 OF 7
3 JANUARY 2000
II MnNDnToRvll/lllll/l//Il MnNDnToRv/l/lll/llll111 MnNonToRvll
*ONLY REMOVE
i
1/2 DEPTH OF
CORROSION INHIBITING
SEALER AT LOCATION
WHERE SLIPPAGE MARK IS
TO BE APPLIED.
UPPER ROOT FITTING
SLIPPAGE MARK
LOCATIONS
SLIPPAGE MARK
LOCATIONS
(INSIDE SURFACES)
DO NOT APPLY
SLIPPAGE MARK TO
CROSS-HATCH
AREAS
LOWER ROOT
FITTING
VIEW LOOKING UP
SLIPPAGE
MARK LOCATIONS
(LAG SIDE SHOWN)
(LI~AD SIDE OPPOSITE)
UPPER LOWER
88-675
Figure 2. Application of Slippage Mark to MIR Blade Bushings and Ropt Fittings
This docu~nt may be repmducpd and distribnted prouided no fee is charged.
Copyrig~t 1999-2000 by MD Xelieopters Inc.
the text is not this copyright notice is included.
modified, and
MaNonToRv 1111/IIII11111 MaNonToRvll
II MnNonToRvlllll~/lllll/l
EN-32
FN-21

PAGE 1 OF 1
22 FEBRUARY 2000
SERVICE BULLETIN SERVICE INFORMATION NOTICE

CANCELLATION
SUBJECT: SHIMMING OF ELASTOMERIC TAIL ROTOR BEARINGS

This Service Bulletin i Service Information Notice, dated 11 July 1986, has been
cancelled in its entirety.
For 369H Model helicopters, refer to CSP-H-5 (Component Overhaul Manual), dated
15 July 1989, or later, for current shimming procedure.
For 369D/E/FF Model helicopters, refer to CSP-COM-5 (Component Overhaul
Manual), Revision 10, or later, for current shimming procedure.
Copyright O 1999-2000 by MD Helicopters Inc. This document

may be reproduced and distributed prooided no fee is charged, the text is
not modified, and this copyright notice is included.
MANDATORY MANDATORY MANDATORY
r
c
SB369D-191 SB369E-OS4
SB369F-071 SB500N-012
SB600N-002
SERVICE BULLETIN
MAIN ROTOR TRANSMISSION ACCESSORY DRIVE INSPECTION
1. PLANNING INFORMATION:
k Aircraft Affected: All McDonnell Douglas Helicopter Systems (MDHS) 369D, 3693,
369FF, 500N and 600N Series Helicopters equipped with 369F5100-503 Main Rotor
Transmissions. All 369F5100-503 Main Rotor Transmissions in Spares
Inventories.
B. Assemblv/ComDonents Affected by this Service Bulletin: Main Rotor Transmission

(P/N 369F5100-503, Serial Numbers 005570-0001, 0003 thru 0010, 0012, 0015
thru 0018, 0020 thru 0028, 0030 thru 0051, 0053 thru 0065, 0067 thru 0088, 0090
thru 0098, 0100 thru 0103, 0106, 0108 thru 0109, 0111, 0135).
C. Time of Compliance: The requirements of this Bulletin shall be accomplished

within the next 50 hours of operation or no later than 31 December 1997.
D. Reason: A fielded transmission was found not to have cotter pins installed on the
nuts of the accessory drive idler gears. Failure to comply with the requirements of
this Bulletin may result in an emergency landing situation.
E. Description: Procedures in this Bulletin provide owners and operators with

information pertaining to having the main rotor transmission inspected and if
necess~v replacement information.
NOTE: It is recommended that the Service Bulletin regarding the inspection of

input shaft coupling assemblies be accomplished concurrently with Service Bulletin
(Ref SB369D-192, SB369EO85, SB369F-072, SB500N-013 and SB600N-003).
F. FAA The technical design aspects of this Service Bulletin are FAA
Approved.
G. ManDower: One (1) manhour will be required to inspect transmissions in spares
inventories and eight (8) manhours will be required to inspect those transmissions
installed in helicopters.
H. Interchanereabilitv: None
I. MateriaVPart Availability: Contact MDHS Warranty and Repair Dept.
REPLACEMENT PARTS/SUPPLIES
Main Rotor Transmission 369B5100-503 A/R MDHS
MANDATORY MANDATORY
SB369D-191 SB369E-OS4
SB500N-012
SB369F-071SB600N-002
DATE: 26 SEPTEMBER 1997
PAGE 2 OF 2 SERVICE BULLETIN
J. Warranty Policy: MDHS will provide replacement parts at no cost to the operator.
Contact MDHS Commercial Warranty and Repair Department for replacement
parts.
H. Tooling: Provided by ~DHS Field Service Representative as needed.
L. WeiPhtand Balance: N/A
M.Electrical Lo~d Data: N/A
N. Other Publications Affected: NIA
2. ACCD1MPLISHMENT INSTRUCTIONS:
A. Contact your local MDHS Field Service Representative or the MDHS Commercial
Field Service Department in Mesa, Arizona, to schedule MDHS or ACR approved
personnel to perform this Service Bulletin.
NOTEi Operators wishing to have MDHS Approved Service Centers perform this
operation must contact MDHS Field Service Department for approval, procedures
and replacement items needed for transmission disassembly and reassembly.
3. DISPOSITION OF PARTS REMOVED:
If the transmission has to be removed and replaced, immediately contact MDHS

Commercial Warranty and Repair for a replacement transmission.
Removed transmissions shall be retwned to ACR Industries, Inc.
ACR Industries, Inc.

15375 Twenty Three Mile Road
Macomb, Michigan 48042
Phone: (810) 781-2800
FAX: (810) 781-0152
Contact person: Mike Gallagher
4. COMPLIANCE RECORD:
Record compliance to this Service Bulletin in the Compliance Record section of the
helicopter Log Book and Component Record Card.
POINTS OF CONTACT: For further assistance, contact your local NIDHS Field Service
Representative (refer to the latest revision of the "At Your Service"
handbook for address and telephone numbers) or contact the Field Service
Department at MDHS, Mesa, Arizona. Telephone: 1-800-38&3378 or (602)
891-6342. DATAFAX: (602) 891-6782.

_I
r SB369H-240
SB369E-085
SB500N-013
SB369P-192
SB369F-072
SB600N-003.
SERVICE BULLETIN DATE:PAGE 6SEPTEMBER

23
1 OF
1997
INPUT SHAFT COUPLING ASSEMBLY INSPECTION
1. PLANNING INFORMATI[ON:
k Aircraft Affected: All McDonnell Douglas Helicopter Systems (MDHS) 3691-1 Series,
369D, 3693, 369FF, 500N and 600N Series Helicopters equiped with 369F5133-1
Input Shaft Coupling Assemblies. All 369F5133-1 Input Shaft Coupling Assemblies
in spares inventories.
B. Assemblv/ComDonents Affected by this Notice: Input Shaft Coupling Assemblies

(P/N 369F5133-1, serial numbers 030829-0126 thru 030829-0207) installed on
main transmission (P/N 369F5100-503) input shafts and overrunning clutches (P/N
369F5450).
C. Reason: Input shaft coupling assemblies (P/N 369F5133-1) have been returned
from operators in the field due to observed pitting on the internal spline teeth.
Further examination indicates that the corrosion pitting is occurring below the solid
film lubricant layer. Failure to comply with the requirements of this Bulletin may
cause premature failure of spline teeth and subsequent loss of drive to the main
rotor system resulting in an emergency landing situation.
D. Description: Procedures in this Bulletin provide owners and operators with

information pertaining to removing affected input shaft coupling assemblies,
inspecting those couplings for unacceptable conditions and, as required, replacing
them with acceptable couplings.
E. FAA The technical design aspects of this Service Bulletin are FAA
Approved.
F. ManDower: One (1) man-hour is required toinspect input shaft couplings for
affected serial numbers and an additional two (2) man-hours if the input shaft
coupling has to be replaced.
G. Time of Compliance: The requirements of this Bulletin shall be accomplished
within the next 100 hours of helicopter operation or no later than 31 December
1997.
H. Interchangeabilitv: None
I. MateriaYPart Availability: Contact MDHS Field Service Dept.
Input Shaff Coupling 369F5133-1 1 MDHS
L MANDATORY MANDATORY MANDATORY

MANDATORY MANDATORy MANDATORY
SB369H-240 SB369D-192
SB369EO85 SB369F-072
SB500N-013 SB600N-003

I
J. Warranty Policy: MDHS will provide replacement parts at no cost to the operator.
Contact MDHS Commercial Warranty and Repair Department for replacement
parts.
K. Tooling: N/A
L. WeiPht~and Balance: N/A
M.Electrical Loa~ Data: N/A
N. Other Publications Affected: NIA
2. ACCOMPLZSHIMENT INSTRUCTIONS:
A. Verify affected serial numbered coupling is installed on helicopter either by Log

Book entry or by visual inspection.
B. If coupling serial number is one on the affected list, remove coupling per HMI.
Visually inspect for evidence ofpitting under the solid dim lubricant in the
spline
area of the coupling. If there is evidence of
pitting in the splines, replace coupling.
Install acceptable coupling per CSP-HMI-2.
3. DISPOSITION OF PARTS RFMOVED:
Return all affected components to MDHS

Warranty Repair within five days of
removal.
4. COIMPLLANCE RECORD:
Record compliance to this Service Bulletin in the

Compliance Record section of the
POINTS OF CONTACT: For further assistance, contact your local MDHS Field Senrice
Representative (refer to the "At Your Service" handbook for address and
telephone numbers) or contact the Field Service Department at MDHS,
Mesa, Arizona. Telephone: 1-800-388-3378 or (602) 891-6342. DATAFAX:
(602) 891-6782.
MANDATORY MANDATORY
MANDATORY
r SB369H-240
SB369E-085
SB500N-013
SB369D-192
SB369F-072
SB600N-003
SEPTEMBER 1997
SERVICE BULLETIN DATE:PAGE 623
3 OF
INPUT SHAFT COUPLING ASSEMBLY INSPECTION
PARTS REQUEST FORNL: Please 611 in the following information and return to MDHS
for parts/supplies required for compliance. This form may be fared to MDHS
Warranty and Repair Department at (602) 891-3952.
AircraR Ser. No.
Aircraft Total Time
Date
Part Ser. No. (if required)
Ship to:
MANDATORY MANDATORY
9BS698-241R1 SBaBSD-1BSRI
SB369EOS6R1 SB369F-073R1
SERVICE BULLETIN DATE: 03 MAY 1999

PAGE 1 OF 5
I/ MANDAToRvl/ll/lllllll/l MANDATORYI/I/II/I/II/II MANDATORYII
SB369H-241, SBS69D-19S. SB369E-085 and SB369F-073, datsd 18 Deesmber

I
TAIL ROTOR BLADE, LEADING EDGE INSPECTION FOR CRACKS
A Aircraft Affected:
MD Helicopters, Inc. (MDHI) models 369A, including the OH-6A, 369B, 369HE, 369HS,
369HM, 369D, 3693 and 369FF Series Helicopters.
B. Assembl~v/ComDonents Affected by this Notice:
369A1613 (equipped with abrasion strips), 369D21606, 369D21613 and 3691)21615 series
tail rotor blades that have had the abrasion strip replaced and have not been inspected for
skin thickness with more than 100 hours time in service. New tail rotor blades and tail
rotor blades that have had the abrasion strips replaced and have been properly inspected
for skin thickness are not affected by this Service Bulletin but are still subject to inspection
requirements contained in the Handbook of Maintenance Instructions.
C. Reason:
Boeing has received a tail rotor blade from an operator that shows evidence of blade skin
cracking at the inboard end of the abrasion strip. No cracks are allowed at this or any
other location on tail rotor blades. Failure to comply with the requirements of this Bulletin
may result in tail rotor blades failing in service
and subsequent loss of directional control of
the helicopter.
D. Description:
Procedures in this Bulletin provide owners and operators with information pertainingto
inspecting tail rotor blades for any evidence of cracking.
E. FAA A~Droval:
The technical design aspects of this Service Bulletin are FAA Approved.
F. ManDower:
0.5 manhours for the inspection and an additional 4.6 manhours if the tail rotor blades
have to be replaced.
G. Time of Comnliance:
100 hours of
The requirements of this Bulletin shall be accomplished within the next
the requirements
helicopter operation. Repetitive inspections should be accomplished per
contained in the Handbook of Maintenance Instructions. NOTE: MDHI approved blade
repair facilities now incorporate the requirement to inspect the leading edge skin thickness
as partof their repair procedures. The minimum thickness for leading edge skin 0.024
inch.
H. Interchaneeabilitv:
None
Inc. This document may be reproduced and distributed provided no fee is charged, the tert is not
Copyright 1999 by MD Helicopters
modified, and this copyright notice is included.
II MANDATORY 111/111111111/ MANDATORY 11111111111111 MANDATORYI/
SB369H-241R1 SB369D-193R1
SB369EQ86R1 SB369F-073R1
DATE: 03 MAY 1999 SERVICE BULLETIN

PAGE 2 OF 5
II MANDATORY IIIIII/1/11/11 MANDAToRVII/I/IIIIII111 MANDATORVI/
I. Material/Part Availability:
I Contact Warranty and Repair Dept.
Tail Rotor Blade 369A1613-507 (369H Series) A/R MDHI
Tail Rotor Blade 369D21606-511 (369FF) A/R MDHI
Tail Rotor Blade 369D21613-61 (369D/E) A/R MDHI
Tail Rotor Blade 369D21615-31 (4-Bladed Tail A/R MDHI

Rotor)
Transparent Protective Tape 3M 8671-1 A/R 3M (1-800-453-8116 or
1-800-362-3550)
Promoter 3M #86 A/R 3M (1-800-453-8116 or
1-800-362-3550)
304 Stainless Steel Tape 87-369[321104 30ft. A/R MDHI or Teledyne Rodney
(0.0027 inch thickness) Metals (800-325-1455)
Abrasive Paper (400 grit) N/A A/R Commercial
Naphtha, aliphatic TT-N-95 Type II or equivalent A/R Commercial
Dye Penetrant Kit Per Mil-1-25135 (or A/R Commercial

equivalent)
J. ~7arrantv Policy:
Standard warranty policy applies.

K. Tooline:
NIA
L. WeiPht and Balance:
N/A
M. Electrical Load Data:
NIA
N. Other Publications Affected:
NIA
2. ACCOMPLISHMENT INSTRUCTIONS:
(Refer to figure 1)
(1). Inspect tail rotor blades with the new style abrasion strips as follows:
CoWright 1999 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the text is not
modified, and this copyr~ht notice is included.
I/ MANDAToRvllll/ll/lll111 MANDATORY 1/1/1111111111 MANDATORYII
sBa8982(1R1 SBS88D-18SR1
SB369E-OS6R1 SB369F-073R1
SERVICE BULLETIN DATE: 031~AY1999

PAGE 3 OF 5
II MANoAToRvllll/llll//111 MANDATORY /1111111111111 MANDATORYII
(a). Inspect leading edge for any evidence of cracking in the area shown in Figure i.
No cracks are allowed. If cracks are suspected, perform a dye penetrant inspection
of the suspect area as follows:
i). By lightly abrading the blade skin, carefi~lly remove the paint from the suspect
area.
r~P
CAUTION
Do not use any chemicals to remove the paint and do not penetrate the metal skin of
C- -------I the blade.
2). Perform dye penetrant inspection on the suspected area per MIGI-25135 (or
equivalent).
3). Tail rotor blades with evidence of cracking must be removed from service.
NOTE: Tail rotor blades with the new abrasion strip configuration cannot be
intermixed with tail rotor blades that have the old abrasion strip configuration.
4). If there is evidence of cracking, the blade

no can be cleaned and touch-up epoxy
paint applied to the affected area.
(b). To reduce errosion, up to a 2 inch length of 3M transparent protective tape may be
applied to allblades. An equal length of tape must be applied to all blades. The
protective tape should be applied spanwise centered on the leading edge and overlap
the inboard end of the abrasion strip by appro~imately 1/2 inch. The square corners
of the tape should be rounded off before application to reduce the chance of peeling.
3M Promoter 86 may be used to improve adhesion of the tape.
DO NOT cut or trim tape after applied to the blades.

CAUTION
(c). The tape should be inspected for condition and security during the preflight inspec-
tion. Evidence of erosion, lifting or movement requires tape replacement.
(2). Inspect tail rotor blades with old style abrasion strips as follows:
(a). Remove stainless steel tape from the leading edge at the inboard end of the abrasion
strip.
(b). Inspect that areafor evidence ofcracks. No cracks are allowed. If cracks are
suspected, perform a dye penetrant inspection of the suspect area as follows:
i). Carefully remove the paint from the suspect area.
Do not use any ehemieals to remove the paint and do not abrade or penetrate the
C- -----I metal skin of the blade.
2). Perform dye penetrant inspection of the suspected area per MIGI-25135 (or
equivalent).
3). Tail rotor blades with evidence of cracking must be removed from service.
NOTE: Tail rotor blades with the new abrasion strip configuration cannot be
intermixed with tail rotor blades that have the old style abrasion strip.
4). If there is no evidence of cracking, the blade can be cleaned and touch-up epoxy
paint applied to the affected area.
Copyright 1999 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged the text is not
II MANDAToRvlllllllllllII/ MANDATORY 11/111111111/I MANDATORY II
SB3698-241R1 SB369D-193R1
SB369E-086R1 SB369F-073R1
DATE: 031~AY1999 SERVICE BULLETIN

PAGE 4 OF 5
II MANDATORY /1111111111/11 MANDATORY 11/1111111/111 MANDATORYII
~C). Installnew stainless steel tape in the same location as follows or perform PART II of
HN-238, DN-187, EN-80 and FN-66:
i). Lightly abrade faying surface of tail rotor blade in the area where the tape is to
be installed with 400 grit abrasive paper.
2). Wipe faying surface of blade with solvent to eliminate grease and dirt film.
3). Use heat gun or equivalent to warm blade surface. Temperature must not
exceed 120 deg. F.
4). Remove backing and apply stainless steel abrasion tape to leading edge of tail
rotor blade. Apply 3.0 in. x 1.0 in. tape so that it overlaps each side of blade
equally. Tape should overlap the inboard end of the abrasion strip 0.5 inch
0.03 in. at the leading edge of the blade.
5). Smooth and press tape into place by hand.

6). Re-apply pressure by hand following initial installation to ensure proper
bonding. Abrasion tape must be free of wrinkles and air bubbles.
(3). Check tail rotor balance per the requirements of CSP-H-2 or CSP-HMI-2 after
installation of tape.
Return to MDHI.
Recordcompliance to this Service Bulletin in the Compliance Record section of the helicopter
Log Book.
5. POINTS OF CONTACT:
For further assistance, contact your local MDHI Field Service Representative (refer to the
latest revision of the "At Your Service" handbook for address and
telephone numbers) or contact
the Field Service Department at MDHI, Mesa, Arizona.
Telephone: 1-800-38&3378 or (602)
891-6342. DATAFAX: (602) 891-6782.
Copyri~ht 1999 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the text is not
moditied, and this copyright notice is included.
I/ MANDATORY 11/1/11/11/I/1 MANDATORY 111/1111//1/11 MANDATORY II
SB369H-241R1 SB369D-193R1
SB369E-086R1 SB369F-093R1
SERVICE BULLETIN DATE: 03 MAY 1999

PAGE 5 OF 5
II MANDATORY 1111/11/111111 MANDATORY 11111111111111 MANDATORY 11
"oP
i~ PAY PARTICULAR
ATTENTION TO THIS
AREA FOR CRACKING
OLD STYLE ABRASION STRIP
Po
PAY PARTICULAR
ATTENTION TO THIS
AREA FOR CRACKING
NEW STYLE ABRASION STRIP
Figure i. Tail Rotor Blade Inspection

88-754
Copyright 1999 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the text is not
modified, and this copyr~ht notice is included.
11 MANDAToRv/ll/l/lllllII/ MANDATORYIIIIIIIIIIIII/ MANDATORYII
SB389H-a~a 9BSBBD-1PQ/
SB369E-087 SB369F-074
SB500N-014
McDonnell Douglas Helicopte~ Systems
SERVICE BULCETIN
I/ MANDAToRvll/llllllllIII MANDATORYI/I/IIIIIII/II MANDATORYII
MAIN ROTOR BLADE ROOT END INSPECTION
I I Failure to comply with the requirement of this Bulletin (Notice) may result
WARNING I i, separation of the main rotor blade from the helicopter during operation.
1. PLANNING INFDRMATION:
All McDonnell Douglas Helicopter Systems (MDHS) 369 and 500N series helicopters
equipped with main rotor blades that have1,500 or more hours of operation.
B. Assemblv/ComDonents Affected by this Bulletin:
All 369A1100-507, 369D21100-517 and 369D21102-517 main rotor blades.
C. Reason:
Due to a separation, MDHS is requiring all operators to perform a

recent main rotor blade
inspection of all main rotor blades for cracking of the lower surface of the blade, root fitting
and doubler at the inboard end of the blade. Specifically, the inspection contained in this
Bulletin, concentrate on the outermost two root fitting attachment bolts and the outermost
end of the lower root fitting and adjacent doubler area. The inspections required by
this Bulletin are to be accomplished in conjunction with main rotor blade
inspections already required as referenced in paragraph G. below.
D. Description:
This Bulletin contains a visual inspection of the main rotor blade root end for chordwise
cracks in the doubler; also, paint/sealant ~cracking between the lower root end fitting and
the doubler. This Bulletin is to be performed with the main rotor blade installed and raised
offofthe droop stop.
E. Time of Compliance:
This Bulletin shall be accomplished prior to next flight and at each subsequent 25 hours of
helicopter operation.
F. FAA ADDroval:
The design engineering aspects of this Notice have been shown to comply with the
applicable Federal Aviation Regulations, and are FAA Approved.
G. Reference Inspections:
(1). FAA Airworthiness Directive 95-03-13, referencing Service Information Notices

HN-211.4, DN-51.6, EN-42.4 and FN-31.4, dated 27 January 1993 or later
for 100 hour inspection of main rotor blade root fitting and lead-lag links.

HN-239, DN-188, EN-81, FN-67 and NN-008, dated 27 October 1995 or later
for 100 hour inspection of main rotor blade lower root end fitting and doublers.
(3). Pilot Flight Manual daily preflight check of main rotor blade root end fitting for
chordwise cracks.
II NIANDAToRvll/ll/ll/lI/II MANDATORYIIIII/IIIIIII/ MANDATORYI/

SB369H-242 SB369D-194
SB369E-087 SB369F-074
SB500N-014
MoDonnell Douglas Helicopter Systems
DATE:PAGE 2 OF 42~FDE4CEMBER1B97 SERVICE BULLETIN

/I MANDATORY 111/1/11111/1/ MANDATORY 11111111111111 MANDATORY I/
H. Warranty Policy:
N/A.
Refer to Figures 1 and 2.
The following inspections must be accomplished using a 10X magnifying glass.

(1). With the main rotor blade lifted off of the droop stop, observe the
area shown in Figure 1
for any indications of chordwise cracking emitting from the root fitting edge on the blade
low~r surface doubler and skin or cracks on the doubler adjacent to the root end fitting.
Cracking can travel toward both the leading and trailing edges of the blade.
NOTE: Based on field reports, chordwise cracking is most likely to be found in line with
the two outermost bolts and the outermost end of the lower root fitting. If any chordwise
cracking is noted, the blade is unserviceable. Operators should contact their local Field
Service Representative for disposition of unserviceable blades. If no cracking is noted,
proceed to Step 2.
(2). With the main rotor blade lifted off the droop stop, inspect the lower surface for missing
or cracked adhesive/paint at the root end to doubler bonding line in the area shown in
Figure i. If there is any missing or cracked adhesive/paint in the root end fitting to
doubler bond line, proceed to Service Information Notices HN-239, DN-188, EN-81,
FN-67 and NN-008 and perform the required inspections contained in that Bulletin.
CFacked main rotor blade root end or lead-laglinks may produce a sudden change or
GYY~rrmnmJ increase in helicopter vibration. If operators experience sudden onset of unusual or
a
excessive vibration, a precautionary landing must be made. No further flights shall
be attempted until the cause of the vibration has been identified and corrected.
Contact a MDHS Field Service Representative for disposition of unserviceable blades.
Record compliance to this Service Information Notice in the Compliance Record section of
the helicopter Log Book.
For further assistance, contact your local MDHS Field Service Representative (refer to the
latest revision of the Business Development and Customer Support handbook for address
and telephone numbers) or contact the Commercial Field Service Department at MDHS,
Mesa Arizona. Telephone: 1-800-38&3378 or (602) 891-6342. DATAFAX: (602)891-6782.
I/ MANDAToRYIIII/II/II/l/l MANDATORY /11111/11/I/II MANDATORY/I

S83688-~42 5836911-19~
SB3BBE-087 SB969F-074
SBS00N-014
DATE; 24 DFCEMBER 1991

SERVICE B W LLETIN PAGE 3 OF 4
I/ MnNonToRvlllllll////I/I MnNonToRv//l//l/l/ll/ll MnNDnToRvN
IRE~ToBEINSPECIEO.
IHE ROOi ENO F ~IING
XI DOUBLER BOND LINE
ISIOBEINSPECTEOFOR
MISSINGORCRACKINO
I\OHESIVUP*INI
SEE F GURE 2 FOR

WAMPLEOFCRACKS
NIHEBONOLINE~ND
88-155
Figure i. Main Rotor Blade Lower Surface Root Fitting and Doubler Inspection.
ORIGINAL
As Received By
ATP
/I MnNDnToRvlllllllllll/Il hnnNonToRvllllllll/l1111 MnNDnToRvll

SB969H-142 SBS68D-1Ba
5B3693-097 SB369~-074
SB500N-014
DATE: 24 DECEMBER 1997

PAGE 4 OF 4
SE RVICE B U LLETI N
/I MnNDnToRv//lll//l//l/Il MnNonToRvlll/l///lllII/ NlnNonToRvN
itr
i-ral
CRACKSINTHE
BONOLINE
CHORDWSE
CRACK
8~688
Figure 2. Example of Main Rotor Blade Lower Surface Root End Cracking.
ORIGINAL
As Received By
ATP
/I MaNonToRvlllllllllllII/ MAND~.TORYIII/IIIIII111/ MPINDP~TORYII

SB369H-243R3 SB369D-195RShl
SB369E-088R3 SB369F-075R3
SBS00N-015R3 SB600N-007R2
McDonnell Douglas Helicopter Systems DATE: 13 JULY 1998
SERVICE BULL ETI N;;i PAGE 1 OF 6
I/ MANDATORY 1111/1111111/1 MANDATORY 111111/1111/11 MANDATORY II
Supersedes Service Bulletins SB369H243R2, SB369D-195R2, SB369E-088R2,

SB369F-075R2 SB500N-015R2 and SB600N-007R1, dated 26 March 1998. Reason for
Revision: To further define a torque event for the replacement of affected main rotor blades
and to be specific which models use the 369A1100-507 main rotor blade.
MAIN ROTOR BLADE ROOT END INSPECTION AND

TERM1NATION ACTION FOR SUSPECT MAIN ROTOR BLADES
I I Failure to comply with the requirements of this Bulletin (Notice) may result
WARNING I in separation of a main rotor blade from the helicopter during operation.
A Aircraft Affected:
500N and 600N series helicopters
equipped with any of the main rotor blades listed below.
B. Assemblv/Com~onents Affected by this Bulletin:
Affected Main Rotor Blade Part Numbers and Serial Numbers listed below;
P/N 369A1100-507 with S/N: D139 thru D203, D209 thru D223,
P/N 369D21100-517 with S/N: H664, H665, H667, H669, H671, H672, H674, H676, H679,
H680, H683 thru H724, H726 thru H999 and 5000 thru 5039, 5041 thru 5055,
P/N 369D21102-517 with S/N: 1976 thru 2100, 2106 thru 2115.
C. Reason:
Due to a recent main rotor blade separation, MDHS is requiring all operators with any of
the above noted serial numbered main rotor blades to perform an inspection for cracking of
the lower surface of the blade, root fitting and doubler at the inboard end of the blade.
Specifically, the inspection contained in this Bulletin, concentrates on the outermost two
root fitting attachment bolts and the outermost end of the lower root fitting and adjacent
doubler area. The inspections required by this Bulletin are to be accomplished in
conjunction with main rotor blade inspections already required as referenced in
paragraph H. below. I
In addition to main rotor blade inspedions, this Service Bulletin now defines a terminating
action for the suspect main rotor blades. MDHS is introducing flight hour factoring as a
means of addressing low cycle fatigue associated with the affected
serial number main rotor
blades referenced in this Bulletin. MDHS data indicate that those affected blades are
sensitive to "torque events (TE)" and therefore are being assigned a number of TE that
corresponds with the maximum allowable fatigue damage that the blades can withstand.
Those operators equipped with those affected main rotor blades must log the number of TE
throughout the service life of those blades. When those affected blades have reached the
maximum number operation hours or maximum number of TE, those blades must be
removed from service.
The definition of"Torque Event" and some recommended methods of logging the TE are
included in this Bulletin. In addition to this Service Bulletin, MDHS will issue
corresponding revisions to applicable sections of the Handbook of Maintenance Instructions
and Type Certificate Data Sheets for those affected model aircraft.
II MANDATORY 111/1111111/II MANDATORY 11111111111111 MANL)ATORYII

SB369H-243R3 SB369D-195R3
SB369E-OSSR3 SB369F-07SR3
SB600N-01SR3 SB600N-007R2
McDonnell Douglas Helicopter Systems

JULY 1998
DATE:PAGE 2 OF 316 SERVICE BULLETIN
11 MANDATORY /11/11111/1111 MANDATORY 1//II/1/11/1/1 MANDATORYI/
D. DescriPtion:
This Bulletin contains a visual inspection of the main rotor blade root end for chordwise
cracks in the doubler; also, paintlsealant cracking between the lower root end fitting and
the doubler. This Bulletin is to be performed with the main rotor blade installed and raised
off of the droop stop.
Additionally, this Bulletin now contains a terminating action for those suspect main rotor
blades. The terminating action is based on the total number of (TE) or time in service (Ref.
Section F. below).
E. Time of Comaliance:
This Bulletin shall be accomplished prior to next flight. Also, perform the inspection on
main rotor blades with 600 or more hours of operation and at each subsequent 25 hours of
Suspect main rotor blades shall be removed from service after reaching those life limits
listed below or torque events defined below, whichever occurs frrst.
F. Definition and Example of a Toraue Event:
A torque event (TE) is defined "the transition from forward flight to hover" (see
I as a
examples below).
Examples:
1) Taxi, takeoff and a flight which terminates into a hover and landing will record one (1)
TE.
2) A flight which includes multiple transitions to a hover, such as external load operations,
will record one (1) TE for each transition to a hover.
Main Rotor Blade Life Limits with Suspect Doublers
Part Number Model Current Bulletin Life Torque Events (TE)

Life of 588 Suspect
Blades
I
369A1100-507 369A(Army 2,440 Hr. 1,750 Hr. 10,600
OH-6A), 369H,
369HM, 369HS,
369HE
369D21100-517 369D/E 3,530 Hr. 2,500 Hr. 15,000

369D21102-517 369F/FF/500N 3,430 Hr. 2,500 Hr. 15,000
For blades that presently do not have TE logged, the following criteria applies:
(1). If the number of TE are known, then the operator shall. log that number in the appropri-
ate sections of the helicopter Log Book.
(2). The previous operator(s) may be contacted to get an accurate number of TE from
previous usage(s).
unhoun. then (6)
1 (3)
eb
operators,
used. lia hs
hoot if the number of TE is su
11 MANDATORY 1/11111111/111 MANDATORY 11111111111111 MANDATORYJjl

SB369H-243R3 SB369D-195R3
SB369E-0S8R3 SB369F-075R3
SBS00N-015R3 SB600N-007R2
McDonnell Douglas Helicopter Systems DATE: 13 JULY 1998

SERVICE BULLETIN PAGE 3 OF 6
I/ MANDATORY 1/11/11/III1/I MANDATORY I/I/1111//IIII MANDATORYII
(4). If the number of TE is unknown, then 20 TE/hour shall be used.
Hnown/determined TE shall be recorded on a separate/blank rotorcraft log book form as
required above. As additional TE are experienced, this information shall be updated in the
helicopter log. If there are any questions on the above contact MDHS Product Support.
G. FAA Approval:
The design engineering aspects of this Bulletin have been shown to comply with the
H. Reference Inspections:
(1). FAA Airworthiness Directive 98-03-15, referencing Service Bulletins SB369H-243R1,

SB369D-195R1, SB369E-088R1, SB369F-075R1, SB500N-015R1, and SB600N-007
dated 23 January 1998.

(Bulletins) HN-211.4, DN-51.6, EN-4214 and FN-31.4, dated 27 January 1993 or later,
for 100 hour inspection of main rotor blade root fitting and lead-lag links.
(3), FAA Airworthiness Directive 96-10-09, referencing Service Information Notices
(Bulletins) HN-239, DN-188, EN-81, FN-67 and NN-008, dated 27 October 1995 or
later, for 100 hour inspection of main rotor blade lower root end fitting and doublers.
(4). Pilot Flight Manual daily preflight check of main rotor blade root end fitting for
chordwise cracks.
I. Warranty Policy:
Contact MDHS Warranty and Repair Dept. for warranty consideration.

J. Disposition of Parts Removed:
Contact a MDHS Warranty and Repair Dept. for disposition of unserviceable blades.
K. Points of Contact:
For further assistance, contact your local MI)HS Field Service Representative (refer to the
latest revision of the "At Your Service" handbook for address and telephone numbers) or
contact the Commercial Field Service Department at MDHS, Mesa, Arizona. Telephone:
1-800-388-3378 or (602) 891-6342. DATAFAX: (602)891-6782.
Refer to Figures 1 and 2.
(1). Inspect all 600N helicopters to verify what part number/dash number main rotor blades
are installed. If any of the above listed 3693321102-517 (Ref. Paragraph 1. B.) main
rotor blades installed, those blades shall be removed and returned to MDHS.
are
Removed blades shall be replaced with part number/dash number main rotor blades not
listed in 1.B. NOTE: 369D21102-517 main rotor blades not listed in 1.B. are not
subject to the inspection requirements of this Bulletin.
(2). Inspect all 369 and 500N helicopters to verify what part number/dash number main
rotor blades are installed. If any of the above listed (Ref. Paragraph 1.B.) main rotor
blades are installed, those blades must be inspected per the following requirements of
this Bulletin at the above defined intervals (Ref. 1.E.)
II MANDAToRvlllll/lllllII/ MANDATORY 11/1111/1111/1 MANDATORY I/

gBJ888-i~L9 SBs880-19583
SB3BgE-088R3 SBS69F-01SR3
SBSWN-O1SR3 9BBM1N-007R2
I
~F"a"""" SERVICE BULLETIN
MnNDnToRvl/
II MnNDnToRvl/l//lll////ll MnNDnToRvNI/III//IIII/
The following inspections must be accomplished using a 10X magnifying glass.
(3). With the main rotor blade lifted off of thedroop stop, observe the area shown in Fi~re 1
for any indications of chordwise cracking emanating from the root fitting edge on the
blade lower surface doubler and skin or cracks on the doubler adjacent to the root end
titting. Cracking can travel toward both the leading and trailing edges of the blade.
NOTE: Based on field reports, chordwise cracking, present, is most likely to be found
if
in line with the two outermost bolts and the outermost end of the lower root fitting. If
is noted, the blade is unserviceable. Operators should contact
any chordwise cracking
their local Field Service Representative far disposition of unserviceable blades. If no
cradling is noted, proceed to Step 4.
for missing
(4). With the main rotor blade lifted off the droop atop, inspect the lower surface
doubler bonding line in the
or cracked adhesive/paint at the root end fitting
to area
shown in 1. If there is any missing or cracked adhesive/paint in the root end

Figure
fitting to doubler bond line, proceed to Service Information Notices HN-239, DN-188,
that
EN-81, FN-67 and NN-008 and perform the required inspections contained in
Bulletin.
Cracked main rotor blade root end lead-lag links may produce a sudden change or
or
I CAUTION 1 vibration. If operatorsexperience a sudden onset of unusual or

increase inhelicopter
excessive vibration, a precautionary landing must be made. No further flights shall
be attempted until the cause of the vibration has been identified and corrected.
(5). Record compliance to this Service Information Notice in the Compliance Record section
of the helicopter Log Book. The current Lag Book Rotorcraft Log must have Attach-
ments 1 2 inserted and the necessary TE information must be included.
(6). Complete the attached compliance form and return (faxisend to MDHS).
ORIGINAL
As Received By
ATP
AAE~TOBEINSPECTED.
THERWTENDFI~ING
TOOOUBLERBoNOUNE
ISTOBEINSPECTEDFOR
MISSINOORCIUCKINO
ADHESIY4PAINT
SEEFIOURE~FOR
OUMPLEOFCRICKS
INTHEBONOUNE*ND
ACHOROWISECRICK
INMEOOUBCER
BB-ISB
Figure i. Main Rotor Blade Lower Surface Root Fitting and Doubler Inspection.
I/ Mnnon70Rvlllllllllll111 MnNonToRvlllllllll/l/Il
Mn~DnToRvN
9BSBBR-a(3R1 SBS69D-19mL9
883693-08683 883668-07383
SBS00N-01SR3 88600N-007R2
DATE: 13 JULY 1608
SERVICE BULLETIN pAae 5 DP B
11 MnNon~oRv IIII/I/IIIII~ MnNoa~oRv 11111111111111 MnHDnToRvl/
CRACKS IN THE
BONDLINE
CHOROWISE
CRACK
811-BE
Figure 2. Example of Main Rotor Blade Lower Snrfaee Root End Craoking.
ORIGINAL
As Received By
ATP
MANDPITORYN
.11 -MnNonToRvll//l/llllI/Il MANDnToRvl//llllllllII/
SB369H-243R3 SB369D-195R3
SB369E-OSSR3 SB369F-075R3
SB500N-015R3 SB600N-007R2

DATE: 13 JULY 1998
/I MANDATORY 111/11111/1/1/ MANDATORY 11/1/11/11111/ MANDATORYI/
Compliance Recording Form:
Aircraft Serial Number:
Main Rotor Blade Part No.:
Main Rotor Blade Serial No.:
Total Hours on Blade:
Owner/Operator:
TE Established on this Blade:
Date of Compliance:
Address:
Telephone/FAX No.:
FAX this form to 602-891-6782
II MANDATORY 11/1/1111//1/1 MANDATORY 111111/IIII/11 MANDATORY II

ROTORCRAFT LOG
MAIN ROTOR BLADE SERVICE BULLETIN
Attachment 1 (Ref. SB369H-243R3, SB369D-195R3, SB369E-086R3, SB369F-075R3, SB500N-015R3 8 SB600N-007R2)
Model No. Serial No. Pg.
OWNER "N" NO.
TE HOUR INSPECTION DUE HRS. HOUR INSPECTION DUE HRS.

FLIGHT TIME BROUGHT FORWARD HR
SIGNATURE AND INSPECTION AND MAINTENANCE REMARKS SIGNATURE AND

DATE NATURE OF FLIGHT TIME IN FLIGHT
LICENSE NO. LICENSE NO.
HR TE DISCREPANCY CORRECTIVE ACTION

DEPART ARRIVE
TOTAL FLIGHT TIME (HR/TE)

COMPONENT RECORD
MAIN ROTOR BLADE SERVICE BULLETIN
Attachment 2 (Ref. SB369H-243R3, SB369D-195R3, SB369E-088R3, SB369F-075R3, SB500N-015R3 3 SB600N-007R2)
Model No. Serial No. Pg.
P/N S/N Component Time Rotorcraft Time Date Removed/Signa-

ture
To Retire Prior To Inst. Time When Retire At Total Time

Installed Total Time When Re-
moved
HRS HRS HRS HRS HRS
TE TE TE TE TE
HRS HRS HRS HRS HRS
TE TE TE TE TE
HRS HRS HRS HRS HRS
TE ITE ITE ITE TE
HRS HRS HRS HRS HRS
TE TE TE TE ITE
HRS HRS HRS HRS HRS
TE TE TE TE TE
HRS HRS HRS HRS HRS
TE TE TE TE TE
HRS HRS HRS HRS HRS
TE TE TE TE TE
HRS HRS HRS HRS IHRS
TE TE TE TE TE
HRS HRS HRS HRS HRS
TE TE TE TE TE
HRS HRS HRS HRS HRS
TE TE ITE TE TE
S83BgD-1SBj SB369E-088
SB369F-076 SB500N-016
SB600N-012
SERVICE BULLETINPAGE 1 OF
APRIL 1998
823
I/ MANDAToRvllll/llll//I/I MANDATORY 1/1/1111/II/11 MANDATORY/I
OIL COOLER BRACKET REPLACEMENT
i. PLANNING INFORMATION
All 369D, 3693, 369FF, 500N and 600N Series Helicopters equipped with upgraded main
transmissions (P/N 369F5100-503 and -505).
NOTE: 3693 (Serial Number 05263 and subsequent), 369FF (Serial Number 0115F and
subsequent), 500N (Serial Number LN079 and subsequent) and all 600N Series Helicopters
were the only aircraft equipped with the upgraded transmissions in
production.
B. Assemblv/ComPonents Affected By This Notice:
Oil Cooler Blower Bracket, P/N 369F5190-1.

C. Reason:
Field reports indicate that oil cooler blower brackets are subject to
cracking. Failure to
comply with the requirements of this Bulletin may result in loss of engine/transmission oil
cooling which in turn may cause damage to those components, possible failure of these
components and resultant forced landing situation.
D. Descri~tion:
Procedures in this Bulletin provide owners and operators with information pertaining to
removing affected oil cooler blower brackets and replacing them with an improved design
bracket.
E. FAA A~Proval:
The technical design aspects of this Bulletin are FAA Approved.

F. ManPower:
2.5 manhours to remove and replace affected oil cooling blower brackets.
G. Time of Corm~liance
The requirements of this Bulletin shall be accomplished within the next 100 hours of
helicopter operation or no later than 30 November 1998.
H. Interchan~eabilitv:
None
Contact MDHS Warranty and Repair Dept.
Oil Cooler Blower Bracket 369F5194-1 1 MDHS
/I MANDATORY lllllllllllrlll MANDATORY 11/11/IIII/11/ MANDATORY I/

8B1BBD-le6 58589&-1)89
SB369F-076 SB500N-016
SB600N-012
DATE:PAGE 2 OF
SERVICE BULLETIN
II MANDATORY 111111/11/IIII MANDATORY 1111111/11/11/ MANDATORY II
J. Warranty Policy:
Replacement oil cooler blower brackets will be provided at no cost to the customer and a
labor credit up to 2.5 hours will be issued upon request.
K. Disposition of Parts Removed
Return to MDHS.
L. Tooline:
N/A
M. Weieht and Balance:
N/A
N. Electrical Load Data:
N/A
O. Other Publications Affected;
Illustrated Parts Catalog, CSP-IPC-4.

P. Points of Contact
For further assistance, contact your local NDHS Field Service Representative (refer to the
contact the Field Service Department at MDHS, Mesa, Arizona. Telephone
1-800-388-3378 or (602) 891-6342. DATAFAX: (602) 891-6782.
(1). Remove 369F5190-1 oil cooler blower bracket per instructions contained in CSP-
HMI-8, Section 63-00-00.
(2). Install 369F5194-1 oil cooler blower bracket per instructions contained in CSP-HMI-2,
Section 63-00-00.
(3). Record compliance to this Service Bulletin in the Compliance Record section of the
II MANDATORY I1/111111/1111 MANDATORY 111111/IIII/11 MANDATORYII

CGsB~I/IYo S8369D-196 SB369E-L)89
SB369F-076 SB500N-016
SB600N-012
SERVICE BULLETIN
II MANDATORY 1111/11/1111/1 MANDATORY 111//I/1//I/11 MANDATORY II
OIL COOLER BLOWER BRACKET REPLACEMENT
PARTS REQUEST FORM: Please fill in the following information and return to MDHS
Aircraft Ser. No.
Aircraft Total Time
Date
Part Ser. No. (if required)
Ship to:
II MANDATORY 111/111111111/ MANDATORY 1111111111/III MANDATORY I/

SB369D-197 SB369E-091
~BCIE/IYD. SB500N-018
McDonnell Douglas Helicopter Systems 23 FEBRUARY 1999

DATE:
SERVICE BUL LETIN PAGE 1 OF 2
MANDATORYII
II MnNDAToRvllllllllllll/l MANDATORY 11111111111/11
ENGINE FUEL FILTER PRESSURE SWITCH REPLACEMENT
All McDonnell Douglas He]icopter Systems (MDHS) 369D, 3693 and 500N Series
switches.
Helicopters equipped with 369D28144-1 fuel filter pressure
fuel filter
NOTE: Only aircraft equipped with C20R/2 SP engines having the 369D28144-1
pressure switch installed.
B. AssemblvlComDonents Affected By This Notice:
number 001 thru
Switch, Engine Fuel Filter Pressure Switch (P/N 369D28144-1, serial
261).
C. Reason: Replacement of the fuel filter pressure switch.
Failure toperform the requirements of this Bulletin, or performing the necessary

result in a fuel filter
procedures if an impending bypass condition has occurred, may
which could result in loss of engine
by-pass condition without any warning indication
in a precautionary/emergencSr landing situation.
power. This condition may result
result in the
Additionally, failure to perform the requirements of this Bulletin may
contamination from a
requirement to clean the entire engine fuel system due to suspected
filter bowl has mechanical
potential bypass filter condition. The C20RJ2 SP engine a
fuel filter pressure switch to

impending bypass indicator along with the airframe installed
indicate fuel filter condition. If the engine filter bowl mechanical impending bypass
from
indicator has been triggered, then the fuel system is suspect far contamination
possible filter bypass.
D. Description:
thru 261.
replacing the fuel filter pressure switches, serial numbers 001
E. Time of Comdliance:
The requirements of this Bulletin shall be accomplished at the next 100 hour inspection or
no later than 31 July 1999.
F. FAA ADDroval:
The technical design aspects of this Bulletin are FAA A~proved.
G. NanDower:
1.0 man-hours.
H.
None
Contact MDHS Warranty and Repair Dept.
II MANDnToRvll/lllll//lIII MANDATORYIIIIIIIIII/~II MANDATORYII

SB369D-197 SB369E-091
SB500N-0~8

FEBRUARY 1999
DATE:PAGE 2 OF 322 SERVICE BULLETIN
/I MANDATORY 111/1111/11/1/ MANDATORY 11111111111111 MANDATORYII
J. Warranty Policy:
MDHS will provide replacement switches at no cost to the operator.
Switch, Engine Fuel Filter 369028144-3 1 MDHS

Pressure Switch
It. Disposition of Parts Removed
ReturntoMDHS
L. Tooline
N/A
N/A
N/A
O. Points of Contact
For further assistance, contact your local MDHS Field ~Senrice Representative (refer to the
latest revision of the "At Your Seroice" handbook for address and telephone numbers) or
contact the Field Service Department at MDHS, Mesa, Arizona. Telephone
1-800-388-3378 or (602) 891-6342. DATAFAX: (602) 891-6782.
Pressure switch is easily damaged. A slight shearing force applied to half of the
I---------- -I pressure switch can cause leakage and/or operational failure. Always grip both
halves of the pressure switch hex flats with wrench when loosening or torquing
attaching hardware.
Pressure switches are not field repairable.

(1). Per instructions contained in the Handbook~of Maintenance Instructions (CSP-HMI-8,
Section 28-00-00) replace 369D28144-1 fuel filter pressure switches with acceptable
switches (serial number 262 and subsequent). NOTE: Serial number is ink stamped on
switch. If unable to determine the serial number, replace the switch with one that is
known outside of the affected serial number range.
I I Air in the fuel system will cause a power reduction or flameout. Perform a
_
I WARNING I fuel system vacuum leak check and system air bleed after opening fuel
system to atmosphere and prior to releasing the helicopter for flight.
(2). Bleed fuel system per instructions contained in the Handbook of Maintenance Instruc-
tions (CSP-HMI-8, Section 28-00-00)
(3). Record serial number of installed fuel filter pressure switch and compliance to this
Service Bulletin in the Compliance Record section of the helicopter Log Book.
II MANDAToRvllll/ll/llll/l MANDATORY IIIIIIIIII1111 MANDATORYII

SB968D-198 SBSB9E-092
SERVICE BULLETIN DATE: 10MAY1999

PAGE 1 OF 5
11 MANDAToRvlllll/llll/11/1 MANDATORY /11/11/1111/11 MANDATORYII
TAIL ROTOR FORK INSPECTION, FOUR-BLADED

k Aircraft Affected:
All MD Helicopters, Inc. (MDHI) MD369D and MD369E Series helicopters equipped with
four-bladed tail rotor assemblies.
B. Assemblv/ComDonents Affected By This Notice:
Tail Rotor Fork Assembly, Four-Bladed, P/N 369D21701

-21, with the two ridges on each of
the long fork arms machined off.
NOTE: Tail Rotor Fork Assembly, Four-Bladed, P/N 369D21701-21M, is not affected by this
bulletin.
C. Reason:
MDHI has discovered that a number of P/N 369D21701-21 tail rotor forks
may develope
cracks during normal senrice. Failure to perform the
requirements of this Bulletin may
result in loss of the tail rotor and directional control of the
helicopter.
D. Description:
Procedures in this Bulletin provide owners and

operators with information pertaining to
inspecting all affected four-bladed tail rotor fork assemblies.
E. Time ofCom~liance:
The requirements of this Bulletin shall be accomplished

prior to next flight. After the initial
inspection, fork assemblies without ridges must be inspected at each subsequent 50 hours
of helicopteroperation. Fork assemblies without ridges must be replaced within one year
from the date of this Bulletin. The 50 hour
recurring inspection and the fork replacement
do not apply to forks with ridges.
F. FAA ADProval:
The technical design aspects of this Bulletin FAA

are Approved.
G. ManDower:
0.2 man-hours for initial inspection and 2.0 man-hours for dye penetrant inspection.
H. Points of Contact
latest revision of the "At Your Service" handbook for address and
telephone numbers) or
contact the Field Service Department at MDHI, Mesa, Arizona.
Telephone 1-800-388-3378
or (602) 891-6342. DATAFAX: (602) 891-6782.
I. Interchaneeabilitv:
N/A
Copyright 1999 by MD Helicopters Inc. This doc~ment may be reproduced and distributed
provided no fee is charged, the terl is not
11 MANDATORY 11111111111111 MnNonToRv 11111111111111
MANDA~ORYII
583690-196 ,,,,,,,p
DATE: 10 MAY 1999 SERVICE BULLETIN

PAGE 2 OF 5
II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORYJ/
J, Material/Part Availability:
Nomenclature Part No, aty, Source
Paint Remover Turco 5873 A/R Commercial
Dye Penetrant Inspection Kit Mil-1-25135 A/R Commercial
Tail Rotor Fork Assembly, Four 369021701-21 or A/R MDHI

Bladed 369021701-21M
K. Warranty Policy:
Labor reimbursement as specified in paragraph G.
L. Disposition of Parts Removed
Return to MDHI.
M. Weieht and Balance:
N/A
N, Other Publications Affected:
N/A
(Ref. Figure 1)
(1). Inspect tail rotor fork assembly for ridges on the two long arms which support the
outboard tail rotor hub.
(2). Parts with ridges are acceptable and do not require any further inspection.
NOTE: Operators must report to MDHI Field Service the presence or absence of ridges on their tail
rotor fork assemblies.
(3). Parts without ridges must perform the following inspection:
Tc~O
CAUTION
Do not allow paint remover to contact other than the inspection area.
(a3. Chemically remove paint from machined area. Do not use any abrasive materials.
(b). Perform a dye penetrant inspection in accordance with MIGI-25135 in area of
paint removal. Fork assemblies that show any indications of cracking must be
replaced.
(c). Using a 10X magnifying glass inspect for cracks in area of paint removal. Fork
assemblies that show any indications of cracking must be replaced.
(d). Repeat step (3).(c). at each subsequent 50 hours of helicopter operation until fork
assembly has been replaced with an acceptable fork assembly.
Copyright 1999 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the text is not
modified and this copyri~ht notice is included.
I/ MANDATORY 11/IIII/11/I/1 MANDATORY I/I/11/1111/11 MANDATORY /I
spsssn-lss sa968Mse
SE RVICE B U LLETI N DATE: 10 NIAY 1999

PAGE 3 OF 5
II MnNDnToRvlllllll/lllII/ MnNDAToRvllllll/l////ll MANOATORYN
(4). Reco;d compliance to this Bulletin in the compliance section of the helicopter Log Book.
RIDGEB
Figure i. Fork Assembly with ridges (Sheet 1 of 2).
ORIGINAL
As Received By
ATP
COpyllghl 1999 by MD H~iicoplrs Inc T6i~ daeum.nt may )B rapmduc~d and distributed pmuidld no IP~ is cholged. Ulp (o* ia not
modified.ond this nalica is indud.d
II MnNonToRvlllllllllll/Il MnNonToRvll/l/ll///lIN MnNonToRvll

SBSBBD-lsB S~989E-091
DATE: 10 MAY 1999 SERVICE B U LLETI N

PAGE 4 OF 6
N MnNDnToRvNI////IIII/I/ MANonToRvlll//lll/l//ll MnNDnToRvN
NO RIDGES REMOVE PAINT AND

INSPECT WITHIN
THIB AREA
FOR CRACKS
Figure 1. Fork Assembly without ridges (Sheet 2 of 2).
ORIGINAL
As Received By
ATP
Copyrigh, 1999 by MD H~(icoplrs Inc. This documml may bp rPprwlued and dislribut.d pmuidpd no PP ii ehorg~d, th. bxl is na
mociilicd.Ilnd this copyright notiep is inciuded
II MaNDnToRvl///l//l/ll111 MnluonToRvll
SB368D-198 8B366E-66P
SERVICE BULLETIN; 10 MAY 1999

PAGE 5 OF 5
I/ MAN~>AToRullll/lllll1111 MnNDAToRv//l/~/llll/II MANDATORY/J
TAIL ROTOR FORK INSPECTION, FOUR-BLADED
Bulletin Response Form: Please fill in the following information, as applicable, and
return to MDHI Field Service Department. This form may be fared to MDHI Field
Service Department at (480) 891-6782.
Operator or Company Name:
Name of Contact Person:
Address
Telephone
Fax:
Aircraft Ser. No.:
Aircraft Registration Number:
Component Part Number:
Component Serial Number:
Date:
Date of Co~pliance:
Comments/I~nformation
/I MANDATORY /lllll/I/lllrll MANDATORY IIIIIIIIIIIIII MANDATORY II
PAGE 1 OF 6
11 JANUARY 2000
II MANDAToRYI/IIIII/III111 MANDATORYI/III/IIII/111 MANDATORYII
TURBINE OUTLET TEMPERATURE ~OT) INDICATING SYSTEM,

ONE TIME INSPECTION
500N helicopters, SM LN001 thru LN088, equipped with analog/digital TOT indicator
3693 helicopters, S/N 001 thru 543, equipped with analog/digital TOT indicator
369D helicopters equipped with analog/digital TOT indicator.
The TC300 terminal block located over the left-hand engine bay door.
P120W connector located in the battery compartment.
P5 connector located on TOT indicator.
C. Reason:
There have been reports from the field of erroneous turbine outlet tenj;ijerature. (TOT)
readings on aircraft equipped with analog/digital TOT indicators. To verify:TOT system
calibration and prevent the possibility of erroneous TOT indications. Paili~e to perfdrm the
requirements of this Bulletin may result in a condition that could damage criticalengine
components.
D, Description:
verifying the installation of proper termination hardware in the aircraft TOT wiring
circuitry.
The requirements of this Bulletin shall be accomplished within the next 100 hours of
helicopter operation or no later than 15 March 2000.
F. FAA ADDroval:

G. ManDower:
PartI: 0.5 man-hours

Part II: 3.0 man-hours
None
This document may be reproduced and distributed prooided tee is ch4rged, the
Copyright 1999-2000 by MD Helicopters Inc. M
tea is Mt modi~ied, andthis copyri~hl Mtice is included
II MANDATORY 1/111111111111 MANDATORY 11111111111111 MANDATORY II

SB369E-093
SB500N-019SB369D-199
DATE: 11 JANUARY 2000 SERVICE BULLETIN

PAGE 2 OF 6
II MANaAToRv/ll/lllllllII/ MANDATORY 1111111111111/ MANDATORYII
NOTE: Parts are individually packaged. Do no remove from package until you are ready to install.
Terminal sockets may be impossible to distinguish from each other.
REPLACEMENT PARTS/SUPPUES
Nomenclature Part Na, Qty. Source
Terminal Lug, Chromel (stud size #8) 1-321897-0 1 MDHI
Terminal Lug, Alumel (stud size #10) i -321898-0 1 MDHI
Terminal Pin, Chromel M39029/87-480 1 MDHI
Terminal Pin, Alumel M39029/87-479 1 MDHI
Terminal Socket, Chromel M39029/88-492 1 MDHI
Terminal Socket, Alumel M39029/88-491 1 MDMI.:
Terminal Socket, Chromel M39029/32-245 MDHII.
Terminal Socket, Alumel M39029/32-244 i MDHI
TOOLS AND EQUIPMENT
Nomenclature I Source
Crimping tool P/N 46673-L AMP Inc.

(for terminal lugs) 1441 Friendship Rd.
Harrisburg, PA 17111
Phone: (717) 564-0100
FAX: (717) 986-7575
Crimping tool P/N MS22520/1-01 Daniels Manufacturing Corp.

526 Thorpe Road
Crlando, FL 32824
Phone: (407) 855-6161
FAX: (407) 855-6884
Positioner PIN MS22520/1-02 IDaniels
(for M39029/10-140, -141 sockets)
Positioner P/N MS22520/1-04 Daniels
(for M39029/88-491, -492 sockets, and
M39029/87-479, -480 pins)
Thermocouple tester Fluke, Model No. 714 Fluke Corp.
P.O. Box 9090
Everett, WA 98206
Phone: (425) 347-61 00
FAX: (425) 356-5116
Copyright 1999-2000 by MD Helicopters Inc. This document mqy be reproduced and distributed provided no fee is chwged. the
text is not modified, cmd this copyright notice is included.
II nnANDAToRvlllllllll/1111 MANDATORY 11111111111111 MANDATORYII
SB369E-093

PAGE 3 OF 6
11 JANUARY 2000
I/ MANDAToRv/ll~ll//ll1111 MANoAToRvlllllllll/lI/I MANDATORYII
TOOLS AND EQUIPMENT (Cont~

Nomenclature Source
Omega, Model No. CL-307A-K OMEGA Engineering Inc.

One Omega Drive, Box 4047
Stanford, CT 06907-0047
Phone: (203) 359-1660
FAX: (203) 359-7700
Barfield, Model No. TT-1000A Barfiefd Instrument Corp.
P.O. Box 025367
Miami, FL 33102
Phone: (305) 871-3900
FAX: (305) 871 -5629
J. Warranty Policy:
Parts will be provided at no cost to the operators. Tools will not be provided by MD
Helicopters. MD Helicopters will compensate operators for labor, via a spares credit, not to
exceed three (3) hours.
IL Wei~ht and Balance:
N/A
L. Other Publications Affected:
Latest revision of applicable Rolls Royce AUison Operation and Maintenance Manual.
A. Part I
(1). Disconnect the engine thermocouple wire harness at the TC300 terminal block located
over the left-hand engine compartment door.
(2). Connect tester CRef. Figure 1) to TC300.
(a). Connect tester wire to #8 stud onTC300 (white chromel wire)

(yellow lead for Fluke and Omega, red for Barfield).
(b). Connect tester wire to #10 stud on TC300 (green alumel wire)
(red lead for Fluke and Omega, black for Barfieid).
FO~ Omega and Fluke testers, do not force lead into tester, one lead prong of plug is
ICAUTION_I larger than the other, damage to tester connection will occur.
(c). Connect lead to tester.
(3). Set power switch to source for Omega and Fluke or ON position for Barfield.
(4). Set indicator to temperatures in Table i.
(5). Turn on aircraft electrical power.
NOTE: TOT indicator requires appro~mately five seconds to reset internal circuitry.
This document may be reproduced and distributed provided no fee is charged, the
Copyright r999-2000 by MD Helicopters Inc.
tart is not modified,and this copyright notice is included.
/I MANDATO RY 1111111/1/1111 MAN DATORY 11111111111111 MANDATORY II
SB369D-199SB500N-019
DATE: 11 JANUARY 2000 SERVICE BULLETIN

PAGE 4 OF 6
II MnNDAToRvlllll/llll/111 MANDATORYII/II/I/IIIl/l MANDATORYI/
(6). Verify TOT gauge indicates same as tester, within tolerance CRef. Table 1).
(a). If TOT indicator matches temperatures in Table 1, no fiuther action is required.
(b). If TOT indicator does not match temperatures in Table 1;
1). Refer to applicable Rolls Royce Allison Operation and Maintenance Manual for
possible maintenance actions, if TOT gauge indicates 30" lower than tester.
2). Perform Part II of this service bulletin.
(7). Turn off aircraft electrical power.
(8). Set source switch to offposition.

(9). Disconnect tester from TC300.
(10). Reconned engine thermocouple wire harness to TC300 tenninal block.
(11). Record compliance to the Service Bulletin in the Compliance Record section of the
I~able 1. TOT System Test

Tester Setting ("C) Indicator Reading ~C)
700" 7000~10"
725" 725"~10"
752" 1 752" t10"
810" 810" ~10"
B. Part n
NOTE: Terminal lugs and connector pins and sockets must be crimped on, no soldering allowed.
(1). Disconnect the airframe thermqcouple wire harness from the TC300 terminal block.
(2). Using a magnet, verify that the terminal attached to the Chromel wire (white jacket) is
not attracted to the magnet and that the terminal is silver (not gold) in color.
(3). Using a magnet, verify that the terminal attached to the Alumel wire (green jacket) is
attracted to the magnet and that the terminal is silver (not gold) in color.
(4). If either is discrepant, replace the terminal lug(s) with the correct terminal lug(s).
(5). Reconnect the airframe thermocouple wire harness to the TC300 terminal block.
(6). Disconnect P1202 from 51202 in battery compartliient.
(7). Remove pins K and N from P1202.
(8). Using a magnet, verify that pin N is magnetic and pin K is not magnetic and that the
pins are silver (not gold) in color.
(9). If either is discrepant, replace the pints) with the correct pints).
(10). Reinstall pins in P1202.
(11). Remove and replace sockets K and N from 51202.
Copyright 1999-2000 by MD Helicopters Inc. This document may be reproduced and distributed prouided M fee is charged the
tart is Mt moditied. and this copyright Mtice is included.
II MANDAToRvlll/lllllll111 MANDATORYII/II/I/II/111 MANDATORYII
SB369D-199 SB369E-093
SB500N-019

PAGE 5 OF 6
II JANUARY 2000
MANDATORY 11111/111/IIII MANDATORYIII/IIIII/I111 MANDATORYII
(12). Reconnect P1202 to 51202.
(13). Disconnect P5 from TOT indicator.
(14). Remove and replace sockets F and G from P5.
(15). Reconnect P5 to TOT indicator.
(16). Perform Part I of this bulletin again.
NOTE: If TOT indicat~ng system fails again, replace the indicator and re-test the system.
(17). After TOT system passes test, record compliance to the Senrice Bulletin in the Com-
pliance Record section of the helicopter Log Book.
M39029132-245 M39029/87-480 1-321897-0 CHROMEL

PIN TERMINAL LUG FOR
SOCKET
NUMBER BSTUD
(NON-MAGNETIC))
M39029/88-492
SOCKET
fOT INDICATOR
Pg TC300
I
DISCONNECT ENGINE
CHROMEL WHITE K WHITE
:_
MERMOCOUPLELEAOS
I FROM STUDS ON TC300.
ALUMEL G GREEN GREEN CONNECT TESTER HERE
M39029/88-491
SOCKET
1-321898-0 ALUMR
TERMINAL LUG FOR
NUMBER 10 SND
M3902932-244 M39029187-479
SOCKET (MAGNR1C)
PIN
88-T13-1
Figure 1. TOT Wire Harness Termination Verification
3. DISPOSITION_I)F PARTS REMOVED
RRtun indicators to MDHI for disposition.

NOTE: Ifinstrument was not supplied by MDHI, return to vendor for disposition.
latest revision of the "At Your Service" handbook for address and telephone numbers) or contact
the Field Service Department at MDHI, Mesa, Ari~ona. Telephone 1-800-388-3378 or (480)
891-6342. DATAFAX: (480) 891-6782.
Copyright 1999-2000 by MD Helicopters Inc. This document may be reprod~eed and distributed provided no fee is c~rged, the
tert is not moditZed, and this copyright notice is included.
I/ MANDAToRvll/lll/llllI// MANDATORYIII/III//II111 MANDATORYII
SB369D-199SB500N-019
DATE: 11 JANUARY 2000 S:ERVICE BULLETIN

PAGE 6 OF 6
II MANDAToRvlllll/llll/111 MANDATORYII/IIIIIIII111 MANDATORYI/
Compliance Recording Form

Customer/Operator Name
Aircraft Serial No.
Helicopter Total Time
Date of Compliance
Signature of Person Confirming Compliance
FAX this form to MDHI (480) 891 -6782
Copyrig~ 1999-2000 by MD Helicopters Inc. This document may be reproduced rmd distributed provided no fee is chorged. the
tert is not modiFed, and this copyright notice is included.
I/ MANDAToRvll//llll/ll/II MANDATORYII/II/IIIIIl/l MANDATORYI/

SB369H-244 SB369D-200
SB369E-094 SB369F-078
SB500N-022
SERVICE BULLETIN DATE: 7 APRIL 2000

PAGE 1 OF 7
I/ MANDATORY IIIIIIIIIIIIII MANDATORY IIIIIIIIIIIIII MANDATORY II
LANDING GEAR STRUT INSPECTION AND F=AIRING

MODIFICATION
A. Air~
All Model 3698 (OH-6A) Helicopters,

All Model 369H Series Helicopters,
Al Model 369D Helicopters,
Model 3693 Helicopters, serial number 0001 thru 0528,
Model 369F/FF Helicopters, serial number 0001 thru 0114, 0600 thru 0602, 0700 thru 0702
Model 500N Helicopters, serial number 001 thru LN-077.
Mid Aft Fairing Assembly (P/N 369H6200-61, -62, standard gear)

Aft Support Assembly (P/N 369B6200-23, -24) (-23 to be reinstalled on RH side and -24 to
be reinstalled on LH side, all configurations)
Aft Fairing Assembly (P/N 369H92113-91, -92, extended gear)
Aft Filler Assembly (P/N 369H92113-131, -132, extended gear)
Aft Fillet Assembly (P/N 369A6200-45, -46, standard gear)
Aft Fillet Assembly (P/N 3691192113-111, -112, extended gear)
Mid Fwd Fairing Assembly (P/N 369B6200-41, -42, standard gear)

Fwd Fairing Assembly (P/N 369H92113-81, -82, extended gear)
Fwd Support Assembly (P/N 369B6200-23, -24) (-23 becomes RH side and -24 becomes
LH side)
Fwd Filler Assembly (PM 369H92113-121, -122, extended gear)
Fwd Fillet Assembly (F/N 369A6200-57, -58, standard gear)
Fwd Fillet Assembly (P/N 369H92113-101, -102, extended gear)
C. Reason:
To inspect and clean up rivet hole and provide a convenient means for future inspection.
Failure to comply with the requirements of this Bulletin may allow landing gear struts to
break which could cause extensive damage to the helicopter.
D. I)escrit~tion:
exchanging the left and right-hand landing gear fairing support assemblies aeaving the
inboard fairing support rivet holes open), inspecting each rivet hole for cracks, and
modifying each fairing to allow for future inspection of the rivet holes without removing the
fairings.
E. Time of Comr,liance
The requirements of this Bulletin shall be accomplished as parts become available or no
later than 31July 2000.
F. FAA ADDroval:
by MD Helicopters Inc. This document may be reproduced cnd distributed provided fee is charged, the
CoWright 1999-2000 no
tert is n4t moditied,cmd this copyright nctice is included.
II MANDATORY II/III/II//111 MANDATORY II/I/11111/I/1 MANDATORYJ/

SB369H-244 SB369D-200
SB369E-094 SB369F-078
SB500N-02~
DATE: 7 APRIL 2000 SERVICE BULLETIN

PAGE 2 OF 7
/I MANDATORY IIIIIIIIIIIIII MANDATORY IIIIIIIIIIIIII MANDATORY II
G. ManDower:
12.0 Man-hours.
H.
None
Contact MDHI Parts Sales Dept.
Nomenclature Part No. aty. Source
Rivet NAS139884-1 A/R MDHI or Commercial
Rivet MS20470A3-3 A/R MDHI or Commercial

or
NAS1919804S04
Washer AN960KD10L A/R MDHI or Commercial i

or
NAS1149D0332K
Nut MS21042-3 AIR MDHI or Commercial
Screw MS24693S272 A/R MDHI or Commercial
Screw NAS603-8 EI~R MDHI or Commercial
Screw NAS603-7 AIR MDHI or Commercial
Screw NAS603-6 A/R MDHI or Commercial
A1133-4-3 A/R MDHI or Commercial

Nut-Clips
Button HS4248-C56 4 ICommercial

Plug,
Chemical Coating Iridite 14-2 A/R Richardson Co.

A-Coat Allied-Kelite Products
Alodine 1201 Division
2400 E. Devon Ave
Des Plains, IL
Adhesive Scotch-Weld A/R MDHI or
EC1838 3M Co
(Part A B) 8 8ldg. 223-N
(RM002214) 3M Center
St. Paul MN 55155-1000
(612) 733-1110
This document may be reproduced c~nd distributed provided fee is charged the
Copyright 1999-2000 by MD Helicopters Inc. no
text is not modifed, and this copyright notice is included.
/I MANDATORY 1111111111/111 MANDATORY IIIIIIIIIIIIII MANDATORYII

5B369H-244 5B369D-200
SB369E-094 58369B-078
SB500N-022

PAGE 3 OF 7
/I MANDATORY IIIIIIIIIIIIII MANDATORY 1/11/I/II111/I MANDATORYII
J. Warranty Policy:
In accordance with the existing warranty policy.

K. DisPosition ofParts Removed
Return to MD Helicopters, Inc. (MDHI) Warranty and Repair Dept.

L. Toolin~
N/A
M. Wei~ht and Balance:
N/A
NIA
O. OtherPublications Affecteds
Basic Handbook of Maintenance Instructions (CSP-HMI-8), Illustrated Parts Catalog

(CSP-IPC-4).
P. Points of Contact
contact the Field Service Department at MDHI, Mesa, Arizona. Telephone 1-800-388-3378
or (480) 346-6387. DATAFAX: (480) 346-6813.
A. InsPect Fairin~ Support Assemblies
(1). Remove all landing gear fairings (CSP-HMI-8, Section 32-10-00).
(2). Inspect each fairing support assembly and note number and location of rivets attaching
support assembly to landing gear strut.
(a). If three rivets (forward, aft and inboard) are present, continue with rework instruc-
tions below.
(b). If onlytwo rivets (forward and aft) are present, fairing modification is not required.
Reinstall fairings and record compliance with this Bulletin in Compliance Record
section of helicopter Log Book.
NOTE: Landing Gear Fairing Fillets that have already been modified by procedures in the Hand-
book of Maintenance Instructions may not have to accomplish some steps in this Bulletin.
B. Rework Aft Landinet Gear Assemblies
NOTE: Refer to CSP-HMI-8 and CSP-IPC-$, Section 32-10-00 for illustrations and part number
callouts and Figure 1 and Figure 2 for location of inspection hole and fairing/fillet reworM
installation.
(1). Remove applicable aft fillet assembly CP/N 369~616200-45, -46, 369H92113-111 -112).
Remove rivets.
I999-2000 by MD Helicopters Inc. This document may be reproduced and distributed prouided no fee is charged the
CoWright
text is not modi~ied. and this copyright notice is included.
II MANDATORY II/1/III/111//I MANDATORY IIIIII111111/1 MANDATORYII
SB369H-244 SB369D-200
SB369E-094 SB369F-078
SB500N-022
DATE: 7APRn2000 SERVICE BULLETIN

PAGE 4 OF 7
MANDATORY
/I MANDATORY I/1111~/III/I MnNoAToRY
(2). Remove 369H6200-23 and -24 support assemblies.

inboard surface
(3). Clean and dye penetrant inspect 0.125 inch (3.18 mm) diameter hole in
of 369B6001-31, -32, -51, or -52 strut assemblies as shown in CSP-IPC-4, Section
32-10-00 and Figure I.
with rework.
(4). If a crack is found, replace strut assembly. If no crack is found, continue
surface.
(5). Ream hole to 0.132 inch (3.35 mm) diameter to provide smooth (63 RMS)
Leave hole open and apply chemical coating to bare metal.
0.132 inch
(6). Drill 0.87 inch (22.09 mm) diameter hole through aft fairing in line with
(3.35 mm) diameter hole in strut as shown in Figure 1.
match
(7). Seal exposed edges of composite fairings using adhesive. Touch-up f~nish to
aircraft finish. Install HS4248-C56 button plug in hole.
0.125 inch (3.35
(8). Install 369116200-23 and/or -24 aft support as required, using existing
mm) diameter holes on forward and aft surfaces of strut assembly. Install support using
two NAS1919B04-04 rivets.
(9). RR-install 369116200-61. andlor -62 aft fairing assembly.
(10). Re-install 369A6200-45 and -46 aft filled assemblies using (1) NAS603-7
with (2)
AN960KD10L washers (top position) and NAS603-6 screws with (1) AN960KD10L at
each of the three bottom positions. 1~

369H92113-131 andlor -132
(11). Re-install 3691192113-91 and/or -92 aft fairing assembly,
filler assembly.
(12). RR-install 3691192113-111 and/or -112 aft fillet assembly (extended gear) using (1)
NAS603-7 with (2) AN960KD10L washers (top position) and NAS603-6 screws with 1
AN960KD10L at the three bottom positions.
to the
(13). Install (3) NAS603-8 screws and (3) AN960KD10L w~shers (both sides)
369A6200-73 and -74 guide assembly-fiuet.
C. Rework F~d Landina Gear Assemblies

number
NOTE: Refer to CSI~-HMI-8 and CSP-IPC-4, Section 32-10-00 for illustrations and part
callouts and 1 and Figure 2 for location of inspection hole and fairinglfillet rework/
Figure
installation.
and -504.
(1). Remove 3691192113-101 and -102 fwd fillet assemblies for 369H92113-503
Remove 369A6200-57 and -58 fwd fillet assemblies for 369H6200-507 and -508.
Remove rivets.
(2). Remove 369H6200-23 and -24 support assemblies.

surface
(3). Clean and dye penetrant inspect 0.125 inch (3.18 mm) diameter hole in inboard
of 369H6001-1, -2, -41 or -42 strut assemblies.
(4). If a crack is found, replace strut assembly as required. If no crack is found, continue
with rework.
(5). Ream hole to 0.132 inch (3.35 mm) diameter. Leave hole open and apply chemical
coating to bare metal.
1999-2000 by MD Helicopters Inc. This document m~y be reproduced and distributed provided no fee is charged, the
CoWright
text is not madifi~d,and this copyright notice is included.
II MANonToRv/l/lll/lll/~I/ MANDATORY /111/1111//III

MANDATORYI/
SB369H-244 SB369D-200
SB369E-094 SB369F-078
SB500N-022

PAGE 5 OF 7
7 APRIL 2000
/I MANDATORY /~/111111111/41 MANDATORY MANDATORY Ij
line with
(6). Drill 0.87 inch (22.09 mm) diameter hole through fwd fairing assemblies in
0.132 inch (3.35 mm diameter hole in strut.
(7). Seal exposed edges of composite fwd fairings using adhesive. Touch-up finish to match
aircraft finish. Install HS4248-C56 button plug in hole.
(8). Install 369H6200-23 and -24 fwd supports assemblies using existing 0.125 inch (3.35
mm) diameter holes on forward and aft surfaces of strut assembly. Install support using
two NAS1919B04-04 rivets.
(9). Reinstall applicable 369H6200-41 and -42 and 369B92113-81 and -82 (extended gear)
fwd fairing assemblies and 369B92113-121 and -122 (extended gear) fwd filler
assemblies using NAS1398B4-1 rivets.
(10). Install 369A6200-57 and -58, 369H92113-101 and -102 (extended gear) fwd fillet
assemblies using (1) NAS603-7 with (2) AN960KD10L washers (top position) and
NAS603-6 screws with 1 AN960KD10L at the three bottom positions.
(11). Install (3) NAS603-8 screws and (3) AN960KD10L washers (both sides) to the
369A6200-73 and -74 guide assembly-fillet.
(12). Record compliance to this Service Bulletin in the Compliance Record section of the
This document m4y be reprwluced and distributedprouided no fee is chorged. the

Copyright 1999-2000 by MD Helicopters Inc.
te~t is not moditied, and this copyright notice is included.
/I MANDAToRvll/lll/l/l/III MANDATORY /IIIIII1111111 MANDATORYII
TM
SB369H-244 SB369D-200
SB369E-094 SB369F-078
SB500N-022
DATE: 7 APRIL 2000 S:ERVICE BULLETIN

PAGE 6 OF 7
II MANDATORY IIIIIIIIIIIIII MANDATORY IIIIIIIIIIIIII MANDATORY II
I,
i)
,I
\I
\I.
~U,S,!
0.75 INCH
.e
.c-
(19.05_mm)
c
j i
i-. ~(II-.
II
0.87 INCH (22.09 mm)
VIMI LOOKING OUTBOARD NORMAL TO

FUSELAGE CONTOUR AT CENTERLINE OF STRUT
LH SIDE SHOWN. RH SIDE OPP
BOTH AFT AND FWD
88-762
Figure i. Landing Gear Strut Inspection Hole
Copyright 1999-2000 by MD Helicopters Inc. This document m4y be reproduced cmd distributed provided no fee is c~4rged, the
text is not modified, ond this copyrigk~ notice is included.
/I MANDATORY IIIIIIIIIIIIII MANDAToRY/IIIIIIIII/III MANDATORY II

SB369H-244 SB369D-200
SB369E-094 SB369F-078
SB500N-022

PAGE 7 OF 7
/I MANDATORY IIIIIIIIIIIIII MANDATORY MANDATORY II
NOTE1
FILLET ASSY, FWD .E~ 7 ,FIII1~ ASSY, AFT
FAIRING ASSY, MID FWD

~1B NOTEP
FAIRING ASSY, MID I~F

SUPPORTASSY
/1- SUPPORTASSY
NOTE1
1X NAS603-7 SCREW
2X AN960KD10L WASHER
fX MS21042-3 NUT
d\ (5AME FOR ALLGEAR)
CS
NOTEP
FORWARD AFT 3X NASM)3-6 SCREW
6X AN960KD10L WASHER
3X MS21042-3 NUT
FAMEFOR~LLDEAR)
G~
Mid Fwd Fairing Assembly (P/N 369H6200-41, -42, std gear) Mid AR 369H6200-61, -62; std gear)
Fwd Fairing Assembly (P/N 369H92113-81, -82, extended gear) Aft Fainng Assembly (P/N 369H92113-91, -92, extended gear)
Support Assembly (P/N 369H6200-23, -24, std a extended) Support Assembly (P/N 369116200-23, -24, extended and std gear)
Fwd Filler Assembly (P/N 369H92113-121, -122, extended gear) Aft Filler Assembly (P/N 369H92113-131, -132, extended gear)
Fwd Fillet Assembly (P/N 369A6200-57, -58, std gear) Aft Fillet Assembly (P/N 369A6200-45, -46, std gear)
Fwd Fillet Assembly (P/N 369H92113-101, -102, extended gear) AR Fillet Assembly (P/N 369H92113-111, -112, extended gear)
OUTBOARD II INBOARD OUTBOARD INBOARD
O
LOOKING DOWN
ORIGINAL CONFIGURATION NEW CONFIGURATION 88-AAA
Figure 2. Landing Gear Modification
CoWright 1999-2000 by MD Helicopters Inc. This document m4y be reproduced and distributed provided no fee is charged, the
te~t is not modified, and this copyright notice is included.
/I MANDAToRvllllllll/llI/I MANDATORY /I/I/III/IIIII MANDATORYI/
BB869H-alBRa 8Ba89D-20LR2
J
SB369E-095R2f SB369F-079R2*
SB500N-023R2+ SB600N-031R2+
SERVICE BULLETIN DATE: 4 FEBRUARY 2004

PACE 1 OF 4
MANDATORY MANDATORY ~I/ MANDATORY~
MAIN ROTOR BLADE ASSEMBLY TORQUE EVENT INSPECTION
Supersedes Service Bulletin SB369H-245R1, SB369D-201R1, SB369E-095R1, SB369F-079Rl,

SB500N-023R1, SB600N-031R1, dated 24 July 2001. This revision adds cross-reference blade
information, revises the aircraft affected (369H/HE/HS/HM series helicopters are no longer
affected), and adds additional inspection instructions.
All 369D/E/FF, 500N, and 600N series helicopters I

B. Assemblv/ComDonents Affected~bv this Bulletin:
Main Rotor Blade Assembly (P/N 369A1100 BASIC thru -511)
Main Rotor Blade Assembly (P/N 369D21100 BASIC thru -523)
Main Rotor Blade Assembly (P/N 369D21102 BASIC thru -523)
Main Rotor Blade Assembly (P/N 369D21120-501)

This blade is also known as Helicopter Technology Company (HTC) P/N 500P2100-101
(STC Number SR09074RC) and carries HTCs PMA data plate as well as MDHIs data plate.
All references in HTCs Maintenance Manual, HTCM-001 and HTCs Mandatory Service
Bulletin Notice No. 2100-3R3 that pertain to P/N 500P2100-101 pertain to MDHI P/N
369D21120-501, as well. The blades are identical.
Main Rotor Blade Assembly (P/N 369D21121-501)

This blade is also known as Helicopter Technology Company (HTC) P/N 500P2300-501
(STC Number SR01050LA) and carries HTCs PMA data plate as well as MDHIs data plate.
All references in HTCs Maintenance Manual, HTCM-003 and HTCs Mandatory Service
Bulletin Notice No. 2100-3R3 that pertain to P/N 500P2300-501 pertain to MDHI P/N
369D21121-501, as well. The blades are identical.
NOTE: E-ITCs Mandatory Service Bulletin Notice No. 2100-3R3 also pertains to P/N 500P2100
Basic (foreign military helicopters).
Table 1 provides a cross reference of the MDHI and HTC blade part numbers and
applicable helicopter model.
Table 1. Main Rotor Blade Part Numbers and Helicopter Models
MDHI M/R Blade Part Number Helicopter Model HTC M/R Blade Part Number
NIA Foreign Military 500P2100 Basic
369D21100 Basic thru -523 3690, 369E N/A
369D21102 Basic thru -523 369FF, 500N, 600N N/A
369D21120 Basic, -501 369D, 369E 500P2100-101
369021121 Basic,-501 369FF, 500N, 600N 500P2300-501
Copyryht 1999-2003 by M1) Helicopters Inc. This documenl may be reproducfd a~td distnbuteci provided no /ee is charged,
the lext is not modified, and this copyright notice is included.
/I MANDATORY /1111111/III/1 MANDATORY 1/1/111/////1/ MANDATORY

SB369H-245R2* SB369D-201R2*
SB369E-095R2* SB369F-079R2*
SB500N-023R2* SB600N-031R2*
DATE: 4 FEBRUARY 2004 SERVICE BULLETIN

PAGE 2 OF 4
II MANDATORY 11111111111111 MANDATORY ~III/1111/11/ MANDATORYI/
c.
Some operators have experienced cracking of main rotor blades. These cracked blades have
been associated with a high number of torque events/external lifts per hour which exceed
the original design fatigue spectrum. This bulletin references criteria to assist operators in
understanding their level of usage, the impact of that usage on the main rotor blade life
and the corresponding inspections required to locate cracks that might occur. Failure to
comply with this bulletin may result in the loss of a main rotor blade.
D. Descrir,tion:
performing the main rotor blade torque event inspection and determining an inspection
interval.
This Bulletin shall be accomplished at the next 100-Hour inspection, or no later than 90
days after the issue date of this Bulletin.
F. FAA ADDroval:
G. Warranty Policy:
N/A
H. Disposition of Parts Removed:
Scrap
I. Other Publications Affected:
Handbook of Maintenance Instructions (CSP-HMI-8), Revision 34 dated 21 August 2003,

TR03-004, 9 January 2004 or later.
Rotorcraft Log Book (CSP-RLB), Revision 4 dated 31 May 2002 or later.
J. Points of Contact:
or (480) 346-6387. DATAFAX: (480) 346-6813.
A.
(1). Review the definition of a Torque Event (TE) (Ref. CSP-HMI-8 Section 04-00-00,
Torque Event (TE)).
(2). Review Rotorcraft Log Book entries to determine current number of TE accumulated on
each main rotor blade. If the current number of TE cannot be reliably determined,
13,720 TE shall be used.
t3). Record current number of TE accumulated on each main rotor blade in Rotorcraft Log
Book. Continue to record the number of TE accumulated tactual usage) throughout the
life of the main rotor blades.
Copyright 1999-2003 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged.
the tert is not modified, and this copyright notice is included.
II MANDATORY /II/1//11/~11 MANDATORY 11111111111111 MANDATORY /I

SB500N-023R2* SB600N-031R2*

PAGE 3 OF 4
4 FEBRUARY 2004
II MANDATORY 11111/IIII/1/1 MANDATORY 11111111111111 MANDATORY
B. Ins~ection
(1). Determine the main rotor blade TE inspection interval, using current number of ?E
(Ref. CSP-HMI-8, Section 04-00-00, Table 1. Airworthiness Limitations Component
Mandatory Replacement Schedule).
(2). Inspect main rotor blades at the required interval (Ref. CSP-HMI-8, Section 62-10-00,
Main Rotor Blade Torque Event Inspection), to include the following.
NOTE:
A record of TEs must be kept (Ref. CSP-HMI-8, Section 04-00-00, ?able 1, Airworthiness
Limitations Component Mandatory Replacement Schedule).
It is recommended to paint the inboard 24 inches (not to be exceeded) of the blade gloss
white to aid in crack detectability. If this is done, all blades must be painted alike and
re-balanced. (Ref. CSP-HMI-8, Section 20-30-00, Main Rotor Blade Painting.)
(Ref. Figure 1)
(3). When inspecting bottom side of blade, using bright light and 10x magnifying glass,
inspect for chordwise cracks protruding from under root fitting and doubler.
3. COMPLIANCE RECORD
Record compliance to this Service Bulletin in the Compliance Record section of the helicopter
Log Book.
Copyright 1999-2003 by MD Helicopters Inc. This document may be reproduced and distnbuted provided no lee is charged.
II MANDATORY 1/1111/1111111 MANDATORY 11111111111111 MANDATORY II

SB369H-245R2* SB369D-201R2*
SB369E-095R2* SB369F-079R2*
SB500N-023R2* SB600N-031R2*
DATE:
PAGE 4 OF 4
4 FEBRUARY 2004 SERVICE BULLETIN
/I MANDATORY 11111111111111 MANDATORY 111/111///1/1/ MANDATORY /I
MAIN ROTOR
BLADE
1
j
\b
DOUBLER
ROOT FITTING
NOTE
CQP~
~clL
O
USING BRIGHT UGHT AND tOX NIAGNIP(ING GLASS, INSPECT
FOR CHORDWISE CRACKS PROTRUDING FROM UNDER ROOT
FITTING AND DOUBLER. 88-820
Figure 1. Main Rotor Blade Torque Event Inspection
Copyright 1999-2003 by ML) Helicopters Inc. This document may be reproduced and dislnbuted provided no fee is charged.
the tezt is not modified, and this
copyright notice is included.
I/ MANDATORY IIIIIIIIIIIIII MANDATORY /11111//111/I1 MANDATORY II

SB369D-202 SB369E-096
SB369F-OSO SB500N-025
SB600N-037

PAGE 1 OF 4
14 AUGUST 2002
II MANDATORY 11111111111111 MANDATORY 1/111/III//1/1 MANDATORY I/
MAIN TRANSMISSION BONDING JUMPER INSPECTION AND REWORK
All Model 369D Helicopters*

Model 3693 Helicopters, serial number 0001 thru 0562*
Model 369F/FF Helicopters, serial number 0001 thru 0144*
Model 500N Helicopters, serial number LN001 thru LN097*
Model 600N Helicopters, serial number RN003 thru RN066*.
"Equipped with upgraded main rotor transmission, P/N 369F5100-501, -503, -505. -507.
B. AssemblvlComuonents Affected b~v this Bulletin:
Upgraded Main Rotor Transmission (P/N 369F5100-501, -503, -505. -507).
C. Reason:
Some helicopters equipped with the upgraded main rotor transmission may not have a
bonding jumper installed between the transmission and the helicopter structure.
Failure tocomply with this Bulletin may result in an insufficient ground path for
Electromagnetic Interference (EMI) and High Intensity Radiated Fields (HIRF) potential,
causing radio or other electrical equipment interference.
D. Description:
This Bulletin contains inspection instructions to determine if a jumper is installed between

the main rotor transmission and the helicopter structure and rework instructions to install
a jumper, if required.
E. FAA A~Droval:
F. Man-oower:
0.5 man-hour
G. Time of Com~liance:
This Bulletin shall be accomplished at the next annual inspection or no later than 03
December 2003, whichever occurs first.
H. Interchang~eabilitv:
N/A
Copyright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the
tert is not mod~ied, and this copyright notice is included.
II NlnNDnToRvl/llll//ll111/ MnluDnTaRvl/l/llllll1111 MANDATORYII
SB369D-202 SB369E-096
SB369F-080 SB500N-025
SB600N-037
DATE: 14 AUGUST 2002 SERVICE BULLETIN

PAGE 2 OF 4
II MANDATORY /Irllllllllllll MANDATORY IIIIIIIIIIIIII MANDATORY II
The parts listed below are included in Kit (P/N SBK-006). Contact MDHI Warranty and
Repair Dept.
Jumper Assembly 369A7719-19 1 MDHI
MHS5509-06DD
Screw NAS604-14P 1 MDHI
Nut MS35650-3255 1 MDHI
Washer N1835338-44 1 MDHI
Nut MS21 043-4 1 MDHI
Washer NAS1149D0416J 3 MDHI
J. Warranty Policy:
MDHI Warranty and Repair Department will provide parts at no cost to the operator.
K. Tooline:
N/A
L. Weig~ht and Balance:
N/A
M. Other Publications Affected:
Handbook of Maintenance Instructions (CSP-HMI-S).

Illustrated Parts Catalog (CSP-IPC-4).
N. Points of Contact:
or (480) 346-6387. DATAFAX: (480) 346-6813.
(Ref. Figure 1)
A. Ins~ection Procedure
(1). Inspect for a jumper connected between the tach generator/cover and Station 124.00
canted frame.
(2). If jumper is present, no further action is required.
Copyright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributedprouided no fee is charged, the
text is not mod~ied, and this copyright notice is included.
II MANDATORY 11111/11111111 MANDATORY 11111111111111 MANDATORY II

SB369D-202 SB369E-096
SB369F-080 SB500N-025
SB600N-037

PAGE 3 OF 4
14 AUGUST 2002
II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY I/
(3). If no jumper is present, perform Rework Instructions below.
B. ReworkInstructions
(1). Remove and retain lower outboard nut and washer from tach generator/cover mounting
stud.
(2). Prepare surface of tach generator/cover mounting flange and existing hole in Station
124.00 canted frame for electrical bond (Ref CSP-HMI-3, Section 96-00-00, Mainte-
nance of Electrical Bonding Connections).
(3). Install one end of jumper on tach generator/cover mounting stud and secure with
retained nut and washer.
(4). Attach other end of jumper to Station 124 canted frame with screw, washers and nuts.
(5). Seal both jumper connections (Ref CSP-HMI-3, Section 96-00-00, Maintenance of
Electrical Bonding Connections).
3. IDENTIFICATION:
N/A
N/A
Record compliance to this Service Bulletin in the Compliance Record section of the helicopter
Log Book.
Copyr~ht 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed prooided no fee is charged, the
text is not modified and this copyright notice is included.
II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II

SB369E-096
SB369D-202SB369F-080 SBS00N-025
SB600N-037
DATE: 14 AUGUST 2002 SERVICE BULLETIN

PAGE 4 OF 4
II MnNDAToRvll;~llllll1111/ MANDATQRY 11111111111111 NlnluonTORvl/
-I-dk~i"
TACH GENERATORICOVER (REF)
EXISTING GROUND MODULE

ON FORWARD SIDE OF FRAME
(REF)
NAS604-14PSCREW
MS35650-3255 NUT
MS35338-44WASHER
MS21043-4NUT
NAS114900416J
124
NOITASREHAW
GANTED FRAME
WL 0
60.75
li*
C JUMPER
ASSEMBLY
O
LOOKING FORWARD
88-808
Figure i. JumperInstallation
Copyr~ht 1999-2001 by MD Helicopters Inc. This document nay be reproduced and distributed prouicled no fee is charged, the
text is not modified, and this copyright notice is included.
II NlnwonToRv 11111111111111 MANDATQRY 11111/11111111 MANDATORYII
SIL
k$~101 South Hill Drive

Brisbane, CA 94005
6AM-5PM PST M-F
(800)227-4610
MD Helicopters Inc.
369[) Series
SERVICE INFO LETTERS
1) Applicable AD
2) Part Kit (1)
DL-02 POWER TURBINE (N2) RUB OR 1)

02/04/1977 LOCKUP IN 250-C20B ENGINE 2)
3)
4)
DL-3 INTERIM RESTRICTION OF ENGINE 1~

02/04/1977 N2 OPERATING SPEED 2) SEE SV
3)
4)
DL-05 RESTRICTION OF ENGINE N2 1)

06/22/1977 OPERATING SPEED 2)
3)
s
4)
DL-7 UTILIZATION OF ENGINE AIR 1)

0211411978 PARTICLE SEPARATOR AND ENGINE 2) P/N 369A90148-
COMPRESSOR WATER WASH KITS 3) 503 AND -508
4)
DL-8 TRANSMISSION, MAIN ROTOR AND 1)

02/27/1978 TAIL ROTOROIL CHANGE AND 2)
FILTER CHANGE PERIODS 3)
EXTENDED FROM 150 TO 300 HRS. 4)
DL-9 PAINT SCHEDULES AND ORDERING 1)

04/10/1978 PROCEDURES 2)
3)
4)

HU 0203 SI SV
1) Applicable AD
2) Part Kit (1)
DL-10 (INSCO) INSTRUMENT SPECIALTIES 1)

05/22/1978 CO. INC.-AUTHORIZED REPAIR 2)
STATIONS OFFICIAL SALES 3)
SERVICE FACILITIES 4)
DL-ll REDUCTION GEARBOX, MODEL 1)

06/26/1978 250-C20B ENGINE TIME BETWEEN 2)
OVERHAUL (TBO) REQUIREMENT 3)
ELIMINATED 4)
DL-12 PARTICLE SEPARATOR INSTALLA- 1)

09/08/1978 TION INSPECTION AND POSSIBLE 2)SEE ISSUE
REMOVAL OF CIRCULAR FILTER 3)
SCREENS 4)SEE ISSUE
DL-15 FINITE PART LIFE-TAIL ROTOR 1)

12/29/1978 DRIVE SHAFT FLEX COUPLINGS, 2)
P/N 369A5501 369H92564 3)
4)
DL-18 APPROVED IGNITER ASSY IGNI- 1)

07/20/1979 TION EXCITER ASSY FOR HUGHES 2) SEE ISSUE
P/N 369H90118 SERIES AUTOMATIC 3)
ENGINE REIGNITION KIT INSTALL 4) SEE ISSUE
DL-19 OPERATION AND MAINTENANCE 1)

08/01/1979 GUIDELINES FOR MODEL 250-C20B 2) SEE ISSUE
ENGINE FUEL SYSTEM 3)
4) SEE ISSUE
DL-21 NEW COMFORT CLIPS FOR SEAT 1)

12/10/1979 BELT AND SHOULDER HARNESS ASSY 2) SEE ISSUE
P/N 369H6541, 369H6541-21,-23, 3)
AND -25 4)SEE ISSUE
DL-24 ENGINE COMPRESSOR CLEANING- 1)

04/18/1980 DAILY WATER RINSE AND PERIODIC 2)
WATER WASH 3)
4) SEE ISSUE

HU 0203 SI SV
1) Applicable AD
2) Part Kit (1)
DL-25 NEW SEAL REQUIREMENT FOR OVER- 1)

05/26/1980 HAUL OF P/N 369023600 AND P/N 2) P/N 369[)26304
369023601 LANDING GEAR DAMPER 3)
ASSEMBLIES $)SEE ISSUE
DL-27 COMPLIANCE WITH FAA ADS AND 1)

09/30/1980 HUGHES MANDATORY (RED BORDER) 2)
SERVICE INFORMATION NOTICES 3)
4)SEE ISSUE
DL-28 PERIODIC INSPECTION CLEANING 1)

09/30/1980 OF P/N 3690290125-21 MIST 2)
ELIMINATOR ASSEMBLY 3)
4) SEE ISSUE
DL-29 NIGHT FLIGHT OVER WATER WITH 1)
01/05/1981 FLOATS NOW PERMISSIBLE WITH 2)
P/N 3690292032 NIGHT LANDING 3)
LIGHT KIT INSTALLED 4) SEE ISSUE
DL-31 SUBSTITUTION OF WET SPLINE 1)

03/13/1981 DRIVE STARTER-GENERATOR FOR 2)
EXISTING DRY SPLINE DRIVE 3)
STARTER- GENERATOR 4) SEE ISSUE
DL-33 NEW MAIN ROTOR HUB FAIRING 1)
07/17/1981 ATTACH SCREWS 2 NAS 10 96 3 10
3)
4)
DL-34 GROUND HANDLING PRECAUTIONS 1)
07/31/1981 FOR MAIN ROTOR BLADES WITH 2)
ELASTOMERIC DAMPER ASSEMBLIES 3)
4) SEE ISSUE
DL-35 CORROSION CONTROL MANUAL NOW 1)
08/21/1981 AVAILABLE FOR GENERAL 2)
DISTRIBUTION AND PURCHASE 3)
4) SEE ISSUE

HU 0203 SI SV
1) Applicable AD
2) Part Kit (1)
DL-36 TAIL ROTOR DRIVE SHAFT 1)

08/21/1981 FLEXIBLE COUPLINGS, P/N 2)
369A5501 AND 369H92564- 3)
TREATMENT WITH MOLYKOTE,CONTD. 4)SEE ISSUE
DL-38 NEW PROTECTIVE BOOTS FOR MAIN 1)

09/01/1981 ROTOR HUB AND TAIL ROTOR 2)SEE ISSUE
ASSEMBLIES 3)
4)SEE ISSUE
DL-40 FIELD REPLACEMENT OF O RING 1)

11/02/1981 FOR P/N 369A8321 OIL TANK 2)2-223, N304-75
FILLER CAP 3)
4) SEE ISSUE
DL-41.1 INSTALLATION OF SURPLUS 1)
02/10/1984 MILITARY PARTS. SALVAGED OR 2)
USED PARTS ON MODEL 5000 3)
HELICOPTERS 4)
DL-42 "LUBRICATION OF DRIVE END 1)

03/26/1982 BEARING LINER IN AIRCRAFT 2)
PARTS CORP MODEL 150SG SERIES 3)
STARTER-GENERATOR 4) RECOMMENDED
DL-43 NEW P/N 369028237 CUSHION FOR 1)

02/01/1982 TAILPIPE HANGER ASSY DESIGNED 2)SEE ISSUE
FOR LONGER WEAR 3)
4) SEE ISSUE
DL-44 NEW ONE-PIECE P/N 369021725 1)

03/26/1982 TAIL ROTOR STOP SUPPORT AND 2) 369[)21725
RETENTION NUT 3)
4)SEE ISSUE
DL-47 SERIAL NUMBER IDENTIFICATION- 1)

08/16/1982 P/N 369025100 MAIN 2)SEE ISSUE
TRANSMISSION ASSEMBLY 3)
4) SEE ISSUE

HU 0203 SI SV
1) Applicable AD
2) Part Kit (1)
DL-48 DISTRIBUTION AND SHIPMENT OF 1)

11/01/1982 HHI 269/369 COMMERCIAL AND 2)
MILITARY PUBLICATIONS 3)
4)SEE ISSUE
DL-49 GROUND TESTING-ENGINE 1)

11/22/1982 AUTOMATIC REIGNITION ENGINE 2)
ANTI-ICE FUEL FILTER SYSTEMS 3)
4)
DL-50 PREVENTION OF WATER LEAKAGE 1)

01/10/1983 THROUGH CANOPY GEON STRIPS 2)
3)
4)
DL-51 HANDLING AND SHIPPING GYROS 1)

02/01/1983 2)
3)
4)
DL-52 NEW ATTITUDE GYRO INDICATOR 1)

02/25/1983 AND SUPPORT ASSEMBLY 2) 369H92831-3
3) 369H6455-51
4)
DL-53 VOLTAGE REGULATOR SETTING FOR 1)

03/20/1983 THE HEAVY DUTY. 17 AMP HR, 20 2)
CELL BATTERY (P/N 3698290011) 3)
4)
DL-54 TRI-FLOW WASH PROCEDURE MAIN 1)

04/01/1983 ROTOR HUB 2)
3)
4)
DL-55.1 STRUCTURES CATALOG FOR 3690 1)

04/13/1984 SERIES HELICOPTERS 2)
3)
4)

HU 0203 SI SV
1) Applicable AD
2) Part Kit (1)
DL-56 LANDING GEAR DAMPER ASSEMBLIES 1)

11/14/1983 (PN 369026300 SERIES AND 2)
369026301 SERIES) 3)
4)
DL-57 SURPLUS OR BOGUS 369[321100 1) 84-12-01 R1
02/10/1984 SERIES MAIN ROTOR BLADES 2)
4) IMMEDIATELY
DL-58 UNAUTHORIZED TAIL ROTOR TEETER 1)

05/16/1984 BEARINGS 2)
3)SEE ISSUE
4)SEE ISSUE
DL-59 MAJOR INSTALLATIONS AND 1)

11/12/1984 ALTERATIONS TO YOUR HUGHES 2)
HELICOPTERS 3)
4)
DL-61 EXPLANATION OF PARTS 1)
09/15/1985 SERIALIZATION 2)
3)
4)
DL-64 UNAUTHORIZED OVERHAUL OF MAIN 1)

03/17/1986 ROTOR HUB ASSEMBLIES 2)
$)SEE ISSUE
DL-66.1 AVAILABILITY OF KAMATICS CORP. 1)
08/05/1989 KAFLEX MAIN DRIVE SHAFT (MDHC 2)
P/N 369025515 AND TAIL ROTOR 3)
DRIVESHAFT COUPLINGS, CONTD. 4)
DL-67 RE-LUBRICATION OF BEARINGS 1)
04/06/1987 IN STORAGE 2)
3)
4)

HU 0203 SI SV
1) Applicable AD
2) Part Kit (1)
DL-68 EXTERNAL SCAVENGE OIL FILTER 1)

05/01/1987 SYSTEM 2)
3)
4)
DL-70 UNAUTHORIZED DISTRIBUTION 1)

06/15/1987 OF MAIN ROTOR HUB OVERHAUL 2)
MANUAL. 3)
4)
DL-71.1 REPLACEMENT OF 369D25132-BSC 1)

09/01/1990 AND -5 OUTPUT SHAFTS (RING 2) 369[)25132-3
GEAR CARRIERS) WITH 369025132- 3)
3 OUTPUT SHAFTS 4)
DL-73 FINITE SERVICE LIFE INCREASE 1)

02/10/1988 FOR 369H5655-3 -5 OIL COOLER 2)
BEARINGS 3)
4)
DL-74 ILLUSTRATED PARTS BREAKDOWN OF 1)

02/19/1988 GROUND HANDLING WHEEL ASSEMBLY 2)SEE ISSUE
(P/N 36902610)
4)
DL-75 IMPROVED STRENGTH PC FILTER 1)

04/04/1988 HOUSING 2)
4)
DL-76 ADDITION OF IDENTIFICATION 1)

05/06/1988 DECAL ON AIRCRAFT EXTERIOR 2)SEE ISSUE
(COMPLIANCE TO FAR 45.11 (D)) 3)
4)
DL-77 AVAILABILITY AND DISTRIBUTORS 1)

05/09/1988 OF TRI-FLOW LUBRICANT/WASH 2)
3)
4)
HU 0203 SI SV
1) Applicable AD
2) Part Kit (1)
,DL-78 FINITE SERVICE LIFE INCREASE 1)

05/18/1988 OF 369025623 OIL COOLER BLOWER 2)
BELT 3)
4)
DL-79 ADDITIONAL INSPECTION 1)

05/18/1988 REQUIREMENTS OF THE BREEZE- 2)
EASTERN RESCUE HOIST SYSTEM 3)
4)
DL-80 CHAFE WRAPPING OF STAINLESS 1)

05/26/1988 STEEL TUBE ASSEMBLIES AND 2)
ALLISON COMMERCIAL SERVICE 3)
LETTER CSL 145, CONTD. 4)
DL-81 IMPROVED FUEL DRAIN VALVE 1)

07/01/1988 ASSEMBLY 2)
3)
4)
DL-82.2 FACET SCAVENGE OIL FILTER 1)

11/21/1990 KITS, P/N 1741050 (369H 2)
SERIES, 3698 AND 369E) AND P/N 3)
1741300 (369F/FF) 4)
DL-84 VALIDITY OF SPECTRUM OIL 1)

01/15/1989 ANALYSIS PROGRAM (S.O.A.P.) 2)
3)
4)
DL-86.1 NEW MDHC AUTHORIZED HELICOPTER 1)

09/15/1989 AIRFRAME REPAIR FACILITIES 2)
4)
DL-90 AVAILABILITY OF MAIN ROTOR 1)

08/05/1989 TRANSMISSION FILLER CAP 2)
EXTENSION (MDHC P/N 369025112) 3)
4)
HU 0203 SI SV
1) Applicable AD
2) Part Kit (1)
DL-91 AVAILABILITY OF WIRE STRIKE 1)

09/15/1989 PROTECTION SYSTEM (TRADEMARK 2)
WSPS) ON ALL MDHC 369 SERIES 3)
HELICOPTERS 4)
DL-92 FEDERAL INVESTIGATION OF 1)

10/27/1989 CENTRAL AVIATION AND MARINE 2)
CORPORATION (CAMCO) 3)
4)
DL-93.1 AVAILABILITY OF AUTRONICS 1)

09/27/1991 CORPORATION ELECTRICAL 2)
COMPONENT EXCHANGE PROGRAM 3)
4)
DL-94 COMPLIANCE TO BREEZE-EASTERN 1)

12/15/1989 CUSTOMER SERVICE BULLETIN CSB- 2)
120 (WARNING PLATE FOR CARGO 3)
HOOKS) 4)
DL-95 STORAGE TIME LIMITATIONS OF 1)

09/01/1990 THE ENGINE N2 AND ROTOR 2)
TACHOMETER INDICATORS 3)
(P/N 369D24518(BSC), -3 -5) 4)
DL-96 AVAILABILITY OF IMPROVED 1)
05/01/1991 SPACERS TO BE USED ON THE 2)
SHOCK-MOUNTED SKID TUBE 3)
POSITION LIGHT ASSEMBLIES 4)
DL-97 MAIN ROTOR HUB BALANCING 1)
10/11/1991 2)
3)
4)
DL-99.1 POLICY PRICE OF 369H8108 FUEL 1)
09/10/1992 VENT EMERGENCY SHUTOFF VALVE 2)
4)

HU 0203 SI SV
1) Applicable AD
2) Part Kit (1)
DL-100.2 MAINTENANCE AND OPERATION 1)

01/25/1993 REQUIREMENTS FOR SAFE 2)
OPERATION OF SURPLUS 369A 3)
(OH-6A) SERIES HELICOPTERS 4)
DL-101 MAIN ROTOR BLADE INSPECTION 1)

01/27/1993 PROGRAM 2)
3)
4)
DL-102 ANTENNA LOCATION AND FLIGHT 1)

03/22/1993 MANEUVER CAUTION 2)
3)
4)
DL-104 kTRANSPORT AIRPLANECOMPLIANCE 1)

12/21/1994 TO SERVICE INFORMATION NOTICES 2)
DN-185, EN-78 FN-64, DATED 3)
23 SEPT. 1994 FAA, CONTD. 4)SEE ISSUE
DL-105 TAIL ROTOR ABRASION STRIP 1)

05/10/1995 WARRANTY POLICY/COMPENSATION 2)
3)
4) NONE GIVEN
DL-106 ALTERNATE/IMPROVED ENGINE OIL 1)

07/01/1997 TANK SEAL 2)
3)
4) NONE FOUND
DL-107 LIFE LIMIT INCREASE OF 1)

07/18/1997 HORIZONTAL AND VERTICAL 2)
STABILIZER 3)
4) NONE FOUND
End of Index

HU 0203 SI SV
I
LETTER NO. DL-2
4 Feb 1977
I
DATE
HU GH E~
PAGE 1 OF_1
SERVICE INFORMATION
LETTESR
TO All owners and operators of Helicopters
SUBJECT: POWER TURBINE (N2) RUB OR LOCKUP IN 250-C20B ENGINE
MODELS AFFECTED: PL11 Hughes 500D Model 369D Series Helicopters
Reference
Detroit Diesel Allison Commercial Service Letter 250-C20/C20B No. CSL-1037,

dated 12 March 1975
Detroit Diesel Allison Commercial Service Letter 250-C20/C-20B No. CSL-1056,
dated 8 November 1976
In most cases, the cause for N2 rub or seizure is carbon buildup on the rotating
labyrinth seal of the power turbine rotor. When this problem is experienced,
owners and operators should refer to the above referenced DDA Commercial
Service Letters reprinted as part of this Hughes Service Information Letter.

As stated in CSL-1037, walking the main rotor backwards while the engine is
cooling after shutdown will definitely help to eliminate this cause for seizure and
will not harm the engine.
Tn the event binding due to carbon formation cannot be relieved by walking the
main rotor backward, field disassembly and cleaning of the power turbine
unit may be accomplished, per CSL-1056, and the engine returned to service.
If power turbine rub or Lockup occurs, it is recommended that owners and
operators refer to both of these DDA service Letters to help resolve the problem.
-L3yec~aL4
Edward Koch,
~L
Manager
Customer Service Department
Hughes Helicopters
j/
Customer ServLce Department Hughes Helicopters Culver City, California
FOA*( hlO. os7a HTt*D REV L1.67

250-C20 CSL-1037
COMM ERCIAL SERVICE LET"T~R
ct~ Oetmit Diesel Allisee

Indianapolis, Indiana 46206
Division ot General Motors
Page 1 of 2
Corporation
March 12, 1975

FAA-DER Approved
SUBJECT: Power Turbine (N2) Rub
PROBLEM:
i. The helicopter n~ajn rt,tor (NR) does not ~utnte by ti~e time the gas
producer rotor (N1) has reached 25~ during start. a
2, NR cannot be Iotated backward.
CAl7SE:
Assuming binding or seizure is not. in the helicopter transmission,

the
tail rotor gearbox or associated shaftin~, there is one majorcause
for N2 rub in the engine which is carbon formation.
1. Carbon formation in the labyrinth seal between the small dianieter

of the power turbine support sump cover and the knives on the ro-
t tating seal attached to the aft side of the third-stage turbine wheel.
During operation, the knives clear their p~ith in the carbon. At
rest after cooldown, the axia.l movement of the: knives into the carbon
causes seizure,
A second relatively infrecluent enRine is metal-to-

cause for N2 rub in the
metal contact.
i. Metal-to-metal contact can occur at either of two locations on the

third-stap;e turbine wheel.
a.. The OD knives affainst the fourth-stage turbine nozzle shroud,
b, The knives on the forward face of the third-strySe wheel and the
interstaffe seal on the 1l) of the fourth-staffe turbine nozzle,
Both of these melal-~to-metal places of interference experience very
minor contact proven
as on disassembly of the turbine. Disassembly
of many turbines at DDA shows few of them have made contact. When
i
contact is matle, the wear is .001-.002 inch.
DDA now believes that carbon formation in the labyrinth seal is Ihe cause
s
for N2 rub in the majority of cases encountered.
250-C20 CSL-1037
Page 2
COMMERCIAL SERV1CE LETTER

J
CORRECTIVE ACTION:
(Maintenance)
i, DDA recommends and operators report success with a

some
procedure to "wear in" the knives, This procedure entails

walking the main rotor while the engine is cooling
after a shu tdown, During t~le cooldown period, the relatively
thin sections of the fourth-staffe turbine nozzle a.t the third-
stage wheel shroud and interstt~e seal cool rather quickly.
The third-stage turbine wheel being heavier, cools nlore
slowly, It is the differential coolillff that ca~lses seizure,
~hen the temperature of the internal, parts has,st:nbilized, this
type of rub disappears,
Walking the main rotor ba.ckwards will definitely help to elimi-

nate this causefor seizure and will not hLzrm the engine,
2, Binding due to carbon formation may or may not be helped by

walking the main rotor backwards, DDA recommends that it
be tried, If the engine begins to "chatter" during this proce-
dure, the action should be stopped until the next convenient
shutdown when the main rotor can be nalked backwards again i/
until improvement is noted.
3, The best action an operator take to combat the carbon

can
formation problem is to use oil or MIL-L-

23699 oil as listed in the latest revision of 250-C20 CSL-1002,
4. Operators can also help the situation by slrictly following t~he

two minute dwell at idle prior to -shutdown per the Operation
and Maintenance Manual, Publication No. 20W2,
5, If bindingpersists, the operator should still keel, the turbine in

service provided N2 will. rotate after the second or third start
attempt. The heat generated by a start attenlpt almost always
frees the binding condition. Some operators have reported that
the problem eventually clears itself,
L, O, Davidson
Service Manager i/
Aircraft:
RNB /bs c
g
250-C18 CSL-86
250-B15G TP CSL-23
250-B17/B17B TP CSL-1028
250-C20/C20B CSL-1056
COMMERCIAL SERVICE LETTER
O~trPlt DCesel Alliison Division of General Motors Corporation

FAA-DER Approved
SUBJECT: Field Cleaning Procedure Relative November 8, 1976

td Carbon Caused Turbine N2 Lockup Page 1 of 4
All Series I and II Model 250 Engines
There have been instances wherein N2 Turbine lockup has been the result
of carbon buildup on the Rotating Labyrinth Seal of the Power Turbine
Rotor. As a result of this condition, several engines have reportedly
been removed from service.
The intent of this Cormnercial Service Letter is to provide a procedure

by which the operator, if he chooses, may disassemble the Turbine Unit
and clean the affected area shown in Figure 1 as required.
Procedure:
i. Remove the Turbine Section from the Gearbox as outlined
L4 1 in the applicable Operations and Maintenance Maaual.
2. Remove the No. 6 and 7 External Oil Sump (Ref. Figure i),
and the No. 8 Bearing Scavenge Oil fitting and discard the
metallic crush type seal ~ings.
3. Remove the two nuts and bolts and separate the firewall
from the Turbine assembly,
4. Remove the retaining ringe which lock the Air Discharge

Tubes in the Outer Combustion Case and remove the tubes.
5. Remove the twenty-four (24) split line bolts between the

Exhaust Collector Support and the Power Turbine Support,
(Ref. Figure i).
6. Separate the Power Turbine Support from the Exhaust Collector,

being careful the Third Stage Turbine NozzLe does not come out
of the Power Turbine Support.
7. Using a equivalent and No. 26 City Service

stiff wire brush or
Carbon Solvent or equivalent, clean the carbon and/or varnish

deposits from the Rotating Labyrinth Seal at the rear face of
the Third Stage Turbine Wheel, (Ref. Figure 2).
:a
259-018 CS~cgg
250-B15G TP CSL-23
259c817JS17 5P C6LL1028
250cC20/e2OS CSLL1056
C30MM:W1ICIAb
I
1976
Psage 2
ClbUTION: Do not. use carbon solvent on the stationary

member seal surface,
8, After the e~an nbtesamble fhe

Turbine using the reversal of the p~oce8uJra! outlined
above
CAUTIObl! Uss care in 86 bearing inner race
to %6 bearing X8nf, Figure i),
g, important Torques:
26 Spliflins bolts, in, lba,
1/8 bearing Scsv4Eag~er 051 ~FdfFng, 40 in, Iha,
1Sand 7 Extbtrnal Oil Sump BQlts, 35-45 in, Sbhl
~wt, Fir9wall Shield to ~8 bump Pit~lns, 54-60 in, Ibs,

~J--
Apply nt2-selas ;to tbraads on all of the above items,
cj,.BY;a,
L, Q, Davidaon
Isrv;lce Manager
6Aa Turbine Dn$Snee
RFR/3 t
250-C18 CSL-86
250-B15G TP CSL-23
Page 3 CSL-1028
250-B17/B17B TP
250-C20/C20B CSL11056
REMOVE SPLIT LINE BOLTS ----i
POWER TURBINE GIS PRODUCER

IWII*O(QU)II
SUPPORT oil
1)1117
EXHAUST COLLECTOR )OlillOlllC )IY(

I
j/,
011 11111
SUPPORT
0 79
11 19,lg
WIRR I1~II 11191
IOLLLI IQIILI :IOLllt
It
;: :i
iR
Zwl!l
ILIIL V/////X-X\\\\\\rl ~1( "0"
Xt 1111118
__111)OU
CARBON FORMS IN THIS AREA

1~6 BEARING 11111111111
INNER RACE
011 II~L
:ii3;~
jj
I :~ii"r
I; I I NI 1 111
a \,::F
O
IIIIILL Imru
OB OUl~tl
~L ~Cwc. W tl~ 1~6 AND Q7

EXTERNAL
OIL SUMP %il
TYPICAL TURBINE
FIGURE 1
250-C18 csL-sg
Page 4 250-B15G TP CSL;-23~
250-B17/B17B TP CSL-1028
250-C20/620B CSL- 105G
It
~3 TURBINE WHEEL
t~---------L7
;II: I
~YI11( (IltlUI
I ROTATING
LABYRINTH
SEAL
----l~j
Q
CLEAN THIS AREA
If I f
~di------i
-1-~
r=--~ RICI MLUI tL_J
TYPICAL POWER TURBINE ROTOR i

FIGURE 2
2
LETTER NO. DL-3
DATE: 1 Feb 1977

H UGH ES
PAGE 1 OF 1
SERVICE INFORMATION
LEI rER
TO All owners and operators of Hughes Helicopters
OF ENGINE OPERATING SPEED

SUBJECT: INTERIM
RESTRICTION N2
MODELS AFFECTED: All Hughes 500D Model 369D Series Helicopters
Reference
Detroit Diesel Allison Commerical Service Letter 250-C20/C20B, CSL-1062,

dated January 7, 1977
Your attention is directed to the above referenced DDA Commercial Service

Letter which is reprinted as part of this Service Information Letter.
Due to blade failure experienced in the third stage wheels, Part Number 6887113
and 6888633, DDA recommends that the 250-C20B engines incorporating these
part number wheels not be operated between 85~0 and 98q6 Ng RPM until the cause
of failure can be determined and corrective action can be implemented in the field.
Edward Koch, Manager

Hughes Helicopters
\I/
Customer Service Department Hughes Helicopters Culver City, California
FORM NO. D178R HTC-AD REV. 11~67

250-e20/C20B CSL-1062
250-B17/B17B TP CSL-1031
COMM ERCIAL SERVICE LETTER
DetrPit Diesel Allison Division of General Motors Corporation
.dlanapolls. Indiana 48206 Page 1 of

January 1871
FAA-DER Approved
Subject: Engine N2 Operating Speed Recommendation
The 250 Series TZ engine hasrecently elr~erienced a blade

failure on several third stage wheels, Part Numbers 6887~13 and
6888633. An investigation is underway to determine the cause
and ,,,,,,,e adion.
In the interim DDA recommends that the 250-C20, -C20B,

-B~7
and -B17B engines incorporating these part number wheels not be
operated between 858 and 98W Na RPM except during transients
while maintaining safe flight pradices.
L. O. Davidson
Service Manager
Cas Turbine Engines
............I
LETTER NO. DL- 5
DATE 22 June 1977

HUGHES 1
PAGE 1 OF
SERVICE INFORMATION
_.___
LETTER
T.O All owners end operators of Hughes Helicopters
SUBJECT: RESTRICTION OF ENGINE N2 OPERATING SPEED
MODELS AFFECTED: All 500D Model 369D Series Helicopters
Refer enc e
FAA Airworthiness Directive AD 77-10-13, Amendment 39-2904,

effective 24 June 1977
Detroit Deisel Allison Commercial Engine Bulletin 1119
or later FAA Approved Revisions
Detroit Deisel Allison Commercial Service Letter 1065

or later FAA Approved Revisions
Hughes Service Information Letter DL-3, dated 4 February 1977
i/
Your attention is directed to the above referenced FAA

Airworthiness
Directive AD 77-10-13 which engine operation between 90 and

prohibits
98percent specific exceptions. The restriction of N2 speed is
N2 with
applicable toModel 250-CZOB engines equipped with PN 6887113 or

6888633 third stage turbine wheels that do not incorporate DDA Commercial
1065 later FAA
Service Bulletin 1119 and Commercial ServiceLetter or
approved revisions.
hours time
It is to be noted that compliance is required within ten(l0)
of the AD.
in service after 24 June 1977, the effective date
-L7~ib9 ~e
Hughes Helicopters
LI
ronM NO 8?)7811 HTC*D REV 11.67

LETTER NO. DL-7
DATE 14 February 197E

HUGHES 2
PAGE 1 OF
SERVICE INFORMATION
LETTER
TO-All owners and operators of Hughes Helicopters
SUBJECT: UTILIZATION OF ENGINE AIR PARTICLE SEPARATOR AND
ENGINE COMPRESSOR WATER WASH KITS
MODELS AFFECTED: All 500D Model 369D Helicopters
Reference
369D Basic HMI-VolI, Issued 15 Sep 1976; Revision No. i, 15 Nov 1977
369D Optional Equipment Installation and Illustrated Parts List;
Publication No. CSP-004
FAA Approved Rotorcraft Flight Manual for 500D Model 369D Helicopter
Supplement: to Approved Rotorcraft Flight Manual, Engine Air Particle Separator Kit,
PN 3691190148-503 and -508; Publication No. CSP-D-1C
Hughes Service Information Notice No. DN-17, dated 6 Feb 1978.
Detroit Diesel Allison Commercial Service Letter 250-C20 CSL-1020
The PN 369A90148-503 particle separator kit is available as

and -508 engine air
optional equipment to filter and scavenge the engine intake air of contaminants
(dirt, dust, debris, etc) which can be detrimental to the operation and life of the
helicopter engine.
Field reports indicate that on helicopters equipped with the particle separator, some
the SCAV-ALR switch to obtain maximum filtration. This

pilots are not turning on
switch should be turned off during engine start up and on during take off and landing.
Based on atmospheric conditions at cruise altitudes over 500 feet the particle
separator may be deactivated at the discretion of the pilot, by turning off the
SCAV-ALR switch during cruise flight. The loss in power at TOT limiting conditions
is approximately 7 horsepower or 60 pounds in hover performance.
Operating procedures and performance helicopters equipped with the particle

datafor
separator kit are provided in the above referenced Supplement to the Rotorcraft
Flight Manual.
FORM NO. 91178R HTC*D REV L1-61

LETTER NO. DL- 7 Hughe H~licopters
DATE 14 February 1978
PAGE 2 of 2
When thehelicopter is used for agricultural spraying or operated in an
atmosphere containing corrosive chemicals or salt water air, smoke, fumes,

etc, it is recommended that owners and operators perform a daily water
wash of the engine to clean corrosive from the compressor blades.
deposits
A PN 369H92537 engine compressor water wash kit is available for this
purpose for 369D helicopters. Initial installation instructions provided
are
inHughes Notice No. DN-17. Wash procedures, flow requirements, etc are
provided in the referenced DDA Commercial Service Letter CSL-1020.
Installation and proper use of the engine air particle separator and engine
compressor water wash kits will help ensure optimum performance and
improve service life of the engine.

Customer Service Department:
Hughes Helicopters
LETTER NO. DL-8

HUGHES
PAGE 1 OF
SERVICE INFORMATION
LETTER
SUBJECT: TRANSMISSION, MAIN ROTOR AND TAIL ROTOR

OIL CHANGE AND FILTER CHANGE PERIODS
EXTENDED FROM 150 HOURS TO 300 HOURS
Reference
500D Basic HMI Volume I Issued 15 September 1976; Revision No. i,,
15 November 1977
500D Basic HMl Volume II Issued 14 September 1976; Revision No. i,.
14 January 1977
Based on recent transmission test results and analyses, the time between oil
and filter changes for the main rotor and tail rotor gearboxes has been extended
from 150 hours to 300 hours of operation. This data is to be considered a part
of the HMI and will be incorporated in the next scheduled revision to the above
refe rence d handbooks.
It is to be noted that as more service information becomes available in the future,

the oil and filter change period will be increased beyond the 300 hour interval.
Z7~19
Edw~ard Koch, Managei
Hughes Helicopters
ronM NO 95708 )IT~-AO HEV 11-67

LETTER NO. DL-9
DATE 10 April 1978

HUGHES PAGE 1 OF
5
SERVICE INFORMATION
LETTER
SUBJECT: PAINT SCHEDULES AND ORDERING PROCEDURES
Reference
Vol I, Issued 15 September 1976; Revision No. i, 15 November

500D Basic HMI
1977 Model 500D Helicopter Log Book
The color code numbers for finish paints used on each new Model 500D helicopter
are now being entered in the helicopter Log Book prior to delivery of the aircraft.
It is recommended that and operators of earlier Model 500D helicopters

owners
listed for the aircraft, and to

check the helicopter Sales Order for paint numbers
so they will be readily avail-
enter these paint numbers in the helicopter Log Book,
able for service personnel.
Advance Coating finish

paint schedule is provided to assist in ordering
The attached
400D helicopter. When ordering
paints for touching up or repainting your Model
paints from Advance Coating, specify each paint by type (i. e., acrylic, epoxy,
number. Also include the
polyurethane), by description (color), and by AC part
Fed Std No., listed, to ensure that the correct type and color
compatible HS or as
paint is provided.
helicopter Log Book Sales Order may identify paint

It is to be noted that the or
(Andrew Brown Co. Lf so, when ordering Advance Coating

finishes by SA No.
paints, check that the AC No. and the SA No. are compatible.
and Chemicals,
Advance Coating paints may ~e procured direct from Advance Coating
2213 No. Tyler, South El Monte, California 91733. Contact
Mr. Thomas Hughes;
telephone (213) 579-6270.

Customer Se rvice Department
j~
Hughes Helicopters
Customer Service Department llughes Helicopters Culver City, California
FORM NO 9~788 HTC-*D REV 11-67

ADVANCE COATING AND CHEMICALS
dtir
0~3t3
ACRYLIC PAINT .t? .t? tr!
N~3
oZ
AC Part No. HS or
m
O
Description (Advance Coating) Fed Std No.
,r
Red Matador Gloss 6R-3 HS814-1008 \D
Dune Beige Flat 6N-1 HS814-3015
Red Insignia Closs 6R-4 11136
60-1
Ih
International Orange Gloss 12197
U)
Sea Blue Gloss 6A-1 15042 F
Q
White Gloss 6w-6 17875
Orange/Yellow- Flat 6Y-3 33438 1

g
Olive Drab Flat 6G-1 34087 ij
Blue Flat 6A-2 35044
Gull Gray- Flat 6X-3 36231 3
Black- Flat 6B-7 37038
Off White Gloss 6W-7 14722

ADVI4NCE COATING AND CHEMICALS (CONT)
EPOXY PAINT
AC Part No. HS or SA Part No.

De sc ription (Advance Coating) Fed Std No. (Andrew Browne Co.
Yellow Semigloss 1-1Y-84 HS814-2091 SA-13043
Black Flat 1-1B-38 37038
Blue Semigloss 1-1A-86 HS814-2021 SA- 1 3 0 44
Harbor Blue Gloss 1-1A-87 HS814-1023 SA-13419
Brigade Blue Gloss 1-1A-88 HS814-1024 SA- 146 02
Red Insignia- Gross 1-1R33 11196 om

I
International Orange Gloss 1-10-28 12197
Gray Alabaster Gloss 1-1X-94 HS814-1011 a

Pebble Tan Flat 1-1H-94 HS814-3014
P
Clear Gloss 1-1C-22 ij
Light Gray Gloss 1-1X-67 16440
White Gross 1-1W-46 17875 a
Dark Gray Semigloss 1-ix-gs 26044
Black Semigloss 1-1B-41 27038
Orange/Yellow- Flat 1-1Y-33 33538

dtlr
Dark Gray Flat 1-1x-96 36076
MMF~
ADVANCE COATING AND CHEMICALS
(CONT) r; i3 L~
nc3c3
POLYURETHANE PAINT m m c~
~p
AC Part No. HS or SA Part No. o
c Z
Description (Advance Coating) Fed Std No. (Andrew Braw-ne Co.)
Teak Brown Gloss ti

1-1N-95 HS814-1031 SA-52 ,r
Endevor Blue Gloss 1-1A-89 HS814-1026 SA-76
Orange Gloss 1-10-47 HS814-1042 SC-6389

Edison Yellow Gloss 1-1Y-85 H5814-1094 SA-9751
International Orange Gloss 1-10-44 12197 SA-12197
Red Matador Glass llR-54 HS814100R SR 12797 ,m
Hughes Blue Gloss 1-1A-90 HS814-1027 I
SA-13420
International Red Gloss 1-1R-53 H5814-1083 SR-13421 PO~
Black Gloss 1-1B-33 HS814-1051 SA-13422
Firemist Gold Palomino Gross 1-1Y-86 e
HS814-1062 SA-13626
Forest Green O
Gloss 1-1G-68 HS814-1071 SA-13627 0~
Italian Coast Guard Yellow Gloss 1-1X-87 4
HS814-1095 SA-13651
Cocoa Brown Gloss l-1N-gb HS814-1032 SA-13870
Channel Blue Gloss I-1A-ql HS814-1022 SA-13871
Creme Yellow Gloss 1-1Y-88 HS814-1093 SA-13872
La Ro Yellow Gloss 1-iu-sg HS814-1092 SA-13qg3
Sun Yellow Gloss 1-1Y-90 HS814-10ql SA-14333
Calypso Coral Red Gloss I-1R-55 HS814-1082 SA-14476

Light Orange Gloss 1-10-48 H5814-1041 SA-14550
White Gloss l-1W-60 17875 SA-13417
Golden Haze Yellow Gloss 1-1Y-91 HS814-1061 SA-14650
ADV~UCE COATING AND CHEMICALS (CONT)
POLYURETHANE PAINT (CON T)
AC Part No. HS or SA Part No.
Fed Std No. (Andrew Browne Co.

Description (Advance Coating)
Plum- Gloss 1-1R-64
Violet- Gloss 1-1R-65
1-1A-137 HS814-1025 SA-14661

Flag Blue Glos s
Semi Gloss 1-1A-138 HS814-2028

Dresdon Blue
1-1R-81 HS814-1081 SA- 14660

Flag Red Gloss
Ih
White Gross 1-1W-98 H5814-1007 LR-12796 UI
Cadillac Olympic
SA-12774
Alabaster Gray Gloss (269 Series) 1-1X-94 HS814-1011
h
Pebble Tan Gloss 1-1N-142 HSB14-1014 SA-12775 I
Lincoln Pebble Tan Semi Gloss 1-1N-143 HS814-2014
cdtlr
MM3
r~a
oZ
rr
s
LETTER NO. DL-10
DATE 22 May 1978

HUGH E~i
PAGE 1
SERVICE INFORMATION
C LETTER
SUBJECT: (INSCO) INSTRUMENT SPECIALTIES CO. INC. AUTHORIZED

REPAIR STATIONS AND OFFICLC~L SALES AND SERVICE
FACILITIES
MODELS AFFECTED: All 500D Model 369DHelicopters
Refe rences
400D Basic HMI-Vol I, Issued 15 September 1976; Revision No. i, 15 November 1977.
Hughes Service Information Notice No. DN-16, dated i-February 1978
The Instrument Specialties Co. Inc. authorized repair stations listed in this letter
are fully equipped to handle maintenance
and repair problems for the Insco instru-
ments (TOT indicator, torque pressure indicator, etc) installed on your Model 500D
helicopter. The official I~sco sales and service facilities listed can also provide
direct contact and assistance whenever and wherever needed.
It is to be noted that the referencedHughes Service Notice No. DN-16, which pro-
vides instructions for optional upgrading of early configuration TOT indicators,
specifies that the hermetically sealed instrument be evacuated and protected by
trained personnel. If the TOT indicator is unsealed by any facility other than an
Insco-approved repair station, the vendor warranty is automatically voided.
Hughes Helicopters feels that utilization of these listed support facilities can
service and repair of the Insco instruments installed

improve the time involved for
on your helicopter.

Hughes Helicopters
Customer Service Department Hughes Helicopters Culver Qty, California
CORW NO. D178R NTC-ClO REV. L1-6~

LETTER NO. DL-IO Hugh
DATE: 22 May 1978
PAGE: 2 of 9
INSCO AUTHORIZED REPAIR STATIONS
USA EASTERN
Consolidated Instrument Co. Inc.

Teterboro Airport
Teterboro, New Jersey
Durham Aircraft Service

56-15 Northern Boulevard
Woodside, New York 1:1377
Hermetic Aircraft Instrument Corporation

200 Marine Street
Farmingdale, New York. 11735
NASCO International Inc.

P. O. Box 48-515
Miami, Florida 33148
Olmstead Instrument Co.

28 Fourth Street
Harrisburg International Airport
Middletown, Pennsylvania 17507
USA CENTRAL
Aircraft Instrument and Development, Inc.
317 East Lewis

Wichita, Kansas 67202
Beacon Instrument Service Inc.

Detroit City Airport Bay 9
Detroit, Michigan 48213
Castleberry Instruments and Avionics

Tims Airpark
817 Dessau Road
Rt. 3
Austin, Texas 78753
C
OHug~ Hlicoptor LET TER NO, DL-I 0
DATE;: 22 May 1978
PAGE: 3 of 9
.Cem Instrument and Manufacturing Co.

331 North Briarly
Suite 325
Irving, Texas 75061
Vernon G. Gillette
Meacham Field
Fort Worth, Texas
MASCO Instrument Co.

2822 Century
Dallas, Texas
Mitsui and Co. (USA)Inc.

5000 One Shell Plaza
Houston, Texas
USA WESTERN
Air Asia Co., Ltd.

C P. O. Box 3957
No. Hollywood, California 91604
Air Stream Instrument Labs, Inc.

3605 East Spring Street
Long Beach, California 90806
Airtronics
1650 East 18th Street
Unit X
Tucson, Arizona 85719
Alaskan Aircraft Equipment Supply, Inc.

4707 Spenard Drive
Anchorage, Alaska
American Instruments, Inc.

6860 Perimeter Road
Boeing Field
Seattle, Washington 98108
LETTER NO. DL-10 E~ HU9h Hellcoptslu
DATE: 22 May 1978
PAGE: 4 of 9 C
Ansett Industries of Australia
10881 Latuna Canyon Road
Sun Valley, California 91352
Astro AirEnterprises
P.O. 2335, Airport Station
Box
Oakland, California 94614
Bemm Aircraft Instrument Service, Inc.

Stapleton International Airport
Denver, Colorado 80207
Bill Johnson Instrument Inc.

7705 Woodley Avenue
Van Nuys, California 91406
Paine Field Instruments

Paine Field
Everett, Washington 98204
Scott Instrument Co.

3734 W. Slauson Avenue
4
Los Angeles, California 90043
Thompson Instrument and Avionics

AMF Box 22190
Salt Lake City, Utah 84122
AUSTRALIA
A.E.O.S. Ltd.
29 Norman Street
Peakhurst N. S. W.
Australia
Aircraft Instrument Service Pty. Ltd.

69 Caroline Crescent
Georges Hall, 2198
Sydney, N.S.W.
Aus tralia
L
~b HUBk+ Helicopten LETTER NO. DL-10
DATE: 22 May 1978
PAGE: 5 of 9
BRAZIL,
O. L. D. I.
Av. Dr. Alberto Benedetti
No. 121
Santo Andre S. P; Brazil
CANADA--- EASTERN
Aviation Electric Ltd.

P. O. Box 2140
Montreal, Quebec, Canada
J. H..McKinnon Ltd.
3120 Sartelon Street
M.ontreal, F.a. Canada
CANADA WESTERN
Airborne Precision Instruments, Ltd.

Field Aviation Hanger
International Airport
Calgary, Alberta, Canada
Aviation Electric Pacific Ltd.

482 Hoffar Street
Inte rnational Airport South
Vancouver, B.C. Canada
ENGLAND
Aeronautical and Commercial Instrumentation Ltd.

143A London Road
Apsley, NR. HemelHempstead, Herts
HP3 ssa
Aviation Activities OVHL Services Ltd.

Willow Lane
Mitcham, Surrey, England
Aviation Engineering and Maintenance Co.

Haine Industrial Estate
C; Ramsgate, Kent, England

LETTER NO. DL-10 Hugh ~llcoplr
DATE: 22 May 1978
PAGE: 6 of 9
BritishAirways Helicopters Ltd.

Gatwick Airport South
Horley, Surrey, England
C, S. E. Aircraft Service Ltd.

Oxford Airport
Kidlington, Oxford, England
Field Aircraft Services Ltd.

121mperial Way
Croydon Airport
Croydon, England
FINLAND
Instrumentointi Oy
Sarankulmankatu 20
SF-33900, Tampere, Finland
MO Z AM BIC2UE
C
D. E. T. A.
P. O. Box 2060
Marquee
Lourenco
Mozambique
SOUTH AFRICA
Dart Aircraft Components (Pty) Ltd.

P. O. Rand Airport
Germiston 1419 R. S. A.
SWEDEN
Osterman s Aero AB
S161 10 Stockholm, Bromms 10
Sw ed en
SWITZ ER LAND
Air h;iaintenance S. A.
B.P. 110
1215 Geneve 15 Aeroport C
Geneve, Switzerland
LETTER NO. DL-10
Q~ Hughes Helicopters DATE: 22 May 1978
PAGE: 7 of 9
OFFICIAL SALES AND SERVICE FACILITIES

FOR INSCO PRODUCTS
USA
West Coast: A. Biederman

1045 Air Way
Glendale, Calif. 91201
Central: INSCO, Inc.

1111 Stanley Drive
Euless, Texas 70039
East Coast: Barfield Instruments Corporation

4101 N.W. 29 Street
Miami, Florida 33142
Canada
Western Rpgion: Pacific Avionics

Vancouver Internat;ion Airport
Vancouver, B.C.
Eastern Region: Wright Instruments Ltd.

27 62 Slough St.
Mississauga, Ontario
Greece
Nicos Gr. Drettas

12 Messogion Ave. and 2,
Farantaton Str.
Athens, 610, Greece
Singapore
Hell-Orient (PTE) Ltd.

Jalan Kayu Post Office Box No. 17
Singapore 28
(East Camp, Seletar Airfield)
t
LET TER NO. DL- 1 O
~nughes Helicopters
DATE: 22 May 1978
PAGE: 8 of 9
India
Indian Avitronics
Flat No. 1
10 Hailey Road
New Delhi
India 110001
West Ce rmany
Mote rflug GMBH
Flughafen
7570 Badeb-Baden
West Ge rmany
South America
Braxil Arthur G. Hirsch LTDA

Rua Rafael Iorio, 67-CJ. 709
CX. Postal 18666
Sao Paulo SP Brasil
C
Bolivia Mr. Peter Koechlin Von Stein
Aero Ai~des LTDA
Edificio Literal
Piso 11
Calle Colon 140
La Pat, Bolivia
Chile Mr. Albert Le Blane

Valport LTDA
Bandera 75-OFS. 106-108
Santiago, De Chile
Columbia James Leaver, Sr.

Aero Me rcantil LTDA
Apt. Aereo 6781

Bogota, Columbia
Peru Mr. Pedro Larranaga

Aero Comercial Peruana S. A.
Las Magnolias 791
Oficina 702-703
SanIsidro, Lima, Peru C
LETTER NO. DL-10
Hughee Helicopters 22 May 1978
PAGE: 9 of 9
Venezuela Taven SRL;
Aeropue rto International

Maiquetia, Veneauela
E gypt
Mr, Kamel Abdel Fattar

#30 Abbel Rahin Sabry
Dokki, Cairo, Egypt
C-:
LETTER NO. DL-11
DATE 26 June 1978

HUGH ES 1
PAGE 1 OF
SERVICE INFORMATION
LEI IER
SUBJECT: REDUCTION GEARBOX, MODEL 250-C20B ENGINE TIME

BETWEEN OVERHAUL (TBO) REQUIREMENT ELIMINATED
MODELS AFFEC TED: All 500D Model 369D Helicopter s
R efer enc e
FAA-DER Approved DDA Telex to Hughes Helicopters, dated 12 January 1978

Detroit Diesel Allison Operation and Maintenance Manual
Turboshaft Engine Model 250-C20B, 10W2
500D Basic HMI-Volume i, Issued 15 September 1976; Revision No. i,
15 November 1977
5000 Basic HMI-Volume 2, Issued 15 September 1976; Revision No. i,
14 January 1977
The designated time between overhaul(TBO) for the Model 250-C20B engine
reduction gearbox has been eliminated and the reduction gearbox is now to be
considered an "on condition" item.
This.FAA-DER approved data will be incorporated in the next scheduled revision

to the above referenced Allison Engine Operation and Maintenance Manual and will
also be reflected in a forthcoming Allison Commercial Service Letter.
For further information, contact Detroit Diesel Allison Division of GMC.
k=t
Hughes Helicopters
Customer Service Department -Hughes Helicopters Culver City, California
FORM NO. 98788 HTC~D REV. 11.67

LETTER NO. DL12
DATE 8 September 1978

HUGHES r
PAGE 1 OF
SERVICE INFORMATION
LETTER
SUBJECT: PARTICLE SEPARATOR INSTALLATION INSPECTION AND

POSSIBLE REMOVAL OF CIRCULAR FILTER SCREENS
MODELS AFFECTED: 500D Model 369D Helicopters equipped with PN 369H90148-503

or -505 Particle Separator Kit
Re fe r enc e
500D HMI-Volume I, Issued 15 Sept 1976; Revision No. i, 15 Nov 1977

369D Optional Equipment Lnstallation and Maintenance Instructions, Engine Air Inlet
Filter, PN 3691-190148-503 or -505, dated 15 May 1976
Field reports indicate that the circular, fine mesh screens which snap on the
forward end of the particle separator filter have become worn, broken or lost
in servic e.
If inspection reveals that one or more of these 80 plastic screens are damaged or
broken, they can be removed and need not be replaced. Operation of the engine air
filter system is permissible, with or without the plastic screens installed.
It is to be noted that early configuration particle separator filters did not

incorporate these fine meshed screens.

Hughes Helicopters
FORM NO. 95788 HTC-*D REV 11-67

LETTER NO. DL-15
DATE 29 December 1978

HUGHES 1
PAGE 1 OF
SERVICE INFORMATION
LETTER
SUBJECT: FINITE PART LIFE TAIL ROTOR DRIVE SHAFT FLEX
COUPLINGS, PN 369A5501 AND 3691192564
Reference
500D Basic HMI Vol II, Issued 15 September 1976; Revision No. i, 14 January 1977
tail rotor drive shaft flex couplings is

The finite part life for both of the subject
4980 hours total time in service.
The PN 369A5501 flex coupling is the standard configuration; the PN 369H92564

installed as optional
coupling is used when the PN 369H90123 rotor brake is
equipment on the Model 500D helicopter.
and will be
The above limited life data is to be considered as part of the HMI
in the next scheduled revision to the above-referenced HMI Vol LI.
incorporated

Hughes Helicopters
FORM NO. 95788 H.Tt-AO REV 11-67

LETTER NO. DL-18
DATE 20 July 1979

HUGHES 1
PAGE 1 OF
SERVICE INFORMATION
LETTER
TO-Ail owners and operators of Hughes Helicopters
SUBJECT: APPROVED IGNITER ASSEMBLIES AND IGNITION EXCITER ASSEM
BLIES FOR MUCHES PN 369H90118 SERIES AUTOMATIC ENGINE
REIGNITION KIT INS TALLATIONS
MODE LS AF FE C TE D: All 500D Model 369D Series Helicopters equipped with

PN 3691-190118 Series Automatic Engine Reignition Kit
Re fe re nc e
500D Basic HMI-Trolume I, issued 15 September 1976; Revision No. 3, 15 March 1979
IPL and Maintenance Instructions for PN 369H90118 Series Engine Automatic Reignition
Kit Installation, Publication No. CSP-003, Issued 15 May 1976
The following igniter assemblies and ignition exciter assemblies are approved for use
with the PN 3891-190118 Series Automatic Engine Reignition Kit installed on Hughes
Model 500D Series helicopters:
Igniter As semblie s
(Champion) Allison Part No. 6843984
(AC Spark Plug) Allison Part No. 6874271
(AC Spark Plug) Allison Part No. 6877418
Ignition Exciter Assemblies
(Simmons Precision) Allison Part No. 6895573
(GLA) Allison Part No. 6870885
(Bendix) Allison Part No. 6870891
It is to be noted that the above igniter assemblies and ignition exciter assemblies are
and equally compatible for the Allison

provided as original engine equipment are
Model 2 5 0- C2 OB engine,

Hughes Helicopters
11-67
LETTER NO. DL-lq
1 August 1979
I
DATE
H ~IG%-B ES
PAGE 1 OF 1
SEFS~ICE PNFBRMB~TIOIV
LET~IEIR
TO---AII owners and operators of Hughes Helicopters
SUBJECT: OPERATION AND MAINTENANCE GUIDELINES FOR MODEL 250-C20B

ENGINE FUEL SYSTEM
Refer ence
Detroit Diesel Allison Commercial Service Letter CSL-1080, dated 11 May 1979
500D Basic HMI-Volume I, Issued 15 September 1976; Revision No. 3, 15 March 1979
The attached Allison Commercial Service Letter CSL-1080 lists basic guidelines for
maintenance and operation of the Model 250-C20B engine fuel system.
It is recommended that these guidelines be used by owners and operators of Hughes

Model 369D helicopters to help preclude engine fuel problems and ensure reliable
fuel system service.

Customer Service Department:
Hughes Helicopters
Customer Service I)epc~rtment Hu~hes Nellcopters Culver City, California
FORM NO. 9578R HIC-*D REV 11-67

2 50- C20 /C20B CS L 10 80
COMM ERCsAe LETTER
itc~ DetrPit Diesel Allisen

Oivision of General Motors Corporatio
y11,
aM5
Page 1 of
~979
FAA-DER Approved
SUBJE CT: Model 250 Fuel System Operational and Maintenance

Guideliner
The purpose of this CSL is to provide a summary of operational and

maintenance guidelines for the Model 250 engine fuelsystem. It is
advisable that both pilots and maintenance personnel utilize this information
to best prevent problems such as flamoouts and power
I~Se
1. The engine demands clean, dryfuel. Refer to FM Advisory

~4
Circular No. 00-34, "Aircraft Ground Handling and Servicing",
paragraph 8, "Aircran Fueling" for important tips on fuel
handling.
2. The aircraft fuel tanks and related system must be clean.

Mainiain and clean the fuel tan&s and Lines according to ihe
i,,,,,,,,, in the airframe manual. Drain
the fuel tank sump daily in accordance with the aircraft
flight manual.
3. All fuel lines must be properly torqued. It is possible to have

a leak in
a line, anywhere from the tank to the outlet of the
fuel
.engine fuel nozzle, which will "suck" air but wont leak fuel. A
slug of air to the fuel nozzle may cause a flameout.
4. If the aircraft flight marmal
"on: then they must be "on"

head of pressure to the engine pump, but will reduce the probability
of "sucking" air thru a tiny fuel line leak.
5. The uncovering of a fuel boost pump or the fuel inlet fitting in

thetank, due to a low fuel level and/or flight manuever, can
result in a slug of air entering the engine fuel system.
~t
250-C20/C20B CSL-1080
Page 2
COMMERCIAL SERVltE LETTER

AND MAINTENANCE GUIDE LINES
c
MODE L 2 50 FUE L
6. All pneumatic lines, double check valves, and accumulators must

be properly torqued with special care to avoid any twists that may
develop cracks later on. A leak in the pneumatic section can cause
erratic operation, power loss, or a flameout.
7. If the aircraft has an engine fuel filter differential pressure warning

system, it must be checked periodically for proper operation. De-
pressing the caution light in the cockpit in most installations only
confirms that the light bulb is functional, hence, a functional check
of the total system is necessary. Refer to the aircraft maintenance
manual for instructions,
8. The fuel pump filter (low pressure) is not cleanable. Current

engine
instructions in the engine maintenance manual require that this filter
be replaced only when the engine fuel filter differential pressure
warning system indicates filter contamination. If the aircraft is not
equipped with a fuel filter differential pressure- warning system the
filter must be replaced every 300 hours unless operating experience
demonstrates that lower time increments are advisable. DDA NOW
RECOMMENDS THAT THE LOW PRESSURE FUEL FILTER BE
REPLACED EVERY 300 HOURS (regardless of whether the aircraft
C
has a differential pressure warning system) or whenever the warning
system is activated, whichever comes first,
CAUTION: Some operators have inadvertently installed the old ten

micron low pressure fuel filter (P/N AN6235-3A) in place
of the recommended five micron filter (P/N 6895177). This
is a critical for those engines utilizing CECO
item, especially
fuel systems. Please inspect your engine and spare stock
to ensure the correct filter is installed. The ten micron filter
is identifiable by its brown paper element, whereas the five
micron element contains a wire mesh surrounding a white
element.
9. The engine fuel pump will not pump fuel with a sheared spline.
Certain Sundstrand pumps require periodic backlash checks or visual
inspections for spline wear. Refer to the engine operation and maintenance
manual for instructions.
10. If the low pressure fuel filter has bypassed, the CECO control and
governor should be flushed per DDA CSL-~034 and CSL-~035.
250-C20/C20B CSL-1080
P~e 3
COMMERCIAL SERVICE DETTER

MODEL 250 FUEL SYSTEM-OPEIRATI~MAL AND MAINTENANCE GUIDELINES
11. DDA CEB-P095 recommends inst~laeion of a high pressure fu.el

filter assembly if the engine is equ-ipped with a CECB system.
If you have the CECO system and dont Bmaa~e the high pressure
fuelfilter, please get one,
12, The high pressure fuel filter ~aas done a tremendous job in reducing
the number of incidents resulting from contaminated CECO controls
and governors. Now that the filter has been in service for several
years, it is evident that additional :naineenance is necessary. DDA
NOW RECOMMENDS THAT THE H"RESSUPSE FUEL FILTER
ELEMENT BE WEPLACED WITH a. Nlew OR THOROUGHLY CI,EAN
ELEMENT AI\TD THAT THE BY-BASS VALVE BE INSBECTED FOR
WEAR EVERY 100 HOURS. See the B~ November 1978 revision to
Operation and Maintenance Manual for by-pass
the C2(i valve
assembly wear inspection,
13. Recent information provided to QA4Pa revealed that ultrasonic

cleaning of high pressure filter may not provide the best renlov;il
of imbedded contaminates. Therefore, the following procedure
C is recommended as a primary and/or additional method,
a. Fill the inside of the filter with a clean liquid bio-degradable,

undiluted, dishwashing detergent, such as Joy, Ivory,
Palmolive, Dove, Dawn, AmMray k,O.C.,

etc, Immerse into a container of undiluted detergent.
b. Lee the detergent soak for a minimum of 5 minutes.

Then remove from container.
c. Apply filtered shop air to the inside of the? filter thru

the opening forcing detergent out via
in the end cap,
convolution/pleats. Repeat application of detergent
and water flush.
d. Run hot clean water into the inside of the Filter thru the
hole, until the water suns clear of soap bubbles and
cont;sminates. The more efforr~ e~pended will result in
a cleaner Filter element,
e. Remove excess moisture.

250-C20/C20B CSL-~080
Page 4
COMMERCIAL SERVICE
LETTER ,J
AND MAINTENANCIE GUIDELINES
MODEL 250 FUEL SYSTEM-BPERATIONAL
14. Quickcheck for Filter Element cleanliness.

CAUTION: P3e aware of the potential fire
hazard when using
the below procedure.
flat bottom container with fuel or Stoddard solvent,

a. Fill a
at ~tpl?roximately room temperature, to 1 3j~d 1/16 inch

~his is level which will. cover the convolutions/
deep, a
but does not reach the center

pleats; opening with the
element st,znding upright-open end on toy?.
b. Throughly wet the filter element media with fuel or

This can
Stoddard solvent to reduce surface tension
be accomplished by forcing the liquid through the element
tube in the element
utilizing a 3/8 inch outside diameter
opening and forcing fuel thru.
Pour out any liquid from the inside and

immerse the element in
the above contai.ner.

I,
inside the
Determine the time it takes for the fluid to rise
element to the level of the surrounding liquid.
If cleaned sufficiently, the element should fill within 5 seconds.
if necessary. If unable to meet

Repeat cleaning procedures
the element with one that meets
the 5 second limit, replace
the 5 second limit.
accumulate
15. The pneumatic lair) circuit of the Bendix System will
of
dirt during normal operation. The Troubleshooting section
the C20 Opera.tiorr and Maintenance Manual currently lists
troubles that can be corrected by cleaning the Bendix air
circuit. The manual also provides instructions for proper
cleaning. DDA NOW RECOMMENDS THAT THE BENDIX
AIR CIRCUITS I3E CLEANED EVERY 300 HOURS.
250-C20/C20B CSL-~080
Page 5

SWTEM-OPERATIONAL A ND MAINTENANCE GUIDELINES
MODEL 250 FUEL
The DDA Operation and Maintenance

Manual recommends a
16.
DDA CSL-~047
postflight deceleration check of the Bendix system.
the CECO system.
recommends a daily deceleration check for
These deceleration checks are a good method impending
to uncover
DDA RECOMMENDES THAT A POSTFLIGHT

DECELERATION
problems.
BENDM AND CECO
CHECK BE CONDUCTED ON BOTH THE
S YS TE MS
~7. Rigging to the fuel control and governor is veryimportant. Dont

in
overlook the aircraft and engine manual requirements. Wear
the linkages can sneak up on you and cause a flameout.
18. Co over the again. if there is something you dont

above list
of
understand, please ask questions. The reliable operation
your engine is your responsibility.
L. O. Davidson
Service Manager
Gas Turbine Engines
NJB/bw
LETTER NO. DL-21

HUGHES 3
PAGE 1 OF
SERVICE I N FOR MATION
LETTER
SUBJECT: NEW COMFORT CLIPS FOR SEAT BELT AND SHOULDER HARNESS
ASSEMBLIES, PN 3691-16541, 369H6541-21, 369H6541-23, AND
369H6541-25
MODELS AFFECTED: 500D Model 369D Helicopter Serial No. 0003D

thru 0604D
Reference
369D Series Basic HMI Volume I, issued 15 September 1976
A new comfort
clip (PN E3403) designed to maintain proper strap tension, and
relieve excessive pressure of the inertia reel shoulder harness on the
pilot or
passenger during flight, is
now available for the above affected
helicopters
equipped with Sam Browne seat belt assemblies.
After each seat belt and shoulder harness

assembly is fastened and adjusted for
individual comfort and safety, the comfort clip is moved from its original
position next to the buckle and relocated by sliding up on the harness strap as
close as possible to the inertia reel(see Figure i). The clip prevents any
further retraction of the strap into the inertia reel, thus keeping a constant yet
comfortable tension of the harness strap against the pilot or passenger. After
each flight, the comfort clip is to be returned to its original location on the
harness strap next to the buckle.
The comfort clips may be obtained without charge by contacting year authorized
HH Service Center. Please order by helicopter Serial Number; and specify four
PN E3403 comfort clips and three PN 369D24042-3 decals for each helicopter.
Hughes Service Centers may procure the comfort clips by contacting Warranty
and Repair.

Hughes Helicopters
FORM NO. 98788 HTCID REV L1-61

LETTER NO. DL-21
DATE: 10 December 1979
Hughes Helicopter.
PACE: 2 of 3
DECAL
CENTER DECAL BETWEEN END OF

DOOR FRAME PANEL AND FIRST SCREW.
o
VIEW LOOKING OUTBOARD
FROM OF SHIP
TO LH SIDE
TO APPLY DECAL: (NOTE 2)
1, CLEAN DOOR FRAME AREA WHERE DECALS ARE

TO BE APPLIED. DECALS WILL NOT ADHERE (NOTE 1)
TO A CREASY OR SOAPY FILM.
2. MARK LOCATION OF DECAL PER THE ILLUSTRATION.

O
REPEAT ON THE OTHER DOOR FRAME,
COMFORT CLIP INSTALLATION
3. PEEL BACKING OFF DECAL AND POSITION, USE A

CLOTtl TO SBUEEZE ALL BUBBLES FROM UNDER THE (NOTE 3)
DECAL, WORKING FROM THE CENTER OUTWARD.
REPEAT ON THE OTHER DOOR FRAME.
fi
TO INSTALL COMFORT CLIP:
i. PRY OPEN SLOT ON UNDERSIDE OF CLIP.
2. INSERT HARNESS STRAP IN SLOT,
AFTER SEAT BELT AND SHOULDER HARNESS ASSEMBLY

IS FASTENED AND ADJUSTED FOR INDIVIDUAL
COMFORT AND SAFETY:
3. SLIDE COMFORT CLIP UP ON HARNESS STRAP

AND POSITION AS CLOSE AS POSSIBLE NEXT
TO INERTIA REEL.
AFTER EACH FLIGHT:
REPOSITION COMFORT CLIP ON HARNESS STRAP

AT ORIGINAL POSITION NEXT TOBUCKLE.
(NOTE 4)
88-2188
Figure i. Comfort Clip Decal~Application

And Clip Installation Instructions
LETTER NO. DL-21
L
~nughas Hslicopten DATE: 10 December 1979
PACE: 3 of 3
I
nY
SHIP
DECAL
5.00,25 INCHES
PANEL ASSEMBLY
TO APPLY DECAL:
1. CLEAN PANEL AREA WHERE DECAL IS TO BE

APPLIED, DECAL WILL NOT ADHERE TO A
CREASY OR SOAPY FILM.
2. MARK LOCATION OF DECAL PER THE ILLUSTRATION,
3, PEEL BACKING OFF DECAL AND POSITION, USE A CLOTH
TO SQUEEZE ALL BUBBLES FROM UNDER THE DECAL, WORKING
FROM THE CENTER OUTWARD.
88-350
Figure 2. Comfort Clip Decal Application Rear Seat

LETTER NO. DL-24
DATE 18 APRIL 1980

HUGHES PAGE 1 OF 2
SERVICE INFORMATION
LETTER
ENGINE COMPRESSIOR CLEANING DAILY WATER RINSE AND

SUBJECT:
PERIODIC WATER WASH
MODELS AFFECTED: All 500D Model 3691) Series Helicopters
Reference
Issued 15 September 1976; Revision No. 3, 15 March 1979

369D Basic HMI Volume I,
Service Informntion Notice No. DN-17,
dated 6 February 1978
Hughes
and Maintenance Manual,
Detroit Diesel Allison Model 250-C20 Engine Operation
Publication No. 10W2
Manual
The above referenced DDA Model
250-C20 Engine Operation and Maintenance
two different methods to be used

for cleaning engine compressor components
specifies
helicopters operating in a corrosive

First, a daily water rinse is recommended for
particles from the
environment, to remove any contaminants and corrosive air
cleaning solvents, and is
compressor. daily water rinse uses no soap or
This
(Pc) sensing
accomplished without disconnecting the compressor discharge
pressure
tube. A five minute required

ground run is to purge and evaporate any residual water
water
after rinsing. Hughes PN 369H92437 engine compressor
It is to be noted that
later Model 500D helicopters) is
wash kit (installed as standard equipment on
with a clean water spray only.
designed specifically for compressor rinsing
For helicopters operating in smoggy areas, aperiodic (200 to 300 hours) compressor
to
water wash is also recommended. The periodic water wash uses cleaning solvents
dirt buildup in the compressor. The P, tube must therefore be disconnected
remove
into the controls
and the opening capped prevent introduction of chemical agents
to
connection during the wash operation.

system Pc
FDRM NO 95788 HTC-*O REV 11-67

I.ETTER NO, I)L-24
~b HUBhsl Mslic~er6
DATE 18 APRIL 1)80
PACE 2 OF 2
Whether rinsing with a clear water spray or washing with cleaning solvents, it is
important that owners and operators adhere to the compressor cleaning procedures
specified in the engine maintenance manual.
Edward Koch, ~vlanager

Hughes Helicopters
LETTER NO. DL- 24
DATE 26 May 1980

HUGHIES 1
P~GE 1 OF
SERVICE INFORMATION
LETTER
PN 369D23bOO
SUBJECT: NEW S.EAL REaUIREMENT FOR OVERHAUL OF
AND 369D23601 LANDING GEAR DAMPER ASSEMBLIES
MODELS AFFECTED: All 500D Model 369D Helicopters~
Refe rence
500D Basic HMI-Volume I, Issued 15 September 1976; Revision No. 3,

15 March 1979
500D Illustrated Parts Catalog, Publication No. CSP-D-4, Reissue No. 2,

15 January 1979
IPL and Maintenance Manual for Extended Landing Gear Installation,
PN 369D290007, -401 and -503, Publication No. CSP-001, Reissued 15
15 November 1979
IPL and Maintenance Manual for Extended Landing Gear Installation,

PN 369D290007-507, Publication No. CSP-065, Issued 14 March 1979
A new PN 369D26304 piston seal is now to be installed as replacement for the
existing PN A2046 seal during reassembly and overhaul of the subject poppet
type landing gear damper for Model 500D helicopters.
Use the attached errata sheets to incorporate the replacement 369D26304 seal
in the 500D Illustrated Parts Catalog, and in the parts listings for the above
referenced optional equipment IPLs and Maintenance Manuals.
:fl

Hughes Helicopters
Customer Service Department Hu~hes Helicopters Culver City, California
11-67
LETTER NO. DL-27

HCJG#ES 1 2
PAGE OF
SERVICE INFORMATIQN
LETTER
SUBJECT: COMPLIANCE WITH FAA AIRWORTHINESS DIRECTIVES AND

MUCHES MANDATORY (RED BORDER) SERVICE INFORMATION
NOTICES
MODELS AFFECTED: All 400D Model 369D Series Helicopters maintained by

Hughes Service Center or Distributor
Re fe re nc e
Hughes Helicopter/Hughes Service Center and Distributor Policy Agreement
Model 500D Series Helicopter Log Book Compliance Record

Applicable
A policy covering compliance with FAA Airworthiness Directives and mandatory

new
C (red border) Hughes Service Information Notices is now in effect for all Model 500D
Series Helicopters maintained by authorized Hughes Service Centers and Distributors.
In the future, the above 500D helicopters compliance with all

must have a record of
FAA
applicable Hughes Service Information Notices (red border), and all applicable
before releasing the helicopter for
(or equivalent government agency) AD notes,
flight.
If non-compliance is noted in the helicopter Log Book Compliance Record, the

Hughes Service Center or Distributor must notify the owner/operator
in writing.
If the owner/operator declines to comply, the Service Center or Distributor must
receive such a declaration in writing, and the written declination kept on file by
the Service Center or Distributor.
Commercial Service Publications Department distributes

It is to be noted that Wughes
Model 500D Notices and Letters to all Hughes Service Centers and Distributors.
However, it is the responsibility of the Service Center and Distributor to obtain and
maintain an active FAA file (or equivalent foreign government documents) including
ADs applicable to the 500D Series helicopter.
(_
FORM NO 9~788 HTC-ID REV 11.67

LETTER NO. DL-27
Hughes Helicopters DATE 30 September 1980

PAGE 2 OF 2
in forthcoming amendment to the

The abovepolicy changes will be included a
Center and Distributor poiicy agreement.

Hughes Helicopters Hughes Service

Hughes Helicopters
C
LETTER NO. DL-28

HUGHES PAGE 1 OF 2
SERVICE INFORMATION
LE i r ER
PERIODIC INSPECTION AND CLEANING OF PN

369D290124-21
SUBJECT:
MIST ELIMINATOR ASSEMBLY
Helicopters equipped with

MODELS AFFECTED: All 400D Model 369D Series
369H90148-509 Engine Air Inlet
PN 369H90148-507 or
Filter (Particle Separator) Assembly
Reference
Revision No. 3, 15 March 1979

400D Basic HMI-Volume I, Issued 15 September 1976;
IPL and Maintenance Instructions for 3691-190148-507 and -509 Engine Air Filter
No. CSP-004, Reissued 4 April 1980
(Particle Separator), Publication
C Field reports indicate that
relatively short period of time, when operating

assembly can occur in a
clogging of the mist eliminator
the helicopter in areas where there
loose leaves. When operating in such areas
is lightweight debris such as cut grass or
may be desirable
to remove and inspect
.where rotor blast will cause flying debris, it
clean the mist eliminator more frequently than normal.
or
is indicated by a
Partialclogging particle separator and/or mist: eliminator
of the
warning light on the instrument panel. However, if the TOT gage shows a moderate
increase in operating temperature with everything else being
normal(OAT, power,
mist eliminator and a check
may indicate a partially plugged separator
or
etc. it
CSP-004 for
Refer to the above referenced Publication No.
re-
is recommended.
for the particle separator and mist
moval, inspection, and cleaning instructions
eliminator assemblies.
with lightweight debris, it may

If the mist eliminator has become partially clogged
from the front face of the eliminator to
only be necessary to remove the debris
of the eliminator can be accomplished.
allow continued operation until normal cleaning
Temporary cleaningcan be by shaking, brushing the surface, or blowing

accomplished
If the debris is lodged in the wire mesh of
air from the back side of the eliminator.
the eliminator, steam or solvent application may be required.
C\
Customer Service Department Hug;hes Helicopters Culver City, California
F6RM NO. 9578~ HTC-~0 REV 11-67
-Laiiill-- 7 u
LETTER NO. DL-28
E~ Huehes Helicopters DATE 30 September 1980

PAGE 2 OF 2
It is to be noted that: the mist eliminator is of all stainless

steel construction
solutions.
and therefore will not be harmed by conventional metal cleaning
alkalies may
A hot water spray and/or any household cleaner not containing
be
be used. Also, solvents normally used for cleaning alumini~m parts may
used. Be to a thin film of engine oil on both faces of the mist
sure spray
eliminator prior to reinstallation.
2R-R P~
Hughes Helicopters
C
LETTER NO. DL-29
DATE 5 January 1981

HUGHES 1
PAGE 1 OF
SERVICE INFORMATION
LETTER
NOW PERMISSIBLE
Subject: NIGHT FLIGHT OVER WATER WITH FLOATS
INSTALLED
WITH PN 369D292032 NIGHT LANDING LIGHT KIT
Models Affected: All Model 500D Series Helicopters equipped with

PN 369D290086 Series Utility Feats or PN 369D290121
Series Emergency Float Kit Installation
Reference

500D HMI-Volume I, Issued 15 September 1976;
500D Rotorcraft Flight Manual, Publication No. CSP-D-1, Issued
8 December 1976, Revised 10 March 1980
500D Rotorcraft Flight ManualSupplement, Publication No. CSP-D-1G,

PN 369D290121 Series, Issued
Rotorcraft Emergency Floats,
15 June 1977, Revised 28 November 1979
500D Rotorcraft Flight Manual Supplement, Publication No. CSP-D-1M,
10 August 1978,
Rotorcraft Utility Floats, PN 369D290086 Series, Issued
Revised 28 November 1979
available for
An optional Night Landing Light Kit PN 369D292032 is now
kit installations,
Model 500D helicopters equipped with utility or emergency float
to permit night flight over water, and night landing

and takeoff operations
with floats installed.
The night landing light primarily of dual belly-mounted sealed

kit consists
installed
beam lights, relays, a circuit breaker, and a.three-position switch
on the collective control. Forward position illuminates the standard nose

illuminates the
mounted landing light; center position is off; and aft position
belly landing lights.
For further information, contact your Hughes Service Center or Distr~3utor.

Hughes Helicopter s
Culver City, California

Customer Service Department Wi~ghes Helicopters
InnM NO RJ~I1B L(T~-AD HEV 11-67

McDonnell Douglas HL-71.12*//
DL-30.12*
EL-8.6*
Helicopter Systems 07
n-25.4*
ApFil 1995
SERVICE INFORMATION LETTER Page 1 of 3
"Supersedes Service Information Letters HL-71.11, DL-30.11, EL-8.5 and FL-253,

dated 20 March 1992.
TO: ALL OWNERS AND OPERATORS OF MCDONNELL DOUGLAS

HELICOPTER SYSTEMS HELICOPTERS.
SUBJEC~ ANNUAL LISTING OF FEDERAL AVLATION ADMINISTRATION

AIRWORTHINESS DIRECTIVES AFFECTING MDHC HELICOPTERS.
The attached listing covers all active FAAAirworthiness Directives issued for 369H, 369D,
3693 and 369FF Series helicopters through February 1995. Opposite each entry is listed
the applicable MDHS Service Information Notice which is associated with the Airworthi-
ness Directive. In some cases, associated infonnation is supplied by the vendor of the af-
fected component or system. This listing will be updated annually.
t. ii
~2--
J
Jt~hn Reagan, Manager,

MD500 Customer Support Dept.
McDonnell Douglas
Helicopter Systems
Commercial Customer SuppMt
McDonnell Douglas
FORM 95788 (AEV 1/94)
Helicopter Syst~ems
LETTEEND.: HL-71.12*
DL-30.12*
EL-g~6*
FL-25.4"
DATE: 07 April 1995
Page 2 of 3
APPLICABLE MDHC SERVICE NOTICULEITER
AD Number SUBJECT 369H 369D 369E 369FF

69-21-01 T/R TRANSMISSION INPUT SHAFT INSPECTION HN-1.1
70-16-07 M/R BLADE INSPECTION HN-8
72-16-09 Tm GEARBOX OVERHAUL SCHEDULE HN-53.1
72-1&04 VNE LIMITATIONS HN-45
74-07-02 ALUMINUM T/R BLADE INSPECTION HN-65
74-20-04 MAIN ROTOR BLADE INSPECTION HN-73
75-06-02 CARGO RACK INSPECTION
75-09-17 PROTECTION OF PASSENGERS HN-91
75-10-04 T/R BLADE INSPECTION HN-83
75-22-03 Tm DRIVESHAFT INSPECTION HN-BG
75-22-04 INSPECTION OF FIBERGLASS T/R BLADES IHN-88

76-19-03 INSPECTION OF SHOCK-MOUNTED STABILIZER STRUT AS- HN-102.3
SEMBLY
77-05-03 INSPECTION OF T/R CONTROL SYSTEM i" IDN-l

77-09-01 EMERGENCY FLOAT REWORK HN-114
77-15-09 R1 AD SUPERSEDED BY 89-02-01 R1
77-19-03 M/R RETENTION STRAPS INSPECTION i" IDN-154

77-1 9-04 AD SUPERSEDED BY 89-02-01 R1 I- I- I- I_ I
77-21-04 INSPECTION OF OVERRUNNING CLUTCH ASSEMBLY HN-188.2 ON-9.2
78-20-03 INSPECTION OF FIRE SUPPRESSION SYSTEM r
78-26-04 T/R HUB ASSEMBLY INSPECTION HN-128.1 DN-27.1

79-10-09 Tm PITCH CONTROL ASSEMBLY INSPECTION i IDN-37
79-18-11 R1 AD SUPERSEDED BY 8911-08
80-24-04 AUTO-REIGNITION PLACARD RELOCATION HN-160 DN-100

80-25-01 T/R DRIVESHAFT COUPLING NONE NONE
81-07-10 R1 AD SUPERSEDED BY 90-19-02
81-10-08 AD SUPERSEDED BY 89-02-01 Rt
81-17-02 R1 AD SUPERSEDED BY 8620-07
81-26-01 R1 M/R DRIVESHAFT INSPECTION i" IDN-99

82-01-08 RPM GOVERNOR CONTROL ROD REPLACEMENT HN-169 DN-B7
82-14-01 INSPECTION OF AUXILIARY FUEL SYSTEM r in
82-1 7-01 MIR TRANSMISSION RING GEAR CARRIER INSPECTION I DN-148.1

84-01-02 R1 MIR SWASHPLATE BEARING INSPECTION HN-191 DN-125 EN-12
84-11-01 INSPECTION OF LOGITUDINAL CONTROL ROD i" i" IEN-13.1
84-12-01 RI CIRCULATION OF BOGUS M/R BLADES i" IDL-SI EL-5
84-1&-08 AD SUPERSEDED BY 86-01-04
85-18-02 Rf INSPECTION OF T/R BLADES HN-197.2 DN-130.2 EN-19.2 FN-17.1

86-01-04 RIVETING T/R BLADE TIP CAP (Supersedes
84-18-08) HN-195 DN-129 EN-18 FN-9.1
HN-1 99.1 DN-132.1 EN-21.1
86-19-12 ENGINE TURBINE INSPECTION I I* I* In
LETTER NO.: HL-71.12*
DL-30.12*
EL-8.6"
FL-25.4"
DATE: 07 April 1995
Page 3 of 3
APPLICABLE MDHC SERVICE NOTICE/LEITER
AD Number SUBJECT 369H 36913 369E 369FF
86-20-07 T/R DRIVESHAFT FAILSAFE DEVICE INSTALLATION (Super- HN-206.1 DN-143.1 EN-31.1
sedes 81-17-02)
87-18-11 M/R TRANSMISSION T/R OUTPUT PINION INSPECTION I* IDN-147.1 EN-35.1 FN-24.1
87-18-12 R1 M/R TRANSMISSION RING GEAR CARRIER INSPECTION I* IDN-148.1 EN-36.1 FN-25.1
88-10-04 R1 I OVERRUNNING CLUTCH OUTER RACE INSPECTION HN-215.1 DN-156.1 EN-46.1 IFN-34.1
8&17-09 R1 INSPECTION OF TAIL ROTOR TRANSMISSION MOUNTING I* IDN-151 EN-39 FN-28

STUDS
89-02-01 R1 M/R HUB STRAP PACK INSPECTION AND TRI-FLOW WASH HN-214 DN-154 EN-44 FN-33
PROCEDURE (Supersedes AD 77-15-09 R1)
89-11-05 FINITE LIFE REDUCTION OF TAIL ROTOR STRAP PACK AS- HN-219
SEMBLY
89-11-08 SUPERSEDED BY AD 90-20-15
89-20-02 ONE-TIME INSPECTION OF FOUR-BLADED T/R HUB AS- I* JDN-160 EN-50

SEMBLY
89-23-14 INSPECTION AND REWORK OF MAIN AND TAIL ROTOR TUN- HN-217.1 DN-158.1 EN-48.1 FN-36.1
NEL-ROUTED CONTROL TUBES
90-01-08 ENGINE-TO-TRANSMISSION COUPLING INSPECTION/AE- HN-216 DN-157 EN-47 FN-35

PLACEMENT
90-12-03 TAIL ROTOR SWASHPLATE BEARING INSPECTION/REPLACE- I f

1DN-167 EN-SB FN-46
MENT
90-1 902 OVERRUNNINGCLUTCH INSPECTION/RNVORK (Supersedes If I DN-164.1 EN-54.1 FN-44.1

AD 61-07-10)
90-24-07 ONE-TIME INSPECTION AND REPLACEMENT OF AIR INDUS- I* I DN-166.1 EN-57.1 FN-45.1
TRIES MS21250-04036 BOLTS
91 -0&02 TAIL ROTOR BLADE ROOT FlmNG INSPECTION HN-230.1 IDN-ITI.1 EN-68.1 FN-55.1
93-07-10 UCTERNAL CARGO CONTAINER KTT (BAGGAGE POD) NONE NONE NONE NONE
93-18-05 INSPECTION/REWORK OF FUEL VENT SYSTEM (HELICOP- HN-234.1 DN-181.1 EN-73.1 IFN-60.1
TERS EQUIPPED WITH 369H8108, 369H8108-501 OR
369H8108-503 FUEL VENT LINE EMERGENCY SHUT-OFF
VALVE)
94-18-08 ONE-TIME INSPECTION OF TAIL ROTOR BLADE LEADING HN-197.2 DN-130.2 EN-19.2 FN-17.1
EDGE ABRASION STRIP BONDING, PILOT PREFLIGHT CHECK HN-232 DN-179 EN-70 FN-57
OF TAIL ROTOR BLADE LEADING EDGE ABRASION STRIP
Supenedes AD 92-02-15 and 92-24-14)
94-24-04 TAIL ROTOR SWASHPLATE LOCKWASHER INSPECTION I* IDN-185 EN-78 FN-64
95-03-11 1 TAIL ROTOR BLADE ABRASION STRIP MODIFICATION HN-238 DN-187 EN-80 FN-66
95-03-13 M/R BLADE ROOT FITTING INSPECTION: LEAD-LAG LINK HN-211.4 DN-51.6 EN-42.4 FN-31.4
INSPECTION (Supenedes AD 91-17-04)
Not Applicable
Vendor supplied maintenance information

LETTER NO. DL- 31
DATE 13 March 1981
E~SI
HUGH ES PAGE 1 OF~
SERVICE IN FORMATION
LETTER
SUBJECT: SUBSTITUTION OF WET SPLINE DRIVE STARTER-GENERATOR

FOR EXISTING DRY SPLINE DRIVE STARTER-GENERATOR
MODELS AFFECTED: 500D Model 369D Helicopter

Serial No. 00031) through 0993D
A wet spline drive will be applied to all 500D Model 369D helicopters beginning
with serial number 0994D (Allison engine number productionCAE833741). This
will reduce and associated gearbox

replacement and costs for both
change wear
starter-generator drive splines. A modification kit is available for replacement

of existing dry spline drive, if desired, during engine-gearbox repair or major
overhaul. Contact your local Allison Distributor for further information.

Hughes Helicopters, Inc.
FORM 91788 (2/81)

Hughes Helicopters. Inc. culver city, california 90230
LETTER NO. DL-33
DATE 17 July 1981

HUGH ES PAGE 1
SERVICE IN FORMATION OF~

LETTE R
SUBJECT: NEW MAIN ROTOR HUB FAIRING ATTACH SCREWS
MODELS AFFECTED: 500D Model 369D Helicopters Serial No. 0003D
through 0627D.
Reference
500D Model 369D Basic HMI-Volume I, Issued 15 September 1976, Revision

No. 4, 1 December 1980
The existing PN NAS603-14 Phillips screws, used to attach the main rotor hub
be replaced with PN NAS1096-3-10 hex head Phillips Use
fairing, may screws.
of the hex head screws will make it easier to torque the screws to the required
20-25 inch-pounds.
The above~ information is to be considered as part of the HMI and will be
incorporated in the next scheduled revision of the above referenced HMI-Vol I.
zec
FORM 8~788 (2/81)

Hughes Helicopters, Inc. culver city, California 90230
LETTER NO. DL-34
DATE 31 JULY 1981

HUGHES paoE 1 OF 1
LETTER
SUBJECT: GROUND HANDLING PRECAUTIONS FOR MAIN ROTOR BLADES

WITH ELASTOMERIC DAMPER ASSEMBLIES
MODELS AFFECTED: All Model 369D Helicopters
Reference
369D Series Basic HMI-Volume I, Issued 15 September 1976; Revision No. 5,

1 December 1980
main rotor
Field reports indicate that excessive lead-lag loads applied to the
blades during ground handling can result in damage to the elastomeric damper
bun and failure of the damper assembly.
Operators and maintenance personnel should use extra caution, therefore,

to
avoid lead-lag loads in excess of 35 pounds at the tip of the main rotor blades.
The above information is to be considered as a part of the HMI and will be
incorporated at the next scheduled revision of HMI-Volume I.
Koch, Manager
rd
FORM 91788 (2/81)

Hughes Helicopt~rs, Inc. culver city, california 90230
LETTER NO. DL-35
DATE 21AUGUST 1981

HUGH ES PAGE 1 OF~
SE RVICE IN FOR MATION

LETTER
SUBJECT: CORROSION CONTROL MANUAL NOW AVAILABLE FOR

GENERAL DISTRIBUTION AND PURCHASE
MODELS AFFECTED: All Model 369D Series Helicopters
Reference
500D Series Basic HMI Volume I, Issued 15 September 1976; Revision No. 4,
14~vlay 1981
Hughes Helicopters Corrosion ControlManual, Publication No. CSP-A-3,

Issued 9 February 1481
In response to additional requests for the subject Corrosion Control Manual, this
publication is now available for general distribution for $10. 00 per copy.
This manual is the basic information source for corrosion control for all models
of Hughes helicopters. It provides comprehensive data for operating and mainte-

nance personnel in repairing and preventing corrosion attack. Specific topics
include corrosion classification, corrosion detection and removal, refinishing and
metal surfaces, preventive maintenance, special corrosion control
preserving
techniques, and inspection guides.
To obtain copies of the Corrosion ControlManual, Publication No. CSP-A-3,

contact your Hughes Service Center or Distributor; or order direct from Hughes
Helicopters, Inc. Customer Service Department.

rose osTee (2/sil

Hughes Helicopters, Inc. culver city, california 90230
LETTER NO. DL-36
DATE 21AUGUST 1981
HUGHES PAGE 1
SE RVICE I N FOR MATI O N OF~
LETTER
SUBJECT: TAIL ROTOR DRIVE SHAFT FLEXIBLE COUPLINGS, PN 369A5501 AND

3691-192564 TREATMENT WITH MOLYKOTE METAL PROTECTOR
Reference
15 May 1981
Whenever the subject Bendix couplings are washed with a solvent or detergent,
a light coating of Molykote Metal Protector should be applied to the coupling before
reinstallation on the helicopter.
Molykote Metal Protector is available in 16-ounce aerosol cans and in 15-gallon

drums (liquid form), from Dow Coming Corporation, Midland, Michigan. Apply
Molykote from an aerosol can to the interior and exterior of the coupling diaphragm
packs. Or spray or dip the coupling flange in Molykote; remove any excess liquid
by gently blowing with compressed air.
When applying Molykote MetalProtector, it is important that the work area be well
ventilated and maintenance personnel follow all safety precautions normally used
with a chlorinated solvent. Also follow the handling precautions on the container
label. Cure time for the Molykote coating is 8 hours at room temperature and
14 minutes at 650 C.
that-couplings should not be immersed in fluids or cleaners such

It is to be noted
as magnetic particle, fluorescent penetrant, visible dye, etc. Any application of
corrosion protective fluids should also be done very sparingly.
The information given in this Letter will be incorporated in the next scheduled
revision to the above referenced Basic HMI Volume I.
zea~e
rose oslss (1/81)

Hughes Helicopters. Inc. culver city, California 90230
LETTER NO. DL- 38

HUGHES
PAGE 1
LETTER
SUBJECT: NEW PROTECTIVE BOOTS FOR MAIN ROTOR HUB AND TAIL
ROTOR ASSEMBLIE S
Reference
Model 500D Basic HMI-Volume I, Reissued 15 September 1976; Revision No. 5,

15 May 1981
New protective boots designed for extra stiffness and longer wear are now
available as replacement for the existing flexible boots installed on the main
rotor hub assembly and tail rotor assembly. Made of neoprene impregnated
nylon fabric for greater rigidity and toughness, the new PN 369D21811 inboard
boot and 369D21812 outboard boot for the tail rotor assembly must be safetywired
in place at installation. This safetywire requirement also applies to the new
PN 369D21011 upper boot when installed on the main rotor hub assembly.
The new boots are to be secured at: each end with a double wrap of MS20995C32
safetywire, drawn snug andtwisted together per standard safetywire techniques.
When ordering, specify the 369D21811 tail rotor inboard boot as replacement for
existing 369D21806 or 369D21806-3 nonrotating boot; the 3691321812 tail rotor
outboard boot as replacement for existing 369D21807 rotating boot; and 369D21011
boot as replacement for existing 3691-11001 upper boot on the main rotor hub.
zQI
Edward
~I_
Koch, Manager
FORM Ba18B (2/81)

Hu(lhes Helicopters. Inc. culver city, california 90230
LETTER NO. DL-40
DATE 2 November 1981

HUGHES pnoE 1 OF
1
LETTER
SUBJECT: FIELD REPLACEMENT OFO RING FOR PN 369A8321 OIL TANK

FILLER CAP
MODELS AFFECTED: 500D Model 369D Helicopter SerialNo. 0003D
thru 1209D
Reference
500D Model 369D Basic HMI-Vol I, Reissued 15 September 1976; Revision No. 5,
15 May 1981
There were several reports from operators that on occasion the oil tank filler
An investigation revealed that
cap would stick and was thus hard to remove.
the oil cap 0 ring caused the cap to stick.
Animproved ring (Parker PN 2-223, N304-75) is now available for field

O
installation as replacement, if desired, for the existing 0 ring, to minimiee
cap removal problems. The new 0 ring is a special Parker Lube treated
ring and is available only through Hughes Helicopters, Inc.
It is to be noted that the ring is incorporated on oil tank filler caps

new 0
on pr6duction Model 500D Helicopter Serial No. 1210D and subsequent.
For further information, contact your authoriz;ed HHI Service Center or
Distributor, or HHI Parts Sales Department.
z;e/ k~
Customer Services Department
Hughes Helicopte rs, Inc.
rose 95788 (2/81) Inc.

Huehes Helicopters, Culver City. California 90230
LETTER NO. DL-41. 1~
BIU@#ES10 February DATE 1984
%EBP~IGE INIF=ORWnA~818N
~Supersedes Service Information Letter
No. DL-41, dated 11 January 1982.
SUBJECT: INSTALLATION OF SURPLUS MILITARY PARTS,

USED PARTS ON MODEL 500D HELICOPTERS
SALVAGED OR
I
REFERENCE
Model 500D HMI-Volume 1 (CSP-D-2), Reissued 15 January 1982; Revision No.3,

15 August 1983.
Model 500D Illustrated Parts Catalog, Reissue No. 3, 15 July 1982.
Model 500D Illustrated Parts List and Maintenance Instruction, Optional Equipment
Manuals, Publication No. CSP-001 and subsequent
HHI Service Procedures Manual, Publication No. CSP-A-1, Reissued

15 May 1983.
FAA Advisory Circular, AC No. 20-62C, dated 8/26/76.
Field reports indicate that the use of surplus military, salvaged and/or used parts
have been contributing factors for incidents involving Hughes Model 369D
helic opters.
Hughes Helicopters, strongly emphasizes that surplus military parts

Inc. are not
approved by HHI for Model 500D helicopters.

use on Also, surplus items are not
eligible for overhaul or repair by the Hughes Factory Repair Station, nor are they
acceptable for the Hughes Exchange Program.
It is to be noted that any owner or operator who installs a surplus military part,
a salvaged or a used part purchased from other than HHI or its authorized
sources does so at his own risk. responsibility as the part
HHI disclaims
may not have been made under HHI control and/or may not be in an airworthy
condition. Moreover, any existing warranty applicable to the helicopter
involved becomes null and void.

FOAM 85788 (2/81)

Hughes Helicopters, Inc. Culver city, California 90230
LETTER NO. DL-41. 1~(
pncE 2 of Z Inc.
Hughes Helicopters.
It is highly probable that the physical condition and/or finite life of such
if
parts will be marginal or unacceptable for operational use. Therefore,
it is necessary to buy any used component, be sure to check the source
of
purchase and obtain all historical records regarding the finite life and ser-
vice usage of the part, and make a thorough inspection as to airworthiness
of the part before installation on the helicopter. Following installation of
an acceptable used part, transfer all records to the appropriate helicopter
log.
Prior to purchasing ally part: orcomponent exchange item from a source

other than HHI, remember the following, as stated in FAA Advisory Circular
No. AC 20-62C: "In accordance with Federal Aviation Regulations, certifi-
cation ofmaterials, parts, and appliances for return to service, for use on
an aircraft, is the responsibility of the person or agency who signs the
approval. The owner/operator is responsible for the continued air-
worthiness of the aircraft.
All new spare parts procured from HHI include warranty (1000 hours of
a
service or one year, whichever occurs first) that starts the date the part is
sold authorized Hughes Service Center Distributor. As stated
by an or
above, this warranty becomes null and void, if any surplus military item,
I e
helicopter. htno part purchased from othe. than HHI is installed
If you have any question as to whether a component assembly

or is acceptable
for installation onyour helicopter, contact your Hughes Service Center or
Distributor, or call HHI Commercial Parts Sales.
~rd Koch, P\ilanager

Hughes Helicopters, Incorporated
LETTER NO. DL-42
26 March 1982
HUGHES
LETTER
SUBJECT: LUBRICATION OF DRIVE END BEARING LINER IN AIRCRAFT

PARTS CORP MODEL 150SG SERIES STARTER-GENERATOR
369D Series Helicopters equipped with

MODELS AFFECTED: All 500D Model
subject APC Model 150SG Starter-Generator
Refe rence
500D Series Basic HMI Volume I, Issued 15 January 1982
Aircraft Parts Corporation Service Bulletin No. SB150SG103
The attached APC Bulletin, reprinted as part of this HHI Service Information
of the subject drive
Letter, provide s instructio~s for inspection and lubrication
loosen-
end bearing liner during overhaul of the starter-generator, to p"eclude
ing of the liner in the generator housing.
It is recommended that owners and operators of affected Model 500D helicopters
comply with the APC Bulletin, as indicated, to help ensure optimum generator
performance and service.

Customer Service Dep"rtment
Inc.
Hughes Helicopters,
FORM 911788 (2/81)

Hughes Helicopters. Inc. Culver City, California 90230 1
SERVICE BULLETIN
AIRCRAFT PARTS CORP. Number: SB?50SG103
160 Finn Court, Farmingd~le, N. V., 11735. U.S.A Page 1 of 1
SUBJECT: Lubrication of Drive End Bearing Liner in Model

150SG series Starter-Generators
A. PURPOSE: To prevent the outer race of the drive end

ball bearing from seizing to the mounting
head bearing liner.
B. PROCEDURE: Apply a continuous film of NEVER-SEIZE,

anti-seize and lubricating compound, or
equal to the dnside diameter of the steel
bearing liner in the drive end housing,
prior to assembly at the time of overhaul.
NOTE: Seizure of the ball bearing outer race induced by

abnormally high engine mounting pad heat, or insufficient
generator cooling can cause the mounting head steel
bearing liner to loosen in the~ aluminum housing.
Inspect the generator mounting head bearing liner at
overhaul and replace the mounting head if bearing liner

looseness is noted.
ZI-
LETTER NO. DL- 43

HUGHES PAGE 1 OF 1
SERVICE INFORMATIO~
LETTER
NEW FN 369D28237 CUSHION FOR TAILPIPE HANGER

SUBJECT:
ASSEMBLY DESIGNED FOR LONGER WEAR
Reference
Reissued 15 September 1976; Revision No. 5,

Model 500D Basic HMI-Volume I,
15 May 1981.
rubber material to
A new PN 3691328237 tailpipe hanger cushion made of silicone
is available for installation on all 400D helicopters.
provide longer wear, now
the
A component: of the new PN 369A8236-9 and -11 tailpipe hanger assemblies,
PN 369D28237 cushions may be ordered as replacement,
when required, for
inconel mesh pads or tabbed wire cushions used
existing
on early PN 369A8236-5
assemblies. Installation of the new rubber cushions up-
and -7 tailpipe hanger
assemblies to the PN 369A8236-9 and -11 coa-
grades early -5 and -7 hanger new
Model 500D helicopter Serial No. 1235D and

figurations now used on production
subsequent.
provided in
Instructions for replacement of the tailpipe hanger cushions are
Section 15 of the Basic HMI-Volume L

Install the new PN 369D28237 cushions
with
by bonding 3691-18233 saddles and PN 369A8234-1 and -2 clips
to the PN
or equivalent compound.
Also
GE High- Temp Instant Gasket RTV 106 (Red)
around the spring attach points.
inject gasket compound into cavity in area
369D28237 PN silicone
When ordering replacement cushions, specify the new
assemblies, specify the
rubber cushions. When ordering tailpipe hanger new
PN 369118236-9 and -11 assemblies.
-zes
Hughes Helicopters, Incorporated
culver City, california 90230

FORM 9s788 (2/81)
Hughes Helicopters, Ibc
LE~TER NO. DL-44
26 March 1982
HUGH ES
LETTER
SUBJECT: NEW ONE-PIECE PN 369D21725 TAIL ROTOR STOP SUPPORT

AND RETENTION NUT
500D Model 369D Helicopter Serial No. 0003D thru 1024D

MODE LS AF FECTE D:
Re fe re nce
15 May 1981
and Retention Nut is available

A new PN 369D21725 Tail Rotor Stop Support now
as replacement, when required, for the existing PN 369D21724-3 Stop Support

the tail rotor assembly the
and PN HS1550A328 Retention Nut used to secure on
one-piece stop support

The and retention
tail rotor transmission output shaft.
nut is designed provide to security simplify field maintenance for the
added and
tail rotor assembly. At installation of the PN 369D21725 stop support and reten-
to 400 inch-pounds is to be applied, the same torque as
tion nut, a torque of 440
for the existing HS1540A328 retention nut. It is to be noted that a new
specified
PN HS1551S238 tang washer must also be used whenever the
tail rotor assembly
is removed and reinstalled on the transmission output shaft.
The new PN 369D21725 support and retention nut is installed on

tail rotor stop
For further
production Model 500D helicopter Serial No. 1025D and subsequent.
information contact your HHI Service Center or Distributor or HHI Customer
Service Parts Sales Department.
z~ ~e
Hughe s Helicopters, Inc.
FORM 9~788 (2/81) Inc. culver city, California 90230

Hughes Helicopters,
LETTER NO. DL-47
DATE 16 August 1982
HUGHES PAGE 1 OF 1
LETTER
PN 369D25100
SUBJECT: SERIAL NUMBER IDENTIFICATION
MAIN TRANSMISSION ASSEMBLY
to date
MODELS AFFECTED: All 500D Model 369D Helicopters delivered prior
of this Letter
in Spares
All PN 369D25100 Main Transmission Assemblies
Inventory at date of this Letter
Reference
Vol I, Reissued 15 January 1982; Revision

No. 1, 15 March 1982
500D Basic HMI
Record
500D Helicopter Log Book, Components
Main Transmission Assemblies

We are trying to locate nine (9) PN 3693)25100
identified by the Serial Numbers listed below:
0536 0544 0552 0562

0529
0530 0537 0549 0557
Number for the PN 369D25100 main

transmission assembly installed on
The Serial
Record of the Helicopter Log Book.
the helicopter is entered in the Components
main transmission assemblies, the
Serial Number can be located on the
For Spares
ID plate on the transmission housing.
of those listed above, please

If the Serial Number of your transmission is one
call HHI Warranty and Repair Dep.artment.
contact your HHI Service Center or
Your cooperation is appreciated.
Thank you,

Customer Service Dep artment
Inc. Culver city. California 90230

~ORM 91188 (2/81)
Hu(lhes Helicopters,
LE~TER NO. DL-48

HUGH ES PAGE 1 OF~
SE RVICE IN FORM AT ION

LETTER
SUBJECT: DISTRIBUTION AND SHIPMENT OF HHI 269/369 COMMERCIAL AND

MILITARY PUBLICATIONS
As owner/operator of a Hughes Model 369D helicopter, you will find that there
an
are
many HHI service publications available to help you

service, maintain, repair and
otherwise keep your aircraft in optimum operating condition.
With delivery of each new helicopter, for example, HHI provides a data package includ-
ing a Pilots Flight Manual, Handbook of Maintenance Instructions, Illustrated Parts
Catalog, Service Information Notices and Letters, and a log book. The original owner
also receives a complimentary one-year subscription service for new issues and revi-
sions to the above publications. Secondary publications such as Price Lists, Kit
Installation Instructions, Lubrication and Inspection Check Sheets are also available
through HHI Customer Service Publications Department. To maintain the subscription
service, ownersloperators must renew the subscription each year, with a reduced
renewal fee applicable after the first paid subscription year.
to all
Distribution of publications is accomplished (1) through periodic general mailings
subscription service customers, HHI Service Centers and Distributors, and to perti-
nent Government departments and agencies; and (2) by individual shipments of sub-
scription service customer orders for additional publications, refills, forms, etc.
and of individual orders to domestic subscription service

General mailings shipments
via surface transportation with postage prepaid by HHI. Bulk
customers are shipped
and individual orders to foreign subscription customers are shipped via air, collect, to
expedite delivery. Foreign subscription service customers who cannot receive collect
shipments, but still desire air shipment of publications should contact tile HHI
Commercial Service Publications Department.
If there are anyquestions regarding subscription services, or shipment and distribu-

tion of publications, contact the HHI Commercial Service Publications Department
(T el: 213-30 5-303 8)
Ze-j k~t
FOAM 95788 (2/81)

Hughes Helicopters, Inc. Culver City, california 90230
LETTER NO. DL-49

HU~H ES PAGE 1 OF
1
SER~OCE INIFORMATIORI
LETFER
SUBJECT: GROUND TESTING ENGINE AUTOMATIC REIGNITION AND ENGINE

ANTI-ICE FUEL FILTER SYSTEMS
MODELS AFFECTED: All 500D Model 369D Series helicopters with Engine Automatic
Installed
Reignition and/or Engine Anti-Ice Fuel Filter System(s)
Anti-Ice Fuel
When ground testing the Engine Automatic Reignition System or Engine
the automatic reignition system RE-IGN
Filter System using helicopter battery power,
FUEL FILTER caution indicator may not light
indicator or the anti-ice fuel filter system
if the battery used is not fully charged.
The RE-IGN indicator and the anti-ice FUEL FILTER caution indicator lights are
activated by solenoid switches which require 23.8 vdc, minimum, to assure operation.
If the helicopter28 volt battery bus does not supply at least 23.8 vdc during ground
testing of either system, the RE-IGN indicator the FUEL FILTER caution indicator,
or
as applicable, may not light. Other components of the systems are not affected by the
low voltage.
the
To assure ground testing of the Engine Automatic Reignition System, or
valid
Engine Anti-Ice Fuel Filter System, ensure that the battery is fully charged,
or use
an approved auxiliary power unit.
Ground testing procedures for theEngine Automatic Reignition System and the Engine
Anti-Ice Fuel Filter System are contained in the FAA Approved Rotorcraft Flight Manual
and the FAA Approved Supplements applicable to the affected systems.

Hughes Welicopters, Inc.
FORM oa7ee (2/sil

Huehes Helicopters, Inc. culver city, california 90230
LETTER NO. DL-50
DATE 10 January 1983

HUG# ES
PAGE 1
SE WVI~IE
LETTER
SUBJECT: PREVENTION OF WATER LEAKAGE THROUGH CANOPY GEON STRIPS
Reference
500D Model 369D HMI-Vol. 1, Reissued 15 January 1982; Revision No. 1, 15 March 1982.
500D Model 369D-SRM (CSP-D-6), Reissued 15 September 1981.
Should water leakage through the geon strips of the forward canopy occur, seal all
faying strip(s)
surfaces of the geon where the leakage occurs with PR1221 sealant
(Product Research, Glendale, CA). Remove any existing sealant bead in the area of
the leak using a plastic or other non-metallic scraper which will not scratch the canopy
glass. Apply a 0.06-inch bead of sealant (refer to manufacturers instructions) along
faying surfaces in the affected area.
When replacement of components mating with the geon strips and removal of the canopy
glass is required, apply a 0.010- to 0.020-inch coating of PR1221 sealant to all faying
surfaces of the geon strip and to the adjoining components prior to reinstallation,
Carefully align and join mating surfaces with as few movements as possible. Do not
reposition or shift the faying surfaces once they are joined, Install any attaching
hardware necessary during the working life of the sealant (refer to manufacturers
instructions). Remove any sealant squeeze-out in excess of 0.125-inch using a
non-metallic spatula or scraper.
The information given in this Service Information Letter is to be considered as a part

of the HMI, and will be incorporated in the next scheduled revision to the above
referenced manuals.

FOAM 81788 (2/81)

i. REFERENCE SHEET
SERVICE INFORMATION NOTICES AND LETTERS
ACTION REFERENCE: When installing or repairing forward canopy windows

refer to Service Information Letter No. DL-50.
HMIREFERENCEI Insert this sheet in 369D SRM, Section 2, page 2-40.
This reference sheet shall be kept as a part of the manual

until the data is incorporated at the next revision to the
369D SRM. (See Service Information Summary, 369D
SRM, page i.)
f
LETTER NO. DL-51

HUGH ES PAGE 1 OF~
SE RV ICE IN FORM AT ION

LETTER
SUBJECT: HANDLING AND SHIPPING GYROS
MODE LS AF FECTED: All 400D Model 369D Series Helicopters equipped with Rate
Gyros, Vertical Gyros, Directional Gyros or Attitude Gyros.
Gyros, whether rate gyros, vertical gyros, directional gyros or attitude gyros,
are the most delicate instruments in your helicopter.
The gymbal bearings in
with very little friction, and as a result are very
gyros are designed to operate
if the is mishandled, and repairs
fragile. The bearings are easily damaged gyro
are very expensive.
Guidelines for the proper handling and shipping of gyros are attached to this
letter. If followed, they will help you eliminate gyro bearing damage caused by
mishandling and the expensive repairs that result from such damage.

FORM 95788 (2/81) Inc.

Hughes Helicapters, culver city. California 90230
GYRO HANDLING AND SHIPPING GUIDELINES
CAUTION
The gyro transmitter operates

Handle gyro as if it were an egg.
a
in a gymbal, which allows it to swing in any direction. Some

device is installed to
gyros are caged, which means a locking
prevent the gyro transmitter from swinging during ground hand-
ling shipment. If caging is provided,
or ensure the gyro is caged
before and during all ground handling of the gyro, or a helicopter
with the gyro installed.
SHIPPING AND TRANSPORTING GYROS
with the dunnage used

I. Always transport or ship agyro in its original container,
by the manufacturer. If the original container and dunnage is not available, use
substitutesapproved by supplied by
or gyro the manufacturer. Extensive dam-
age to gyro bearings frequently occur when a gyro is shipped or transported

improperly packed. Shipping in other than approved containers can void the
manufacturers warranty.
2. Outer containers for gyros are clearly marked THIS SIDE UP.
shipping Placing
a container with a gyro inside in any position
other than the position indicated
on the container can cause the gyro to be damaged.
3. Do not remove the gyro from its shipping container until it is beside the heli-
When it is necessary to
copter for installation, or the work bench for testing.
see the gyro at any other time, open the top
of the container and remove the
dunnage. Before moving the gyro, replace the dunnage and reseal
the
container
4. When moving the gyro locally, use a foam padded cart with large rubber wheels,
not small casters. If a truck is used, the truck must have pneumatic tires, and
the container must be positioned where it will not be bounced or jarred during
movement of the truck.
5. Do not drop, kick, toss, bump or tumble a container housing a gyro.
6. When it is necessary to ship a gyro, use air shipment.
7. Retain all gyro shipping containers and dunnage for reuse.
GYRO HANDLING
Ii When installing a gyro, place the container housing the gyro as near as possi-
ble to the point of installation. If applicable, remove the gyro to be replaced
and gently place it next to the shipping container. Remove the new gyro from
the shipping container and install it in the helicopter. If applicable, properly
the removed in the shipping container for transport to the shop, etc.
pack gyro
2-
GYRO HANDLING (CONT)
2. Where practical,do not ground handle a helicopter in which an installed gyro

has been energized, for 20 minutes after power has been removed from the
gyro.
running. Allow 20 minute down

gyro if the gyro rotor is a run
3. Do not move a
after power is removed.
4. Do not rotate or tumble the gyro during handling.
be treated like
5. When removing or installing a gyro, remember, it is to an egg.
Do not bump it, drop it, strike it, tumble it or jolt it.
6. Be extremely careful when setting a gyro on a fixture, bench, table or any

surface. Dropping one end of a gyro 3/4-inch is equivalent to a 20g impact
for the gyro. A 2-1/2 inch drop can ruin the gymbal bearings.
3
LETTER NO. DL- 52

HUGHES PAGE 101
LETTER
SUBJECT: NEW ATTITUDE GYRO INDICATOR AND SUPPORT ASSEMBLY
MODELS AFFECTED: All 400D Model 369D Series Helicopters equipped with optional
369H90038-501 Attitude Gyro Indicator Kit.
Reference
Revision No. 1,
500D Model 369D HMI-Vol. 1 (CSP-D-2), Reissued 15 January 1982;
15 March 1982,
1 August 1976.
400D, Model 369D Attitude Gyro Indicator Opt. Eqpt. Manual (CSP-008),
from the vendor,

Attitude Gyro Indicator (P/N 369H92831) is no longer available
is exhausted, Attitude
R.C. Alien. When the existing stock of R,C, ellen indicators
Indicator (PIN 369H92831-3) manufactured by Aviation Instrument Manufacturing,
Gyro
R.C. Alien indicator
Inc. supplied. The AIM indicator is longer than the
(AIM) will be
and uses the 369H645551 Support Assembly. The 369H6445-41 Support Assembly is to
be installed using the same type rivets and the same rivet pattern used for the
P506 must be modified when replacing an
369H6455-11 Support Assembly. Connector
the blue wire attached to
R.C. Alien indicator with the AIM Indicator by removing
it pin A.
pin D of the connector and reattaching to
replacement for Attitude Gyro Indicator (P/N 369H92831),

order
When ordering a
P/N 3691-192831.-3, Attitude Gyro Indicator and PIN 369H6455-51, Support Assembly.
Ze91~
FORY 95188 (P/B11 Inc. Culver City. California 90230

Hughes Hellcopterar
LETTER NO. DL-53
DATE 20 March 1983

HUGHES
~21 SE RVICE fN FORM AT ION

LETTER
PAGE 1 OF~1_---
SUBJECT: VOLTAGE REGULATOR SETTING FOR THE HEAVY DUTY, 17 AMP HR,
20 CELL BATTERY (PN 369D230011)
Reference
Illustrated Parts List and Maintenance Instructions for the Heavy Duty (17 amp hr,
20 Cell) Battery Installation (CSP-093), Issued 15 January 1983.
369D HMI Volume 1 (CSP-D-2), Reissued 15 January 1982; Revision No. 3,
1.5 August 1982.
is installed in the
W12(:n theHeavy Duty 17 Amp Hr, 20 Cell Battery (PN 369D290011)
the ambient temperature voltage
helicopter, the voltage regulator must be adjusted to
the voltage regul~tor will pre-
setting given in Section 2, CSP-093. Failure to adjust
vent the 17 amp hr battery from fully recharging during helicopter operation.
must never be used

Voltage regulators adjusted for use with the Heavy Duty Battery
readjusted to the ambient tempera-
with the 19 cell, 13 amp hr battery before they are
ture voltage settings given ih ~ection 19, I-IMI Vol i. Failure to readjust the voltage
with the 13 amp hr battery will
regulator to the lower voltage setting prior to use
cause overcharging of the battery, which can result in a premature battery malSunction,
~124
Inc. Culver city. California 90230

Foam es~ee (Ilel) Hughes Helicopters,
tETTER NO. DL -54
DATE 1 April 1983

HUGHES PAGE 1 OF
1
SERVICE INFORNIATION
LETTER
TO-All owners and operatorsof Hughes Helicopters
SUBJECT5 TRI-FLOW WASH PROCEDURE MAIN ROTOR HUB
M3DELS AFFECTED: All 500D Model 369D Series Helicopters
hub
The attached Tri-Flow Wash procedure is designed to help prevent main rotor
in marine environments. Preliminary
component corrosion on helicopters operated
be effective in preventing
results of field testing have shown the procedure to
recommended. Fresh water, spray lubricant (Tri-Flow)

corrosion when applied as
Wax or equivalent) are the materials required.

and washing compound with wax (Zip
noeele is required to apply the materials.
Spraying app"ratus with an adjustable
daily
recommends application of the wash prodedure,
ehutdown following the last flight of the day, for all he2icopters
prior to engine
environment. For helicopters operated and based
operated or based in a marine
should be applied at each 25-hour inspection
in other environments, the procedure
frequently if desired.
interval, or more
Costa Mesa Lubricant, P. O. Bqx 125,

Tri-Flow Lubricant is available from
Inc.,
Olive Branch, MZ 38654. Zip ~Wax is produced by Turtle Wax,
5655 West 73rd Street, Chicago, IL 60638.

Customer Service ]Depertment
Culver City, Cslifornis 90230

FORM OCTIOB (2/B1) Hushes Clelicoptetcl, Inc~
Hugh~ Hsllo~ptrr. InC;
TRI-FLOW WASH PROCEDURE
NOTE
Perform step a. below prior to engine shutdown, following

the last flight of the day if possible. When the rotor
stops turning, the laminates of the strap-pack spread
apart slightly. Contaminates collected on the edges of
the strap-pack assembly can enter the area between the
laminates as they spread apart. If the rotor continues
turning until the contaminants are washed away, centri-
fugal force will keep the laminates compressed and not
allow the corrosive substances to enter the area between
the laminates.
a. Bring engine t~o ground idle (64 65 percent N1); set SCAV AIR to
on (Pilots Flight Manual). Perform the following:
WARNING
Use care when working around turning rotor blades.

Stay low. Remain on right side of helicopter to avoid
tail.rotor blades.
i. Spray fine fresh water mist on main rotor blades.
2. Direct a strong stream of fresh water into main rotor hub and
control system at main rotor hub.
3. Spray entire rotor hub with Tri-Flow Lubricant.
b. Shutdown engine (Pilots Flight Manual). When rotor blades stop

turning, spray strap-packs with Tri-Flow Lubricant. Lift blades to separate
laminates and spray Tri-Flow between laminates.
c. Perform engine water wash ~Section 2, HMI Volume i).
d. Wash remainder of helicopter exterior using fresh water spray.
Wash main rotor blades with Zip Wax or equivalent, mixed per
e.
manufacturers instructions.
2-
LETTER NO. DL-55. i.
DATE 13 April 1984

HUGHES pnoE i oF_1____
j SE RVICE I N FORMATION
LETTER "Supersctlcs Service
Information Ilcttcr DL-45,
dated 14 July 1983,
SUBJECT: STRUCTURES CATALOG FOR 369D SERIES HELICOPTERS
An Illustrated Structures Catalog, Publication No, CSP-D-7, for 500D Model 369D
Series helicopters is now available; price $90.00
The Illustrated Structures Catalog (369D-ISC) provides a complete parts breakdown

and parts lists.
of the 400D helicopter structure using exploded isometric drawings
should be used when ordering replacement or spare parts for the 369D helicopter
It
structure.
369D-ISC, contact your Hughes Service Center or Distributor.

To obtain a copy of the
ai~ard Koc Manager

Hughes Helicopters; Inc.
Denotes portion of text added or revised.
FORM 95788 (2/81) Inc. Culver city, California 90230

Hughes Helicopters.
LETTER NO. DL- 56

HUGH E~ PAGE 1 OF~
SERVICE INFORMATION
LETTEW
TO-All owners end operators of Hughes Helicopters
SUBJECT: LANDING GEAR DAMPER ASSEMBLIES (PN 369D26300 Series and

369D26301 Series)
MODELS AFFECTED: All 500D Model 369D Series helicopters.
Reference
Illustrated PartsCatalog, CSP-D-4 (369D-IPC), Reissued 15 July 1982.

Optional Equipment Instruction and Illustrated Parts List for Extended Landing Gear
Installation PN 369D290007-BSC, -501, -503 (CSP-001), Reissued 15 November 1979.
Optional Equipment Instruction and Illustrated Parts List for Extended Landing Gear
Installation PN 369D290007-507 (CSP-065), Issued 15 March 1979.
There has been some concerning replacement parts for 369D26300 and
confusion
369r)26301 Landing Gear Damper Assemblies. The parts used for 369D26300 or
369D26301 Damper Assembly Basic, -21, or -31 versions are identical, except for the
Damper Service Decal (PN 369H6322-3, -5, and -7). This decal and the damper part
number suffix indicate the temperature range for which the damper has been
serviced.
Following are the 3691)26300 and 369D26301 damper suffixes, with corresponding
servicing, and 369H6322 decal, with the temperature range shown on the decal:
369D26300 and
3693[)26301 Damper Type 3611-16322 Decal Temp Range
S uffix S er vicin g Suffix Shown
-BSC Normal -3 1250 to 100F

-21 Winterized -5 700 to -400F
-31 Mid Temp -7 900 to -240F
For servicing and overhaul of all 369D26300 and 369D26301 series landing gear dampers,
refer to Part VI, 369D-COM. Parts information in the 369D-IPC for 369D26300 landing
gear damper assemblies and in Section 1 of CSP-001 and CSP-065 for 369D263011anding
gear damper assemblies applies to all suffixes, except for the 369H6322 decal. Order
decals to correspond with servicing as shown above.
Foam oslee (vec)

Hughes He(ioopters, Inc. culer city, california 90230
LETTER NO. DL-56
14 November 1983
ETAD2
PACE 2 OF Hughsa Helicopters. Inc.
The information contained in this Letter will be added to the above referenced manuals
at the next scheduled revision,
EDWARD KOCH, Manager

"LETTER NO. DL-576
EL-5
FL-1
~al
HUGH ES HL-88
PAGE 1 of 2
hE~T E R
*Include a copy of this Letter in
the Notice/Letter file for each
affected model
SUBJECT: SURPLUS OR BOGUS 369D21100 SERIES MAIN ROTOR BLADES.
MODELS AFFECTED: All Model 369D, 369E, 369F, 369H, 369HE, 369HM and
369HS Series Helicopters.
Hughes Helicopters recently obtained five bogus main rotor blades which had
has
been sold to a 369D owner/operator as 369D21100 blades. The blades were in
fact, surplus military blades (PN 369A1100 Series) designed for the OH-6A
and
sold by HHI to the U. S. Army in 1967/8. The identification plate and markings
the 369D21100 blade configuration. When
on the blades had been altered to reflect
there records with them to indicate
these blades were examined by Hughes, were no
total time in service. Such blades are not designed for use with 369D helicopters
and must not be used under any circumstances.
been sold. These

It is possible that more of these bogus main rotor blades have
blades have probably exceeded their FAA assigned service
life. If used, they could
fail, causing an accident in which personal injury could occur. In addition, use
of these blades could void insurance claims.
blade acquired from other than Hughes authorized Service Center

Any main rotor a
or Distributor must be considered suspect, and should be checked closely to
determine if it is an369D21100 Series blade,

authentic 369A1100 of if it is an altered
Series main rotor blade designed for use on OH-6A and Hughes 369H Series heli-
Because the 369D blade required improved structural design to accomodate

copters.
the following checks be made to determine
increased loads at higher airspeeds, can
is authentic 369D blade, altered 369A Series blade:

if a suspect blade an or an
ribs in the blade.

1. The tap test can be used to identify the number of
coin
Carefully tap along the length of the blade, from the tip end, using a
Note the
heavy coin, e.g., U. S. quarter, half dollar, or equivalent.
number of ribs in the blade by the difference in sound. The 369D blade
has 20 ribs, 1.5 inches apart, beginning 1.5 inches from the blade tip.
The 369A Series blade has only four ribs, three inches apart, beginning
three inches from the blade tip. (See figure 1.)
2. The bogus 369D blades have a painted over, flush plug installed to fill
a 0.218 0.224 inch diameter hole required in all 369A1100 Series blades.
(See figure 1.) There is no such hole or plug in 369D blades.
FORM 8JTBB (2/81) Inc.

Hughes Helicopters, culver city, california 90230
LETTER NO. DL-57
EL-5
FL-1 Hughes Helicopters. Inc.
HL-88

PAGE 2 of 2
-..---rr-,-
:I
RIB
i (20 PLACES)
ii
11/2"---1 C--l 1/2"

NO HOLE
369[3 BLADE
-------rt
i RIB
(4 PLACES)
iji_l
3"-6 t~i "1 ~-3"
HOLE 369A BLADE
0. 218-0. 224 INCH
88-589
Figure 1. Bogus 369D Main Rotor Blade Identification
Any main rotor blade found that has been altered or suspected of having been
altered, should be removed from service or spares inventory immediately. Con-
Service Hughes Service Center if
tact HughesCustomer Department, or your
found, if you have questions concerning this
any such blades are or any
matter.
We have also received information concerning a PN 369A1200-501 main rotor

hub, serial No. 3425, that we suspect does not meet our quality standards.
Owner/operators who have had the main rotor hub replaced within the last
six months should ascertain whether this particular hub is installed. When
purchasing a main rotor hub from other than a Hughes approved source, be
aware that bogus hubs are being marketed. If you. find that the suspect hub,
serial No. 3424, has on your helicopter,
been installed or ii anyone attempts
to sell you a main rotrob hub you suspect is not authentic, please notify
Hughes Customer Service Department immediately.
EDWARD KOCH, Manager

DL- 58J
EL- 9
LETTER NO.
H~t- 89
DATE 16 May 1984
f~SI
HUGH ES PAGE 1 OF~
1
SERVICE IN FORI~IATIONI
LETTER Snclude a copy of this Letter in
the Letter File for each affected

Model.
SUBJECT: UNAUTHORIZED TAIL ROTOR TEETER BEARINGS.
MODELS AFFECTED: All 369D, 369E, 369H, 369HE, 369HM and 369HS Series
helicop ters
Ball Bearings, Inc., manu-

During the period 1981 through 1983, New Hampshire
factured and sold tail rotor teeter bearings marked with Hughes PN 369A1726 and
and AHEPSCO,
369A1727 to JEPCO, 10919 N. W. Third Place, Belleview, Washington,
216 West Florence, Inglewood, California. These bearings were not subjected to
Hughes inspection and quality control, and their use is not authorized on any Hughes
FAA quality control
Helicopter. Since these bearings cannot be shown to meet
and can result in
requirements their use violates Federal Aviation Regulations,
warranty or insurance claims being rejected.
between the unauthorized and authorized

There is way to visually differentiate
no
tail rotor teeter bearing inner/outer
parts; therefore, all 369A1726 and 369A1727
from other than Hughes authorized distributor or service center
races purchased a
authorized
should be removed from service immediately and replaced with Hughes
All such parts
369A1726 and 369A1727 bearings from Hughes authorized sources.
should be removed from spares inventory.
If you have cluestions concerning this matter, please contact your Hughes Service
any
Center or Distributor.
Edward Koch,Manager
Customer Service Dept.
Foam 85788 12/81) Inc.

Hughes Helicopters, Culver City, California 90230
HL-9L
DL-59J
LETTER NO. EL-10
FL-2
DATE 12 Nov 1984
HOGHES PAGE 1 OF~
SERVICE IMFORMATIOM
LETTER
SUBJECT: MAJOR INSTALLATIONS AND ALTERATIONS TO YOUR HUGHES

HELICOPTERS
MODELS AFFECTED: All Hughes Model 369D, 3693, 369F, 369H, 369HE, 369HM and
369HS Series helicopters.
Hughes Helicopters, Inc., recommends that extreme care be used when selecting
a facility to make major structural repairs, install major systems or components,
or make any alteration to your Hughes Helicopter. The facility selected should
use only parts, materials and procedures authorized by Hughes for accomplishment
of the task.
Major structural repair, system or component installation, and helicopter alteration

can change the structural load paths of the helicopter. The application of greater
loads to structural components, not designed or tested for such loads, can reduce
the fatigue life of those components. Any such repair, installation, or alteration
that changes the structural load paths which were determined during testing and
certification of the original helicopter design revokes the FAA certification of that
helicopter. Recertification requires sufficient stress and fatigue analysis/testing
to determine if the certificated service and fatigue life of the helicopter has been
affected. Additionally, modification of a basic system which is part of the original
design, should not be made without conducting a failure mode and effect analysis.
Hughes t~elicopters, Inc., will not accept responsibility or liability for any Hughes
Helicopter on which work beyond the scope authorized by Hughes maintenance
instructions has been performed. These instructions are not intended for the
purpose of major structural modifications or rebuilding of helicopters. If you
have any questions concerning major repairs, installation or alterations to your
Hughes Helicopter, contact your Hughes Service Center or Distributor.

Customer Service Dept.
h/~
Customer Service Depeltment
rose OStBB (1/1)()

Hughes Melicopters. Inc. Culver City. Caiitornia 90230
HL-93
DL-61J
LETTER NO. EL-12
FL-5
HUGH ES PAGE 1 OF~
SERVICE INFORMATION
LETTER
SUBJECT: Explanation of Parts Serialization
MODELS AFFECTED: All Model 500H, 500D, 500E, 530F and 530F Plus Helicopters.
The following is a brief explanation of the part serialization system used

at Kughes Helicopters, Inc. All parts are assigned a basic part number. The
basic part number of an assembly or component may be further identified by
a serial number. In most cases, the serial number consists of a four digit
number. Serialization of each basic part number starts with 0001 and progresses
through numerical and alphanumerical combinations as follows:
0001-9999
A001-Y999
~I
To further explain, identical part numbers with serial numbers 0001 through
9999 were manufactured prior to serial numbers A001 through Y999. Identical
serial
part numbers with serial numbers A001-Y999 were manufactured prior to
numbers AA01-YY99, etc. It should be noted that the alphabetic characters I,
O, Q, X and Z are not used for regular production parts.
~Ja"rd Ko~h, ~Lan7Lger

Product Support Technical
FORM 85188 (1/81) Inc.

Hughes Helicopters, culver city, California90230
HL-94
DL-64J
LETTER NO.
EL-14
DATE FL-6
March 1986
PAGE i
1
SERVICE IN FORMATION LETTER
TO-- All owners and operators of MDHC Helicopters.
SUBJECT: UNAUTHORIZED OVERHAUL OF MAIN ROTOR HUB ASSEMBLIES.
MODELS AFFECTED: All 369B, 369HE, 369HM, 369HS, 369A, 369D, 369E, 369F and 369FF
~lodel Helicopters.
McDonnell Douglas Helicopter Company (MDHC) has learned that some operators
of MDHC helicopters have had main rotor hub assemblies (lead lag links, strap
pack assemblies, blade root fittings, etc.) overhauled at repair facilities
outside of MDHC or MDHC Approved overhaul Licensees. MDHC does not recommend
or ;Iplrove ovcrllnul of tile ni;iin rotor hub assemblies outside of F1T)HC or Apprt,vc\tl
ovcrll;lul I,iccnsccs. Sucl~ ainy tile safety of tile helicnptcr
and tt~e eligibility of the part to be qualified for MDHCs major component
exchange program.
Edward Koch~
dL
Manager
McDonnell Douglas
Helicopter Company
ORIGINAL ns
Product Support Department RECEIVED Ry ATP
FORM 95788
IWCDBNAI1Erkb
HL-95.3*
DL-65.3*
EL- 16.3*
FL-7.3*
SERVICE LETTER DATE: 23 MAY 2000
PAGE 1 OF 1
December
Iniormation Letters HL-95.2, DL-Gj.Z, EL-16.2 and FL-7.2, dated
18
1
LIGHT HELICOPTER PRODUCT SUPPORT DEPARTMENT
COMMUNICATIONS INFORMATION
This Service Letter has been cancelled in its entirety.

is available on the Internet at:
Contact information for the various product support functions
?lttp://www.mdhelicopters.com". Customers may contact the Product Support Department at:
(800) 388-3378 or (480) 346-6387.
Remove this letter from your files one year after the issuance date.
Inc. This document may be reproduced and distributed provided no fee is charged,
Copyright 1999-2000 by MD Helicopters
the text is not modified, andthis copyright notice is included.
"o: HL-96. 1"
McDonnell Douglas DL-66.1*
EL-1 7.1"
FL-I 2.1"
Helicopter Company
PAGE t of 1
SERVICE INFORMATION LETTER
X
This Letter supercedes Service Information Letters, HL-96, DL-66, EL-17 and FL-12, dated 10
July 1987.
TO: All owners operators
and of McDonnell Douglas Helicopter Company (MDHC) 369 Series
helicopters.
SUBJECT: AVAILABILIN OF KAMATICS CORP. KAFLU( MAIN DRIVE SHAFT (MDHC P/N
369025515) AND TAIL ROTOR DRIVESHAR- COUPLINGS (MDHC P/N 36925501-3).
MODELS AFFECTED: All 369 Series helicopters.

Kamatics Corp. Kaflex main drive shaft (P/N369D25515) and tail rotor drive shaft
couplings (369025501-3) are now available. The 369025515 main drive shaft
supercedes and is two-way interchangeable with 369A5510 main drive shaft. The
369D25501-3 tail rotor drive shaft coupling supercedes and is two-way inter-
changeable with the 369A5501 and 369H92564 tail rotor drive shaft couplings.
NOTE
The 369D25515 main drive shaft and 369D25501-3 tail rotor
drive shaft couplings are the only parts allowed for use on 36988
series helicopters.
Both the main drive shaft and tail rotor drive shaft couplings are
currently being installed on all production aircraft at MDHC.
Kamatics and Bendix couplings can be intermixed on the same
tail rotor drive shaft as long as a failsafe device is used with the
Bendix coupling.
Converting to the Kamatics main drive shafts and tail rotor drive shaft couplings offer
several advantages. As a condition item, there is no service life limit. The Kaflex
system provides a built-in failsafe.design which eliminates the requirement of
installing the failsafe device used with Bendix couplings, The open truss design
allows ease of inspection without disassembfy.
The 369025515 main drive shaft can be purchased from MDHC for $5908.16 and the
369D25501-3 tail rotor drive shaft coupling for $3152.28 (list price) U.S. funds
through December 31, 1989.
The applicable HMls have been revised to show any differences in installation and
inspection procedures.
Cary Bro~an, Manager,

Product Support Department,
McDonnell Douglas
Helicopter Company
Product Support Department
McDonnell Douglas
FORM 95788 (AEV 11187) Helicopter Company
LETTER NO.: HL-97
DL-67j
EL-18
FL-B
COIHI3#NY DATE: 06 April 1987
PAGE 1 of 1
TO: All owners and operators of McDonnell Douglas Helicopter Company helicopters
and MDHC Approved Service Centers.
SUBJECT: Re-lubrication of Bearings In Storage.
MDHC re-lubricates all pre-lubricated bearings (lubricated by manufacturer) af-

ter four years of shelf life (storage) or prior to installation into a helicopter. Own-
ers, operators and service centers should also comply with this requirement of
relubricating any pre-lubricated bearing which has been in storage more than
four years since date of manufacture or before installing the bearing into a heli-
above
copter. Spares inventories should be checked periodically to ensure the
re-lubricating requirement is complied with. Re-lubrication shall be performed in
accordance with the applicable portions of the Handbook of Maintenance In-
structions.
Cary Brown, Manager

McDonnell Douglas
Helicopter Company
FORU OSTL)B IDCeUQLAI

HEUCOP~ER COMP#NY
GETTER NO,: HL-98
DLSB
~LdY.rZIRUILZT-L ~ouorae
DATE: 01 May 1987
PAaE lofl
SE~ICE INF;ORMATIOM LETTER
To: ALL OWNERS.AND OPERATORS OF MCDONNELL DOUGLAS HEUCOPTER COM-

FANY(MoMO) 969 SERIES HEUCOPTERS.
S~J&IECT: External scavenge oil filter system,
The Allison Oas Turbine Commercial Service Letters referenced below outline
the benefits of the use of an approved scavenge oil filter. MDHC has been
informed that Alison plansto make this type of filter mandatory on new
applications and we sirongly endorse the addition of any approved external
scavenge oil: filter system to existing 369 Series helicopters.
The oil ~cavenge filter kit and vendor listed below have been approved by
Supplernental Type Certificate to be installed, on all 3~9A, 369HE, 369HM,
309HS, 869D and 3699 Series helicopters. A Supplemental Type. Certificate is
currently in the approval cycle at the Feder~ Aviation Administration and should
be approved to be Installed on all 369F/FF SBries helicopters by the Fall of 1987.
Kit Number.......l741 050

Facet Enterprises, Inc.
&439 Triad Drive
Greensboro, N,C, 27400
Tele: (919)668-4444
t
Cary Brown, Manager
McDonnell Douglas
Helicopter Company
REFERENCES
Allison Publication CSG128 (230018 Series Engines)

Alltson Publication CSL-1118/CSL-1093 (250-C20 Series Engines)
1 Alllson Publication CSL~MG1 (2SC1-C30 Series Engines)
Product Support Departmeot

TORLP &"7~1 MObOlMMIL~ C~OL#LIU
LETTER NO.: HL-99
DL-70 Y
EL-21
FL-11
i DATE: 15 June 1987
PAGE 1 of 1
TO: All owners and operators of McDonnell Douglas Helicopter Company (MDHC) 369 Series
helicopters.
SUBJECT: UNAUTHORIZED DISTRIBUTION OF MAIN ROTOR HUB OVERHAUL MANUAL.
MDHC has learned that unauthorized copy of Publication No. CSP-0731L, Main
an
Rotor Hub (P/N 369D21200-711) overhaul procedures may have been inadvertantly
delivered to some owners and operators of MDHC helicopters.
This manual is not approved for general usage and should be destroyed. MDHC
does not approve overhaul of the main rotor hub assemblies outside of MDHC or
MDHC Approved Overhaul Licensees.
C3
Oary Brown, Manager,
McDonnell Douglas
Helicopter Company
1981 91188 klCOONN11LL 00UQlLU

COIL~NY
DL-71.1* J
McDonnell Douglas EL-22.1*
FL-13.1*
Helicopter Company DATE: 01

EGSeptember
AP0991
1 of 1
Supercedes Service Information Letters DL-71, EL-22, and FL-13, dated 06 November 1987.
TO: AUL OWNERS AND OPERATORS OF MCDONNELL DOUGLAS HELICOPTER COMPANY

(MDHC) 369 369D, 3698 and 369F/FF SERIES HELICOPTERS.
SUBJECT: Replacement of 369D25132-BSC and -5 Output Shafts (Ring Gear Carriers) with
369D25132 3 Output Shafts.
MDHC has developed an improved 369025132 output shaft which will eliminate the
current 300 hour repetitive inspection for the BSC and -5 shafts, per DN-148.1,
EN-36.1 and FN-25.1.
The 369D25132-3 output shaft will be made available at a special price of $3600.00
(U.S. dollars) until 31 December 1991.
The $3600.00 price is for replacement shafts installed in aircraft or Spares
transmissions only. It will be necessary for operators to provide transmission serial
number and helicopter serial number information with your order. In addition, the
shaft being replaced must be returned to MDHC.
The 369D25132-3 shaft is now available. It should be noted that delivery of the new
improved part to MDHC is in weekly incremental quantities. Customer orders will be
filled as soon as possible as the improved shafts ate received from the vendor. If
requested by the customer, estimated delivery dates will be provided.
Orders should be placed through the MDHC Warranty and Repair Department.
Phone: 1-800-445-1516
TELU<: 98-1 557
Answer Back: MD HC SERV MESA
Datafax: (602)891-6782
TMS: LBHHD
~La
lag,~ns,ager,
MD500 Product Support Dept.
McDonneil Douglas
Helicopter Company
McDonnell Douglas
FORM 95788 (REV 11187) Helicopter Company
DL-73
McDonnell Douglas EL-24
FL-15
Helicopter Company DATE: 10 Februaty

EGAP8891
1 of 1
TO: ALL OWNERS AND OPERATORS OF MCDONNELL DOUGLAS HELICOPTER COMPANY

(MDHC) 3690, 369E AND 369F/FP SERIES HELICOPTERS.
SUBJECT: FINITE SERVICE LIFE INCREASE FOR 3691156553 -5 OIL COOLER BEAR-
INGS.
The finite service life of the 369H5655-3 and -5 oil cooler bearings has been
increased from 900 hours to 1200. This increase in the finite life of the 369H5655
bearings, which support the blower unit, is effective immediately.

McDonnell Douglas
Helicopter Company
McDonnell Douglas
FORM 88788 (REV 1~ 187) Helicopter Company
HL-1
McDonnell Douglas 0 DL-74
EL-25
Helicopter Company 19februaly 19BB

FL-16
PAGE 1 of 3
helicopters, including the 369A (OH-6A) Series helicopter.
SUBJECT: ILLUSTRATED PARTS BREAKDOWN OF GROUND HANDLING WHEEL ASSEMBLY

(PN 369D2610).
MDHC has received requests from operators in the field to provide them with a parts
breakdown of ground handling wheel assembly which will enable them tcj procur
individual items when needed. Unless ottherwise noted, all items shown in the
attached parts breakdown are available from:
AER-BEA CO. INC.

1925 Doreen Ave.
South Ei Monte, CA. 91733
j Tele: (818)443-1757
Oary Brown, Manager

McDonnell Douglas
Helicopter Company
McDonnell Douglas
FORM 95788 (REV 11 187) Helicopter Company
LEITER NO.: HL-100
DL-74
EL-25
FL-16
DATE: 19 February 1988
PAGE 2 of 3
PARTS LIST
Item/ Nomenclature Part No. Qty. Source
2 Spring AB2472-2 2 Aer-Bea Co., Inc.
3 Base AB2472-3 1
5 Cotter Pin AB2472-5 4
6 Bearing AB2472-6 4
7 Tire AB2472-7 2
8 Tube AB2472-8 2
9 Fork AB2472-9 1
10 Washer AB2472-18 4
11 Axle AB2472-11 2
12 Pivot Pin AB2472-12 1
14 Snap Ring AB~472-14 2
15 Roll Pin AB2472-15 1
16 Roll Pin AB2472-16 2
17 Retainer AB2472-17 1
18 Roll Pin AB2472-18 1
19 Ball Lock Pin AB2472-19 1

with Lanyard
22 Lock AB2472-22 1
24 Washer AB2472-24 A/R
25 Hub AB2472-25 2
x
26 Inner Wheel AB2472-26 2
27 Outer Wheel AB2472-27 2
Aer-Bea Co., Inc.

LETTER NO.: HL-100
DL-74
EL-25
FL-16
PAGE 3 of 3
~2
;1
[f
:31
6Iioill
Figure 1. Ground Handling Wheel Assembly.

HL-101
McDonnell Douglas DL-75
EL-26
FL-17
Helicopter Company DATE: 04 April 1988
PAGE 1 of 1
ALLISON ALERT BULLETIN ISSUED
SUBJECT: Improved Strength PC Filter Housing
Allison Gas Turbine Division has issued an Alert Commercial Engine Bulletin to
prevent the possibility of fatigue failure of the PC air filter inlet fitting which may result
in sudden unintended engine power loss.
As part of this bulletin, Allison has extended a special pricing policy for compliance
to this bulletin within a specifiedtime period.
To obtain a copy of this bulletin or for information regarding the special policy
pricing, contact your local Allison Distributor.
REFERENCE
CEB-A-246* (250-C1 8)
CEB-A-1233* (250-C20)
CEB-A-75-3017* (250-C30)
Allison Publications Dated February 15, 1988
McDonnell Douglas
FORM 957881REV 11187) Helicopter Company
LETTER NO.: HL-102
72-LE~
FL-18
Helicopter Company DATE: 06 May 1988
PAGE 1 of 4
helicopters that are registered in the United States.
SUBJECT: ADDITION OF IDENTIFICATION DECAL ON AIRCRAFT UCTERIOR. (COMPLIANCE

TO FAR 45.11[01)
The FAA has imposed a requirement for all U.S. registered aircraft to have
identification information displayed on the exterior surfaces of the aircraft. This
Service Information Letter provides instructions for ordering and installing a new
identification decal on the exterior of the aircraft in order to comply with this new
regulation.
MDHC will an identification decal to registered owners of MDHC helicopters

provide
atno cost one-time basis for a limited period of time. Orders must be placed
on a
prior to September 1, 1988 to receive parts at no charge. All orders must include the
specific helicopter model and serial number as shown on the.existing data plate
together with the current U.S. registration number along with the name and address
of the registered owner. Orders must also reference this Service Information Letter.
Orders may be telexed, telecopied or mailed to:
McDonnell Douglas Helicopter Company

Light Helicopter Center
5000 E. McDowell Rd. Bldg. LH1/G25
Mesa, Arizona 85205
ATTN: Les Ottem
Telex: 98-1557 Answer back: MD HC SERVICE MESA

Datafax: (602)891-6782
Telephone: (602)891-8515
MATERIAL
Nomenclature Source
Sealant (per PR1436G, PR1422G or com- Commercial

merciallv eauivale
McDonnell Douglas
FORM 95788 (REV 11 187) Helicopter Compan,y
LETTER NO.: HL-102
DL-76
EL-27
FL-18
DATE: 06 May 1988
PAGE 2 of 4
PROCEDURE
a. Ensure surface is clean and dry prior to installation of decal.
b. Install decal in location shown on Figure I attached.
c. Apply a bead of sealant around the faying surfaces of the decal.
d; Use the attached form when ordering exterior identification decals.

NO.: HL-102
DL-76
EL-27
FL-I 8
DATE: 06 May
Q8 91
PAGE 3 of 4
6=
II ~i
~u
GROWID RECEmCLE
3
LOCATION OF MISTING GROUND RECEPTACtE
CENTERED ON 3TA 135.72 a WL 17.38 (REF)
"8"
(1) INCH
J
McDonnall Oou01~r
Hdkoptcr tompny
Mou, AZ
Modl
S~W No.
MTERIOR IDENTIFICATION DECAL
Figure i. Location of ~cterior Helicopter Identification Decal.

LETTER NO.: HL-102
DL-76
EL-27
FL-18
DATE: 06 May 1988
PAGE 4 of 4
USE THIS PAGE TO ORDER IDENTIFICATION DECALS
ONE (1) EACH PER AIRCRAFT
SHIP TO:
A quantity of each is required for the following United States registered aircraft.
MDHC helicopter model, MDHC helicopter Serial Number and current U.S. registra-
tion number are required for each decal issued. Orders will not be accepted or
honored unless required information is complete.
MODEL MDHC S/N CURRENT U.S. REGISTRATION NO.
NAME
TITLE
HL-103
McDonnell Douglas DL-77 J
EL-28
FL-19
PAGE 1 of 2

369 SERIES HELICOPTERS, INCLUDING THE 369A (OH-6A) SERIES HELICOP-
TER.
SUBJECT: AVAILABILITY AND DISTRIBUTORS OF TRI~FLOW LUBRICANT/WASH.
Tri-Flow lubricant, used to clean and treat the main rotor hub and the main rotor
strap pack assemblies, can now be obtained from those distributors listed below.
Operators in Central and South America are advised to obtain their Tri-Flow lubricant
from Thompson and Formby, Inc. of Memphis, Tennessee.
NOTE
Operators are advised to adhere to the manufacturers instruc-
tions when preparing and applying Tri-Flow lubricant. Tri-Flow
lubricant must be thoroughly mixed before being applied as
Tri-Flow ingredients seperate when left standing for long peri-
ods of tCme.
Operators may obtain Tri-Flow lubricant from the following sources when accom-
plishing the requirements of Part I of Service Information Notices HN-214, DN-154,
EN-44 and FN-33 dated 15 January 1988.
Hy-Gun Products
100 Jane Street
West End 4101, Queensland
Australia
Bondis Ltd.
Italielei 215
2000 Antwerp
Belgium
Mac Lubes Ltd.

119-255 West Ist St.
North Vancouver, B.C. V7M 3G8
Canada
McDonnell Douglas
FORM 95788 (AEV 11187) Helicopter Company
LETTER NO.: HL-103
DL-77
EL-28
FL-19
DATE: 09 May 1988
PAGE 2 of 2
Tech Sales Co.

3989 Chesswood Drive
Downsview, Ontario M3J 2R8
Canada
SKF Danmark A/S

Sdr. Ringvej 55
DK-2600 Glostrup
Denmark
A.R.M. Lubricants Ltd.

97 Cato Street
Vauxhall Industrial Park
Birmingham, England
Deutsche Calypsol Gmbh Co.

Fringsstr. 20-26
4000 Dusseldorf 1
West Germany
Hissan Trading Co. Ltd.

Daini Maruven Bldg.
9-2 Nihonbachi 3-Chome, Chou-Ku
Tokyo 103, Japan
IKS American Corp.

1555 W. Rosecrans Ave.
Gardena, CA 90249
D. A. Dean
Thompson and Formby, Inc.
825 Crossover Lane
Memphis, TN 38117
Mr. A.F. Coenen

Sterling/Winhtrop B.V.
Postbus 615
2003 RP Haarlem
The Netherlands
IVlcDonnell Douglas LE~ER NO.:
FL-21

PAGE 1
May
of 1
1988
SERVICE INFORNIATION LETTER
HELICOPTER COMPANY
SERIES HELICOPTERS.
(MDHC) 3690, 3698 AND 369F/FF
BLOWER BELT.
SUBJECT: FINITE SERVICE LIFE INCREASE OF 369[)25623 OIL COOLER
The finite service life of the 369D25623 oil cooler blower belt has been increased
from 900 hours to 1200 hours. This increase in the finite life of the 369D25623 oil
cooler blower belt, which drives the main transmission oil cooler fan, is effective
oil
immediately. It should be noted that the finite service life of the 369H5655-3 -5
and
cooler bearings was increased to 1200 hours earlier in 1988. (Ref. DL-73, EL-24
FL-15.)
CDC-*_L~_
McDonnell Douglas
Helicopter Comapny
McDonnell Douglas
McDonnell Douglas LETTER NO.:
HD::~JJDL-79 J
DATE: 18 May 1988
Helicopter Company PAGE 1 of 1
TO: All Owners and Operators of McDonneil Douglas Helicopter Company (MDHC) 369H Series
helicopters, including the 369A (OH-6A) Series helicopter, and 369D Series helicop-
ters that have passengerlcargo hoists installed.
SUBJECT: ADDITIONAL INSPECTION REQUIREMENTS OF THE BREEZE-EASTERN RESCUE

HOIST SYSTEM.
Breeze-Eastern, a division of TransTechnology Corporation, has issued a Customer
Advisory Bulletin (CAB-100-30) which outlines a procedure to significantly improve

the reliability of the rescue hoist system and, more importantly, further limit the
possibility of personnel safety hazard.
Owners and operators can obtain copies of the Bulletin referenced below at 700
Liberty Avenue, Union, New Jersey, 07063.
TELEPHONE: (201)686-4000
-TELD( (TWX): 138212
REFERENCE
CAB-100-30, Customer Advisory Bulletin, Breeze-Eastern Corp.
McDonnell Douglas
McDonnell Douglas LETTER Nd.:
J
EL30

FL22
PAGE 1 of 1

(MDHC) 369 SERIES HEUCOPTERS.
SU&IECT: Chafe Wrapping of Stainless Steel Tube Assemblies and Allison Commercial Service
Letter CSL 145, CSL 1140 and CSL 3092, dated May 1, 1988.
It has been determined that wrapping stainless steel tube assemblies with chloride
based materials (such as neoprene tubing and fiberglass tape) can result in
premature tube failure. The referenced CSLs provide instruction to properly mount
and maintain the mounting hardware in the area of the engine compartment. MDHC
urges owners and operators to obtain copies oithe referenced CSLs and adhere
to
the instructions provided by Alison. Copies of the referenced CSLs can be obtained
from Allison at the following address:
Allison Gas Turbine Division

Genereal Motors Corporation
P.O. Box 420
Indianapolis, Indiana 46206-0420
Telephone: (317)230-2725
Telex: 6876067 Ans Back: 250PROD
Datafax: (317)242-0966
REFERENCE
CSL 145" (250-C18 Series engines)

CSL 1140* (250-C20 Series engines)
CSL 3092* (250-C30 Series engines)
Dated May 1, 1988.
McDonnell Douglas
McDonnell Douglas
EL-31
Helicopter Company DATE: 01 July 1988

FL-23
PAGE t of 1

(MDHC) 369 SERIES HELICOPTERS.
SUBJECT: IMPROVED FUEL DRAIN VALVE ASSEMBLY.
MDHC has developed an improved fuel drain valve assembly (P/N 369D28099)
which replaces the existing CAV170-H4 fuel drain valve. The improved drain valve
incorporates a backup washer behind the valve closure O-ring. The O-ring used for
installing the valve itself is MS29513-012. The O-ring used as the quick drain closure
seal is MS29513-006. Improved fuel drain valve assemblies and associated O-rings
are currently available from the Spares Department at MDHC.
Cary Brow)r\, Manager,

McDonnell Douglas
Helicopter Company
McDonnell Douglas
McDonnell Douglas
Helicopter Company DL-82. *FL-40
EL-33.2*
SERPIICE INFORMATION LETTER
R
Supersedes Service lnforrnation Letters HL-108.1, Dr-82.1 and EL-33.1, dated 25 July 1990.

(MDHC) 369 Series helicopters.
SUBJECT: Facet Scavenge Oil Filter Kits, P/N 1741050 (369H Series, 3690 and 369E)
and P/N 1741300 (369F/FF).
The Filter Products Division of Facet Enterprises, Inc. has recently been granted a
STC by the FAA for a scavenge oil filter kit for the 369F/FF series helicopter.
Scavenge oil filter kits were developed for other models in 1988. Those operators
that are currently using the Facet scavenge oil filter kit must change the filter
element per the following Facet Service Bulletin (tef. Serial No. 041888). Installation
of the retrofit kit removes the 100-hour element change restriction.
NOTE
The Facet scavenge oil filter kit is required equipment in the
Alison 250-C20R/2 engine installation.
Additional Facet Service Bulletins involving the scavenge oil filter kit are as follows:
NOTE
The following Facet bulletins should be accomplished concur-
rently with Facet bulletin No. 041888, if not already accom-
pi ished.
No. 020689, dated 5 February 1989
Subject:Incorrect installation of
Facet scavenge oil filters.
No. 090589, dated 5 September 1989

Subject: Facet filter assembly
functional check tool PN 171145.
an,
Manager,Rp~-
MD500 Customer Support,
McDonnell Douglas
Helicopter Company
McDonnell Douglas
FORM 95788 (REV 11187)
Helicopter Company
8O Facet
Serial No. 041888
Filter Products Division
April 18 1988 Facet Enterprises. Inc.
GLP 8439TriedDrive
Page 1 of 1 Oreensbcro, N.C. n409

(919) 6884444
SERVICg BULLETIB
Date: April 18, 1988
Subject: Facet Scavenge Oil Filter Kit, P/N 1741050
Models Affected: McDonnell Douglas (Hughes) 500 Series
Because of a potential for exceeding the engines Scavenge pressure

limits, operators with Facet Scavenge Oil Filter Kit 1741050 installed must
change filter element, P/N 038088-08, if the filter

goes into a bypass
condition or at 100-hour intarrrals instead of every 200 hours.
Filter Products Division is in the process of obtaining approvals for

a retrofit kit for operators flying with Kit 1741050. This kit, P/N
1741050-02, will include only those items needed to stay in the pressure
limits and will also satisfy the mandatory filter requirements for the 0208
engine
Installation of the retrofit kit removes the 100-hour element change

restriction. Retrofit kits and pricing will be available from our distrib-
utor network July, 1988. Filter Products Division strongly recommends this
update be accomplished upon availability of retrofit kits.
Facet Fluid Technology Group

Filter Products Division Facet/Quantek, Inc.
2k
Serial No.: 0~0689
February 6, 1989.
1 KGN
Page 1 ot 1
SERVICES BULLFT1N
owe: FBkLIPY 6. Isss Facet Enterprises, Inc. has learned of an instance where
subieot: Inxxrea Installatbnof
Facet filter assembly 1740001-03 was installed incor-
Face Scavenge Oil Fniees rectly on a helicopter. The 10-micron filter was installed
in reverse with the engine oil out line connected to the
PIN 174000101
filter outlet port (marked OUT") in~tead of the filter inlet
PM 1740001-03
port (marked "IN").
Such an incorrect installation could cause carbon accu-
Modets Aftected: mulation on the outlet strainer, with no possiblity of
by-
Kite Alrentt pass. With this reverse oil how, the bypass valve will not
1741010-01 Bell 20BA a a open and the red bypass indicator will not function.
17410#M1 Bel~Bt An incorrectly installed filter could lead to excessive back
1741030-01 Bell 206L-1
pressure in the scavenge system, causing damage to
1741140 Bell 206L-3
scavenge pumps, oil tanks, and other related compo-
14104091 Bell M6&lll nents,
1 741050-01 Mcoonnell Doughs 500
We, therefore, urge all operators of aircraft equipped with
174107~ MBB BO~OS
Facet scavenge oil filters to veriiy the correct installation
1741080 S78A of the filter assembly in accordance with the
1741090 proper Facet
OA.F. Nomad
Installation and Service Manual. If an inconect installa-
1741150 43355 Twinstar tion is discovered, we suggest a thorough
1741280
investigation of
Agustp Af 09A the oil tank for signs of distortion which would indicate
1741270 Agusta A109A-ll extreme back pressure has developed during operation.
NOTE: This Service Bulletin does not apply to Facet

scavenge kits
with 10-micron filter assembly 037738-04 or 9micron fitter
1742500.

8439 Tried Drive
I 668-4444
FAX: (919) 668-4452
Serial No.: 090589
September 5, 1989 SERVICE BULLETIN
KON
Page t of 1
Considering the fact that the first Facet(Ni-Cad filter was
installed in 1976, some filters have been in sennce over
1 3 years. We are providing this Facet filter test tool to give
the operator a simple way of ensuring the impending
06~ september 5 1989
bypass indicator is still functioning property,
QUbjed= F&Cet Flltm466696ly
Funcbional Chedr Tool
PIN 1741145 Instructions for Use
Purpau: Provides smpb chede Note: Do not attempt to adjust or replace indicator.
of opeation of Bbw
bypass indloator, At next scheduled filter element change after receipt of tool
and each subsequent 800-hour intenlal:
ApplruMl~y: Used on bw following
Fitcet Peer Assemblies: 1. Rgmove safety wire from tilter bowl, unscrew.bowl,
03773&04 remove and discard installed filter element.
174000161
2. Install tool P/N 1741 145, reinstall bowl (do not safety wire
1746661-62
1740001-05 at this tirile), leave cowling lod(ed open or remov~d for
visual access to fitter assembly.
Alrmee Fleet Wt
9. Slanengine.operateatgmundidleumil normal~peratlng
3doy Hiller UH12 E, O lf41006
temperatures am reached and filter bypass indicator
Bell 266 A a B It4lolo button extends (approxirnately 10 minutes). 8ypass
1741010-01 indicator must reach 100 degrees plus or minus 15
Bell 206L 174102a degrees Fahrentleit to operate.
1141020-01
4. If
bypass indicator fails to extend, shut down the engine,
Be11206t1 1f46131)
wait 3 minutes, then repeat Step 3 while oil is still wan.
1741030-01
Bell 206&111
5 Secure engine, remove bowl and tool, install new seal kit
17$1040
and filter element, reinstall and safety wire bowl, reset
174104091
Bell 206L-3
indicator, drain and reservice engine oil system.
1741140
McDonnell Douglas 500 1741050 6 If bypass indicator fails to extend or will not reset, contact
lf4105091
Facet Enterprises, Inc. Do not attemptto adjust or replace
Soky Bet 47 indicator.

1741666
M88 B0~05 1741070
Siko~sky S76A 1741080
GA.F. Nomad
48355 Twinstar
1741091)
1741150
Facet
AgustaA1OSA
8L139 Triad Drive
Agusta A109All 1741276
Greensboro, NC 27409
(919) 668-4444
FAX: (919) 66&4~52
LETTER NO.: HL-110

53-LEb
FL-28
Helicopter Company DATE: 15 January 1989
PAGE 1 of 1

SUBEJECT: Validity of Spectrum Oil Analysis Program (S.O.A.P.).
MDHC does not have a recognized S.O.A.P. involving the main rotor or tail rotor
transmissions. As limitations have not been established involving a S.O.A.P., MDHC
does not recommend removing from service any main rotor or tail rotor transmis-
sions due to the results of such a program. Serviceable limits for the main rotor and
tail rotor transmissions can be found in the applicable HMI Vol.l and Component
Overhaul Manuals. All applicable HMI Vol.ll manuals state that when any filters or oil
are changed due to illumination of chip detector lights, chips in the associated oil can
not measure larger than .025 inches in any direction.
Cary Brown, Manager,

McDonnell Douglas
Helicopter Company
McDonnell Doug.las
McDonnell Douglas DL-86.1
EL-37.1*
Helicopter Company DATE: 15 September 1989FL-30.1*

PAGE 1 of 2
*::Su-percedes Service Information Notices HL-112, DL-86, EL-37 and FL-30, Dated 10 July
1989.
T~:-; AU. OWNERS AND OPERATORS OF MCDONNELL DOUGLAS HELICOPTER COMPANY

$UBJECT: NEW MDHC AUTHORIZED HELICOPTER AIRFRAME REPAIR FACILITIES.
An additional airframe repair facility has been approved by MDHC. WESTERN

HELICOPTERS, INC. of Rialto, California, has been authorized by MDHC as a
domestic airframe repair facility.
In July 1989, MDHC authorized E.M. HELI-LOGISTICS, LTD. in British Columbia

and RO-WING AVIATION, INC. in California as MDHC Authorized Airframe Repair
Facilities. These Service Centers are authorized to repair and/or re-skin 369 series
tailbooms in addition to making airframe damage repairs.
Owners and Operators will be notified in the future as additional Service Centers are
approved by MDHC for helicopter airframe repair.

Contact these repair facilitites at the locations listed below.
Cph-~,
McDonnell Douglas
Helicopter Company
RO-WING AVIATION, INC.

275 E. Pleasant Valley Road
Camarillo Airport
Camarillo, CA 93010
(805)484-0556, TMS: L8RWA
DATAFAX: (805)388-9906
Mr. Gary D. Foster
McDonnell Douglas
EnF~M 9R7RB IREV 11 18~n HF~lirnnter C~omnanv
NQ.: HL-112.1*
DL-86.1*
EL-37.1*
FL-30.1*
DATE: 15 September 1989
PAGE 2 of 2
E.M. HELI-LOGISTICS, LTD.

Langley Airport, Hanger 6
5333 216th Street
Langley, B.C. V3A 4Rt, Canada
(604)533-4464, TMS: LBEHM
DATAFAX: (604) 533-2500
Mr. Bob; Randall
WESTERN HELICOPTERS, INC.

Rialto Municipal Airport
P.O. Box 579
Rialto, CA 92377
(71 4)829-1 051; 1-800-624-9506
Telex: 676421 WHI RLTO
Datafax: (714)829-4904
Mr. Clair T. Merryweather, President
I:i
"0: HL-115
McDonnell Douglas 09-LD/
EL-41
Helicopter Company DATE: 05 August 1989

Ft-34
PAGE 1 of 1
hel ico pters.
SUBJECT: AVAILABILIP/ OF MAIN ROTOR TRANSMISSION FILLER CAP EXTENSION (MDHC

P/N 369025112).
MDHC has developed an extension to the main transmission filler/breather cap to

eliminate the possibility of standing water entering the transmission. The 369025112
filler cap extension can be used on 369A5100 and 369025100 main rotor transmis-
sions and is now available to operators in the field. Filler cap extensions can be
installed at the next removal of the main rotor transmission. Refer to the applicable
Component Overhaul Manual, FINAL REASSEMBLY OF MAIN TRANSMISSION,
for installation instructions and proper parts orientation of the filler cap extension.

McDonnell Douglas
Helicopter Company
McDonnell Douglas
mmnln\/
McDonnell Douglas HL-116
/DL-91
EL-42
Helicopter Company DATE: 15 September

FL-35
1989
PP~GE 1 of 1
TO: ALL, OWNERS AND OPERATORS OF MCDONNELL DOUGLAS HELICOPTER COMPANY

369 SERIES HELICOPTERS.
SUBJECT: Availability of Wire Strike Protection System (Trademark WSPS) on all MDHC 369
Series Helicopters.
Aeronautical Accessories, Inc., of Bristol, Tennessee, has made available for

installation on all 369 Series aircraft a wire strike protection system. The WSPS kit
consists of three major components: a roof-mounted deflectorlcutter, a windshield
mounted protector/cutter and a belly-mounted deflector/cutter.
The WSPS is certified under Supplemental Type Certificate (STC) by the Federal
Aviation Administration. No restrictions or flight manual revisions are necessary
according to the STC. There are no changes in the flight characteristics or handling
qualities of the aircraft.
The WSPS is designed to offer a proven of
protection aaainst horizontally
measure
strung mechanical, electrical and communication cables, ihesystem consists oftwo

deflector cutters and a windshield protector/cutter. The wedge type cutters are
designed to provide the required mechanical advantage to handle the most:
commonly used electrical and telephone cables. As an integral part of the cutters,
sawtoothed deflectors are provided to guide the cables into the cutting wedges while
inflicting damage to the cable.
Fabricated of a special high tensile steel selected to handle multi-strand mechanical
and electrical cables, the WSPS kit comes complete with hardware and instructions
necessary for installation of the kit. There are no moving parts and the system is
maintenance free. For further information contact:
Aeronautical Accessories, Inc.,

P.O. Box 3689
Bristol, TN 37625-3689
(615)538-5151 or 800-251-7094
TELU(: 55-3446, Datafax: (615)538-8469

McDonnell Douglas
Helicopter Company
McDonnell Douglas
FORM 95788 (REV 11187) Helicooter ComDanv
LET1TR NO.: HL-117
McDonnell Douglas DL-92EL-43
8L36
He~copterCompany DATE: 27 October 1989
PAGE 1 of 1

SUBJECT: Federal Investigation of Central Aviation and Marine Corporation (CAMCO).
NOTE
CAMCO is an aircraft overhaul and repair facility in
Ronkonkoma, N. Y.
A Federal Aviation Administration investigation recently disclosed "...that Camco, in

aircraft appliances from
many instances, improperly approved for return to service
engines and airframe (parts) received from customers.
"CAMCO was fou nd to su bstitute the customers part with a similar part, change the
serial number and/or data plate, and send the part back to the customer. The part
returned faisely indicated the original parts serial number and/or data plate. A parts
serial number may have changed several times."
For the reasons above, appropriate action should be taken to determine whether
parts maintained by CAMCO and installed on 369 series helicopters meet all
applicable airworthiness requirements.
REFERENCE
FAA Open Letter To All Customers of: Central Aviation and Marine Corporation
(CAMCO), dated June 29, 1989.
*Reprinted on the reverse side of this letter.
cDJL~B------
McDonnell Douglas
Helicopter Company
McDonnell Douglas
FnRlu 987ee IREV 11187) HelicoDter Com~anv
O
800 InaDcnance ~ve.Sw
wasningcon. DC 2059~
dTnrmspcrtctK)n
Feckrd
~dmkJltmtkr,
5
RECU!
Juwllrsas
pROCU~
Open Letter To All Customers Of:
Central Aviation and Marine Corporation (CAHCO)
This is to inform you that a Federal Aviation Administration investigation of

CAMCO, Long Island MacArthur Airport, 2125 Snithtow1 Avenue, RonkonkoPa,
New York 11Y79, Repair Station No. 3585. has concluded that CAMCd, in many
instances, improperly approved for return to service aircraft appliances from
engines and airframes thereinafter referred to as parts) received from
customers.
CA~CO was found to substitute the customers part with a similar part, change
the serial number and/or data
plate, and send the substituted part back to the
customer. The part returned falsely indicated the original parts serial
number and/or data plate. A parts serial number mayhave been changed
several times,
By reason of the above, the part returned to the customer approved far was not
return to service in accordance with Federal Aviation Required
maintenance, per a customers program, may not have been performed. Requested
service bulletins or other modifications which lay apply to parts by specific
serial number or operator may not have been accomplished. Customers with
.reifabillty or data collection programs may have been tracking performance on
the wrong units,
We recommend that appropriate act:on Se :8ken to d~tcriine whether par=9

maintained by C~NCO and Installed on aircraft owned or operated by you meet
all applicable airworthiness requirements,
Ail contacts on subject of this letter should be directed ~o tne ~cderjl

the
Aviation Administration. FJrminpdaie ~light Standards District Office.
PSDO 11, Administration Building, Republic Airport, Paroingdale.
New York 11738, telephone (516) 894-5530.
Sincerely.
~Robert L. Gosdrich i
Director. Plight Standards Service
LEITER NO.: HL-118.1*
DL93.1*
McDonnell Douglas FE37.1*
Helicopter Company M"

PAGE:
z?sEaeMseRlssl
1 of 1
*Supercedes Service Information Letters HL-118, DL-93, EL-44 and FG37, dated
12 December 1989.
(1) Denotes portion of text added or revised.
TO: All and operators of McDonnell Douglas

owners Helicopter Company
(MDHC) 369 Series helicopters.
SUBTECT: Availability ofAutronics Corporation Electrical Component Exchange

Program.
Autronics Arcadia, California, is now offering a factory exchange

Corporation in pro-
gram involving dimmer controls and engine power out (EPO) units.
Autronoics charges $960.00 (U.S. Funds) for a factory exchange unit on any of the
369H6425 series dimmer controls and 369A4514 series EPO units. The 369A4540-3
EPO unit is no longer available from Autronics or MDHC. The 369A4540-3 EPO unit
was used on early configuration 369H
series helicopters equipped with C-18 engines.
I
Autronics is located at:
Autronics Corporation
314 E. Live Oak Drive
Arcadia, CA. 91006-5695
Phone: (818)445-5470
BacnrP--b-b
Jbhn Reagan, Manager,
McDonnell Douglas
Helicopter Company
McDonnell Douglas
"0"
E L-45
Helicopter Company DATE: 15 December 1989

FL-38
PAGE 1 of 1

(MDHC) 369 SERIES HELICOPTERS EQUIPPED WITH CARGO HOOK INSTALLA-
TIONS.
SUBJECT: Compliance to Breeze-Eastern Customer Service Bulletin CSB-120 OiYarning Plate

for Cargo Hooks).
Breeze-Eastern, division of TransTechnology Corporation, has informed MDHC

a
that they have issued a Customer Service Bulletin requiring Beeze-Eastern cargo
hook operators to affix a warning plate to those affected cargo hooks. Instructions
as to where and how to affix the warning plate (Breeze-Eastern Part No. 13830-1)
are included in CSB-120, dated 01 May 1989. Breeze-Eastern request operators to
provide them with the Part No. and Serial No. of their cargo hook and they will send
a copy of the CSB and
a warning plate directly to the operator. Breeze-Eastern is
providing the warning plate to cargo hook operators free of charge.
Send cargo hook Part No. and Serial No. along with operators name and address
to:
Breeze-Eastern
700 Liberty Avenue
Union, New Jersey 07083
Phone: (201)686-4000
Datafax (201)686-9292
Ce~JBhec-,
McDonnell Douglas
Helicopter Company
McDonnell Douglas
LE~ITER NO.: DL-95 iJ
McDonnell Douglas EL46
FL-39
Helicopter Company Sor41ember 1990
TO: ALL OWNERS AND OPERATORS DF MCDONNELL DOUGLAS HELICOPTER COMPANY

369D/E/F/FF SERIES HELICOPTERS.
SUBJECT: Storage Time Limitations of the Engine N2 and Rotor Tachometer Indicators
(P/N 369D24513(BSC), 13 15).
MDHC has set a limit to the time that the N2/NR tachometer indicator can remain in
storage before it has to either be tested prior to installation into a helicopter or
returned to an approved repair station for relubrication and/or function testing prior
to installation into a helicopter.
NOTE
Indicators stored longer than 12 months must be sent to an
approved repair station and function tested prior to being

delivered to a customer or installed in a helicopter.
Any indicator stored in excess of 24 months is to be sent to an
approved repair station for relubrication and function testing
prior to installation in a helicopter.
If it cannot be determined how long an affected indicator has
been held in storage, the indicator must be returned to an
approved repair station for relubrication and function testing
prior to installation in a helicopter.
Reagager,
McDonnell Douglas
Helicopter Company
McDonnell Douglas
McDonnell Douglas LETTER NO.: HL-120
69-LD/
EL-47

FL-41
PAGE 1of2
TO: ALL OWNERS AND OPERATORS OF McDONNELL DOUGLAS HELICOPTER COMPANY

(MDHC) 369 SERIES HELICOPTERS EQUIPPED WITH SHOCK-MOUNTED SKID
TUBE POSITION LIGHT ASSEMBLIES (P/N 369H92041-35/-36).
SUBJECT: improved spacers to be used on me shock-mounted skid tube position light
FADHC has received reports that some Lord shock mounts on the skid-mounted position
light assemblies have been tearing in service. MDHC has improved the design with a
c~ange in mounting hardware and mounting procedures. The following parts list and
procedure provides operators with instructions to modify their light assemblies to the
Improved configuration.
PARTS UST
Spacer 369H92041-45 2 MDHC or field fabricate
Spacer 3691-192041-47 2 MDHC or field fabricate
Spacer 369H92041-49 2 MDHC or field fabricate
Screw 1 MS51957-32 2 MDHC or Commercial
Screw MS51957-33 2 MDHC or Commercial
Screw MS51957-124 2 MDHC or Commercial
Sealant RTV 731 1 A/R Commercial
a. Remove the left and tight hand base sub-assemblies by removing (3) screws and associated
hardware teach side). Discard existing spacers and mounting screws.
b. Bond the three J-8483-5 isolator mounts to their respective base sub-assemblies using RTV 731
sealant.
c. Reinstall base sub-assemblies using the spacers and screws called out in Figure 1 and the above
parts list. Other associated hardware is shown in Figure 1 and called out in the applicable illustrated
parts catalogs.
The resultant alteration to affected models as described by procedures in this Notice has been
shown to comply with Federal Aviation Regulations and is FAA Approved.
McDonnell Douglas
LETTER NO.: HL-120
DL-96
EL-47
FL-41
DATE: 01 May 1991
PAGE 2 of 2
MS51957-32SCREW
SHELL
MS 51957-124 S CREW
APPLY RTV 731 TO

FAYINC SURFACES
~I i~ , , ,o ,.369H9M4!-45
J-8483-5
EACH SIDE)
.177 N
369H92041-49i;l
DIA. HOLE
8
BASE SUB ASSEMBLY
369H92041SPACERS -45 -47 -49 369H92041-47

SPACER THICKNESS (INCHES) .09 .28 .51
ALL SPACERS 318 INCH DIA. MADE FROM M551957-33
DELRIN ACETAL ROD (PER ASTM 04181-86) SCREW
88658A
Figure 1. Skid Tube Position Light Assembly.

LETTER NO.: HL122
DLg7
McDonnell Douglas EL-48FL42
DATE: 11 October 1991
Helicopter Company PAGE: 1 of 1

HELICOPTER COMPANY 369 SERIES HELICOPTERS.
SUBJECT: MAIN ROTOR HUB BALANCING
All new, overhauled or repaired main rotor hubs are not balanced at the factory unless re-
quested by the customer to do so. These main rotor hubs must be balanced at the time of
installation onto a helicopter per the r~quirements of CSP-HMI-8, Sections 18-10-00 and
62-20-00.
If you have any questions regarding balancing of the main main rotor hub, contact your
local MDHC Field Service Representative or the Warranty and Repair Department at
(602)891-8565.
8ir32%
John Reagan, Man~ger,
McDonnell Douglas
Helicopter Company
Product Support Depertment
McDonnell Douglas~
LETIER NO.: HL123.1*
DE99.1*
McDonnell Douglas EESO.1*FE44.1*
i Helicopter Company10 September 1992
"Supercedes Service Information Letters HL-123, DL-99, EL-50 and FL-44, dated 21
February 1992.

HELICOPTER COMPANY (MDHC) 369 SERIES HELICOPTERS.
SUBJECT. POLICY PRICE OF 369HS108 FUEL VENT EMERGENCY SHUTOFF

VALVE.
MDHC has established a policy list price of $900.00 (U.S. Funds) for the 369H8108-505
fuel vent emergency shutoff valve. The policy price has been established because the
369H8108-505- shutoff valve is needed to comply with the requirements of HN-234,
DN-181, EN-73 and FN-60, dated 17 January 1992. The policy price will remain in effect
until 30 June 1993.
Rsagan, Manager,
McDonnell Douglas
Helicopter Company
McDonne~ Douglas
FORM 95788 IREV ~lle7) mmnnn~/
LETTERNO.: HL-124.2*
DL-100.2*
McDonnell Douglas EL-51.2*
FL-45.1*
Helicopter Company ~i
Letters HI-1241, DL-100.1, EL511 and FL-IS.

Supercede3 Service Information
dated 10 September 1992.
DOUGLAS
TO: ALL OWNERS AND OPERATORS OF MCDONNELL
HELICOPTERS
HELICOPTER COMPANY(MDHC) 369A(OH-6A) SERIES
(MARKETING DESIGNATION: HUGHES MODEL 500).
FOR SAFE
SUBJECT: MAINTENANCE AND OPERATION REQUIREMENTS
OPERATION OF SURPLUS 369A (OH-6A) SERIES
HELICOPTERS.
43 and 91)
REFERENCE: FederalAviation Regulations (Parts 21, 39,
Type Certificate Data Sheet HSWE (latest issue)
Manual)
U.S. Army Technical Manual, TM55-1520-214-10 (Operators
U.S. Army Technical Manual, TM55-1520-214-23 (Maintenance
Manual)
AnnyTechnical Manual, TM55-1520-214-23P (Illustrated

U.S.
Parts
Tools)
I
Manual including Depot Maintenance Repair Parts and Special
Applicable U.S. Army Safety of night Messages
Applicable FAAAirworthiness Directives
MDHC 369H Basic HMI, (Revised 15 June 1990)
MDHC 369B Basic HMI, Appendix B (Reissued 17 March 1992)
ISSUE: In 1960, Hughes Tool Company (currently MDHC) initiated the design of the 369A
369 (Army YOH-6A)
(OH-6A) Series helicopter. On June 30, 1964, the Model
Certificate Data Sheet
was approved as a normal category helicopter.I~pe
H3WE was approved and issued June 30, 1964.
and are being oper-

OH-6A Series helicopters were owned by the U.S. Army
ated as Public Service Aircraft. These helicopters were
maintained in accor-
and inspection pro-
dance with the then applicable U.S. Army maintenance
such, these ~elicopters zoere not required to be operated
or
grams. As
certificated
maintained in accordanee with FAA Regulations regarding
aircraft.
Ainvorthi-
WARNING: Failure to comply with established FAA Regulations,
overhaul life limits and proper in-
ness Directives, mandatory retirement,
lead to lass of mntrol of Wle heli-
spsction and maintenance pmcedures may
copter and subsequent injury, death and/or property damage.
McDonnell Douglas
LETTERNO.: HL-124.2*
DL-100.2L
EL-51.2*
FL-45.1*
DATE: 25 JANUARY 1993
PAGE: 2 of 2
If you are the current operator of an OH-6A helicopter, or plan to

owner or
acquire one, you must operate and maintain your helicopter as either a Public
Service Aircraft (for other government agencies) or a civil aircraft with an
FAA Certificate ofAirworthiness. Civil aircraft must be maintained and oper-
ated in accordance with applicable Federal Aviation Regulations (FAR) and
Type Certificate Data Sheet HSWE.
MDHC strongly recommends that any OH-6A aircraft used as Public Service
Aircraft be operated and maintained in accordance with the applicable U.S.
Anny Technical Manuals: TM 55-1520-214-10 Operators Manual, TM
55-1520-214-23 Organizational Maintenance Manual and TM
55-1520-214-23P Illustrated Parts Manual. Additionally, owners and oper-
ators should ensure that all applicable FAA Airworthiness Directives, Man-
uafacturers mandatory Service Information Notices and U.S. Army Safety

of Flight Messages have been complied with.
Operators of OH-6A helicopters can 369H maintenance manuals

purchase
and Service Information Notices from MDHC. However, MDHC does not sell
or distribute U.S. Army technical manuals or
FAA Airworthiness Directives.
It it. further recommended that ownera/opsrators contact a hbDHC autho-

rized Service Center or the MDHC Field Service Department with any ques-
tions or problems that may arise.
n~etn
John Reagan, Dept. Manager,
Commercial Customer Support
McDonnell Douglas
Helicopter Company
POINTS OF CONTACT For further information, contact your local MDHC

authorized Service Center or Field Service Representative (refer to the
latest revision of the Product Support handbook for address and
telephone numbers) or contact the Field Service Department at MDHC,
Mesa Arizona. Telephone: 1-800-388-6342 or (602) 891-6342.
Datafax: (602)891-6782.
LEITER NO.: HL-125
DL-101/
FL-46
Helicopter Company
PAGE: 1 of 2
ALL OWNERS AND OPERATORS OF MCDONNELL

DOUGLAS
TO:
HELICOPTER COMPANY (MDHC)369 SERIES HELICOPTERS.
SUBJECI~ MAIN ROTOR BLADE INSPECTION PROGRAM.
all reissues of currently

The purpose of this Service Information Letter is to assure that
of Service Informa-
applicable Ser?rice Information Notices and all cancellations existing
and justified.
tion Letters required to implement this change are clearly explained
which
MDHC: is implementing a revised main rotor blade root fitting inspection procedure
blade root fittings by
will enhance the capability of operators to detect cracked main rotor
visual inspection. This revised procedure allows elimination of
the mandatory require-
ment to inspect 369D21100-515 and 369D21102-501
main rotor blades every 25 hours in
accordance with PART I of DN-183.1, EN-75.1 and FN-62.1.
The service information package that accompanies this Service Information Letter in-
cludes the following:
which supersedes
1. Service Information Notice, DN-183.2, EN-75.2 and FN-62.2
the requirement of PART I to re-
DN-183.1, EN-75.1 and FN-62.1. This revision cancels
move affected main rotor blades every
25 hours and inspect the main rotor blade root fit-
be removed and
The revised Notice still requires that the affected main rotor blades
tings.
returned to MDHC for rework to a new configuration in accordance with PART II.
2. HN-211.4, DN-51.6, EN-42.4 and FN-31.4 which su-

Service Information Notice,
revision requires a one-time
percedes HN-211.3, DN-51.5, EN-42.3 and FN-31.3. This
hours to inspect the
removal inspection ofthe affected main rotor blades within the next 25
to enhance the visual inspection
root fittings and add a slippage mark to the root fittings
links on the aircraft
procedure. The requirement to inspect the root fittings and lead-lag
the blades to inspect the rooting fittings and lead-lag links
every 25 hours and to remove
every 100 hours remains in
affect after installation of the paint stripe.
3. Service Information Letter Cancellation Notification: SILs HL-114.1, DL-89.1,

EL-40.1 and FL-33.1 are cancelled.
McDonnell Douglas
FORM 95788 (REV 11187) HelicoPter Com~anv
LETTERNO.: HL-125
DL-101
EL-S2
FL-46

PAGE: 2 of 2
eliminate the
Issuance of Service Information Notices, DN- 183.2, EN-75.2 and FN-62.2 to
25 hour removal inspection requirement is justified by the enhanced inspection procedure
incorporated by compliance with Senrice Information Notices HN-211.4, DN-51.6,
EN-75.4 and FN-31.4.
The revised inspection also reminds operators of actions that must be taken if they experi-
ence a sudden onset or increased level of main rotor vibration. Historically, there has been
an immediate onset of main rotor vibration after a single root fitting lug failure.
John Reagan, Dept. Manager,

McDonnell Douglas
3
Helicopter Company
LETTERNO.: HL-126
DL-102
McDonnell Douglas EL-S3FL-47
Helicopter Company
PAGE: 1 ot 2
TO: ALL OWNERS, OPERATORS AND PILOTS OF MCDONNELL DOUGLAS

HELICOPTER COMPANY (MDHC) 369 SERIES HELICOPTERS THAT HAVE
ANTENNAS INSTALLED ON THE UPPERSURFACE AREAS OF THE AFT
BOOM FAIRING.
SUBJECT: ANTENNA LOCATION AND FLIGHT MANEUVER CAUTION
RECOMMENDED HELICOPTER REWORK
MDHC has received information from operators indicating that antennas (e.g., LORAN
antennas) installed on the upper surface of the aft boom fairing have been struck by the
main rotor blades during practice touchdown autorotations. MDHC strongly recommends
that operators who have installed antennas on the upper surfaces of the aft boom fairing
relocate those installations to a position where contact between any rotating component
and an antenna will not be possible. Figure 1 shows an acceptable location for such installa-
tions
PILOT NOTIFICATION
Pilots flying MD500 series helicopters with antennas located on the upper surface of the
aft boom fairing are cautioned that under certain operational maneuvers, such as practice
touchdown autorotations, main rotor blades may contact the antenna. This contact occurs
when the blades flap to an extreme downward position while, at the same time, the anten-
na moves to its most upward position.
NOTE: If a pilot suspects that contact has occurred between the main rotor blades and the
antenna during any flight maneuver they must land as soon as possible and check the
blades for damage. Further flight is prohibited if damage has exceeded HMI limits. Contact
your local MDHC Field Service Representative if you have any doubt as to damage limits.
John Reagan Dep Manager,

McDonnell Douglas
Helicopter Company
McDonnell Douglas
LETTER NO.: HL-126
DL-102
EL-53
FL-Q7
DATE: 22 March 1993
PAGE: 2 of 2
RECOMMENDED LOCATION FOR

ANTENNACOMPONENTS
ICROSI TCH AREA)
RECOMMEND THAT ANfENNA NOT BE INSTALLED AFT OF THIS AREA
3"
Q
I~I STA
108.50
cANTSTA STA
STA
146.62
STA
STA
164.87
STA
STA
185.89
CANT STA
124.00 137.50 155.75 174.00
197.78
WL 76.7 r:
Il,,i ",.,;ii..
WL45.36
~BEAM
WL 11.98
WL13.10
JACKING POINT STA 96.89

8Lse5.6
WL 0.00
STA STA STA STA STA

84.79 96.421) 108.04 119.67 137.50
CANT STA STA STA STA STA

78.50 90.61 102.23 113.85 124.00
STA
100.00
Figure i. Recommended Antenna Location.

88-676
DL-104
FL-49
Helicopter Systems DATE: 21 DECEMBER 1994

PAGE: 1 of 1

HELICOPTER SYSTEMS HELICOPTERS.
SUBJECT: COMPLIANCE TO SERVICE INFORMATION NOTICES DN-185,

EN-78 AND FN-64, DATED 23 SEPTEMBER 1994 AND FAA
AIRWORTHINESS DIRECTIVE 94-24-04.
MODELS AFFECTED: All Model 369D, 3693 and 369F/FF series helicopters.
MDHS issued Service Information Notices DN-185, EN-78 and FN-64 requiring
within specific limits.
operators to check torque of locknut to ensure torque on nut is
Lockwashers do not have to be removed if the torque is within acceptable limits.
Subsequent to the issuance ofDN-185, EN-78 and FN-64 the FAA issued AD 94-24-04.
AD 94-24-04, Para: (a) and (b) requires operators to disassemble the tail rotor swashplate
and remove and inspect the lockwasher. This is not a requirement of DN-185, EN-78 or
sub
FN-64. The FAA has agreed to an equivalent means of compliance with AD 94-24-04
Service
paragraphs (a) and (b) by complying with PART II, paragraph A., of the subject
Information Notice and replacing the lockwasher (P/N MS172209) at the next annual
inspection. Therefore, operators can apply far this equivalent means of compliance to AD
94-24-04 by contacting Brent Bandley, Aerospace Engineer, Airframe Branch,
ANM-123L, Northwest Mountain Region, FAA, Los Angeles Aircraft Certification Office,
fax
3960 Paramont Blvd., Lakewood, California 90712. Telephone: (310)627-5237,
(310)627-5210.
~iea ~agan,
McDonnell Douglas
Helicopter Systems
CommercialCustomer Support
McDonnell Douglas
FORM 95788 (AEV 1184) Helicopter Systems
TRANSPORT AIRPLANE DIRECTORATE
AIRCRAFI CERTIFICATION SERVICE
LOS ANGECES AIRCRQPT CERTIFICATION OFFICE
3960 PARAMO~NT BLVD.
LAKEWOOD, CALIFORNU 90712-4131
OEC 2 1 1191
Mr. Rogcr Carfin

FAA Coordinator
BLDC 543/D201
Mcl)onnell Douglas Helicopter Systems (MDHS)
5000 Fast McDowell Road
Meals Arizona 852159797
Reference; a) MDHS Service Infmmation Notice (SIN) DN-lsS, EN178 and FN-64, dated
September 23, 1994
b) FAA AD 94-24-04
c) Savice Letter DL104, ELS5 and FG49, dated December 21, 1994
Dear M. Carlin:
Alternate Means ofCompiiance to AD
After discussions with MDHS, the Los Angeles Aircnff and the Rotorcraft
Db.cctorlat, an alternate means of comphance to AD 9412~04 haa been agreed mt by an parties
involved. As stated in the referenced Service Later, the FAA has agreed to an ohern?te rneans of
PA~T n, prn~ph
comphenee with AD 94124-04 dib plngapll (I) ssd (1) by COPPplyhPg With
the lodEWlshQ (PM MS112269) a the nad LMUJ
k, afthe referenced SIN end replsChDa
inspection.
If?n opent4r desires to we this shuaae meens thee atdpy dfthis Janae
of compliance approves tha action. If yen have my qaestions on this subject, pkese
means
contact Mr. Brent BnAlty ofthe Airfinme Branch, (310)
Smcerely,
5
Ulbsrt L fhaplan
Gil,ert L. ThamCuOQ
Manager, Los Angetea Aircraft
Of~e
ANM- 123L:B.BsndteyndZ37; 12/2

File: 369/AD9G2e011
CC: B. BANDLEY(ANM1123L)
St~Bng Stsndsrds: Ah Means ofCompltnce Apprend
LETTER NO.: HL-128 i
McDonnell Douglas DL-105~EL-57
FLSO
Helicopter Systems
SERVICE INFORMATION LETTER DATE: 10 MAY 1995
PAGE: 1 of 1
ALL OWNERS AND OPERATORS OF MCDONNELL

DOUGLAS
TO:
HELICOPTER SYSTEMS 369H, 369D, 3693 AND 369F/FF HELICOPTERS.
SUBJECT: TAIL ROTOR ABRASION STRIP WARRANTY

POLICY/COMPENSATION.
3693 and
MODELS AFFECTED: All Model 369H, 369HE, 369HM, 369HS, 369D,
369F/FF Series Helicopters.
MDHS has issued the following warranty policylcompensation regarding operators re-
and
quirement to comply with Service Information Notices HN-238, DN-187, EN-80
FN-66, dated 26 October 1994.
to PART II of the Service In-

Warranty Policy/Compensation for compliance
formation Notices listed above.
still within the warranty period, MDHS will assume the cost to replace the
If blades are
debonding has occurred, at an Authorized MDHS blade

abrasion strips, whether or not
repair facility.
If debonding of abrasion strip occurs on a blade that is outside of the normal warran-
an
the cost for replacement of the abrasion strip(s)
ty period, MDHS will pay a portion of
on the entire set of blades for
that aircraft. The costs to be covered by MDHS will be
Re-
prorated based on hours on the blades. Contact the MDHS Commercial Warranty
pair Administrator for determination of coverage.
If blades are outside the warranty and abrasion strips are replaced, even though
period
will be at the op-
no debonding has occurred, the cost of the abrasion strip replacement
erators expense.
Jbhn Reagan, p
Commercial Customer Support Dept.,
McDonnell Douglas
Helicopter Systems
McDonnell Douglas
FORM 95788 (REV 1/94) Helicopter Systems
LETTER NO: HG130 I
DG~106\1
EG58
~HCDOArrmELL IDOUOULS
M~Donnell Douglas Helicopter Systems FG51
NU)O3
JULY 1997
SERVICE LETTER01
ALTERNATUIMPROVED ENGINE OIL TANK SEAL
MODELS AFFECTED: All 1McDonnell Douglas Helicopter Systems (MDHS) 369H/D/E/FF

and 500N Series Helicopters.
MDHS is discontinuing the sale of 369118308 engine oil tank seals. Owners/operators
needs
should install a 369A8322 engine oil tank filler seal when the 369118308 seal
replacing. The 369A8322 seal has improved resistance to oil and
is one-way
with the 369318308 seal. The 369A8322 seal is now available at MDHS.
interchangeable
This letter is valid for one year after issuance date and may
be removed from your files at
that time.
Copyright 1996 by McDonnell Douglas Corporation.

This document may be reproduced and distributed provided nofee is
charged, the text is nor modified, and this copyrghrnotice is included.
LETT~RND: DL107J
EG59
DOUGLAS FG52
McDonnell Douglas Helicopter Systems MG004
DATE: 18 3ULY 1997
SERVICE LETTER PAGE 10F 1
LIFE LIMIT INCREASE OF

HORIZONTAL AND VERTICAL STABI1IZER
MODELS AFFECTED: All McDonnell Douglas Helicopter Systems (MDHS) 369D/E/FF

and 500N Series Helicopters.
MDHS has increased the life limits of the following horizontal and vertical stabilizers:
For Model MDS00N, the following part numbers have unlimited lives:
500N3800-7 (vertical stabilizer, upper),

500N3800-9 (vertical stabilizer, lower).
For Models 369D/E/FF the following horizontal stabilizer part number life limits have
been increased to 7700 hours:
369D23601 (Model 369D),

421-087-505 (Model 3693),
421-087-905 (Model 3693),
421-087-503 (Model 369FF),
421-087-903 (Model 369FF).
NOTE
421-087-903 and 421-087-905 require addition of tip plates, tip weights and
attaching hardware before installation (ref. CSP-HMI-2, Section 53-00-00).
This Service Letter is for information only; refer to CSP-HMI-2, Section

04-00-00, for the current life limits of all life-limited components and assem-
blies.
This Service Letter is valid for one year after issuance date and may be removed fiom
your files at that time.
SIN
Technical Publishers Customer Service
C~-Aircraft
101 South Hill Drive
Brisbane, CA 94005 (800)227-4610

369[) SERIES
SERVICE INFO NOTICE
1) Applicable AD
2) Part Kit (1)
DN-O1 INSPECTION OF TAIL ROTOR 1)

03/23/1977 OUTPUT SHAFT: INSTALLATION 2)
OF PROTECTIVE DUST BOOTS 3)
4) MANDATORY
DN-03 MAIN ROTOR CONTROLS- RIGGING 1)

08/30/1977 OF CYLIC AND COLLECTIVE 2)
CONTROLS; REWORK OF MIXER 3)
CONTROLS 4) MANDATORY
DN-06 MAIN ROTOR PITCH CONTROL ROD 1)

08/30/1977 ASSEMBLY REPLACEMENT OF 2)
PITCH ROD AND INSPECTION OF 3)
ROD END BEARINGS 4) MANDATORY
DN08 INSTALLATION OF SUPPORT 1)

08/30/1977 RING-TAIL ROTOR STATIONARY 2)
BOOT 3)
4) MANDATORY
DN-9.2 OVERRUNNING CLUTCH ASSY P/N 1)77-21-04

10/27/1978 369A5350-603- INSPECTION OF P/N 2) SEE ISSUE
369A5350-11 CLUTCH SUBASSY 3)
P/N 369A5361 BALL BEARING 4) MANDATORY
DN-10 INSTALLATION OF AUXILIARY 1)

10/03/1977 DRAIN VALVE, FUEL SYSTEM 2)
INSTALLATION DRAIN KIT 3)
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-11 MODIFICATION OF P/N 1)

10/03/1977 369A4516-3 N1 TACH INDICATOR 2) SEE SX
4) MANDATORY
DN-12 INSTALLATION OF MODIFIED 1)

11/18/1977 (ROTOR BRAKE HANDLE) TRIM 2)
COVER PANEL ASSEMBLY 3)
4)
DN-13 INSPECTION LITTER DOOR 1)

11/30/1977 INSTALLATION 2)
4) MANDATORY
DN-14 MOSIFICATION KIT MAIN 1)

12/15/1977 TRANSMISSION LUBRICATION 2)
PUMP 3)
4) MANDATORY
DN-16 REWORK OF TURBINE OUTLET 1)

02/01/1978 TEMPERATURE (TOT) INDICATOR 2) P/N 369A4521-7
AND TORQUE PRESSURE INDICATOR 3) 369H4526-7
4) OWNER OPTION
DN-17 INSTALLATION ENGINE 1)

02/06/1978 COMPRESSOR WATER WASH KIT, 2) P/N 369H92537
P/N 369H92537 3)
4) SEE SX
DN-18 REMOVAL OF CAPACITOR- VOLTAGE 1)

02/06/1978 REGULATOR, INSTALLATION OF 2) P/N MS24166D1
VARISTOR-LANDING LIGHT RELAY 3)
4) SEE SX
DN-19 ENGINE COMPRESSOR WATER WASH 1)

04/14/1978 KIT INSTALLATION- INSPECTION 2) P/N 369H92537
AND REPLACEMENT OF RIVETS 3)
4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-20 REPLACEMENT OF PLENUM WALL 1)

06/06/1978 FITTINGS-TORQUE PRESSURE GAGE 2)SEE ISSUE
TUBING AND ENGINE OIL PRESSURE 3)
GAGE TUBING 4) DISCRETION
DN-21 REWORK OF STANDARD LANDING 1)

06/06/1978 GEAR SKID ASSEMBLY; REWORK OF 2) SEE ISSUE
EXTENDED LANDING GEAR SKID 3)
ASSEMBLY 4) MANDATORY
DN-22 SEALING-VERTICAL STABILIZER 1)

06/26/1978 ASSEMBLY, P/N 369023600 2)SEE ISSUE
P/N 369923600-501 3)
4) MANDATORY
DN-23.2 INSTALLATION OF STANDOFF 1)

09/05/1979 CLAMPS-HEATING SYSTEM HOSE AND 2)SEE ISSUE
MAIN ROTOR TRANSMISSION OIL 3)
COOLING LINES 4) MANDATORY
DN-24 FIELD INSPECTION CORROSION 1)

07/05/1978 REPAIR-MAIN ROTOR DRIVE SHAFT, 2)SEE ISSUE
P/N 369925510 3)
4) DISCRETION
DN-25.1 REWORK OF FUSELAGE STRUCTURE, 1)

03/07/1980 FORWARD SECTION 2) SEE ISSUE
4) MANDATORY
DN-26 INSPECTION POSSIBLE REPLACE- 1)

07/15/1978 MENT SEAT BELT ASSEMBLIES, 2) SEE ISSUE
P/N 369H6541-5 369H6541-21 3)
4) MANDATORY
DN-27.1 INSPECTION REWORK OF TAIL 1)78-26-04

12/08/1978 ROTOR HUB,P/N 369A1725-5 &-501 2)SEE ISSUE
-INSPECTION OF TAIL ROTOR 3)
BLADE ATTACHMENT BOLTS 4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-27.1 INSPECTION REWORK OF TAIL 1)78-26-04

12/08/1978 ROTOR HUB,P/N 369A1725-5 &-501 2) SEE ISSUE
-INSPECTION OF TAIL ROTOR 3)
BLADE ATTACHMENT BOLTS 4) MANDATORY
DN-30 INSTALLATION OF ANTI-ICE FUEL 1)

09/08/1978 FILTER, P/N 369H90022 2)SEE ISSUE
4) DISCRETION
DN-31 INSTALLATION OF NEW P/N 3690- 1)

09/08/1978 21012 RUBBER WASHERS-ATTACH- 2)P/N 369821012
MENT OF PITCH CONTROL RODS TO 3)
MAIN ROTOR SWASHPLATE ASSEMBLY 4) MANDATORY
DN-34 REPLACEMENT P/N 369D28309 1)

10/17/1978 HOSE ASSEMBLY, ENGINE OIL 2) P/N 369[)28311-3
COOLER TO ENGINE OIL TANK 3)
4) MANDATORY
DN-35 FIELD REPAIR CYCLIC TRIM 1)

01/29/1979 ACTUATOR ASSEMBLIES, P/N 2)SEE ISSUE
369A7170 SERIES AND P/N 3)
369A7171 SERIES 4) DISCRETION
DN-36 INSTALLATION OF AIR BAFFLE, 1)

11/14/1978 SEAL AND COVER ASSEMBLIES 2)SEE ISSUE
TRANSMISSION COMPARTMENT 3)
4) DISCRETION
DN-37 P/N 369821800 TAIL ROTOR PITCH 1)79-10-09

12/01/1978 CONTROL ASSY-SEATING OF DUAL 2) SEE ISSUE
BEARING INNER RACES,CONTD. SEE 3)
ADS 78-26-04 79-10-09. 4) MANDATORY
DN-39 INSTALLATION OF STAINLESS 1)

06/01/1979 STEEL ABRASION TAPE, P/N 2) SEE ISSUE
369D21104-MAIN ROTOR BLADE 3)
LEADING EDGE 4) DISCRETION
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-40 EXTENSION OF P/N 369A8010-615 1)

12/15/1978 OVERBOARD VENT TUBE ENGINE 2) SEE ISSUE
ACCESSORY DRIVE 3)
4) DISCRETION
DN-42 P/N 369H7825 DROOP CONTROL 1)

02/15/1979 BELLCRANK ASSEMBLY (STATION 2)SEE ISSUE
68.0)-RELOCATION OF LOCKNUT 3)
INSTALLATION OF SPACER 4) MANDATORY
DN-43 FIELD REPAIR TRIM TAB,MAIN 1)

02/15/1979 ROTOR BLADE, P/N 369[)21100 2)SEE ISSUE
SERIES 3)
4) DISCRETION
DN-44.1 P/N 369D23601 HORIZONTAL STAB- 1)

06/22/1979 ILIZER ASSY-ADJUSTMENT OF P/N 2) SEE ISSUE
369823678-3 TRAILING EDGE TABS 3)
RELOCATION OF P/N 369H66105 4) MANDATORY
DN-45.2 P/N 369[321400-501 MAIN ROTOR 1)

10/22/1979 LEAD-LAG ELASTOMERIC DAMPER 2) SEE ISSUE
ASSEMBLY-INTERNAL MODIFICATION 3)
AND REIDENTIFICATION 4) MANDATORY
DN-46.1 FIELD MODIFICATION OF P/N 1)

08/15/1979 369[)21002 SCISSORS CRANK ASSY, 2)SEE ISSUE
MAIN ROTOR HUB-UPGRADE TO P/N 3)
369[)21002-21 CONFIGURATION 4) DISCRETION
DN-47 FIELD RIGGING CHECK P/N 1)

04/16/1979 369A8013-503 HEATER CONTROL 2)SEE ISSUE
VALVE ASSEMBLY 3)
4) MANDATORY
DN-48 REPLACEMENT OF RADIO TRANSMIT/ 1)

05/10/1979 INTERCOM TRIGGER SWITCH;REWORK 2) SEE ISSUE
OF CYCLIC PITCH STICK GRIP 3)
ASSEMBLY 4) DISCRETION
04/08/2000 Copyright O Aircraft Technical Publishers Page 5 of 21
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
Issue Date Issue Description 4) ComplianceTime
DN-49 INSPECTION AND REPAIR-STATION 1)

06/11/1979 142 TAIL ROTOR CONTROL BELL- 2)SEE ISSUE
CRANK SUPPORTS, P/N 369A3035- 3)
11 AND -15 4) MANDATORY
DN-50.1 INSTALLATION OF VOLTAGE 1)

11/26/1979 TRANSIENT SUPPRESSORS 2) SEE ISSUE
3)
4) DISCRETION
DN-52.2 KIT INSTALLATIONS, P/N 1)

09/15/1980 36902901-40-501 AUX ILIARY 2) SEE ISSUE
FAIRINGS AND SEALS, ENGINE AIR 3)
FILTER (PARTICLE SEPARATOR) 4) MANDATORY
DN-54.1 INSPECTION-COLLECTIVE TORQUE 1)

03/07/1980 TUBE SUPPORT BRACKET COLLEC- 2)SEE ISSUE
TIVE BUNGEE SUPPORT BRACKET 3)
4) MANDATORY
DN-55 REWORK OF GROUND HANDLING 1)

08/20/1979 WHEEL ASSEMBLIES (FLOAT TYPE) 2)SEE ISSUE
3)
4) DISCRETION
DN-56 INSTALLATION OF FUSELAGE 1)

03/07/1980 ACCESS PANELS FOR CYCLIC TRIM 2)SEE ISSUE
ACTUATOR ASSEMBLIES 3)
4) DISCRETION
DN-58.2 INSPECTION AND REPAIR OF AFT 1)

05/11/1981 FUSELAGE SKIN CRACKS; 2) SEE ISSUE
INSTALLATION OF DOUBLERS ON 3)
BOOM FAIRING LOWER LONGERONS 4) MANDATORY
DN-59 INSTALLATION OF CABIN HEAT 1)

01/15/1980 DUCT (FIBERGLASS) ASSEMBLIES, 2) SEE ISSUE
P/N 369022009-101 P/N 3)
369022009- 103 4) DISCRETION
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
Issue Date Issue Description 4)
DN-60 FILTER GASKET-ENGINE AIR INLET 1)

03/03/1980 (PARTICLE SEPARATOR) FILTER 2)SEE ISSUE
KIT INSTALLATION, P/N 3)
369H90148-503, -505 AND -507 4) MANDATORY
DN-62 INSPECTION AND REWORK OF TAIL 1)

03/03/1980 ROTOR TRANSMISSION HOUSING 2) SEE ISSUE
ASSEMBLY, P/N 369025401 3)
4) MANDATORY
DN-63 HORIZONTAL STABILIZER ASSEMBLY 1)

03/03/1980 -ADDING DRAIN HOLES SEALING 2)SEE ISSUE
DOUBLER EDGES 3)
4) MANDATORY
DN-65.1 REWORK OF COOLING BLOWER 1)

12/19/1980 MOUNTING BRACKET 2)SEE ISSUE
4) MANDATORY
DN-66 REWORK OF P/N 3690290125-21 1)

05/16/1980 MIST ELIMINATOR ASSY-ENGINE 2) SEE ISSUE
AIR INLET FILTER (PARTICLE 3)
SEPARATOR) ASSY 4)SEE ISSUE
DN-67 REWORK OF ONE-WAY LOCK 1)

06/02/1980 ASSEMBLY, P/N 369A7010 SERIES 2)SEE ISSUE
4) DISCRETION
DN-68.1 RELOCATION OF TAIL ROTOR 1)

12/08/1980 BUNGEE SPRING FORWARD 2) SEE ISSUE
ATTACHMENT; TAIL ROTOR FORCE 3)
ADJUSTMENT 4) MANDATORY
DN-69 POLARITY CHECK OF DIODE 1)

06/30/1980 ASSEMBLIES 2) P/N IN3210
4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-70 IDENTIFICATION AND POSSIBLE 1)

07/11/1980 REWORK OF SEAT BELT AND 2)
SHOULDER HARNESS ASSEMBLIES 3)
4) MANDATORY
DN-71 WIRING MODIFICATION-UTILITY 1)

09/30/1980 LIGHT CIRCUIT TRANSMISSION 2) MS25036-149
OIL PRESSURE TEMPERATURE 3)
WARNING LIGHT CIRCUIT 4) MANDATORY
DN-72.1 DRAIN KIT INSTALLATION, P/N 1)

02/06/1981 369028300-501 ENGINE OIL TANK 2) SEE ISSUE
OIL COOLER; DRAIN KIT 3)
INSTALLATION, CONTD. 4) DISCRETION
DN-73 PERIODIC INSPECTIONS BONDING 1)

08/22/1980 PROCEDURE-TAIL ROTOR DRIVE 2)SEE ISSUE
FORK ELASTOMERIC TEETER 3)
BEARINGS, P/N 369A1724 4) MANDATORY
DN-76 REWORK OF STATIC PRESSURE TUBE 1)

12/08/1980 INSTALLATION TO MINIMIZE 2) 369H6610-23
ALTIMETER NEEDLE OSCILLATION 3)
4) DISCRETION
DN-78.1 INSPECTION OF P/N 369A7003-3 1)

07/28/1981 SWASHPLATE BEARING 2) SEE ISSUE
4) MANDATORY
DN-79 SEALING OF INTERFACES OF 1)

01/30/1981 ABRASION STRIP AND MAIN ROTOR 2)SEE ISSUE
BLADE SKIN 3)
4) MANDATORY
DN-80 REPLACEMENT OF TAVCO P/N 1)

03/20/1981 23111369 SOLENOID VALVE, FLOAT 2) SEE ISSUE
INFLATION SYSTEM-EMERGENCY 3)
FLOAT ASSY, HUGHES P/NS,CONTD 4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
Issue Gate Issue Description 4) Compliance Time
DN-81.1 INSPECTION OF OVERRUNNING 1)

05/10/1983 CLUTCH SPRAG ASSEMBLY 2)SEE ISSUE
3)
4) SEE ISSUE
DN-82 FIELD INSPECTION REPAIR OF 1)

04/15/1981 TAIL ROTOR GEAR BOX MAIN 2) SEE ISSUE
HOUSING ASSY P/N 369[)25301 OR 3)
369[)25401-3 4) MANDATORY
DN-86 SHIMMING PROCEDURE FOR GAS 1)

05/06/1981 PRODUCER INTERCONNECTING 2)SEE ISSUE
TORQUE TUBE ASSEMBLY 3)
4) MANDATORY
DN-87 REPLACEMENT OF P/N 369A7706-3 1) 82-01-08

05/1511981 RPM GOVERNOR LEVER CONTROL ROD 2) 369A7706-5
4) MANDATORY
DN-88 ELIMINATION OF POSSIBLE 1)

05/19/1981 INTERFERENCE OF SAFETY WIRE 2) NAS1224-1L
WITH OIL COOLER BLOWER DRIVE 3)
BELT 4) MANDATORY
DN-89.2 BALANCING OF MAIN ROTOR HUB 1)

09/24/1982 ASSY, P/N 369[)21200 2)SEE ISSUE
4) DISCRETION
DN-91.1 INSPECTION OF MAIN ROTOR HUB 1)

07/22/1981 STRAP PACK RETENTION BOLTS AND 2)SEE ISSUE
REPLACEMENT OF BUSHINGS 3)
4) MANDATORY
DN-92 CORROSION INSPECTION/TREATMENT 1)

06/04/1981 ONE-WAY LOCK SUPPORT ASSY, P/N 2) SEE ISSUE
369A7314 AND 369N2648 3)
4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-93 "INSPECTION/MODIFICATION OF 1)
06/18/1981 BREEZE CORPORATION INC. HOIST, 2)
P/N BL-16600-12 3)
4) MANDATORY
DN-94 DEACTIVATION OF MAIN ROTOR 1)

06/25/1981 BRAKE SYSTEM (IF INSTALLED): 2)
PERIODIC INSPECTION TAIL ROTOR 3)
DRIVE SHAFT FORWARD, CONTD. 4)SEE ISSUE
DN-95 INSTALLATION OF FAILSAFE 1)86-20-07

08/07/1981 DEVICE AT TAIL ROTOR DRIVE 2) SEE ISSUE
SHAFT FORWARD FLEXIBLE 3)
COUPLING, P/N 369A5501,CONTD. 4) MANDATORY
DN-96 ONE-TIME INSPECTION-ATTACHMENT 1)

08/21/1981 HARDWARE FOR STA-STRAP 2)SEE ISSUE
SECURING ELECTRIC WIRING TO 3)
BOOM FAIRING AT STA 138.50 4) MANDATORY
DN-97 MAIN ROTOR BRAKE SYSTEM, P/N 1)

10/05/1981 369H90123 SERIES-INSTALLATION 2)SEE ISSUE
OF MASTER CYLINDER STOP, P/N 3)
3690292585 4) MANDATORY
DN99 PERIODIC INSPECTION OF MAIN 1) 81-26-01 R1

11/30/1981 ROTOR DRIVE SHAFT, P/N 2)SEE ISSUE
369D25510 3)
4) MANDATORY
DN-100 RELOCATION OF AUTO 1)

02/22/1983 REIGNITION CONTROLS 2)SEE ISSUE
AND MODIFICATION OF SYSTEM 3)
FOR FULL-TIME OPERATION 4) DISCRETION
DN-101 INSTALLATION OF P/N 1)
02/01/1982 369H4237-21 RESISTOR BOARD 2) 369H4237-21

ASSY FOR EASIER, MORE ACCURATE 3)
ADJUSTMENT OF TOT INDICATOR 4) DISCRETION
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-102 INSPECTION OF P/N 369A7006-5 1)

02/01/1982 TAIL ROTOR CONTROL ROD; REWORK 2) SEE ISSUE
OF P/N 3698290128-11 PARTICLE 3)
SEPARATOR FAIRING ASSY,CONTD. 4) MANDATORY
DN-103 MODIFICATION K/N M50459-505- 1)

03/10/1982 DOUBLE LAYER ABRASION TAPE FOR 2)SEE ISSUE
P/N 369021100-505 369021100- 3)
509 MAIN ROTOR BLADES 4) DISCRETION
DN-104 INSTRUMENT CLUSTER 3-PACK 1)

03/05/1982 CONVERSION-AC TO ROCHESTER 2)SEE ISSUE
4) MANDATORY
DN-106 REWORK OF P/N 369A9905-BASIC 1)

06/29/1982 369A9905-3 GROUND HANDLING 2) SEE ISSUE
WHEEL ASSYS TO ACCOMMODATE 3)
INSTALLATION OF NEW P/N,CONTD. 4) DISCRETION
DN-107 INSTALLATION OF FUSELAGE 1)

07/01/1982 ATTACH POINTS (P/N 369H90070- 2)SEE ISSUE
211/212 SUBASSEMBLIES) FOR 3)
ACCESSORY KIT ATTACH FITTINGS 4) MANDATORY
DN-108 REPLACEMENT OF INTERCOM (ICS) 1)

07/01/1982 SWITCH AND JACK ASSEMBLY 2)SEE ISSUE
4) MANDATORY
DN-110.1 INSPECTION AND MODIFICATION OF 1)

10/27/1989 P/N 3698292028, AFT PASSENGER 2) SEE ISSUE
STEP ASSEMBLIES, ON EXTENDED 3)
LANDING GEAR, CONTD. 4) MANDATORY
DN-111 NEW SHIMMING PROCEDURE FOR 1)

09/27/1982 TAIL ROTOR DRIVE SHAFT FORWARD 2) SEE ISSUE
FLEXIBLE COUPLING, P/N 3)
369A5501 OR 369H92564,CONTD. 4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-112 INSPECTION-LANDING GEAR STRUTS 1)

11/19/1982 AND FEET 2) SEE ISSUE
4) MANDATORY
DN-113 RELOCATION OF ENGINE AIR INLET 1)

01/10/1983 FILTER BYPASS DOOR AFT PULLEY 2) SEE ISSUE
(P/N 369A8448) BRACKET (P/N 3)
369A8447), PARTICLE,CONTD. 4) MANDATORY
DN-114 MAIN ROTOR TRANSMISSION DRAIN 1)

02/15/1983 LINE BRACKETRY MODIFICATION 2)SEE ISSUE
4) MANDATORY
DN-115 PILOTS COMPARTMENT, CENTER 1)

02/15/1983 PASSENGER SEAT LAP BELT 2)
INSTALLATION CHECK; PREFLIGHT 3)
CHECK OF PASSENGER,CONTD. 4) MANDATORY
DN-117 INSTALLATION OF 510 OHM 1)

03/20/1983 RESISTOR IN P/N 3699296303, 2) SEE ISSUE
3699296303-701 AND 369A4245 3)
SERIES FUEL QUANTITY CONTD. 4) MANDATORY
DN-118 FUEL VENT SYSTEM HOSE (P/N 1)

05/02/1983 369A8131-19) INSPECTION 2) 369A8131-35
3)MS20995H32
4) SEE ISSUE
DN-119.1 INSTALLATION OF COLLECTIVE 1)

11/23/1983 STICK SUPPORT BRACKET 2)SEE ISSUE
REINFORCEMENT STRAP 3)
4) MANDATORY
DN-120 INSTALLATION AND REPLACEMENT 1)

05/31/1983 OF PROTECTIVE SLEEVE (SPEEDI- 2)SEE ISSUE
SLEEVE P/N 084957) ON TAIL 3)
ROTOR TRANSMISSION, CONTD. LF)SEE ISSUE
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-121 BUTTON PLUG INSTALLATION 1)

06/27/1983 MAST SUPPORT STRUCTURE. AFT 2) SS148155-K1110
CHANNEL 3)MIL-S-86608
4) MANDATORY
DN-122 INSPECTION AND OVERHAUL OF 1)

07/29/1983 FUEL SHUTOFF VALVE (P/N 2)1595-1000
369A8104-5) 3)
4) MANDATORY
DN-123 BATTERY CASE AND MAIN DC POWER 1)

10/28/1983 WIRING INSPECTION 2)
4) MANDATORY
DN-124 MAIN TRANSMISSION OIL LINE 1)

11/10/1983 (PN 369[)25709 369[)25710) 2)SEE ISSUE
INSPECTION; REPLACEMENT OF 3)
MAIN TRANSMISSION OIL, CONTD. 4) MANDATORY
DN-125 MAIN ROTOR SWASHPLATE BEARING, 1)84-01-02 R1

12/23/1983 PN 369A7003-3, INSPECTION AND 2) FED-STD-15102
POSSIBLE REPLACEMENT 3)rT-I-735
4) MANDATORY
DN-126 FUEL SHUT-OFF VALVE CONTROL 1)

04/09/1984 CABLE (PN 369A8137-503 AND 2)
-603 PULL TEST 3)
4) SEE ISSUE
DN-127 REMOVAL OF GRAY COATING FROM 1)

06/12/1984 PN 369[)21700 AND 369[321700-3 2)2-025 C873-70
TAIL ROTOR HUBS 3)
4) MANDATORY
DN-129 RIVETING TIP-CAP TO TAIL ROTOR 1) 86-01-04

08/27/1984 BLADE 2)SEE ISSUE
4) SEE ISSUE
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
4) Compliance Time
Issue Date Issue Description
DN-130.2 INSPECTION OF TAIL ROTOR 1) 941808

03/23/1987 BLADE LEADING EDGE ABRASION 2)
STRIP BONDING 3)
4) MANDATORY
DN-131.1 CORROSION REMOVAL AND 1)

10/30/1987 MAGNETIC RUBBER INSPECTION OF 2)SEE ISSUE
MAIN ROTOR DRIVE SHAFT I.D. 3)
4) MANDATORY
DN-132.1 RIVETING TIP-CAP TO TAIL ROTOR 1) 86-01-04

05/01/1985 BLADE 2)SEE ISSUE
4)SEE ISSUE
DN-133 CANCELLATION OF WARRANTY 1)

03/18/1985 2)
4) MANDATORY
DN-134 NON-AIRWORTHY CLUTCH 1)
03/18/1985 ASSEMBLIES 2)
4) MANDATORY
DN135 JC EXIT WARNING DECAL P/N 1)

08/07/1985 369[324043 2) 369024043
4) MANDATORY
DN-136 REPLACEMENT OF MAIN ROTOR 1)

08/07/1985 COOLING INSTALLATION BRACKET 2) SEE ISSUE
FROM 369025701-3 TO 3)
369[)25701-11 4) MANDATORY
DN-137 TAIL ROTOR BELLCRANK 1)

12/20/1985 INSPECTION P/N 369027514 AND 2)
369927515 3)
4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)

4) Compliance Time
Issue Date Issue Description~
DN-138 FARGO AUXILIARY FUEL TANKS 1)
01/10/1986 P/N A1066-1082 2)AW1066-1082
4)SEE ISSUE
DN-139.1 COOLING FAN PULLEYS P/N 1)

03/18/1986 369025620, 369825622, 2) SEE ISSUE
369825622-3, AND 369025624 3)
INSPECTION 4)SEE ISSUE
DN-140 OIL TANK FILLER NOZZLE 1)

04/15/1986 ASSEMBLY 3691328318 2) 369928318
369928318 3)
4)SEE ISSUE
DN-141 REMOVAL OF SEAT BELT 1)

05/15/1986 ASSEMBLIES MANUFACTURED BY 2)
THE EON CORPORATION 3)
4) MANDATORY
DN-142 "UNITED INSTRUMENTS, INC. 1)
05/20/1986 ALTIMETERS (MDHC PART NO. 2)

369924174, 369H4505 AND 3)
369H90124) 4) MANDATORY
DN-143.1 INSTALLATION OF FAILSAFE 1)

11/28/1986 DEVICE AT TAIL ROTOR DRIVE 2)SEE ISSUE
SHAFT AFT FLEXIBLE COUPLING, 3)
P/N 369A5501, CONTD. 4) MANDATORY
DN-145 FABRICATION AND INSTALLATION 1)
04/09/1987 OF 3691325704 OIL FLEX-LINE 2) SEE ISSUE

HOSE ASSEMBLIES IN THE MAIN 3)
TRANSMISSION, CONTD. 4) MANDATORY
DN-146.1 DAILY PREFLIGHT EXAMINATION OF 1)

09/10/1992 MAIN ROTOR BLADE LEADING EDGE 2)
ABRASION STRIP BONDING 3)
4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)

DN-147.1 ONE-TIME INSPECTION OF MAIN 1)

10/30/1987 TRANSMISSION TAIL ROTOR OUTPUT 2) SEE ISSUE
DRIVE PINION SHAFT (P/N 3690 3)
25125-BSC AND 3691)25125-11) 4) MANDATORY
DN-148.1 INSPECTION OF MAIN 1) 87-18-12 R1

10/30/1987 TRANSMISSION OUTPUT SHAFT 2)SEE ISSUE
ASSEMBLY RING GEAR CARRIER 3)
(P/N 369D25132-BSC OR -5) 4) MANDATORY
DN-149 369A8010 ENGINE OIL PRESSURE 1)

09/15/1987 AND TORQUE TUBING PULL TEST 2)SEE ISSUE
4) MANDATORY
DN-150 START PUMP WIRE ROUTING AND 1)

09/15/1987 FUEL QUANTITY SENDER 2)
INSPECTION 3)
4) MANDATORY
DN-151 INSPECTION OF TAIL ROTOR 1)88-17-09 R1

10/10/1987 TRANSMISSION MOUNTING STUDS 2)SEE ISSUE
4) MANDATORY
DN-152 REPLACEMENT OF 369A8442-8ASIC 1)

12/18/1987 LATCH ASSEMBLY ON THE PARTICLE 2)SEE ISSUE
SEPARATOR BYPASS DOOR 3)
4) MANDATORY
DN-153.2 ONE-TIME INSPECTION AND 1)

04/21/1989 REPLACEMENT OF TAIL ROTOR FORK 2)SEE ISSUE
BOLT (369A1602) 3)
4) MANDATORY
DN-154 MAIN ROTOR HUB ASSEMBLY STRAP 1)89-02-01 R1 C2

01/15/1988 PACK LAMINATION INSPECTION AND 2) SEE ISSUE
TRI-FLOW WASH PROCEDURE OF THE 3)
MAIN ROTOR HUB ASSY, CONTD. 4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-155 MAIN ROTOR BLADE UPPER AND 1)

01/15/1988 LOWER TRAILING EDGE WEIGHT 2)SEE ISSUE
REWORK 3)
4) MANDATORY
DN-156.2 OVERRUNNING CLUTCH OUTER RACE 1) 98-09-02

04/11/1997 INSPECTION 2) 369A5352-5
3)W1593-018
4) MANDATORY
DN-157 ONE-TIME INSPECTION OF THE 1) 90-01-08

04/05/1989 ENGINE TO TRANSMISSION 2)
DIRVESHAFT COUPLINGS 3)
369H5660 4)SEE ISSUE
DN-158.1 INSPECTION AND REWORK OF MAIN 1)89-23-14

07/21/1989 AND TAIL ROTOR CONTROL TUBES 2)SEE ISSUE
(PNS 369A7007, 369A7009, 3)
369A7011 AND 369A7012) 4) MANDATORY
DN-159 ONE-TIME INSPECTION OF 1)

06/12/1989 AEROQUIP HOSES (P/NS 2)
269A8352, 369H8306, 369H8025, 3)
369H8024-5 AND 69028651) 4)SEE ISSUE
DN-160 ONE-TIME INSPECTION OF FOUR- 1)89-20-02

06/19/1989 BLADED TAIL ROTOR HUBS 2)
(PN 369821700-3) 3)
4)SEE ISSUE
DN-161 ONE-TIME INSPECTION OF TAIL 1)

07/10/1989 ROTOR TRANSMISSION OUTPUT 2)SEE ISSUE
SHAFT DUPLEX BEARINGS (P/N 3)
369[)25420) 4) MANDATORY

06/30/1989 EMERGENCY AND UTILITY FLOAT 2)
SKID TUBE EXTENSION ASSEMBLIES 3)
4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)

10/27/1989 369A5358 LOCKWASHER IN THE 2)
OVERRUNNING CLUTCH ASSEMBLY 3)
INSPECTION OF ENGINE, CONTD. 4) MANDATORY
DN-164.1 CONVERSION TO 369A5350-41 1)

05/04/1990 OVERRUNNING CLUTCH 2)SEE ISSUE
SUB-ASSEMBLIES 3)
4) MANDATORY
DN-165 INSTALLATION OF OIL FLOW 1)

10/27/1989 RESTRICTING DEVICES INTO THE 2)SEE ISSUE
ENGINE OIL AND TORQUE PRESSURE 3)
SENSING SYSTEMS 4) MANDATORY
DN-166.1 ONE-TIME INSPECTION AND 1)90-24-07

03/14/1990 REPLACEMENT OF AIR INDUSTRIES 2) SEE ISSUE
MS21250-04036 BOLTS AND 3)
VERIFICATION OF PROPER, CONTD. 4) MANDATORY
DN-167 ONE-TIME CHECK/PERIODIC 1) 90-12-03

03/14/1990 INSPECTION/REPLACEMENT OF TAIL 2)SEE ISSUE
ROTOR SWASHPLATE BEARING SET 3)
4) MANDATORY
DN-168 ONE-TIME REPLACEMENT OF 1)

06/15/1990 POLYCARBONATE COVER ASSEMBLIES 2)SEE ISSUE
(369A9817) 3)
4) MANDATORY
DN-169 ONE-TIME REPLACEMENT OF TAIL 1)

06/15/1990 ROTOR BLADE PITCH ARM BOLT 2) MS17826-4
PiTTACHING NUTS 3)
4) MANDATORY
DN170.1 ONE-TIME TORQUE CHECK AND 1)

05/15/1991 INSPECTION OF MAIN ROTOR 2)
BLADES 3)
4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-171.1 ONE-TIME INSPECTION OF 1)

11/21/1990 369[)25623 OIL COOLER BLOWER 2)369025623
BELT 3)
4) MANDATORY
DN-172.1 ONE-TIME INSTALLATION OF 1)

09/04/1990 369024054-3 WARNING DECALS IN 2)369024054-3
THE ENGINE COMPARTMENT AREA 3)
4) MANDATORY
DN-173 INSPECTION OF LEAD-LAG LINK 1)

09/04/1990 ATTACH NUTS 2) 369A1219
4) MANDATORY
DN-174 INSPECTION OF T/R INPUT 1)

11/21/1990 GEARSHAFT (P/N 369[)25434) IN 2)SEE ISSUE
THE T/R GEARBOX 3)
4) MANDATORY

11/21/1990 369H8407 ENGINE BLEED AIR TUBE 2) 369H8407
FLEXIBLE AREA 3)
4) MANDATORY
DN-176 ONE-TIME REINSTALLATION OF THE 1)

11/21/1990 369A1602-3 TAIL ROTOR FORK 2) "369A1602-3
BOLT 3)
4) MANDATORY
DN-177.1 PRE-FLIGHT CHECK AND ONE-TIME 1)91-08-02

03/01/1991 INSPECTION OF TAIL ROTOR 2)SEE ISSUE
BLADES 3)
4) MANDATORY
DN-178 ONE-TIME REWORK OF MAIN ROTOR 1)

02/01/1991 TRANSMISSION OIL COOLING FAN 2)AN960KD416L
MOUNTING BRACKET 3)MIL-8-8802
4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)
DN-179 ONE-TIME ADDITION OF RIVETS TO 1) 94-18-08

09/27/1991 TAIL ROTOR ABRASION STRIP 2)
3)
4) MANDATORY
DN-180 INSPECTION OF OVERRUNNING 1)

01/17/1992 CLUTCH OUTER RACE 2)
3)
4) MANDATORY
DN-181.1 INSPECTION/REWORK OF FUEL VENT 1)

09/10/1992 SYSTEM 2) SEE ISSUE
3)
4) MANDATORY
DN-182 ONE-TIME INSPECTION/REWORK OF 1)

03/20/1992 ENGINE AIR INLET AREA 2)SEE ISSUE
4) MANDATORY
DN-183.2 MAIN ROTOR BLADE REPLACEMENT 1)

01/27/1993 2)SEE ISSUE
3)
4) MANDATORY
DN-184 FOUR-WAY TRIM SWITCH 1)

03/10/1994 REPLACEMENT PROGRAM 2)SEE ISSUE
3)
4) MANDATORY
DN-185 LOCKWASHER INSPECTION 1) 94-24-04

09/23/1994 2) MS172209
3)
4) MANDATORY
DN-186 FIREWALL FUEL FITTING 1)

09/26/1994 MODIFICATION 2)SEE ISSUE
3)
4) MANDATORY
HU 0203 SI SX
1) Applicable AD
2) Part Kit (1)

DN-187 TAIL ROTOR BLADE ABRASION 1) 95-03-11

10/26/1994 STRIP MODIFICATION 2)SEE ISSUE
3)
4) MANDATORY
DN-188 MAIN ROTOR BLADE ROOT END 1) 96-10-09

10/27/1995 INSPECTION 2)
4) MANDATORY
DN-188 MAIN ROTOR BLADE ROOT END 1)98-15-26

10/27/1995 INSPECTION 2)
4) MANDATORY
DN-189 MAIN ROTOR TRANSMISSION 1)

01/10/1997 COMPONENT INSPECTION 2)369[)25127-11
(369025127-11) 3)
4) MANDATORY
DN-190 OVERRUNNING CLUTCH INSPECTION 1)98-21-12

07/25/1997 2) SEE ISSUE
4) MANDATORY
End of Index
HU 0203 SI SX
NOTICE NO. DN-1
1BILsGHIESN
DATE 23 March 1977
3
SE~Mag=[g HMFOWIRn~$ON "GE 1OF
~B g~ E
ILIAN DAIOH\C WIARI DAT~ RY--4~ I\I1AN DATBRV
B SUBJECT: INSPECTION OF TAIL ROTOR OUTPUT SHAFT:

INSTALLATION OF PROTECTIVE DUST BOOTS
MODELS AFFECTED: 500D Model 369D Helicopter SerialNo. 0003 thru 0039
TIME OF COMPLIANCE: Part I Shall be accomplished at each Preflight Inspection

until compliance with Part II of this Notice.
B PREFACE: The Model

Part II Shall be accomplished
369D helicopters with Serial Numbers listed above
presently equipped with protective dust boots between the tail
as soon as possible.
are
rotor
not
gearbox and nonrotating swashplate, and between the rotating swashplate

and drive fork. The output shaft is thus exposed dirt, moisture and
to
other contaminants which, if not removed, can cause scoring of the shaft
or binding of the tail rotor control system.
Part I of this Notice lists a preflight inspection procedure to check for

build-up of dirt, grit, moisture and other contaminants; and to clean and
relubricate the exposed part of the tail rotor output shaft.
Part II of this Notice lists aprocedure for installing protective dust

boots, PN 369D21806 and 369D21807. Compliance with Part II removes
the requirement for the Part I preflight inspection.
A return coupon to record compliance with Part II of this Notice is

attached. Owners and operators of the above affected helicopters are
to fill out and return the
coupon following installation of the protective
dust boots. The dust boots, and required tang washer, will be provided
j
without cost.
R efe r en c e
369D Series Basic HMI, Volume i, Issued 15 September 1976
Customer Service Department Hughes Helicopters Cul~er City, California
Form 8578
NOTICE NO. DN-1 H~hes Hdicopters
DATE: 23 March 1977
Il
PAGE: 2 of 3
PARTS LIST
Nom enc latur e Part No. Qty Mfr
Boot, nonrotating 369D21807 1 HH
Boot, rotating 369D21806 1 111-1
Washer, tang HS1 5 5 1 S2 3 8 1 HH
MA T ERI[A LS
Grease MIL- G-25537 AeroShell 14 Shell Oil Co.
TG-4831 Texaco Inc.
Solvent, cleaning P-D-680 Comme re ial
PART I-Preflight Inspection
a. Checkexposed part of tail rotor output shaft, between tail rotor gearbox
and nonrotating swashplate, and between rotating swashplate and drive fork,
for any evidence of dirt, grit moisture and other contaminants.
b. Remove all evidence of any contaminants, using a soft clean cloth and
cleaning solvent. Operate tail rotor control through full cycle to ensure that
all exposed areas of the output shaft have been cleaned.
c. Relubricate exposed areas of shaft with grease.
d. Record compliance with Part I of this Notice in Compliance Record of

PART II Installation of Protective Dust Boots
a. Remove tail rotor assembly, per Basic HMI.
b. Inspect, clean and relubricate output shaft, per Part I above.
c. Reinstall tail rotor assembly, with 369D21806 rotating boot and 369D21807
stationary boot, per Basic IIMI.
d. Inspect installed tail rotor assembly, per Basic HMI.

Hu9hes Helicopte~s NOTICE NO. DN-1
DATE: 23 March 1977
PAGE: 3 of 3
e. Record compliance with Part II of this Notice in Compliance Record of
NOTE
Fill out and return attached coupon to HH Customer

Service Department.
WEIGHT AND BALANCE DATA
FAA APPROVED
NOTICE NO. DN-3
I HUGHESNOTICE
DATE 30 August 1977
Oi 18
SERVICE INFORMATION
PAGE 1
MAN DATO RY MAN DATO RY

M AN DA TO RY
SUBJECT: MAIN ROTOR CONTROLS RIGCINC OF CYCLIC AND COLLECTIVE

CONTROLS; REWORK OF MIXER CONTROLS; INSTALLATION OF
PITCH HOUSING STRIKER PLATE SUPPORT NUT
MODELS AFFECTED: Al Model 369D and 369lviD Helicopters
TIME OF COMPLIANCE: Shall be accomplished within next 100 hours of

helicopter operation
PREFACE: Part I of this Notice lists procedures and criteria for rigging main
new
rotor controls for all 369D and 369MD helicopters. The new procedures
supersede existing rigging instructions for main rotor controls provided

in the below referencea Basic HMI Volume I, and will be incorporated
in the next scheduled revision to the HMI.
The new rigging proceduredesigned to provide necessary clearances

is
for the main rotor control components, and increase upper limits of
collective and right cyclic pitch angles. It is noted that rigging is to be
accomplished whenever helicopter operation reveals a rigging deficiency

or immediately after replacement of linkage that cannot be measured
accurately (by trammeling, etc).
Part ZI of this Notice lists instruction and criteria for rework of the
mixer controls to preclude interference between mixer components.
Rework: is applicable to 369D helicopter SerialNo. 0001D through 0129D
only, unless already accomplished, and is to be performed prior to
riggin~ the main rotor controls per Part I.
Part UCI is applicable only to early 369D and 369MD helicopters having
serial .numbers as noted on page 15 of this Notice. Instructions are
provided for installing a new plate supportstriker pitch bearing nut and
housing attach hardware, to minimize deformation of the striker plate

and lower lead lug of the housing and prevent droop stop override.
Parts required are to be provided without cost to operator; contact your
authorized HH Service Center. A new 369D21334 pitch bearing housing
designed to preclude the requirement for the support nut will be incor-
porated on later modelhelicopters, and will be available in ship sets,
when required, for existing 369D21304 pitch bearing housing assemblies.
Customer Service Department Hughes Helicopters tuhcr City, California
Form9578
NOTICE NO. DN-3
DATE: 30 August 1977 Hu~ho
PAGE: 2 of 18
Reference
500D Model 369D Basic HMI, Volume I, issued 15 September 1976
PART I RIGGING OF COLLECTIVE, CYCLI.C AND MAIN ROTOR CONTROLS
TOOLS AND ECLUUPMENT
Mixer Rigging Plate, PN 369A9930

Collective Rigging Fixture, PN 369119925 C369D only)
Collective Rigging Fixture, PN 369A9927 (369MD only)
Longitudinal Rigging Fixture, PN 369D29929-9 (369D only)
Longitudinal Rigging Fixture, PN 369D29929-5 (369MD orily~
Lateral Rigging Fixture, PN 369A9928-9 (369D only)
Lateral Rigging Fixture, PN 369A9928-5 (369MD only)
NOTE
i. For 369D/MD.Helicopter SerialNo. 0001D through 0129D,

perform Part II Rework of Mixer Controls before rigging
the main rotor controls.
2. Rigging the main rotor control system must be accomplished

immediately after replacement of linkage that cannot be
measured accurately before it is installed in the main rotor
system; or if helicopter operation reveals a rigging deficiency.
3. Cyclic and collective controls must be rigged in sequence,

starting with collective controls. Control rod end bearing
adjustments are to be made to nearest half-turn that produces

correct rigging, When tightening jam nut at adjustable end of
control rods, always hold rod end with wrench to prevent
jamming of bearing.
a. Rigging Collective Control.
(1) Remove main rotor blades per Basic HMI.
(2) Release friction and raise pilots collective stick. Position collective
rigging fixture 369119925 (for 369D3 in outboard lower end of slot in collective friction
guide link (C, Figure i).

NOTICE NO. DN-3
Huehs Hllcogt~s DATE: 30 Augus t 19 77

PAGE: 3 of 18
LONGITUOINIL
PITCH IOLB
BILLCRIWK
MIIIIUPPORI
BIIICILI
aorr I,
Z O
BOL1 IHtlO UTTI

WIIHrRI. NUI.
COTIIR PIN
MIXIR RIGGING PL
i RIGGING
INIII11 RIGGING PL*lt Mtl~URtMLNT
PLIIT
MIITIuPPORI
\:r
LONG11UOINIL PIILH
MIXIR BIII(R*NL
ca~tcrlvr PITCH
MIXIR BILLCRLNI
Ca~tCIIYt PITCH
CWTROL
YOlt
COUCTIYI
R1G01No
IIXIUL
O~
uan~isr RIGGING PL*. MIIIU(IM\.I
GRIP
loRlvi
cmn,
Norrr;
--coiiicrlvr
I. IGTUIL olriuicr TO srmasunro PILOT I _I I ~RICIION
INO RtCORIltD. cOurcrlvr outer lur
PITCH
2. TO Pr IIMI Is ICTUIL Dl)aPICI
MrIIURID NIIW II. IRBTR TO Trxr. 1 11-1.
Figure i. Rigging 369D main rotor control system (sheet 1 of 2)

NOTICE NO. DN-3
DATE: 30 August 1977 HWcoptn
PAGE: 4 of 18
LONCI.DINLL VyV%
PITCH
0l0n )1
BOL1 IHtlD Ltll).
W*IHIRI. NUI.
COTIIR
RIGGING PLIII
LONGIIUOINIIPII(H
PITCHM(XLR CGNIROL ROD~
_
srucn*hlr
/"I /I
BUIHING
BILICRLNI
rltRIL
mlcClohl
IRICr(ON
OUIOIIINI
IINOB
IWITHPLIE
MIXIR LINI
--I(NURL[O
IHUMBNUI
~E S1ICI LON~IIUDINIL
RIGGING mlxranrvn.
rluJvnt i
conlna Roo
inlcrlGN nNos
ulm~l
ra!nlon~..
I(NURUD X CYCLICiTICI
RIGGING rlXrURt
illtRII RIGGING IIXTURI

INITILI*TION
11-111
Figure i. Rigging 369D main rotor control system (aheet 2 of 2)

NOTICE NO, DN-3
Hu9hee Helicopters DATE: 30 August 1477
PAGE: 5 of 18
NOTE
For 369MD, use collective rigging fixture 369A9927 on inboard

lower end of collective friction guide slot (A, Figure 2),
t3) Lower collective stick on rigging fixture and tighten friction grip (drive
gear).
support fitting and secure

(4) Position mixer rigging plate 369A9930 on mast
firmly with two toggle clamps.
of mast support
(5) Measure and record distance from horizontal centerline
and collective pitch mixer
bracket hing eline bolt (attaching longitudinal idler bellcrank
bcllcrank to mast support bracket) to surface of mixer rigging plate (Al Figure
i).
the mixer controls,
This dimension shall be used as the basic dimension in rigging
Measure distance from horizontal centerline of bolt that

attaches collective
(6)
pitch mixer bellcrank to longitudinal pitch (B, Figure l)to surface of
mixer bellcrank
recorded in (5) above. If not,
mixer rigging plate; it should be same as basic dimension
loosen checknut, disconnect upper end of collective control rod
and adjust rod end (to
nearest half-turn of rod end bearing) until dimensions are equal.
collective stick rigging fixture and check

(7) Rcconnect control rod, remove
mixer travel as follows:
(a) With stick at downstop, centerline of collective pitch mixer bellcrank

that dimension recorded in (5) above decreases
holt (B, Figure 1) should move down so
not less than 0.74 inch (1.88 cm),
mixer bellcrank bolt

(b) With stick at upstopl centerline of collective pitch
should move so that dimension recorded
in (5) above increases minimum of
up
0.74 inch (1.88 cm),
rod end of collective pitch control rod to meet

(c) If necessary, adjust
complete, tighten checknut
limits specified in (a) and (b) above. When adjustment is
and make certain that length of control rod does not change.
CAUTION
Do not adjust control rod end beyond witness hole. Tighten locking
jamnut after final adjustment. Failure to observe this precaution
failure.
can result in parts damage and/or equipment
(8) Reconnect collective pitch control rod.

__
~_
~T
NOTICE NO, DN-3

DATE: 30 August 1477 Hu~e Itdkopt~n
PAGE: 6 of 18
cr
COUECTIVL
FRICTION
GUIDE
RICCINGCOLLCCTIVE
FIXTURE
O COLLECTIVE RIGCINC FIXTURE INSTALLATION
LONGITUDINAL
FRICTION
KNOB
LATERAL
FRICTION
KNOB LATERAL
FRICTION
GUIDE
CYCLIC STICK r
LINK
LONCITUI)INAL
RICCING ~IXTURE
h
(~C"\
CYCLIC STICK
CNICGIRLAREIU
FIXTURE
LONG INDINALFRICTION
GUIDE LINK
CYCLIC STICK LATERAL RIGCINC FIXTURE INSTALLATION
O CYCLIC 5TICI: LONCITUOINALRIGGING FIXNRL INSTALUTION
Il-~LS
Figure 2. Rigging cyclic and collective conerols (369MD)

NOTICE NO. DN- 3
HU9hes Helicapters DATE: 30 August 1977

PAGE: 7 of 18
(9) Reinstall collective rigging fixture.
NOTE
All mixer~ rigging is done with collective controls at midposition.
b. Rigging Cy die Control.
knob and set longitudinal cyclic trim for no

(1) longitudinal friction
Loosen
load by neutralizing cyclic stick.
(2) Position cyclic stick so longitudinal rigging fixture 369D29929-9 (for

that
369D) fits on outboard slot in longitudinal friction guide link. Bushing end of fixture
stud fits in fixture detent (H,
butts against forward end of slott and friction knob
end of slot, tighten knurled thumbnut to seat
Figure i). Secure fixture hook in aft
friction knob.
bushing at forward end and tighten
NOTE
For 369MD, longitudinal rigging fixture 369D29929-5 on

use
outboard side of longitudinal friction guide, with fixture cutout

fixture butts
positioned over friction knob stud. Bushing end of
Secure fixture
against upper end of slot in guide (B, Figure 2).
bush-
hook in lower end of slot, tighten knurled thumbnut to seat
ing at upper end, and tighten friction knob.
end of longitu-
(3) Measure distance from hori~ontal centerline of bolt at aft
surface of mixer rigging plate; it should
dinal pitch mixer bellcrank (B, Figure 1) to
basic dimension recorded in step a(5) above. If not, loosen checknut,
be the same as
rod end (to nearest: hall-turn of
disconnect longitudinalpitch control rod and adjust
rod end bearing) until dimensions are equal.
longitudinal stick rigging fixture and

(4) Reconnect control rod, remove
check mixer travel as follows:
mixer
(a) With stick at: forward stop, centerline of longitudinal pitch
recorded in a(5) above
bellcrank (B, Figure 1) should move up so that basic dimension
maximum of 1.22 inches (3110 cm).
is increased a minimum of 1.19 inches (3.02 cm) or a
(b) Repositionrigging plate to clear longitudinal pitch mixer bell-

mixer
bellcrank holt (B,
crank. With stick at aft stop, centerline of longitudinal pitch mixer
in a(4) above decreases
Figure 1) should move down so that basic dimension recorded
a minimum of 0.57 inch (1.45 cm).
control rod to meet

(c) if necessary, adjust rod end of longitudinal pitch
L limits specified in (a) and (b) above. Adjust carefully; tolerance is only one-half turn.
make certain that length of control
When adjustment is complete, tighten checknut and
rod does not change.
NOTICE NO. DN-3
DATE: 30 August 1977 Hug~ Hdioopters
PAGE: 8 of 18
CAUTION
Do not adjust: control rod end beyond witness hole. Tighten

locking jamnut after final adjustment. Failure to observe this
precaution can result in parts damage and/or equipment failure.
(5) Reconnect control rod to longitudinal pitch idler.
(6) Reinstall longitudinal rigging fixture; reposition and mixer

secure rigging
plate.
(7)
Loosen friction knob and set lateral
cyclic trim for no load by neutralizing
cyclic stick. Position cyclic stick so that lateral rigging fixture 369A9928-9 fits in
forward side of slot in lateral friction guide link.
(Bushing end of fixture butts against
outboard end of slot, and friction knob stud fits fixture detent
(G, Figure i). Secure
fixture hook ininboard end of slot, tighten knurled tbumbnut
to seat bushing at out-
board end, and tighten friction knob.
NOTE
For 369MD, use lateral rigging fixture 369A9928-5 on forward

side of lateral friction guide, with fixture cutout positioned over
friction knob stud (C, Figure 2), Secure fixture hook in lower
inboard end of slot, tighten knurled thumbnut to seat I
bushing at
upper outboard end and tighten lateral friction knob,
(8) Measure distance from horizontal centerline of bolt

connecting lateral
bellcrank to stationary swashplate (F, Figure 1) to surface of mixer rigging
mixer link
plate; it should be sameas basic dimension recorded in a(5) above. If not, loosen
checknut, disconnect lateral pitch control rod and
adjust rod end (to nearest half-turn
on rod end bearing) until dimensions are
equal.
(9) Reconnect control rod, remove lateral stick rigging fixture and check
mixer travel as follows:
(a) With stick at left

stop, centerline of lateral bellcrank bolt (F, Figure 1)
should move down sothat basic dimension recorded in a(4) above
decreases a minimum
of 0,50 inch (1.27 cm) or a maximum of 0,53 inch (1.35 cm).
(b) With stick at

right stop, centerline of lateral bellcrank bolt should
move up so that basic dimension recorded in a(5) above increases a minimum of
0.43 inch (1.09 cm).
(C) if necessary, adjust rod end of lateral pitch control rod to meet limits
specified in (a) and (b) above. When adjustment is complete, tighten checknut and make
certain that length of control rod does not change.
NOTICE NO. DN-3
Hushes Hd~eopters DATE: 30 August 1977

PAGE: 9 of 18
CAUTION
Do not adjust control rod end beyond witness hole. Tighten

locking jamnut after final adjustment. Failure to observe this
precaution can result in parts damage and/or equipment failure.
(10) Reconnect control rod to lateral bellcrank.
(11) Loosen friction control, friction knobs, knurled thumbnuts and hooks of
rigging fixture and remove all three fixtures.
CAUTION
Check for interference between 369A1011 rod end bearings and

lugs of 369D1300 pitch control housing. Adjust bearings as
required to provide clearance.
NOTE
Next step establishes initial adjustment of main rotor pitch

control rods. Final adjustment of the links is to be made by
tracking and autorotation rpm setting.
(12) Remove and adjust length of each pitch control rod (E, Figure 1) so that
centerline -to -c enterline distance between rod end bearings is 6.29 inche s (15.98 cm),
Tl~cn install the pitch control rods.
c. C1~cck for InCerference,
(1) With collective stick full down and cyclic stick full forward and full left,
c]lcck clearance between the rotating swashplate and the longitudinal pitch idler bell-
cranlc, Minimum clearance is 0,125 inch (0i308 cm). Adjust the collective control
rod as required.
(2) Witl1 collective stick full up and cyclic stick full left (any position fore or
aft), cl~eck clearance between lateral bellcrank and collective pitch mixer bellcrank
of the niiser controls. clearance is 0.030 inch (0.076 cm). Adjust lateral
control rod as required.
(3) ~Vith collective stick full down and cyclic stick full aftt check clearance
between the aft longitudinal bellcrank and the mast base. Minimum clearance is
0.030 inch (0,076 cni). Adjust longitudinal control rod (preferably) or collective
control rod as required.
NC>TICE NO. DN-3
DATE: 30 August 1977 Hugheb Hdiaopters
PAGE: 10 of 18
(4)
With collective stick full up and cyclic stick full forward and full left,
check clearance between rotating swashplate and scissors fitting. Also check
clearance between scissors rotating link and lower hub shoe. Minimum clearance in
both cases is 0.030 inch (0.076 cm). Rotate hub 360 degrees to determine location of
minimum cleara_n~. Adjust collective control rod as required.
(5) Repeat (4) above with collective stick full up and cyclic stick full forward
and full right.
(6) With collective stick full up and cyclic stick full aft and full left, check
clearance between scissors link and edge pocket of
rotating swashplate. Minimum
in
clearance is 0.006 inch (0.015 cm), Rotate hub 360 degrees to determine location of
minimum clearance. Repeat clearance check with cyclic stick full aft and full right.
(7) Repeat steps c(l) through c(6) above to recheck all clearances.
(8) Repeat: steps a(7)1 b(4) and b(9) above to recheck mixer control motion
travels and see that minimums are met.
d. Blade Tracking and Autorotation RPM Check.
(1) Install main rotor blades per Basic HMI.
(2) Track main rotor blades and check autorotation rpm per Basic HMI.
CAUTION
All autorotation rpm adjustments shall be made at the main rotor

pitch control rods (links) ONLY. Do NOT readjust mixer control
rods after rigging is accomplished. Failure to observe this prc-
caution can result: in serious damage to rotor system and controls.
DO NOT ADJUST CONTROL ROD END BEYOND WITNESS HOLE.
NOTE
Change length of all five pitch control rods as necessary to adjust
autorotation rpm. Be sure to lengthen or shorten all five rods

exactly same amount or blade track is changed. One flat (1/G-turn)
of control rod body causes approximately four rpm change in
autorotation rpm.
e. Record compliance with Part I of this Service Information Notice in

Compliance Record of helicopter Log Book.
NOTICE NO. DN-3
HU9hes Helicopters DATE: 30 August 1977
PAGE: 11 of 18
PART II REWORK OF MIXER CONTROLS
369D21002-3 Scissors Crank

369A1003 Scis sors Link
369B27611 Rotating Swashplate
369N2670 Lateral Mixer Bellcrank
369N2664 Collective Mixer Bellcrank
369N2666 Idler, Longitudinal Mixer
369A7607 Link, LongitudinalMixer
NOTE
i. Rework is applicable to 369D helicopter SerialNo. 0001D

through 0129D unless already accomplished,
2, Rework is applicable to all above listed assemblies in

Spares Inventory for 369D helicopters.
TOOLS AND EC)UIPMENT
Portable grinder or commercial mill file

India stone or very fine rattail file
-J
MATERIALS
Chemical film aluminum alloy TvIIL-C-5541 Iridite 14-2 Allied Kelite

Alcoat Des Plaines, IL
Primer, zinc chromate MIL-P-8585 C omm e r c ial
Thinner MIL- T 19 544 Pr ep sol E,I. DuPont

DuPont 3919 L.A., CA
Paint, black acrylic lacquer FED-STD-595 Commercial
Ink stamp, permanent MIL-M-43719 Commercial

TT-I-5 58
Varnish, moisture resistant MIL-V-173 Commercial

Type LI
a. Remove and rework the 369D21002-3 scissors crank 369A1003

assembly and
scissors link assembly as follows:
(1) Chamfer 369D21002-3 scissors crank (unless already accomplished) and

369A1003 link per dimensions shown in Figure 3.
NOTICE NO. DN- 3
DATE: 30 August 1977 Hugt~s Hdicopters
PACE: 12 of 18
369D21002 x 450 CHAMFER

0. 0%0
SCISSORS AND BLEND BOTH A --A
CRANK ENDS SMOOTHLY
ZONE
ROTOR
HUB a38a38CHAMFERED
(P/P 2 PLACES)
LOWER
SHOE
r SECTIONA-A 0.20
o.a
(TYP 4 PLACES)
P TS/~ 369/\1003
SCISSORS
P BOTH SIDES)
D.WD
O.Db0
-~33 LINK
BLEND BOTH ENDS
AT aa
aa
B
V 425
0
CIYP BOTH SIDES)
0.040
-i~r7 0.060
X 450 CHAMFER
BLEND BOTH ENDS

SMOOTHLY
B
LONGITUDINAL stnl~NB-B
O (iOF 0.625 SLOT
LONGITUDINAL
369021611 ROTATING
PITCH IDLER
~ec----, I lII SWASHPLATE
COLLECTIVE PITCH
MIXER BELLCRANK
O
COLLECTIVE PITCH
CONTROLROD~
1 I~ a to x 30" CHAMFER
dC Li.50(TYP)(TYP)
LONGITVDINAL BLEND BOTH ENDS
PITCH WITH SMOOTH
CONTROL 225 RADIUS TO 2.25 DIM.
LATERAL M
BELLL~RIK C
o:lo
(r/P BOTH SIDES)
LATERAL PITCH FAR SIDE

CONTROL ROD\ I U SECTION C-C
O as-tie-1
Figure 3, Rework of main rotor and mixer controls (sheet 1 of 2)

NOTlCE NO. DN- 3
HU9h68 Helicopte~ DATE: 30 August 1977

PAGE: 13 of 18
ACHAMFER
369J2666 0. 15
0.040 MAX x
LONGITUDINAL 0.20
PITCH IDLER 3691\7607 BLEND BOTH ENDS
LONGITUDINAL SMOOTHLY
CONTROL MIXER L,
~I
-e ^_,,,,,,.,
:8~
369N2670
LAT~RALMIXER STATIONARY
,~1 (7 BELLCRANK SWASHPLATE
CHAMFER
o
-0-$ 0.080 MAX x O. 180
O BLEND BOTH ENDS
SMOOTHLY
0,
120.25
MIXER
LINK
1.
D.
MIXER
0. 45
PYT(NIM 4 PLACES)
O
SUPPORT 369N2664
a BRACKET (TYP4 PLACES)

COLLECTIVE PITCH
MIXER BELLCRANK
300
0.500
ITYP4
3 PLACESI
O 320
1 8
"I ...a440
a425
ii
f O
(TYP)
ss-zle-a
Figure 3. Rework of main rotor and mixer controls (sheet 2 of 2)

NOTICE NO, DN- 3
DATE: 30 August 1977 Hugh(n Hdko9tc~HI,
PAGE: 14 of 18
(2) Touch up rework areas and refinish niti~ black paint per Section 2 of
Basic Hhl~ Volume 1.
(3) Using permanent illk stamp, reidentify scissors link. part nuniber as
369A1003-501.
(4) Apply coat of varnish over ink stamp.
NOTE
For future replacement of scissors link asseinbly, specify and

install 369A1003-501 assembly.
b, Rework installed 369D27611 rotating swashplate as follows:
(1) Chamfer 369D27611 swashplate per dimensions shown in Figure 3,
(2) Touch up rework area and refinish with black paint per Section 2 of HMI
Volume i,
(3) Usingpermanent ink stamp, reidentify rotating swashplate assenibly

part number as 369A27611-501.
(4) Apply coat of varnish over ink stamp.
NOTE
For future replacement of rotating swashplate assembly, specify

and install 369D27611-401 assembly.
c, Remove and rework 369N2664 collective mixer bellcrank and 369N2670 lateral
mixer bellcrank as follows:
(1) Chamfer collective and lateral belcrank assemblies per dimensions

shown in Figure 3,
(2)Touch up rework areas and refinish with black paint per Section 2 of Basic
HMI: Volume i,
(3) Using permanent ink stamp, reidentify collective bellcrank part number as
369N2664-501; reidentify lateral bellcrank part number as 36~N2670-501.
(4) Apply coat of varnish ink stamp.

NOTICE NO. DN-3
Hushes Hdkoptets DATE: 30 August 1977
PAGE: 15 of 18
NOTE
For futurereplacement, specify and install 369N2666-503 idler,

and 369A7607-501 link assemblies.
The 369N2666-503 longitudinal mixer idler is compatible and

installed with the 369N2668 basic longitudinal mixer bellcrank
only. If the 369N2666-505 idler is installed, the 369N2668-503
bellcrank must be used.
e. Reinstall removed components per Basic HMI Volume i.
f. Record compliance with this Service Information Notice in Compliance Record
of helicopter Log Book.
g. Perform rigging of main rotor controls per Part I of this Service Information
Notice,
PART LII MAAIN ROTOR PITCH BEARING HOUSING ASSEMBLY PN 36913~21304,

INSTALLATION OF NEW STRIKER PLATE SUPPORT NUT
AND AT TACH HARDWARE
h~. NOTE
Part: III of this Notice is applicable only to the following

Model 369D -helicopter serial numbers, unless already
accomplished: through 0020D; 0022D,
0001D 0023D, 0026D,
0027D, 0030D, 0031D, 0033D through 0036D; 0038D, 0040D
through 0042D; 0044D, 0046D through 0049D; 0052D through
0054D; 0056D, 0059D, 0060D, 0062D through 0067D; 0070D
through 0d72D; 0076D, 0078D through 0080D; 0082D.
PARTS LIST
(Parts required are provided without cost; contact your authorized HH Service Center.
Nomenclature Part No. atY Mfr
369D21330 5 HH
Nut, striker plate support
Washer, shim ~8449818012 4 HH
Bolt MS21250H04032 10 Commercial
Washer MS 2 1 2 06 C4 10 Co mm e r c i al
MATERIALS
i,
Lockwire MS20995C32 AR Co mmercial

NOTICE NO. DN-3
DATE: 30 August 1:977 HughSe;Hdlcopkrs
PAGE: 16 of 18
INSTALLATION PROCEDURE
Remove main rotor blades from

a.
helicopter (refer to Basic HMI Volume i).
b. Disconnect pitch control rod from pitch

bearing housing.
CAUTION
i. When rotating pitch housing to facilitate bolt removal, do

not twist:strap packs beyond normal. Excessive twisting
will damage strap packs. Rotate housing only enough to
clear lug of lower shoe.
2. When removing existing lower lead and lag bolts, do not

bend deform striker plate.
or Do not drive bolt past
striker plate. Rotate bolt head so that flat clears striker
plate, or grind bolt head for clearance.
3. If droop stop shims are installed between spacer and

striker strip, they must be retained for reinstallation
to maintain correct static
droop angle between pitch
housing and hub.
c. Identify lower LEAD lug of 369D21304 pitch bearing housing assembly and
perform the following (see Figure 4):
(1) Remove existing bolt, washers and nut securing bearing housing at lower
lead lug. Observe precautions noted above.
(2) As shown, install new MS21250H04032 bolt (with bolt head outboard); new
MS21206- C4 washer (under bolt head); existing
droop shim washers (if applicable);
new HS4598-80-2 shim washer (if required); and new 369D21330 support nut.
NOTE
Install HS4598-80-2 shim washer,

new as required, so that new
369D21330 nut contacts and supports striker plate overhang.
If interference with 369D21322 housing is encountered when
installing the new support nut,chamfer sharp edges of housing
to provide clearance (maximum allowable chamfer 0.060 inch x 45").
(3) Torque bolt 50 to 70 inch-pounds.
d. At lower LAG lug of pitch bearing housing assembly, perform the following:
(1) Remove existing bolt, washers, and nut securing bearing housing at lower
lag lug. Retain existing MS21042L4 nut and NAS620A416L washer.
NOTICE NO. DN-3
Hugko Hdicopten, DATE: 30 August 1977
PAGE: 17 of 18
NOTES:
o o
1. INSTALL BOLT HEAD OUTBOARD: LOCKWIRE BOLT HEADS TOGETHER,
2. REINSTALL DROOP SHIM(SI AS APPLICABLE.
3. INSTALLSHIMWASHER IFREQUIRED.
4. REINSTALL EXISTING WASHER AND NVT.
5. INSTALLED WITH BOLT HEAD INBOARD IUPPER

ATTACH LUG ONLY). o o
MAIN ROTOR HUB~ ~CJ/
EXISTING BOLT (NOTE
WASHER (NOTE41 ~I
UPPER ATTACH
1D42L4NUT(NOTE4)
LOWER LAG ATTACH LUC
)j
WASHER (NOTE 4)
SPACER
369[321330 SUPPORT NUT
DROOP SHIM STRIKER
(NOTE 2)
PLATEWASHERINOTE3) 84598-80-2 SHIM
DROOP SHIM
LOWER LEAD ATTACH LUG,
PITCH BEARING EXISTING WASHER
HOUSING (NOTE 4)
EXISTING NUT
INOTE41
PITCH CONTROL HOUSING

ASSEMBLY
MS21M6-C4
63 WASHER
MS212HH04032
BOLT 44018 I)
as-zlz
Fieure -l. Attachment hardware-main rotor pitch bearing housing assembly

NOTICE NO. DN-3
DATE: 30 August 1977 )IkYI~ HdicoOters
PACE: 18 of 18
(2) As shown, install new MS21240H04032 bolt (with bolt head outboard); new r
MS21206-C4 washer (under bolt: head); existing droop stop shim washers (if applicable);
and existing washer and nut.
(3) Torque bolt 50 to 70 inch-pounds.
e. Check installation of new support nut and attach hardware for discrepancies.
f. Lockwire new MS21240H04032 bolt heads together.
g, Reconnect pitch control rod to pitch housing.
h. Repeat steps b through e for remaining pitch bearing housing assemhlies.
i. Reinstall main rotor blades on helicopter.
j. Record compliance with Part III of this Service Information Notice in

FAA APPROVED
NOTICE NC:. DN-6
HUGHES
I SERVECE BIIMFOWM~IBN
DATE
P~GE
30
I()F
August 1977
3
N!~M DB~URV IVIARIUATU MANDABORY
1
SUBJECT: MAIN ROTOR PITCH CONTROL ROD ASSEMBLY REPLACEMENT OF
PN 369A1009-3 PITCH ROD AND INSPECTION OF ROD END BEARINGS
MODELS AFFECTED: 500D Model 369D.Helicopter SerialNo. 0001D thru 0043D

All PN 369A1008-3 Pitch Control Rod Assemblies in 369D
Spares Inventory
TIME OF COMPLIANCE: Shall be accomplished within next 50 hours of helicopter

operation.
~For Spares Assemblies, shall only be accomplished prior

to installation on 369D helicopter
,PREFACE: The information given in this Service Information Notice lists instructions
fo~r(l) replacement of existing PN 369A1009-3 pitch rod with a new and
shorter PN 269A1338-3 pitch rod to preclude interference between the
pitch rod end and arm of pitch housing assembly, and (2) inspection of the
upper and lower rod ends to ensure serviceability of the rod end bearing.
It is to be noted that incorporation of the new PN269A1338-3 pitch rod

upgrades the
pitch control rod assembly to the new PN 369D21008 con-
figuration. The new pitch rods will be provided by HH for the above
affected helicopters. Fill in and mail the attached return reply coupon.
~Existing Spares Inventory of 369A1008-3 pitch control .rod assemblies

may still be used on Model 500C (369HS, 369HM and 3k9HE) helicopters.
Reference
500D Model 369D Basic HMI-Volume I, Issued 15 September 1976
Form P578
Hugh(H, Hdicopters
NOTICE NO. DN-6
DATE 30 August 1977
PAGE 2 of 3
PARTS LIST is
Nomenclature Part Number Qty Mfr
Pitch control rod 269A1338-3 5 MH
Upper Rod End Bear~ing, pitch 369A1011 AR HH

control rod assembly
Lower Rod End Bearing, pitch 369A7951-11 AR HM

control rod assembly
PROCEDURE
NOTE
Prior to removal of each pitch control rod, color code or
otherwise identify assembly at upper and lower rod end

bearing to ensure reinstallation at original location.
a. Remove pitch control rods from helicopter, as applicable. (Refer to
Basic HMI Vol I.
b. Measure and record exact centerline-to-centerline distance between
upper and lower rod end bearings for each pitch control rod assembly (not applicable
to assemblies in spares inventory).
c. Remove upper and lower rod ends from existing PN 369111009-3 pitch rod.
NOTE
Prior to upper and lower rod ends, inspect

installing
each rod end bearing for evidence of excessive axial
play (0.040 inch maximum); or any extrusion, displace-
ment or damage to bearing teflon liner. Discard the
rod end assembly if excessive axial play; or extrusion,
displacement or damage to bearing liner is noted.
d. Install PN 369Al0ll upper rod end and PN 3691\7951-11 lower rod end
bearing on new PN 269111338-3 pitch rod; adjust rod ends to exact centerline-toe
centerline measurement recorded above. (For spares assemblies, preset rod
length to optimum length of 6.29 inches.
NOTICE NO. DN-6
Hughes Helicopters
DATE 30 August 1977
PAGE 3 of 3
e. Using ink stamp, reidentify each pitch control rod assembly as
PN 369D21008.
f, Reinstall pitch control rod assemblies at original locations, per

Basic HMI Vol I; check that lower rod end bearing has "0" ring installed on
trailing side of bearing, and that upper rod end bearing is centered and does not
contact pitch housing attach clevis.
g. Record compliance with this Service Information Notice in Compliance

Record of helicopter Log Book.
FAA APPROVED
I/
TO: Hughes Helicopters
Centinela and Teale Streets
Cu,lver City, California 90230
Te3: (213) 390-4451, extension 6200 or 6219
ATTENTION: Warranty and Repair Depot

Building 15, Mail Station T-172
In accordance with Hughes Helicopters Service Information Notice No. HN-

the following Model 369D helicopter(s) will require five (5) each PN 269A1338-3
pitch rods to upgrade existing main rotor pitch control rod assemblies to the
369D21008 configuration.
Model 369D Helicopter Serial No.
Also, PN 369A1008-3 Main Rotor

Pitch Control Rod Assemblies in
369D Spares Inventory (Indicate auantity)
NOTE: Existing 369A1408-3 Main Rotor Pitch Control Rods in
Spares may beused on Model 500C Helicopters.

IHUGHES NOTICE NO. DN-8
ISERVICE INFORMATION
DATE
PAGE
30
1
August 1977
OF 3
INOTICE
MANDATORY I
MANDATORY
NIAN DATO RY
EJECT: INSTALLATION OF PN 369D21808 SUPPORT RING

TAIL ROTOR STATIONARY BOOT, PN 369D21806
ODELS AFFECTED: 500D Mddel 369D Welicopter SerialNo. 0001D thru 0209D
IME -OF COMPLIANCE: Shall beaccomplished within next 50 hours of helicopter

operation.
>REPACE: ~helmrormation given in this Service Information Notice lists instructions

c, :for of a support ring in the inboard bellows of the subject tail
-.-~idtcsr stationary boot, to preclude possible collapse and damage to the boot.
The ~PN support ring will be provided-by Hughes Helicopters.
Contact your authorieed Ill-i Service Center.
Reference
500D ~Model 369D WMI-Volume I, Issued 15 September 1976
Form 9578
Hugh~bo HrJicapten,
NOTICE NO. DN-8
DATE 30 August 1977
PAGE 2 of 3
PARTS LIST ~c/
Nom enc lature Part No. Qty Mfr
~Support ring 369D21808 1 HH
:Provided by HH; contact your authorixed HH Service Center.
PROCEDURE
a. Displace inboard end of stationary boot from tail rotor transmission.
b. Position PN 369D21808 support ring on tail rotor shaft between boat and
transmission; ins ert ring inside boot at inboard bellow as shown in Figure i.
c. Reinstall stationary boot in place on tail rotor transmis sion; check that
support ring is seated fully 360" in inboard bellow of boot.
d. Record compliance with this Service Information Notice in Compliance

FAA APPROVED
HuIlhes HeHcopters
NOTICE NO. DN-8
DATE 30 August 1977
PAGE 3 of 3
369D21806 STATIONARY
,369D218M8
BOOT
SUPPORTRING
(NOTE I)
I INBOARD BELLOW
(NOTE 2)
j
\i
I
3d
O
NOTES:
i. SUPPORT RING IS SPLIT SO MAT IT CAN BE

INSTALLED WITHOUT REMOVING TAIL ROTOR
ASSEMBLY.
2. ENSURE THAT SUPPORT RING, SEATS FULLY 3600
IN INNER CIRCUMFERENCE OF INBOARD BELLOW.
88-224A
Figure I. Installation of Dust Boot: Support Ring

NOTICE NO. DN-9, 2$
HUGHES
DATE 27 Octobar 1~7H
SERVICE INFORMATION PnGE L OF 7
NOTICE aSupersedes Service Information

Notice No. DN-9. 1 dated
1 May 1978
MAN DATORY MAN DATO RY NIAIU BATO RY
SUBJECT:~ OVERRUNNING CLUTCH ASSEMBLY, PN 369A5350-603 REWORK

AND INSPECTION OF PN 369A5350-11 CLUTCH SUBASSEMBLY
AND PN 369A5361 BALL BEARING; PERIODIC INSPECTION OF
PN 369A5350-21 CLUTCH SUBASSEMBLY
MODELS AFFECTED: All Model 369D and 369MD Helicopters
All new and overhauled PN 369A5350-603 Overrunning Clutch

Assemblies and PN 369A4350-11 Clutch Subassemblies in
Spares Inventory
TIME OF COMPLIANCE: PART I Shall be accomplished within next 10 hours of
Shall be accomplished prior to installation of

Spares clutch assembly or subassembly on
helicopte r
PART II Shall be accomplished at each 300-Hour Periodic
Inspection interval.
PREFACE: PART I of this Service Information Notice lists procedure for a
purging the existing grease used on the PN 369A5361 ball bearing in

the PN 369A5350-11 clutch subassembly, and repacking the bearing
with Aeroshell 22 or Mobil 28 grease to ensure that proper grease is
used in the bearing. Upon completion of initial regreasing of the
PN 369A5361 ball bearing per Part I of this Notice, the suffix latter
"G" is to be added to the Serial Number onplate of the clutch

the ID
subassembly. A conditional engine-to-transmission alignment check

is also included.
Instructions are also provided for replacement of the PN 369A5368

a new 369A5368-3 seal.
clutch retainer seal with With the -3 seal
369A5350-11 clutch subassembly is reidentified
installed, the PN
as the PN 369A5350-21 configuration,
Part II of this Notice lists aperiodic inspection and

procedure for
regreasing of the PN 369A5350-21 overrunning clutch assembly, to

be accomplished at each S00-Hour Periodic Inspection Interval.
~enotes portion of text added or revised.
HTC*D RLV 11-67

Hughes Helicopters
NOTICE NO. DN-9.2,~(
PAGE: 2 of 7
Reference
500D Series-Model 369D Basic HMI-Vol I, Issued 15 Sep 1976; Rev No. i,
14 Nov 1977
500D Series-Model 369D Basic HMI-VolII, Issued 15 Sep 1976; Rev No. I,
14 Jan 1977
500D Series-Model 369D Component Overhaul Manual (369D-COM),
Sep 1976
Issued 15
500D Series-Model 369D Structural Repair Manual (369D-SRM),
Is sued 15 Sep 1 97 6
FAA Airworthiness Directive, Telex dated 31 August 1977

FAA Airworthiness Directive 77-21-04, dated 11 Oct 1977;
Amendment 39-3057, effective 23 Nov 1977
MAT ERIALS
Crease Aeroshell 22 Shell Oil Co.

or
Mobil 28 Mobil Oil Co.
Solvent Varsol or
equivalent
PART I INITIAL REWORK
NOTE
Rework and inspection per Part I of this Notice is NOT

applicable to PN 369A5350-21 clutch subassembly.
a. Remove clutch subassembly PN 369A5350-11 per Basic HMI-Vol I.
b. Check serial number ID plate retainer of clutch

on on
subassembly
(see Figure i).
NOTE
The clutch subassembly serial number consists of six

or sevendigits. The first two or three digits indicate
date of manufacture (i.e., 77 indicates
July 1977; 116
indicates November 1976). The last: four digits indicate
sequence of manufacture and are to be considered as
the basic serial number of the clutch
subassembly.
i. If the basic serial number (last four digits) of the
clutch subassembly is 4836 or lower and does not
have both suffix letter "G" and suffix letter "S"
fol~
lowing the serialnumber, rework the subassembly
per steps cthrug below.
Hughes Helicopters
NOTICE NO. DN-q. 21,
PAGE: 3 of 7
2. If the basic serial number (last four digits) of the clutch

subassembly is 4837 or higher, or if a lower serial number
has both suffix letters "G" and "S", perform the following:
(a) As applicable, reidentify 364A5350-11 clutch subassembly

to -21 configuration on ID plate on forward side of retainer.
(b) Perform Part II of this Notice only.
c. Temporarily install coupling bolt, to maiutain internal fluid,
d. Remove clutch retainer to expose 369A5361 ball bearing (see Figure 1).
e. Check 369A5361 ball bearing for excessive loss of grease.
NOTE
If ball bearing is dry or grease is caked, inspect

bearing as follows:
i. Inspect ball bearing for roughness, pitting,
scoring, or discoloration from overheating.
Replace bearing, if any of the above is
noted.
2. Check for bearing preload. If no discernible

radial play is noted in the bearing, remove
bearing per Component Overhaul Manual
(369D-Com) and measure journal OD. If OD
of journal exceeds 1.2505 inche s return clutch
subassembly to HH for rework,
f. Using solvent: and brush, thoroughly remove existing grease from both
bearing and retainer. Do NOT use compressed air to remove grease from
ball bearing. Inspect bearing for condition; if roughness, pitting or scoring
is noted, replace bearing.
Hughes Helicopters
NOTICE NO. DN-9. 2~
PACE: 4 of 7
NOTE
I. New 369r45368 seals in spares may be upgraded

to369A5368-3 configuration by removal of
garter spring from seal,
2. Used 369A5368 seals may NOT be reworked to

the 369A5368-3 configuration.
3. Installation of 369A5368-3 seal upgrades

369A~350-11 clutch subassembly to -21
configuration.
g. Remove existing 369A5368 seal and install new 369A5368-3 seal in

retainer. Indicate new -3 seal installed by reidentifying 369A5350-11 clutch
subassembly to -21 configuration on ID plate on forward side of retainer.
(See Note above.)
h. Repack;bearing 50 percent: of capacity with Aeroshell 22 or Mobil 28

grease by packing open side of bearing level without: forcing grease through
bearing cage.
i. Fill void in retainer 75 percent full with grease; reinstall retainer,

Flat side of retainer faces unit; bevel side is out.
NOTE
Some clutch subassemblies may also have suffix

letter "T" following Serial Number.
j. Add suffix letter "G"

to Serial Number on ID plate of subassembly(after
suffix letter "T) as applicable).
k. Coat clutch splines with Aeroshell 22 or Mobil 28 grease; carefully

insert clutch subassembly into housing and secure with retaining ring,
i. Remove coupling bolt, as applicable.
m. Check oil level, per Basic HMI-Vol I,
n. Reinstall clutch coupling; torque coupling bolt to no less than 250-300

inch-pounds.
Hughes Helicopters
NOTICE NO. DN-9i 2~
PAGE: 5 of 7
NOTE
If excessive loss of grease was noted in ball bearing in
step perform engine -to-transrhission alignment check

per Structural Repair Manual(369D-SRM). Remedy
cause of misalignment, where noted.
o. Reinstall main transmission drive shaft and other removed components,
per Basic HMI-VolI.
Record upgrade of 369A5350-11 clutch subassembly to -21 configura-

p.
tion in Component Record of helicopter Log Book.
compliance with Part I

Record of this Service Information Notice in
q.
PART II- PERIODIC INSPECTION
a. Remove clutch subassembly PN 369A5350-21, per Basic HMI-Vol I.
b. Temporarily install coupling bolt, to maintain internal fluid.
c. Remove clutch retainer to expose 369A5361 ball bearing (see Figure i).
d. Check 369A5361 ball bearing for excessive loss of grease.
NOTE
If ball bearing is dry or grease is caked, inspect bearing

as follows:
i. Inspect ball bearing for roughness, pitting or scoring;

or discoloration from overheating. Replace bearing
if any of the above is noted.
2. Check for bearing preload. If no discernible radial
play is noted in the bearing, remove bearing per
Component Overhaul Manual (369D)-Com) and measure
journal OD. If OD of journal exceeds 1.2505 inches,

return clutch subassembly to HH for rework.
Hughes Helicopters
NOTICE NO. DN-9. 2~
boF7
e. Using solvent nnd brus~i, tllorougllly rClrlovoo c~iisliiig fl(,tll L~iltll

bearing and retaine r. Do MOT use compressed air to remove
grease from
ballbearing. Inspect bearing for condition; if roughness, pitting or scoring
is noted, replace bearing. Inspect 369A4368-3 seal in retainer; replace seal
I if cracked, broken, worn, or shows evidence of excessive heating.
f. Repack bearing 50 percent to capacity with Aeroshell 22 or Mobil 28

grease by packing open side of bearing level without forcing grease through
bearing cage.
g. Fill void in,retainer 74 percent full with grease; reinstall retainer.

Flat side of retainer faces unit; bevel side is out.
h. Coat clutch splines with Aeroshell 22 or Mobil 28 grease; carefully

insert clutch subassembly into housing and secure with retaining ring.
i. Remove coupling bolt; check oil level per Basic HMI-Vol I.
j. Reinstall clutch coupling; torque coupling bolt to no le ss than 250- 300

inch-pounds.
NOTE
If excessive loss of grease was noted in ball bearing in

step i, perform engine-to-transmi ssion alignment check,
per Structural Repair Manual (369D-SRM). Remedy cause
of misalignment where noted.
k. Reinstall main transmission drive shaft and other removed components,
per Basic HMI-VolI.
i. Record compliance with Part II of this Service Information Notice in

Weight and balance not affected
FAA APPR OVED

Hughes Helicopters
NOTICE NO. DN-9.2,r
DATE: 27 October 1_978
PAGE: 7 of 7
CLUTCH SUBASSEMBLY SERIAL NUMBER

IS LOCATED ON I D PLATE ON FORWARD
SIDE OF RETAINER.
B
I
I/-/~
1...
BEARING
~3"
ID PLATE (NOTE)
REIRINER
3691\5368 SEAL
88-2311\
Figure i. Overrunning clutch assembly

N()TICE N(,. DN-10
HUGHES o~TE 3 Oct 1977
SERVICE INFORMATION PAGt 1 ()~_4

NOTICE
SUBJECT: INSTALLATION OF AUXILIARY DRAIN VALVE, FUEL SYSTEM

INSTALLATION PN 369H92255 DRAIN KIT
MODELS AFFECTED: 500D Model 369D Helicopter SerialNo. 0001D thru 0129D
TIME OF COMPLIANCE: At owners and operators discretion
PREFACE: The information given in this Service Information Notice lists a procedure
for incorporating an auxiliary drain valve at the engine fuel pump filter
housing to facilitate draining of water from the filter.
Ref er enc e
500D Series Model 369D Basic H~III Volume I, Issued 15 September 1976
i ORLI NO 9~1R* )~TC *D REV ll-b7

Hughes Hdicopters
NOTICE NO. DN-10
I:)LITE 3 Oct 1977
PACE 2 of 4
PARTS LIST
Wl~cn c,rtlcring, specify PN 369H92255 drain kit which includes the following:
N latur e Part: No.

orn cn c:
Rty Mfr
rube 369A8100-3 1 HH
Tube 369A8100-5 1 HH
Tube 369A8100-7 1 HH
lee 6151-0250 1 C omme re ia 1
Valve CAV-170H-04 1 Saf Air

Livonia, MI
Packing MS29512-04 1 Commercial
Strap MS3367-1-9 or equivalent 1 Co mmercial
Tyrap TY-25M or equivalent 1 Thomas and Betts
Elizabeth, NJ
MATERIALS
Loc kwire Ms2o99 5N3 2 AR Commercial
PROCEDURE
a. Turn off all electrical switches; disconnect battery and any external
power from helicopter.
b. Cain to engine accessory section and fuel drain firewall

access
fitting.
(See Figure i.)
c. Remove ]ockwire securing existing drain plugs fuel pump filter hous-
on
ing; remove one drain plug and install new CAV-170H-04 valve with MS29512-04
packing as shown. Secure new drain valve and remaining drain plug with
lockwire.
d. Disconnect existing 369A8010184 overboard drain tube from drain valve

on firewallfitting, and from tie base on firewall; remove -84 tube.
e. Install new 369A8100-7 drain tube on drain valve at firewall fitting and
secure with lockwire as shown.
Hughes Helicopters
NOTICE NO. DN-10
DATE 3 Oct 1477
PACE 3 of 4
with
f. Install 6151-0250 tee at other end of -7 drain tube and secure
new
tube on tee as shown and
lockwire; install new 369A8100-5 overboard drain
secure with lockwire.
shown and with

g. Install new 369A8i00-3 drain tube on tee as secure
drain valve installed on fuel pump

lockwire; install other end of -3 tube on new
filter housing and secure with lockwire.
h. Secure -3 drain tube to existing 369H8102 hose assembly as shown,

Allow sufficient slack in -3 tube to permit unrestrained
using MS3367-1-9 strap.
Also position tube that no fluid traps exist.
movement of drain valve. so
tie base firewall, using Tyrap as shown.

i. Secure -7 tube at existing on
Allow sufficient slack in tube to permit unrestrained movement of drain valve.
j. Route -5 overboard drain tube down throuth existing grommet in under-

allow drain tube to extend 0.00 to 0.12 inch beyond grommet.
side of fuselage;
k. Check installation of auxiliary drain valve for discrepancies.
check of fuel drain (Refer to Basic HMI.

i. Perform operational system.
in Compliance
m. Record compliance with this Service I~formation Notice
~zJ
Record of Helicopter Log Book.

Hughes Hdicoptenr
NOTICE NO. DN-10
DATE 3 Oct 1977
PAGE 4 of 4
ANP1P-IIOELBOW
n,-,7) MS29512-05 PACKING
EXISTING DRAIN PLUG

ENCINEASSY
CAV-170H-W VALVE
I FUEL PVMP MS29512-04 PACKING
FILTER HOUSING
MS3367-1-9 STRAP
AN833-8 ELBOW
AN924-8 NUT
MS20Z12-OB PLCKING. 2RmD
YIEWO 369118103 flTTING
6151-0250 TEE
36948100-5 TUBE
MS20995N32 LOCKW IRE
369/\8100-3
369H8102 HOSE ASSEMBLY TUBE (NOTE 1)
12"
16"
YIEWQ
(ROTATEDI NOTES:
369A255rj
i
i. TRIM TUBE AIR ALLOW SLACK
IN TUBE TO ALLOW UNRESTRAINED
MOVEMENT OF DRAIN VALVE.
POSITIONTUBESOTHATNO
FLUID TRAPS EXIST.
2. INSTALL TC-814 WITH EPUAL

CAV-IIOH-W VALVE 0000 SPACING TO EXISTING RIVETS.
MS29512-04 PACKING
3. ALLOW SLACK IN TUBE TO ALLOW
UNRESTRAINED MOVEMENT Of
DRAIN VALVE.
3691\8100-7 TUBE
TC-814 BASE (NOTE 2)
TRIM TUBE A/R
TY-25M PIRAP
NAS1198MW4 RIVET
AN960-4LWASHER
88-a19
Figure i. Installation of auxiliary drain valve, engine fuel system

Drain Kit PN 3691-192255
NOTICE NC?. DN-11
HUGH ES
I SERVICE IN FORMATION
NOTICE
DATE
PAGE:
3 Oct 1977
OF
2
MODIFICATION OF PN 369A4516-3 TACH INDICATOR

sueJEcT: N1
equipped with 369A4516-3 N1 Tach Indicator
All PN 369A4516-3 N1 Tachdicators in Spares Inventory
TIME OF COMPLIANCE: Shall beaccomplished within next 100 hours of helicopter

operation
PREFACE: The information given in this Service Information Notice lists instructions
indicator to
for remarking the glass window of the subject N1 tachometer
and normal oper-
provide maximum/minimum. operating limits (red lines)
referenced FAA Approved
ating range (green are) as specified in the below
Rotorcraft Flight Manual.
helicopters presently equipped with

It is to be noted that above affected
PN 369A4516-7 N1 Tach Indicator are not affected by this Notice.
Reference
500D Model 369D Basic HMI Volume I, Issued 15 September 1976
FAA Approved 369D Rotorcraft Flight Manual, Revised 18 May 1977
Form 9578
NOTICE NO.
DATE 3 Oct 1477
DN-11
E) nU~hd
PAGE 2 of 2
MA TERIA LS
Paint, green FED-STD-595 No, 14260 or Commercial

equivalent
Paint, red FED-STD-595 No, 11136 or Commercial
equivalent
Paint, white FED-STD-595 No, 17875 or Commercial
equivalent
PROCEDURE
NOTE
Do not disassemble
N1 Tach Indicator; instrument
is hermetically sealed.
Clean window glass of

a.
N1 tachometer indicator so that it is free of
dirt, grit, etc; air dry.
b. Using green paint, apply green are (0, 100 inch wide) at circumference
of indicator glass from 64 percent to 105 percent increments on dial.
Using red paint, apply red lines (0, 160 inch long and 0. 020 inch wide)
c.
extending inward from circumference of indicator glass at 59 percent incre-

ment and 105 percent increment on dial.
d. Using white paint, apply sllippage markon glass face of gauge and
gauge housing.
e, Record compliance with this Service Information Notice in

Compliance
Weight and balance not affected,
FAA APPROVED
NOTICE NC. DN-12

HUGHES z
PAGE 1 OF
SERVICE INFORMATION
NOTICE
SUBJECT: INSTALLATION OF MODIFIED (ROTOR BRAKE HANDLE)

TRIM COVER PANEL ASSEMBLY
MODELS AFFECTED: All 500D Model 369D helicopters equipped with left rotor
brake installation PN 3691-190123-31 or right rotor brake
installation PN 3691-190123-32
PREFACE: The information given in this Service Information Notice provides a

procedure for installation of a modified trim cover panel for helicopters
equipped with a rotor brake. It has been found that with the rotor brake
installed, ambient (hot or cold) air is allowed to exit through the brake
handle and handle retainer trim panel cutouts causing discomfort to the
Installation of the modified trim panel will eliminate air

pilot. cover
passage through the brake handle and brake handle retainer (stowage
clip) cutouts.
The modified trim panel cover will be provided by Hughes Helicopters;

contact your Hughes Service Center or Distributor.
Reference
Model 369L) Basic HMI Volume 1; Revision No. i,

Hughes 500D Helicopter
15 November 1977
FORM NO HTC*D REV ll-b7

NOTICE NO.
DATE:
DN-12
18 November 1977
E~ HYahes Helicopters
PACE: 2 of 2
PARTS LIST
Nomenclature Part No. atY Mfr
Trim cover panel as sembly 369D26 524- 25 1 HH

(LH brake handle assembly) (modified)
Trim cover panel assembly 36 9D264 24-26 1 HH
(RH brake handle assembly) (modified)
TOOLS AND EQUIPMENT
No special tools or equipment required.
PROCEDURE
NOTE
The following procedure is applicable for either left or right

rotor brake handle installation.
a. Remove existing (rotor brake handle) trim cover panel; retain attaching
hardware.
b. Carefully trim modified panel to match existing panel.
c. Locate and drill, screw attach holes in modified panel.
d. Slide modified trim panel boot over brake handle, align screw holes and
check panel for fit. If required, remove panel and make minor trim adjustments.
e. Install panel if removed; secure panel with attaching hardware.
f. Push panel boot aft on brake handle approximately 2 inches; secure boot
fastener tape.

N()I.IC:EI N(?. DN-13
I HUGHESNOTICE
I)AIE 30 November 1977
SERVICEINFORMATION "1
MAN DATQRY I MAN DATORY

WI AN DATO RV
I
SUBJECT: INSPECTION PN 369H90084 LITTER DOOR INSTALLATION
AFFECTED: All Model 369D Series Helicopters equipped with PN 3691-190011

MODELS
Rotorcraft Litter Kit
TIME OF COMPLIANCE: Shall beaccomplished prior to next flight, and at each

subsequent 50 hours of helicopter operation thereafter
for a visual inspection of the subject litter door installation to ensure
of the quick-release fastener assemblies,
proper condition and security
and door
and the rubber seal(gasket) installed between the window glass
frame. The visual inspection is applicable to the PN 369H92733-1/-2
bubble window assemblies (or PN 369H92731-11-2 flat window
assemblies,,
if installed) in the PN 3691-190085 litter door installation.
Reference
500D Basic HMI Volume i, Issued 15 September 1976; Revision No. i,

15 November 1977
Farm 9578
NOTICE NO. DN-13
Hughs Welicoptr
EACE 2 of 3
PARTS LIST
Non~cnclature Part No. aty Mfr
Eastener,
quick-release:
Stud 2600-10S AR Camloc Division

2 6 00 1 2S Rex Chain belt, Inc.
2600-13S Paramus, NJ
2600-14S
Receptacle 26R6-1BB AR Camloc Division
Lo ckwa s he r 2600-LW AR Camloc Division
Rivet MS20426AD3 AR Commercial
Seal NE-71A AR Armstrong Cork Co.

(0.125 x 2.00 x 120.00) Lancaster, PA
A cl h c s iv e EC1300L AR 3M Co., St. Paul,

Minn.
INSPECTION PROCEDURE
a. Remove quick-release fasteners securing bubble (or flat) windows

to litter doors.
Visually inspect each fastener for condition, and each anchor

b.
receptacle in door structure for condition and security of attachment. Re-

place fastener if stud is loose or worn. Replace anchor receptacle and/or
rivets as required.
c. Visually inspect rubber seal (gasket) on window assem blies for

con tlition. Seal must be fully intact; rebond seal to door structure, as
reyuirecf. Replace seal if worn, cracked, or hard.
(1. Reinstall window assemblies to litter doors

using quick-release
fasteners. Check for gaps between window
glass, rubber seal, and door
structure. Replace seal and/or use shorter length studs if any gap is noted.
If seal is extruded, use longer length studs; replace seal if extrusion still
exists.
E) nYehl H~liCOptdr. NOTICE NO.
DATE
DN-13
30 November 1977
PAGE 3 of 3
c. Record compliance with this Service Information Notice in
Col-nI~liancee Record of helicopter Log Book.
I;AA APPROVED
NOTICE NC. DN-14
HUGH
NSE
SE RVI C E I N FORMAT I Of~ PAGE OF_5
~T ICE
SUBJECT: MODIFICATION KIT MAIN TRANSMISSION LUBRICATION PUMP,
PN 3691325167
0138D thru
MODELS AFFECTED: Model 369D Helicopter Serial No. 0003D thru 0136D;
0164
0146D; 0148D thru 0153D; 0156D; 0157D; 0159D thru 0162D;
0211
0ibbD; 016gD; 00175D; 0182D; 0189D; 0194D; 0201D; 0207D;
All PN 369D25167 Lubrication Pumps, separate or installed
on PN 36qD25100 Main Transmission Assembly, in Spares

Inventory at date of this Notice

operation
Shall be accomplished prior to installation of Spares
Lubrication Pump or Main Transmission Assembly on
helicopter
for field modification of the subject main transmission lubrication pump.
The rework consists primarily of replacing the existing geroter assembly

the pump input shaft, to improve the reliability of
the
and pump shaft, and
lube pump.
It is to be noted that the modification is applicable only to early type pumps,

2161 and 2161-1. Pneu Devices Part No. 2161-2
Pneu Devices Part No.
lubrication pumps are not affected by this Notice.
contact your
Modification kits will be furnished at no charge to customer;
authorized HH Service Center or Distributor.
Reference
Vol 1, Issued 15 September 1976; Revision No. i,

5OOD Basic HMI
15 November 1977
500D Component Overhaul Manual (369D COM), Issued 15 September 1976
rs Culver City, California
FornP578
~OH*l NO 9~57R* IITC *D RIV 11-67
NOTICE NO. DN-14 Hughas ~elicopters
PAGE 2 of 5
PARTS LIST
Nomenclature Parts No. aty Mfr
Kit modification, KPL-2161-2 Pneu Devices Inc.,

consisting of: Santa Barbara, CA
Rotor/Shaft Mod Assy 12638 1

Stater 11099-3 1
:Lnput shaft 10807-2 1 ~ePreinstalled on
Retaining ring 10464 1 Rotor/Shaft Assy

Screw NAS1352CO8LE6 3
O-ring NAS1543-011 1
O-ring NAS1593-030 1
(Pro cure separate from

kit, if pump is removed
from transmission)
O-ring MS29561-022 1 Commercial
O-ring MS295 61 or 3 2 Comme rcial
O-ring NAS617-8 2 Commercial
MA TERLA LS
Petrolatum (petroleum
jelly) VV-P-236 Commercial
MODIFICATION PROCEDURE
NOTE
For Spares Lubrication pumps not installed on
main transmission assembly, perform steps

b, f, and m only.
a. As applicable, remove sound insulation and transmission access doors
(Section 7, Basic HMI- Vol i).
b. Identify manufacturers Part No. on identification plate on lube pump
(see Figure i).
i. Rework lube pump if Pneu Devices Part Number is 2161 or 2161-1.
2. Pneu Devices Part No. 2161-2 lube pump is not affected by this
Notice. If lube pump 2161-2 is installed on helicopter, perform step m of
this Notice.
E) Hvghas Helicoptan NOTICE NO.
DN-14
PAGE of 5
OIL COOLER TUBE

(TYP 2 PLACESI
_I
LUBRICATION PUMP
AND FILTER
MS29561-013
O-R I NG
MS29561-022 NAS6I7-80-RING
O-RING(TYP 2 PLACES)
i3
MS29561-013
O-RING
o VALVEHOUSING
8 NAS1593-011
O-RING
\,I
RETAINING RING*
INNER ROTOR
NAS1 52C08LE6SCR N (3)

PUMP SHAFT
11099-3 STATOR
10464
RETAINING RING
RETAINING RING*
10807-2
INPUT SHAFT
PART OF 12638 ROTORISHAFT

MOD ASSY
FILTER BOWL PUMP HOUSING

88-2341\
Figure i. Field Modification Main Transmission

Lubrication Pump PN 369D25167
NOTICE NO, DN-14
Hugh~s nslicopters
PAGE 4 of 5
c. Drain oil from main transmission (Section 2, Basic HMI Vol i).
d. Disconnect transmission oil cooler hoses.
e. Remove hardware securing pump housing to transmission mounting

pad. (Section 9, Basic HMI Vol 1); remove pump and discard O-rings.
f. Rework lubrication pt~mp as follows: (see Figure i).
i. Remove three screws securing valve housing to pump housing.
2. Separate valve housing from pump housing and remove and

discard existing O-rings.
3. Remove pump shaft with inner rotor and input shaft in place,
4. Remove outer rotor (stator) from pump housing.
NOTE
Return removed oomponents to Hughes Helicopters.
5.
Scrape any paint or foreign material from mating faces of pump
housing and valve housing; wipe internal surfaces and mating surfaces clean,
assuring that no foreign material is introduced into pump. Thorough clean-
ing of all components is important for satisfactory operation after modification.
6. Install outer rotor (stator) into pump housing.
7. Place pump shaft and inner rotor assembly into pump housing and
rotate to assure free running operation.
8. Apply light coat of petrolatum to new O-rings; install new O-rings

onto valve housing.
9. Install valve housing to pump housing, using three new screws
provided in kit.
10. Rotate pump shaft to assure free running operation.

E) Hushes Helicopters NOTICE NO.
DATE
DN-14
15 December 1977
PAGE 5 of 5
NOTE
Torque required should be less than l0-inch pounds over
several revolutions of puIY1P, If pump exhibits excessive
binding, loosen three screws and rotate valve

torque or
housing until free running operation is obtained. Tighten

three screws and repeat step 10.
11. Reidentify manufacturers Part Number on identification plate

as 2161-2.
g. Install new O-rings in ports and in groove of pump sleeve. Apply

light coat of petrolatum to both O-rings and mating bores in transmission.
square drive of pump with drive

shaft in transmission;
h. Carefully align
carefully insert pump in place.
i. Install three attach nuts and washers; tighten nuts to torque of 50 to
70-inch pounds.
j. Connect transmission oil cooler hoses; use new O-rings.
k. Check pump installation; perform the following:
i. Ground helicopter according to 369D Owners Flight Manual

run
and check pump interface for leaks. (Refer to Fluid Leak Analysis, Section
2 of Basic HMI Vol i.) Verify that pump pressure warning light is not ON
at 550/0 N2.
2. Install access covers and sound insulation.
i. Record rework of PN 369D25167 lubrication pur~p to Pneu Devices

Part No. 2161-2 configuration in Components Record of helicopter Log Book.
m. Record compliance with this Service Information Notice in Compliance

WEIGHT AND BALANCE DA TA
FAA Approved
N()TlcE N(). DN-16
HUGHES
5
SERVICE INFORMATION PAGE I Of:~
NOTICE
SUBJECT: REWORK OF TURBINE OUTLET TEMPERATURE (TOT) INDICATOR,

PN 369A4521-5; AND TORaUE PRESSURE INDICATOR,
PN 3691-14526-5
AFFECTED: 500D Model 369D Helicopter SerialNo. 0003D thru 0212D,

MODELS
0214D thru 0225D and 0227D thru 022913).
Indicators in Spares
All subject TOT and Torque Pressure
Inventory for Model 369D Helicopter
PREFACE: The information given in this Service Information Notice provides

instructions for optional rework of the PN 369A4521-5 TOT indicator
to the current 369A4521-7 configuration, and the PN 3691-14526-5 Torque

Pressure indicator to the current 369H4526-7 configuration, to allow the
that
usage of higher TOT temperatures at 320 horsepower or less, so
an additional advantage on hot day
conditions.
operators may have
Certification of the Model 369D performed at a maximum

helicopter was
of
continuous power setting of 779" C, and the helicopter is fully capable
operating continuously at that power setting.
The engine manufacturer, however, specifies that if the engine is operated

less, the maximum
continuously at 74.3 PSI torque pressure (320 HP) or
TOT is 755"C. The torque pressure indicator is therefore marked with a
755"C
blue dot; at 74.3 PSI and the TOT indicator with a yellow are from
to 810"C.
For continuous power in excess of 74.3 PSI but not exceeding 81.3 PSI,
the maximum TOT is 738"C. The TOT indicator is thus also marked
with a blue dot at 738"C.
It is to be noted that if the engine is operated in excess of the above values,

and torque
the engine warranty will not be honored by DDA. The new TOT
in the below referenced revision to the
pressure data are incorporated
Model 369D Rotorcraft Flight Manual.
Customer Service Department Hughes Helicopters Cuher
IORH No 9j78L~ ~(TC *D REV 11-67

NOTICE NO. DN-16 Hughe nelicopters
PACE 2 of 5
Reference
Model 369D Basic HMI-Vol i, Issued 15 September 1976; Revision No. i,

14 November 1977
Model 369D FAA Approved Rotorcraft Flight Manual, Revised 1 February 1978
Detroit Diesel Allison Engine Operation and Maintenance Manual, 10W2
MA TERIALS
Paint, red No. 11136 Fed Std 595 Commercial
Paint, white No. 17875 Fed Std 595 Commercial
Paint, blue No. 15123 Fed Std 595 Commercial
Paint, green No. 14260 Fed Std 595 Commercial
Paint, black No. 37078 Fed Std 594 Commercial
PART I REWORK PROCEDURE FOR TORaUE PRESSURE INDICATOR
a. Rewdrk FN 3691-14526-5 torque pressure indicator to the 3691-14526-7

configuration as follows: (See Figure I.)
i. Clean and wipe dry the glass face of indicator; apply a 0. 06 inch
diameter blue dot on glass face of torque pressure indicator at
74.3 PSI as shown.
2. Apply a 0. 06 inch wide white slippage mark on glass face and

indicator housing at three oclock position as shown.
3. Reidentify instrument with PN 3691-14526-7.
b. Record rework of PN 3691-14526-5 torque pressure indicator to

369H4526-7 configuration in Components Record of helicopter Log Book.
PART II REWORK PROCEDURE FOR TOT INDICATOR
NOTE
The TOT indicator is hermetically sealed and

must be evacuated and protected by trained
personnel. If the instrument is unsealed by
any facility other than an Insco-approved repair
station, the vendor warranty is automatically
voided.
nughss Halicopte~s NOTICE NO. DN-16
PAGE 3 of 5
ADD BLUE
90 100
DOTAT74.3PSI 110
80 ADD WHITE
TORQUE
SLI PPAGE MARK
70
80 10
PSI
80 20
40 30
REWORK OF 369H4526-5
TORPUE PRES SU RE I ND I CATOR
ADD BLACK DOT TO

OBSCURE EXISTING RED
DOT AT 860DC
ADD RED DOT

AT 10 11
EXTEND GREEN ARC

FROM 7380 C TO 7550 C
ADD BLUE DOT

tX100
AT738"C
REWORK OF 369A4521-5
TOT INDI CATOR
88-2391\
Figure 1. Rework of TOT indicator and torque pressure indicator

NOTICE NO. DN-16
Hughss Helicopters
PAGE 4 of 5
a. Asapplicable, remove TOT indicator from helicopter. (Refer to
Basic HMI-Vol i.)
b. Rework PN 369A4521-5 TOT indicator to the 369A4521-7 configuration

as follows: (See Figure i.)
1. Using soldering iron, soften solder bond at center of instrument.

Peel off strap and retain. Remove screws from case and remove
instrument from case.
2. Re-mark indicator dial to extend green are from existing 73 8" C

to 7450 C; width of green are is 0. 100 inch.
3. Apply a 0.06 inch diameter blue dot on indicator dial at 7380 C.
4. Apply a 0.06 inch diameter red dot on indicator dial at 843" C

as shown.
5. Apply a 0.06 inch diameter (or larger) black dot to obscure
existing red dot on dial at: 8600 C.
c. Check TOT indicator as follows:
i. Red line at 8100 C
2. Yellow are from 755" C to 810" C
3. Green are from 360" C to 7450 C
4. Red dot at 8430 C (refer to DDA Engine Operation and Maintenance

Manual)
5. Blue dot at 7380 C
d. Insert instrument in case and secure with existing screws and strap.
Apply solder bond at center of instrument.
1. Reidentify instrument with PN 369A4521-7.
e. Reinstall TOT indicator, per Basic HMI-Vol i.
f. Perform calibration check of TOT indicating system, per Basic

HMI-Vol i.
g. Record rework of PN 369A4521-5 TOT indicator to 369~614421-7

configuration in Components Record of helicopter Log Book.
NOTICE NO. DN-16
Hughes Helicopter+
PAGE 5 of 5
FAA APPROVED
N()TICE N(). DN-17
6 February 1978
HUGHES DATE
SERVICE INFORMATION FA(;t 1 ()F-__7

NOTICE
SUBJECT: INSTALLATION ENGINE COMPRESSOR WATER WASH KIT,
PN 3691-192537
MODELS AFFECTED: 500D Model 3691) Series Helicopter SerialNo. 0003D thru 0089D
TIME OF COMPLIANCE: At Owners and Operators discretion.
PREFACE: The information given in this Service Information Notice lists procedures
installation of engine compressor water wash kit on the
for optional an
above affected 369D Series helicopters. The kit is desi.gned to provide

convenient method for removing any contaminants or corrosive
a quick,
air particles (smoke, funnes, salt water air, etc) from compressor
service life
components, and to help ensure optimum. performance and
of the engine.
Detailed information to operating procedures, equipment, water

cover
availability and flow requirements are provided in the attached below

referenced Detroit Diesel Allison Commercial Service Letter and subse-
quent revisions. The DDA Service Letter, reprinted as part of this
Notice, also provides an abbreviated check list for performing the
engine water wash.
Reference
i, 15 Novem.ber 1977
369D Basic HMI, Issued 15 September 1976; Revision No.
Detroit Diesel Allison Commercial Service Letter 250-C18 CSL-69;

250-CZO
CSL-1020, dated 25 June 1973; Revision No. i, 17 January 1975 or subsequent

r evi s ion s.
Customer Service Department Hughes Helicopters City, California
FORH NO 9578* HTC *D REY 11-67

NOTICE NO, DN-17
Hughes Hdicoptan
PAGE 2 of 7
PARTS LIST
The following com.ponents are provided for the PN 369H92537 Engine Com.-
pressor Water Wash Kit:
Nomenclature Part No. Qty Mfr
Hose 369H3048-5 1 HH
Hose 369H3048-3 1 HH
Support 3691-13047 1 HM
Cap and lanyard assy 3691-13046 1 HH
Spray assy 36 9H3 042 1 HH
Washer A N96 OPD7 1 6L 2 Comme r c ial
Washer AN960FD1 OL 3 Comm, ercial
Nut AN924-4D 2 Commercial
Hose elbow AN848-4D 1 Commercial
Hose adapter AN807-4D 1 Commercial
Clamp A N7 3 7 T W2 2 4 C omm e r c ial
Gr omm e t MS35489-11 1 Comm e rc ial
Clamp MS25281 -4 1 C omm e r c ial
Nut MS2 1 042 3 1 C omm e r c ial
Rive t NAS1 3 9 8B4 -2 b Comme r cial
,I: Rivet NAS17 3 8M4 -2 8 Comm ercial
Screw NAS632-3-3 2 Comm e r c ial
:::MS20615-3M4 Rivet may be used as alternate
TOOLS AND ERUIPMENT
Drill motor portable

Drill bit No. 29/64 (0. 4531 in. dial
Drill bit No. 8
Drill bit No, 30
Flycutter or equivalent
Gun, Rivet
r2
NOTICE NO. DN-17
Hughss Hslicopter
PACE 3 of 7
MATERIALS
Sflicone adhesive/sealant RTV732 or equivalent Dow Coming
Zinc chromate primer Commercial
INSTALLATION INSTR.UCTIONS WATER WASH KIT
a. Perform the following, per I-IMI, to. gain access to work area:
i. In aft compartment, remove seat assemblies, LH bulkhead trim,
access cover and insulation; gearbox access cover.
2. Remove engine air inlet forward fairings; open plenum chamber

access door.
CAUTION
Install temporary cover of cardboard or suitable
material over engine air intake.
3. Remove engine air shield screen or engine air inlet screen, as
applicable; remove access cover from mast support structure panel;
4. Open LH engine compartment access door.
b. Position 3691-13047 support on Station 137.50 lower section ring at
dimensions shown in Figure i, view E-E. Mark and drill rivet holes and
install support with six NAS1398B4-Z rivets. Install rivets with ~ine
chromate primer.
c. Drill No. 8 hole in ring assembly as shown; locate from existing

hole in support.
d. Install AN807-4D hose adapter in support with hardware as shown;

install lanyard clip in No. 8 hole with hardware as shown. Install
369H3046 cap on hose adapter.
e. Drill or cut 29/64 (0.4431 inch diam.eter) hole in firewall assembly

at dimensions shown in view A-A. Position and install AN848-4D hose elbow
in Eirewall with hardware as shown.
f. grommet in forward wall of plenum

Cut hole for MS35489-11 chamber
with silicone sealant.
per dimensions shown; install grcwmet
NOTICE NO.
DATE 6
DN-17
E~ lluglvs Hlicoptir
February 1978
PAGE 4 of 7
STA STA
127. 00 137. 80
0. 22 R
TYPICAL
BL
0.00
MS35489-ll
GROMMET-1REQ
(DO NOT SPLITI
j
WL L
50. 00
0.76
O.M)
IJ\ i
0. 38
(NOTE 1)
C.L. ENGINE
FOR
CROMMET
AN717TW22
CLAMP 2REQ AN848-4D HOSE ELBOW
AN960P07161 WASHER
i. 75 f O. Ip IV AN924-4D NUT
369H31148-5 HOSE
irl
369H3W6 CAP AND

YW LANYARD ASSEMBLY
AN807-40 HOSE ADAPTER
j
AN9MIPD716L WASHER
d
AN737TW22 CLAMP
ZREP
AN924-40 NUT
~1
NOTES:
i. SEAL WITH SILICONE SEALANT.

AFT SECTION ASSEMBLY
FUSELAGE STRUCTURE
369H3048-3 HOSE
AN737TW22 CLAMP
II
2. ALL DIMENSIONS IN INCHES.
88-240-1
Figure i. Installation Engine Compressor Water Wash Kit, PN 369H92537

(sheet 1 of 3)
31
E~ HUehe Hlrcopfers NOTICE NO. DN- 17
FATE 5 of 7
16.00
F~REWALL ASSY
C-I ?os~
15"\-~
APPROj(
c TRACE
WL 40. 00
29164 DIA HOLI
.79
B-A 3.00
TRACE
WL 30. 00
C. L. ENGINE
BL
0.00
INLET ASSEMBLY, ENGINE

AFT SECTION
078
NAS1738M4-2 RIVET
MFD HEAD FAR SIDE 3691-13042 SPRAY ASSEMBLY
LOCATE FROM 369H3042
8 REPUIRED (NOTEI
NOTE: BIB
ALTERNATE MSZ0615-3M5 RIVET MAY
BE VSED IN PLACE OF NAS1738M4-2.
88-240-2
Figure i. Installation E~ngine Compressor Water Wash Kit, PN 369H92537

fsheet 2 of 3)
NOTICE NO.
DATE 6
DN-17
E) HUok n~licopter
February 1978
PAGE 6 of 7.
o.oo
-t--
Tj
oloilI I L
WL
5a00

AFT SECTION
RING ASSEMBLY-LOWER
SECT. STA 137. 50\ CC 0. 198
ING. 8) DIA HOLE
0.204
WL NAS6n-3-3 SCREW
34. 50 AN96)P01M. WASHER 2 REQ
MSn281-4 CLAMP
MS21042-3NUT
3691-13024 REF
0. 50
NAS13988-4-2 RIVET 0. 50
LOCATE
FROM369H047
6 REQD
j,
boo
1- i. 18
8.45-BL STA
o o
369H3047SUPPORT 124.M)
CANT D-D
0. 198
(NO. 8) DIA HOLE LOCATE FROM 369H3047
0. 204
623-3-3 SCREW
E-E
88-2403
Figure 1. Installation Engine Compressor Water Wash Kit, PN 369H92537

(sha~t3 of 3)
\p
NOTICE NO. DN-17
Hughes Helicopter~
PACE 7 of 7
of plenum chamber
g. Position 369H3042 spray assembly on inner side
with tube inserted forward
forward wall as shown in Figure i, view B-B,
through grommet. Mark and drill rivet holes and install spray assembly
with eight NAS1738M4-2 rivets. Install rivets with zinc chromate primer.
tube and on hose elbow

h. Install 369H3048-5 hose spray assembly
on
at firewall; secure hose at each end with AN737TW22 clamps.
i. Mark and drill No. 8 hole in 369H3024 channel and install MS25281-4
clamp with hardware as sho~vn. Secure -5 hose with clamp.
of firewall, and
Install 3691-13048-3 hose on hose elbow at aft side
on
j.
Secure hose at each end
hose adapter at forward side of lower section ring.
with AN737TW22 clamps.
k. Check installation of water wash kit for discrepancies.
i. Carefully check and/or vacuum plenum chanlber for any foreign

the
objects or debris. Remove protective cover from engine air intake.
NOTE
Spray kit using 369H3042 nozzle requires 60 pounds

PSI to establish water flow rate of one quart in 9 to
valve equivalent installed

10 seconds. A bypass or
recommended, in order
at source hose connection is
disconnection at
to relieve pressure and facilitate
hose adapter.
m. Perform operational check of water wash kit installation; refer to
attachment Detroit Diesel Allison Com.mercial

Service Letter for operating
procedures and check list.
and
Reinstall removed components and assem.blies; install
secure
n.
access covers and doors.
water wash kit

o. Record installation of 3691192537 engine compressor
in Components Record of helicopter Log Book.
zsa:-cls~ a-
250-:20 CSL-~02O
COMMERCIAL SERV1~3E LETTER
Ct~ O~tRn Oissel I\lllsan

o.uan or oeneral Mon. caoonnion
Page i of 4
June 25, 1973
FAA-DER Approved
SUBJECT: Contamination Removal (Water Rinse) Instructions Usin~
Water Only
A. The followingprocedure applies to the removal of all forms of

of con-
contamination, using a daily water rinse. Some examples
fumes smoke from
tamination are industrial smoke particles, or
the
chemicalplants, and salt water a.ir. These a.re but a few of
in the atmosphere. These
many types of corrosive particles
the
instructi6ns should not be confused with instructions covering
washing of a compressor with cleaning compounds--examples:
Srulin or Safety-Solv.
that bare hand be

engine must be sufficiently cool so a can
The
placed on the combustion section.
i. Clean water must be used. Demineralized, distilled or rain

lake or
water is preferred. City drinking water, wellwater,
river water may be used if free of contaminants.such as mud,
sulphur, sand, sa.lt, etc~.
2, Install the block in the Compressor Bleed Valve (closed position)

valve and
to prevent rinse water from exiting through the bleed
to
improperly rinsing the aft blade stages. It is not necessary
disconnect any lines,.
at a flow
3. The spray nozzle shall provide a diffused spray of water
rate of one quart in nine to eleven seconds at the pressure concii-
flow the
tions used during compressor rinse. The-spray must
to in-
water.as close to the bullet nose of the engine- as possible
sure that all of the water is.injected into the engine.
valve shall be installed in the; supply tube as close

4. A quick opening
to the nozzle as practical.
inlet
5. Start water injection for three seconds into the compressor
1 (slow count to three) before energizing the starter. The three
Revision No. 1
January 17, 1975
2.5Q:.C 18 1_ CS L 69
28_ ~2C) CSL~- 1020
Page 2
~30MMERCIAL SERVICE L;ETTEB
second delay in energizing the starter after initiating the water

spray is to provide full water flow rate to the compressor at
start of motoring. This will reduce the tendency for the
engine
to accelerate above 10~310 HPM during the M second
injection.
The three second time is based on filling three to four feet of
line from the va.lve to the nozzle a.nd
initially wetting the com-
pressor. With shorter or longer lines between the valve and
nozzle, the time delay can be reduced or increa.sed. For
equipment used, establish optimum time to obtain full flow
into Do not flood the compressor with water prior
to motoring.
6. While motoring, observe engine speed

during the ten seconds
rinsing operation. The engine RPM will generally stagnate
at or just below 10~o, but in a new ship, when
using a fully
charged battery or when using an A. P. U., the RPM may tend
to exceed 100/o. The N1 compressor RPM must not exceed 10~o
to prevent possible blade damage and to assure
adequate rinse
at the base of the blades. If the
N1 RPM reaches 100/o, release
the starter and continue the water spray. Permit
N1 RPM to
reduce to approximately 5~0 and then re-energize the starter to
obtain full ten seconds of engine rotation while water is
a,
sprayed into the compressor.
7. Continue injection of water spray during coast down until N1

stops, this improves the rinse of the base of the blades. Do
not continue spray after engine stops,
8. While engine drains, remove the bleed valve block.
9, After rinse, it is
important to fire up the engine to idle for
five minutes to purge and evaporate all residual water as soon
as possible (actuate anti-icing system for one minute).
~O. if exposure to excessive salt or other corrosive media has

occurred, repeat of the rinse procedure may be necessary.
a
In cases where the engine has not been

receiving regular daily
water rinsing, double rinse ma.y be required to prevent cor-
rosive attaclr of meta~s in the eagine.
q
250-CI8 CSL- 6-9
250-C20 CSL-1020
Page 3
B. Equipment
The source of pressure most readily available is water supply

systems which usually are 40-70 Ibs, per square inch (PSI).
Portable equipment using air pressure up to I00 PSI is satis-
to provide
factory for use, but nozzle should always be sized
maintained during
proper flow rate at the average pressure
each rinse cycle.
2. Test for proper water flow at pressure to be used by placing

the nozzle in a large container so no spray can splash out;
time the flow for ~O seconds and measure the quantity col-
lected. Proper nozzle size for pressure used should accumulate
I to 1 ~/8 quarts in the 10 second test. Adjust nozzle size if
necessary to meet the specified flow
limits.
CAUTION
DO NOT TRY TO PERFORM RINSE PROCEDURE WITH

ENGINE AT IDLE SPEED.
2. THE ENGINE MUST BE COOL.
3. THE NOZZLE MUST PROVIDE A DIFFUSED SPRAY

PATTERN. DO NOT INJECT A SOLID STREAM OF
WATER INTO THE ENGINE.
4. N1 SPEED MUST NOT EXCEED ~OOlo RPM DURING WATER
SPRAY INJECTION.
5. USE CLEANEST WATER AVAILABLE.
6. HOLD THE NOZZLE SO THAT THE SPRAY IS CENTERED

AROUND THE BULLET NOSE OF THE ENGINE INLET
AND INSURE THAT ALL OF THE WATER IS INJECTED
INTO THE ENGINE.
250-C18 CSL- 69
250-Ca0 CSL-1080
Ps~e4
COMMERCIAL ~ERVICE LE~TER
SUGGESTED ABBREVIATED CHECK LIST
SUBJECT: Contamination Removal (Water Rinse) Using Water Only
CAUTION: DO NOT ATTEMPT TO PERFORM THIS RINSE PROCEDURE

WITH ENGINE OPERATING AT IDLE SPEED.
Install Bleed Valve Block (bleed valve closed).

2, Pull engine ignition Circuit Breaker (Ignition inoperative).
3, It is not necessary to disconnect any lines.
CAUTION: A SPRAY PATTERN OF WATER MUST BE USED. ONE

SOLID STREAM IS NOT ACCEPTABLE.
4, Water spray one quart from portable sprayer into compressor

inlet.
5, One quart is minimum required.
6, Initiate spray three (3) seconds prior to rotation of the engine
with starter,
7. Spra.y during starter rotation for 10 seconds.
8. If N1 starts to exceed 10Cro,
release starter while continuing water
spray until N1 is reduced to 510 then re-energize the starter to get
a total 10 seconds with spray.
9. After 10 seconds of engine rotation with spray, release the starter

and continue the water spray until N1 stops, (DO NOT CONTINUE
WATER SPRAY AFTER ENGINE STOPS)
10. Repeat the above procedure if you are not positive all salt or other
contamination has been removed,
Permit engine to drain for one or two minutes, (REMOVE BLEED
VALVE BLOCK)
12. Make dry-out run. A five minute ground run at idle and actuate
engine anti-ice system for one minute during dry-out run.
NOTE: SEE DETAILED INFORMATION TO COVERPROCEDURES,

EQUIPMENT, WATER AVAILABILITY, WATER FLOW
REQUIREMENT, AND NOZZLE FEATURES,
L, O, Davidson
LJI~.
Service Manager
Aireraft Engines
-FHM/bst
NOTICE N(? DN-18

HUGHES
4
SERVICE INFORMATION Pace 1 (i~
NOTICE
REMOVAL OF CAPACITOR VOLTAGE REGULATOR, :::AAE OR LSI

SUBJECT:
MODEL VRZ04; INSTALLATION OF VARISTOR LANDING LIGHT
RELAY, PN MS24166D1
500D Model 36913 Helicopter SerialNo. 0003D thru 024C)D

MODELS AFFECTED:
All Subject Voltage Regulators in spares at date of this notice.
TIME OF COMPLIANCE: At owners and operators discretion.
PREFACE: The information given in this Service Information Notice lists a proce-
dure for removal of the 8 Cifd capacitor (C5) incorporated subject in the
Model VR204 voltage regulator to reduce EMI. The C5 is paralleled

the same function. Since
by a 1 Cifd capacitor which accomplishes
been reported,
failure of the C5 capacitor due to voltage spikes has
recommended to the operating
removal of this capacitor is ensure
reliability of the voltage regulator.
varistor the landing light relay is also recommended

Installation of a on
voltage regulator, and

to help prevent failure of other components of the
other installed avionics.
::c(AAE) Aircraft Appliance and Equipment, Div of Aerospace Div;

(LSI) Lear Siegler, Inc.
Reference
i, 15 November1977
500D HTVIT Vol I Issued 15 September 1976; Revision No.
Customer Service Department Hughes Helicopters Cuher City, California
FOR~I N~ 9578* HTC*D REV 11-67

NOTICE NO. DN-18 E) Huehes Helicopters
PAGE 2 of 4
PARTS LIST
Nomenclature Part No. aty Mfr.
Variator V47ZA7 1 GE
Terminal MS25036-102 2 Corn me rc ial
VOLTAGE REGULATOR REMOVAL OF C5 CAPACITOR
NOTE
Applicable to voltage regulator in
spares or installed on 500D Model

Helicopter Serial No. 0003D thru
0249D.
a. Check that all electrical power is OFF.
b. Gain access to voltage regulator and disconnect electrical connector.

(R.efer to HMI Vol I).
c. Rem.ove hardware securing regulator to support and lift out regulator.
d. Remove cover from, regulator: remove four screws, spacers and

nuts securing upper circuit board of regulator. (See Figure i.)
e. Remove capacitor C5 shown; clip wire leads close

as as as possible
to circuit board.
f. Reinstall upper circuit board and cover.
g. Using ink stam.p, add "MOD 5C" on vendor nam.eplate to indicate

modified voltage regulator.
h. Reinstall voltage regulator and attach electrical connector.
i. Perform anoperational check of the voltage regulator and make

adjustments as necessary. (Refer to HMI Vol I).
E~ Huehes Helicopters NOTICE NO.
DATE 6 February
DN-18
1978
PAGE 3 of 4
LANDING LIGHT RELAY INSTALLATION OF VARLSTOR
NOTE
Applicable to 500D Model 369D

Helicopter Serial No. 0003D
thru 0l49D only.
b. wiring leads from X1 and X2 on relay (See Figure 2).

Disconnect
of instrument
Disconnect relay panel 369H2502-66 located on lower support
panel assembly. (Refer to HMI Vol I),
varistor (trim varistor leads

Crimp terminal to each lead of
as
c.
close as practical to body of resistor).
d. Install varistor leads to relay terminals as shown in Figure 2;

connect wire leads at X1 and X2.
e. Reinstall relay panel.
WEIGHT AND BALANC E DATA

NOTICE Nd, DN-18 nughss Hlieopt~
DATE 6 F~ebruary 1978
PAGE 4 of 4
UPPER
CIRCL)IT
SCREW
eoAao
WASHER
MIM001
436 RHOVE CS
ETON(YL~FO
CAPACITOd
1)
o
AA
2N3053
512
ca
SPACER
d
s~,,, U
NOTES:
L C5 UPACITOR MAY BC ID~NTIFIED AS

NLW, 2-100, 8MF0, laMIV, 105 elcDel.
TAIWAN, T309; ORIECEI, lj100, VldIT;-~
10 MFD, NATIONALI PANASONI C.
2 COVER RUHOMD fOR CURIM.
Figure i. Field Rework Voltage Regulator
K101
Al T A2
-I-~
I-- LANDING LI GHT

VARISTOR
V47ZA7 RELAY
X2 L ---J
Figure Z. Installation of Varistor Landing Light Relay

NOrlCE N<?. DN-19
HUGHES
I
Dare 14 April 1978
"3
SERVICE INFORMATION
NOTICE
MANDATORY. I. MAN DATO RY- MAN DATORY
SUBJECT: ENGINE COMPRESSOR WATER WASH KIT INSTALLATION,

PN 369H92537 INSPECTION AND REPLACEMENT OF RIVETS
AFFECTED: 500D Model 369D Helicopter Serial No. 0003D thru 0129D
MODELS
with subject water wash kit installed
PREFACE: The information given in this Service Information Notice lists a
procedure for a one-time inspection of the non-monel solid rivets or
pull-type rivets used to secure the PN 369H3042 spray assembly to
the inner side of the plenum. chamber forward wall, to ensure that
these rivets are intact prior to removal and replacement with new
NA S1 7 3 8M4 2 r ivets
It is to be noted that Model 369D Helicopter Serial No. 0003D thru
0089D with subject water wash kit field installed as optional equipment
Notice No. DN-17 NOT affected
per Hughes Seryicei Information.
are
by this Notice.
Reference
Vol I, Issued 15 September 1976; Revision No. i, 15 November 197

369D Basic HMI
Service Information Notice No. DN-17, dated 6 February 1978
Hughes
Del;roit Diesel Allison Engine Operation and Maintenance ManJal 10W2
Form 0578
rORM NO 95784 HTC ID REV 11-67
LETTER NO. 3)N-19
f) Hugher nslico~ers
DATE: 14 April 1978
PAGE: 2 of 3
PARTS LIST
Part No. Qty. Mfr

Nomenclature
Rivet NA S1 7 3 8M4 2
or MS20615-3M5 8 Commercial
TOOLS AND EQUIPMENT
Gun, rivet
Motor, drill
Drill bit -No. 30
MATERIALS
Primer, zinc chromate
PROCEDURE
a. Open plenum chamber access door.
CAUTION
suitable material
Install a protective cardboard cover or
over engine air intake.
rivets
b.Visually inspect NAS1398B4-2 non-monel solid or pull-type
side of plenum chamber
securing PN 369H3042 spray assembly to inner
forward wall.
CAUTION
If any NAS1398B4-2 rivets or removable stems are missing,

perform inspection of engine compressor, per DDA Engine
Operation and Maintenance Manual, prior to removal of
and installation of rivets.
existing rivets new
rivets
c. Remove existing NAS1398B4-2 non-monel solid or pull-type
and install new NAS1738M4-2 or MS20615-3M5 rivets, eight (8) places.
LETTER NO. TN-19
Hughes nslicopters DATE: 14 April 1978
PAGE: 3 of 3
discrepancies; clean and check

d. Check rivet installation for
plenum chamber for foreign objects.
Remove temporary cover over engine air intake; close plenum

e.
chamber access door.
Notice in Com-
f. Record compliance with this Service Information
pliance Record of helicopter Log Book.
FAA APPRO VED

NOTICE NC). DN-20.
DATE 6 June 1978

HUGHES
PAGE 1 3
SERVICE INFORMATION
NOTICE
REPLACEMENT OF PLENUM WALL FITTINGS TORQUE PRESSURE

SUBJECT:
GAGE TUBING AND ENGINE OIL PRESSURE CAGE TUBING
500D Model 369D Helicopter SerialNo. 0003P thru 02321)

MODELS AFFECTED:
PREFACE: Field reports indicate that breakage and damage to the reducer
installed on the plenum chamber pan fitting has occured during normal
service or removal and installation of the engine oil pressure line.
Installation of new type fittings is recommended for both the torque
pressure gage and the engine oil pressure gage lines, to facilitate
removal and installation of the tube assemblies and preclude possible
breakage or failure of the fittings.
R efe re nce
500D Basic HMI-Volume I, Issued 14 September 1976; Revision No. I, 15 November 197
FORLI NO 9~78* tlTC *D REV 11-67

NOTICE r\rO. DN-20
DATE 6 June 1978
PACE 2 of 3
PAR TS LIST
Union ASI 2 3XH2 BZ -SS- T 2 HH
PROCEDURE
b. Remove left forward engine air intake fairing, and left aft bulkhead
access cover in cargo compartment. Refer to Basic HMLVol I.
c. Open LH engine compartment access door.
d. Disconnect pressure line nuts at forward and aft sides of both plenum
chamber fittings. Cap pres sure lines, Refer to Basic HMI-Vol.I.
pan
e. Remove existing fittings (reducers and unions) from plenum chamber pan.
f. Install new ASI Z-3XHZBZ-SS-T fittings at plenum. chamber pan, as
shown in Figure i.
lines and connect forward and aft sections of engine oil pressure
g. Uncap
and torque pressure gage lines to new fittings,
h. Check installation of new fittings for discrepancies.
engine and gages

i, Perform pressure and leak test of both lines between
at 200 psi,
j. Bleed and service oil pressure lines, per Basic HMI-Vol I.
k. Close engine compartment access door. Reinstall aft bulkhead access
cover and engine air intake fairing.

NOTICE NO. DN-20
DATE 6 June 1978
PAGE 3 of 3
~V _-~----
~"iB
i,
i-,
NYLONTUBEORCRES
STEEL TUBE
COLLAR (NOTE)
NUT
\L1~
PLENUM CHAMBER
PAN
UN ION AND NUT
C.ti Plt~LTUBt
PLENUM CHAMBER PAN B/(TO MCINE CONNECTION)
NOTE:
INSTALL COLLAR W ITH TAPER DOWNWAR D

AS SHOWN TO FIT INTO UNION.
88-253
Figure i. Replacement of Plenum Wall Fittings Torque

Pressure Gage Tubing and Engine Oil Pressure Gage Tubing
NOTICE NC. DN-21
H 881~i l~sB
ShI~E
~p I g~
aP\1Fg~WMATION
DATE
PAGE 1
6 June 1978
OF 3
~4 MAN DATE)RY MANDATORYL I I

IMANDATORY
I SUBJECT: REWORK OF STANDARD LANDING GEAR SKID ASSEMBLY,

P~J 369D26100-101; REWORK OF EXTENDED LANDING GEAR
SKID ASSEMBLY, PN 369D292114-101
equipped with Standard Landing Gear Assembly,

PN 369D26000-101/-102
i 500D Model 369D Helicopter SerialNo.

equipped with Extended Landing Gear
0070D thru 0270D
Assembly,
PN 369D90006-101/-102
Allsubject landing gear skid assemblies in Spares

Inventory at date of this Notice
TIME OF COMPLIANCE: Shall be accomplished at next 100-Hour Periodic
Ins pec tion inte rval
g Shall beaccomplished at installation of Spares

skid assembly, separate or part of Spares landing
gear assembly
PREFACE: The subject landing gear skid assemblies are predrilled with
additional attachment holes for the forward foot assemblies,

for LH and RH Skid interchangeability. The information
to provide
given in this Service Information Notice lists a procedure for sealing
the open attachment holes at the forward foot location on each skid
assembly, to prevent water seepage and entrapment and possible

corrosion damage to the skid assembly.
I 500D Basic HMI-VolI, Issued 15

R efe re nce
September 1976; Revision No. I, 15 November 1977
hlanual No. CSP-001, Extended Landing Gear Installation,

500D Optional Equipment
PN 369D290007
~stomer Service Department Hughes Helicopters Culver City, Call~ornia
HTC*D RLV 11~67

NOTICE NO. DN-21
DATE 6 June 1978
PAGE 2 of 3
MATERIALS
Sealing Compound MIL-S-7502 PR 1221 Product Research,

Burbank, CA
EP711 Coast ProSeal

Compton, CA
ProSeal 247 Coast ProSeal

Compton, CA
Primer, Zinc Chromate MIL-P-8585 Fuller and 0 Brien Co.

S. San Francisco, CA
PROCEDURE
a. Locate the two open attachment holes between the forward foot assembly
and abrasion strip on LH and RH skid assemblies. (See Figure i.)
b. Clean open hole areas of dirt, debris, etc.; seal open attachment holes
in each skid with sealing compound.
c. Record compliance with this Service Information Notice in Compliance

FAA A PPROVED
NOTICE NO, DN-21
DATE 6 June 1978
PAGE 3 of 3
xI
\o
LANDING GEAR SKID
BOLTS
1
FORWARD FOOT ASSEMBLY
ILH SHOWN)
PN 369[)26004-1011-102
(STANDARD CEARI
R\1 369829113-1011-102
(EXTOI~DED GEAR)
SCREW
SEAL ATTACHMENT HOLES

(2 PLACES EACH SKIOI
SCREW
ABRASION STRIP
O FORWARD FOOT ATTACHMENT 88-250.
Figure 1. Rework of landing gear skid assemblies

NOTICE NO. DN-22
HUGHES
01 SERVICE INFORMATION
N8T IGE
oaTE 26 June 1978
MAN DATBRV I L MAN DATORY MAN DATORY
SUBJECT: SEALING VERTICAL STABILIZER ASSEMBLY, PN 369D23600

AND 369D23600-401
TIME OF COMPLIANCE: Shall be accomplished at next 100-hour Inspection

Interval, or at next removal of horizontal stabilizer,
whichever is sooner.
for sealing the top rib assemblies of the vertical stabilizer, to prevent
water from collecting internally and freezing during cold weather operation~
R efe renc e
400D Basic HMI-VolI, Issued 14 September 1976; Revision No. i, 14 November 1977
MATERIALS
Sealing Compound MIL-S-7 502 PR 122182 Product Research

Burbank, CA
EP711 Coast Pro Seal
Compton, CA
Customer Ser~ce Department Hughes Helicopters Culver City, Callornia
RCV 11.67
Forn9578
NOTICE NO.
DATE
DN-22
26 June 1978
E~ HUehe Hlleoptal.
PACE 2 of 3
7
PROCEDURE
a. Remove horizontal stabilizer, per Basic HMI Vol I; inspect top

of vertical stabilizer forwater accumulation.
b. Apply 0. 030/0. 040-inch bead of sealant around outer perimeter of

top rib assemblies and at attach fitting, shown in
as Figure i. Also apply
sealant around electrical conduit and seal over tooling holes. Do not seal
drain holes.
c. Reinstall horizontal stabilizer, per Basic HPVLI Vol I.
WEIGMT AND BALANCE DATA
FAA APPROVED
j
Wug~ M~licop(sn NOTICE NO. I)N-ZZ
DATE 26 June 1978
PACE 3 of 3
TOP OF RIB
0.25
-O.WO
O.M
+0.010
vrm B -B
TOP OF RIB
369023609
-O.MM
0.03
t0.010
VINV C-C
(E~
Q
SEALANT OJON-HARDIING~, EDCCS ~SEALANT TO BE APPLIED
AND TOOLING HOLES, EXCEPT GRAIN /AROUND ELECTRICAL
HOLESPRmIORRN /CONDUIP
or /O
HOLE 0.06
DIAMETERNIURHT
SEALANT SHOOLO
NOT COVER DRAIN
HOLE
o O
TOOLING HOLES
DRAIN HOLE R06 DIAMETER TNRLI
SEALANT SHOULD NOT COVER 369023600 VERTICAL STABILIZER
DRAIN HOLE ASSEMBLY
VIEW AIA
NOTE:
ALL DIMENSIONS IN INCHES.

A j I\I I A
88-aU\
i i. Figure i. Sealing- Vertical Stabilize+

Assembly
;2
NOTICE NC. DN-23. 2

HUGHES DATE 5 September 1979
SERVICE INFORMATION 1
M 8T ICE: ~Supersedes Service Information Notice
No. DN-Z3. i, Dated 16 April 1979
MANDATORY I MAN DATO RY I MAN DATO RY
SUBJECT: INSTALLATION OF STANDOFF CLAMPS HEATING SYSTEM HOSE
AND MAIN ROTOR TRANSMISSION OIL COOLING LINES.
AFFECTED: 500D Model 369D Helicopter SerialNo. 00o3D through 0539D. 1

MODECS

ope ration.
for installing standoff clamps on heating system hose
the PN 369D292490
and on the PN 369D25710 main rotor transmission oil cooling line, to

eliminate chafing between the oil cooling lines, and chafing of the oil
cooling lines by the heating system hose. A protective bushing is also
installed to prevent chafing between the oil cooling lines.
Reference
500D Basic HMI Vol I, Issued 15 September 1976; Revision No. 3, 15 March 1979.
369D Operational Equipment Instruction and Illustrated Parts List Heating System,
PN 3691-1900200-517; CSP-013, Issued 15 August 1976.
Hughes Helicopters Culver City, California

HTC-~D REV 11-67

NOTICE NO. DN-23. 2~
DATE
PAGE 2 OF 4
5 September 1979 E~ Huehes Helioopter.
PARTS LIST
Nomenclature Part No. Qty Mfg
Clamp NAS1713D30N 1 Commercial
Clamp NAS1 7 1 3D8N 1 Co mm e r c i al

Screw NAS1096-3-7 1 Commercial
Nut MS2 1 04 3 3 1 C omme rcial
Wa she r P1N96 OPD 1 OL 2 C ommer cial
s~ Bushing c-SB-16-8 1 Parker Fluid
Connector s
Cleveland, OH
Bracket HS41 94-6 1 HH
Rivet M S2 047 OAD 3 2 C omme r c ial
Clamp MS21919DG30 1 Commercial

~$a Washer AN960 PD 10L 1 Commercial
Screw NAS1096-3-7 1 Commercial
PN C-SB-16-8 Bushing may be obtained without cost from HH Service

Center or Distributor. Service Centers and Distributors process orders
through HH
Waranty and Repair Department.
As required
INSTALLATION STANDOFF CLAMPS
a. Remove aft compartment interior trim panels and left station 124. 0
bulkhead access door to gain access to work area. (Refer to Basic HMI-
Vol I.
NOTE
Inspect PN 369D292490 heating system hose, and

PN 36913~24709 and 369D25710 main transmission
oil cooling lines for evidence of chafing, kinking,
or damage at area of LH aft section channel assembly.
b. If not already installed, install NAS1713D30N clamp on heating system
hose, and NAS1713D8N clamp on PN 369D25710 oil cooling line, as shown in

Figure I. Connect clamps with screw, washers and nut.
c. If not
already installed, install new PN C-SB-16-8 bushing snug against
nut on PN 369D25709 oil cooling tube assembly. (See Section A-A.) Reposition
clamp assembly securing PN 369D25709 (lower) and 369D25710 (upper) oil
cooling tube assemblies, as shown, to accommodate installation of bushing.
Hughes Helicopter~ DATE 5 September 1979
PAGE 3 OF 4
d. Check installation of standoff clamps to adequate clearance

ensure
between PN 369D25709 and PN 369D25710 oil cooling lines, and between

oil cooling lines and PN 36913292490 heating system hose.
NOTE
i. Later Model 500D helicopters have PN 369D26444-3

closure plate (with grommet) installed on LH aft
section channel (See Detail B). Remove plate from
channel, if presently installed, to preclude inter-

ference with oil cooling lines.
2. Later Model 500D helicopters have PN HS~4194-6

standoff bracket installed on channel, with
PN MS21919DG30 clamp to secure heating hose
(See figure i). Install standoff bracket and
clamp, if not presently Installed on helicopter.
e. Reinstall bulkhead access door and interior trim panels.
f. compliance with this Service

Record
Compliance Record of Helicopter Log Book.
Information Notice in
I
FAA APPROVED
NOTICE NO. DN-23. 2s~
DATE
PAGE 4
5 September 1979
OF 4
E~ Hushes Helicopters
ic
i CLAMP (RELOCATE)
ASSY
369D25710O1LCOOLING
TUBE ASSY
PN 369[)26544-3 CLOSURE PLATE-REMOVE

o ~-V IF PRESENTLY IN STALLED ON AFT
SECTION CHANNEL.
(ROTATED)
369[)25709 011
COOLING TUBE ASSY
BUSHING
SECTION A-A
369D25710011COOLING
ii
TUBE ASSEMBLY (REF) -6 STANDOFF INOTE II
C-SB-16-8 MS20470AD3RIVET(2)
BUSHING
369[)25709 OIL COOLING
369[)23024 AFT SECTION CHANNEL
TUBE ASSEMBLY
ASSEMBLY (CANTED STATION
NAS171308N CLAMP (NOTE 2) 11 124. 0)
NAS1096-3-7 SCREW
O
AN960PD10L WASHER 12)
O
MS21043-3 NUT
ol j MS21919DG30 CLAMP (NOTE 1)
369025709 OIL
NAS1096-3-7 SCREW
COOLING TUBE ASSEMBLY-------c~3 AN960PD10LWASHER
NAS171308N CLAMP (EXISTING)

AN743-12BRACKET 3690292490 HEATING HOSE
NAS1096-3-7 SCREW (21 I
MS21043-3 NUT (2)
AN960P010L WASHER (4) NAS1713030N CLAMP INOTE 2)
000
NAS1713030N CLAMP (EXISTINGI
NOTES:
1. PRESENTLY INSTALLED ON LATE MODEL HELICOPTERS: INSTALL AS

REOU IRED ON EARLY HELICOPTERS.
2. LOCATE NEW CLAMPS APPROXIMATELY AS SHOWN ON COOLING TUBE
AND HEATING HOSE ASSEMBLIES.
3. AFTER INSTALLATION OF BUSHING, ROTATE BUSHING SO THAT SPLIT

IN BUSHING IS FAC ING DOWN.
Figure 1. Installation of standoff clamps heating system installation

PN 36H90020-517
NOTICE NC. DN- 24
onTE 4 July 1978

HUGHES
4
SERVICE INFORIWATION PAGE 1 OF
NOTICE
SUBJECT: FIELD INSPECTION AND CORROSION REPAIR MAIN ROTOR

DRIVE SHAFT, PN 369D25510
TIME OF COMPLIANCE: At owners and operators discretion; recommended whenever

subject main rotor drive shaft is removed from helicopter
PREFACE: The information in this Service Information Notice lists

given a procedure
for field repair of the main rotor drive
shaft, if evidence of corrosion
pitting through the original phosphate coating on the drive shaft is noted.
Refer ence
500n Basic HMI-- VolI, Issued 15 September 1976; Revision No. i, 15 November
1977

NOTICE NO. DN- 24
Hughe Helicopters
DATE: 5 July 1978
PAGE: 2of4
MATERIALS
1 1 1 Trichloroethane 0-T-620 C omm e r cial
Surface Cleaner TT;C-490 or WO#1 Turco Products Inc
MIL-C-10578, Wilmington, CA
Type II
Crocus Cloth P-C-458 C omm e re ial
Zinc Chromate MIL-P-8585 W. P. Fuller Co.

Primer,
Los Angeles, CA
Oil Preservative VV- L-800 Commercial
MIL-S-7502 PR 1221 Product Research

Sealing Compound
Burbank, CA
EP711 Coast ProSeal
Compton, CA
PROCEDURE
a. Remove main rotor drive shaft, per Basic HMI-Vol I.
b. all surfaces of drive shaft for dents, nicks, scratches and

Inspect
evidence of deformation. Inspect splines on end of drive shaft for excessive
wear. (Refer to Basic HMI-Vol I.
c. Inspect all external surfaces of shaft for corrosion. Remove
corrosion as follows:
i. Degrease corioded area of drive shaft with clean cloth

saturated in trichloroethane.
WAR NING
Surface cleaner irritates hands on
repeated exposure. Rubber gloves

should be worn.
of surface cleaner
2. Swab shaft exterior with diluted solution
four water). Keep wet with
(mix one part Turco #1 with parts
to be
solution for ten, minutes, or until corrosion appears
removed. Wipe, clean and inspect, and repeat as necessary
until there is no further evidence of corrosion.

NOTICENO. DN-24
Hugher Helicopters
DATE: 5 July 1978
PAGE: 3 of 4
3. Rinse with water and dry thoroughly with compressed air.
CAUTION
Exercise care when

removing pits to
ensure peening is not completely
that shot
penetrated. Also, remove only minimum

material necessary to remove pits. Mini-
mum wall thickness of 0. 1775 inch must

be maintained.
4. Lightly abrade corroded surface with crocus cloth to remove
pits. If pit removal exceeds depth of O. 0012-inch in Area 1 or
0. 0008-inch in Area 2 (See Figure i), shaft is unserviceable

and must be replaced.
5. Repeat 1 through 3 above.
6. Spray two coats of zinc chromate primer on shaft exterior.

Do not prime spline teeth or mounting surface.
d. Apply preservative oil to spline teeth.
e. Immediately reinstall main rotor drive shaft, per Basic HMI.
f. Apply a O. 06-inch bead of sealing compound around interface of hub

anti drive shaft.
NOTE
Main rotor drive shafts on early Model 500D
helicopters have a recessed area at the top of

the drive shaft ID to accommodate phasing
tool. This recess is no longer required and
should be filled to prevent water accumu-
lation and possible corrosion. Clean the

recessed area (shaft ID and cork plug) of any
dirt, debris, water, etc. and fill recess flush

to top of shaft with sealing compound. On late
Model 400D helicopters, the cork plug is
installed flush with top of shaft to eliminate

the recessed area.

Hughe~Hdieapters
NOTICE NO, DN- 24
DATE: 5 July 1978
PAGE: 4 of 4
t
i. 7 INCHES
::::::il 81NdHES
5.4 INCHES
REA i: MAXIMUM PIT DEPTH 0.0012-INCH.
~3 2: MAXIMUM PIT DEPTH

AREA 4
3: MAXIMUM PIT DEPTH O. 0020-INCHi
AREA 4: CHECK TEETH 8Y MEASURING ACROSS

NVO O. IQ-INCH-DIAMETER PINS
PLACED IN OPPOSITE INTER-TOOTH
GROOVES. MEASURED DIMENSION
SHOULD BE A MINIMUM O 2648
INCHES.
88-246
Figure i. Inapection and repair main rotor drive shaft
-tF!:;-!
NOTICE NC. DN-25. 1:I:
MUGHIE$ DATE 7 March 1980
SERVICE INFORMATION P"GEIOF 5
NOTI~E :eSupersedes Service Information Notice

No.. DN-Z5, Dated 15 July 1978
I IIMAI\IDATORY I I~P MAN DAIO RY
rMAIUDAIORYssb-.e
UBJECT: REWORK OF FUSELAGE STRUCTURE, FORWARD SECTION
MODELS AFFECTED: 500D Model 369D Helicopter SerialNo. 0003D through 0339D;
0341D through 0385D; 0387D through 0401D; 0403D through 0406D;
0408D through 0417D; 0419D through 042913; 0431D through 0434D;
i0436D through 0442D; 0444D through 0491D; 0493D through 0503D;

0505D through 0507D; 0509D; 0510D; 0512D through 0519D; 0521D
through 0552D; 0554D through 0568D; 0572D through 0590D; 0594D
through 0596D; 0599D through 0620D; 0622D through 0625D; 0627D
through 0633D; 0635D; 0636D; 0638D through 0645D; 0647D; 0649D
TIME OF COMPLIANCE: Shall be accomplished at next 100 hour

periodic inspection after receipt of parts
fuselage
assemblies to the frame
procedure installing support
for
structure, provide
to reinforcement at the forward attach points
for the engine inlet fairing assemblies. Field reports indicate

that cracking and/or damage has occurred in the area of the
forwardmost attach nutplate assembly, for both left-hand and

right-hand sides of the fairing assemblies. Instructions are also
provided for field fabrication and installation of doublers and
repair angles, if cracking or damage to the upper fuselage skin
or frame structure is noted.
The fuselage support assemblies may be obtained without charge

from your authorized HH Service Center or Distributor.
Re fe r e nc e
500D Model 369D Basic HMI-Volume i, Issued 14 September 1976; Revision No. 3, i
15 March 1979
I Denoees portion of text added or revised
Hrc"D Rev 11-67

NOTICE NO, DN-Z4. l::c
DATE: 7 March 1980
PACE 2 of 5
PARTS LIST
Nomenclature Part No. atv Mfr,
Support 80-369~22400-3 1 HH
Support 80-369D22400-4 1 i-ill
~,I: Nutplate NAS697A3 2 Comme re ial
Rivet M S2 047 0AD3 A/R Commercial

"As required
MATERIALS
jl:::Doubler 0. 030 inch 2024-T3 AL ALY SH Field Fabricate
0. 020 inch 2024-T3 AL ALY SW Field Fabricate

Commercial
required
TOOLS AND EaUIPMENT
Gun, rivet:
Drill motor, portable

Drill bit 0.198/0.204 inch diameter
Drill bit 0. 096 inch diameter
REWORK PROCEDURE
a. Remove engine inlet forward fairing assemblies from helicopter.

(Refer to Basic HMI-Vol i.)
b. Remove interior trim panels, and wire harnesses as

applicable, to gain
to work area at forward attach
access
nutplate assembly for LH and RH engine
inlet forward fairings. (Refer to Basic HMI-Vol i.)
c. Remove existing forward nutplate (for both LH and RH fairing assemblies)

from fuselage frame structure.
NOTICE NO. DN-25.1~:
DATE: 7 March 1480
PAGE 3 of 5
d. Inspect upper fuselage skin for cracks or damage at area of forward

nutplate attachment holes. Also inspect repair doublers if previously installed
on upper fuselage skin.
NOTE
If cracking or damage to fuselage skin or repair doublers
is noted, perform the following:
I. Stop drill all cracks or remove damaged skin area or

damaged repair doublers prior to rework. Perform all
work in accordance with FAA AC 43.13-1A Aircraft
Inspection and Repair.
2. Field fabricate and install doublers on outerfuselage

skin, as shown in Figure I, View A. 0.196/0.204
Drill
inch diameter hole in each doubler to match existing
hole in fuselage skin for fairing attach screw. Use
existing rivet pattern as shown; install rivets with zinc

chromate primer.
3. Prime and paint doubler to match finish color of heli-
copter. Refer to Basic HMI-VolI.
e. Inspect fuselage frame structure (channel) for cracks or damage at
forward nutplate attach areas.
NOTE
If no cracking or damage to fuselage frame is noted, install

80-369D22400-3 and -4 support assemblies at FORWARD side of
frame structure, using rivets as shown in Figure i, View C.
Drill holes in support assemblies for nutplates and for conduit

clearances as required. Install nutplate rivets through support,
frame, upper skin and doubler, if installed.
If cracking or damage to fuselage frame is noted, perform

the following:
I. Stop drill all cracks or remove damaged area prior to
installation of repair angles and support assemblies.

Perform all work in accordance with FAA AC 43. 13-1A
Aircraft Inspection and Repair.
NO T:ICE NO. DN- 2 5. 1
7 March 1980
t
DATE:
PAGE 4 of 4
2. Field fabricate and install repair angles at AFT side of

fuselage frame structure (channel); and install
80-369D22400-3 and -4 support assemblies at FORWARD
side of frame structure, using rivets as shown in
Figure i, View B, Drill 0. 096 inch diameter rivet
holes in angles to match support assemblies.
3. Drill holes in support assemblies and repair

angles for
nut plates and for conduit clearances as
required. Install
nutplate rivets through support, frame, angle, upper skin
and doubler if installed.
f. Cheick installation of 80-3691)22400-3 and -4 assemblies, and repair

anges and doublers if installed, for discrepancies.
g. Reinstall removed components.
h. Record compliance with this Service Information Notice in Compliance

FAA APPROVED
NOllCE NO. DN-25. 1,:(
DATE: 7 March 1980
PACE 5 of 4
INOTE 1)
0. 030 2024-T3
AL ALY SHEET
6.00
CANTED
:H /IP10 0
00,O P_O STA
t-------- o./ 78, 50
FWD 01
\O
Oi
!01 /OUTER SKIN
0,
O i 0.19610.204HOLETO MATCH
EXISTING SCREW HOLE O
0,
--,--1---- -LO
P 00 o;o o o
ot-
0,
1 369A2400-5 ANGLE
OI I I STA
-I------------
O 00 O O O O O O
3 RIVETS EACH SlbE VIEW A 369H2508 FRAME DOUBLER

DFDAMAGE(AD3)
SKIN
iO O O
TE (NOTE 5)
!O O O O
80-369022400-3, -4
O
o I~ o SUPPORT FORWARD
SIDEOFFRAME
SUPPORT MarE 31 II
(LH SIDE OF FRAME
ANGLE (NOTES 2, 3)
(NOTES 2, 3)
FRAME
UP
,,,,,,J
SKIN
NOTES:
i. DOUBLER ON OUTER SKIN TO PICK UP EXISTING

RIVETS.
IS NOTED. 80-369022400-3, -4
2. REPAIR ANGLE INSTALLED ONLY IF FRAME DAMAGE
SUPPORTFORWARD
FOR CONDUIT
3. DRILL HOLES IN SUPPORTIANGLE AS REPUIRED SIDE OF FRAME
CLEARANCES. (NOTE3)
AREA.
4. STOP DRILL ALL CRACKS OR REMOVE DAMAGED
ANGLE
5. INSTALL NUTPLATE RIVETS THRU SUPPORT, FRAME,
(IF INSTALLED), SKIN AND DOUBLER.
6. INSTALL RIVETS WITH ZINC CHROMATE PRIMER. VIEW C

88-2438
Figure i. Rework of fuselage structure forward section

N0TICE NC). DN-26
DATE 15 July 1978

2
PAGE 1 OF
~rm NIANDATBRYP---s MAI\IBA70 Rd IB IWANISAIOI-:Y E~I.
SUBJECT: INSPECTION AND POSSIBLE REPLACEMENT SEAT BELT ASSEMBLIE~,

:1 369H6441-21
PN 3691-16541-5 AND
&I
MODELS AFFECTED: All 500D Model 369D helicopters delivered prior to

i
ii 1 June 1977.
All subject seat belt assemblie s in Spares Inventory,
i-i
TIME OF COMPLIANCE: Part I _
INSPECTION OF SEAT BELT ASSEMBLIES
ij
i! shall be accomplished prior to next flight.
:1
i
Part LI REPLACEMENT OF SEAT BELT ASSEMBLIES
shall be accomplished within next 25 hours
after receipt of replacement belts.
PREFACE: American Safety Flight Systems, Inc., has modified the Sam Browne
ij seat belt inertia reel retractor mechanism to improve its operation.
This Notice provides instructions for inspection of the seat belt

assemblies on the above affected helicopters and in Spares Inventory ::i
to determine if ASFSI seat belt assemblies are installed; and for
of these assemblies with the improved seat: belt
replacement assem-
blies to be provided without cost by ASFSI.
A returnreply coupon is provided as part of this Notice to expedite

replacement of seat belt assemblies where applicable,
Refe rence
i
500D Series 3691) Basic HMI Volume i, Issued 15 September 1976
15 November 1977 :;i
Revision No. i,
ri
:-i Customer Service Department Hughes IIe].icopters Cuhcr City, C;alifornia

P~
,clr *D Rev ll~h7

NOTICE NO. DN-26 Hughes Helicoptecs
DATE: 15 July 1978
PAGE: 2 of 2
PART I INSPECTION OF SEAT BELT ASSEMBLIES
a. Visually inspect labels on PN 3691-16541-5 (passenger coml~artment,

2 places)
seat belt assemblies to deter-
and 369116541-21 (crew compartmentt 2 or 3 places)
mine belt assembly manufacturer and date of manufacture,
NOTE
If label indicat:es that manufacturer is American Safety

and date of manufacture rework
or
Flight Systems, Inc.,
is prior to May 3977, notify your authorixed HH Service
Center -or Distributor immediately for replacement seat

belt assembly. Also, fill out and return attached reply
of Distributor.
coupon to HH Service Center
with Part I of this Notice in Compliance Record of

b. Record compliance
PART II-- REPLACEMENT OF SEAT BELT ASSEMBLIES
369H6541-21 seat belt

a, Asapplicable, remove PN 369H6541-4 and assem-
blies (American Safety Flight Systems, Inc.). Refer to Basic HMI Volume I.
NOTE
Return the seat belt assemblies to Hughes Helicopters.

Charges will be applied by Hughes Helicopters for the
replacement seat belt assemblies sent to customer.
An offsetting credit will be applied to customer account
when the original seat belt assemblies are, received by
Hughes
-25 seat belt assemblies

b. improved PN 3691--16541-23 and 3691-17 541
Install
manufactured May 1977 later, or reworked
provided by Hughes Helicopters (units
or
and identified with "RW" May 1977 or later).
Part .II of this Notice in Compliance Record of

c. Record:compliance with
helicopter Lqg Book.
WEIGHT AND.BALAJCE DATA
FAA APPROVED
In accordance with. Hugh.es Service Information Notice No. DN-26, inspection
of PN 3691-16541-5 and 3691-16541-21 seat belt assemblies has determined that
American Safety Flight Systems, Inc., seat belt assemblies (PN 500878-403
and 500879-401) manufactured prior to May 1977 are presently installed on the
following helicopter(s) or in Spares Inventory:
Number of Seat Belt

Assemblies Installed
Model 369D Helicopter Serial No.
Spares Inventory (indicate quantity)
Signature Title
Company Organization
Complete Address
HUGH ES DATE 8 December 1978
SERVICE I]NFQRPhn~TIB%V 10F~ P~GE
N~TBCE .1Supersedes Service Infa~matian Notice

No. DN-27, dated 1 September 1978
MANDPITORVPPs [VIAN BUT~ RV

MAN DAPORY I "I~Ps ----ppe~il---
F~I
SUBJECT: INSPECTION AND REWORK OF TAIL ROTOR HUB, PN 369A1725-5

AND 369A1725-501; INSPECTION OF TAIL ROTOR BLADE ATTACH-
MENT BOLTS; PN MS21250-06040
MODELS AFFECTED: r 500D Model 369D Helicopter Serial No. 0003D through
0355D
Part I
The following Tail Rotor Hub Assemblies (separate or
installed as component of PN 369D21600 Serial Tail Rotor

and this Notice:
Assembly) in Spares Inventory at date of
Part II PN 369A1725-5 Tail Rotor Hub Assembly having
Serial Numbers 001 through 862.
All PN 369A1725-501 Tail Rotor Hub Assemblies.
Part III All 500D Model 369D Series Helicopters i;

il
TIME OF COMPLIANCE: Shall be accomplished at next 100-Hour Periodic Inspection;
or prior to installation of Spares assembly on helicopter;
or within six months after date of this Notice, whichever is
soonest.
PREFACE: Part I and Part II or this Service Information Notice provides instructions I
for inspection of the subject tail rotor hub assemblies, and application of a
corrosion resistant coating at the radius area between the spindles and
center portion of the hub. ~1
Part III of this Notice

MS21250-06060 tail
bolt heads are seated
provides
rotor
instructions for
properly against the PN 369H5308

inspection
blade attachment bolts to determine that the
of the PN
bushings.
Ii
Reference t~
500D Basic
27 November 1978
HMI-VolI, Issued 15 September 1976; Revision No. 2
I
500D Component Overhaul Manual COM-369D, Issued 15 September 1976.
Hlc*o REY 11-67

DATE
Page
8 December
2 of 5
1978
TOOLS AND EQUIPMENT
Magnetic Particle Inspection Kit MIL-I-6868

Magnifying Glass 10X
Oven, Baking or Heat Lamp

Brush, Paint -1/16"
Torque Wrench O to 1000 inch-pounds
MA TERIALS
Coating, Aluminum Alumazite Z HH

4 oz, can
Methylethylketone (MEK) TT-M261 Commercial
Emery Cloth, Medium Commercial
Emery Cloth, Fine Commercial

or
Crocus Cloth, Fine P-C-458 Commercial
I Primer, Zinc Chromate Commercial
NOTE
Authorized HH Service Centers may obtain one 4 oz.

can of Alumazite Z without cost, if ordered prior to
30 November 1978. Owners/operators may purchase
Alumaeite Z through HH Service Centers.
PART I-HUBIDENTIFICATION
a. Identify tail rotor hub as follows:
(1) PN 369A1725-501 hub is identified by Part Number and Serial

Number on one of two data plates on hub (see Figure 1) and is to be reworked
per Part II of this Notice, unless identified with letter "Z" or letters "SP"
following hub serial number.
(2) PN 369A1725-5 hub is identified by Part Number and Serial

Number of two data plates hub (see Figure 1) and is to be
on one on
inspected
and reworked per Part II of this Notice, except as noted below.
E) HUshe8 Helicopters NOTICE NO.
DATE 8 December
DN-27. 1~C
1978
PAGE 3 of 5
NOTE
i. PN 369A1725-4 Tail Rotor Hubs having Serial
No. 001 through 862 and identified with either

Letter "Z" or letters "SP" following hub serial
number do NOT require rework per Part II of

thi s Notice.
2. PN 369A1725-5 Tail Rotor Hubs having Serial

No. 863 and subsequent do NOT require rework
per Part II of this Notice.
b. compliance with Part I of this Service Information Notice in

Record
Compliance Record of helicopter Log Book or tag Spares hub assembly and
record compliance when assembly is installed on helicopter.
PART II HUB INSPECTION AND REWORK
a. As applicable, remove tail rotor assembly from helicopter and
remove tail rotor blade assemblies, per Basic HMI-Vol I. Disassemble
hub and drive fork assembly, per Component Overhaul Manual (COM-369D).
b. Clean hub with MEK.
for cracks and corrosion other

c. Using 10X glass, inspect hub or
damage. Pay particular attention to area of 0. 13 radii between the
spindles and center portion of the hub. (See Figure i.)
NOTE
i. Indications of cracking are cause for hub regection,

except as noted below.
(a) Minor surface imperfections or discontinuities
in the unmachined center of the hub may appear

to indicate cracking. This area may be dressed
with medium grade emery cloth for minimum
material removal to remove the imperfections.
2. If corrosion or pitting is noted, clean hub surface
with fine emery cloth or crocus cloth.

NOTICE NO. DN-27. 1~C
DATE 8 December 1978 Hughes Helicopters
Page 4 of 5
3. If surface repair was performed in i. or 2.

above, clean hub with MEK and reinspect hub
with 1OX glass. Pay particular attention to
0. 13 radius areas on both sides of the hub.
4. If hub is
rejected, contact HH Customer Service
Department for disposition.
d.Magnetic particle inspect hub for cracks, per MIL-I-6868. Pay

particular attention to O. 13 radius areas on both sides of the hub. If hub
is rejected, contact HH Customer Service Department for disposition.
e. Rework hub as follows using Alumazite Z:
(1) Shake contents of container thoroughly.
(2) Brush a thin (0.0002 to 0.0005 inch) even coat onto cleaned sur-
face of 0. 13 radius areas on both sides of the hub. (See Figure I.) Limit
width of aluminum coating to 0.25 inch, to prevent contact with feathering
bearings.
(3) Allow a flash-off (drying) time of 8 to 10 minutes.
(4) Bake hub for 1 hour at 3740 to 4250 F in oven or use heat lamp.
(5) Air cool hub.
f. Add letter "Z" following serial number on hub data

plate, to denote
rework of 369A1725-5 or 369A1725-501 hub. (See Figure 1.)
g. Reassemble tail rotor hub and drive fork assembly, per Component
Overhaul Manual (COM-369D), Reinstall tail rotor blade assemblies, per
Basic HMI-Vol I.
h. Perform Part III of this Notice.
i, As applicable, reinstall tail rotor assembly on helicopter, per Basic

Hh/LI-Vol I,
j, Record
compliance with Part II and Part III of this Service Information
Notice in Compliance Record of helicopter Log Book; or tag Spares assembly
and record compliance when assembly is intalled on helicopter.
NOTICE NO. DN-27, l~r
E~ Huehu Hslicopfers DATE 8 December 1978
PAGE 5 of 4
TAIL ROTOR ASSEMBLY

DATA PLATE
0. 13 RADIUS (TYPI
i j
1 369A1725-5 1
ISIN--------- 1
HUB SPINDLE
0. 25 INCH WIDE ALUMINUM~ O. 25-INCH WI DE ALUMINUM

COATING (NOTE) COATING INOTEI
HUB DATA PLATE (169A1725-5

OR369A1725-501)
NOTE:
LIMIT WIDTH OF ALUMINUM COATING

TO O. 25-INCH TO PREVENT CONTACT
WITH FEATHERING BEARINGS.
88-249
Figure i. Rework of tail rotor hub assembly
PART III INSPECTION OF TAIL ROTOR BLADE ATTACHMENT BOLT
the two PN MSZ 1250-06 040 tail rotor blade attachment bolts
a. Inspect
No gap is permitted; bolt head must
for gap between bolt head and bushing.
seat plush against PN 369H5308 bushing.
NOTE
If gap is noted between bolt head and bushing, replace

with
serviceable PN MS21250-06040 bolt and PN 369H5308 bush-
HMI-VolI. Coat bolt, bushing

ing,per Section 8 of basic
and washers with unthinned zinc chromate primer at instal-
lation. Install nut and torque to 600 to 650 inch-pounds
while zinc chromate primer is wet.
FAA APPROVED
NOTICE NC. DN-30
HUGHES oarEf 8 September 197&

SERVICE INFORMATION PAGE 1 OF 10
NOTICE
SUBJECT: INSTALLATION OF ANTI-ICE FUEL FILTER, PN 3691-190022
MODELS AFFECTED: 500D Model 369D Helicopter SerialNo. 0003D and subs
equipped with PN 369H6416 Instrument Panel
Installation of the PN 369H90022 anti-ice fuel filter deletes the

requirement for use of fuel containing anti-ice additives.
PREFACE: The information given in this Service Information Notice pro-
vides instructions for incorporating an anti-ice fuel filter

between the helicopter fuel system and the engine fuel sys-
tem. The filter is designed to strip the fuel of ice particles
prior to entering the engine fuel system. Electrical and

mechanical equipment sense the build up of ice in the filter
unit, and automatically illuminate a cockpit caution and
activate the helicopter start pump. When the filter becomes
fully clogged, a bypass valve contained in the filter unit

opens and the fuel bypasses the anti-ice fuel filter
element.
Reference
500D Model 369D Basic HMI Volume I, Issued 15 September 1976
FORLI NO 9578* HTC*D REV 11-67

NOTICE NO.
DATE 8
DN-30
September 1978
QHUB)IHI
PAGE 2 of 10
PARTS LIST
When ordering, specify PN 369H90022 Anti-Ice Fuel Filter Installation which

consists of the following:
Nomenclature Part No, aty Mfr
Doubler 3691-190022-1 1 HH
Tube 369H90022-3 1 HH
Filter Ass embly 369H8021 1 HH
Fitting 3691-18023 1 HH
Hose Assembly 369H8024-5 1 HH
Hose Assembly 369H8025 1 HH
Bracket 369H8032 1 HH
Placard 369H8100 1 HH
Drain Valve CAV-170H-4 1 Commercial
Tie Wrap TY-Z5M 1 Commercial
Tee 6151-0250 1 Commercial
Clamp AN737TW38 2 Commercial
Bolt AN775-4 1 Commercial
Gasket AN901-4A 2 Commercial
Reducer AN919-19 2 Commercial
Washer AN960PD416L 3 Commercial
Wa she r AN960PD1 OL 2 Commercial
Washer AN960-10 4 Commercial
Rivet rurszo615-3M 30 Commercial
Rive t MS20615-4M 10 C omme r c ial
Lockwire Mszo995c32 AR Commercial
Nut MS21 042-3 5 Commercial
Clamp MS21919H2 5 Commercial
Screw NAS603-7 5 Commercial
Bolt NAS1304-5H 3 Commercial
Spacer NA S4 3 DD4 1 9 3 Comme r c ial
Anti-Ice Fuel Filter 369H90161
Electrical Installation:
Harne s s A s sembly 36 9H901 61 -3 1 HH
Panel 3691-14735 "A" 1 HH
Cover 369H4739 1 HH
Rivnut S10K80 3 BF Goodrich
Washer AN960PD1 OL 3 Comme re ial
Spa ce r NAS43DD3 1 O 3 Comme re ial
Screw SFSW8CP-LO1 BK 5 Commercial
Sleeve MS21266-2 AR Commercial
Rotorcraft Flight Manual CSP-D-1I 1 HH
Supplement
NOTICE NO. DN-30
Hughe Helicopters
PAGE 3 of 10
TOOLS AND EaUIPPvlENT
Rivnut tool C800 Heading Tool BF Goodrich
or equivalent
Rivet gun
Cutting shears
Drillmotor, portable
Drill bit- No. G
Drill bit- No. 2
Drill bit -No. 30
MATERIALS
MIL-T-5544B Thread Lube Par ker-Hannifin

Anti-seiae compound
or equivalent Cleveland, OH
Sealant ~IIL-S-8660B 732RTV Dow. Coming

or equivalent
MIL-P-8585 Commercial
FED-STD-595 No. 17875 Commercial

Paint, heat resistant
epoxy white
C omm e r c ial
Primer epoxy
yellow, polymide
INS T A LLA TIO N PRO C E D URE
WA RNING
Prior to performing modification of fuel system, perform the

ignition fire:
following to avoid possibility of fuel vapor or
i. Turn OFF all electrical power
2. Electrically ground helicopter (Section 2, Basic HMI)
3. Disconnect battery and external power (Section 17)
NOTE
Perform the following to gain access to work areas:
i. Open engine access doors (Section 2)

2. Remove aft compartment seats; remove upper LH aft
bulkhead panel and lower aft bulkhead panel (Section 4)
~H iloor door
compartment access
4. Remove instrument panel hood and instrument panel

LH side fairing (Section 17)
NOTICE NO. DN-30
DATE 8 September 1978 E) Hu9hes Helicopten
PAGE 4 of 10
Part I Installation of Anti-Ice Fuel Filter
a. Close fuel shut off valve; drain fuel from supply line drain valve.
(Section 2, Basic HTUII.)
b. Disconnect and remove existing fuel supply hose from engine driven
fuel pump and from elbow on Station 124. 0 firewall fitting. (Section 12,
Basic HMI.
NOTE
Remove insulation from aft side of Station 124. O firewall at
area shown (View C). Clean firewall area with MEK or
equivalent. Removal of L-shape section of insulation is
required to install 369H90022-1 doubler.
c. Using existing rivet pattern on Station 124. 0 firewall, drill 0. 1295-
inch diameter holes and install 369A90022-1 doubler FORWARD side of
on
firewall as shown. Install rivets with zinc chromate primer. (View A-A and
A, Figure i.)
d. Using 369H8032 bracket as template, mark and drill O. 1285-inch
diameter rivet holes and install bracket AFT side of firewall
on as shown. Use
existing rivet pattern as applicable. Install rivets with zinc chromate
primer.
e. Touch up firewall area where insulation was removed with primer
and heat resistant paint.
f. Remove 369A8050-11 clip securing engine gearcase cooling duct to
fuselage structure; drill 0.260-inch diameter hole and relocate clip on struc-
ture per dimension shown.
g. Install 3691-18021 filter assembly on bracket with three bolts and

washers as shown; lockwire bolts.
h. Connect new 3691--18024-5 hose with firesleeve to filter and to engine

driven fuel pump as shown.
i. Connect new 3691-18025 hose with firesleeve to filter and to existing

369H8103 fitting and elbow on firewall; reposition fitting and elbow as shown.
As required, install clamp hose and clamp
on secure to stiffener, to prevent
chafing of hose on structure.
j. Install new CAV-170H-4 valve with packing to filter,

using anti-seize
compound. Install new 3691-190022-3 drain tube to valve with lockwire.
k. Splice new 6151-0250 tee into existing drain tube arrangement as shown;
allow slack to permit unrestrained movement of drain tube. For helicopter
with 369H92255 drain kit installed, reposition existing tee as shown.
i. Connect other end of 369H90022-3 drain tube to tee with lockwire.

NOTICE NO. DN-30
Hughes H~licoptsrs DATE 8 Septem~ber 1978
PAGE 5 of 10
m. 369H90161-3 wiring harness from filter down and aft, then

Route
forward through 369H2500 conduit left side, Install clamps four places at
harness with
existing tooling holes in structure as shown; secure wiring
clamps. Route wiring forward through conduit to pilot compartmen.
Part II- Electrical Installation
template, mark and drill three O. 219-inch

a. Using 369H4735 panel as
instrument console as shown in Figure 2; install

diameter holes in LH side of
rivnuts.
NOTE
Use existing nutplate andlor hole as reference point.
LH side of instrument console, using three

b. Install 369H4735 panel on
washers and spacers as shown.

screws,
tie
Route filter wiring harness from, conduit to instrument console;
c.
in with existing wiring harness.
wiring diagram and wire table.

d. Connect electrical wiring per
of anti-ice
e. Reconnect battery and perform ground operational check
CSP-D-1I.
fuel filter installation, (Refer to Section II of RF~VI Supplement No.
Record helicopter serial number on 369H8100 placard; install placard

f.
at location shown.
on overhead duct in pilot compartment
369H4735 panel, using five screws.
g. Install 369H4739 cover on
LH fairing shown; reinstall

Make cutout in instrument console
as
h.
fairing.
hood shown; reinstall hood.
Make cutout in instrument console
as
i.
with 732RTV sealant.

Reseal both ends of 369H2500 conduit
Reinstall removed components and access doors and panels.

k.
Flight Manual Supplement in Section IX of flight

i. Insert Rotorcraft
manual
fuel filter installation in
m. Record installation of 369H90022 anti-ice
Components Record of helicopter Log Book.
112. 4-inch Moment: 840 inch-pounds

Add: 7. 5 pounds at arm
NOTICE NO. DN-30
Hughes Helicoptars
FACE 6 of 10
MS20615-4M RIVET7 REQD

B 369H90022-1 (PICK UP EXISTING RIVET LOCATION
DOUBLER 7PLACES
STA 51304-5H BOLT 9 RE~D

124. 0 AN960PD416 WASHER 3 REQD
MS20995C32 LOCKWIRE A/R
369H8024-5
16-1
HARNESS)
369H8032
VIEW LOOKING INBD LH SIDE \\~I/ ii ii BRACKET
MS21919H2 CLAM P 2 REOD \369H8025

NAS601-7SCREW2REQD
AN960-10 WASHER 2 REQD f j69H90161 369H8032
369H90022-1 MS21042-3 NUT 2 RE9D HARNESS BRACKET
J I~
DOUBLER (USE EXISTING TOOL HOLE-ZPLACES) 0. 260 DIA THRU
0. 75
MS20615-3M RIVET 12 REO i. 92 MOVE EXISTING 369A8050-1l
NAS43DD4-19 CL IP OR AN743-7 CLI P AS
MS20615-4M RIVET
SPACER, 3 REPD SHOWN
MS20615-3M RIVET
AN919-19 369H90161HARNES 3691\8008-3 DUCT
REDUCER, 2 REQD
WL
MS29512-12 AN717TW38
22.85 ENGINE
PACKING, 2 REQD CLAMP (21 FUEL PUMP
369H8024-5 MS20615-4M RIVET
MS20615-4M RIVET
HOSE ASSY WL
369H8032 MS20615-4M RIVET
18. 34 EXISTING 369H8103
369H8025
(NOTE 6) FITTING AND AN831-8
HOSEASSY MS20615-3M RIVET ELBOW ASSY (REPOSITION
369H8023 FITTING AS SHOWN)
(NOTE 71 WL
(NOTE 3) ISTINC CAV-170H-4
13.10
CAV-170H-4 VALVE DRAIN VALVE
LDG BUNGEE
MS29512-04 PACKING MS20995C32 LOCKWIRE, AIR
~1
1
151-0250 TEE
369H90022-3 TUBE INOTES 1 AND 2)
TY-25M AN775-4 BOIT D EXISTING TUBING.
22"
STA TYRAP AN901-4A GASKET 2 REQD CUT A/R
124.0 WL \W
5. 14 REPOS ITION EXISTING
NOTES:
TEE AS SHOWN
i. SPLICE TEE INTO EXISTING DRAIN TUBE 369H2500 CONDUIT ~IOTE 5) LBL
ARRANGEMENT AS SHOWN. 3. 23 LBL f 0. 00 FROM LOWER FACE OF
8. 45
2. ALLOW SLACK IN TUBE TO GIVE UNRESTRAINED 0. 12 GROMMET TRIM AS
MOVEMENT OF DRAIN VALVE. ROUTE TUBE AS REOUIRED
SHOWN TO CLEAR LANDING GEAR STRUT. MS21919H2 CLAMP A-A
NAS603-7SCREW
3. REPOS ITION EXI STING DRAIN TU BE AS SHOWN
AN960P010L WASHER (2)
FOR AIC E9U I PPED WITH 3691\8100-507 FUEL
MS21042-3NUT
SYSTEM OR 369H92255 DRAIN KIT
4. ROLL EDGE OF PLACARD TO FOLLOW CONTOUR

OF DUCT AS SHOWN, TYPICAL 2 PLACES. 369H90022-1 DOUBLER
BOM ,NOS OF TAFTER

iJ
INSTALLATION WITH 732 RTV SEALANT. +I
6. AS REOU IRED, INSTALL CLAMP TO PROVIDE O

CLEARANCE BETWEEN 369118025 HOSE AND
STRUCTURE. II;1II 11 1 111+1
369H8021 FILTER
7. POSITION 369H8023 FITTING AS SHOWN TO
CLEAR LANDING GEAR DAMPER AND STRUCTURE. tl
I+ c c c
8. ALL DIMENSIONS IN INCHES. 88-228-1C
Figure i. Installation 369H90022 Anti-Ice Fuel Filter (Sheet 1 of 2)

NOTICE NO. DN-30
Hughes Helicopters
PAGE 7 of 10
369[)22008-13
1. 00
3691-12523-23 STIFFENER
_Ij
0.
(3(9H1241~
l0ll\J//~1 j 251. 00 369[)22008-25
PANEL
369H81o0 PLACARD 5.00

1, on n\lOTE 41
(369H6403)
3
369H2523-9
STIFFENER
B-B 369[)22008-19 PANEL
369H2523-7 STIFFENER
O
369[)22008-27 PANEL
369H2500 CONDU IT
STA
124. O
~U=_ FIREWALL FITTING
DRAIN
(NOTES 1 AND 2)
FROM ANTI-ICE
FILTER DRAIN VALVE
MS 21919H2 CLAMP
U1 16151-0250 TEE
NAS 603-7 SCREW
AN960-10WASHER
-MS21919H2 CLAMP
MS21042-7NUT
NAS603-7 SCREW
(USE EXISTING TOOL HOLE)
AN960-1OWASHER
(SIZE FOR X10 SCREW)
MS21042-3 NUT
(USE EXRTING TOOL HOLESI
FOR AICNOT EQU I PPED WITH 369A8100-507
.Wj\ 369H90161-3 FUEL SYST OR
137. 50-- 1 HARIUESS ASSY
D-o
88-228-2C
i. Installation 369H90022 Anti-Ice Fuel Filter (Sheet 2 of L]

Figure
NOTICE NO.
DATE 8
DN-30
E) Huahe
September 1978
PAGE 8 of 10
369H6423HOOD
0. 30 ~C_ 369H4206 HOOD
o. 50 1
EXISTING HOLE
SEE 369H90022 FOR ROUTING

OF WIRES IN THIS AREA
1. 25 1
369H2500 CON DU IT LEFT S I DE 0. 75
3691190161-3 HARNESS II i
ROUTE WIRES WITH EXISTING HARNESSES

25 R TYP SLOT AS SHOWN
WHERE POSSIBLE
ZPLACtl
O
369H4737TERMINAL 369H6416CONSOLE
BOARD ASSEMBLY 3691-14260 CON SOLE
369H4229 FAIRING~ 369H6423 HOOD
C, MS21266-2 369H4206HOOD
o
SLEEVINGAIR
r~viii
i Y I:
ILL 0.219 DIA 3 HOLES TO
MATCH 369H4735 PANEL
S1OKBO RIVNUT 3 REQD (IN PANEL)
NAS603-10 SCREW 3REQD
AN960P010L WASHER 3 REPD
IN3210 DIO
NAS43DD3-8 SPACER 3REQD
ICR26)
C
369H4742 0. 65 CLEAR RIVET HEADS AS
11 110
j.j :j
SWITCH 0. 85 MUCH AS POSSIBLE
o_0 P ICK U P EX I STING NUTPLATE AN DIOR HOLE

AS A REFERENCE POINT
i/5"
o ~I SFSW BC6CP-LO1BK
369H4735 PANEL
SCREW 5 REQD
O"a"a i~
RT110-227 RELAY TIME DELAY

a
TILT PANEL
OoooooO
B C-C
000 1 11 ,369H4229 FAIRING
TRIM AS SHOWN
3.75
369H4229 FAIRING EXISTING HOLE
0. 38R
369H4736 PANEL
369H6423 HOOD I it--0.04
NAS43D03-B SPACER 369H6416 CONSOLE O

DD NOTE:
(TYPICAL 3 PLACESI
ALL DIMOI1SIONS IN INCHES.
88-229-18
Figure 2. Electrical Installation 3691-190022 Anti-Ice Fuel Filter

(Sheet 1 of3
369H90161-3 HARNESS ALL NUMBERED
369H4742 SWITCH ASSEMBLY TB6
WIRE-20 GA MS17821-1-9 STRAP Alft
3
START PUMP
"ON"LT SPn
SP24
AMBER
2 2 7
ccm E561822 E5M)822 E560A22N-- -I 6
E23~I IrcRu 6
X0S7
_A W CRB (NOTE)
2 2
STARTPUMP
CR26
1J~2 -(NOTE)
28 VDC
CB118
7.5A
4503820
I /,Ne
NC
o~P
52 ,-GRD
wm
NO
521
ETC~--1 I,NC (REF)WARNINGLGT
NC I 1 r\51 1 I 1 E509820 1 LAMP TEST
=r
v
Cl~r II I I I I I I 1 51 +28 VDC (P
No No II,
si I
I
Nc r.
CI
No
s2 ~I
i
CR27
xl II I I I I I I --~Q501A20----) TO START PUMP
a
VARISTOR
369H8021 FILTER SPLICE PERMISSIBLE
K254
P252
3
32
1
~XZ_1 TB22
RT170-277 PRESS TO RESET
TIME DELAY
Cd tl
NC NOTE:
CBU5 3) O
CAP AND STOW ENDS OF EXISTING WIRE ~3 ~-3
7.5 H
ANTI-ICE BRIGHT P501C20 AT CB118-2 AND EXISTING WIRE M M C1
PRESS SWITCH E561A22 AT SP24A.
FUEL FILTER
R254 DIM 9507AM B AIF FUEL FILTER 9
M
co
FUEL FILTER
ANTI-ICE CAUTION LIGHT TB101 O Cn
100 R 5 114W m n, O
DIMMER SWITCH CA3108ER 125 -3S
3 88-229-28 CI
CONNECTOR
(D t~
03z
a
Figure 2. Electrical Installation 369H90022 Anti-Ice Fuel Filter (Sheet 2 of 3)
co
NOTICE NO. DN-30 Hugh Hlicoptsr
PAGE 10 of 10
ETC
oo ICNC
o
Q-
KDI
o INO
PIN 3908 M jK254
L --~d X2
ALTERNATE WIRING FOR 3809 RELAY
WIRE TABLE
WIRENO. FROM TERMINATION TO TERMINATION
Q507A20 CB135-2 MS25036-149 P252-8 CRIMP
a506A20 7822-3 MS25036-101 P252-A CRIMP
E509B20 T822-5 MS25036-101 521-S1(NO) SOLDER
951002(3\1 E23 MS25036- 101 T86-3 MS25036-101

TO START
95011\20 7822-1 MS25036-101
_
PU_M_P
P501CC20 7822-7 M525036- 101 SP24A 32445 IAMP)
0503820 T822-6 MS25036- 101 CB118-2 MS25036-149
P5068A20 CB135-1 MS25036-149 78101-3 MS25036-101
88-229-3A
Figure 2. Electrical Installation 369H90022 Anti-Ice Fuel Filter
(Sheet 3 of 3)
NOTICE NC. DN-31
e~l HUGHESNOT September 1978

DATE 8
SERVICE INFORMATION P~GELOF

2
ICE
MAN DATO R Y -MANBATORY- I I MAN DATO RY
SUBJECT: INSTALLATION OF NEW PN 369D21012 RUBBER WASHERS

ATTACHMENT OF PITCH CONTROL RODS TO MAIN ROTOR
SWASHPLATE ASSEMBLY
MODELS AFFECTED: 500 Model 369D Helicopter SerialNo. 0003D thru 0319D;
0323D thru 0340D

ope ration

reduce wear on the pitch
procedure for installing rubber washers to
of the
control rod end bearings, and to protect the inboard surface
attach devises on the main rotor swashplate assembly.
The new PN 369D21012 rubber washers replace the existing MS28774-

112O-rings used for attachment of the pitch control rod to the rotating
swashplate
Reference
1, 15 November 1977
500D HMI-Volume I, Issued 14 September 1976; Revision No.
Hughes Helicopters Culver City, California

(=uetomer Service Department
Form 9578
9~78* HTC-~D RLY 11-67
FORY ND
NOTICE NO. DN-31 Hughes Helicopters
PAGE 2 OF 2
PARTS LIST
Ring, elastomer 369D21012 10 HH
INSTALLATION OF RUBBER WASHERS (ELASTOMER RINGS)

PN 369D21012
a. pitch control rods at rotating swashplate,

Disconnect lower end of
per Section 7 of Basic HMI-Vol I. Discard existing MS28775-112 O-ring used

at each pitch rod lower end bearing.
b. Reinstall pitch control rods, per Basic HMI-VolI, using two
PN 369D21012 rubber washers at attachment of each lower rod end bearing.

Position rubber washers at each side of bearing and swashplate clevis.
c. Check:installation of rubber washers and pitch control rods for

discrepancies.
d. Record compliance with this Notice in Compliance Record of
helicopter Log Beak.
FAA APPROVED
NOTICE NC. DN-34
HUGHES
F~I
17 October
SERVICE INFORMATION
oarEPAGE 1
fo8791
2
NOTICE
MAN DATORY MAN DATO RY~ MAN DATO RY
SUBJECT. REPLACEMENT PN 369D28309 HOSE ASSEMBLY,

ENGINE OIL COOLER TO ENGINE OIL TANK
MODELS AFFECTED: 500D Model 369D Helicopter SerialNo. 0003D

through 0374D
accomplished within next 100 hours of

TIME OF COMPLIANCE: Shall be
of
helicopter operation after receipt parts.
procedure for replacement of the subject oil tank return hose

assembly with a longer hose assembly, to reduce possibility
of vibration induced damage to the engine oil tank or oil
cooler assemblies.
It is to be noted that installation of the new PN 369D28311-3 hose
at either the engine oil

assembly requires no additional fittings
tank or engine oil cooler.
R efe re nc e
15 November 1977
500D Basic HMI-VolI, Issued 15 September 1976; Revision No. 1,
Customer Service Department Hughes Helicopters Culver City,Callfornia
Form9578
FORM NO 9~78* HTC~D REV 11-67
NOTICE NO. DN- 34
D ATE 17 O ctober 19 78
PAGE 2 of 2
PAR TS LIST
Nomenclature Part No. atv MEr
IReturn Hose Assembly, 369D28311-3 1 HH
Engine Oil Tank
~Incorporates male hose fittings, both ends
PROCEDURE
a. Remove trim and aft RH bulkhead access panel.
b. Remove existing PN 369D28309 oil tank return hose from elbow at oil
cooler assembly; use receptacle to drain oil from disconnected hose assembly.
(Refer to Basic HMI-Vol I and Figure 13-1.
c. Remove existing AN837-8D elbow from oil cooler assembly.
d. Remove oil tank return hose assembly from union on oil tank:
remove AN832-8D union from oil tank.
e. Install straight male fitting of new PN 369D28311-3 hose assembly to

oil tank; install 45" male fitting of new hose assembly to oil cooler.
Check installation of new PN 369D28311-3 oil tank return hose assembly

for discrepancies.
g. Reinstall bulkhead access panel and trim.

FAA APPROVED
NOTICE NC. Dr\r-35
HUGHES DATE: 29 January 1979

NOTICE
SUBJECT: FIELD REPAIR CYCLIC TRIM ACTUATOR ASSEMBLIES,

SERIES:::
PN 369A7170 SERIES AND PN 369A7171
MODELS AFFECTED: 500D Model 369D Helicopter Serial No. 0003D through 0439D
All spares trim actuator assemblies with actuator having

Calco Part Number and Serial Number listed below:
Calco P/N Calco S/N
8222M7:1: 212 or below
8222M6:1: 860 or below
:I:Actuators identified with letter "R" following

Calco Part Number on housing are NOT
affected by this Notice.
Tests at HH indicate that loosening of the drive gear retention nut of

PREFACE:
trim actuator may The information given in this
the cyclic occur.
procedures to and reinstall

Service Information Notice lists remove
the retention nut with a Loctite sealant. In addition, procedures are

given to determine whether the actuator is inoperative due to a stalled
rather than an electrical failure.
be operated safely with the

It is to be noted that the helicopter can
trim actuators inoperative, even at the extreme of trim travel.
For helicopters not problems with the trim actua-

experiencing any
and operators discretion the
tors, it is recommended that at owners
actuator be reworked per this Notice at the next major inspection
period.
Reference
2, 27 November 1978
500D Basic HMI VolI, Issued 15 September 1976; Revision No.
FORY NO 9578C. HTC*D REV 11-67

NOTICE NO. DN-35
DATE: 29 January 1979 Hughes Helicopters
PAGE 2 OF 3
TOOLS AND EQUIPMENT
DC Milliammeter 0 5 amperes Weston Model 931 or equivalent
DC Voltmeter O 50 volts Weston Model 931 or equivalent
Variable DC 10 36 volts NJE Model SY 36-10 or

Power Supply equivalent
MATERIALS
Sealant Loctite #290 Loctite, Inc.
PROCEDURE
NOTE
i. Rework of operative trim actuators is

recommended at major inspection period.
2. Rework is NOT applicable to actuators
having letter "R" following vendor part

nuwLber on actuator housing.
a. Remove cyclic trim actuator from helicopter, per Basic HMI

Vol I.
NOTE
i, If actuator is inoperative, bench test unit

to determine whether mechanical (stalled),
electrical or other mechanical failure exists.
(a) A reading of 0.0 to 0.1 amperes indicates

electrical failure; replace actuator.
(b) The motor runs, but the output shaft does

not move, indicates a mechanical failure;
replace actuator.
NOTICE NO. DN-35
Hughes Helicopters EGAP9791

3 3
(c) A reading of 0.7 amperes (approximately),

or actuator extends part way and stalls,
indicates stalled failure; rework actuator
per steps b through h below.
b. Remove lockwire and six crews securing actuator cover to housing.
CAUTION
When removing housing, note location
and number of shims on each gear for
reassembly in proper location.
NOTE
Step c not applicable if actuator is operative.

Perform steps d through h below.
gear drive retention (hex) nut

for loose-
c. Using fingers only, check
If nut is loose, rework per instructions below. If nut is NOT loose,
ness.
replace actuator assembly.
d. Remove nut and clean threads. Reinstall nut using Loctite #290 on
threads. Torque nut to 30 to 40 inch-pounds.
e. Reinstall actuator cover with existing screws; lockwire screws.
f. Add letter "R" at end of vendor part number on actuator housing.
reinstall trim actuator, per Basic HMI Vol I.

g. As applicable,
h. Record rework of trim actuator per this Notice in Components

FAA APPROVED
NOTICE NC. DN-36
HUGHES DATE 14 November 197~
NOTICE
SUBJECT: INSTALLATION OF AIR BAFFLE, SEAL AND COVER

ASSEMBLIES TRANSMISSION COMPARTMENT

Serial No. 0003D through 0333D
TIME OF COMPLIANCE: At Ow"ers and operators discretion
~PREFACE: The information given in this Service Information Notice

lists a procedure for field installation of air baffles and
seals and assemblies in the upper section of the aft
cover
transmission compartment to prevent entry of plenum air

and moisture into the cabin area.
R eference
5000D Basic HMI-Volume I, Issued 15 September 1976; Revision No. I,

15 November 1977
Hughes Service Information Notice No. DN-12, dated 18 November 1977
Customer IPervice Department Huehes Helicopters Cuiver City, Calldornda
FOI)Y WO ,~TIC1 ~rv 11

NOTICE NO. DN- 36 Hugha~ Hlicoptan
PAGE 2 of 7
PARTS LIST
Nomenclautre Part No. Qty Mfr
Aft Baffle Assembly, Upper 3 6 9D 26 541 19 1 HH
-Aft Transmission Compartment
Aft Baffle Assembly, Lower 369D26542 1 HH
Air Seal Assembly, LH Aft 369D26543-11 1 HH
Compartment
Trans mi s s ion
Air Seal Assembly, RH Aft 369D26543-21 1 HH
T r an s mi s s ion Co mpartment
Cover Assembly, LH 80-369D26545-11 1 HH
Transmission Compartment
80 36 9D26 545 2 1 1 HH
Cover Assembly, RH
Screw NAS603-8 16 Co mm er c ial
Washer AN9 6 OPD 10L 16 C o mm e r c ial
Nut MS2 1042L3 4 Co mm e r c ial
aTrim Cover Panel Assembly 36 9D265 24-25 1 HH
(LH Rotor Brake Handle (Modified)

As sembly)
or
*Trim Cover Panel Assembly 36 9D265 24 26 1 HH
(RH Rotor Brake Handle (Modified)

Assembly)
installed helicopter, Hughes Notice

~Not applicable if presently on per
No. DN-12.
NOTICE NO, DN-36
Hu(lh Hlkop~r
PACE 3 OF7
MATERIALS
Sealing Compound EP711 Coast ProSeal

Compton, CA
PR1221 Product Research
Burbank, CA
Caulking Compound
Seal, Sponge Rubber DE-41 Armstrong Cork Co

(Adhesive Backing) Lancaster, PA
a. Remove engine air inlet forward fairings. (Refer to Basic

HMI- VolI.
b. Remove PN 369D25640 coolin~ fan inlet screw.
c. Remove aft compartment interior trim panels and blower access
door.
d. Install PN 369D26541-19 upper baffle assembly as follows:
i. Position baffle between main transmission and mast support

structure; align four attach holes in baffle with existing
holes in structure. (See Figure I.)
2. Install baffle with screws, washers and nuts; seal screw
heads with sealant.
e. Install PN 369D26542 lower baffle assembly as follows:
NOTE
During installation of lower baffle, disconnect

heater duct at forward attach point and insert
duct through 2. GO-inch diameter hole in baffle.
i. Secure lower baffle to upper baffle with two screws and

washers at matching nutplates in upper baffle.
2. Disconnect 4/8-inch diameter drain tube at mast support

base and insert tube through hole in baffle. Safetywire
drain tube to structure.
NOTICE NO. DN-36 f) Hugh~ Welieopt~n
PACE 4 of 7
f. Reinstall PN 369022070 blower access door.
g. Position and install PN 369D26543-11 and -21 seal assemblies at

lower baffle and blower access door as shown. Install seal assemblies with
screws and washers at matching clipnuts on lower baffle and on blower

access door.
NOTE
If excessive gap (0. 06 or more) exists between

structure and rubber extrusion on seals, fill gap
by bonding strip of adhesive-backed gasket to

str ucture. (See Detail A.
h. Position PN 369D26445-11 and -21 cover assemblies as shown;

align cover attach holes with existing fairing attach
nutplates. Temporarily
secure cover assemblies with screws and washers, 5 places each.
i. Check installation of baffles, seals and cover assemblies for
discrepancies.
Using caulking compound, seal all gaps between fuselage structure
and baffle, seal and cover assemblies.
k. Remove screws securing cover assemblies; reinstall engine air

inlet fo rwar d, fa ir ing s.
i. Reinstall aft compartment trim.
m. For helicopters equipped with Rotor Brake Kit, perform the

follow ing
NOTE
Not applicable if modified rotor brake handle

trim cover panel has already been installed,
per Hughes Notice No. DN-12.
i. Carefully trim modified trim panel assembly (for

cover
LH or RH rotor brake handle assembly); locate and drill

screw attach holes in modified panel.
2. Slide modified trim panel boot over brake handle; align

screw holes and check panel for fit. As required,
remove panel and make minor trim adjustments.
NOTICE NO. DN-36
Wughe Hlico~ers
PACE 5 of 7
3. Install panel, if removed; secure panel with attaching

hardware.
4. Push panel boot aft on brake handle approximately two
inches; secure boot with fastener tape.
WEIGHT BALANCE DATA
Changed Weight:
Weight (Ibs) Arm (inch) Moment (inch-lbs)
+1.5 Station 110.2 +169

NOTICE NO. DN-36 Hughes Hslkoptr
PACE 6 of 7
369[)26541-19 BAFFLE SHIP STRUCTURE

O
EXTRUSION
369[326543 SEAL
CI GASKET )69026Mi-IP
CAP (NOTE 3~ BAFFLE
i I l~kT7
369026543-21 SEAL
NAS603-8 SCREW (4)
AN960P810L19ASHERI41 i
I1H SHOWNI
B (NOT~ 2)
3690265428AFFLE 369026543-11S8AL
(L H SHOWN)
369022070 ACCESS DOOR 369(322070

ACCESS DOOR
NAS608-3 SCREW
369[)26545-21 COVER
ANP60P0OLWASHER
(-I1OPPOSITEI
3690265428AFFLE
369(326543-11 SEAL NASb1)3-8 SCREW (21
ANPdOPDLOLWASHER(2l
364[)22025-31 FAIRING PLATE
5) VIEW B-B
1(NOTE
T
INOTE 4)
j(
3~9022025
FblRING~I
ij :o ~li
i
e
YIEW D-0
(TYPICAL BOTH SIDES)
Lo ,wa2ssdl-lps~nr
NASb03-8 SCREW (4)
VIEW CC AN960PDOLWASHER(4)
MS21042U NUT (41
NOTES:
i.DURING INSTALLATION OF 369D26542 BAFFLE. DISCONNECT

AND INSERT HEATER DUCT THRU HOLE IN BAFFLE.
2. AFTER 369[)26542 BAFFLE IS INSTALLED, DISCONNECT AND
ROUTE DRAIN TUBE THRU HOLE IN BAFFLE.
3. IF EXCESSIVE CAP (0.06 X 1.00OR MORE) EXISTS BETWEEN
STRUCTURE AND RUBBER EXTENSION ON SEALSFILL GAP BY
BONDING STRIP OF ADHESIVE-BACKED GASKET TO STRUCTURE.
4. NO. 10 SCREW HOLE IN FAIRING ON SHIPS. DO NOT USE THIS
HOLE TO INSTALL COVER OR FAIRING.
5. TRIM PLATE AS REQUIRED TO CLEAR SCREW HEAD.
88-83-2
Figure 1; Installation of air baffle, seal and cover assemblies
(Sheet 1 of 2
NOTICE NO. DN-37
HUGH
F~I NSE SERVICE INFORMATION

~T ICE
MANDATORYr I II MAN DATO RY MAN DATO RV
ASSEMBLY
SUBJECT: PN 369DZ1800 TALL ROTOR PITCH CONTROL
SEATING OF DUAL BEARING INNER RACES: TORQUE
INCREASE FOR PN 369D21803-3 LOCKNUT
500D Model 369D Helicopter SerialNo. 0003D

MODELS AFFECTED:
through 040 9D
All subject PN 369D21800 Basic and -501 PitchControl

Assemblies, separate or component of Tail Rotor Assembly,
in Spares Inventory at date of this Notice
TIME OF COMPLIANCE: Shall be accomplished within next 100 hours

the tail rotor pitch
procedure for seating the dual bearings of
controlassembly, to ensure that the bearing inner races are
At reas-
firmly in contact with the shoulder of the swashplate.
sembly of the pitch control assembly, the locknut
is torqued to
550 to 600 inch-pounds. Reseating of the dual bearings and
increasing the torque for the locknut is designed
to prevent
the bearings
loosening of the locknut and premature wear of
during tail rotor operations.
It is to be noted that PN 369D21800 Basic and-501 Pitch Control

Assemblies identified with a white dot on the locknut (See Figure 1)
are not affected by this Notice,
Reference
500D Basic HMI Vol I, Issued 15September 1976; Revision No, i, 15 November 1977
500D Component Overhaul Manua1(369D COM), Issued 15 September 1976
Form 9578
FOIIY HO 91781 HTC*D RE.V 11-67
NOTICE NO. DN-37
PAGE 2 of 4
E) Hueh Hellcopter
PARTS LIST
Washer, tang MS 172209 1 Commercial
Washer, tang HS1551S238 1 HH
MATERIALS
Paint, white Commercial

lacquer
TOOLS AND EQUIPMENT
Adapter, Wrench 369D29822-5 HH
Wrench, torque 369D29823 HH
Block, holding 369D29822-3 HH
Press, arbor Commercial
PROCEDURE
As applicable, tail rotor

a. remove assembly from helicopter.
(Refer to Basic HMI Vol I.
NOTE
Tail rotor pitch control assemblies identified

with white dot on locknut are NOT affected by
this Notice (see Figure i). Perform steps 1~
and k only.
b. Remove and inspect tail rotor pitch control assembly, per

Basic HMI Vol I.
NOTICE NO. DN-37
f) Hughs~ Helicopter~ DATE 1 December 1978

PAGE 3 of 4
c. Remove locknut and tang washer from threaded end of swashplate.

Use PN 369D29822-5 wrench adapter, PN 369D29823 torque wrench, and
PN 369D29822-3 holding block to remove locknut. Discard tang washer.
Do not remove swashplate from housing.
d. housing and swashplate assembly on arbor press bed with

Place
swashplate end down. Apply 2000 pounds of pressure to press inner races
of dual bearings firmly in contact with shoulder of swashplate. Use suitable
tube or sleeve to press INNER races of bearings only. Remove assembly

from arbor press.
e. Install new MS172209 tang washer; reinstall locknut and torque

locknut to 550 to 600 inch-pounds. Use wrench adapter and torque wrench,
while assembly is held in holding block, to tighten locknut.
f. Check for sufficient clearance (0. 015 inch minimum) between
swashplate and housing (see Figure i).
g. Check for smooth, easy and free rotation without binding.
h. Bend a tang of thetang washer into bottom of any aligned slot on
lo cknut.
i. Paint a 0. 12 to 0.:18 inch white dot on locknut, as shown in
Figure i, to denote reseating of dual bearings and locknut torqued to 540 to
600 inch-pounds.
j, As applicable, reinstall pitch control and tail rotor assembly,

per Basic HMI Vol I. Use new HS1551S238 tang washer; or tag spares
assembly to denote compliance with this noeice.
k. Following installation of pitch control/tail rotor assembly,

record compliance with this Service Information Notice in Compliance
FAA APPROVED
NOTICE NO. DN-37
DATE 1 December 1978 nughes Helicopter~
PAGE 4 of 4
0.015 INCH
IMIN CLEARANCE)
HOUSING
(NOTE 2)
(NOTE 1)
DUAL BEARINGS
-mttftT-~y- fttt5tfit~- t
_LRS
SWASH PLATE
NOTES:
i. INNER RACE FIRMLY SEATEDAGAINST SHOULDER OF SWASH
PLA~
2. AFTER TORQUE, COLOR CODE WITH WHITE DOT (0. 12 0. 18 IN.
DIAI
88-294
Figure i. Tail rotor pitch control assembly seating

of dual bearings and increased torque for
locknut
NOTICE NC. DN-39
HUGHES DATE 1 June 1979

SERVICE INFORMATION PAGE 1 OF4
NOTICE
SUBJECT: INSTALLATION OF STAINLESS STEEL ABRASION TAPE,

PN 369D21104 MAIN ROTOR BLADE LEADING EDGE
MODELS AFFECTED: 500D Model 369D Helicopter Serial No. 0003D and subs

procedure for installing stainless steel abrasion tape to the leading
edge of the main rotor blades. Installation of the stainless steel
abrasion tape is recommended for blades which are subject to a
highly abrasive environment, so that blade life will not be reduced
by erosion.
It is to be noted that Rotorcraft Flight ManualSupplement

CSP-D-1S must be incorporated in the Flight Manual when helicopter
isoperated with Main Rotor Blade Abrasion Tape Kit Part No.
369 D21104 installed.
Re fere nce
500D HMI Volume I, Issued 15 September 1976; Revision No. 2,

2 7 Nove mbe r 19 7.t~.
500D Rotorcraft Flight Manual Supplenient No. CSP-D-1S, Dated 21 May 1979.
Service Department Huahes Helicopters Culver City. California
roiw NO )18~ ~tlC O ~C* 11-67

NOTICE NO. DN-39
DATE 1 June 1979
PAGE 2 OF 4
PART LIST
Abrasion tape, stainless steel

(1.5 in, wide x 0.0027 in. thick):
30 ft length roll 87-369D21104 1 HH
or
100 ft length roll 88-36 9D21104 1 HH
MATERIALS
Solvent aliphatic naphtha TT-N-95 Commercial

(Standard
No. 200
Thinner)
nbrasive paper 400 grit Commercial
TOOLS AND EQUIPMENT
Heat gun or equivalent
INSTALLATION PROCEDURE ABRASION TAPE
a. Lightl~r, abrade faying surface of main rotor blade with 400 grit
abrasive paper. (See Figure I.)
i,. Wipe fa~infi surface of blade Mlith solvent to eliminate grease or dirt
lilm.
c. Use heat gun or eyuivalent to warm blade fa):ing surface; tempera-

ture is not to e~ceed 120"F.
d. Remove I,acking and apply stainless steel abrasion tape to outboard
leading ed~e of main rotor. blade as follo\vs:
i. Apply the 6.40 inch wide and 24.00 inch long abrasion
tape along blade leading edge, as shown, so that tape over-
lap over bottom and top of blade edge is equal.
Huah nelicoptr NOTICE NO. DN-39
DATE 1 June 1979
PAGE 3 OF 4
2, Smooth and press abrasive tape into place by hand,

using
heat gun or equivalent to maintain temperature.
3. Reapply pressure by hand following initial installation to

ensure proper bonding; the abrasive tape must be free of
surface wrinkles or air bubbles.
NOTE
A second abrasion tape may be applied on top of the

first tape at
owner/operator option, to facilitate
futurereplacement when top tape becomes eroded.
Perform step e below, if installation of second abra-
sion tape is desired for all blades.
e. Apply a second abrasion tape, by wiping surface of installed strip

\~ith solvent and peating steps
re c and i above. Abrasion tape must be evenly
aligned at top surface of blade as shown.
f. Check installation of stainless steel abrasion tape for discrepancies.
Insert RFM Supplement CSP-D-1S in Rotorcraft Flight Manual,

Section IX.
FAA APPROVED
NOTICE NO, DN-39
OHuphe
DATE 1 June 1979
PAGE 4 OF 4
I.%
jkI
a
tl,\
B 24.00
INCHS
NOTE 1
IN ROTOR BLADE
B O
NOTEZ
NOTES:
1. END OF TAPE TO BE FLUSH WITH
OUTBOAR D END OF BLADE SKIN.
TAPE TO BE SYMMETRICAL
ABOUT LEADING EDGE.
t~ir369DZllW
B-B
TAPE
369021101 BLADE
2. ABRASION TAPE MUST BE ALIGNED

AT TOP PART OF BLADE,
88-2866
Figure i. Installation of Stainless Steel Abrasion Tape,

PN 369D21104, Main Rotor Blade Leading Edge
NOTICE NO. DN-40
at HUGHES DATE 15 December 1978

SERVICE INFORMATION PAGE 1 OF
NOTICE
VENT TUBE
SUBJECT: EXTENSION OF PN 369AB010-615 OVERBOARD
ENGINE ACCESSORY DRIVE
0519D
MODELS AFFECTED: 500D Model 369D Helicopter SerialNo. 0004D through
for adding an extension tube to the existing engine accessory drive over-
board vent tube, The rework extends the vent tube four inches below
the skin of the helicopter, to reduce oil spattering onto the lower fuselage.
Refer enc e
Volume I, Issued 15 September 1976; Revision No. 2,

500D Basic HMI
27 November 1978
GORY NO ~178C, nrcID i~rv 11-67

NOTICE NO. DN-40 Hugha~
PAGE 2 of 3
PAR TS LlST
Part No. Qty Mfr

Nomenclature
NAS 1738B4-2 2 Commercial

Rivet
Grommet M834489-222 1 Commercial
MATERIALS
Commercial
Tubing long X 0. 875 in, OD x 0. 058 in wall
4. 85 in,
(5052-0 Al Aly, WW-T-700/4, Type I, Temp O)
Sealant PR 1221 Product Research
or
Pro-Seal 247 or 890 Coast Pro-Seal
T OOLS AND EQUIPME NT
Gun, rivet
Drill bit 0. 1285 in. (No. 30)
PROCEDURE
a. Open engine access doors.
b. Disconnect accessory drive overboard vent tube from elbow on
tube from helicopter.

engine accessory case; remove vent
Install extension tube to existing vent tube as follows:

c.
i. Position extension tube over vent tube as shown in Figure 1;

drill rivet holes in line thru tubing; install two NAS1738B4-2
rivets.
2. Apply sealant between tubes as shown; fillet seal about circum-

ference of tubes.
Hughw Helicopters NOTICE NO. DN-40
PA.GE 3 of 3
FUSELAGE SKIN
STATION 127.00
NAS1738B4-2
RIVET ,MS35489-22 GROMMET
ZREQUIRED
(NOTE 1)
EXTENSION TUBE
369A8010-615
TUBE ASSEMBLY
0.25
0.84
4.85
NOTES;
i. SEAL BENZIEEN TUBES
BEFORE ASSEMBLY AND
FILLET SEAL ABOUT
CIRCUMFERENCE
2. ALL DIMENSIONS IN
INCHES
88-295
Figure i. Extension of overboard vent tube, engine accessory drive
d. Remove existing grommet at lower fuselage Station 127.0 and

install new MS35489-22 grommet.
e. Insert extension tube thru grommet and connect vent tube to elbow
on engine accessory case. Torque line nut to 120 to 140 inch-pounds.
f. Check installation of vent tube and extension for discrepancies.
g. Close engine access doors.

NOTICE NC. DN-42
HUGHES
SERVICE INFORMATION 5_
NQT IGE
MAN DATORY L I I MAN DATO RY~ MAN DATO RY
SUBJECT: PN 3691-17825 DROOP CONTROL BELLCRAT\JK ASSEMBLY (STATION 68.0)

RELOCATION OF LOCKNUT AND INSTALLATION OF SPACER~C
MODELS AFFECTED: 400D Model 369D Helicopter Serial No. 0003D thru 0429D

operation or at next AnnualInspection, whichever is sooner.
PREFACE: The information given in this Service Information Notice lists

instructions for installing the existing droop compensation adjust-
ment locknut 369A7717-3 extension at a new location
on the PN
above the PN 369A7716 (magnesium) or PN 369N2606 (aluminum)

arm assembly. Relocation of the locknut precludes loosening
and/or loss of the locknut during helicopter operation.
Instructions are also provided for rework of the arm assembly

to provide a flat interface with a new spacer installed between the
locknut and arm assembly.
~It is to be noted that PN 369117825-11 droop control bellcrank
assemblies are NOT affected by this Notice.
Refe ren ce
500D Basic HMI Volume I, Issued 15 September 1976; Revision No. 2,

27 November 1978
Customer Service Department Hu@;hes Helicopters
Form 9578
FORY NO 9~78* HTC*D REV 11-67
NOTICE NO, DN-42
nJicop~rs
PAGE 2 of 5
PARTS LIST
PartNo. aty Mfr

Nomenclature
NAS4ZDD10-10 1 Commercial
Spacer
TOOLS EQUIPMENT
tool 0. 687 in, dia with 0. 030 corner radius

Spotface
and threaded (5/16-24 UNF-3A) stud and female pilot
MATERIA LS
Surface treatment MIL-~vI-3171, Type III Dow 7 Dow Coming

(anodize)
or
MIL-M-45202, Type III Dow 17
(dichromate treat)
MIL-P-8585 Commercial
Primer, sine chromate
PROCEDURE
panels (Section 2, Basic HMI

Vol I)
a. pilots floor
Remove access
Basic HMI Vol I) to gain access to underseat

and control covers (Section 4,
linkage for power turbine governor controls.
control override link

b. Remove PN 369A7717-3 extension from droop
(Section 11, Basic HMI Vol I).
and Station 68.0 bellciank.
NOTE
Spotface thru radius of arm only. DO NOT spotface

below flat surface of arm around circumference of
inse rt in arm.
369NZb06 assembly, as shown in

c. Spotface PN 369A7716 or arm
Figure i.
NOTICE NO. DN- 42
Hugher Helicopters DATE 15 February 1979
PAGE 3 of 5
0.687 IN. DIA

SPOTFACE (NOTEI
369A7717-3
3691\7716- BSC ARM ASSEMBLY
EXTENSION
(NOTEI
AN316-5R
NUT
O
(I I
-C
:I-
2.30,R
NAS42DD10-10 Y
SPACER
BSC ARM ASSEMBLY REWORK-ARM ASSEMBLY
NOTE:
DO NOT SPOTFACE BELOW FLAT SURFACE OF
ARM AROUND CIRCUMFERENCE OF INSERT.
NEWNUTLOCATION 88-296
Figure i. Relocation of locknut Station 68. O bellcrank assembly

NOTICE NO. DN-42
DP;TE 15 February 197q
~:(ugha3 nlJiooptr
PAGE 4 of 4
d. Touch up reworked surface of arm with Dow 7 or Dow 17 chemical

treatment. Apply zinc chromate primer to reworked area.
e. Install existing locknut and new NAS42BD10-10 spacer on -3 exten-

sion; reinstallextension. (See Figure i.)
f. Perform rigging of power turbine governor centrals, per Basic

HMI- VolI.
g. Reinstall control covers and floor access panels.
h. Record compliance with this $ervice Information Notice in Compli-

ance Record of helicopter Log Book.
WEIGHT BALANCE DATA
FAA APPROVED
NOTICE NO. DN-42
Hughss Helicopten DATE 15 February 1979
PAGE 4 OF 5
REFERENCE SHEET
maintenance replacement of power

Action Reference: When performing or
turbine governor controls, refer to Service Information
Notice No. DN-42.
HMI Reference: Insert this sheet in 369D Series, Basic HMI
Volume I, Section ii, Page 11-11.
This reference sheet shall be kept as a part of the manual until data
is incorporated at the next revision of the HMI Volume I, (See

Service Information Summary, HMI Volume I, Page i.)
N0TICE N~. DN-43
oart 15 February 1979

HUGHES
SERVICE INFORMATION PAGE 1 OF 5 _~
NOT~CE
FIELD REPAIR TRIM TAB, MAIN ROTOR BLADE, PN 369D21100 SERIES

SUBJECT:
MODELS AFFECTED: All 500D Model 369D Series Helicopters equipped with subject
Main aotor Blade s
PREFACE: The information given in this Service Inform.ation Notice lists a pro-
of the main
cedure for field repair of the trim tab on the trailing edge
of the trim
rotor blade, and for removal of the trim tab or portions
tab, if required.
specify that the

It is to be noted that instructions in the Basic HMI
for the tab
blade must be rejected, if specified damage limitations
area are exceeded. In the interest of safety and economy, the pro-
of the
cedures given in.this Notice provide a broader cleanup
a larger
damaged trim tab area, which distributes stresses over
and permit continued of the blade.

area to preclude cracking use
In addition, the entire

No minimum length of trim tab is required.
trim tab, or portion of the trim tab, may be removed if required.
Main rotor blades with and without trim tabs are 1000Jo interchange-
able, individually and in ship sets.
The information given in this Service Notice is to be considered as
of the HMI and will be incorporated in the next scheduled revi-

part
sion to the below referenced Basic HMI Vol I.
Reference
lodel 500D Basic HMI VolI, Revised 15 September 1976; Revision No. 2,
27 November 1978
Customer Service Department HughesHelicopters Culver City, California
FORM NO 91i78~ HTC*D REV 11-67

NOTICE NO. DN-43
~Z Hslicoptert
PAGE 2 OF 4
TOOLS AND EQUIPMENT
Shears, Metal Cutting
Saw, Metal Cutting Power, Portable
Grinder or File
MA TERIA LS
Exte rior Surface Touchup Iridite Eichardson Co.

Treatment Allied-Kelite Div
De s Plaine s, 1l1
Paint, Flat Black Advance Coating Co

So. Fl Monte, Ca
Primer, Yellow MIL-P-23377B Commercial
Solvent Aliphatic Naphtha TT-N-95 Commercial
Solvent Dry Cleaning P-D-680 Commercial
Tape #850 3M Company

St Paul, Minn
a. Inspect trim tab area of main rotor blade and repair tab area, as
required, per Basic HMI Vol I.
NOTE
If damage to trim tab area exceeds limitations
specified in Basic HMI Vol I, perform the
following
b. As applicable, remove main rotor blade, per Basic HMI Vol I.
CA UTION
Provide protective surface and/or covering to

prevent scratching, nicking or other damage to
blade during rework. Position blade on work
bench or equivalent.
NOTICE NO. DN-43
Hughes Helicapters
Page 30F5
and around trim tab with clean cloth

away dirt
area
c. Wipe on
dampened with dry cleaning solvent.
of blade around trim tab area with tape; do NOT

d. Mask edges area
blade.
cut tape after it has been applied to
of trim tab by making V-type cut with 45"

e. Remove damaged area
sides joined by a 0.25-inch radius at the bottom of the V, as shown in Fig-
ure i. Blend into trailing edge of the blade with a 0.25-inch radius as
do not cut past trim tab
shown. Maximum V-cut depth is 0.35-inch; area
into m.ain portion of blade.
within 1 inch of either or both ends of trim tab,

f. If damage occurs
remove tab end(s) and restore contour as shown.
partial removal of trim tab

g. If excessive damage requires full or
the following (no minimum length of trim tab is

from blade, perform
re quir e d)
workbench that firm straight edge is

i. Position blade on so a
provided for cutting or filing off trim tab.
CAUTION
Cutting, grinding or filing to remove trim tab,

and deburring of reworked blade trailing edge,
are to be performed in a SPANWISE direction
only. Do NOT use shears or clippers to remove
trim tab.
2. Use metal cutting saw or equivalent to remove
the 0.38-inch wide trim tab per dimensions

shown in Figure i, View A-A. Deburr edges
in a SPANWISE direction only.
h. Peel and remove tape from blade and inspect area around repair;
clean repaired area with cloth dampened in solvent (aliphatic naphtha).
reworked area of blade

Apply chemical film treatment (Iridite) to
i.
of primer and paint lightly.
trailing edge or trim tab; apply a thin film
reinstall main rotor blades, per Basic HMI

Vol I.
j. As applicable,
WEIGHT BALANCE DATA

NOTTCE NO, DN-43
!lughas nelicopten
PAGE 4 OF 5
O ~L-
o. 5---~-- 25R
inlTOP SURFACE
0.25R
(NOTES 2,3)
(NOTE 1)
I
0. DO
O. to i
O. 35(NOTE 3)
I-A
0.38
VIEW A-A Ti f ACI-ll~m C~ NOTE 4)
NOTES:
i. REMOVE DAMAGED END(S) IF THEY OCCUR WITHIN 1 INCH OF

TAB ENDS.
2. 0.25 RADIUS CLEANUP. FINISH PER BASIC HMI.
3. MAXIMUM DEPTH OF REPAIR 0. 35.
4. NO MINIMUM LENGTH OF TAB REQUIRED. IF DAMAGE OCCURS

AT BOTH ENDS, IT IS PERMISSIBLE TO REMOVE AT BOTH ENDS.
5. ENTIRE TAB MAY BE REMOVED IF REQU IRED.
Figure i, Repair and removal of trim tab, main rotor blade

NOTICE NO. DN-43
Hughes Helicopters
DATE 15 February 1)7)
PACE 4 O~F 5
REFERENCE SHEET
Action Reference: When performing maintenance or inspection

of main rotor blades, refer to Service Information
Notice No. DN-43.
HMI Reference: Insert this sheet in 369D Series Basic-HMI

Volume I, Section 7. Page 7-17.
kept part of the manual;lntil

This reference sheet shall be as a
the data is incorporated in the next revision of the Basic-HMI-

Information Surrimary, Basic HMI-
Volume I. (See Service
Volume I, Page i.)
N(,11(:[ 1\1() nN-44.1)::
HUGHES L)Alt 22 June 1973
SEWVBCE PnCE OF~1Q_
laBg~ ICE aSupersedes Service Information Notice

No. DN-44 Dated 18 May lq79
MAN DATQ RV MARI DATE RV----P------------- IVIAI\I DAIQ RY
SUBJECT: PN 369D23601 HORIZONTAL STABILIZER ASSEMBLY ADJUSTMENT

OR REPLACEMENT OF PN 369D23678-3 TRAILING EDGE TABS;
RELOCATION OF PN 3691-16610-5 STATIC PRESSURE TUBE
MODELS AFFECTED: 500D Model 369D Helicopter Serial No. 0001D thru 0534D~::
~Not applicable if helicopter equipped with PN 429-4537

External (Military) Stores
~CMay not beaccomplished on helicopters equipped with

PN 369D290086 Utility Floats, PN 369D290121-501 (or subse-
quent dash No. Emergency Floats, PN 369D290170 Litter Kit,

or PN 369H90085 Litter Kit unless PN M50452 main rotor
dampers have been installed per Hughes Notice No. DN-45.
All PN 369D23601 Horizontal Stabilizer Assemblies in Spares
Stabilizers identified by PN 369D23601-503 and/or

letter "M" following Serial Number are NOT affected by this
No tic e.
TIME OF COMPLIANCE: Shall be accomplished within 100 hours of helicopter

operation following receipt of required parts.
Shall beaccomplished prior to installation of PN 3 69DZ3 601
Horizontal Stabilizer Assembly in Spares Inventory.
PREFACE: Part I of this Service Information Notice lists instructions for revising the
angle of the horizontal stabilizertrailing edge tabs by installing new

369D23678-5 or reworking existing 369D23678-3
tabs tabs to the new -5
tab configuration. The new tab angle provides a reduction in forward

stick travel at high speed flight in order to reduce main rotor hub strap
feathe ring load s. Instructions for installing a reinforcement doubler on
the upper trailing edge surface of stabilizer are also included.
It is to be noted that the service life of the PN 369D23601 Horizontal

Stabilizer modified to the 369D23601-503 configuration per this Notice
is not to exceed 3800 hours total time in service, which is the current
life of the stabilizer.
11-67
NOTICE NO. DN-44. 1
DATE 22 June 1979 E) Hueher nalicopterJ
PAGE 2 OF 14
PREFACE (CONT)
Modification of the horizontal stabilizer per this Notice upgrades the
The
PN 369D23601 Stabilizer Assembly to the -503 configuration.
-503 configuration is to be added to the stabilizer Part Number
recorded in the Component Record of the helicopter Log Book.
Also, the letter "M" is to be added to the stabilizer Serial Number
recorded in the Log Book. In addition, phasing of the main rotor
blades is to be accomplished as specified in the below referenced
HMI-Volume I, Revision No. 2, dated 27 November 1978, if not
already accomplished. Unusable fuel is increased to 12. 5 pounds

when the -503 stabilizer is installed. This data is reflected in the
below referenced RotorcraftFlight Manual, revised 6 July 1179,

which must be incorporated operating helicopter
in RFM when
equipped with 369D23601-503 Stabilizer Assembly.

Part II of this Notice provides instructions for relocating the static
pressure tube port
in the aft engine air inlet fairing; the static port
r elocation i s to be ace omplishe
d in conjunction with Part I of thi s Notice.
R efe rence
500D Basic HMI~Volume I, Issued 15 September 1976; Revision No. 2,

27 November 1978.
500D Basic HMI-Volume II, Issued 15 September 1976; Revision No. 2,
1 Noveniber 1978.
1978. 26 June
Hughes Service Information Notice No. DN-Z2, dated
22 June 1979.
Hughes Service Information Notice No. DN-45, dated
I FAA Approved Rotorcraft Flight
Revised 6 July 1979.
Manual for Model 369D Helicopter,
PART I ADJUSTMENT/INSTALLATION OF HORIZONTAL
STABILIZER TRAILING EDGE TABS
PARTS LIST
N ome nclatur e Part No. aty Mfg
~ctTab, Trailing edge

369D23678-5 2 HH
horizontal stabilizer
369D23688-3 1 HH
~cDoubler
NAS 6 0 1 7 1 C omme rc ial

Sc rew
R ive t MS 2 0 4 7 0AD2 A/R Co mme rc ial
or
Rivet MS20470AD3 A/R Co mmercial
tabs may he reworked in field to 369D23678-5

fExisting 369n23678-3 new
tab configuration.
Service Center Distributor.
~cProvided without cost; contact Hughes or
Service Centers and Distributors process order through HH Warranty

and Repair Department.
NOTICE NO. DN-44. 1"
E) Hushee Helicopters DATE 22 June 1979
PAGE 3 OF 14
Nomenclature Part No. aty Mfg
Rivet, blind NAS 1919B04-01 A/R Co mmercial
or
Rivet, blind NAS 1738B4-1 A/R Commercial
Rivet, blind NAS1919B 04- 02 A/R Comme re ial
or
Rivet, blind NAS 1738B4-2 A/R Co mmercial
Rivet, blind NAS 19191304-03 A/R Commercial

or
Rivet, blind NAS 1738B4-3 A/R Commercial
TOOLS AND E(3UIPMENT

Drill bit 0. 176/0. 182 inch diameter
Drill bit: No. 41
Drill bit No. 52
Drill bit No. 54
Protractor
Fasteners, Cleco or equivalent
C-clamps
Brake, sheet: metal(or use wooden blocks)
MA TE RIALS
Wood blocks (3) 2. 0 x 4. 0 x 31. 0 inches (or use sheet metal brake)
Wood block i. 74 x 0. 75 x 18. O inches
Wood block i. 0 x 2. 0 x 18. 0 inches
Wood rod i. 0 inch diameter x 18. O inches length
Sealant MIL-S-8802 Coast ProSeal 890
TT-N-95 Co mmercial
Naphtha, aliphatic
DN-44. 1:::
NOTICE NO.
DATE 22 June 1979
E) nUsh~L HeliCOptBr8
PAGE 4 of 14
PROCEDURE
a. Remove horizontal stabilizer and tip plates. (Refer to HMI-Vol I.
NOTE
If existing 369D23678-3 tabs are to be

reworked to the -5 configuration, be sure
to identify each tab upon removal from
stabilizer to denote top surface of LH tab

and top surface of RH tab. Reworked tabs
are to be adjusted (bent) downward 15" and
reinstalled at original LH or RH position

on stabilizer.
b. Remove all rivets along trailing edge of stabilizer; remove tabs,

(See Figure i.
c. Remove screw, washer and nut (fastener/ground lug) for position

light bracket; retain nut and washer for reuse.
d. Remove six blind center rivets securing existing 369D23637 upper

skin splice doubler and 369D23662 position light bracket to upper surface of
stabilizer; remove light bracket. (See Figure i.)
e. Wipe upper surface of stabilizer clean, using aliphatic naphtha.
f. Position 369D23688-3 doubler on stabilizer and drill rivet holes

8 places (for locations) through doubler and stabilizer skin, using
field rivet
rivet locating dimensions shown in Figure i. Also, mark and drill rivet
holes land 0. 176/0. 182 inch diameter hole for light bracket ground lug) in
new doubler to match existing holes in stabilizer.
NOTE
Existing 369D23678-3 tabs removed from

stabilizer may be reworked to -4 con-
figuration, using sheet metal brake to

bend tabs downward 15" as shown in
Figure 2, Detail C. Do NOT bend tabs
installed on stabilizer,
NOTICE NO. DN-44. i"
Hughe~ Halicopters .DATE 22 June 1979
PAGE 5 OF14
O.~O(ZPLACES)
CENTER RIVET (3 PLACESI

NAS1919804-03 OR NAS173884-3
CENTER RIVETS (3 PLACES)
NAS1919804-02 OR NA S 173884-2
2 EPUAL SPACES
369023~37 DOUBLER
(2 PLACESI
FIELD RIVET (8 PLACES)
NAS1919804 -01OR NAS173884-1
iNOT~
r /,369023688-3 DOUBLER
X
D~UBLER BREAK
LINEI I /Y I_ )c~J P. 28 (2PLACESI
(NOTE 41 -1 t I +-X"
1. 18
Al I ((2 PLlt\CES)
A MS20470AD2RIVET
0.31 (NOTE 21
0.31(REF)
369D23626(REF)
CLOS ING RIB ASSY.
0. 176
369[)23662 DIA HOLE
0. 182
POSITION LIGHT BRACKET (NOTE 31
Q TRAILING EDGE TAB (TYPI
VIEW LOOKING DOWN

(AT TOP OF HORIZONTAL STABILIZER)
DOUBLER (REF)
0. 19R
0.38
NOTES:
1. SEAL EDGE AROUND PERIMETER OF NEW DOUBLER. -/11

2. MS20470AD3 RIVET MAY BE USED IF HOLES ALONG
TRAILING EDGE ARE ENLARGED.
3. REPLACE ORIGINAL SCREW WITH NAS601-7 SCREW

A-A
AFTER DOUBLER INSTALLATION IS COMPLETE. (TYP ICAL ALONG BAC K EDGE OF DOU BLER)
(ORIGINAL WASHERS AND NUT MAY BE RE-USED)
4. ADDED DOUBLER IS LOCATED ON TOP OF 369023637

UPPER SPLICE DOUBLER AND BENEATH 369023662
POSITION LIGHT BRACKET.
88-312
Figure i. Horizontal stabilizer installation of

doubler and trailing edge tabs
NOTICE NO. DN-44. 1::: Hugha Hlicopters
DATE 22 June 1979
PAGE 6 of 14
g. Position -369D23678-5 trailing edge tabs on stabilizer; for new
-5 tabs, mark and drill rivet holes in tabs to match existing rivet pattern
along trailing edge of stabilizer.
h. Temporarily install doubler and stabilizer tabs and secure with

Cleco fasteners. Using straight edge or beam, check for tab deflection as
shown in Figure 2. Upper surface of tabs shall be coincident (+0. 12 inch

upward/ -0. 03 inch downward) with straight: edge or beam. As required,
remove and deflect tabs as noted below, to maintain this angle.
NOTE
Perform the following if deflection of tab(s)

isrequired. Apply uniform pressure across
entire length of tab when deflecting tab.
i. Use sheet metal brake to deflect tabs as required;

or modify trailing edge tabs as follows:
a. Secure forward end of stabilizer tab between two

wood blocks and clamp blocks securely with
C-clamps or vise.
To fabricate bending tool, sawcut 0. 05/0. 06-inch

slot, 2. O inches deep and 31. 0 inches long, in
center of 2. 0-inch thickne ss of wood block.
b. Slide bending tool onto one tab and apply uniform

pressure across entire length of tab to deflect
tab as required.
2. Repeat step h above to check for proper tab deflection.

Upper surface of tabs coincident (+0. 12 inch upward/
0. 03 inch downward) with straight edge or beam.
i. Install doubler, existing position light bracket, and stabilizer tabs

on horizontal stabilizer as follows: (See Figure i.)
NOTE
When in correct position on stabilizer, new

doubler lies on top of existing 369D23637 splice
doubler, and the 369D23662 position light bracket
lies on top of new 369D23688-3 doubler. All
parts are installed simultaneously.

Hughes Helicopters NOTICE NO. DN-44. 1::
DATE 22 June 1979
PAGE 7 of 14
SURFACE INTERSECTION
POINT
lf3~
0.19R
TAB ADJUSTMENT 3691323678-5 TAB CONFIGURATION
SKIN TRIM LINE
TRBITYPI O
POINT "A"
POINT "B"
(TANGENT TO UPPER SKIN SURFACEI ORIGINAL TAB ANGLE
STRAIGHT EDGE PLANK

CHORD PLANE
(NOTE 1)
TO F. BOOM HEW TAB ANGLE
VIEW B-B
TAB DEFLECTION CHECK
NOTES:
i. TAB UPPER SURFACE COINCIDENT 0. 12 (UP)IO. 03 (DOWNI

WITH STRAIGHT EDGE OR BEAM.
2. ALLDIMENSIONS ININCHES.
88-299-1A
Horizontal stabilizer adjustment of

Figure 2.
trailing edge tabs (Sheet 1 of 2)
Hughet Helicopters
DATE 22 June 1979
PAGE 8 of 14
1,0 x 2,0 (TYP)
STABILIZER
LOWER
ROUND
SLOT FOR 0.75

RIVET RELI
(TYP) ABILIZER
LOWER
SURFACE
DOWN-TAB UP-TAB
FINAL TRIM TAB ADJUSTMENT-TAB RIVETED TO STABILIZER
88-299-2
Figure 2. Horizontal stabilizer adjustment of

~railing edge tabs (Sheet 2 of 2)
E~ HUshU Helieapters DATE 22 June 1474
PAGE 9 of 14
NOTE
i. Use NAS1919B04-03 (or NAS1738B4-3) blind rivets,

3 places, to attach light bracket, new doubler, splice
doubler and stabilizer skin together.
2. Use NAS1919B04-03 (or NAS1738B4-2) blind rivets,

3 places, to attach light: bracket (only one of the
three rivets go through light bracket), new doubler
splice doubler and stabilizer skin together.
3. Use NAS1919B04-01 (or NAS1738B4-1) blind rivets,

8 places (field rivets), to attach new doubler to
stabilizer skin.
NOTE
Solid pull rivets may be

or used to attach
trailing edge tabs. If solid rivets are used,

use hand bucking tool only, to prevent damage
or deformatior? of stabilizer skin. If pull rivets
are used, maintain edge distance per AC 32-13.
4. Use MS20470AD2 solid rivets, or NAS1738134-2 or
NAS1919804-02 pull rivets, to attach both trailing

edge tabs, aft edge of new doubler, and aft edge of
position light bracket (1 place only) to stabilizer.
Use MS20470AD3 rivets if holes are enlarged and
require next size diameter solid rivet.
5. Check installed tabs with straight edge or beam for

proper deflection as shown in Figure 2. As required,
deflect tab(s) as follows to obtain proper tab angle.
(See Figure 2.)
a. To deflect tab downward, position wood block
(slotted for rivet: relief) on upper surface of tab

and stabilizer skin; press down with second
block on lower tab surface at location shown.
b. To deflect tab upward, position wood block (with

half of round wood tube) on lower surface of tab
and stabilizer skin; press down with second block
on upper tab surface at location shown.
NOTICE NO. DN-44. 1:::
DATE 22 June 1979 Hughw Halieoptsrs
PAGE 10 of 14
j. Apply bead of ProSeal 890 sealant around perimeter edge of new
doubler to seal faying surfaces.
k. Add "-503" configuration to Part Number on stabilizer ID plate;

also add suffix letter "M" to Serial Number ID
on plate to denote modification
per this Notice.
i. Reinstall fastener/ground lug for position light: bracket; use NAS601-7

screw and existing nut and washer.
m. Apply primer and surface coat to doubler and reworked area of

stabilizer to match helicopter exterior finish.
NOTE
Prior to installation of horizontal stabilizer,

check that compliance with Hughes Notice No.
DN-22 has been accomplished, As applicable,
seal top rib assembly of vertical stabilizer as
specified in Notice, to prevent water accumulation.
Reinstall horizontal stabilizer and tip plates,

n.
per HMX-Vol I.
o. Record stabilizer Part Number 369D23601-503, and stabilizer Serial

Number with suffix letter "M" in Components Record of helicopter Log Book.
NOTE
Note current time in service for PN 369D2360l

Horizontal Stabilizer installation. The service
life for stabilizer modified to new 369D23601-503
configuration per this notice is not to exceed
3800 hours total time in service.
p. Perform Part II of this Notice.
q. Phase main rotor blades per instructions

given in HMI -Vol I,
Revision No. 2, dated 27 November 1978, if not
already accomplished.
r. Record compliance with this Part I and Part II of this Service

Information Notice in Compliance Record of helicopter Log Book.
FAA APPROVED
NOTICE NO. DN-44. 1)::
Hughes nelic.pters 22 June 1979
PAGE 11OF 14
PAR T II RE LOCATION: OF STAT1C- PRESSURE FOR T
:Screen, protective D3738 1 HH
:::Decal, static port 369H6615-27 1 HH
~eProvided without cost; contact Hughes Service Center or Distributor.

Service Centers and Distributors process orders through
HH warranty and re pair department.
TOOLS AND ECZUIPMENT
Drill bit 0.270 inch diameter
MA TE RIALS
Adhesive, silicone MIL-S-8660B RTV732 Dow Coming

or
Silastic 140
Adhesive, epoxy MIL-A-52194 ScotchWeld 3M Company

EC1838
(Parts A
and B)
Emery cloth or paper 180 grit:
Solvent M114
Cup, unwaxed
Spatula wood
NOTICE NO. DN-44. 1":
DATE 22 June 1979 Hughss H~icopten
PACE 12 OF 14
PROCEDURE
a. Remove plenum access door and cover togain access to static

pressure port location inside aft engine air inlet fairing. (HMI-Vol I,
Section 2.
b. Cut static pressure tube as close as possible to static pressure port

inside aft fairing.
NOTE
Remove bug screen, if installed, from

end of static tube left in f&iring.
c. Drill 0. 270 inch diameter hole in fairing 3. 19 inches above existing

port at centerline of fairing as shown in Figure 3. New port location is at
WL 70. 0; existing port is located at WL 66. 81.
d. Using 180 grit emery, lightly abrade faying surface of static pressure
tube and fairing; clean with solvent.
e. Insert static pressure tube in new port; outer end of tube must be
flush with outer skin of fairing.
f. Mix EC1838 epoxy adhesive per manufacturers instructions; apply

adhesive around tube and against fairing as shown.
g. Plug former static port in fairing (at WL 66. 81)with EC1838 adhesive.
h. Check new static tube aft port for foreign matter; clear and clean
port as necessary.
i. Clean faying surface of bug screen and coat with silicone adhesive;
insert: and seat bug screen in aft end of static pressure tube.
j. Install new 3691-16615-27 decal on aft fairing at new static port

location.
k. Reinstall plenum access door and cover.

NOTICE NO. DN-44. 1:::
E) nu9hu Halieopters DATE 22 June 1979
PP;GE 13 OF 14
C!
INE INLET AFT

0. 27 DIA HOLE SECTION FAIRING ASSEMBLY
O
-5 TUBE (REF)
f
0. 50 MIN EC1838
ADHESIVE (NOTE 11
VIEW BB
W.L. 70.00
1. 00 DIA MIN
-5 STATIC BUG SCREEN
PRESSURE
A 3)
NOTE 1 TUBEbOUBLER 0. 270
WL 66. 81
VIEW A-A 19
NOTES:
i. APPLY EC1818 ADHES IVE.

BRACKETNOTE2 J3.
2. PLUG PORTWITH SEALANT.
3. REINSTALL AS APPLIABLE.
4. ALL DIMENSIONS IN INCHES. 88-308
Figure 3. Relocation of static pressure port

NOTICE NO. DN-44.1)::
DATE 22 June 1979 Hugha Hlicopters
PAGE 14 OF 14
NOTE
Relocation of static port: converts

369H6610-501 static pressure tube
installation to new 3691-16610-503
configuration, Record
update to new
-503 configuration per this Notice in
FAA APPROVED
NOTICE NC. DN-45. 2$
HUGHES 22 October 1979 DATE
SERVICE INFORMATIONA,, 7 1 OF
NOT ICE ~Super sede Service Information

Notice
s
No. DN-45.1, Dated

20 Jultr 1979
MANDATORY MANDATORY 1 111 MANDATORY
SUBJECT: PN 369D21400-501 MAIN ROTOR LEAD-LAG ELASTOMERIC DAMPER

ASSEMBLY INTERNAL MODIFICATION AND REIDENTIFICATION
MODELS AFFECTED: 500 D Model 369D Series Helicopter Serial No. 0003D thru 0555D
equipped with PN 369D21400-501 Elastomeric Dampers)~e
aAll PN 369D21400-501 Elastomeric Dampers in Spares Inventory
~PN 369D21400-501 Dampers installed on helicopters equipped

with PN 429-4537 external (military) stores kit are not affected
by this Notice.
~cDampers identified with PN M50452 and/or with suffix letter

"M" following vendor Part Number are not affected by this
Notice.

operation after receipt of required parts.
Shall be accomplished in conjunction with installation of

PN 369D23601-503 Horizontal Stabilizer Assembly, per Hughes
Service Notice No. DN-44 or DN-44. I.
Shall beaccomplished prior to installation of subject damper

assemblies in Spares Inventory.
PREFACE: The information given in this Service Information Notice provides instruc-
tions for reworking the PN 369D21400-501 Elastomeric Main Rotor Damper
Assemblies in order to reduce operating stresses in the main rotor blade
retention straps. The damper stiffness is reduced by removing one of the
elastomeric components inside the damper and replacing it with an ahimi-
num spacer.
Modification of the damper assemblies is to be accomplished in ship sets of
five (5). Intermixing of M50452 (modified) and 369D21400-501 (standard)

dampers is not permissible.
(I) Denotes portion of text added or revised
Form 9578
NOTICE NO. DN-45.2~ Hughe. Helicopters
DATE 22 October 1979
PAGE 2 OF 7
The life of the M50452 Damper is the

same as the 369D21400-501 Damper
which is 6060 hours. The time in
service prior to modification of the
damper per this Notice must: be in-

cluded as part of the total life on
the M50452 Damper.
Reference
500D Basic HMI VolI, Issued 15 September 1976; Revision No. 3,

15 March 1979
500D Basic HMI Vol II, Issued 15 September 1976; Revision No. 2,
1 November 1978
Hughes Service Information Notice No. DN-44. 1, dated 22 June 1979
PARTS LIST
When ordering, specify one Damper

Modification Kit PN M50452 for each
of the five main rotor dampers in ship
set.
)rC~CHH will provide M50452-3 spacer without

cost. Contact Hughes Service Center or
Distributor. Service Centers and

Distributors process order through
HH Warranty and Repair Department.
Nomenclature Part No. aty Mfr
$*Spacer M50452-3 HH
Washer AN960PD61bL l~ca* Commercial
Lockwire MS20995C32 AR Commercial
required for ship set of dampers
MATERIALS
Primer, zinc chromate Commercial

Hugha~ Hslieopters NOTICE NO. DN-44. 2~
PAGE 3 OF 7
TOOLS AND EC1UIPMENT
Torque wrench O to 2000 inch-pounds Commercial
Ink stamp Commercial
Hot Air Blower or Heat Gun Commercial
Adapter, torque wrench Field Fabricate
Tool, holding Field Fabricate
PROCEDURE
CAUTION
Support main rotor blade parallel to ground

when removing damper assembly from
helicopter.
a. Remove, as applicable, and inspect main rotor damper and attach-
ments, per Basic HMI Vol. I.
NOTE
I. Field fabricate special holding tool (see

Figure 2); use holding tool when securing
damper in vise, to preclude damage to

damper housing.
2. Field fabricate torque wrench adapter (see

Figure 2); use adapter when removing and
torquing damper cap, to preclude damage
to damper cap ears. Insert bolt to secure
tool between damper ears; secure bolt with nut.
b. damper in vise with special holding tool and

Secure remove damper
clevis. Useclose-fitting open-end wrench to avoid rounding hex nut corners.
Use special torque wrench adapter to remove damper cap.

NOTICE NO. DN-45. 2~ E) HBeh Melieopters
PAGE 4 OF 7
NOTE
i. If dampercap does not break loose in torque range

of 840 to 1700 inch-pounds, use hot air blower or
heat gun with hot air directed against periphery of
damper case, to provide differential expansion
between case and cap. Do not exceed case tem-
perature of 1650 F.
2. If force is required to remove damper buns, do not

exceed axial deflection of 0. 20 inch on the elastomer.
If buns do not slip out within this limit, direct hot
airagainst periphery of case concurrent with
application of axial force. Do not exceed case temperature
temperature of 165" F.
c. Remove two damper buns from case.
d. Reinstall threaded damper bun, then install new M50452-3 spacer as

shown in Figure i. Install damper bun, -3 spacer and damper end cap with
wet zinc chromate primer.
e. Using special torque wrench adapter, install and torque damper cap
to 800 to 840 inch-pounds and safetywire as shown. Safetywire to clear slot
in cap.
NOTE
Add a white paint slip-mark. Upon

accumulation of 25 hours flight time,
inspect for movement of cap.
f. Ink stamp Part No. M50452 on damper as shown, and add suffix
letter "M" to vendor part number on name plate. Also paint damper housing
with O. 75-inch band of white paint to identify modified damper assembly.
g. Install AN960PD616L washgr and damper clevis as shown. Preset

main rotor damper length (center-to-center dimension between mounting holes
in damper ears and clevis) to 8. 25 fO, 03 inches and locate turnbuckle approxi-
mately half-way between the washer and clevis. Leave jam nuts fingertight.
Hughes Helicopters NOTICE NO. DN-45. 2~
PAGE 5 of 7
h. damper ear containing bushing up, attach damper ears to

With
pitch bearing lug with bolt (head up), washer and nut. Torque nut to 30 to
60 inch-pounds, and install cotter pin.
i. Adjust main rotor blade for blade phasing, per referenced HMI-
Vol I, Revision No. 3, dated 15 March 1979. Remaining installation and
turnbuckle adjustment steps are provided in blade phasing procedure.
j. Remove main rotor blade support.
k. Record new PN M50452 with respective Serial Number in Components

Record of helicopter Log Book. Total time in service for installed
PN369D21400-501 Damper applies when damper is modified to M50452 con~
figuration and re-installed on helicopter. The total life of the M50452 Damper
is the same as the 369D21400-501 Damper, which is 6060-hours.
i. Record compliance with this Service Information Notice in Compliance

WEIGHT BALANCE DATA
Longitudinal Longitudinal
Weight (Pounds) Arm (Inches) Moment (Inch- Pounds)
Added: 2. 1 100. 0 210
Removed: -2. 6 100. 0 -260
Changed: -0. 5 100. 0 50
FAA APPROVED
NOTICE.NO.
Hugh~Welicoptrr
PAGE 6 OF 7
369021400-501MA IN ROTOR DAMPER VENDORS NAME PLATE (NOTE 2)
MS20995C32 LOC KW IRE (NOTE 31 THREADED DAMPER BUN
AN960PD616L WASHER
0.75 INCH BAND WHITE
END CAP I PAINT INOTE 4)
318 DIA THREAD ON
DAMPER BUN
CLEVIS
M5D452-3
(NOTE II SPACER
8.250+ .03
NOTES:
1. INK STAMP PART NO. MS50452 ON DAMPER HOUSING.
2. ADD LETTER "M" TO VENDOR NUMBER ON NAME PLATE.
3. SARY WIRE TO CLEAR SLOT IN CAP.
4. PAINT 0. 75 INCH DIAMETER WHITE BAND AROUND

CIRCUMFERENCE OF DAMPER HOUS ING.
88-303
Figure 1. Main rotor damper internal modification and

j reidentification, M40452
Hughes Helicapte~ NOTICE NO. DN-45.2J~
PAGE 7 OF 7
3.00
3. 06 1 6.00
WOOD
FIELD FABRICATION-DAMPER HOLDING TOOL
1
A A
WELD HEX BAR TO
~ETAL BLOCK o. 34
t
0. 75
T
VIEW A-A
0. 250 DIA HOCE

7
-flii
0. 82
METAL BLOCK--~----cJ
_U
i~-----------I
NOTE:
ALL DIMENSIONS IN INCHES
FIELD FABRICATION TORPUE WRENCH ADAPTER
88-307
Figure 2. Field fabrication torque wrench adapter and

damper holding tool
NOTICE NC. DN-46. 1:::
HUGHES DATE 15 August 1979

5
NOTICE
~Supersedes Service Information
Notice No. DN-46, Dated
16 April 1474
SUBJECT: FIELD MODIFICATION OF PN 369D21002 SCISSORS CRANK ASSEMBLY,

MAIN ROTOR HUB UPGRADE TO PN 369DZ1002-Z1 CONFIGURATION
TIME OF C~MPLIANCE: At owners and operators discretion.

procedure a
for modification of the subject 369D21002 main

PN rotor hub scissors
crank assembly to the current PN 369D21002-21 configuration, to preclude
shimming problems experienced with the early crank configuration. Field
rework consists primarily of relocating existing bushings in the crank

outboard attach lugs to the inboard lugs, and installing new flanged type
of the crank outboard
bushings in the outboard lugs. The wall thickness
of the flanged
attach lugs must be reduced to accomodate installation
bushings.
Instructions provided for replacement of existing attach hardware

are also
for the crank assembly. Field reports indicate that existing attach bolts
may have insufficient

thread length which in some cases caused loosening
of the bolts in service.
installation of the
It is to be noted that the field modification and
PN 369D21002-21 crank assembly with new attach hardware per this
scissors assembly to the
upgrades the PN 369D21001
new
Notice also
PN 369 D210 01- 501 configuration.
Refer ence
400 D Basic HMI-Volume I,

15 March 1979
Issued 15 September 1976; Revision No. 3,
I
Denotes portion of text added or revised
FORY NO 91178* HTC-*D REV 11-67

NOTICE NO. DN-46. l~e Hughe~ Halieopter~
DATE 15 August 1979
PAGE 2 OF 5
PARTS LIST
Nome ne lature Fart No. Qty Mfg
Bushing NAS 7 7 4 23 2 C omme re ial
Bolt NAS62 04-18D 2 Commercial
Bolt NAS6204-38D 1 C omm e r c ial
Washer ANq60PD416L 4 Commercial
)IcWasher AN960C416 2 C omm er cial
Nut MS 17826-4 3 Commercial
Pin, cotter MS24665-153 3 Co mmercial
~ANq60PD416L may be used as alternate

Drill bit 0.3750 inch diameter
Ream bit 0. 3750 0. 3754 inch diameter
I Grinder, portable or file
MATERIALS
Chemical film MIL- C-5541, Class 2

I tre atm ent
Iridite 14-2
Al- Co at
Richardson Co.
Allied-Kelite Products
Des Plaines, Ill
PROCEDURE
a. Disconnect scissors crank from hub lower shoe and scissors link.
(Refer to Basic HMI-Vol I.
b. Remove existing HS626-S-4-500 bushings from outboard lugs of

scissors crank. (See Figure i.)
c. Using grinder or file, remove minimum 0. 063 inch material from

inner side of both outboard attach lugs, to obtain distance of 9. 736 inches between
lugs (See Figure i). After removal of material, wall thickness of lug should
not be less than 0. 230 inch. Coat reworked area of lugs with iridite or equivalent
corrosion protection chemical film.
NOTICE NO. DN-46. l,k
Hughes H~licopters
DATE 15 August 1979
PAGE 3 OF 5
NOTE
Remove material from inner

side only of
existing crank out-
board attach lugs.
hole in outboard lugs guide, drill and ream 0. 252

d. Using existing as
inch diameter hole in inboard lugs to 0. 3750 0, 3755 inch diameter for press
fit of HS626-S-4-500 bushings.
Install HS626-S-4-500 bushings in inboard lugs of scissors crank with

e.
zinc chromate primer.
f. Install new NAS77-4-23 flanged bushings with zinc chromate primer

in outboard lugs as shown.
g. Reidentify crank assembly as PN 369D21002-21 on ID plate.
h. Reinstall scissors crank assembly using new attach hardware as
follows:
I. Install scissors crank to hub lower shoe with NAS6204-18D

bolts, AN960PD416L washers, MS178 26-4 nuts and cotter
pins as shown in 2. Torque nuts to 30 to 60 inch-pounds.
Figure
a. Install scissors link to scissors crankassembly with

NAS6204-38D bolt, AN960C416 washers, hIS178 26-4
nut and cotter pins, as shown in Figure i. Torque nut

to 30 to 40 inch-pounds.
i. Record of PN 369D21002 main rotor hub scissors crank

upgrade
assembly to PN 369A21002-21 configuration per this Notice in Component
j. upgrade of PN 369DZ1001 main rotor hub scissors assembly

Record
in Component Record of
to PN 369D21001-501 configuration per this Notice

FAA APPROVED
NOTICE NO. DN-46. l~e
Huahal Helicopter.
DATE 15 August 1979
PAGE 4 OF 5
9,736
NAS77-4-23
BUSHING (TYP 2 PLCS), I (NOTE 5)
HS626-S-4-500
BUSHING 2 REQ /c7- MINIMUM WALL 0. 230 TYP
MAXIMUM WALL 0. 249 TYP
369021002-21 x 450
0. 020 0. 3755
CRANK ASSEMBLY~ CHAMFER, 4 PLACESY ~r\ jl 0.3750DIA
I (NOTE3)
6.421
NAS 6204-380 BOLT ~/PLATE
NOTES:
AN960C416 WASHER
2 RE9D (NOTE 2)
MS17826-4 NUT (NOTE 1)
CT-7
I
NSTALL THIS SIDE
i. TORQUE NUT 30 TO 40 INCH-POUNDS
TOWARD BLADES
2. ONE WASHER EACH UNDER BOLT HEAD AND NUT
3. 1WO HOLES 1N LINE ITYP 2 PLACES) ~I

4. FILL GAP WITH ANP60PD10L WASHERS
5. REMOVE MATERIAL EVENLY FROM INNER SIDES OF \SCISSORS LINK ASSEMBLY

OUTBOARD ATTACH LUGS TO OBTAIN 9.736 OIMENSION.
6. ALL DIMENSIONS IN INCHES
Figure i. Field modification 369D21002-11 crank
assembly to 369D21002-21 configuration

E~ HUehY Helicopters NOTICE NO. DN-4~. I~e
DATE 15 August 1979
PAGE 5 OF 5
369021204 LOWER SHOES
.I
NAS6204-18D BOLT 2 REPD
AN960PD416L WASHER 4 REQD
MS17826-4 NUT 2 REQD (NOTE)
MS24665-153 COTTER PIN 2 REQD
3690 21002-21CRANK ASSEMBLY
NOTE:
TORQUE NUT 30 TO 60 INCH-POUNDS r___
Figure 2. Installation of 369D21002-21 crank to hub lower shoes

NOTICE NC. DN-47
HUGH ES DATE 16 April 1979
%ERVIICE PAGE i OF
N~T ICE
NIAI\IDA70AdP3-SP- MAN BAT8 RY--- MBI\! LSATO R Y
SUBJECT: FIELD RIGGING CHECK PN 369A8013-503 HEATER CONTROL
VALVE ASSEMB LY
MODELS AFFECTED: All 500D Model 369D Series Helicopters with PN 369H90020-517
Heating System Kit Installed

operation
for a one-time inspection of the subject heater control valve assembly to
ensure proper rigging and actuation of the

ball valve and valve vane and
provide sufficient cold air to be mixed with hot air when the heating sys-
tem is operated.
Reference

27 November 1978
PN 369H90020-517 Heating System, Illustrated Parts List and Maintenance

Instructions, Publ.ication No. CSP-013, Issued 15 August 1976
HTC-ID REV 11-67

NOTICE NO. DN-47
Hughes Helicopters
DATE 16 April 1979
PAGE 2 OF 5
TOOLS AND EaUIPMENT
Pin, rigging 1/8-inch drill shank Field Fabricate
:ITemplate, 45" Field Fabricate
~See Figure 2 for template specifications
PROCEDURE
a. Move CABIN HEAT control handle to full forward position to open

he at valve. Control valve should not creep away from ON (full open) position.
b. Remove interior trim and left aft bulkhead access cover.
c. Remove clamp securing cold air connector hose to valve assembly

(see Figure i).
d. Check that valve is in full open

position by inserting rigging pin
(1/8-inch shank) into pulley alignment hole as shown. Rigging pin should
drill
pass through pulley and enter mating alignment hole in valve housing. Remove
rigging pin.
NOTE
If rigging pin cannot be inserted into mating align-

ment hole in valve housing, perform the
following:
i. Remove cable assembly clevis from lever.
2. Rotate drive pulley until rigging pin can be

insertedthrough pulley and into mating
alignment hole in valve housing.
3. Loosen jam nut on cable assembly and

adjust clevis to align with holes in lever.
4. Tighten jam nut and install spring pin

through clevis and lever and safety with
cotter pin.
5. Remove rigging pin.

E~ HUshas Helicoptero NOTICE NO.
DATE 16
DN-47
April 1979
PAGE 3 OF 5
e. Fabricate 45" template per Figure 2. Insert template into open

end of valve as shown. Check that vane surface aligns template edge
with
within rt5"
NOTE
If vane does not align with template, perform

the following:
i. Remove three screws securing lever;

remove lever and timing belt. (Refer
to referenced CSP-013.
2. Reinsert template and properly align vane.
3. Install timing belt and lever.
f. Check that yellow index marks on driven pulley and valve housing
are aligned. Correct index mark on drive pulley as required.
g. Reinstall cold air connector hose with existing clamp.
h. Reinstall left aft bulkhead access cover and interior trim.
i. compliance with this Service Information

Record Notice in
WEIGHT BALANCE DATA
FAA APPR OVED

NOTICE NO. DN-47 E) Hushes Hellcoptera
DATE lbApri11979
PAGE 4 OF 5
CABLE ASSY
CLAMP
~q; CLAMP
INDEX FOR COLD AIR

VANE ALIGNMENT IN
JAM NUT
OPEN POS ITION
CLEVIS
FWD~
SPRING
PIN--~
RIGGING PIN HOLES
(OPEN POSITION)
1/&INCH
DRILL
CONTROL VALVE
ASSY INOTE 2)
Figure 1. Field Rigging Check Heater Control Valve Assembly

NOTICE NO. DN-47
E) Huehea Halicapters DATE 16 April 1979
PACE 4 OF 5
TEMPLATE
1 VANE
i I
I 1 450
8 VANE SURFACE TO ALIGN WITH

TEMPLATE WITHIN 50
~TIMINGBELT
r CONTROLS SHOWN
/---2.50-----f/
-f
0. 50 DIA CUTOUT 1. 50
I-
0.75 450 I
Figure 2. Field Fabrication 45" Template, Rigging Check

E~ Hughes Helicopters
REFERENCE SHEET
Action Reference: When performing inspection or maintenance
of heater control valve assembly, refer to
Service Information Notice No. DN-47.
HMI Reference: Insert this sheet in Publication No. CSP-013,

Illustrated Parts List and Maintenance
Instructions for PN 369D90020-517; Section 2,
page 2-3.
This reference sheet shall be kept as a part

of the manual until the data is incorporated
at the next revision to CSP-013.
NOTICE NC. DN-4S
ai
DATE 10
HUGHES May 1979
NOTICE
SUBJECT: REPLACEMENT OF RADIO TRANSMIT/INTERCOM TRIGGER SWITCH;
REWORK OF CYCLIC PITCH STICK GRIP ASSE~IBLY:I:
~CRework not required Hughes PN 369D27133 or

for
Guardian PN A218-964401-00 Cyclic Pitch Stick
Grip As semblie s
MODELS AFFECTED: 500D Model 369D Helicopter SerialNo. 0003D through 0480D
REFACE: A improved Guardian PN A21 8- 1 5869 8- 05 radio transmitlintercom

new
switch is now provided as replacement, when required, for existing
trigger switches in cyclic grip assemblies installed on the above-affected

helicopters.
given in this Service Information Notice provides instruc-

The information
tions for replacement of the trigger switch, including a one-time modifi-
cation of the cyclic grip assembly, as required to accommodate the design
configuration of the new replacement switch.
It is to be noted that rework of Hughes PN 369D27133 or Guardian

PN A218-964401-00 cyclic grip assemblies is not required for installa-
tion of replacement PN A218-158698-05 trigger switch.
R efer enc e
500D Basic HMI Volume I, Issued 14 September 1976; Revision No. 2,

27 November 1978
Publication No. CSP-023, Illustrated Parts List and Maintenance Instructions for
Cyclic Stick Grip Kit Installation, PN 369H90129-31 and -505, Issued 1 June 1977
Customer Service Department Hughes Helicopters Cu~tr City, C;alifornia
FORU NO 9578* HTC *D REV ll-b7

NOTICE NO. DN-48 E) HUe~ Helicopten
DATE 10 May 1979
PAGE 2 of 4
PARTS LIST
Switch- RADIO/ICS A218-158698-05 1 Guardian Electric
TOOLS EQUIPMENT
Routing tool blade, rotary file or equivalent
MATERIALS
Potting compound
PROCEDURE
b. Disconnect cyclic grip wiring connector from plug at lower end of
cyclic stick.
c. Remove strap securing wiring to stick socket; remove strap mount-
ing plate if it is unserviceable.
d. Remove screw from grip and separate grip from stick tube.
e. string toeach wire bundle

Tie a at lower end of cyclic stick. Push
slackwiring wiring exit holes in stick
into socket while pulling grip wiring
from stick tube. Remove grip and wiring; leave strings in tube for
reassembly.
f. Remove the two exposed spring tension screws, springs, ball and
pin securing trigger switch in grip (located on top and right-hand side of
grip).
g. Drive trigger pivot pin from grip to release the trigger. Pin is
removed from right to left while holding grip in normal position. Remove
Trigger.
h. Remove potting compound and two switch

retaining screws at front
of grip. Pull switch forward out of grip, feeding wiring up through grip at
same time. Unsolder wiring terminals on trigger switch.
NOTICE NO. DN-48
Q) Hughes MelicopOen DATE 10 May 1979
PAGE 3 of 4
CAUTION
Protect all wiring and switches during rework

from
of grip; or remove wiring and switches
grip, noting all electrical connections.
i. Rework cyclic grip as follows (see Figure i):
i. Press or pull insert from top of grip.
2. Make template of profile of new A218-158698-05 trigger switch.
3. Using file, blade or equivalent routing tool, remove material

from lower inside edge of hole for trigger switch to permit:
installation of new switch. Use template to determine amount
and location of material to be removed.
j. Clean grip, wiring and switches. Reconnect (solder) all electrical

wires and reinstall switches, as applicable.. New trigger switch is retained
by trigger pivot pin.
k. Apply potting compound to all open screw holes and insert hole.
i. Reinstall grip on stick tube. Using attaching strings, route grip

wiring through stick tube and reconnect at electrical plug.
m. Check switch operation and wiring continuity.
n. Secure wiring to stick. socket with nylon strap.
FAA APPROVED
NOTICE NO. DN-48
E~ nuoh" HlicL)ptet.s
DATE 10 May 1979
PAGE 4 of 4
REMOVE TH IS INSERT
-158698-05 SWITCH
REMOVE MATERIAL HERE
88-323
Figure 4. Rework of cyclic pitch stick grip assembly

E) Hushes Hslicopters
REFERENCE SHEET
Action Reference: When performing maintenance or replacement

of cyclic pitch stick grip, refer to Service
Information Notice No. DN-48.
HMI Reference: Insert this sheet in Model 369D Basic HMI-

Volume I, Section 7, Pages 7-70.

at the next revision of the HMI-Volume I.
Service Information Summary, Page i
(See
of HMI-Volume I.)
Hughas Helioopters
REFERENCE SHEET
Action Reference: When performing maintenance or replacement

of cyclic pitch stick grip, refer to Service
Information Notice No. DN-48.
HMI Reference: Insert this sheet in Publication No. CSP-023,

Cyclic Stick Grip Kit Installation, Section 2,
Page 2-1.

at the next revision to Publication No.
CSP-023.
NOTICE NC. DN-49
HU~H ES
DATE 11June 1979
SERV%CE Pr~GE I OF b
N ~T I E
W1 A~I DUTOBV Rn M RI DA TO K Y M AN nv
ii
SUBJECT: INSPECTION AND REPAIR
BELLCRANK SUPPORTS,
STATION 142 TAIL ROTOR CONTROL
PN 369A3035-11 AND 369A3035-15
MODELS AFFECTED: 500D Model 369D Helicopter SerialNos. 0003D through 0531D;
0533D, 053513 and 0537D
TIME OF COMPLIANCE: Part I Inspection Shall be accomplished within next 25 hours

of helicopter operation; and at each 100-Hour Inspection
Interval until compliance with Part II of this Notice is
a c com plis hed.
Part II Repair Shall be accomplished prior to next flight

if cracking of support is noted.
PREFACE: Part I of this Notice lists a procedure for a periodic inspection of the
subject Station 142 tail rotor control bellcrank supports for evidence
ofcracking at the bellcrank attach area.
Part II of this Notice provides instructions for field repair of the supports
if cracking is noted, by installing larger doublers on the supports to pro-
vide additional reinforcement at the bellcrank attach area. Rework per
of the
Part II of this Notice lifts the requirement for periodic inspection
bellcrank supports.
if damage to bellcrank supports is noted, rework

It is to be noted that, no
of the supports per Part II of this Notice may be performed at owner or
operator discretion to lift the periodic inspection requirement.
Reference
27 November 1978
500D Basic HMI Volume II, Issued 15 September 1976; Revision No. 2,
1 November 1978
Customer Service I)epartment Hughes Helicopters Culver City, California
HTC*D REV 11-67

NOTICE NO. DN- 49
DATE
PAGE 2 OF 6
11June 1979 E) Huahe~ Helieopter+
PART I--100-HOUR PERIODIC INSPECTION
NOTE
Periodic inspection not required if bellcrank

supports have been reworked per Part II of
this Notice.
a. Remove Station 142 tail rotor control bellcrank assembly, per

Section 8 of HMI-Volume I.
b. Using bright light and mirror, visually inspect PN 369A3034-9

doublers on bellcrank supports for cracking or damage. (See Figure i.)
Pay particular attention to the four spot weld spots attaching doublers to
supports.
NOTE
Perform Part II of this Notice prior to next

flight, if cracking or damage to doublers at
bellcrank attach area is noted.
c. Reinstall Station 142 bellcrank per Basic HMI-Volume I.
d. Record
compliance with Part I of this Notice in Compliance Record
PART II REPAIR OF STATION 142 BELLCRANK SUPPORTS
PAR TS LIST
Nomenclature Part No. atv Mfr
Doubler::: M40455-7 1 Hughes Helicopters
DoubZer:: M50455-5 1 Hughes Helicopters
Spacer;:: M50455-3 2 Hughes Helicopters
May be field fabricated per Figure 2.

NOTICE NO. DN-49
DATE 11June 1979
Hughes
PAGE 3 OF 6
TOOLS AND EQUIPMENT
Drill bit No. 30 through No. E as required
Pin, alignment NAS1304 bolt or equivalent, 0. 25-inch diameter pin
MA TERIALS
Adhesive EA9314 or EC9309 Hysol Div of Dexter Corp
Primer, adhesive EA9210 i-lysol Div
Solvent M- 114M or Comm ercial

Trichloroethane O-T-620 Commercial
abrasive 180 grit Commercial

Paper,
waxed Commercial
Paper,
Bond releasing agent Commercial
Wood block 0. 83 x 4. 50 x 2. 00 inches
REPAIR PROCEDURE
a. As required, remove Station 142 Station tail rotor control bellcrank

I.
assembly, per Section 8 of H~II-Volume
b. Remove existing 369A3035-9 doubler from outboard 369A3035-11

shown
bellcrank support, by drilling out doubler spotwelds, 4 places, as
in Figure 1.
NOTE
i. Removal of 369A3035-9 doubler from

inboard side of 369A3034-15 bellcrank
support is not required.
2. Stop drill any crack or cracks found in
369A3035-11 and -15 bellcrank supports.
c. Lightly abrade faying surfaces of 369A3035-11 and -14 bellcrank

to secure good bonding.
supports; itis not necessary to abrade through paint
and spacers
If abrading removes paint and primer from supports, doublers
must be bonded immediately after abrading.
NOTICE NO. DN- 49
DATE 11June 1979
Hughes Hslicopt~rr
PAGE 4 OF 6
NOTE
Required doublers and spacers may be field

fabricated and adhesive primed per
Figure 2.
d. Wipe faying surfaces of M50455-3 spacers, and M50455-5 and

M-50455-7 doublers, with solvent; apply adhesive to faying surfaces.
NO TE
M50454-3 spacers and M50455-7 doubler
may be bonded on bench beforehand to

facilitate handling.
e. Install spacers and doublers as shown in Figure i. Use NAS1304

bolt or equivalent as alignment pin to align holes while bonding. Coat bolt
or pin with bond releasing agent to prevent possible adhesion to structure.
f. Insert wood block, and metal shims as required, between bellcrank

supports to press doublers against structure and prevent excessive adhesive
build up. Slot wood block to provide relief for alignment pin. Wrap wood
block and shims in waxed paper to prevent possible adhesion to structure.
g. Cure adhesive for 24 hours; remove wood block and shims from
supports.
h. Reinstall Station 142 bellcrank per HMI-Volume I.
i. Record compliance with Part II of this Notice in Compliance Record

NOTE
Compliance with Part II of this Notice

lifts
periodic inspection requirements
per Part I of this Notice.
W~EIGHT AND BALANCE DATA
FAA APPROVED
(NOTE I)
STA146.62
p~l M50455-3
SPACER
M50455-5
B
DOUBLER 369A3035-15
ACCESS HOLE
VIEW C-C SUPPORT
I\
2.24
L
0.2505
DIA
0.2495
(NOTE 3) HOLE~ ~X
C
M50455-3 SPACER
Ih
i (2 REQD) \O
369/\3035-9 PLATE I
0.54t (NOTE 2)
M50455-3 SPACER (2
I
C
M50455-SDOUBLER
REQD)(D
VIEW A-A (r)
P~ 8
369A3035-11
i A
I-, M50455-7 DOUBLER
369A3035-11 DI
/X
/rx K/
~0.80
0.2505
SUPPORT
~irr-
~,369/\7527
BELLCRANK
NOTES:
L.
2.
3.
FILL VOID WITH ADHESIVE, TYP 2 PLCS
EXISTING PLATE NOT TO BE REMOVED
USE NAS1304 BOLT OR EQU IVALENT TO
d
MM
O
W
DIA HOLE ALIGN FOUR HOLES WH ILE BONDING
D. 2495
(NOTE 4)
(NOTE 3) y 4.
5.
APPROXIMATE LOCATION OF SPOMTELDS
REMOVE 369A3035-9 PLATE BY DRILLING
L"
o
r
M
z
THROUGH SPOTWELDS
VIEW B-B 6. ALL DIMENSIONS IN INCHES
r C~ O
EXISTING 369A3035-9
(VIEW LOOKING FORWAR D)
PLATE (NOTE 5)
n,tl
~2X VIEWD-D 88-335 rZ
Figure i. Installation of doublers tail rotor control bellcrank supports \D

NOTICE NO. DN- 49
DATE 11June 1979 Hugh~ Hlicopten
PAGE 6 OF 6
M5(1455-7 DOUBLER
I
0.2495
r
IC--~ 2 IZ
I-------~---- 08-------------------I d.
0,2505
..DIA 1
1.12 M50455-500UBLER
I
2. 24
r M50455-3 SPACER
(2 REQ)
NOTES:
i. FABRICATE FROM ALALY SH 2024-T3, PQ-A-250/5 TEIV\P T3.
3. COAT AND PRIME FAYING SURFACES AS FOLLOWS:

LIGHTLY ABRADE FAYING SURFACES WITH 180 GRIT PAPER
AND WI PE CLEAN WITH M-114M SOLVENT, IMMEDIATELY APPLY
CHEMICAL CONVERSION COATING (CHROMICOAT L-25 OR Mll-C-5541,
CLASS 21 TO PRECLUDE OXIDE BU lLD UP ON ABRADED SURFACES.
BRUSH COAT LIQUID PR IN\ER (HYSOL EA92101 ON FAY ING
SURFACES ONE OR TWO HOURS AFTER CONVERSION COATING:
AIR DRY FOR 30 MINUTES AT ROOM TEMPERATURE; OVEN CURE
PRIMER FOR 60-65 MINUTES AT 2500F to 2600F. 88-338
Figure 2. Field fabrication of bellcrank support doublers and spacers

NOTICE NC. DN-501~"
HUGHES DATE 26 November 1979

PAGE 1 OF
NOTICE
~Supersedes Service information
Notice No, DN-50, dated 29 June 1474
SUBJECT: INSTALLATION OF VOLTAGE TRANSIENT SUPPRESSORS
MODELS AFFECTED: 500D Model 369D Helicopter SerialNo. 0003D through 0539D.
The following optional kits installed on helicopter or in Spares
Inventory at date of this Notice:
PN 3691-190148-503/-505 Engine Air Particle
Separator Filter
PN 3691-190142-501 Manually Operated Searchlight
PN 369D290121-501/-405/-507 Emergency Floats
PREFACE: Part I of this Service Information Notice lists installinga procedure for
voltage transient suppressors to the

helicopter electrical system at the
main bus and at the start relay, to reduce the possibility of voltage spikes
damaging solid state circuits, including the reversing circuit in the longi--
tudinal and lateral trim actuator assemblies installed on the helicopter.
Part II of this Notice provides instructions for installing additional sup-

pressors, if the helicopter is equipped with optional engine air particle
separator filter kit, manually operated searchlight kit, and/or emergency
float kit with solenoid valves. Helicopters equipped with squib actuated
emergency floats are not affected by Part II of this Notice.
Refe r enc e

27 November 1978
PN 369H90148 Engine Air Particle Separator Kit Installation, IPL and Maintenance
Instructions, No, May 1976

CSP-004, dated 15
PN 3691-190141 Manually Operated Searchlight Kit Installation, IPL and Maintenance
Instructions, No. CSP-032, dated 1 December 1977

PN 369D290121 Emergency Float Kit-Extended Landing Gear, IPL and Maintenance
Instructions, No. CSP-025, dated 15 August 1977
Denotes portion of text added or revised
FORM NO HTC*D REV ll-6~

NOTICE NO. DN- 50.1:::
Hughe Helic~ptera
PAGE 2 OF 9
PARTS LIST
Nomenclature Part Number Qty Mfg
Trans ie nt s upp re s s o r 1N6055 Transzorb 2,:: General

Semiconductor
or
Industries
V47ZA7 Varistor 2~ GE
Terminal MS25036-101 2 Commercial

Terminal MS25 036-102 2 Commercial
Nut MS21042-3 1 Commercial
Washer AN9,6 OD1 OL 4 Commercial
Screw NASq 09 6 3 8 1 Commercial
Tubing, thermofit 0. 25x~RNF-100) AR Raychem
Wire, jumper 22GA AR Commercial
Sleeving, insulation No. 20 Commercial
Tie straps MS 17 821-4-9 AR::i::: Commercial
or
M53367-4-0 Commercial
~One each additional required if particle separator and/or searchlight

kit installed; three each additional required if emergency float kit
installed.
if emergency float kit installed.
MATERI[ALS
Solde r SN6 OWR P2
TOOLS AND EQUIPMENT
Drill bit 0. 1 9 0/ 0. 194 inch diam ete r
Soldering iron
PART I INSTALLATION OF VOLTAGE TRANSIENT SUPPRESSORS

(Applicable all Model 369D helicopters Serial No. 0003D
through 0539D.)
a. Install suppressor to main bus as follows:
i. Check that all electrical

pqwer is OFF.
2. Remove instrument console fairing, as applicable, to gain
access to TB101 (369D helicopters) or TB10 (369MD helicopters).
NO TICE NO DN -5 0. 1:I:
E) Hushes Helicopters DA TE 26 November 1979
PAGE 3 OF 9
3. Drill 0. 190/0. 194 inch diameter hole for gro und stud in
instrument panel support at location shown in Figure i.
4. Install new ground stud as shown; connect suppressor to
terminal board TB101 for 369D helicopters, or TB10 for

369MD helicopters, and ground stud.
5. Reinstall fairing as applicable.
b. Install suppressor to start relay as follows:
i. Open engine access door.
2. Disconnect and remove start relay (Section 19, HMI Volume I).
3. Connect suppressor to terminals X1 and X2 of start relay, as
shown in Figure 2.
4. Reinstall start relay, per HMI Volume I.
5. Close engine access door.
PART II INSTALLATION OF VOLTAGE TRANSIENT SUPPRESSORS
(Applicable 369D helicopter Serial No. 0003D through 0539a

equipped with engine air particle separator filter kit, search-
light kit, and/or emergency float: kit.
a. If particle separator filter kit is installed, install suppressor as
follows:
i. Check that all electrical power is OFF.
2. Remove interior trimm and access panels to gain access to
scavenge air solenoid at forward side of canted firewall.

(See referenced No. CSP-004.
3. Disconnect plug (P206) from solenoid valve connector; install
suppressor to solenoid plug (P206) as shown in Figure 3.
4. Connect plug to solenoid valve connector.
5. Reinstall access panels and interior trim.

NOTICE NO. DN- 50. 1:::
1979
PAGE 4 OF
b. If manually operated searchlight kit is installed, install suppressor

as follows:
2. Remove access togain access to K302 and K303

cover
relays.
(See referenced No. CSP-032.)
3. Remove existing diode and install new suppressor to K302 termi-

nals X1 and X2, as shown in Figure 4.
4. Reinstall access cover.
If emergency float kit

c. (with solenoid valves) is installed, install
suppressor as follows:
2. If floats are stowed, unsnap containment cover and loosen

restraining lacing to gain access to solenoid valve and wire
splices on RH and LH floats. (See referenced No. CSP-025.
3. Install suppressor with jumper wires to LH and RH float solenoid

valve wire splices, as shown in Figure 5; use tie straps to
secure sleeving at both ends of each suppressor.
4. Remove pilot left floor access cover; disconnect and remove
relay from floor support forward bulkhead.
5. Remove existing diode between terminals X1 and X2 of relay;

install suppressor as shown in Figure 5.
6. Reinstall access cover; as applicable, tighten restraining

lacing and secure float snap fasteners.
I FAn APPROVED
NOT~CE NO. DN-50.lt
E) nuah WlbOpfl)ll) DATE 26 November 1979
PACE 4 OF 9
MS 25036-102 TERMINAL
7(0
5(01L I MS21042-3 NUT 1 REQD
0. 25 X (RNF-100)
SHR INK TU B ING 2 PL 4 (O r I ~J ,AN960D 10L WASHER 4 REQD
1#6055 (ALT: V47ZA7 VAR ISTOR)

TB101
NAS671C10 NUT 1 REPD

MODEL 3690 HELICOPTERS NOTE
NOTE
INSTRUMENT PANEL OR STRUCTURE
NAS1096-3-8 SC REW
M520659-102 TERMINAL (2 REPOI
1AEPD
CRIMP AND SOLDER
1N6055
O V47ZA7)
0.25X(RNF-10 )SHRINKTUBE(ALT: GROUND STUD (TYPICAL)
(2 PLCS)
O
E46
1 1
3.20~0.20
O
NAS1096-3-8SCREW
TBIO MS21042-3 NUT
NAS671C10 NUT
MODEL 369MD HELICOPTERS AN960D10L WASHER- 4 REOD
369H6422-53
INSTRUMENT PANEL MODEL 369[) HELICOPTERS
(NEAR SIDE)~/ I
0.190
DIA HOLE
0.194
THROUGH -53 AND -35

369H6422-35
INSTRUMENT PANEL
(FAR SIDE)
0.24
t
1. 50
NOTE:
ELECTRICAL BOND PER Mll-B-5087 CLASS A
88-331A
Figure 1. Installation of transient suppressor and ground stud main bus

NOTICE NO. DN-50. 1
Hughes Halicoptsr~i
PAGE 6 OF 9
xl
0. 25 X (RNF-1001
SHRINK TUBING
(2 FL)
1N6055TRANSZORB
MAKELEADS, /(ALT:V47ZA7 VAR ISTORI
AS SHORT
ASPOssleLE ~CRIMP AND SOLDER
(2 REQDI
ART RELAY
(K 101)
88-330
Figure 2. Installation of transient

suppressor start relay (K~01)
NOTICE NO. DN-40. 1
nughes HlicOptars DATE Lb November 1979
P~GE 7 OF 9
P206
UTILITY SCAVENGE AIR
(NOTE)
CB117 CB15
1~2
i P16B20 P16C20------t------P16D20 A
1"" LINE
3A
LOAD SPLICE (NOTE)
1N6055TRANSZORR
i "";""""(I) I
369A8462
~t----P111120N--\--r
(NOTE)
B
P16E22 ---f FILTER CLOGGED LIGHT
SOLDER WITH SN60WRP2

(2 FL)
TRANSZORB (LEADS TO BE
AS SHORT AS POSSIBLEI
0. 25 X (RNF-1001 SHRINK TUBING

(2 FL)
NOTE: PART OF WIRE HARNESS 369A4163
O
88-332
Figure 3. Installationof transient suppressor scavenge air solenoid valve,

particle separator filter
NOTICE NO. DN-50. 1~:
PAGE 8 OF 9
E) Hueh Hlicopters
8US
CB 127 DS401 ILH)

Al ~7- A2
P506AE 10 L557A10-
--o35 A~---- WHT RE
DS4021RH)
A2
GRAY~-
WHT REEN
(NOTE)
K302 K303
X2 X:
CR4
lN6055 OR JUMPERS AWG 20
V47ZA7
JUMPERS AWG 20
L561A16-YEL
NOTE:
MAKE LEADS AS SHORT AS POSSIBLE
88-333
Figure 4. Installation of transient suppressor

manually operated searchlight
NOTICE NO. DN- 50. 1::
Hushes Helicopters DATE 26 November 1979
PAGE: 9 OF 9
M5101(20
.1 ---rTB1-l?i, PLACES)IUMPER
AWGZO
16
IA
___~_
BI O CI 1 i RELAY K105
vj
T M509K20
3 B1) (C1) iD
MSObC20 MS06EZO
1! lir ~CR?O
llA20N M512A20N~ MS19A20N
GND GND
GND
M506N20
BLK-AEO YEL-ALO YEL-AAZO BLK-AAZO
B A A B
SP5 SP4 SP9 SP10 IN6055TkANSZORB
A B B A
(ALT: V47ZA7)
22GA I I I I 22GA
JUMPER JUMPER
11\16055 11\16055
TRANSZORB TRANSZORB
(ALT: V47ZA7) (ALT: V47ZA7)
INOTE 2) (NOTE 2)
BLK (NOTE II YEL YEL (NOTE I) BLK
LEFTSOLENOID RIGHTSOLENOID
FLOAT VALVE LI FLOAT VALVE L2
NOTES:
I. PART OF SOLENOID FLOAT VALVE
2. INSTALL BETWEEN SPLICES WITH NO. 2SLEEVE
AND SECURE SLEEVE 2 PLACES (TYP) WITH THE STRAPS
88-334
Figure 5. Installation of transient suppressors solenoid float valves and
relay assembly
DN~5228
HUGHES NOIICE
NP.
NOT ICE :::Supe ede Service rs s Information

Notice No. DN-52.1 Dated
15 October 1979
MAN DATORY MAN DATO RY I I MAN DATO RY
SUBJECT: KIT INSTALLATION, PN 369I3290140-501 AUXII~IARY FAIRINGS I

AND SEALS, ENGINE AIR FILTER (PARTICLE SEPARATOR)
MODELS AFFECTED: 500D Model 369D Helicopters equipped with PN 369H90148-503

or PN 369H90148-505 Particle Separator kit.
NOTE
A 369H90148-503 and -505 Particle Separator kit installation

may be identified by the scavenge air ejection port located at
the rear of the engine inlet fairing on the left side of the air-
craft.
TIME OF COMPLIANCE: Shall be accomplished within 100 hours of helicopter operation

after receipt of parts.
for installing auxiliary fairings and seals, to preclude possible entry of
foreign materials or objects through gaps between the particle separator
filter assembly and the fuselage structure.
Instructions and material specifications are provided for field fabrication

ofauxiliary fairings, supports and seals required for the kit installation.
Optionally, complete kits are available through your authoriz~ed
HH Service Center or distributor.
It is to be noted that the 369A8402-7 pressure switch is required for the

kit installation. A procedure for optional retrofit of the existing pressure
switch to the new -7 configuration is provided.
R:eference

15 March 1979
Installation and Maintenance Instructions for Engine Air Inlet Filter,
PN 3691-190148-503 and -505; CSP-004, Issued 15 May 1976
I) Denotes portion of text added or revised.
FORLI NO 9~78* HTC~D RCV 11-67
Form 9578
NOTICE NO. nN-42. 2:1:
Hughes Helicopters
PAGE 2 OF 13
PAR TS LIST
The following components included in Particle

are
Separator Auxiliary
Fairing Kit, PN 369D290140-501:
Nom enclatur e Part No. aty Mfr
Fairing Assembly 369D290140-11
Fairing 369D290140-3 1 HH:~

Plate 369D290140-9 1 HH:~
Fairing Assembly 369D290140-12
Fairing ~690290140-4 i Hi-i,::

Plate 36 9D290140-9 1 HH:~
Supp or t 3 69D 2 9 0 14 0 5 1 Hl-l::c

Supp or t 3 69D290 140 7 1 HH~
Seal 36 9D290 140-13 2 HH:I:

Seal 369D290140-15 1 HH:I:
Seal 369D290140-17 2 HHs
Seal 369D290140-19 1 HH::e
Seal 369D290140-23 1 131i:::
Seal 369D290140-25 1 HH~
C;r omm e t MS35489-19 2 C omm e r cial

Rivet NAS 1 7 3 8 B4 2 5 C omm e r c ial
Rivet MS20470AD2 4 Commercial
Switch, Pressure:::9 3 69A 84 0 2 7 1 1-ill

or
Kit, Modification::::(: 800-174 (Jens en) 1 HH
:::May be field fabricated per materials and

specifications
listed below. Also see Figure 2.
:I:~:Rework of existing 369A8402-3 pressure switch to

369A8402-7 configuration with mod kit is optional.
NOTICE NO. DN-42. 2,1:
Hug~M Hslicoptsr.
PAGE 3 OF 13
MA TERIA LS
Aluminum alloy sheet 2024-T3; QQ-A-250/4 Commercial
for 369D290140-3 fairing (0. 032 x 6. 00 x 4. 00)

for 369D290140-4 fairing (0. 032 x 6. 00 x 4. 00)
for 369D290140-5 support (0. 020 x 2. 50 x 2. 75)
for 369D290140-7 support (0. 020 x 2. 40 x 2. 75)
for 369D290140-9 plate (0. 032 x 0. 75 x 2. 03)
Pressure sensitive tape No. 4504 0. 240 in.

Thick Foam Tape
3M Co.
St. Paul Minn I
for 369D290140-13 seal (0. 88 x 0. 75 x 3. 00)
for 369D290140-15 seal (0. 88 x 0, 75 x 4, 00)
for 369D290140-17 seal (0. 13 x i. 00 x 2. 50)
for 369D290140-19 seal (0. 13 x 2. 00 x 10. 00)
for 369D290140-23 seal (0. 13 x 2. 00 x 11. 00)
for 3691)290140-25 seal (0. 50 x 0, 75 x i. 75)
Sealant Silastic RTV No. 732 Dow Coming

Primer Fed Std 595 No. 20371 C omm e r c i al
TOOLS AND EQUIPMENT
Rivet gun/nose assembly
Drill bit 0. 250 inchdiameter (No. E)
Drill bit 0. 1285 inch diameter (No, 30)
Drill bit 0.067 inch diameter (No. 51)
KIT INSTALLATION, PN 369D290140 AUXILIARY FAI~RINGS,

PAR TICLE SEPARA TOR
a. Remove engine air inlet forward fairings. (Refer to Basic
HMI-Vol. I.)
b. Remove, clean and inspect particle separator filter assembly.

(Refer to Installation and Maintenance Instructions, CSP-004.
NOTICE NO.
DATE 15
DN-52. 2,1:
September 1980
E) Huah HliEOpfQ+
PAGE 4 OF 13
NOTE
i. The 369D290140-5 and -7 supports, and

-11 and -12 fairing assemblies may be
field fabricated per dimensions shown in
Figure 2. Apply coat of primer to parts.
2. Refer to Materials listing for dimensions

for all seals (pressure sensitive tape).
c. install auxiliary fairings and seals to LH side of helicopter as
follows:
i. Position -5 support forward of filter mounting frame on LH aft

engine air inlet fairing, per dimensions shown in Figure i,
Detail A and Section B-B. Install -5 support to fairing with two
NASI 73 8B4-2 rivets. Apply -13 seal to support as shown in
Detail A.
2. Apply -25 seal to aft inlet fairing, with -25 seal forward of and
in line with -13 seal as shown in Detail A.
3. Position -11 fairing with

flanges in mast support structure
fitting and on forward side of mounting frame of aft inlet fairing.
Mark and drill 0. 250 inch diameter hole in -11 fairing to match
existing nutplate location on aft engine air inlet fairing.
4. Split grommet and install grommet on wiring/controls bundle;

insert grommet into -11 fairing as shown.
5. Temporarily install -11 fairing with grommet to aft engine air

inlet fairing with existing hardware.
6. Install -17 seal on underside of 369H90151-31 fairing; locate

-17 seal on aft outboard side of fairing as shown.
7. install -19 seal on underside of 369H90151-31 fairing; locate

-19 seal at forward edge of
fairing as shown. Trim -19 seal
to match contour of fairing.
8. Seal gaps between flanges of -11 fairing and mast support

structure fitting. Also seal all openings and gaps in areas
shown in Detail A.
NOTICE NO. DN-52. 2j::
Hughee Helicopters
PAGE 4 OF 13
d. Install auxiliary fairings and seals to RH side of helicopter as
foil ow s:
i. Position -7 support forward of filter mounting frame on RH I

aft engine air inlet fairing, per dimensions shown in Figure 1,
View A-A and Section C-C. Install support to fairing with
three NAS1738B4-2 rivets. Apply -15 seal to support as
shown.
2. Position -12 fairing flanges in mast support structure

with
fitting on mounting frame of aft inlet fairing.

forward side of
Mark and drill 0. 250 inch diameter hole in -11 fairing to match
existing nutplate location on aft engine inlet fairing.
3. Split grommet and install grommet on wiring/controls bundle;

insert grommet into -12 fairing as shown.
4. Temporarily fairing with grommet

install -12 to aft engine
inlet fairing with existing hardware.
5. Install -17 seal on underside of 3691-190151-41 fairing; locate
-17 seal on aft outboard side df fairing as shown.
6. Install -23 seal on underside of 369H90151-41 fairing; locate
-23 seal at forward edge of fairing as shown. Trim -23 seal
to match contour of fairing.
7. Seal gaps between flanges of -12 fairing and mast support

structure fitting. Also seal all openings and gaps in areas
shown in Detail A.
e. Check installation of auxiliary fairings and seals for discrepancies.
f.Replace existing 369A8402-3 pressure switch with new 369A8402-7

rework existing switch to 369A8402-7
pressure switch (Refer to CSP-004); or
configuration as follows:
angle inside
i. Disconnect and remove pressure switch from
plenum chamber. (Refer to CSP-004.)
2. Remove lockwire and three retaining screws; carefully separate

switch body halves; remove switch diaphragm-magnet assembly
and diaphragm return spring. (See Figure 3,)
NOTICE NO.
DATE 15
DN-42. 2~e
September 1980
E) Hushb Helicopters
PAGE 6 OF 13
3. Clean both body halves of any dust or debris.
4. Install new diaphragm-magnet assembly in cavity of switch

b ody wi th thr ead ed por t. The diaphragm-magnet assembly
should be placed in the cavity with magnet facing up as shown.
5. Install new diaphragm return spring on spring centering boss

of diaphragm-magnet assembly.
6. Carefully lower remaining half of switch body onto the partial

assembly; check that magnet and diaphragm return spring are
centered in their proper bores.
7. Before bringing the two switch

body halves completely together,
carefully rotate either body half to align the three ietaining
screw holes. After proper alignment, check the diaphragm to
ensure that it has remained centered in the body cavity, and
that it has not folded or twisted.
8. Install the three retaining screws until snug and install lockwire.
9. Install new nameplate over existing nameplate on switch body.
g. As applicable, perform function test of reworked pressure switch as
follows:
i. Fabricate test set-up per Figure 4 and install reworked switch

as shown.
2. Apply suction source to cycle switch "closed" and "opened

several times. Watch ohmmeter or continuity tester for
indication of switch actuation. Suction may be produced orally
or by use of suction bulb.
3. After cycling switch, apply suction

slowly and note the differ-
ential in water height, from the static height, on both legs of
the U-tube when the ohmmeter or continuity tester indicates
switch actuation.
NOTE
The total of the differential heights of both

legs of the Uitube is equal to the switch
actuation pressure. Switch actuation (closing)
pressure should be 10. 25 to 10. 75 inches H20.
6~ Hueh Helicopte~s NOTICE NO.
DATE 15
DN-52. 2,1(
September 1980
PAGE 7 OF 13
h. Reinstall particle separator filter assembly, per C,$;P-OO4.
i. Remove hardware that is temporarily holding the -11 and -12 fairings
to the aft engine inlet fairing.
j. Reinstall forward engine air inlet fairing assemblies, per HMI-Vol. I;

ensure that hole in -11 and -12 fairings align with nutplate on aft engine inlet
fairing.
k. Record compliance with this Service Information Notice in Compli-

FAA/ DER APPROVED 3 September 1980

NOTICE NO.
DATE 15 September
DN-52. 2~
1980
E~ nueh Hlicopfers
PACE 8 OF 13
A A -12 FAIRING ASSY
L _F/369H90152 PARTICLE SEPARATOR TRIM -12 FAIRING AS RE9UIRED TO CLEAR

EXISTING STRUCTURE IN 3691\3059
TYPFOR INSTLOF-1IFAIRING
-17 SEAL
-23 SEAL D D
3691-190151-41 I C I
r
MOUNTING FRAMEFOR
FILTER I/ 1 I I
AT STA 124.00
TRIM -19 AND -23 SEALS

B
MATCH CONTOURS OF r
369H90151 FAIRINGS
.L. 67.00
3.31
I B.L. 865 RN
369H90151-31
FAIRING
B
STA 3691\3053
SEE DETAIL A 1 124. OD FAIRING
11 FAIRING ASSY
NAS 173884-2 RIVET \-15 SEAL -17 SEAL
3 REQD
-7 SUPPORT
VIEW A-A
SUPPORT SECTION CC SEAL ALL OPENINGS OR
GAPS USING SILASTIC
ROTATED 900 CCW
NO. 732 OR EQUIV.
-11FAIRtlNG ASSY
MOUNTING FRAME FOR
369H90152 FILTER
AT STA 124.00
W.L. 68.36
E
B. L. 8.70 LH
-13 SEAL :j/
-25 SEAL
-5 SUPPORT
1. 25
APPLY SILASTIC NO. 732 OR/ L

EQU IV. BETWEEN FLANGE OF E ALL OPENINGS OR
FAIRING AND 369H3003
NAS 173884-2 RIVET GAPS USING SILASTIC
2REQD NO.7320REQUIV.
DRILL 369A305310 STA
MATCHHOLESINSUPPORT 124.00
SECTION B-B DETAIL A
ROTATED 900 CCW TYP FOR INSTL OF -12 FA IRING
88-287-1A
Figure i. Installation of
auxiliary fairings and seals,
particle separator (Sheet 1 of Z)
NOTICE NO. DN-52. 2:!:
Hughas Helicoptar~ DATE 15 September 1980
PAGE 9 OF 13
-4 FAIRING FOR -12 ASSY (NOTE)

3 FAIRING FOR -1IASSY(NOTE)
MS2d470AD2 RIVET(2)
-9PLATE, I,-7SUPPORT
0.19 I-15SEAL
rl
19 369H90151-41
FAIRING
SECTION D-D
2. 03~ ROTATED 1800
35489-19
SPLITGROMMET
APPROX. AS SHOWN
PRIOR TO INSTL.
369[)2301
FITTING
0. 250 DIA THRU

-11 FAIRING ASS
-11 FAIRING ASSY TO
MATCHEXISTING
VIEW E-E NUTPLATE LOCATIONS
ROTATED 900 CCW

TYP FOR INSTL OF -12 FAIRING
NOTE: ASSY
DRILL 0.063 DIA HOLES IN -3 AND--4

FAIRINGS TO MATCH HOLES IN -9 PLATE, 2 PLCS.
88-287-2A
Figure i. Installation of auxiliary fairings and seals,

particle separator (Sheet 2 of 2)
NOTICE NO. DN-52. 2~k
DATE 15 September Iq8Q nugk(n Hllcopten
PAGE 10 OF 13
4.098 DIA 3 PILOT HOLES
3.51
--i
0,31~-;-I 0.12
0.4340T
0.07 0.80
0.68
IML(TYP)
d~L (NP)
4 PLACES
BEND UP X 0.09 R
2PLACES
-7 SUPPORT (FLAT PATTERN)
BEND UP X 0.09 R
0.098 DIA 2 PILOT HOLES, t)--2.

1- 60304PLACES
i-
0.31 \1 0?5
i
0. 07
ITYP)
t I
o.u a,l
0.770. 18
0.40 1
0.37
IML (TYP)
OML
BEND DN X 0.09 R
BEND UP X 0, 09 R
-5 SUPPORT (FLAT PATTERNI
T 0. 19
0.75 0.44T
I
I
-9 PLATE
88-285-1A
Figure 2. Field fabrication auxiliary fairings

and supports (Sheet 1 of2)
Hughes Helicoptars NOTICE NO. DN-52. 2,1:
PAGE 11 OF 13
300~
1.70
i. 56 -t
93
I
2.00
a.B1 a. 12 R 2 PLACES
06 X 450
PLACES
_i
-J D.3i
t
IJ
o. ,-I-- IML
ITYPI
5:63 ZPLACES 1.44
I
2. 13
-f-
1. 06
rOMLi
I
_1(TYF t t_
\L-o. as 2 PLACES
f
0. 92 2 PLACES
0 DN
300 OPEN
X. 12 R
30"
o. 12 R 2PLACES
2PLACES/ BEN00Nx.l2R
ZPLACES
-4 FAIRING IFLAT PATTERN) SHOWN

-3 OPP
88-285-2A
Figure 2. Field fabrication auxiliary fairings

and supports (Sheet 2 of 2)
Hughe~ Helico~ersl
PAGE 12 OF 13
NAMEPLATE
BODY~ I I
SWITCH
DIAPHRAM RETURN
SPRING
IAPHRAM-MAGNET
ASSEMBLY
SWITCH BODY
88-339
Figure 3. Rework of pressure switch to 369A8402-7 configuration

~Hughes Helicopters NOTICE NO,
DATE 15
DN-52. 2:::
September 1980
PAGE 13 OF 13
SUCTION
SOURCE
HOSE TEE
OHMN\ETER
OR
CONTINUITY TESTER
121N.
SCALE
121N.
STRAIGHT
SECTIONI 6 IN. H20

STATIC HEIGHT
TYGONTUBING(OREPUIV.)
BENT IN SHAPE AS SHOWN
AND FILLED WITH H?O TO STATIC
HEIGHT AS SHOWN.~
88-)40
Figure 4. Function test switch reworked to

369A8402-7 configuration
H~ylhes Helicopters
TO: Hughes Helicopters

Centinela and Teale St.
Culver City, CA 90230
Attn: Customer Service Department

Bldg. 15, TZ06
This is tocertify that dust boots have been installed; one between the tail rotor
gearbox and nonrotating swashplate and on- between the rotating swashplate
and fork.
The modification was accomplished on Hughes Model 369D Helicopter/s on the

date/s noted.
Serial Number Date
Serial Number Date
Serial Number Date
Serial Number Date
Serial Number Date
Serial Number Date
Signature Title
Company/Organi zation
Complete Address
Hughes Helicoptera
REFERENCE SHEET
maintenance inspection of engine air

kit installation, refer to Service

filter particle separator
Information Notice No. DN-42. 2.
HMI Reference: Insert this sheet in Publication No. CSP-OO4, Optional

Equipment Manual, Section 2, page 2-1.
This reference sheet: shall be kept as a part of the manual
until the data is incorporated at the next revision of
Publication No. CSP-004.

DN- 54. 1~
HUQ~iBQES NOTICE NC.
DATE 7 March: 1980

gN PAGE 1 OF
6
9~ ~ST [I E Service Information

~Supersedes
Notice No. DN-54, dated
,,1- B~P-l1
t\JIAIIIL1)B.PBRV---
SUBJECT: INSPECTION COLLECTIVE TORQUE TUBE SUPPORT BRACKET

(PN 369A7304 MAGNESIUM, PN 369NZ608 ALUMINUM) AND COLLECTIV
BUNGEE SUPPORT BRACKET (PN 369A7339 MAGNESIUM, PN 369N265
A LUMINUM
MODELS AFFECTED: 500D Model 369D Helicopter Serial No. 0003D thru 0642D;
0646D thru 0654D; 0646D; 0663D thru 0671D; 0684D thru
0687D; 0692D thru 0701D.
TIME OF COMPLIANCE: Shall be accomplished at next 100-Hour Periodic
Inspection inte rval.
for a one-time inspection of the subject support brackets for evidence of
cracks, gouges or other visible damage in the attach lug areas; and for
gaps between the bracket and

cradle cap of the collective torque tube
s upport b rac ke t. Also included is an inspection of the collective bungee
support bracket to ensure that thickness of the machine web surface in

the aft lug of the bracket; is 0. 065 inch or more.
I
area
I Reference
400D Basic HMI-Volume I, Issued 15 September 1976; Revision No. 3, 14 March 1979.
Form P578
FORW NO HTC*D REV 11-67
D-N-54. 1:~
NO:TlCE NO.
DPi;TE 7~ ~arcB 1980
E) Huclhes Helicoater~
P~,GE 2OF 6
MA. TE R IA LS
Primer, aine chromate MIL-P-8585 Co mmerc ia I
TOOLS A.ND EQUIPMENT
Gage, feeler 0. 001 0. 002 inch thickness or
Probe, thin blade edge
Mirror dental or equivalent
Drill bit No. F (0.247 inch diameter)
Bolt, square ends 0. 240. inch diameter; min length 1.25 inches
Micrometer, depth
a. Remove collective control cover or center seat panel to gain access to
collective bungee.
b;. Us:ing mirror and bright light, visually inspect aft lug areas of
collective bungee support: bracket,, and collective torque tube support: bracket.
and cradle cap for cracks, gouges, nicks or other surface damage, Replace
bracket if any cracking is noted. Smooth and blend minor gouges, nicks, etc.
cougesj de:eper than 0. 060 inch require replacement of support bracket. CSee
Figures 1 and: 2. Gouges deeper than machine cut in web areas of bungee
support bracket: require replacement of bracket. (See Figure 2.)
c. Using feeler gage or thin blade as probe, check for gaps between
torque tube support bracket and cradle cap. Pay particular attention for
gaps at mating area of bracket and cap next to OD of torque tube bearing.
(See Figure i.
NOTICE NO. DN-54. l::c
Hughes Helicopters
DATE
PAGE 3 OF 6
NOTE
loosen cradle cap and

If gap(s) exist, or remove
remove all zinc chromate residue from ID of

tube
cradle cap and support bracket, and torque
Apply new coat of zinc chromate
OD mating surface.
on OD of tube bearing and ID of support
torque
primer
bracket: and cradle cap. Reinstall cradle cap while
is wet. Check that cap-to-cradle index grooves
primer
are matched. Reinspect for gaps between cradle cap
and support bracket: mating surfaces.
depth of machine cut between the

d. Using depth micrometer, measure
aft lugs of bungee support bracket. (See Figure 2.
NOTE
i. If depth of machine cut is 0. 034 inch or less,

no further action is required; perform steps
and k.
of machine cut is than 0. 035 inch,

2. If depth more
determine thickness of machined web surface

as follows.
machined
e.Drill 0.257 inch diameter hole in bracket on side opposite
0. 63 inch forward from centerline of lug bolt: hole,
web surface, and 0. 50
as shown.
f. Fabricate measuring pin from 0.240 inch diameter bolt with squared
inches.
ends; minimum length of bolt is 1.24
of pin; record dimension "A"

g. Measure length as
h. Insert and seat pin in 0.247 inch diameter hole in bungee support
and outer
bracket; measure distance between machined web exterior surface
end of pin; record as dimension "B"
to obtain thickness of
i. Subtsact dimension "A" from dimension "B"
machined web surface.
NOTE
If thickness of machined web is less than

0. 065 inch, replace bungee support bracket.
Prior to installation of replacement bracket,
measure depth of machine cut between bracket
lugs, per step d above.
NOTICE NO. DN-54. 1~(
DATE 7 March 1980
Hugho Hblico~ers
PAGE 4 OF 6
j. Reinstall center seat panel or controls cover.
k. Record compliance with this Service Information Notice in Compliance

FAA APPROVED
NOTICE NO. DN- 54. I)le
Hughas Helicopten DATE 7 March 1980
PAGE 5 OF h
LOLL[:CT!~I CDII:ROLS
SUPPORI RIIACKET ASSTMRIY
CRADLE CAP
(NOIE 1)
(NOTE 2)h CCCY 2)
COLLECTIVE TOROUE TUBE

SUPPORT BRACKET (NOTE 1)
o~O
VIEW C-C
O
O
NOTES:
i, PAY PARTICULAR ATTENTION TO

ATTACH LUG AREAS FOR CRACKS,
2, CHECK FOR GAPS BETWEEN CRADLE

CAP AND BRACKET;PAY PARTICULAR
ATTENTION TO MATING AREA NEXT TO
TORGIUE TUBE O,D, FOR GAPS,
88-3115
Figure i. Inspection collective torque tube support

bracket and cradle cap
NOTICE NO.
DATE 4 Nlarch 1980
DN-54. l~e
~3 ~ehr Helico~n
PAGE 6 OF 6
oi ~O o
\9
COLLECTIVE STICK BUNGEE
Q SUPPORT BRACKET ASSEMBLY
ROTATED
(NOTE 3) 0,257 INCH DIA HOLE

COLLECTIVE
BUNGE I\ ~m
ORI11 0.257 DIA
THIS WEB ONLY
3~PORT
BPRCKE:
P "81
t O (NOTE 1) (NOTE 1)
0,035 MAX (NOTE P)
MEASURING PIN
MACHINED WEB
EXTERIOR SURFACE ~EB EXTERIOR
THICKNESS OF WEB AT
MACHINED SURFACE
MACHINED SURFACE 0,065 EOLLECTIVE BUNGEE
SUPPORT BRACKET
MINIMUM
O
YIEW C-C METHOD OF MEASURING IHICKNESS
METHOD OF MEASURING THICKNESS OF MACHINED WEB P/N 369A7339
OF MACHINED WEB P/N 369A7339
NOTESI
i, CHECK LUG AREAS FOR CRACKS,

NICKS,GOUGES,SURFACE DAMAGE,
2, IF DEPTH IS GREATER THAN 0,035,
CHECK THICKNESS REMAINING AS SHOWN,
3, MAKE PIN FROM 0,250 BOLT,SQUARE
ENDS,MINIMUM LENGTH 3,25,
4, ALL DIMENSIONS IN INCHES,
Figure 2. Inspection of collective bungee support bracket

NOTICE NC. DN-55
HUGHES DATE 20 August 1979

NOTICE
SUBJECT: REWORK OF GROUND HANDLING WHEEL ASSEMBLIES (FLOAT TYPE)
MODELS AFFECTED: All float type ground handling wheel assemblies not equipped
with wheel fender guards$
PREFACE: Field reports indicate that chafing and damage to and/or shearing
floats,
of the bolts attaching the floats and gravel guards landing gear
to the
skids, have occurred when using early t~pe ground handling wheel
assemblies that do not have protective fender guards.
The information given in this Notice lists instructions for reworking the
early float type ground handling wheel assemblies, to add wheel fender
guards and protective padding to help prevent handling damage.
~eIt is to be noted that PN 3691-190126-1 and -2 ground handling wheel

the wheel fender guards and padding and do
assemblies incorporate
not require rework per this Notice.
Reference
500D Basic HMI-Volume I, Issued 15 September 1976; Revision No. 3, 15 March 1979.
FORn NO 9~78* HTC*D REV 11-67

NOTICE NO. DN-55
DATE 20 August 1979 Hughe~ Helicoptero
PAGE 2 OF 3
MA TERIALS
Neoprene rubber sheet 0. 12 x 2. 50 x 16.50 Commercial

Rubber cement Grip Taylor Industry
Lockbond Industrial Rubber
Cement Co.
EC1300L 3M Co.
Al Aly Sheet (2)- 0. 092 x 2. 50 x 6.00 6061-O;aa-A-25111; Temp O

Al Aly Sheet (2)- 0. 093 x 3.25 x 6. 00 6061-O;QQ-A-25/11; Temp 0
TOOLS AND EQUIPMENT
Welding equipment
Shears or saw, metal cutting
Grinder, portable
REWORK OF GROUND HANDLING WHEELS
a. Fabricate fender guards (2) and supports (2) per dimensions shown in
Figure 1; bend supports 30 degrees as shown; weld supports to fender guards.
b. Cut off existing channel to 0.75 inch dimension shown.
c. Weld fender guard assemblies in place on wheel assembly.
d. Clean channel and bond neoprene rubber sheet to channel.
e. Grind off burrs or sharp edges on fender guards and channel.

NOTICE NO. DN-55
E~ Hueh HlicOpter DATE

PAGE 3 OF 3
20 August 1979
nEOPRtNt
I~NOER(V RLOUIREO)
IHRNNLL
~P APPROXIIATtLY TO
0.12 TliilK nEDPRENE RUBBER
10 FENDER GURRD EENDER(Z REBUIREO)
CLEAR5
LINER nonn iN pmlt
i.iO LENGTH iLAT

(APPROXIMATLLY)~
uiu
wEUI\ BUPPORT
r6 111 11 SUPPOR
o.li lUToFi rHnaNEL
THIT OIMENSION
cT~
Figure i. Rework of Ground Handling Wheel Assemblies

NOTICE NC. DN-56
HUGHES DATE 7 March 1980

pace 1 OF
NOTICE
SUBJECT: INSTALLATION OF FUSELAGE ACCESS PANELS FOR CYCLIC

TRIM AC TUATOR ASSEMBLIES
TIME OF COMPLIANCE: At and

owners operators discretion
PREFACE: ?he information given in this Service Information Notice lists

instructions for rework of the helicopter lower fuselage section
and installation of two access panels to facilitate removal,
inspection, maintenance, etc of the cyclic trim actuator assemblies.
Refer ence
500D Basic HMI-Vol I, Issued 14 September 1976; Revision No. 3, 15 March 1979
Transponder Installation Instructions (KT-76), Publication No. CSP-012
Automatic Direction Finder Installation Instructions, (KR-85), Publication No. CSP-O1
Automatic Direction Finder Installation Instructions, (KR-86), Publication No. CSP-O1
FORY NO Pa78L~ HTC *D REV 11-67

NOTICE NO. DN-56
Hughes Helicopters
DATE 7 March 1980
PAGE 2 OF 7
PA R TS LIS T
I Door Assembly (LM) 369D22501-11 1 HH

Door As sembly (RH) 369D22501-21 1 HH
Doubler 3 69H2 5 00 41 1 HH
Doubler 369H2500-43 1 HH
~e Washer AN960C416L 2 Comma re ial
)k~e Washer AN960C8 8 Commercial
Rivet MS20470AD3 A/R Comme ial
re
Nutplate MS2 1 076L4 2 Co mme re ia 1

Screw NAS 6 02 7P 8 C omme r c ial
Sc rew NAS604-6P 2 Comme rcial
Nutpiace NAS697C08M 8 C omme re ial
Not required if ADF loop antenna installed.

::s 4 ADF
required if loop antenna installed.
TOOLS AND EQUIPME NT
Shears, metal cutting
Gun, rivet
Drill bit No. 41 (0. 096 inch dial

Drill bit No. 5/16 (0. 311/0. 318 inch dial
Drill bit No. 11/64 (0. 169/0. 174 inch dial
::C):C~ Flycutter hole

or punch (0.74 inch dial
Required if transponder antenna installed.
MA TE R IA LS
Sealing Compound MIL-S-7502 PR-1221 Product

Research
Burbank, CA
Sealant MIL-S-8802 ProSeal Coast Pro Seal
890 Compton, CA
NOTICE NO. DN-56
Hughe. Helicopters DATE 7 March 1980
PAGE 3 OF 7
PROCEDURE
a. Gain access to pilots underfloor compartment (Section 2, HMI-Vol I.
b. helicopter to provide access

Jack up to work area at underside of
fuselage structure. (Section 2, HMI-Vol I.
NOTE
If ADF or transponder antenna is
installed, remove antenna per
referenced instructions (page 1.
c. Drill out rivets securing 369A2500-163 stiffener and 369A2500-169

doubler(see Figure I). Drill out rivets securing 369A2500-164 stiffener and
369A2500-169 doubler. Drill out rivets securing 369A2500-165 doubler.
Remove doublers and stiffeners; remove any sealing compound residue.
d. Drill out: rivetssecuring 369A2500-9 stiffener, 369A2500-10 stiffener,

and 369A2524 center beam assembly to fuselage skin between Station 60. 73
and Station 74. 287 as shown in Figure 2. Remove any sealing compound
residue.
NOTE
Read step 1 below (criteria for reinstalling

rivets in existing holes) completely, before
drilling or riveting per steps through k,
e
since the number and placement of rivets to

be installed may have to be altered accordingly.
e. Insert:369D22501-43 doubler (RH) in position between -10 stiffener

and 3691-12524 center beam assembly, and fuselage skin. Mark rivet: hole
centers on doubler; remove doubler and drill rivet holes.
f. 369D22501-41 doubler (LH) in position between -9 stiffener

Insert
and 369H2524 center beam assembly, and fuselage skin. Mark rivet hole
centers on doubler; also mark hole centers on doubler for two existing
0. 311/0. 318 inch diameter holes in fuselage skin. Remove -41 doubler;
drill rivet holes and two 0. 311/0/318 inch diameter holes In doubler.
NOTICE NO. DN-56
Hughes Wellcoptars
DATE 7 March 1980
PAGE 4 OF 7
g. Position 369D22501-21 door on -43 doubler; mark and drill four

0. 169/0. 175 inch diameter holes and eight 0. 096 inch diameter rivet holes
in doubler for nutplates. Install four NAS697C08M nutplates on upper side
of doubler as shown. Drill fourteen 0. 096 inch diameter rivet holes in
doubler around circumference of cutout as shown.
h. Position 369D22501-11 door on -41 doubler; mark and drill four
0. 169/0. 175 inch diameter, 096 inch diameter rivet: holes for six
and 0.
nutplate s. Install four NAS697C08M nutplates and two MS2 1 076L4 nutplate s
on upper side of doubler as shown. Drill sixteen 0. 096 inch diameter rivet
holes in doubler around circumference of cutout as shown.
i. Using doublers as templates, mark and make cutouts in fuselage

skin to match doublers as shown. Drill four 0. 169/0. 174 inch diameter holes
in skin to match nutplate holes in doublers, as applicable. Also, cut or drill
0. 75 inch diameter hole thru skin to match -41 houbler if transponder antenna
is to be installed. Drill 0. 096 inch diameter rivet: holes in skin to match
rivet: around circumference of each cutout as shown.
j. Insert -43 doubler in place between -10 stiffener and center beam
assembly, and fuselage skin; secure with rivets 34 places as shown; install
additional rivets 14 places around circumference of cutout.
k. Insert -41 doubler in

place between -9 stiffener and center beam
assembly, and fuselage skin; secure with rivets 39 places as shown; install
additional rivets 16 places around circumference of cutout.
i. Where removed in step d above, replace rivets as required to secure

stiffeners and center beam assembly fuselage skin between Station 60. 73
to
and Station 74. 287. Also, install rivets (through both skin and doubler) to
plug any open rivet holes th&t exist in skin due to step c above, follow ing
criteria specified below:
i. Rivets reinstalled in existing holes must NOT be closer than

1.5 x diameter ledge distance) minimum from edge of applicable
parts involved. If this criteria cannot be met, leave rivet hole
in skin blank and fill in with ProSeal 890 sealant.
2. Rivets reinstalled in existing holes must NOT be closer than

3. 0 x diameter (rivet: spacing) minimum from location of any
new rivet added per this installation. If this criteria cannot
be met, install ONLY the rivet: through the existing hole in
the structure and eliminate the new rivet intended.for this
location.
NOTICE NO. DN-56
Hughe~ Hallco~ers
DATE 7 March 1980
PAGE 5 OF 7
m. Apply a 0. 06 inch bead of PR1221 sealant on inside skin surface at
stiffeners and center beam assembly; apply a 0. 03 inch bead of sealant at

doubler attachments.
NOTE
Perform step n below if AD% antenna

is not to be installed.
n. Install two NAS604-6P screws and AN960C416L washers as plugs in
MS21076L4 nutplates on LH side installation as shown.
o. Install door(s) using NAS602-7P screws and AN960C8 washers.

access
The PN 369D22501-11 door (LH) and its attaching hardware to be eliminated

if antenna is to be installed.
p. Check installation of doublers and access doors for discrepancies.
NOTE
Paint access door(s) to match exterior
finish of helicopter, if desired.
q. As applicable, install ADF or transponder antenna, per referenced

instructions.
Weight and balance change negligible.
FAA APPROVED
~dcz
~pC
o~,
02
r~e
3C
rZ
s
CENTER BEAM ~-n 03 cn
KR80 LOOP AFmNNA
;t
BLO.
STA
ti 61.m ~f?
-t
AOs R(VET AO~RIYEI ~O
(REMOVE 4 PLCS IREMOVE 24 PtCS)
J
-t
f\ II f _C 369A25m-1M ill
STIFFENER
3691\2500-163
3-
d)
STIFFEMR-, I I I ill r
BL 275 1 I r x
_
ye /X~L_X\ ii I 111 =s
ILH SIDE)
169
II/ OOUBLER
ii I IC 369H2508
FRAME CANTED
O
STITION7g50
R\VET
IREMOVE 7 PLCS PIP) DOUBLER
CI
i I -e
--I- I i-i-
CANT
STA STA
60.73 6~365 SjA
74. 287
F~igure i. Removal of stiffeners and doublers

10 STIFFENER
f f f +_ t i-f;f
TOOLING 1NAS697C08M NUTPLATE (8)
HOLE u MSM470AD3 RIVET 116)
STA
0. 169/0. !75 DIA-
FUSELAGE 369H2500-43
65.00
i369D2501-21
DOOR (RH)
(TYP 8 PLCS)
0.096 DIA
iiO L
SKIN~ DOUBLER (RH)

t
(NP 16 PLCS)
BL(RH)
3.55
I
(NOTE 2)
n
1 I II -11 ~rllTnllT
0.096DIA
1 II1 IN SKIN (TYP 14 PLCS)
369H2524
CENTER tl RIVETS (TYPI
(NOiE 1)
t
iff m
L
F
tT f
BL 0.00---
1
i
-C i; t t t i L
f t t
t cn
TOOLING i- i s
HOLE--~-O (D
a
FWD L
096 DIA C
MS21076L4
!T~P16PLCSI 0. 750 DIAMETER ge
NUTPLATE (2)
i a)
VIEW LOOKING DOWN I MS20470AD3

RIVET
i
I iN SKIN
J(T ti
-(NOTE 21
t
BL(LH) a,
369A2515-25 (REF)
LL 4.02
__t~i I---
DOUBLER
0.31110.318 DIA
r
NAS t04-bP SCREW (2) tll d tr
(NOTE 1) 3691322501-11 AN960C416L WASHER (2)
O I II
DOOR (LH) (NOTE 3)
i
I i
mM
T
L
C1
_
369DZ5M1-9 STA 0]
STI 64.73
r
NOTES: 5:P
i. APPLY 0. 06 BEAD SEALANT ON INSIDE SKIN SURFACE AT STIFFENERS AND CENTER BEAM ASSEMBLY
C~
2. APPLY 0. 03 BEAD SEALANT AT DOUBLER ATTACHMENTS STA 2:
STA
74. 287 i
60.73 3. INSTALL SCREWSIWASHERS IF ADF ANTENNA NOT INSTALLED.
rLn
90
Figure 2. Installation of trim actuator assembly access panels

NOTICE NC. DN-58. 23~C
HUGHES 11
May_1981 DATE
PAGE OF 1
NOTICE ~Supersedes Service Information
Dated Notice No. DN-58.1,
2 September 1980
MAN DATORY MANDATORY I I-~--I --~-I MANDATORY
SUBJECT: INSPECTION AND REPAIR OF AFT FUSELAGE SKIN CRACKS;

INSTALLATION OF DOUBLERS ON BOOM FAIRING LOWER LONGERONS
MODELS AFFECTED: 500D Model 369D Helicopter SerialNo. 0003D thru 05291)
P"rt I Visual Inspection Shall be accomplished within

TIME OF COMPLIANCE:
next 50 hours of helicopter operation, and at each
50-hour inspection interval until compliance with
Part II of this Notice is accomplished.
Part II Field Modification Shall be accomplished as
required per Part I, or at next removal of engine,

or within next 600 hours of helicopter operation,
whichever occurs first.
PREFACE: Field reports indicate that incidents of cracking of the aft fuselage skin
lower longerons.
has occurred in the area adjacent to the boom fairing
This area is noncritical for either static or fatigue loads.
Part I of this Notice lists a procedure for a periodic visual inspection

of the aft fuselage skin for evidence of skin cracking at the boom fairing
and aft engine air inlet fairing attach areas.
Part II of this Notice provides instructions for repair of skin cracks in
of support
the aft fuselage skin, as applicable; and for installation
doublers on the boom fairing lower longerons to preclude skin cracking.
Performance of Part II is to be accomplished if cracking is noted during

the Part I inspection, or at next removal of engine, or within the next
600 hours of helicopter operation; whichever occurs first.
Compliance with Part II lifts the periodic inspection requirement speci-

fied in Part I of this Notice.
Denotes portion of text added revised

(I) or
Customer Service Deptlrtment
Foam 8578 (2/81)

NOTICE NO. DN-58. 2
DATE 11 May 1981
PACE: 2 OF 5
Reference
500D Basic HMI-- Volume I, Issued 15 September 1976; Revision No. 3,

15 March 1979.
500D Basic HMI-- Volume II, Issued 15 September 1976; Revision No. 2,
1 November 1978.
500D HMI Structural Repair Manual(369D-SR1LI) CSP-D-6, Issued
15 September 1976.
PARTS LIST
Nomenclature Part No. Qt;v. Mfr.
Doubler 369D23018-136812-3 1 HH
Doubler 369D23018-136812-4 1 HH
Shim 3 69D23 018 13 6812 5 2 HH
Shim 36 9D23018-136812-7 2 HH
Rivet NAS 173 8134- 2 A/R Commercial
Rivet NA S173 8B4 3 A/R Commercial
NAS1738B5-2 A/R Commercial
)k~Rivet NA S 1 73 8 B 5 3 A/R Co mme r c ial
295097 A/R HH
t~Oversize rivet.
required unless damaged during removal of firewall/heat

blanket.
MA TERIA LS
Primer, zinc chromate 908-L-02110 GZidden-Durkee Div.,

(TT-P-1757) SCM Corp.
900 Union Commerce Bldg.
Cleveland, Ohio 44115
1063-166 E. I. DuPont de Nemours Co.
3500 Grays Ferry Ave.
Philadelphia, PA 19146
Tape, aluminum foil No. 425 3M Co.

Drill bit No. 30
Drill bit-- No. 31
Cleco fasteners
E) HUahI Welicapters NOTICE NO. DN-58. 2
DATE 11May 1981
PACE 3 OF 5
PART I PERIODIC INSPECTION (50 HOUR INTERVALS)
a. Visually inspect fuselage exterior skin for evidence of

upper aft
air inlet fairing.
cracking at junction of skin with boom fairing and aft engine
Use bright light and mirror. Remove inspection panel in boom fairing.
NOTE
i. If cracking is noted, perform Part II
of this Notice.
2. If cracking is noted, install inspection

no
panel and perform stepb below.

b. Record compliance with Part I of this Notice in Compliance Record

PART II FIELD MO6IFICATION
NOTE
Removal of engine is recommended to facilitate
field modification. (Refer to Hh/II Vol I.
a. Remove fasteners securing aft fuselage heat blanket/firewall; displace

heat blanket: to gain access to work area at boom fairing lower longerons, LH
and RH sides.
NOTE
If cracks were noted in aft fuselage skin
during inspection per Part I of this Notice,

repair cracks by stop drilling and/or patching
per FAA AC 43. 13-1A,
Aircraft Inspection
and repair.
b.Drill out existing rivets securing 369D23018-1 and -2 boom fairing

00 and
lower longerons to fuselage structure and skin, between Station 129,
Station 149. OO,:as shown in Figure i.
c. Position and nest -3 and -4 doublers in place inlongerons; mark and

drill rivet holes in doublers to match rivet pattern in longerons,
NOTE
If rivets are in radius of -3 or -4 doublers,
relocate rivet adjacent to problem hole
(approximately 3. 5 x rivet diameter spacing)

and maintain a minimum of i. 5 x rivet diameter
edge distance on 369D23018 longeron.

NOTICE NO. DN-58. 2
DATE 11May 1981
E) nuclhe~
PAGE 4 OF 5
NOTE
For Model 369MD (Military) Helicopters

equipped with Black Hole Ocarina (BHO)
Infrared Suppressor System, trim up to
3. OO:inches (maximum) on No. 136812-7
shim on installation
(See Figure i.
d. Install doublers temporarily on longerons with Cleco fasteners or

equivalent. Position 14 and -7 shims in place on each doubler as shown.
Mark and drill rivet holes in doublers and shims. Install shims to doublers
with NAS1738B4 rivets; install rivets with wet zinc
chromate primer.
e. Remove Cleco fasteners and install doublers with NAS1738B4

rivets.
Rivets may be installed from inside or outside
engine compartment; install
rivets with wet zinc chromate primer.
f. Remove all debris from work area;

inspect modification of longerons
for discrepancies.
g. Reinstall heat blanket/firewall with existing fasteners.
h. Record compliance with Part II of this Notice in

Compliance Record
NOTE
Compliance with Part II of this Notice lifts

inspection requirements per Part I of this
Notice.
ADD: 0.9 at 138,7 inch-arm
FAA/DER APPROVED 14 May 1981

Hughe~ NOTICE NO. DN-58, 2
DATE 11May 1981
PACE 4 OF 5
NAS1738B4 RIVET
oOO
NAS1738Bll RIVET o
O
---t c
o, c
o-c
o O,--t t
O
o
~---e
0,0----~-5
f
000
o o__-- C --3 oo
MRX
I
i
++r+f+C.i.
__-------/
VIEW LOOKING DOWN

136812-7 STA
SHIM 2 REQ 129,00
136812-5A
SHIM 2 REQ
136812-3 DOUBLER SHOWN

130,00
136812-4 DOUBLER OPPOSITE

136,00
STA
129,00
NAS1738B4 RIVET
A
I i
STA
1 369023018-1 LONGERON SHOWN
1112,00
369D23O18-2 LONGERON OPPOSITE
STA
ML FAIRING 136,00 1
136812-3 DOUBLER REF r
136812-4 DOUBLER REF 136812-5 -WL 50, -1116,62
SHI~ e-,
STA STA
ML FUSELAGE-- 137,00 142,00 o-2
VIEW LOOKING INBOARD

136812-7
STA
SHIM (NOTE)
146,62
369D23018-1 LONGERON STA

STA
369023018-2 LONGERON 149.00
1119.00
A-A
NOTE:
TRIM UP TO 3,00 IIICHES ~AXIMUM AC SHOWN

ON SHIM NO,136812-7, FOR 369nU HELICOPTER
EOUIPPED WITH INFRARED SUPPRESSOR SYSTEM,
88-~
Figure 1. Field Modification 369D23018-1 and

-2 Boom Fairing Longerons
c-
5~ Huehl Hellcopfers
REFERENCE SHEET
Action Refer enc e When performing Special Inspection (every other 25

hours), refer to Service Information Notice
No. DN-58. 2 for inspection, repair and rework of aft
fuselage skin area.
HMI Reference: Insert this sheet in HMI-Volume II, Section 2, Table

2-3 Special Inspections, Every 25 Hours, Page 2-16.
This reference sheet shall be kept as a part of the

manual until the data is incorporated at the next re-
vision on HMI-Volume II. Refer to Service Informa-

tion Summary, HMI-Vol II, page i.
NOTICE NC. .1~N-59
HUGHES DATE 15 January %980

SERVICE INFORMATION PAGE 1 OF_ 5
NOTICE
ASSEMBLIES,
SUBJECT: INSTALLATION OF CABIN HEAT DUCT (FIBERCLASS)
pN 369D22009-101 AND PN 369D22004-103
0660D
equipped with PN 3691190020-517 Heating System
COMPLIANCE: At owners and operators discretion, when duct replacement

TIME OF
is required
in this Service Information Notice lists

instructions
PREFACE: The information given
heat duct,
for replacement of the existing Lexan-type cabin
PN 369H92475-83 or fiberglass-type cabin heat duct,
-107, with a new
PN 37 9D22 009- 1 01 The fiberglass duct configuration is designed to

deformation and wear.
provide greater resistance against heat,
It is to be noted that the PN3691-14535-7 and 369H4535-9 control cable

duct are also
assemblies utilized with the existing PN 3691-192475-107
duct assembly. For
to be used with the new, 369D22009-101 fiberglass
with 3691-192475-83 duct
369D helicopter Serial No. 0003D throuah 0330D
the existing 369H4534-3 and 5 control cable assemblies must
installed,
reworiced per this Notice to the 369H4535-7 and -9 con-
be replaced, or
duct installation.
figurations, to be compatible with the new fiberglass
Instructions are also provided for replacement of PN 369H92475-31
lower duct with a new fiberglass duct assem-
or -101 lexan cabin heat
bly, PN 369D22009-103.
Reference
Issued 15 3, 14 March 1979

September 1974; Revision No.
500D Basic HMI-Volume I,
for PN 369H90020-417,
Illustrated Parts List and Maintenance Instructions
Publication No. GSP-013, Issued 15 August 1976
FORY NO 9178~ HTt*D REV 11~67

NOTICE NO. DN-59
Hughes Helicopters
DATE: 15 January 1980
PAGE: 2 of 5
PARTS LIST
Duct, cabin heat 369D22009-101 1 HH
Duct, cabin heat 369D22009-103 1 HH
Contr ol As sembly 3 6 91-145 3 4 7~ 1 HH

Cabin Heat
Control Assembly 3 6 91-145 35- 9~ 1 HH

Engine Anti Ic e
::369H4535-3 369H4535-5 control assemblies used with

and
369H92475-83 cabin heat duct assembly
may be reworked
to 369H4535-7 and -9
configurations required for use with
new 369D22009-101 heating duct assembly. See Figure 1
for rework dimensions.
PROCEDURE
a. Remove outer box from PN 369H92475-83 or -107 cabin heat duct and
canopy frame. (Refer to referenced CSP-013.)
b. Remove hardware securing heating and anti-ice control cable assem-

blies to heat duct; heat duct
remove
assembly. Remove existing
PN 369H92474-31 or -101 cabin heat (lower) duct assembly. (See Figure i.)
NOTE
i. If PN 369H92474-83 heat duct was installed,

rework existing PN 369H4535-3 and -5
control cable assemblies to new 369H4535-7
and -9 configurations below.
per step c
2. If PN 369H92475-107 heat duct was installed,

rework of existing 369H4535-7 and -9 con-
trol cable assemblies is riot
required.
c. Using file or equivalent, rework control handle shafts to provide

detents, per dimensions shown in Figure 1.
d. Install PN 369D22009-103
new and 369D22009-101 fiberglass heat
duct assemblies.
NOTICE NO. DN-59
Hughes Hslieoptars
PACE: 3 of 5
e. Install control cable assemblies to new -101 duct assembly; secure
retainers with hardware as shown.

clamps and position
f. Adjust spring plunger in position retainers so that 5 to 8pounds of

and -9 controls out of locked position
force is required to pull 369H4535-7
in detents.
g. Remove aft bulkhead access cover; open plenum chamber access
to Section 2 of Basic HMI Volume I.

door. (Refer
NOTE
Performance of step h below required only

if PN 369H4535-3 and -4 control assemblies
were originally installed.
h. Adjust preload of new PN 3691-14535-7 and -9 control assemblies as
follows: (See Figure 1.)
i. Remove clevis from lever of applicable valve and loosen jam

nut above clevis.
2. With handle of 369114535-7 or -9 control assembly in CLOSED

control cable clevis to initially align holes in
position, adjust
clevis and valve lever.
has been made, turn clevis 1 to 2 turns,

3. After initial adjustment
in extension, to achieve offset as shown.
4. Tighten jam nut and install clevis pin.
i. Perform operational check of heating system, per referenced
CSP-013. Reinstall aft bulkhead access cover and interior trim.
Perform operational check of anti-icing system, per Section 11 of

j.
chamber door.
Basic HMI-Volume I. Close plenum access
PN 369D22009-45 with hardware as shown.

k. Install new cover
FAA APPROVED
NOTICE NO. DN-59
Hughes Helicopters
PACE: 4 of 5
SFSW6C12DLO18K SCREW
2 REQUIRED (NOTE 1)
SFSW6C12DL018K i 1~9,80
SCREW 2 REQUIRED 1,50
I
C B
NAS1738-B~ RIVET NOTE 2)
4 REQUIRED (OR EQUIV,) D
U"
a.llo.3~ I ~-IA o.sr
1: 0,98
(NOTE 3)
D C B
t
1, 369022009-45 COVER
369D22009-51
A
DUCT ASSEMBLY
At~t
369028059-13 POSITION RETAINER
369H~535-7 CONTROL ASSEMBLY (REF)
369822009-115 COVER (REF)
369H92475-91 ANGLE
iP
MS2O117O113 RIVET
NAS620C3 WASHER
369022009-51 DUCT ASSEMBLY (REF)----t) 1 101) ,2PLACES
369H921175-103 359H921175-109 CLIP (REF)

ANGLE
369H4535-9 CONTROL
ASSEMBLY (REF) 369028059-11 POSITION I I~RFN 100 x 0.38 DIA,
RETAINER U BLACK TUBING (REF)
A-A
369022009-51 369022009-31 CLAMP ASSEMLBY
DUCT ASSEMBLY (REF) 369022009-45
2 REQUIRED
COVER
(REF)0,6 (TYP)
0,66
359022009-31 CLAMP ASSEMBLY

2 REQUIRED
DD CC B-B
NOTES:
i, 0,165 2, 0,165 ii, 369H92475-109 CLIP RFN 100 x 0,38

DIAMETER HOLE TO MATCH HOLES
0,177 0,177 DIAMETER HOLE TO MATCH HOLES DIAMETER BLACK TUBING,
IN 369022009-5 BLOCK AND IN 369022009-31 AND 369022009-41
369028059-11 AND 369028059-13 POSITION CLAMP ASSEMBLIES II PLACES, 5, 0,250 DIAMETER HOLE THUR 369022009-115
RETAINER 2 PLACES, COVER TO MATCH 369D22OO9-51 DUCT ASSY,
3, NAS620C6 WASHER 8 REQUIRED
INSTALL EXISTING SCREW.
NAS6O1-4P SCREW 8 REQUIRED, 88-352-1
Figure i. Installation of fiberglass cabin heat ducts,

PN 369D22009-101 and -103 (Sheet 1 of 2)
~HughatHelicopters NOTICE NO. DN-59
PAGE: 4 of 5
3,250
-t--1,943
369H4535-7
~t--e
O
i0,630 2.030
369H4535-9
O
0,060 R
0,010
0,020
G-G
TYPICAL FOR DETENTS ON
36984535-7 AND -9
HEATER VALVE LEVER

DE-ICERVALVE LEVER
CLEVIS ON 369H4535-9 IN THE CLOSED POSITION
IN THE CLOSED POSITION
ASSEMBLY
FOR OFFSET SEE PRE-
PRE-LOAD ADJUSTMENT LOAD ADJUSTMENT
WITH THE HANDLE OF THE 369H4535-7
OR -9 In THE CLOSED FOR OFFSET SEE PRE-
POSITION DETENT,ADJUST THE CONTROL LOAD ADJUSTMENT
CABLE CLEVIS TO INITIALLY ALIGN HOLES
IN THE CONTROL CABLE CLEVIS AND THE
VALVE LEVER OF APPLICABLE VALVE, AFTER
INITIAL ADJUSTMENT HAS BEEN MADE,TURN
CLEVIS 1/2 FULL TURNS,IN EXTENSION,TO f CLEVIS ON 369H4535-7
ACHIEVE OFFSET AS SHOWN.TIGHTEN JAM NUT
AHD INSIALL MS20392-2Cll LLNIS PIN Q UINTROL ASgMBLY
O
88-352-2
Figure i. Installation of fiberglass cabin heat ducts,

.PN 369D22009-101 and -103 (Sheet 2 of 2)
NOT\CE NC. DN-60
HU~H ES
E131 i kll
DATE
PAGE 1
3 MARCH 1980
OF 4
MARIDATORYI ~---MA[\IUATORP/
SUBJECT: FILTER GASKE T ENGINE AIR INLET (PARTICLE SEPARATOR)

PN 3691-190148-503, -405 AND -507
FILTER KIT INSTALLATION,
I
ei Helicopters equipped with
MODELS AFFECTED: All s00D Model 369D
j PN 369H90148-403 or -505 Air Inlet (Particle

Separator) Filter Kit Installations
0003D through
500D Model 369D Helicopter SerialNo.
H
0626D equipped with PN 369H90148-507 Air Inlet
(ParticZe Separator) Filter Kit Installation
All PN 369H90148-403, -505 and -507 Particle

Filter Assemblies,
Separator Kits, PN 369H90152-3
Assemblies
and PN 369D290124-11 Particle Separator
in Spares Inventory at date of this Notice
COMPLIANCE: Shall beaccomplished within next 50 hours of

TIME OF
Shall be accomplished prior to installation of

Spares filter kit or filter assembly on helicopter
in this Service Information Notice

lists a procedure
material bonded to the aft side of the PN 369B90152-3
for removal of gasket
in the where the gasket does not
particle separator filter assembly area
The PN 369H90152-3 filter is

contact the helicopter mounting structure.
kit
a component of the PN 369H90148-503
and -505 particle separator
installations.
aft
Instructions are also installing a new filter gasket to the
provided for
side of the PN 369D290125-11 particle separator

assembly, a component
kit installation. The new gas-
of the PN 369H90148-507 particle separator
Helicopters Service Cente
ket will be provided without cost by yOur Hughes
Reference
15 March 1979
500D HMI-Vol I, Issued 15 September 1976; Revision No. 3,
15 September 1976; Revision No. 2,
1 November 1978
500D HMI-Vol II, Issued
Air Inlet (Particle
369D Optional Equipment Installation Instructions, Engine
-507 and -409; CSP-004, Issued
Separator) PN 369H901148-503, -504,
15 November 1979
Customer Service Department Hughes Helicopters CulverCity, California
Furm9578 11-67
FORW NO 91178~ HTt*D REY
NOTICE NO. DN-60
DATE: 3 MARCH 1980 HughMs Helicopters
PAGE: 2 of 4
MA TE RIALS
Gasket Pressure sensitive tape

0. 125 thick x 0.380 width
aApplicable PN 369D290125-11 particle separator assembly (369H90148-507

kit configuration) only. Provided without cost by your Hughes Helicopters
Service Center.
REWORK /INSTALLA TION OF FILTER GASKE T
a. Remove particle separator filter assembly. (Refer to referenced
CSP-OO 4).
b. (For 369H90148-503 and -405 kit installation only) Trim and cut off
gasket seal bonded to aft side of 369H90152-3 filter assembly at lower area
of filter not in contact with helicopter mounting structure. (See Figure 1.)
c. (For 369H90148-507 kit installation only) Install new gasket on aft

side of 369D290125-11 particle separator filter assembly, as shown in
Figure 2.
d. Reinstall particle separator filter assembly.
e. Record corYipliance with this Service Information Notice in Compli-

FAA APPROVED
NOTICE NO. DN-60
E) HUehel Helicol~tan DATE: 3 MARCH 1980
PAGE 3 of 4
MOUNTING
GI\SKET(NOTF 1)
c,
I
AFT ENGINE
AIR INLET
FAIRING
II
LTER
TURF
FILTER
GASKET
StREEN
(NDTE 1)
(TYPICAL)
PARTICLE FILTER
SEPARATOR
IIOTES
1, EXISTING GASKET CONFIGURATION

O11 AFT SIDE OF FILTER, I;-----------:
2, NEW GASKET CONFIGURATION GASKET

CUT AND TRIM OFF LO~IER SECTION (NOTE 2)
AS SHOWN,
88-367
Figure i. Removal of Filter Gasket 369B90148-503

and -505 Filter Installation
NOTICE= NO. ]DN- 60
DATE: 3 MARCH 1980 E) Wueh Helicopten
PAGE 4 of 4
_L
GASKET (NOTES 1 AND
4-
0,380
369D290125-11
PARTICLE SEPARATOR ASSEMBLY
NOTES:
1, INSTALL AS SHOWN ON AFT MOUNTING SIIRFACE OF 369D290125-11

PARTICLE SEPARATOR FILTER PRIOR TO INSTALLATION,
2, PRESSURE SENSITIVE TAPE

88-372
Figure 2. Installation of Filter Casket 369H90148-507

Filter Installation
NOTICE NC. DN-62
R~I E I N F~W
DATE
PAGE 1
3 March
OF
20891
IWAl\1 13A1(4 I\nA~j DA~O RW

M AN L)n rC) F%J
-ac--l-u
F~-----
TRANSMISSION HOUSING
SUBJECT: INSPECTION AND REWORK OF TAIL ROTOR
ASSEMBLY, PN 369D25401
I
Helicopters
ii MODELS AFFECTED: All 500D Model 369D Series
accomplished
Shall be Pt next scheduled Annual or
TIME OF COMPLIANCE:
300-Hour Inspection
1 PREFACE: The information given in this Service Information Notice lists a
for one-time inspection to check for adequate

procedure a
housing and the

clearance between the tail rotor transmission
right pedal travel.
ii tail rotor control bellcrank at extreme
for rework of the housing if interference
Instructions are provided
with the bellcrank is noted.
Reference

400D HMI- Volume I, Issued 15 September 1976;
Revision No. 2, 1 November 1978
500D HRII-Volume II, Issued 15 September 1976;
i:or nl B 5 78
FORM HO 9~78* HTC-*D REV ii-61
NOTICE NO. DN-62
o~
DATE:~ 3 March 1980

Hugh. Hlicoptn.
PAGE 2 of 2
a. Check for contact between tail rotor bellcrank and tail rotor
transmission housing, at extreme right pedal travel.
NO TE
If contact and interference between bellcrank

and housing is noted, perform the following:
i. Chamfer the web on transmission housing,

per dimensions shown in Figure 1 below.
2. Blend chamfer into existing radius at the

bottom and radius it at the tap. Do not
remove excess material; width of chamfer
is 0. 06 to O. 09 inch.
3. Apply surface touchup treatment, per

Section 2 of HMI-Vol I.
b. Record compliance with this Notice in Compliance Record of

helicopter bog Book.
WEIGHT BALANCE DATA
FAA APPROVED
0.35 MIN,
0,09
0,06 X 450- 1,50 R
BLEND INTO
EXISTING
RADIUS 369025401
VIEW A-A
Figure 1. Field rework of tail rotor transmission housing assembly

NOTICE NC. DN-63
HU~MES
~31
DnrE 3 March 1980
R~I E N ~bi PAGE 1 OF 4
B E
MANUA1ORY
HORIZONTAL STABILIZER ASSEMBLY ADDING DRAIN HOLES AND

SU BJ ECT:
SEALING DOUBLER EDGES
05341)
All PN 369D23601 and PN 421-087 Horizontal Stabilizer
Assemblies in Spare s Inventory at Date of this Notice
~TIME OF COMPLIANCE: Shall be accomplished at next Annual or 300-Hour Inspection

tl
Shall be accomplished prior to installation of above affected
ii
Spares Horizontal Stabilizer Assembly on Helicopter
of the horizontal
for incorporating drain holes in the lower surface
stabilizer assembly, to provide drainage for possible water seepage.
lower doubler
Instructions are also provided for sealing the upper and
edges, and any gaps between the doublers and stabilizer skin, to prevent
from collecting and freezing during cold weather operation.
I have infinite life. When

It is to be noted that the stabilizer tip plates an
may be reinstalled condition

replacing the stabilizer, the tip plates as
w ar rant s
REFERENCE

500D Basic HMI-VoZume I, Issued 15 September 1976;
500D Basic HMI-Volume II, Issued 15 September 1976;
(mRW ~j aQer. HTE*D RCV 11-67

Hu(ghe~ #Qlicopteos
NOTICE NO. DN- 63
DATE 3 March 1980
PAGE 2 OF 4
TOOLS AND EQUIPMEN T
Drill bit #10
MATERIALS
Sealant PR1221B2 Product

or Research,
equivalent Burbank, CA
Naphtha, aliphatic TT-N-95 Commercial
PROCEDURE
a. Remove horizontal stabilizer assembly, per HMI-Vol I.
b. Support horizontal stabilizer with lower surface facing upwards.
c. Mark and drill three No. 10 drain holes in lower surface of

stabilizer, at dimensions shown in Figure I.
d. Seal all edges of lower doubler and

any gaps between doubler and
stabilizer skin, as shown in Figure 2, Leave drain holes open. Remove
excess sealant with cloth and naphtha.
e. Reposition stabilizer assembly with upper surface facing upwards.
f. Seal all edges of both upper doubler s as shown. Remove excess

sealant with cloth and naphtha.
g. Seal holes at leading and trailing edges of horizontal stabilizer

adjacent totip plates, LH and RH sides, as shown in Figure i. Also seal
holes in trailing edge of stabilizer at each side of light bracket, as shown
in Figure 2.
h. Repaint sealed areas; check that drain holes are open.
i. Reinstall horizontal stabilizer

assembly, per HMI-Vol I.
j. Record compliance with this Service Notice in

Compliance Record
FAA APPROVED
8 Hueh n.licop~r NOTICE NO. DN- 63
DATE 3 March 1980
PACE 3 OF 4
TIP PLATE
.P
SEAL HOLES
(LH AND RH SIDES)
IIORIZONTAL
S1AB ILIZER
LEADING EDGE
0.811
REF
ftlO DP,ILL HOLES
i. 55
STUD
1,50
(11 PLACES)
REF:
1,55
#10 DRILL HOLE
0.84REF
LOLIER DOURLER
(361D2361il)
i
88-362
O
Drilling of Drain Holes, Horizontal Stabilizer Lower Surface

Figure i,
NOLLCE NO. DN-63
E) Huclha~ Halicoptt
DATE 3 March 1980
PAGE 4 OF 4
P 369D23662-11 BRACKCI
SEAL ALL EDGES/GAPS AROUND
ASSEMBLY
PERIMETER OF HORIZONTAL
STABILIZER UPPER
DOUBLER 369D23637
"Ilr
LOWER DOUBLER
SEAL ALL EDGES/GAPS AROUND
SEAL EDGES AROUND
PERIMETER OF HORIZONTAL
PERIMETER OF UPPER ~L=r
STABIL12ER LOWER WUBLER
DOUBLER 369023688-3
369023619
SEAL
O
HORIZONTAL STABILIZER
UPPER SURFACES
TRAILING EDGE
O
HORIZONAL STABILlilER
LOWER SURFACES
?R-~h?
Figure 2. Horizontal Stabilizer Sealing of Doubler Edges

NOTICE NC. DN-64. li
HUGHES DnsE 19 December 19.

5
SERVICE INFORMATION P1GC 1OF
NOT ICE uSupersedes Se rvice Information

Notice DN-65, Dated 16 May 1980
MANDATORY MANDATORY II M AN DATO RY
SUBJECT: REWORK OF COOLING BLOWER MOUNTING BRACKET
MODELS AFFECTED. 500D Model 369D Helicopter

TIME OF COMPLIANCE: Shall be accomplished within ne~ 300 hours of

procedure for reworking the cooling blower mounting bracket
P/N 369D25626, to provide increased clearance for the blower
drive belt and preclude interference between bracket and belt.
This revision is issued to clarify the dimensions of the spotface
as shown in Figure i.
Reference
500D Model 369D Basic HMI-Volume 1, Issued 15 September 1976; Revision No. 3,
15 March 1979.
Customer Service Department Hughes Helicopters- Culver City, California
Form 9578
FORH NO 9578* HTC*D REV 11-67
NOTICE NO. DN-65.1
DATE: 19 D~cember 1980 E) Hughes Helicopters
PAGE: 2 of 4
PARTS LIST
NOMENCLATURE PART NO. aTu MFR
Screw NAS 1164-2L 2 Commercial

Wa she r MS 21 206 C6 2 Commercial
MA T ER IA L
Spotface tool-0. 750 inch diameter, 0. 267/0. 260 inch diameter pilot
Countersink tool-100 degrees x 0. 330 inch diameter
REWORK PROCEDURE
a. Remove transmission cover. (Refer to Section 2 of Basic HMI-Vol i.
b. Remove cooling blower. (Refer to Section 9 of Basic HMI-Vol i.
c. Remove four bolts and four washers attaching mounting bracket to

cooling blower. Retain two bolts and two washers.
d. Rework mounting bracket as follows: (See Figure 1)
i. Increase spotface of two lower holes to O. 750-inch diameter and

to O. 124-inch material thickness.
2. Countersink two spotfaced holes, using 100degree countersink to

0. 330 inch diameter. Remove any burrs as required.
e. Install reworked mounting bracket as shown in Figure 2. Install two

bolts and two washers retained above in upper holes of bracket and
safety
wire with MS 2099 5 C3 2 wire. Install two NAS 1 1 64- 2L screws and two
MS2106C6 washers in reworked holes.
f. Reinstall cooling blower and adjust cooling blower belt tension. (Refer
to Section 9 of Basic Hn/MI-Vol i.
g. Reinstall transmission cover. (Refer to Section 2 of Basic HMI-Vol 1.

NOTICE NO. DN-65.1
E) Hueh) Hlitopf~n DATE: 19 December 1980

PACE: 3 of 5
FAA/DER APPROVED 5 December 1980

1
NOTICE NO. DN-65. 1
DATE: 19 December 1980 E) nush Hlicopf~n
PAGE: 4 of 5
II (A
0.750 DIA SPOTFACE TO

0.125 MATERIAL THICKNESS
1000 X 0,330 DIA COUNTERSIHK
TYP 2 PLACES
OBLOWER IIOUHTIHG BRACKET
too"
:i 750
0,125 1 1 0,190
A-A
88-3806
Figure i. Rework of Cooling Blower Mounting Bracket

NOTICE NO. DN-65. 1
Hughl
PAGE: 5 of 5
EXISTING BOLTS
AND WASHERS
MS20995C32
SAFETY WIRE
NAS11611-2L SCREW
MS21206C6 WASHER
OBLOWER IIOUIIT1116 BRACKET
NOTE
AFTER INSTALLATION OF SAFETY

WIRE, INSURE THAT THE BELT
DOES NOT INTERFERENE WITH WIRE
88-383
Installation of Reworked Cooling Blower Mounting Bracket

Figure 2.
NOTICE NC. DN-66
p~ij
U~ H ES
6 j
DATE 16 May 1980
PAGE 1 OF
)BTI)K1 I%~--------------- iiilnRI DATO Rd IV1Ai\l I)/?i~i)llV
SUBJECT: REWORK OF PN 3691)290125-21 MIST ELIMINATOR ASSEMBLY ENGIN
AIR INLET FILTER (PARTICLE SEPARATOR) ASSEMBLY,

PN 3691-190148-507 AND 369H90148-509
jj MODELS AFFECTED: All ~vlodel 500D Helicopters equipped with subject

PN 3691-190148-50? and -409 Particle Separator Assemblies
at date of this Notice. ki
All PN 369D290125-21 (APM PN AE-AZZ4-ID2) Mist Eliminatori
Assemblies in Spares Inventory at date of this Notice.
If TIME OF COMPLIANCE: Shall beacco~iplished within next 50 hours of helicopter

operation.
Shall beaccomplished prior to installation of subject Mist
i
Eliminator Assembly in Spares Inventory.
63REFACE: The information given in this Service Information Notice lists a procedure
ii for removal of wire staples from the subject mist eliminator assemblies,
j
to preclude the possibility of dislodged or damaged staples being ingested
by the helicopter engine.

The attached Aircraft Porous Media Inc Service Bulletin provides detailed
instructions for staple removal.
Ref er enc e
September 1976; 3,
W Model 400D Basic Hh/LI Volume I, Issued 14 Revision No.
14 March 1979
3
IPL and Maintenance Instruction Publication No. CSP-004 for Engine Air Inlet Filter
(Particle Separator) PN 369H90148-503, -505, -509, Issued 15 March 1979

-507 and
Aircraft Porous Media Inc Service Bulletin No. APM-TM-79-14, dated 15 March 1980
ti CoslomPr S.rrlrs Ds~.nmsnt Nugapa Cul~r Clfy. CIUmmu
i:l,i HTC*D REV 11-67

NOTICE NO.
DATE
nN-66
16 May 1980
PAGE 2 OF 2
PROCEDURE
a. As applicable, remove niist eliminator assembly from helicopter.

(Refer to Publicston No. CSP-004).
Check Aircraft Poro,s Media (AI>M) Serial Number on mist

b.
eliminator assembly.
NOTE
If APM Serial Number is 005 through 069,

perform steps c, d and e below; otherwise
perfornl steps d and e only.
c. Remove wire staples from.mist eliminator assembly per attached

RPM Service Bulletin No. APM-TM-79-14.
d. Reinstall mist eliminator assembly on helicopter, as applicable.
e. compliance with this Service Information Notice in

Record
Compliance Record of helicopter Log Book; or tag Spares mist eliminator

assembly and record compliance with this Notice in helicopter Log Book at
installation of tagged unit.
FAA APPKOWED
Use or disclosure of this data is subject to the restriction on the Title page of this Document. (1966 DEC)
AIRCRAFT POROUS MEDIA, INo.
SUdSIDI*AY Or P~LL CORPOR*TION
GL~N COV~. L. i.. NPW YORK
SERVI~CE
P*LL
BULLETIN
Airframe Engine Air Mist Eliminator Removal of Wire Staples
from Mist Eliminator Assembly.
A. Effectivity
Mist Eliminator Assembly, Serial Nos. 005 to 069, Part No.

AE-A224-1D2 (Hughes Part No. 369D290125-21) installed on
Hughes Model 500D Helicopters or stocked as spare parts are
affected by this Service Bulletin.
B. Reason
To eliminate the possibility ofdislodged or damaged wire

staples attached to the Mist Eliminator Pad and/or Screen
being ingested by the engine.
As staples are not required for the safe physical or

the
functionaloperation of the Mist Eliminator, removal will
preclude engine damage from this source.
C. Description
This Service Bulletin provides removal instructions of all

staples from the Mist Eliminator Assembly.
D. Compliance
It is recommended that this Service Bulletin be accomplished

within the next 50 hours.
E. Approval
None
F. Manpower c
With the Mist Eliminator readily accessible on a bench, approximately

0.5 manhours will be required to accomplish this Service Bulletin.
Mar. 15/80 APM-TM-79-14

Page 1
AIRCRAFT POROUS MEDIA, INa
A SUBSIDIARY O~ PALL CORPORATION
OLEN COVE. L. i.. NEW YORK
SERVI~CE
PL~LL
BULLETIN
Airframe Engine Air Mist ~liminator Removal of Wire Staples
G. Material
No new materials are required to accomplish this Service Bulletin,
H.
No special tools are required to accomplish this Service Bulletin.
Common tools consisting of a needle nose pliers and possibly a
wire cutter will be required to accomplish this Service Bulletin,
I. WeiRht and Balance
Not affected.
J. References
None
R. Previous Modifications
l~here are no previous modifications,
MaL,15/80 APM-TM-79-14
Page 2
AIRCRAFT POROUS MEDIA, I~o.
SUBSIDI*Ry OF P*LL CORPOR*IION

GLEN COVE. L. NEW YORK
SERVI~CE
P*LL
BULLETIN
Airframe Engine Air Mist Eliminator Removal of Wire Staples
With the Mist Eliminator Assembly removed from the helicopter,

accomplish the following:
WARNING: IT IS MANDATORY THAT EVERY PIECE OF A REMOVED

STAPLE BE
ACCOUNTED FOR AND PROPERLY DISPOSED OF. FAILURE TO DO SO
CAN CAUSE A REMAINING PIECE TO BE INGESTED BY
THE ENGINE.
CAUTION: THE INSTALLED WIRE STAPLES DO NOT NECESSARILY

CONFORM TO
ONE SPECIFIC SHAPE.. CARE MUST BE EXERCISED
NOT TO DAMAGE
THE MIST ELIMINATOR PAD DURING-THE REMOVAL
PROCESS, REFER
T~FIGURE i,
PAD STAPLE-~ WIRE SCREENV----I
Figure i. Sample Staple Installacions
A. Place Mist Eliminator

on a clean bench that is free of all
materials that i
snag and damage the Mist Eliminator Pad
can
or
the wire screening, or become entrapped therein.
Mar. 15/80
APM-TM-79-14
Page 3
AIRCRAFT POROUS MEDIA, INc.
SUdSIDIIRY O~ P~LL CORPOR*IION
CiLEN COVE. L. i.. NEW YORK
SERVI~CE
P*U
BULLETIN
Aiff~ame Engine Air Mist ~liminator Removal of Wire Staples
NOTE: If difficulty is experienced in straightening the staple legs

described in Step B, below, suspend allefforts and proceed to
Step C.
B. Using a needle
pliers straighten one or both legs of the
nose
installedstaple. Carefully pull the staple through the pad

material and the wire screen. Refer to the above "WARNING" note.
Repeat until all staples are removed.
C. Should Step B, above, prove unsuccessful, perform the following

operations:
(1) Without damaging the pad material or wire screening, cut

the staple in the bend area(s) using an appropriate wire
cutter.
(2) Remove all pieces of the staple without damaging the pad
Or screening,
t
(3) Match all pieces from sharpened end to sharpened end to
ensure that the complete staple has been removed(approximately
inches long). Refer to the above "WARNING" note.

i
(4) Repeat steps C (1) through C (3) until all staples are removed.
3. MATERIAL INFORMATION
A. Material Requirements
No new materials are required to accomplish the intent of this

Service Bulletin.
B. Bill of Materials
None
Mar. 15/80 APM-TM-79-14

Page 4
NOTICE NC. DN- 67
DATE 2 June 1980

H UGH ES
PAGE 1 OF_3~_
SERVICE INFORMATION
NOTICE
SUBJECT: REWORK OF ONE-WAY LOCK ASSEMBLY, PN 369A7010 Series
MODELS AFFECTED: 500D Model 369D helicopter

Serial No. through 0818D
0003D
All PN 369A7010 Series One-Way Lock Assemblies
in Spares Inventory at date of this Notice.
TIME OF COMPLIANCE: At Owners discretion if not already accomplished;

or if bowl is leaking.
PREFACE: This Service Information Notice lists a procedure to seal the One-Way
Lock Assembly to preclude leakage and loss of fluid from around base of
bowl.
NOTE
fluid to
Rapid movement of the cyclic stick can cause
under the filler If
splash against and leak from cap.
a leak is suspected, clean the bowl area of the lock
assembly with isopropyl alcohol and allow to set static

for several hours. Recheck and if no leakage is
oil may be from splash out rather than a leak.
evident,
Reference
500D Model 369D Basic HMI-Volume 1, Issued 15 September 1976; Revision No. 3,
15 March 1979
FORM NO 9178~ HTC*D REV II

NOTICE NO. DN-67 Hughe+ Helicopters
DATE 2 June 1980
PAGE 2 of 3
MATERIALS
No. 2216 Sealant 3M Co.

or
PR1221 Sealant Products Research and

Chemical Corp.
GlendaZe, Ca
TOOLS AND EC)IUIPMENT
Spatula of Extrusion Gun
REWORK PROCEDURE
a. Remove one-way lock from helicopter, lRefer toSection 7 of Basic

HMI-VoZ 1.)
b. Prepare No. 2216 or PR12Z1 class B per manufacturers

instructions.
c. Using extrusion gun or spatula, apply 0. 18/0. 13 inch bead of sealant

full circumference between base of reservoir and bowl flange and dry per
manufacturers instructions. (See Figure i.)
NOTE
If reservoir is wet with hydraulic fluid, wipe

area clean with isopropyl alcohol (LTT-1-735)
and dry before applying sealant.
d. Reinstall one-way lock assembly in helicopter. ~Refer to Section 7

of Basic HMI-VoZ i.)
DER/FAA APPROVED 27 May 1980

NOTICE NO. DN-67
Huehe~ Hslicopt~rs
DATE: 2 June 1980
PAGE 3 of 3
PILOTS CYCLIC
CYCLIC PITCH INTERCONNECTING STICK ASSEMBLY
TORPUE TUBE
LONGITUDINAL
CONTROL
FRICTION
MECHANISM
jd
WASHER
!u SLO~ITED
BUSHING
INOTE 1)
STATION 67
LATERAL CYCLI
BELLCRANK
d6
CYCLIC
ci~
STICK
GUARD LATERAL
P~ILOTS CONTROL
LATERAL FRICTION
CONTROL MECHANISM
GUARD SLEEVE BUSHING ROD (NOTE 2)
ATTACHMENTS
COMPONENTS
APPLY BEAD NO. 2216 OR PR1221

SEALANTI FULL tlRCUMFRENCE
0.18
0,13
NOTEI
IF RESERVOIRIS WET WITH HYDRAULIC
FLUID, WIPE AREA CLEAN WITH ISOPROPYL
ALCOHOL [LTT-1-~I) nKo ORY BEFORE
APPLYING SEALANT,
Oonr-wav LOCK nssEMBLv
88-387
Figure 1. Rework of One-Way Lock Assembly

NOTICE NC. DN-68.
HUGHES
SERVICE INFORMATION PAGE1OF
NOT ICE
~CSupersedes Service Information Notice
No. DN-68, Dated 30 June 1980
MAN DATORY MAN DATO RY I I MAN DATO RY
SUBJECT: RELOCATION OF TAIL ROTOR BUNGEE SPRING FORWARD

ATTACHMENT; TAIL ROTOR FORCE ADJCTSTMENT

SerialNo. 003D through 0467D

ope ration.
to relocate the tail rotor bungee spring forward attachment to allow
installation of washers for bungee adjustment, to adjust for minimum
for the
pedal loads in cruise. This revision corrects existing dimensions
new bungee spring attachment hole
location shown in Figure i.
Reference
Issued 15 September 1976; Revision No. 3

500D Model 369D Basic HMI-Volume I,
15 March 1979.
I) Denotes portion ai text added or revised.
Formch~d;ad3 ss7er. Hrc~D REV 11-67

NOTICE NO. DN-68. 1
DATE 8 December
PAGE 2 of 4
1980 f~ Hugh(a Hdicoptan
PARTS LIST
Eyebolt AN4 213 C1 OA 1 Comme rcial

Washer AN970-3 8 Commercial
TOOLS AND EQUIPMENT
No. 10 drill
Torque wrench 0 to 100 in. Ibs
MA TE R IA LS
Scotchweld EC1838 3M Company
REWORK PROCEDURE
a. Remove access cover between pilots seats and/or passengers

footwell on aft side of canted bulkhead. (Refer to Section 2 of Basic
HMI-VolI.
b. Block left tail rotor control pedal at full forward position to relieve
tension on bungee spring.
c. Disconnect bungee spring from eyebolt and remove and retain nut
and washer attaching eyebolt to bracket at Station 63. Discard eyebolt.
d. Locate positi~n and drill new hole using No. 10 drill. Remove any
burrs as required. (See Figure i.)
e. Seal old eyebolt hole with Scotchweld EC1838 and dry per manufac-
turers instructions.
f. Treat edge of new hole per exterior touchup treatment magnesium

alloy per Section 2 of Basic HMI-Vol I.
I g. Install eight AN970-3 washers on one AN42B-C10A eyebolt and hook

forward end of 369D27521 bungee spring to eyebolt. Insert eyebolt in new hole
in 369A2541 bracket and secure with washer and nut retained above. Torque
nut to 20-25 in. Ibs.
NOTICE NO. DN-68. 1
Hugh(N Hslicoptsrs DATE 8 December 1980
PAGE 3 of 4
NOTE
If tail rotor pedal forces are not zero during

level flight at 130 to 140 knots, tail rotor force
adjustment may be accomplished by removing

a desired number of AN970-3 washers.
h. Remove block from left tail rotor control pedal.
i. Reinstall access cover between pilots seats and/or passengers

footwell. (Refer to Section 2 of Basic Hh/II-Vol I.
j. Record compliance with this Service Information Notice in Compli-

FAA/DER APPROVED: 2 December 1980 I

NOTICE NO. DN-68. 1
DATE 8 December 1980 Hughr H~licopters
PAGE 4 of 4
i/
ESHIP(RF)1 3OLD HOLE
(REF)
NEW HOLE (REF)
(REF) 1,75
,1911
DIA HOLE
,190
C-C VIEW LOOKING AFT
AN112B-CIOA EYEBOLT
AN970-3 WASHER (8 REQUIRED)
STA MS21O42-3 NUT
63.00 AN96O-1OL WASHER
369A2R1
E SHIP
tTEKCARB
3,37
B LTli~
1.75
0,190 DIAMETER
0,194 369927521 SPRING
THRU BRACKET
B-B VIEwlWKINIWWN Q
VIEW LOOKING INBOARD
LH SIDE
88-386A
.;t Figure i. Relocation oi Tail Rotor Bungee Spring Forward Attachment

Hughes Helicoptero
REFERENCE SHEET
AND LETTERS
SERVICE INFORMATION NOTICES
When performing maintenance or inspection of tail rotor

Action Reference:
bungee spring or tail rotor force adjustment, refer to
DN-68. I.
Service Information Notice No.
Section 8,
HMI Reference: Insert this sheet in Basic HMI-Voll,
paragraph 8-26.
page 8-17,
kept part of
incorporated at the
the manual until the data is
Refer to Service
next revision of HMI-Vol I.
Information Summary, HMI-VolI, page i.
NO.IICE NO, nN-69
HUGH ES r>~rt_ 30 June 1380
SERVICE INFORMATION (;i I ,,,:~b
NOT ICE
MANDATORY MAN DATORY I r MAN DATO RY
SUBJECT: POLARITY CHECK OF DIODE ASSEMBLIES
MODELS AFFECTED: All Model 400D Series Helicopters equipped with PN 369H90118
Series Auto Reignition Kit and/or PN 3691-190022 Series Anti-Ice
Fuel Filter Kit delivered and installed on helicopter during 1979
All PN 3691-190118 Series Auto Reignition Kits and PN 3691-190022

Series Anti-Ice Fuel Filter Kits delivered and in Spares
Inventory during 1979
TIME OF COMPLIANCE: Shall be accompl.ished within next 40 hours of helicopter

operation
Shall he accomplished prior to installation of above affected
Spares on helicopter
Icits
for a one-time check of the subject 1N3210 diode assemblies incorporated
in PN 3691-190118 Series Auto Reignition Kits and PN 3691-190022 Series
Anti-Ice Fuel Filter Kits delivered and installed on Model 500D Series
helicopters or in Spares Inventory during 1979.
l"ee.d reports indicate that a srr~all number of the above affected kits
del.ivered during 19/9 inadvertently incorporated diodes with reversed
polarity (IN3 210 R), The two above kit installations are the only
places the reverse polarity diodes would be installed on 500D ~-ieli-

copters. Installation o~ diodes with improper polarity can result in
inability to start the engine or in malfunction of the automatic reig-
nition system.
Reference
500D Basic E-IMI Volume I, Issued 15 September 1976; Revision No. 3,

14 March 1979.
IPL and Maintenance Manual Publication No. CSP-003 for Engine Automatic
Reignition Kit Installation, Issued 1 February 1978.
IPL and Maintenance Manual Publication No. CSP-034 for Anti-Ice Fuel Filter Kit
Installation, Issued 1 March 1979.
HTt*D REV 11-67

NOTICF: NO I)N- 6)
13AllE: 3() 1)80 Hughes Helicopters
I>ACE 2 of G
PARTS T,IST
Nomene i l>art No. Oty Mfg
:::Diode Assembly 1. N3210 A/R Commercial
~Provided without cost, if required, by HH Service Center or
Distributor. I-IH Service Centers and Distributors order
from HH Warranty and Repair Department.
TOOLS AND EaUIPMENT
Ohmmeter (with forward polarity)
NOTE
Check as follows to determi.ne ~orward
polarity:
1. Set ohrri~7eter to ohms position.
2. Connect leads to a second voltmeter to deter-

mine which lead of the ohnlmeterr is positive.
3. Use meter as noted in body of notice.
PROCEDURE
FART I PN 369H90118 SERIES AUTO REIGNITION KITS INSTALLED

ON I-I~ELICOPTER OR IN SPARES INVENTORY
a, As app].icable, open RH engine access door.
b. Locate diode assemblies (CRI and CRZ) installed on helicopter

right oleo support fitting. (See Figure 1.)
c. Check Fart Number on diode assemblies.

NOTICE NO, DN-69
E) Huehu Hdicopfn DATE 30 June 1980

PAGE 3 of 6
TERlflAL PIP
WIRE BUNDLE
STUD
WIRE BUNDLE
O1O0E ISOLATOR
ASSEMBLY (CAI. 002) ---~6alllllll 1 \RICHTo~osuPPoRr
P303 WIIIII I I FITTING
START
(K301)
RING
SECTI ON
SP17 SP18
STATION
EHCINE AREA ~UGHT SIDE
-l/psm ~1
nPS~-PD20SK- c-~
M C--PIIZFUI--4 tXClltR p..t

?_c,
1001 3
r"7 GAP
9
L----~--rme2o-------ti 1
~sj
CRZ
X1 OIODE ISOLATOR ASSEMBLY 2)
I START RELAY
.4 ENGINEAREA
WIRING DIAGRAM
gTES:
i, IF CR1 REVERSED. AUTMAATIE REIGNITION SYSTM I1UIPERATIVE.

2, IF tRZ RMRSED. EI(GII(E START HOT WSSIBLE,
8&388
Figure i. Diode check engine automatic reignition kit installation

NOTICE NO. DN-69
DATE 30 June 1380 Hugh Halicopts~a
PACE 4 of 6
NOTE
perform steps f
1. If PN of diodes is 1N3210,
and g only.
1N3210R, replace diodes

2. If PN of diodes is
with new PN 1N3210 diodes; perform steps e,
f and g below.
3. If PN of diodes cannot be determined, perform

steps e, f and g below.
electrical
using ohmmeter (with forward polarity)
at
d. Test diodes,
lead applied
connector pins. Check for low forward resistance with positive
Reverse leads and
lead applied to stud end.
to terminal end and negative
check for very high back resistance.
NOTE
Ifpolarity of diode is reversed, replace

existing diodes with new 1N3210 diodes.
e. Perform function check of auto reignition system.
f. Close engine access door.
Notice in Com-
g. Record compliance with this Part I of this Service
pliance Record of Log Book; or tag Spares isolator diode assembly

helicopter
and record compliance with this Notice at installation of assembly on
helicopter.
PART II PN 369H90022 SERIES ANTI-ICE FUEL FILTER KITS

INSTALLED ON HELICOPTER OR IN SPARES INVENTORY
a. Remove cover from PN 3691-14735 anti-ice fuel filter panel assembly.

(See Figure 2.
b. Check Part Number of diode CR 26 in panel assembly.

NOTICE NO. DN-69
Hughes Helicopters DATE 30 June 1980
PAGE 5 of 6
389114742 SWITCH ASSUM_B~
r 2
AMBER
2 1 I _T
E23
1
X
PU-I CRb
2 2 CR26
I
NC
CS31 NO
TERMINAL
NCII 1 ,5
snm
~A II I I I NO
orom tcas,~ QS~ ll~Co I II I 1 I st I
Nc
No
st
h L YL
Q tf~0R
K254
3
J d~361Hsm PIWEL RSSMBLY

~bYz--l
STDRES~
TBn
COVER
RTITO-n?DRAY
C8135
7.5
ANTI-ICE BRIGHT
FUEL FILTER
R254D1M
FUEL FILTER
ANTI-ICE CAUTION LIGHT TB101
1M)n5114w
DIMMER SWITCH
UIRING DIAGRAM
88-389
Figure 2. Diode check anti-ice fuel filter kit installation

NOTICE NO. DN-61
DLlTE 30 June
I:nGF: h of 6
1180
E~ Huah Hslicopfara
NOTE:
i. If PN of diode is 1N3210, perform steps e and
f only.
2. If PN of diode is 1N3210R, replace diode with

new PN 1N3210 diode; perform steps d, eand
f below.
3. If PN of diode cannot be determined, perform

steps c, i, e and f below.
c. Test diode, using ohnimeter (with forward polarity) at electrical

connector pins. Check for low forward resistance with positive lead
applied to terminal end and negative lead applied to stud end. Reverse
leads and check for very high back resistance.
NOTE
If polarity of diode is reversed, replace

diode with new 1N3210 diode.
d. Perform function check of anti-ice fuel filter system.
e. Reinstall panel cover.
f. Record compliance with Part II of this Service Notice in Compliance

Record of helicopter Log Rook; or tag panel assembly and record compliance
with this Notice at installation of panel assembly on helicopter.
Weight and balance not: affected.
FAA/DER APPROVED 30 June 19130

E3 HUghss n~iicopters
R EF ER EN C E SHEET
maintenance inspection of anti-ice

fuel filter kit installation,refer to Service Information

Notice No. DN-69 for polarity check of diode assemblies.
HMI Reference: Insert this sheet in CSP-035 IPL and Maintenance Manual
for anti-ice fuel filter kit installation, Section I,
page 1-3, figure 1-1.

at the next revision of CSP-035.
E) Huebs nelicoplers
REFERENCE SHEET
LETTERS
SERVICE INFORMATION NOTICES AND
maintenance inspection of the

refer to Service
automatic reignition installation,
DN-69 for polarity check of
Information Notice No. a
the diode assemblies.
sheet in CSP-003 IPL and Maintenance

Manual
HMI Reference: Insert this
for the automatic reignition installation, Section 3,
figure 3-7.
page 3-1,
kept part of
incorporated at the
the manual until the data is
next revision of CSP-003.
i-i
N( T I<:L_ N(? DN-70
HUGHES oalii 11 July 1980
SERVICE INFORMATION 1";
NOT ICE
SUBJECT: IDENTIFICATION AND POSSIBLE REWORK OF SEAT BELT

AND SHOULDER HARNESS ASSEMBLIES
MODELS AFFECTED: All 500D Model 369D Series Helicopters delivered prior
to 14 May 1980
All Seat Belt and Shoulder Harness Assemblies in
Spares Inventory at date of this Notice
TIME OF COMPLIANCE: Shall be within next 50 hours of

accomplished helicopter
operation
Shall be accomplished prior to installation of affected
Spares Seat Belt and Shoulder Harness Assemblies on
helicopter
PREFACE: The information given in this Service Information Notice lists a pro-
cedure for identification of seat belt and shoulder harness assemblies
installed on the helicopter and in Spares Inventory, and for rework of
the lap belt assemblies, if applicable, per the attached American
Safety Equipment Service Bulletin No. GP-1002.
Reference
500D Series Basic HMI, Vol. I, Issued 15 September 1976; Revision No. 3,
15 March 1979
American Safety Equipment Corporation Service Bulletin No. CP-1002, dated
19 May 1980
Custornel- Service Department Hughes ~lrlicopters C:itp, i~alifornia
)T7RIH7C *L) REY 11-67

PIOTT%CT~ NO. TI)N-70
I1July 118()
~3) Mgkl
PAGE 2 of 4
PARTS REQUIRED
None
TOOLS 8r EaUIPME~T
Punch, flat ended Commercial
MATE RIALS
Paint, green or Permanent Commercial

Ink Felt Tip Marker, green
PROCEDURE
NOTE
Removal of seat belt and shoulder harness assemblies

not required.
a. Visually detesrmiMe whether seat belt w~ sh.ouilder harness assam-

blie s are manufactured by American Safety EquilIs;r~eM,t Corporaeion. Se.e
Figure 1 and refer to attache ASEC Service Bulletin No;. CP-1002 for pr,o-
duct identification data and parts/assemblies affected.
NOTE
If seat belt assemblies are not manufactured by American Safety

Equipment Corporation, perform step donly.
If seat belt as
sembli,e-s are manufactllred by American Safety
;~:orporatjop, and seat b,elt tag i(ee Figure i) has
green hex-sh~Lpe stamp, perform tep d only.
b.. As required, rework American Safety lap belt assemblies per

attachedService Bu.letin No. CP-1002.
c, Apply 3/8-inch,green dot on tag at location shown in Figure i.
d. Record compliance with this Service Information Notice in Com-

NOTICE NO. DN-70
Hughes He(ic~pters DATE 11July 1980
PAGE 3 of 4
WEIGHT BA~,ANCE DATA
FAA/DER APPROVED 2 July 1980

NOTIC~ NOi DN-70 Hughas Ha(keplars
DATE 11Jul.y 1980
PAGE 4 of 4
DATE
0380RIi 0380 nw
PART NO, I B PART NO.
500987-1101-3192 1; 1500987-401-3192
MODEL N0.500530-1 1 I MODEL N0.500530-1
~YI ]iM I::()-C22111
RATED 4500 LBS I I RATED 4500 LBS

LOOPLOADIi"a-I (~IOTE 1) I: L"OP LOAD 2)
NOtES:
1. GREEN STAMP DENOTES LAP BELT
REWORKEl DY AM~RICAN SAFETY E(JUIPMENS CORPORATION
(NO FIELB REWORK REOUIRED),
2; GREEN OOT DENOTES IAP BELT ASSEMBLY REWORK

ACCOMPLISHED PER THIS NOTICE,
58-1102
Figure i. Identification of reworkdd seat belt assemblies
;i
Hughes Helicopters
REFERENCE SHEET
LETTERS
SERVICE INFORMATION NOTICES AND
maintenance inspection of
assemblies, refer
seat belt and shoulder harness
Information Notice No. DN-70 for
to Service
possible rework of seat belt buckle.
Insert this sheet in 400D Series Basic HMI-Volume I,

HMI Reference:;
paragraph 4-22.
Section 4, page 4-3,

at the next revision to the
500D Basic HMI-
Vol I. Refer to Service Information Summary,

HMI-Vol I, page i.
nMeAlcnN snF En Eou IPM ENT COAPORATION
~OMMERCIAL PRODUCTS DIVISION

650 JESSIE STREET
SAN FERNANDO. CALIFORNIA 91340
PHONE: 213/365-4681
SERVICE BULLETIN NO. CP-1002
SUBJECT: Connector/Buckle Interference on Lap Belt Assemblies which have

Adjustable Connector 500950.
PARTS/ASSEE~BLIES AFFECTED: i. Connector numbers 500950, 500950-401, 500950-403

or 500950-405 only when used in combination with buckle models
5000B2,
5000B3 or 6000.
2. Seat belt part numbers 449105-403, 500869-403
-405, 500870-403 -405, 500872-403, 500878-401, -403 -405, 500879-401
-403, 500987-401 -403, 501423-401 and 501429-401,
PRODUCT IDENTIFICATION: i. All buckles and connectors are identified by their

respective model or part numbers. The model number of the buckle is
on the underside of the base. The location of the connector part number
is shown on Figure i.
2. All seat belt assemblies are identified by their

respective part numbers. A white cloth label is sewn or a metal label is
attached to each buckle and connector portion of the The
assembly.
labels identify part number, model number, manufacturing date code and
manufacturer.
EFFECTIVITY: All assemblies delivered between April 1975 and April 1960.
EXPLANATION: There is a possibility that some lap belt assemblies due to the
thickness of the connector may have interference. See Section B-B
of Figure i. This condition makes it possible for the connector to
be pushed in and retained in the buckle without being locked. See
Section A-A of Figure i.
ACCOMPLISHMENT: At the next periodic inspection or sooner.
REWORK INSTRUCTIOEJS:
Rework of lap belt assembly be

can accomplished without removing the assembly
from its anchorage
Follow steps exactly as described below:
Step i: Remove connector from buckle.
Step 2: Using a flat punch, strike each of the two guide of Figure 1 until the
guide dimensions meet .115/.125 inches as shown in Section C-C of Figure i.
Step 3: Verify dimension with thickness (feeler) gauge.
Ej/19/80
_lof 2
AMERICAN SAFETY EQUIPMENT CORPORATION
COMMERCIAL PRODUCTS DIVISION

650 JESSIE STREE~
SAN FEHNANDO. CALIFOHNIA 91:140
PHONE 213/365-4681
CONNECTOR
ADJUSTABLE CONNECTOR
PART NO.
500950
500950-401
500950-403
500950-405
BASE
BUCI(LE MODEL
5000B2
SECTION B-B I 5000B3
AREA OF INTERFERENCE
6000
WEBBING J I rWEBBING
PART NUMBER
o
449105-403
500869-403 -405 II I 8:
500870-403 -405 1 II I v~
500872-403 o ArRIH-~H-rA
I
500878-401, -403 &-405 1 I I I
500879-401, -403
500987-401& -403 I1 I.. I
501423-401
501429-401
BOTIYIM VIEW
FLUSH
.115+.010PAIJL WITH BASE
-.000
SECTION A-A
CONNECTOR IN CORRECTLY UX~XED POSITION
FLAT ENDED PUN(3I
WIDE
SEOI?ON C-C
SECTION A-A
CONNECrOR IN INCORRECT POSITION
Fig. 1.
2 of 2
5/19/80
NOTICE NC. DN-71
HUGH ES DATE 30 September 1980
SERVICE INFORMATION I
NOT ICE
MANDATORY MANDATORY I IMANDATORY
SUBJECT: WIRING MODIFICATION UTILITY LIGHT CIRCUIT AND TRANSMISSION

OIL PRESSURE AND TEMPERATURE WARNING LIGHT CIRCUIT
TIME OF COMPLIANCE: Shall be accomplished within next 100 hours

of helicopter operation
for rewirin~ the
utility light circuit and the transmission oil pressure and
temperature warning light circuit. The purpose of the wiring modification
is to eliminate deactivation of the utility light and transmission warning
light circuits in the event the engine power out (EPO) unit is deactivated
by tripping the EPO circuit breaker.
Reference
Model 500D Basic HMI-Volume I, Issued 15 September 1976; Revision No. 3, 15 March
1979
HTC-*D RCV ll-6~

NOTICE NO. DN-71
1980
i
PAGE 2 of
PARTS LIST
Nomenclatur e Part No. aty Mfr
MS2 503 6- 149 1 Commercial

Lug, terminal
PROCEDURE
b. Remove instrument panel hood and side fairings. (refer to Section
17 of HMI-Volume I.)
c. Remove circuit breaker panel from instrument console. (See Figure

1.)
d. Disconnect electrical wiring harness connector from EPO warning

unit plug (P19). (Refer to Section 19, HMI-VoZ I.
wire No.
e. Disconnect existing transmission warning light circuit
E518A22 from pin K of P19 wiring harness connector plug.
f. Connect wire No. E518A22 to PANEL LT circuit breaker CB104-2,
u sing te rminal lug MS2 50 3 6 149.
NOTE
Performance of step g below is applicable

to369D helicopter Serial No. 0003D thru
0129D only.
g. Remove existing UTIL LT circuit wire No. L531A22 from ENG OUT
circuit breaker CB106-2 on panel; connect wire No. L531A22 to NZGOV
circuit breaker CB103-2 on panel.
h. Check wiring modification for discrepancies.
i. ReinstalZ circuit breaker panel; reconnect EPO wiring harness
connector; reinstall instrument panel fairings and hood.

NOTICE NO. DN-71
Hughas Helicopters PACE 3 of 4
j. Make wiring changes in respective wiring diagrams,

Section 20 of Basic HMI.
k. Recordcompliance with this Service Information in
Compliance Record of helicopter Loff Book.
F~A/DER APPROVED 15 SEPTEMBER 1980

NOTICE NO. DN-71
DATE ?O September 1980 Hughe Helicopters
PAGE 4 of 4
1? 2
a
K504A22
CB1O3 L531A22 --J9-S
E518A22 ----j
CB1011
ENGINE POWER OUT WARNING

UNIT CONNECTOR P19
L531A22 CB1O3-2 MS25035-1119
E518A22 CB104-2 MS25036-149
88-385
modification utility light and transmission warning light

Figure i. Wiring
NOTICE NC. DN- 72.lj(
HUGHES
oaTE 6 February 1981
NOTICE +Supersedes Service Information

Notice No. DN-72, Dated
18 August 1980
SUBJECT: DRAIN KIT INSTALLATION, PN 369D28300-501 ENGINE OIL TANK

AND OIL COOLER; DRAIN KIT INSTALLATION, PN 3 6 9D2 90 12 O
MAIN ROTOR TRANSMISSION OIL COOLER
MODELS AFFECTED: 500D Model 3691) ~ielicopter Serial No. 0003D thru 0604D

procedure for incorporating more readily accessible oil drain
installations on the above affected helicopters, to facilitate draining

and maintaining the engine oil system, and the main rotor trans-
mission oil cooler assembly. Field modification consists primarily
of removing the existing quick-drain valve on the forward side of
the engine firewall, and routing new drain tubes with end caps
located on the aft side of the ring structure in the engine compart-
ment. Decals are also provided to identify each oil drain
installation.
Reference
400D HMI-Volume I, Issued 15 September 1976; Revision No. 3, 15 Marc:1 1979
Foam 9578A (2/81)

Hughes Helicopters, Inc. Culver city, california 90230
NOTICE NO. DN-72.1 nughes nelicopters
PAGE i! OF 9
PARTS LIST
Part No. Qty Mfr
PN 369D28300-401 Engine Oil Tank and Oil Cooler

Drain Kit consisting of the following:
Decal 369D24044 1 HH
Doubler 369D28300-3 1 ~iH
Doubler 36 91-12532-17 1
Tube Assembly 369D28313 2 HH
Tube Assembly 369D28314-11 1
Tube Assembly 369D28314-21 1 HH
Bracket 369D28315 1 HH
Union AN815-45 2 Commercial

Elbow AN833-4J 2 Com me r c ial
Nut AN924-4J 4 Commercial
Cap Assembly AN929-4J 2 Commercial

Elbow AN939-4J 2 Commercial
Washer AN960-C716 8 Commercial
Rivet MS20615-3M 6 Commercial
Tie Strap MS3 3 6 7 2 9 2 Co mm e r c ial
Grommet MS35489-6 1 Commercial
Packing NAS617-4 4 Commercial

Rivet NAS 1 73 8 M4 1 6 Commercial
Union, bulkhead SS-400-61 2 Commercial
Nut SS-402-1 2 Commercial
Ferrule, front SS-403-1 2 Co mmercial
Ferrule, back SS-404-1 2 Commercial
PN 369D290120 Main Rotor Transmission Oil Cooler

Drain Installation consisting of the following:
Decal 369D24045 1 HH
Fitting 36 9D25717 1 H~t-I
Tube Assembly 369D25718 1 H~
Elbow MS20822-4J 1 Co mm e r c ial

Elbow AN833-4J 1 Commercial
Nut AN924-4J 1 Comme re ial
Cap A s s embly AN929-4J 1 Com me r c ial

Was:?er AN960-C716 2 Commercial
E) Hughss Helleopter~ NOTICE NO. DN-72.1
PAGE 3 OF 9
Parts List (Cont)
Nut MS21042-3 1 Co mme re ial
MS 2 1 9 1 9 DF4 1 Commercial
Clamp
MS 2 1 9 1 9 DF 8 1 Comme r c ial
Clamp
Bolt NAS 13 0 3 3 1 Co mme r c i al
thread seal TFE Fluorcarbon AR Parker Fluid

Tape,
Connec tor
Cleveland O
or
L. A. Rubber Co.
LA, CA
MATERIALS
TOOLS AND EQUIPME NT
Gun, rivet
Drill bit 0.500 inch dia (1/2)
Drill bit 0.453 inch dia (29/64)
Drill bit 0. 43 7 inch dia (7/16)
Drill bit 0. 140 inch dia 28)
Drill bit 0.094 inch dia (#41)
PROCEDURE PN 3 6 9D283 00 50 1 DRAIN KIT INSTALLATION
doors; aft compartment interior trim

a. Open engine access remove
and aft bulkhead access covers. (Refer to Section 2 of Basic HMI-Vol I.
b. Drain engine oil system. (Refer to Section 2 of Basic ~tiMI-Vol I.)

NOTICE NO. DN-72.1 E) HUshL
PAGE 4 OF 9
c. Remove existing PN 369A8324 quick drain valve, overboard drain

tube and related components as follows:
i. Disconnect and remove PN 369A8010-41 overboard drain tube

from drain valve and helicopter structure. (Refer to
Section 13 of HMI-Vol I.
2. Disconnect and remove drain valve from PN 369A8010-601 and

-603 tube assemblies (or 369D28314-11 and -21 tube
assemblies, if installed) from engine oil tank and oil cooler.
3. Remove two PN NAS1303-1 bolts, MS21042-3 nuts and

AN960PD10L washers securing PN 369A8325 drain valve
bracket (with drain valve) to firewall. Discard valve and
bracket; retain attaching hardware.
d. Rework helicopter structure as follows:
i. Using PN 369H2532-17 doubler as template, mark and drill

two 0.443 inch diameter holes and six 0. 094 inch diameter
rivet holes in RH side of PN 369H2532 ring assembly.
Install doubler on aft side of ring, using MS20614-3M rivets
with zinc chromate primer. (See Figure i.)
2. Drill 0. 437 inch diameter hole outboard of existing hole in
I 369D23016-6 rib at dimensions shown in View A-A. Install

MS35489-6 grommet in hole in rib.
3. Using PN 369D28300-3 doubler as template, mark and drill

0. 500 inch diameter hole and six 0. 140 inch diameter rivet
holes in 369D23020 firewall at dimensions shown in Detail B.
Install doubler using NAS1738M4-1 rivets with zinc chromate
primer.
e. Install new drain tubes and fittings as follows:
I. Assemble AN815-4J union on AN939-4J elbows as shown,

using NAS617 packings. Install SS-400-61 unions on
369D28315 bracket and AN939-4J elbows and secure with

AN924-4J nuts.
NOTICE NO. DN-72.1
Hughes Helicopter.
PAGE 4 OF 9
2. Install 369D28315 bracket on firewall, using existing attach
hardware.
3. Connect 369D28313 drain tubes to unions with SS-402-1

SS-403-1 and SS-404-1 ferrules as shown. Do not
nuts,
tighten nuts at this time.
4. Route 369D29313 tube assemblies between firewall andring

assembly as shown; secure tubes at ring assembly using
AN833-4J elbows, AN960-C716 washers and AN924-4J nuts
as shown.
4. Connect existing 369A8010-601 and -603 (or 369D28314-11

and -21) tube assemblies to unions on elbows as shown.
6. Secure 369D28313 tube assemblies to 369H8306 oil OUT
tie straps shown. Tighten SS-402-1

hose, assembly with as
nuts (securing drain tubes to unions) 1.25 turns from finger-

tight.
7. Install AN929-4J cap assemblies.
8. Install 369D24044 engine oil drain decal on aft side of ring

assembly as shown.
f. Check new engine oil system drain installation for discrepancies.
HMI-Vol I.
g. Service engine oil system, per Section 2 of Basic
PROCEDURE PN 369D290120 MAIN ROTOR TRANSMISSION OIL COOLER

DRAIN KIT INSTALLATION
a. Drain main rotor transmission oil cooler assembly, per

Section 2 of Basic ~IMI-Vol I. Discard existing AN929-8D end cap.
b. Drill 0.453 inch diameter hole in LH side of 369~t12532 ring

at dimensions shown in Figure 2. Install AN833-4J elbow with
assembly
AN960-C716 washers and AN924-4J nut.
NOTICE NO. DT\T-72.1 Hughs Helicopters
PAGE 6 OF 9
c. Install new 369D25717 fitting with MS20822-4J elbow to tee on oil

cooler.
d. Connect 369D25718 tube assembly to AN821-4J elbow; apply seal
tape to threads of elbow; do not apply to first two threads.
e. Connect 369D25718 tube assembly to AN833-4J elbow at ring

assembly; install AN929-4J cap assembly.
f. Secure drain tube to 3691-18016 engine mount, using clamps and

attach hardware as shown.
g. Install 369D24045 oil cooler drain decal on aft side of ring

as sembly as shown.
h. Check oil cooler drain kit installation for discrepancies.
i. Service main rotor transmission oil cooler assembly per

Section 2 of Basic HMI-Vol I.
j. Reinstall interior trim and aft bulk~ead access covers; close

engine access doors.
Weightand balance c~ange negligible
FAA/DER APPROVED 9 February 1981

E~ HUeh3 HdiCOPt(Lr. NOTICE NO.
DATE 6
DN-72.1
February 1981
PA.GE 7 OF 9
(8534108) OIL COOLER
369025717 FITTING
NAS13O3-3 BOLT
STA
MS20822-4J ELBOW
MS21042-3 NUT
THREAD SEAL TAPE
AN9SOPD1OL WASHER
MS219190F4 ENGINEJMOUNT
32.00
MS21919DF8 CLAMP
369025718 TUBE ASSEMBLY

AN96O-C716 WASHER
2 REQUIRED
AN833-4J ELBOW
AN929-llJ
CAP ASSEMBLY
AN9ZII-4J NUT
VIEW LOOKING INBOARD L,H, SIDE
369H2532
RING ASSEMBLY
NOTES: o,laCm /AN825-8D TEE

i, POSITION DECAL APPROXIMATELY AS SHOWN (EXISTING TEE)
WT~
,oo~--- I I II
8.46
c_rb
0,453 DIA THRU 369H2532

RINGASSEMBLY
369024045 DECAL
1,110
VIEW LOOKING FORWARD

88-378
Figure i. Drain Kit Installation PN 369D28300-401 Engine

Oil Tank and Cooler
NOIICE NO. DN-72.1 Hughes Helicopters
PAGE 8 OF 9
369A8301 TANK ASSEMBLY
3691)283111-11 TUBE ASSEMBLY

AN815-llJ UNION
2 REQD
NAS617-~ PACKING
II REQD
369028314-21 TUBE
ASSEMBLY AN939-4J ELBOW
369023020 FIREWALL. ~z REQD
369A83 (369A8302) OIL COOLER
369H2532 RING ASSEMBLY

SS-400-61 BULKHEAD UNION
fj7
6.as A A
2 REED
AN924-4J NUT
2 REED
;C~ 369H8306 HOSE ASSEMBLY
0,094 DIA THRU TO MATCH 0,1153 DIATHRU TO MATCH

i+i
-7 DOUBLER 6 HOLES -17 DOUBLER 2 HOLES
369024044 DECAL-POSITION
APPROXIMATEL.Y AS SHOWN
VIEW LOOKING AFT R,H, SIDE

,90
0,1137 DIA THRU
0,437 DIA :EXISTING HOLE)

OUIBOARD----~
FWD
0,55
1,00
VIEW A-A 369023016-15 RID BOTTOM VIEW
0,217 TO 0,229 DIA (EXISTING HOLE)

369028300-3 DOUBLER
369H3O2O-13 DOUBLER
0,50 DIA THRU
1,50 DIA
0,50 DIA (EXISTING HOLE)
0,070 PILOT HOLE THRU -3 DOUBLER
NAS1738M4-1 RIVET
6 PLACES EQUALLY SPACED ON 1.00 DIA -tll,00
6 REQD
O 169023020 FIAEWLL LOOKING AFT
88-376-1A
Figure 2. Drain Kit Installation PN 369D290120

Transmission Oil Cooler (Sheet 2)
1 of
E~ Huah~)s Hdlcopf(lls NOTICE NO.
DATE
DN-72. 1
6 February 1981
PAGE 9 OF 9
369A8302
OIL COOLER 369D23O2O FIREWALL
369028315 BRACKET
NAS1303-1BOLT 2 REQD
AN96OPD1OL WASHER 2 REED (EXISTING HARDWARE)
MS21O112-3 NUT 2 REOD
AN960-C716 WASHER
II REQD ~J MS35489-6 GROMMET 2 RE(JD
(369A8309)~ f7~ J4 369H8306 HOSE ASSY

J
WL
MS3367-2-9 TIE STRAP

369H2532-17 DOUBLER
SS-402-1 NUT 2 REOD 2 REOD
MS20615-3M RIVET
SS-403-1 FRONT FERRULE
5 REQD
2 REL;ID
SS-4011-1 BACK FERRUI.E T (369D23016-6) RIB
2 REOD AN833-4J ELBOW
369D28313 TUBE ASSEMBLY
TIGHTEN NUT 1,25 TURNS /STA 2 REQD
2 RE~D
FROM FINGER TIGHT AN929-4J CAP ASSEMBLY
AN924-llJ NUT
2 REQD
VIEW LOOKING INBD LH SIDE I 369H2532 RING ASSEMBLY

AN96O-C716 WASHER
II REQD
88-376-2
Figure 2. Drain Kit Installation PN 369D290120

Transmission Oil Cooler (Sheet 2 of 2)
Hughee Helicopters
REFERENCE SHEET
Act ion Ref er ence: When performing maintenance, inspection etc of main
transmission lubrication system, refer to Service
Information Notice No. DN-72. 1 for relocation of oil

drain lines to a more accessible location to facilitate
maintaining and draining the transmission oil cooler
lines.
HMI Reference: Insert this sheet in B2 sic HMI-Vo1I, Section 9,
page 9-8.
manual until the data is incorporated at the next
revision of HMI-Vol I. Refer to Service Information
Summary, HMI-VolI, page i.

f) Hughe Helicopter
REFERENCE SHEET
Action Reference: When performing maintenance, inspection, etc of

engine oil tank or engine oil cooler installations,
refer to Service Information Notice No. DN-721
for relocation of oil drain lines to a more accessible
location to facilitate maintaining and draining the
engine oil system.
HMI Reference: Insert this sheet in Basic HMI-Volume I, Section 13,
page 13-1.
manual until the data is incorporated at the next
revision of the HMI-Vol I. Refer to Service Information
Summary, HMI-VolI, page i.

Notice No. DN-73
Date: 26 March 1985
Page 1 of 1
ERRATA
Hughes Service Information Notice No. DN-73 dated 22 August 1980.
Change Page 8 of 12 as Follows:
Change Note 1 to read....Maximum allowable number of washers at
pitch arm bolt is 23.(was 32)
Change Page 9 of 12 as Follows:
Change drawing callout to read....adjusting washers (Max 23) was 32.

NOTICE NC. DN-73
UArE 22 August 1980

HUGH
ESNOTICE
SE RVI C E I N FO R MAT ION
PAGE 1 OF 12
MAN DATORY MAN DATO RY I MAN DATO RV
TAIL ROTOR
SUBJECT: PERIODIC INSPECTIONS AND BONDING PROCEDURE
PN 369A1724
DRIVE FORK ELASTOMERIC TEETER BEARINGS,
MODELS AFFECTED: All 500D Model 369D Helicopters equipped with

PN 369D21610 Four Bladed Tail Rotor Installation
TIME OF COMPLIANCE: Part I shall be accomplished at each and every 300-Hour
Periodic Inspection Interval.
the results
Part II shall be accomplished dependent on
of Pa rt I.
Part III shall be accomplished during pilots preflight

inspection.
of bearings is
Part IV shall be accomplished if debond
noted when accomplishing Parts I, II or III.
procedure for
Part I of this Service Information Notice lists a a
PREFACE:
of the subject elastomeric teeter bearings used
periodic inspection
check for permissible
with the four bladed tail rotor installation, to
the
wear and for proper bond
between the concentric metal cones and
A "short method" balance
elastomer rings of the bearing assemblies.
check of the tail rotor assembly is utilized
in Part I of this Notice.
for "long method" balance
Part II of this Notice provides instructions
if more than 15 grams of
check of the tail rotor assembly to be used
blade. Part III of this
tip balance weight is necessary on any one
Notice lists a pilots preflight inspection to
determine of debonding
the bearings
has occurred and Part IV defines a method whereby
in the field.
may be rebonded
Refer ence

500D Basic HMI-Volume I, Issued 15 September 1976;
500D Basic HMI-Volume II, Issued 15 September 1976;
HTC *D REV 1\-67

NOTICE NO. DN-73
DATE
PAGE 2 OF 12
22 August 1980
E~ wuehc niWEdptn
PAR TS LIS T
Nom enc latur e Pa rt No. aty Mfr
Shim Kit 90-369A1717 1 HH

Washer, adjusting HS306-225L AR HH
MATERIALS
Primer EA 9210 AR
Adhesive EA 9314 AR
Scouring Pad Scotchbrite or equiv. 3M Mfg Co.
Cleaner Comet or equiv. Comm
Glass Cloth No. 108 Fabric scrim Comm
Balance Kit, Tail Rotor Chadwick- Helmuth Inc.

Oven Alt. Heat Lamp Comm
O" to 500"F Temp. Range
CENERA L INFOR MA TION
All data currently in Vol I and II of the HMI,

relating to the tail rotor
applies to the two bladed rotor system only. Complete data covering the
four bladed system will be added at the next major revision to the HMI.
Prior to that revision, inspection of the blades may be accomplished in
accordance with the current HMI data but inspection of the elastomeric
bearings shall be accomplished in accordance with this notice.
The following information is applicable to components of the four bladed

tail rotor as related to the overhaul and limited life tables in Vol II.
OVERHAUL
Tail rotor transmission PN 369D25300 1800 hours
LIMITED LIFE
Tail rotor blade PN 36913)21615 10, 000 hours

Tail rotor transmission housing PN 369D25301 36, 640 hours
NOTICE NO. DN-73
Hughe HeliCopt~n DATE 22 August 1980

PAGE 3 OF 12
PART I 300 HOUR PERIODIC INSPECTION PROCEDURE
a. Measure flappin~ resistance of the inboard and outboartl blades,

using a spring scale attached within 1.00 inch inboard of the blade tip.
(See Figure 1.)
i. Tail rotor pedals in full left position.
2. Record spring scale value when blade tip is 3. 00 inches
from the zero position. Record for both inboard and

load
outboard directions (pulling 90" to the plane of rotation).
3. The load measured at the tip with 3. 00 inches deflei~tion

from the zero load position should be i. 5 Ibs to 5. O Ibs.
NOTE
If the measured loads are not within the above
limits, the bearings of the applicable inboard,

or outboard blade set must be replaced.
TAIL ROTOR
SPRING SCALE
STRING
1:Oo I
ZERO LOAD POSITION

VIEW LOOKING AFT
Figure i. Measurement of blade flapping resistance

NOTICE NO. DN-73
DATE
PAGE 4 OF 12
22 August 1980 E~ Huah" Hslicopfers
b. Perform balance check of tail rotor assembly (short method) as
follows:
i. Mount accelerometer as noted in the Chadwick-Helmuth
Operation and Service Handbook for Due-bladed tail rotor
system into the gearbox breather plug.
2. Connect accelerometer and balancer DC power cables as
noted in the Chadwick-Helmuth Operations and Service
Handbook.
3. Apply a retro-reflective target material on blade root fitting

one one blade of the outboard tail rotor assembly.
4. Connect cables and instruments and adjust settings as noted

in Chadwick-Helmuth Handbook, except set "RPM TUNE"
dial to 172 (1720 rpm, 800io N2) for initial balancing.
5. Direct strobe at tail rotor and adjust per Chadwick-Helmuth

instructions for "VERIFY TUNE"
6. Initially balance the tail rotor (at 80~0 N2) until vibration level
is O. 1 IFS (0. 85 MIL) or less as follows:
(a) Add weights to blade tips only. Divide weights as
necessary between the two lower blades to make the

total weight vector in the downward direction. (See
Figure 2.
NOTE
If more than 15 grams of tip weight (including

screw) is necessary on any one blade, use the
"long method" balance procedure per Part II
of this Notice.
7. After the initialbalance, reset "RPM TUNE" dial to 221
(2210 rpm, 1030/0 N2) for final balancing. Direct strobe at
tail rotor and adjust per Chadwick-Helmuth instructions

forVERIFY TUNE. Apply the same method used for
initial balance in step 6 above, to balance until vibration
level is O. 1 IFS (0. 85 MIL) or less.
c. Record compliance with this Service Information Notice in

NOTICE NO. DN-73
E) HUehY DATE 22 Augu.t 1980

PACE 5 OF 12
TOTAL I I t C~t----TOTAL
WEIGHT WEIGHT
TOTAL S~ALLER I\\ VECTOR
VECTOR
WEIGHT I WEIGHT
VECTOR
EBUAL EOUAL
WEIGHT WEIGHT
WEIGHT LARGE WEIGHT
OR OR
NOTE
IF WHEN ADDING WEIGHTS OUT OF BALANCE VIBRATION

LEVEL INCREASES, ADD WEIGHTS TO THE TOP BLADE OR BLADES,
88-1(14
Figure 2. Strobe pattern as seen when directed at tail rotor

NOTICE NO. DN-73
DATE 22 August 1980
PACE 6 OF 12
E~ Huehl Hlicopfn
,1?ART II "LONG METHOD" BALANCE CHECK OF TAIL

ROTOR ASSEMBLY
a. i,Prior to performing "long method" balance check of tail rotor
assembly, disassemble hub and drive fork assemblies and perform the
following
I. Determine the number of 369A1717-3 thru -91 shims required

to center the hub (Typ for inboard and outboard Hub Assy).
a) After torquing 369A1604 threaded bushing to 55-65 inch-

Ibs, measure dim A on hub and calculate shim thickness
B using formula
B 2.252 (2xA)
b) If (2xA) is greater than 2.252 add shim B as shown.

If (2xA) is less than 2.252 add shim B to surface M.
SURFACE fll\
I i I
88-415
Figure 3. Centering of tail rotor hub and drive fork

NOTICE NO. DN-73
E) nus~ nscopts~ DATE 22 August 1980

PACE 7 OF 12
2. Determine 369A1717-3 thru -91 shims required to preload

elastomeric bearing.
a) Measure distance D on fork assembly and calculate

thickness of shim C using formula
D-2.275
b) Install shim C on both sides of fork as shown in

Figure 4.
t
C
88-1116
Figure 4. Preload of elastomeric bearings.
c) Install hub assembly to fork using shims B and C

as shown in Figure 5.
b. Reinstall inboard tail rotor hub and drive fork assembly and
inboard tail rotor blade assembly on helicopter.
c. Perform "long method" balance check of tail rotor assembly as
follows:
i. With outboard blade removed, balance inboard blade by

adjusting tip weights and HS306-225L washers at pitch arm
bolt to achieve 0. 10 IFS (0. 85 MIL) or less vibration level

at 2100 rpm (input shaft of gear box). This corresponds to
a tail rotor rpm of 2168.

NOTICE NO. nN-73
J)ATE 22 AuUusl 19RO E) Hugh. HslicOpt~s
PAGE 8 OF 12
SHIM
il~ SHIM (NOTE)
SHIM
88-1117
Figure 5. Hub and fork installation
ADJUSTING WASHERS
(NOTE 1)
SHIMS (NOTE 2)
SHIM
NOTES:
i, I1AXIMU# ALLOIIACLE NUMBER OF, IIASIIERS AT PITCII ARI" BOLT IS 32.

WHENEVER THIS LIMIT IS AEACIIED AND AEOUIRED BALANCE CANNOT BE
MET, SHIII THE CENTER OF 1HE HUB DY TRANSFERRING SHlnS THLCK-
NESS OF 0.010 FROM PITCII ARM SIDE TO TIIE OPP(ISITE SIDE ns
SI(OWN AliD PICHECK BALANCE, STARTING FROF; ZERO WASHERS,
2. REMOVE 0.010 THICK SHIM FROM PITCH ARII SIDE nND TRANSFER i~iE
SHIM TO THE OPPOSITE SIDE.
88-1118
Figure 6. Long method balance check inboard blade only

NOTICE NO. DN-73
Hughe Hslisopter DATE 22 August 1980

PAGE 9 OF 12
Install outboard blade and hub assembly; check balance of

2.
outboard blades by adjusting weights to obtain 0, 10 IFS
85 MIL) vibration level less, using the same method
(0. or
as used for inboard blade balancing, except as shown in
Figure 7 below.
3. After balancing, color code blades with lacquer per TT-L-32.

Color blue No. 15102 and green No. 14187, per Fed-Std-595.
Dots to be 0. 12 to 0, 18 inch diameter and dashes to be
0. 11 x 0. 38 to 0. 50 length.
ADJUSTING WASHERS (MAX 32)
SHIMS (NOTE
SHIM
NOTES:
i. REMOVE 0,010 TIIICK SHIM FROM PITCH ARM SIDE

AND TRANSFER THE SHIM TO THE OPPOSITE SIDE.
2. DURING BALANCING OF OUTBOARD BLADES, WEIGHTS

ON INBOARD BLADES MUST NOT BE CHANGED.
88-1119
Figure 7. Long method balance check outboard blade only

NO~ICE NO. DN-73
DATE 22 August; 1180 Hughel Helicoptera

PACE 10 OF 12
PART III. PILOTS PREFLIGHT INSPECTION
General. Prior to pilot shall inspect the elastomeric bearing in

flight, the
accordance with the following procedure. This inspection is in addition to

those items of inspection currently stated in the preflight inspection for the
tail rotor, Controls, and transmission.
a. Visual check for failure between the metal cones and the elasto-
meric elements in the bearing assembly, as follows:
i. Apply a teetering force by hand (stop to stop) to both sets of
rotor blades in succession.
2. Visually inspect four elastomeric radial molded ridges on
each bearing outer face as teetering takes place.
NOTE
If ridges assume a shape when fully

continuous curved
deflected, the bearing is intact. Discontinuity in

molded ridges indicates bearing failure. No shape
change is explained under b.
b. Visually check for bond failure between the bearing and the tail
rotor fork as follows.
i. Repeat step a. 1 above, and observe bearing outer cage for
relative motion to fork.
NOTE
There should be no apparent motion between the cage
and fork. Observed motion indicates bond failure.
c. Visually check bearing for general condition.
NOTE
Evidence of light swelling, pock marks and crumbs
are surface conditions and are not indications of
bearing failure.
NOTICE NO. DN-73
Hughsa Halieopters DATE 22 August 1980

PACE 11OF12
CAUTION
If bond or elastomer failure is noted per steps a and b,

rebond bearings per Part IV. If the aircraft is oper-
from remote location, flight not to exceed

ating a a
3 hours duration, may be made back to

base. During
avoid rapid turns and minimize hover
theflight
maneuvering.
PART IV. ELASTOMERIC BEARING REBONDING PROCEDURE
of the elastomeric bearing assembly shall be

General. Rebonding
accomplished per the following:
a. Abrade outer metal surface of bearing with wet Scotchbrite (or

and Comet cleanser (or equivalent). Rinse with distilled water
equivalent)
and dry.
b. Prime faying surface with EA9210 primer by brushing or spraying

for minimum of 30 minutes at ambient temperature. Cure primer
and air dry
one hour minimum at 100" rtlO"F.
NOTE
A heat lamp may be used.
in the bearing of fork.

c. Repeat above procedure area
surfaces with masking tape for protection from

d. Mask all non-faying
excessive adhesive and to expedite clean up.
surfaces. Place ply

Apply mixed EA9314 adhesive to faying
one
e.
of 108 glass fabric scrirn cloth on faying surface

of bearing. Insert bearing
and cure for hour
Align, using 1/4-inch diameter bolt
one
in to fo rk.
~10"F. Alternate is 24 hours at ambient
minimum at 200" cure
temperature. (See Figure 8.
NOTE
Spring loading is required to maintain force during cure.
FAA/DER APPROVED
NOTICE NO. nN-73
DATE 22 August 1980 nughe~ nslicopters
PACE 12 OF 12
1/4 INCH BOLT
AS REQUIRED
HUB
i "I"(HOTE)
NUT
NOTE:
SECURE CLEARANCE OF .00117-.0027

AND TORBUE TEETERING NUT UNTIL
SPACER SITS ON BEARING,
88-1122
Figure 8. Bonding Set Up

N(,11(:[ N(! I)N-76
8 I)eccmber 1C)80
HUGHES
SERVICE INFORMATION I~r\c;t
NOTICE
SUBJECT:
REWORK OF STATIC PRESSURE TUBE INSTALLATION TO MINIMIZE ALTIMETER
NEEDLE OSCILLATION
PREFACE: The information given in this Service Information Notice lists a pro-
cedure for rework of the hardware connecting the crossover tube between
the altimeter and airspeed panel to reduce
indicators on the instrument
needle bounce. The primarily
rework removing
consists the existing of
369B6610-3 plug from the connector at the airspeed indicator and
installing a new 36986610-23 plug in the existing tee at the altimeter
ind icator.
REFERENCE
500D Series Basic HMI-Volume I, Issued 15 September 1976, Revision No. 3,

15 March 1979
Customer Service De~artment Hughcsllcl.icopters Cuhil C-itl, i.;llifolnia
IOHHN(I Itl( ~I)RIV 11-67

NOTICE NO. DN-76 E) Hueh Hlicopfsrp
PAGE 2 OF 3
PARTS LIST
NOMENCLATURE PART NO. QTY MFR
Plug 36986610-23 1 HH
b. Remove instrument panel fairing and hood, per HMI-Vol I.
c. Disconnect drain tube from 369B6628 tee at altimeter indicator.

(See Figure i.)
d. Press fit new 369B6610-23 plug into tee as shown, reconnect drain
tube to tee. (See View B.)
e. Disconnect crossover tube from connector at airspeed indicator.
f. Remove existing -3 plug from 369116610-11 or -21 union assembly.
g. Reconnect crossover tube to connector at airspeed indicator.
h. Reinstall instrument panel fairing and hood.
i. Perform flight test to check instrument operation.
FAA/DER APPROVED 17 December 1980

4~ Huehea Helicopters NOTICE NO. DN-76
PAGE 3 OF 3
COVER PANEL
I: .,AIRSPEED
INDICATOR
NY11OO-1-OR ALTIMEIEK,
0,310
369H6610-11 OR
CONNECTORDETAIL
-J PLUG
0.250
369H6610-21
j
UNION ASSEMBLY
-11 UNION ASSY Ij

0.022
DIA HOLE
0.019 NYLON CROS
NY$00-1-2
TUBE DRAIN
CONNECTOR -3 PLUG VALVE
PANEL
0,310 O INSTRUMENT
ITYPICAL)
0.250
ITOT PRESSURE
i
NYLON TVBE
O DETAIL -21 UNION ASSY
FLUSH THIS SIDE

]q
O PITOT TVBE ASSEMBLY
88-1127
Figure i. Rework of static pressure tube installation

NOTICE NC). DN-78. 1:::
HUGH ES v/\TE 28 July 1181
SERVICE IN FORMATION PAO (31_-ii
NOTICE
Service Information Notice
No. DN-78, dated 14 January 1981
SUBJECT: INSPECTION OF PN 369A7003-3 SWASHPLATE BEARING
MODELS AFFECTED: 400D Model 369D

SerialNo. 0003D
helicopter
through 0830D
I
TIME OF COMPLIANCE: Shall be accomplished within next 300 hour s of helicopter

operation or at next annual inspection, whichever occurs
first.
for inspection of PN 369A7003-3 bearing assembly for

procedure
cracks around mounting holes in the bearing sleeve.
Reference
500D Model 369D Basic I--lMI-Vol I, Issued 15 Septemher 1976, Revision No. 5,
14 May 1981
500D Model 369D Component Overhaul Manual, Issued 15 September 1976
FORM 9578 (2/81)

Huehes Helicopters, Inc. culver city, California 90230
NOTICE NO. DN-78. 1
DATE 28 July 1981
PACE 2 OF 5
PARTS LIST
aTY NFR
NOMENCLATURE
36912700313 1 HII
Bearing assembly:::
369~621605-5 4 HI-I
I Washer
AN960PD416L AR Commercial
MA TE RIALS
908-L-02110 Glidden-Durkee Div.,

Printer, zinc chromate
SCM Corp.
(TT-P-1747)
900 Union Commerce Bldg.
Cleveland, Ohio 44115
1063-166 E.I. DuPont de Nemours Co.

Marshall Laboratory
3400 Grays Ferry Ave.
Philadelphia, PA 19146
INSPEC TION PROCEDURE
from helicopter (refer to Basic

swashplate assembly
I a.. Remove
HMI-Vol i, Section 7).
b. Remove PN 369A7003-3 bearing assembly from swashplate assem-
bly and clean (refer to 369D-COM, Part V, Sections 2 and 3).
for cracks using the dye penetrate

c. Inspect subject bearing assembly
method, with special att8ntion to area ofbearing sleeve around four mounting
holes where bearing assembly bolts to stationary swashplate.
CAUTION
Ensure that solution does not permeate either
ball or teflon bearing.
it be replaced with
d. If cracks are found in bearing assembly, must
and installed per steps f. and g. below.

a new bearing assembly
I aIf required
only when using alternate method of installing bearing attach bolts.
NOTICE NO. DN-78, 1
DATE 28 July 1981
PAGE 3 OF 5
found in bearing assembly, it may be reinstalled

e. If no cracks are
and g. below.
per steps f.
NOTE
Ifsuspect indications are discovered by dye

be definitely
penetrate inspection, which cannot
confirmed, the subject bearing assembly is to
be reinspected using the magnetic particle
method. After magnetic particle inspection,
d. above.
perform step or e.
CAUTION
Ensure that solution does not permeate either
ball or teflon bearing.
f. original (or new) bearing assembly in swashplate assembly

Install
attach bolts as
per 369DICOM, Part V, Section 6, except install bearing
foil ow s
NOTE:
Some bearing assemblies may have sharp

edges around the mounting holes. Ifsharp
file
edges have nicks, dress out: using hand
or emery cloth and apply
zinc chromate
primer.
Bolts may be installed with heads facing inward

i. by installing
one PN 369A1605-5 washer under head of each bolt.
Bolts may be installed with heads facing outward by installing

2.
under bolt head to
PN AN960PD416L washers as required (two maximum)
maintain 1.5 to 2 threads of bolt and a minimum of O. 100-inch dis-
exposed
tance between ball and bolt.
helicopter (refer to Basic

g. Reinstall swashplate assembly on
HMIIVol i, Section 7).

NOTICE NO. DN-78. 1
T)RTE 28 July 1981
PAGE 4 OF 5
CAUTION
If PN NRS1304-15 and NAS1304-16 bolts are
used to uttach bearing assembly to swashplate

and bolts installed with heads
I assembly were
facing outward (step f2 above), position con-
trols full collective down and full forward cyclic

left and full forward cyclic right. Observe if
forward bolts interfere with mast, If interfer-
ence occurs, repeat step a., replace

PN NAS1304-15 bolt with PN NAS1104-I5 bolt
and PN NAS1304-16 with PN NAS1104-16 bolt
and repeat step g-.
h. compliance with this Service

Record Information Notice in
FARIDER APPROVED 29 July 1981

NOTICE NO. DN178. 1
DATE 28 July 1981
PACE 5 OF 5
(NOTE)
d.
nianlr;
MOUNTING HOLES
Ij- 1
i,
81
(1I>i
i,-i
ROTATING SWASHPLATE
L-]E: r:
\:i S 3d
9
leY i
STATIONARY SWASHPLATE
NOTE:
BOLTS MAY BE INSTALLED WITH

HEADS FACING INWARD nS AN
ALTERNATE METHOD, REFER TO
TEXT FOR INSTRUCTIONS,
88-113111\
Figure i. Inspection of Swashplate Aearing

NOTICE NC. DN-79
HUGHES DATE 30 January 1981
SERVICE INFORMATION pact OF
4
NOTICE
SUBJECT: SEALING OF INTERFACES OF ABRASION STRIP AND MAIN ROTOR

BLADE SKIN
MODELS AFFECTED: 500D Model 369D Helicopters equipped with PN 369nZ1l00

Rotor Blade Assemblies with Serial Nos. below 6551.
500MD Model 369MD Helicopters equipped with PN 421-086
Main Rotor Blade Assemblies with SerialNos. below 0377.
TIME OF COMPLIANCE: When main rotor blade(s) show visual signs of adhesive
erosion at interface with abrasion strip.
for sealing of interfaces of abrasion strip and main rotor blade skin to
inhibit corrosion and/or adhesive erosion.
Form9578
9)181 H1C *D RLV 11-67
NOTICE NO. DN-79
I)ATE 30 January 1981 Hueh~ Hslicopt~r
2 of 3
TOO1Js AND ECZUIPMENT
Sealant applicator gun or spatula
MA T ER IA LS
Solvent- M-114M, J.B. Moore Company, 1605 Ventura Blvd., Encino,

CA 91436 or Methyl Ethyl Ketone (MEK), TT-M-261
Los Angeles, CA 90045

~2tlhesive EC2Z16 B/A, 3M Company, 6411 Randlph,
Sealant PR1436G, Class B- 2 or
PR1422G, Class B
Products Research and Chemical Corporation, 2)19 Empire Avenue,

nurhank, CA 91504
Release a~ent TC7-527, EPD Industries, 2055 E. 223 Street, Long neach,
CA 90810 or 225, Ram Chemical Company, Gardena, CA
PROCEDURE
a. Remove screw and tip cap from main rotor blade.
cracked sealant adhesive from areas of main

h. Remove any loose or or
rotor hlade shown in Figure i.
WARNING
MEK is flammable. Use in well ventilated area and
away from smoke and flame.
c. Clean areas to he sealed with clean cloth moistened with M-114M solvent.
Ic,r hard to clean problem areas MEK solvent may be used. Wipe surface
tlry hcfore solvent epavorates.
(1. I~relare EC2216 B/A adhesive per manufacturers instructions.
c. hpp]y.bead of adhesive to interface of abrasion strip and blade skin as
Cure
shown in Figure i. Ensure that there are no gaps or bridges in bead.
adhesive per manufacturers instructions.
NOTICE NO. DN-79
Hughes Helicopter. DATE 30 January 1981

PAGE 3 of 4
f. Seal tilr, cap as follows: (See Figure 1)
i. AI~Ply release agent to inside of tip cap per manufacturers

instructions.
2. Prepare and apply a 0. 010 to 0. 020 inch coating of PR1436Cr

Class B-2 or PR142ZG Class B sealant to faying surfaces per
n~anufacturers instructions.
with zinc chromate primer.

3. Attach tip cap to blade and install screw
4. Wipe off squeezed out sealant flush with surface.
NOTE
To inhibit moisture entering bond joint of abrasion strip

after initial application, reapply sealant, when sealant is
worn away or becomes cracked.
Record compliance with this Service Information Notice in Compliance

Record of helicopter I,og Book.
FAA/L)EII APPROVED 2 February 1981

NOTICI;3 NO, DN-79
I)ATE ?O January 19K1 Hughar Hlicol~or
PACrE 4 of 4
c C ~iL;I":n:
SLn~ WITii
--rR14%2b, (i.ic:: i
SEAL WITII EC2216 B/A FROM L.F. T

0.75 D1M. ON T.t. RAUIIIS C
UPPLH AND L.OWER SIIRIACI.
0.75
369D21100 MAIN ROTOR BLADE ASSEMBLY
369021105 ABRASION STRIP REF

0.003
36961103 SKIN REF

i- 0.005
TYP
ISEAL WITH
CC2216 E/~
0,010
369A1109-501, 269(11186 SEAL
TYP
BAL. WT. REF SKIN/BAL, lil, n~r,Y
:tAL WITH I INTERFACC W1T~i
1C221ti Ic/n U
EC22!h B/Ti
A-A TlP CAP Oi?lTTt0 rOi( CLnP.ITV
f= SEAL SCRfW
369021105 ABRASION STRIP
BY INSIALLING
NAS517-~?:?-
3691\1103 SKIN WITII YiT ZIN(
CHROMATC PPI?IIK
C-C 7YP 2 PLACES
Figure i. Sealing of Abrasion Strip and Tip Cap

NOTICE NC. DN-80
~dl
HUG HES
DATE 20 March 1981
SE RVICE IN FORM A~ION PAGE 1 OF 13
NOTICE
MANDATORY MANDATORY
MANDATORY
SUBJECT. REPLACEMENT OF TAVCO PN 23111369 SOLENOID

VALVE, FLOAT INFLATION SYSTEM EMERGENCY
FLOAT ASSEMBLIES, HUGHES PN 369D290121-501 AND
369D290121-404.
MODELS AFFECTED: All subject float assemblies, incorporating subject
solenoid valve, installed on 500D Model 369D helicopters
or in Spares Inventory.
TIME OF COMPLIANCE: Part I: Shall be accomplished at next replacement of subject

solenoid valve.
Part II: Shall be accomplished after each activation of squib

valve assembly.
PREFACE:
The information given in Part I of this Service Information
Notice lists a procedure for replacement of the TAVCO solenoi
valve, in the emergency float system, with a TAVCO squib

valve assembly. The subject solenoid valve is no longer
available from the manufacturer. Therefore, when replace-
ment becomes necessary, it must be replaced with a TAVCO
squib valve assembly tin sets only). This Notice also provides
for rewiring of the emergency float system to actuate the new
squib valve. Installation of squib valves removes the 32" F
temperature limit. Accomplishment of Part I reidentifies
float inflation system to PN 369D290121-519. Part II lists
procedures for replacement of PN 232626-1 squib valve after

each activation of squib valve assembly.
Reference
I, Issued 15 September 1976; Revision No. 3,

500D Model 369D Basic HMI-Vol
14 March 1979
IPL and Maintenance Instructions for Emergency Float Kit Extended Landing Gear,
Publication No, CSP-025, Issued 15 August 1977
Customer Service Deprutment
FORM 9578 (2/81)

Hu(lhes Helicopters, Inc. culver city, california 90230
NOTlCE NO. DN-80
DATE 20 March 1981
PAGE 2 OF 13
PARTS LIST
When ordering, specify Kit No. M40458 (Commercial) or M50458-5
(Military) consisting of:
N OMENC LA TU R E PAR T NO. QTY MF R
Valve, squib (LH) 23111380-3 1 TAVCO
Valve, squib (RH) 23111380-4 1 TAVCO
Kit squib valve replace- 50014114 2 TAVCO

ment (for valves with sealed
cover)
Kit squib valve replace- 50014115 2 TAVCO

ment (for valves with button
type cover)
Fitting 60056163 2 TAVCO
Packing MS 28 7 7 8- 12 2 C omme re ia I
Packing MS28778-6 4 Comme rcial
Card, VNE 369D2925 74-49 1 HH
Card, VNE 369D2925 74-51 1 HH
Card, VNE 369D292574-53 1 HH
Card, VNE 369D292573-19 1 HH
Electrical Znstl Kit (Comm) 369H92557-511 1 HH
or
Electrical Lnstl Kit (Mil) 369H92557-513 1 HH
consisting of:
Switch assy 369H92557-61 1 HH
Disconnect 32445 2 Amp Inc.
Disc onnect:z 32445 8 Amp Inc.
Sleeve D121# 8 Ra yc he m
Sleeve:l:.-:: o121# 2 Raychem
Sleeving RNF1O OX 1/4 AR Raychem
Cap:": 3/16 PD 4
NOTICE NO. DN-80
DATE 20 March 1981
PAGE 3 OF 13
PARTS LIST (cont)
NOMENC LA TU R E PART NO. Q TY MFR
Contact MPC M2 0 MH2 3 Burndy Corp.
MS2 50 36 1 03 2 C omme r cial

Te rminal
MS2 50 3 6- 1 0 3 3 Commercial
Te rminal:~:::
MS25036-149 1 Commercial
Ter mina 1
MS25036- 149 1 C o mme rcial

Terminal:I:
Sleeving RNF 10 OX 1-8 AR Raychem
MS25181-1 4 Commercial
Splice
P T 0 61- 8 4S 2 Bendix P lug
Connector
Alternate PN NAS1745-3
Component of 369H92557-513
~::::Component of 369H92557-511
TOOLS AND EQUIPMENT
X-Acto knife
Torque wrench
Blow equivalent source of hot flowing air
dryer or
Volt-ohmmeter (VOM), Simpson 260 or equivalent

Alien Wrench 3/16 inch
MA TERIA LS
Wire, MIL-W-5086, Type II, 22 GA, one conductor
Cable, MIL-C-7078, CL A, Type 2, two conductor shielded (red and black)
Wire, MIL-C-7078, CL A, Type 2, 20 GA, one conductor shielded
Wire, MIL-W-5086, Type II, AWG 20, one conductor
Sleeving, MIL-I-631, Type F, No. 20
Grease MIL-G-4343 or equivalent
Alcohol
NOTICE NO. DN180
DATE 20 March 1981
PAGE 4 OF 13
PART I REWORK PROCEDURE
a. Turn off electrical power.
(Refer to CSP-025)
b. Unpack emergency floats.
c. Remove valve protector and unlace cylinder sling lacing cords.

(See Figure 1)
d. Disconnect solenoid valve electrical wiring knife splice at (SP4,

SP5, SP9, and SP10) solenoid.
Loosen nut at outlet port of solenoid valve. Disconnect valve

e.
assembly from union by unscrewing cylinder assembly in counter-

and valve
clockwise direction. Remove cylinder and valve assembly. (See Figure 1)
is not empty, discharge follows:

f. If cylinder as
WARNING
Exercise care when discharging cylinder.

Personnel can be injured by high pressure
air or flying debris.
in chain vise equivalent. Point filler

1. Secure cylinder or
valve outlet in safe direction.
Use two open end wrenches, one on filler valve body and one
2.
on nut. Turn nut slowly counterclockwise 2-1/4 turns and allow all pressure
to es cape. Check gage to verify that no pressure remains in cylinder.
Remove solenoid valve from cylinder. Discard solenoid valve and

g.
packing. (See Figure 1)
h. Install new squib valve (PN 23111380-3 LH float, PN 23111380-4

cylinder. Torque to 360-504 inch
RH float) with PN MS28778-12 packing on
pounds. (See Figure 2)
i. Install fitting with PN MS28778-6 packing on existing union. (See

Figure 2)
Recharge cylinder and test for air leaks. (Refer to CSP-025)

j.
with PN
k. charge cylinder and squib valve assembly
Install
MS28778-6 packing on fitting. (See Figure 2)
NOTIC E NO. DN-80
DATE 20 March 1931
PACE 5 OF 13
i. Revise emergency float electrical system as follows:
1. Remove access panels and/or covers as necessary tu expose
eme rgenc y float wiring, (Refer to Basic I-SMI Vol I)
2. Remove all emergency float wiring except as noted in
Figure 3.
3. Remove and discard relay installation, doubler and attaching

hardware located on pilots floor support, left bulkhead.
4. Remove emergency float switch light assembly and install
new switch light assembly.
5. Install wiring as shown in Figure 3. Do not plug in electrical
connectors (P101 and P102) until after electrical system check.
6. Reinstall access panels and/or covers. (Refer to Basic
m. Turn on electrical power.
n. Perform inflation system electrical control equipment operational

check as follows:
1. Test light check.
(a) Check ship voltage with VOM. Voltage should be 27. 5
VDC.
(b) Open emergency float circuit breaker (CB1Z1).
lead of 0.5 ohm ~50/0, 10W resistor in pin A of

(c) Install one
lefthand connector (P101). Connect one test lead of ammeter (VOM) to other
lead of resistor. Connect other test lead of ammeter (VOM) to pin D of
connector (P101).
(d) Close emergency float circuit breaker (CB121).
(e) Press "PRESS TO TEST" switch and observe current
reading on meter and brilliance of lamps. Current should be 75 MA
minimum and brilliancy of lamps should be fairly bright.

NOTICE NO. DN-80
DATE 20 March 1981
PAGE 6 OF 13
(f) Open emergency float circuit breaker (CB1Z1).
(g) Remove meter and resistor from connector (P101).
(h) Repeat steps (c) through (g) for righthand connector (P102).
2. System check.
(a) Ensure that circuit breaker (CBIZ1) is open and connectors
(P101 and P102) are disconnected.
(b) Install one lead of 40 ohm ~1OJo, 20W resistor in pin A of
lefthand connector (P101) and install other lead of resistor in pin D of
connector (P101).
(c) Connect test leads of volt meter (VOM) across resistor.
(d) Close emergency float circuit breaker (CB121).
(e) Press firing switch on pilots grip and observe voltage on
meter. Voltage should be 25.5 VDC minimum.
(f) Open circuit breaker (CB121).
(g) Remove meter and resistor from connector (P101).
(h) Repeat steps (b) through (g) for righthand connector (P1OZ).
3. Connect connectors (P 101 and P102) to squib valves.
4. Close emergency float circuit breaker (CB121).
5. Press "PRESS TO TEST" switch and observe that lamps light.
6. Open circuit breaker (CB121).
o. Ensure that cylinder is positioned sothat pressure gage is visible
through inspection window when floats are stowed (pressure gage axis
inclined outboard approximately 40"
p. Repack emergency floats. (Refer to CSP-025)

NOTICE NO. DN-80
DATE 20 March 1981
PAGE 7 OF 13
VNE cards (solenoid valve, floats stowed (3) and

q. Remove existing
solenoid valve, floats inflated (1)
Install PN 369D292574-49, -41 and -53 VNE cards (squib valve,

r.
VNE card (squib valve, floatsinflated).
floats s eowed and PnT 369~3292573119
this Service Information Notice in

s. compliance with Part I of
Record
Book.
Compliance Record of helicopter Log
PART II REPLACEMENT OF PN
232626-1 SQUIB VALVE
valves with sealed covers as follows: (See Figure 4)

a. Replace squib
i. Removal of actuated valve.
manifold charge valve to verify that

(a) MANDATORY: Open
vessel.
there is no pressure in the pressure
squib with respect to pressure gauge.

(b) Note orientation of
black plastic all

(c) Using X-Acto knife, cut through
cover
and to uncover four screw heads near

around valve-body to manifold joint
outlet port (See Figure 4).
the four screws near the

(d) Using Alien Wrench, remove
Retain screws to use with new valve.

outlet port.
(e) Pull 232626 valve straight off manifold until separated.
(f) Discard actuated valve.
Installation of Replacement Valve.

2.
lubricate O-ring new valve with ~vIIL-G-4343 or

(a) Lightly on
equivalent pneumatic grease.
Maintaining squib orientation noted in step 1 (b) above,

(b)
Valve must bottom metal-to-metal on
install 232626 valve onto manifold.
of the cover may be
plastic
the face of the manifold. Minor trimming
required. Remove minimum material.
NOTICE NO. DN-80
DATE 20 March 1981
PAGE 8 OF 13
(c) Install the four screws hand-tight (Note: helicoil insert
in manifold has locking thread).
the four evenly until

(d) Using Alien Wrench, tighten screws
a Torque Wrench, apply 38 to 43 Ib-in. torque to the screws.

bottomed. Using
(e) To reseal the black plastic cover clean the surface with
alcohol and apply a thin coat of the black fluid supplied with the 50014114
kit to the valve body and manifold joint. Cure with hot air until it turns
shiny, then remove heat source.
To reseal the screw holes, preheat the screw heads with hot air. Fill the
cavities with the black fluid and cure with hot air until shiny, then remove
heat source.
NOTE
Multiple required to seal the joints

coats may be
completely. Resealing is recommended for

maximum protection from corrosion in a humid
environment. If is not mandatory for valve
o pe ration.
valves with button type follows:

b. Replace squib covers as
1. Removal of actuated valve:
MANDATORY: Open manifold charge valve to verify that

(a)
there is no pressure in the pressure vessel.
(b) Note orientation of squib with respect to pressure gauge.
small
Spread plastic cover at its parting line until the
(c)
round end of the white plastic buttons pull through the black plastic and over
the valve
the squib connector, allowing access to the four screws that retain
body.
the four the

(d) Using Alien Wrench, remove screws near
outlet port. Retain screws to use with new valve.
(e) Pull 232626-1 valve straight off manifold until separated.
(f) Discard actuated valve.

Hughes Helicopters NOTIC E NO. DN-80
DATE 20 March 1981
PAGE 9 OF 13
2, Installation of Replacement Valve:
(a) Lightly lubricate o-ring on new valve with MIL-G-4343 or
equivalent pneumatic grease.
(b) Maintaining squib orientation noted in step 1 (b) above,

install 232626-1 valve onto manifold. Valve must bottom metal-to-metal
on the face of the

manifold.
(c) Install the fout screws hand-tight (Note: helicoil insert
in manifold has locking thread).
the four evenly until

(d) Using Alien Wrench, tighten screws
43 Ib-in. torque to the

bottomed. Using a Torque Wrench, apply 38 to screws.
(e) Remove plug from squib connector, notice the plug only
the squib
fits one way. Realign the black plastic cover and pull it back over
the white plastic buttons
connector. Replace the squib connector plug. Snap
as they were before. Check
back through the holes in the black plastic cover
the plug in squib connector to insure that it is bottomed.
Service Information Notice

c. compliance with Part II of this
Record
in Compliance Record of helicopter Log Book.
FAA/DER APPROVED 16 April 1981

NOTICENO. DN-80
DATE 20 March 1981
PAGE 10 OF 13
VALVE PROTECTOR (REMOVE)
SOLENOID VALVE ASSY (REMOVE)
NUT (DISCONNEtT)
8 D
UNION cROsS
PRESSURE CYLINDER
88-937
Figure 1. Removal of Solenoid Valve Assembly
PT06P8-~S
BENDIX CONNECTOR (REF)
23111380-3 TAVCO SQUID VALVE ASSY (LH)

23111380-4 TAVtO SQUID VALVE ASSY (88)
2370039 PRESSURE tYL (REF)
(INSTALL)
60056 TAVCO FITTING (INSTALL)
(EXISIING)
UNION (EXISTING)
II O
MS28778-6 PACKING CROSS

(INSTALL) (EXISTING)
TORQUE TO
360-5011 ~528778-12 PACKING
INCH POUNDS (INSTALL)
88-1138
Figure 2. Installation of Squib Valve Assembly

PILOTS-INF~ATE FLOATS SWITCH
r- i~ sj
1
369H90129-505 GRIP(REF.)
REMOVE WIRE A510A20 FROM PIN J130-H,
I i
LI3 1)
r.521C20 FROM PIN J13O-D, A507A20 FROM
NOTES:
11.20 PIN J130-M AND A50SB20 FROM J130-N
12 20
17.20 AND STOW WITH 3/16 PD CAPS i. EXISTING EMERGENCY FLOAT
FOR 369H92557 511 16.20 15.20
JUMPER #22 tA. 4 REQD SYSTEM WIRING. DO NOT REMOVE
SEE SHEET 2 FOfi
H N D M 7 1 3/16 PD CAPS 4 REOD 2. SHIELDS TO BE TERMINATED
369H92557-513 J13O B
32445 SPLICE 4 REQD 0.50 INCH MAXIMUM FROM
(NOTL 1)
L _ _ _ C _7_~ _~
F _J SLEEVING A/R END OF INSULATION ON WIRE
MS25036-103 TERMINAL 2 REQD (EXCEPT AS NOTED) JUMPERS
E5) TO BE TO A MINIMUM LENGTH.
~1 MPCM20M-H2 PIN 2 RE(3D
0121 SOLDER SLEEVE 2 REQD
MPCM20M-H2 PIN CI (NOTE 2)

RED OR YELLOW
1REQD
Ttil-18 C A 1 I M506M20 CABLE BLACK OR BLUE I ,TB1-15
(REF.) 28 V. BUS
3~(REF.) I TB1-9
t
36-103 E2 A
A B C D ~JI(NOTE 2)
SP3 B
TERM. I I, IV A,BLACKORBLUE B
SP9
FLOAT SYSTEM M506N20 SQUIB FLOAT
BUS WIRE r
CABLE (REF) (S3)o NO VALUE R.H.
P1O2
C M512A20N
CB121 B
NC
I i I
v
I 2TClf7.5 CIR.
BKR7.5f_ (HOTE 2;
NO
(NOTE
21X: C
MS25O36-149 TERM, (S2)
C 7J NC
ii II I
O NO M925181-1 SPLICS I SQUIB FLOAT

(NOTE 1) RUI OR YELLOW RI
r c
ta, I IIREQD VALVE L.ii.
MS25O36-1119 TERMINAL Nt JUMPER GA.20 BENDIX PLUG
P1O1
LREQD BREQD
7,5A A
~i- MS2529C7.5 R2 i r I MS25O36-103 (NOTE 2) C
CIRCUIT BKR.
CBIlI 5
TERMINAL 2 REQD, M_511A20N rl D
P5O6M20 4 1 0121 SOLDER B
2 v
EMERGENCY FLOAT SLEEVE SREQD crlt)f~
28V. BUS
(REF)
(REF.)
SYSTEM BUS WIRE
L.H, R.H. RNF100X1/4 SLEEVE

2,0 M4~ IF BENOIX PLUG
P/N PTOGP-8-II-S
O c3 3
M m cl
(A/R LH AND RH SIDES)
t_FOR-5Uj M
L 00Z
(NOTE 1) O
i--~3 369H92557-61
r
U SWT/LT ASSY 88-439-1

SYSTEM TEST PRESS O
r
Figure 3. Emergency Float System VViring Diagram (Sheet 1 of 2) r
(X)
g0
Co
r
NOTICE NO. DN-80
DATE 20 March 1981
PACE 12 OF 13
-r ss
1 2
20 GA I
36902973116 GRIP
3 4
(REF)
a a
r:
4 ~1
SP1O1 SP103 SPIOS SP1O5 SP1O4 SP102

J109 B I I B B B BI I B
REF I J A A A A A A
321145 SPLICE
10 RE~D
E5
o o
CI G~
~D
8
P m
3Y~ 4
MPCM20MH2
PIN~I TRI-8 TBI-9 g 5 r
g 8
1Alr I~ cs es
B CABLE
(REF)
M506N20 REF
SP3 A A SP9
A B C D
TBI-15 REF
FOR 369H92557-513 (NOTE 1)
BLACK
M506N2O
2;ri;1 R2;1
5 1 4
II,
(NOTE 2)
o
ONC
(NOTE 2)
Na
RED
(0) I L~C( C
C MPCMZ(IMH2 PIN 1 REQD
MS25O36-1O3 TERMINAL 1 REOD
(S9-3) (S9-2) (S9-1) 0121 SOU)ER SLEEVE 2 REQD
R,H, FLOAT REF L,H, FLOAT REF JUMPER #22 GA
369092557-61 SWITCH LIGHT ASSY

88-1139-2
Figure 3. Emergency Float System Wiring Diagram (Sheet 2 of 2)

NOTICE NO. DN-80
DATE 20 March 1981
PACE 13 OF 13
SQUIB (REF)
OUTLET (REF)
SCREW LOCATION
~PLACES
VALVE BODY
II~NIFOLD JOINT
(CUT ALL AROUND)
88-1175
Figure 4. Replacement of Squib Valve with Sealed Cover

NOTICE NO. DN-81, 1*
~-IUQHES om t 10 Uay 1983
1 ~u6b
N
"B
M~8
hg
.j~
i] ili~u
pY
1~
C~
1 j-~
,j ~i% IBBB
~j t;C~ rm~R
I I ~,B
.yr~:2 ii PAGE OF
6
"Supersedes Service Information Notice

DN-81, dated 13 March 1981
CnAWa~TORY MAN DATORY JZBP111118 PI1AN DATORY

li~gl
-i i
SUBJECT: INSPECTION 01; OVERRUNNING CLUTCH SPRAG ASSEMBLY
MODELS AFFECTED: All 400D ~iodel 369D Series Helicopters equipped with any Cargo Hook
TIME OF COMPLIANCE: ""Shall be accomplished for helicopters with sprag assembly

I
exceeding 600 hours in service, within next 40 hours and there-
after each 300 hours; for helicopters with less than 600 hours in
service, at;next 300-hour inspection and thereafter each
shall be 1800 hours
ii
300 hours. The sprag assembly replaced at
total service time. i
PREFACE: This Service Information Notice lists a procedure for inspection of PN 369~615364
Sprag Assembly, 369A5352 Outer Race and 369A5353 Inner Race of
PN 369A5350-603 Overrunning Clutch Assembly for wear in the cages and sprags
of the sprag assembly, inner race and outer race. Excessive wear can lead to
breakage and malfunction of the sprag assembly. The sprag assembly must be
replaced where specified limits are exceeded.
""To establish TIME OF COMPLIANCE, either clutch total time with hook attached may be
used, or a separate and permanent log of external load operating mission time (take-off
to landing on a flight which involves external load operations) may be used. The log
must meet requirements of FAR 91.173.
Reference
369D H1~II Vol 1(CSP-D-2), Reissued 15 January 1982; Revision No. 2, 15 August 1982.
369D HMI Component Overhaul FAanual (CSP-D-4), Part II, Reissued 14 September 1981.
FAA Airworthiness Directive No. 81-07-10F,1, Dated 30 November 1981.
(1) Denotes portion of text added or revised,
FORM 9518 (2/81)

NOTICE NO. DN-81.1* O HUBheiW~limptarr. Im.
DATE 10 May 1983
PACE 2 OF 6
PARTS LIST
Part No. Q~yl Mfr

Nomen~
Sprag Assembly 369A5364 1 HHI
Outer Race 36 9A 43 4 2 1 HHI
Inner Race 369A5343 1 HHI
TOOLS AND EQUIPMENT
Magnifying Lens, 4x
Outside Micrometer, 1. 0000 to 1.4000 inches
Inside Micrometer, 2. 0000 to 2. 2400 inches
Calip ers
a. Remove overrunning clutch assembly from helicopter in accordance with

Section 9 of HMI Vol 1.
b. Disassemble overrunning clutch in accordance with Section 9 of

HMI Vol 1 and Part II of Component Overhaul Manual.
c. Visually inspect sprag assembly for broken drag: clips, broken drag
strips, cracked cages, broken or distorted ribbon spring, or cracked, broken
or missing sprags. Disclosure of any of these discrepancies requires replace-
ment of the sprag assembly.
CAUTION
Do not remove clips from sprag assembly.

sprags and
Removal requires replacement of sprag assembly.
d. Inspect peening or wear; maximum permissible width across

cages for
inner cage and outer cage windows is 0.208 inch. (See Figures 1 and 2.) If
maximum is exceeded, replacement of sprag assembly is required. Note in Fig-
ure 2 that the most pronounced inner and outer cage wear occurs in the outside
diameter corners of the crossbars. Wear should be measured at the worst point.
Inspect for any wear on inner cage face opposite the flange end.
e. Using 4x magnifying lens, inspect sprag load surfaces. If any flats,

scoring, heavy pitting or heavy scratches are found on sprag inner or outer
surfaces, the sprag assembly must be replaced. (See Figure 3.)

nughanalicoptsn.lnc. NOTICE NO. DN-81.1*
DATE 10 May 1983
PACE 3 OF 6
i
f. Measure distance from edge of sprags to load pattern. Should the
inner surface measurement be less than 0. 050 inch minimum or the outer surface
measurement be less than 0.070 inch minimum, the sprag assembly must be
replaced. On the sprag inner contact surface of all the sprags
(See Figure 3.)
ina sprag assembly the variation in distance from edge of sprag to load pattern
should not exceed 0.030 inch. If this figure is exceeded, replace sprag
assembly.
g. Check dimensions of inner race (369A5353) spragway outer diameter

using outside micrometer and outer race (369A4352) spragway inner diameter
using inside micrometer. Dimensional minimum limit for the inner race spragway
is 1.4990 inches. Dimensional maximum limit for the outer race spragway is
2.1565 inches. (Refer to Part II, Section 2 of Component Overhaul Manual.)
h. Using 4x magnifying lens visually inspect inner race and outer race for
brinelling, scoring or pitting. On the inner pay particular
race attention to
area around oil drain holes for cracks. No defects are allowed. If any are found,
replace inner race or outer race as applicable. (Refer to Part II, Section 2 of
Component Overhaul Manual.)
i. assembly is replaced for any reason other than

If the 369A5364 sprag
broken drag clips or drag stripsof distorted ribbon springs, magnaflux inner
race and outer race per Part II, Table 3-2 of HMI Component Overhaul Manual.
Disclosure of any defect requires replacement of inner race or outer race as

applicable.
j. Reassemble overrunning clutch assembly in accordance with Section 9

of HMI Vol 1.
k. Reinstall clutch assembly into helicopter in accordance with Section 9

of HMI Vol 1.
i. Record compliance with this Service Information Notice in Compliance

Record of helicopter log book.
Weight and balance are not affected.
The resultant alteration to the affected helicopters described by the inspection

procedure in this Notice has been shown to comply with Federal Aviation Regu-
C lations and is FAA Approved.
NOTICE NO. DN-81.1*
G! HU(lhWaliwpters. Inc.
DATE 10 May 1983
PAGE 4 OF 6
OUTER CAGE FLANGE
(---0.208 INCH rJ\Xlllm
CROSS BAR
OUTER RACE CONTACT

POINTS
DRAG CLIP
OUTER CAGE OUTER DIAMETER
INNER CAGE FLA:IGE
0.208 INCH ~U1XIMUn---e
CRSSS BAR
INNER RACE CONTACT

AREA
DRA~STRIP NOTE FOR VEAR ON EDGE

OF CAGE
INNER CAGE INNER DIA~TER
88-467
Figure 1. Cage Wear Limits
j
O HugheHelicopten. Inc.
NOTICE NO. DN-81.1*
DATE 10 May 1983
PAGE 5 OF b
WEAR AREA
OUTER CAGE WEAR AREA
WEAR AREA
INNER CAGE WEAR AREA
88-473
C Figure 2. Excessive Cage Wear

NOTICE NO. DN-81.1*
nUBhIHelicopt~n. Inc.
DATE 10 May 1983
PAGE 6 OF 6
C
OUTER CAGE pRAt CLIP 3 REQD
INNER CAGE
SPW\G I
DRAG STRIP
1B REOD_ I ~3 REOB
OUTER CAGE FLAYGE
RIBBON SPRING
OUTER CAGE FLANGE
1HNER CI~CJE FLA1IGE TORQUE LOAD PAT7ERW
TLiPUt L040 P~II[RH

CROSS BAR ~1
---1 ~-0.050 n!alnUn
DRAG STRIP
OUTER CAGE OUTER DIAMETER

CAGE INI;ER DIA~TER
88-465
Figure 3. Sprag Torque Load Pattern

HUGHES NOTICE NC. DN..82
15 Ap" 1981
SE RVIC E I N FO RMATI ON
PAGE 1 OF 9
NOTICE
SUBJECT: FIELD INSPECTION AND REPAIR OF TAIL

ROTOR GEAR BOX MAIN
HOUSING ASSEMBLY, PN 369D25301 OR 369D25401-3
TIME OF COMPLIANCE: Shall be accomplished if erratic action of the foot pedals is

isolated to station 284 aft boom bellcrank
per table 8-2 of
HMl Vol i, or whenever the bellcrank is
removed for
maintenanc e.
PREFACE: This service notice provides procedures for inspecting and

correcting
an elongation of the bolt hole in the
support arm portion of the main housing
assembly of the tail rotor gear box caused
by looseness of the bellcrank
fulcrum bolt and nut. Elongation of the subject hole could affect
control
response sensitivity or erratic action in tail rotor control,
cause
If the
condition were allowed to persist, it could lead to eventual
of separation the
bellcrank and support lug of the tail rotor gearbox main housing.
Reference
500D Helicopter Model 369D HMI Vol 1, Issued 15 September 1976; Revision No, 4,
1 December 1980
rOCIM BS18 (2/81)

Hughe~ Heliccnfers, Inc. culver city, celilornia 90230
NOTICE NO. DN-82
DATE 15 April 1981
PAGE 2 OF 9
PARTS LIST
Cotter MS24665-153 3 Comm

pin
Shim 369A5516-3 AR HH
Washer AN9 6 0PD5 1 6 1 C omm
MATERIALS
T131 AR Cadillac Products, Inc.

Cadpak
7000 E. 15 Mile Road
(MIL-B-131D,
Class 1) Sterling Heights, Mich.
48077
rod, Aluminum, 2024-T3 AR Comm

Bar, or
tube stock
Turcoat Liquid AR Turco Products Div.,
Accelogold Purer Corp.

(MIL-C-81706) 24600 S. Main St.
Carson, Calif. 90749
Chromic acid O-C-303 AR Comm
Ammonium (reagent grade) AR Comm
sulphate
Amm on i um (reagent grade) AR Comm
hydroxide
acid O-S-809 AR Comm
Sulphuric
Primer coating, 90 8-L-02110 AR Glidden- Durkee Div.,
zinc chromate, SCM Corp.

low- moisture- 9 00 Union Comme rce
sensitive Bldg.
(TT-P-1757) Cleveland, Ohio 44115
NOTICE NO. DN-82
DATE 15 April 1981
PACE 3 OF 9
164-2-1 AR Finch Paint Chemical Co.

Subsidiaryof USM Corp.
20846 S. Normandie Ave.
Torrance, Calif. 90502
PA-1207 AR Egyption Lacquer Mfg. Co.

P. O. Box 444
Newark, N.J. 07101
Methyl- ethyl T T- MI 2 6 1 AR Comm

ketone (MEK)
Demineralized AR Comm
water
Mobilgrease #28 AR Mobil Oil Corp.

(MIL-C-81322) 150 E. 42nd St.
New York, N.Y. 10017
Aeroshell #22 AR Shell Oil Co.

Grease 1 Shell Plaza
(MIL-G-81322) P. O, Box 2463
Houston, Texas 77001
Royco 60R AR Royal Lubricants Co., Inc.

(MIL-G-25760) River Road
P. O. Box 298
East Hanover, N. J. 07936
Kopr-Kote AR Jet-Lube, Inc.

P. O. Box 21248
Houston, Texas 77026
Anti-Seize AR Locktite Corp.

Compound 705 N. Mountain Road
(MIL-A-907) Newington, Conn 06111
Royco #37 AR Royal Lubricants Co., Inc.

River Road
P. O. Box 298
East Hanover, N. J. 07936
Sealing compound, PR1436-G, Class AR Products Research and
corrosion pre- B-2PR14226, Chemical Corp.
ventive Class B PR1221 543 Sn Feriiando Rd.
(MIL-S-81733, Glendale, Calif. 91302
Type II-2)
NOTICE NO. DN-82
DATE 15 April 1981
PAGE 4 OF 9
7/16 inch reamer, or ANSI Standard
7/16 inch drill bit ANSI Standard
Bore gage 599-281-9999 1 Brown Sharpe Mfg. Co.

Intermik Style A Precision Park
0. 275 to 0. 350 in. Frenchtown Road
North Kingstown, R.I.
02852
PART 1 MAIN HOUSING ASSEMBLY INSPECTION
a. Detach bellcrank as follows:
i. Remove cotter pin, nut, washers, and tail rotor swash plate
control pin attaching bellcrank to pitch control assembly.
2. Remove cotter pin, nut, washers, bearing, and bolt attaching

bellcrank to tail rotor gearbox main housing. Be prepared to
receive bearing if it falls away.
3. Swing bellcrank aside.
b. Inspect hole in main housing for out-of- roundness. If visual inspec-

tion is not adequate, insert bore gage. Hole diameter must measure 0. 312
inch to 0.313 inch. (See Figure i.)
If hole is out of tolerance, proceed with part 2,

c.
repair procedures.
d. If hole is still within tolerance, reattach bellcrank to pitch control

assembly and to gearbox main housing.
PART 2 MAIN HOUSING ASSEMBLY REPAIR
a. Finish removal of bellcrank by removing cotter pin, nut, washers,

bushing, and bolt attaching bellcrank to tailboom rotor control rod assembly.
NOTE
The tail rotor drive shaft and the tail rotor

transmission must be removed as a unit.
NOTICE NO. DN-82
DATE 15 April 1981
PAGE 5 OF 9
b. Remove tail rotor assembly. (Refer to Section 8, Basic Hlvl~-Vol i).
c. Remove (or open) tail rotor drive shaft access doors (refer to
Section 2, Basic HMI-Vol 1).
d. Remove three bolts and washers securing tail rotor drive shaft to
output shaft coupling on main transmission.
e. Disconnect chip detector wire from tail rotor transmission.
f. Remove four nuts and washers attaching tail rotor transmission to
tailboom.
CAUTION
To prevent damage to the transmission

input shaft coupling during and after shaft
removal, provide level support for both
transmission and tail rotor. Weight of
these items might buckle the coupling
diaphragm.
g. Obtain personnel assistance in guiding shaft through damper.

Remove tail rotor transmission and tail rotor drive shaft as an assembly.
Slowly and carefully slide assembly aft until drive shaft clears tailboom,
CAUTION
Do not carry or otherwise

support trans-
mis sion by use coupling. Use care
of the
with removal tools to prevent scratching
of the coupling diaphragms.
h. Support assembly along its entire length, remove three coupling

bolts and washers, and remove drive shaft from tail rotor transmission.
Unless other servicing of the transmission is to be performed, no further
disassembly is necessary.
CAUTION
Do not clean magnesium with methanol
(methyl alcohol or wood alcohol). Methanol

is destructive to magnesium.
NOTICE NO. DN-82
I)ATE 15 Hpril 1981
PAGE 6 OF 9
i. Wash oil and grease off transmission with MEK or other mineral
oil distillates, chlorinated solvents, or lacquer thinners, then air dry
thoroughly.
j. Wrap splines and cover chip detector stud with Cadpack T131 barrier
material, or suitable substitute. Apply tape over all crevices to prevent
lodgment of metal chips or entry of contaminants into sheltered areas.
k. Install transmission assembly on milling machine, and mill 0. 060

inch from boss of main housing assembly. (See Figure 2.
i. Transfer transmission assembly to drill press or retool mill with

7/16 inch reamer or drill bit to correct elongated hole in support arm portion
of main housing assembly.
m. Adjust transmission assembly so hole center in support arm will

remain 4. 795 inches and 6. 220 inches for 369D25401-3 and 5. 265 inches and
6. 220 inches for 369D25301 from reference points shown in Figure 3.
n. Ream or drill 0. 438 inch hole.
o. Remove transmission assembly from machining fixture, thoroughly

wash oil and grease from all exposed magnesium surfaces, then dry.
p. Protect magnesium parts that have had protective coating removed

as follows:
i. Prepare solution as follows:
(a) Chromic acid, 20 ounces per gallon.
(b) Ammonium sulphate, 14 ounces per gallon.
(c) Ammonium hydroxide, 12 fluid ounces per gallon.
2. Maintain solution as follows:
(a) To increase pH, add ammonium hydroxide.
(h) To decrease pH, add chromic acid.
(c) When chromic acid content is too high, add sulfuric acid.
NOTICE NO. DN-82
DATE 15 April 1981
PAGE 7 OF 9
3. Apply solution as follows:
(a) Swab area to be touched up with clean cloth or soft brush

dampened in cold solution for 10 to 30 minutes until desired
color is produced.
(b) Desired color ranges from gold through yellow to brown.
(c) When desired color is obtained, rinse or swab part

thoroughly in clean, room-temperature water. Dry parts
and paint as required.
q. Fabricate aluminum bushing to comply with specifications provided

in Figure 2.
r. Wash bushing with MEK, and dry thoroughly.
s.Immediately treat all surfaces of bushing with Turcoat Liquid

Accelogold (this is a premixed, ready-to-use product conforming to military
specification MIL-C-81706).
t. Allow bushing to develop a gold color, then rinse thoroughly with

water and dry.
u. Coat
bushing with zinc chromate primer and, while wet, insert it in
newly enlarged hole in main housing assembly.
v. Seal peripheral faying edges of bushing with PR1436-G, class B-2;

PR14226, class B; PR1221; or M1L-S-81733, type II-2 sealant per manu-
facturers instructions.
w. Allow treated areas to dry thoroughly, then repaint with zinc chro-
mate primer, then apply top coat to match surrounding area.
x. Reinstall tail rotor drive shaft and transmission per instructions in

paragraph 9-67, Basic HMI-Vol i,
y. Record compliance with this Service Information Notice in Compliance

Record of the helicopter log book.
FAA/DER APPROVED 16 April 1981

NOTICE NO. DN-82
DATE 15 April 1981
PAGE 8 OF 9
CAUTIONI DO NOT LIFT ASSEMBLY

FROM FLAWGE,
COUPLING BOLT .~e
f
COUPLING, E3f~ ~W 3.005
2.995
5,1
i? ~i
i
TAIL ROTOR
MOUNTING-FLANGE ~t
TRANSMISSION iS
couPLlns BOU s
O Apr SHln InSTALUTION
TAIL ROTOR DRIVE

SHAFT DAMPER comlNe SHIM
r W\IN TRANSMISSION
OUTPUT GEARSHI\FT
SHAFT DAMPER COUPLING
TAIL ROTOR
SLEEVE
DRIVESHAFT
LOCK RING ANO STUD
(4 PLACES)
COUPLING BOL
"~r DRIMSHAFT INSTALLATION
BREATHER-FILLER
TAIL BOOM
OUTPUT
TRANSMISSION COUPLING
LIQUID LEVEL
PLUG~i! ~C-
tOUPLING SHIII
INPUT SHAFT
INSPECT FULCRUM
HOLE FOR COMPLIANtE
I)
SELF-CLOSING
STATION 289 VALVE
MUtWJIY [p OETE[TOR ~TAIL Rora nuwsnlssros
LOCKWASHER
4a 88-1161
Figure i. Tail Rotor Transmission and Drive Shaft Essential Components

NOTICE NO, DN-82
DATE 15 April 1981
PAGE 9 OF 9
ADD AN96OPD516
\JASHER
,1138 DIR PUSII FIT
(MAX, INTERFERENCE ,0)02) MAIN HOUSING ASSY
GAP
.000
,010
,75
DIA--I31301120 OIn
,060
;IATERIAL ALUnlNUM ALLOY BAR

2024-T3
TAIL ROTOR CONTROL BELLCRANK
O REPAIR BUSHING INSTRLLATION III)TE:
TOKQUE NUT 100-1110 IN,-LBS, ADVANCE NUT TO MEET

HOLE AFTER REOUIRED TORQUE IS REACHED, WASHERS
AS REBUIRED TO STAY WITHIN TOROUE LIMITS,
88-1156
Figure 2. Repair Bushing Fabrication and Installation Details
,313 1_ 4,795 FOR 369025401-3

DIA THRU_ FOR 369025301
,312
2,130
FOR 369025401
2.120
2,065
FOR FOUR-BLADED
2,055
369925301
88-1160
Figure 3, hdain Housing Assembly Support Arm Hole

Center Locating Diagram
NOTICE NC. DN-86
HUGHES onTE 6 May 1981
SERVICE IN FORMATION PAGE 1 OF
OT I C E
MAN DATO RY MAN DATO RY I I MAN DATO RY
SUBJECT: SHIMMING PROCEDURE FOR GAS PRODUCER INTERCONNECTING

TOR CZUE TUBE ASSEMB LY

SerialNo. 0003D through 0929D
TIME OF COMPLIANCE: Shall be accomplished within 100 hours of helicopter

operation.

procedure a
for inspectingthe gas producer interconnecting torque tube clearance to
ensure proper rigging fit and for shimming to achieve proper clearance.
REFERENCE
500 Model 369D Basic HMI-Volume 1, Issued 15 September 1976; Revision No. 4,
1 December 1980
Customer Service Depcutment
FORM 9578 (2/81)

Huehes Helicopters. Inc. culver city, California 90230
NOTICE NO. DN-86
DATE 6 May 1981
PAGE 2 OF 5
PAR TS LIST
NOMENCLATURE PART NO. aTY MFR
Washer):: AN960C816 AR Commercial
~CEquivalent washers in varying thicknesses may be made from

mate rial listed below.
MATERIALS
Corrosion resistant steel sheet -301, 304, 347, cond 1/2 hard. per
aa- s-76 6.
PROCEDURE
a. Remove pilots seat cover and controls access door. (Refer to

Basic HMI-Volume i, Section 2.)
b. Make an index mark on end of collective

torque tube fitting flush
with inboard end of pilot s collective stick assembly housing. (See Figure i.)
Use felt pen or pencil. Do not scribe index mark on fitting.
Remove four bolts securing pilots collective stick

c.
assembly to
end collective torque tube fitting.
d. Loosen pipe plug in end of gas producer interconnecting torque tube

which secures it to gasproducer gearshaft in pilots collective stick assembly.
e. Remove pilots collective stick assembly per paragraph 7-87 of

Basic HMI-Volume i.
f. Using rubber mallet or equivalent soft tool, tap gas producer inter-
connecting torque tube assembly toward copilots collective socket assembly.
Avoid damage to gas producer interconnecting torque tube hex end or
pipe
plug threads.
g. Measure distance between index mark end collective

on torque
tube fitting and hex end of gas producer interconnecting torque tube. (See
Figure i, Gas Producer Interconnecting Torque Tube Measurement.
h. Measure distance between inboard end of

pilot s collective stick
assembly housing and inboard face of gas producer gearshaft in pilots col-
lective stick assembly. (See Figure i, Gear Shaft Recession Measurement.
NOTICE NO. DN-86
DATE 6 May 1981
PAGE 3 OF 5
i. Subtract measurement taken in Btep h. from measurement taken
in step g. Remainder is engagement of gas producer interconnecting torque

tube with gearshaft in pilots collective stick assembly.
j. engagement (remainder) from 0. 750 inch. In addition

Subtract
to thickness of external snap ring, add PN AN960C816 washers to end of
tube to a total thickness equal to the
gas producer interconnectillg torque
remainder from 0. 750 inch less engagement. (See Figure I.) Equivalent
washers in varying thicknesses may be made from corrosion resistant steel
sheet and used in combination with PN AN960C816 washers.
collective stick assembly paragraph 7-92 of

k. Reinstall pilots per
Basic HMI-Volume i.
i. Tighten pipe plug of gasproducer interconnecting torque tube to

obtain zero backlash between torque tube and gearshaft in pilot s collective
stick assembly.
m. Reinstall pilots seat cover and controls access door. (Refer to
Basic HMI-Volume i, Section 2.)
n. compliance with this Service

Record Information Notice in

NOTICE NO. DN-86
DATE 6 May 1981
PACE 4 OF 5
INDEX MARK OR LINE ON GAS PRODUCER

PILOTS COLLECTIVE CONTROL
INTERCONNECTING TORQUE TUBE END
STICK ASSEMBLY,
FITTING FLUSH WITH THE INBOARD
END OF THE PILOTS COLLECTIVE
STICK ASSYEMBLY,
GAS PRODUCER INTERCONNECTING TORQUE

TUBE FITTING,
INDEX MARKING
i:
MEASUREMENT BETWEEN INDEX MARK
AND HEX END OF GAS PRODUCER
INTERCONNECTING TORQUE TUBE,
oo
oo
HEX END
INDEX MARK
359H7355 GAS PRODUCER INTERCONNECTING

TORQUE TUBE END FITTING,
GAS PRODUCER INTERtONNECTING TORQUE TUBE MEASUREMENT
88-1181(-1
Figure i. Shimming of Gas Producer Interconnecting

Torque Tube Assembly (Sheet 1 of 2)
NOTICE NO. DN-86
DATE 6 May 1981
PAGE 5 OF 5
MEASUREMENT BETWEEN INBOARD END

OF PILOTS COLLECTIVE STICK HOUSING
AND END OF GEAR SHAFT IN PILOTS
COLLECTIVE STICK ASSEMBLY
PILOTS COLLECTIVE STICK HOUSING

ASSEMBLY
6EAR SHAFT IN PILOTS COLLECTIVE
STICK ASSEMBLY
GEAR SHAFT RECESSION MEASUREMENT
TOTAL THICKNESS OF AN96OC81G WASHERS

AND SNAP RING, EQUAL TO 0,750 MINUS
ENGAGEMENT LENGTH OF GAS PRODUCER
INTERCONNECTING TORQUE TUBE INTO GEAR
SHAFT IN PILOTS COLLECTIVE STICK ASSEMBLY
ADDED TO END OF GAS PRODUCER INTERCONNECTING
lo TORQUE.
lo
ENGAGEMENT LENGTH OF GAS PRODUCER

INTERCONNECTING TORQUE TUBE INTO
GEAR SHAFT OF PILOTS COLLECTIVE
STICK ASSEMBLY,
0,750 NORMINAL LENGTH OF HEX END ON

THE GAS PRODUCER INTERCONNECTING
TORQUE TUBE,
TORQUE TUBE SHIMMING
88-~811-2
Figure i. Shimming of Gas Producer Interconnecting

Torque Tube Assembly (Sheet 2 of 2)
NOTICE NC. DN-87
HUGH ES DATE 15 May 1981
SE RVICE IN FORM AT ION PAGE 1 OF 5
NOTICE
NIAN DATO RY I MAN DATO RY I MAN DATO RY
SU~JECT: REPLACEMENT OF PN 369A7706-3 RPM GOVERNOR LEVER

CONTROL ROD

TIME OF COMPLIANCE: Order parts immediately on receipt of this Notice and

accomplish no later than 30 days after receipt of same.
for replacing PN 369A7706-3 control rod. Field reports indicate malfunc-
tions of the RPM governor control linkage have occurred due to engine
vibration during helicopter operation, therefore, the subject aluminum
rod will be replaced by a new steel control rod.
Re fe rence
500D Model 369D Basic HMI-Vol i, Issued 15 September 1976; Revision No. 4,
1 December 1980.
Customer Service Deptutment
Foam 8578 (2/81)

Huehes Helicoptets, Inc. culver city, california 90230
NOTICE NO. DN- 87
DATE 15 May 1981 Hughr Hlicoptrs
PAGE 2 of 5
PARTS LIST
Rod 369A7706-5 1 HH
PROCEDURE
a. Open left engine access door to gain access to upper linkage of

RPM governor controls. (Refer to Section 2 of Basic HMI Vol i.)
b. Remove RPM governor lever control rod assembly per para 11-20
of Basic HMI Vol 1.
c. Loosen jam nuts on control rod assembly. Remove rod end bearings
and jam nuts from rod. Discard rod. (See Figure 1.)
d. Install jam nuts and rod end bearings on new steel rod. (See
Figure i.
e. Reinstall RPM governor lever control rod assembly per para 11-20
of Basic HMI Vol i.
f. Rig RPM governor lever controls per para 11-8 of Basic HMI
Vol i.
g. Perform final check and adjustment of power controls per para 11-9
of Basic HMI Vol i.
h. Close left engine access door.
i. Perform deceleration check as follows:
NOTE
Perform deceleration check during engine shutdown.
i. Deceleration check (Bendix fuel control system)
(a) Set Generator (CEN) switch to OFF position.
(b) Set THROTTLE OPEN grip to FULL OPEN.
(c) Set pilots collective control stick FULL DOWN,

FRIC TION ON.
NOTICE NO. DN-87
f~ Hugh~ Hslicoptsrs DATE 15

PAGE 3 of 5
May 1981
(a) Stabili~e N2 at exactly 103percent (beep as required).
Set THROTTLE OPEN grip to IDLE.

(e)
(f) Begin time check with stop watch, Stop time as N2

elapsed time, Minimum
passes through 650/o;
Observe
allowable lapsed time is two seconds,
NOTE
Practice or retakes may be required before
proficiency can be obtained in deceleration
timing.
(g) If deceleration time is less than two seconds, make two

more checks to confirm time.
If confirmed deceleration
time is less than the allowable minimum, refer to the

applicable Allison Operation and Maintenance Manual,
2, Deceleration check (CECO fuel control system)
generator (GEN) switch to OFF.

(a) Set
(b) Set THROTTLE OPEN grip to FULL OPEN,
(c) Set pilots collective control stick FULL DOWN,

FRIC TION ON.
(d) Stabilize N2 at exactly 103"Jo (beep as required).
Set THROTTLE OPEN grip to IDLE.

(e)
(f) Begin time check with stop watch, Stop time as

N2
elapsed time, Minimum
passes through 65~0.
Observe
allowable lapsed time is two seconds.
NOTE
Practice or retakes may be required before
proficiency can be obtained in deceleration
timing,
NOTICE NO. DN -87
DATE 15 May 1981
PAGE 4 of 5
(g) If deceleration time is less than two

seconds, make
two more checks to confirm time. If confirmed
deceleration time is less than the allowable
minimum,
refer to the applicable Allison Operation and
Maintenance
Manual.
j. Record compliance with this Service Information Notice in


NOTICE NO. DN-87
nelico~ers DATE 14 May 1981
Hugh~
PACE 5 of 5
GOVERNOR LEVER
CONTROL RDD
CONTROL IDLER
SUPPORT
~j=ic-
ROD GOVERNOR LEVER; IDLER

ROD
JAM NUT
IDLER BELLCRANK
JAM NUT
CONTROL ROD
ROD END
ENGINE GEARBOX
ACCESSORY PAD
OMVERIIMI
UPPER
(OnTROL IINWIGE
ASSEMBLY
i
i.
O OISISERLUI
GOVERNOR LEVER CONTROL ROD
88-463
Figure I. Installation of Governor Lever Control Rod

NOTICE NC.
HUGH ES
DATE 19 MaY 1981
SE RVI C E I N FO R MATI O N
PAGE 1 OF 3
NOTICE
M AN DATO RY a I
MAN DATORY MAN DATO RY
SUBJECT: ELIMINATION OF POSSIBLE INTERFERENCE OF SAFETY WIRE WITH OIL

COOLER BLOWER DRIVE BELT
TIME OF COMPLIANCE: At next 100-hour inspection or within 30 days after

receipt of parts. Order parts upon receipt of Notice.
PREFACE: The info~lation given in this Service Infannation E!otice lists

j a pro-
cedure for removing the safety wire andreplacing the bolts that attach
the mounting bracket to the cooling blower assembly.with self locking
bolts.
E.EFEEE~CE
500DModel 369D Basic EHI-Volume 1; Issued 15 September 1976, Revision No. 4,

1 December 1980
Foam os7e (usl)

Hushes Helicopters, Inc. culver city. california 90230
NOTICE NO. DN-88 Hugha.HsT~opten. Inc
DATE 19 May 1981
PAGE 2 OF 3
PARTS LIST
Bolt NAS1224-1L 2 HH/Commercial
PROCEDURE
a. Remove transmission cover. (Refer to Section 2, Basic HMI-Volume i.)
b. Remove cooling blower. (Refer to Section 9, Basic HMI-Volume i.)
c. Remove and discard safety wire and two bolts attaching mounting
bracket to cooling blower assembly. (See Figure i.)
d. Install two self locking bolts in place of discarded bolts. (See

Figure i.)
e. Reinstall cooling blower assembly and adjust cooling blower drive

belt tension. (Refer to Section 9. Basic HMI-Volume i.)
f. I(einstall rrannmission cover (Refer ro Section 2, Basic HHI-Voluole i.) j

g. Record compliance with this Service Information Notice in Compliance

E~ HUshHdicopten. Inc. NOTICE NO.
DATE 19
DN-88
May 1981
PAGE 3 OF 3
REPLACE EXISTIHG BOLT

WITH NAS1224-1L BOLT
(2 PU\CES)
~B
s:
MS2O995C32
SAFETY WIRE
(RDIOVE)
EXISTING SCREW
AND WASHER
(2 PLACES)
OSU)YER I(OUII~INE BRMYET
88-1(91
Figure i. Replacement of Blower Mounting Bracket Bolts

NOTICE NO.DN-89.2~
HUGHES DaTE 24 September 1982
SE RVICE IN FOR MATION 1 oF1
NOTICE
"Supersedes Service Information
Notice No. DN-89,1, dated 21 August 1981
SUBJECT: BALANCING OF MAIN ROTOR HUB ASSEMBLY, PN 369D21200
provides procedures for main rotor hub

PREFACE: This Service Information Notice
balancing prior to installing one or more new blades, or one or more new
dampers, when the operator wishes to check the balance of the hub alone.
Reference
500D Model 369D Basic HMI Volume 1, Reissued 14 January 1982; Revision No. i,
I
15 March 1982
of test added revised.

Denotes portion or
FOR~ gaTBA (2/81)

HuIlhe~ Helicopte~. Inc. Culver City, California 90230
NOTICE NO. DN-89.2*
PAGE 2 OF 5
PARTS LIST
When ordering, specify Early Configuration Kit Part No. 3691329999-5 for Model 500D
Helicopter SerialNo. 0003D thru 0259D; specify Current Configuration Kit Part No.
369D29999-7 for Model 500D Helicopter Serial No. 0260D and subsequent.
(Early Configuration) Main 369D29999-5 1 HHI

Rotor Balance Kit, consisting
of the following:
Washer HS1554 10 HHI

Washer HS1555 10 HHI
Washer AN 960C10 100 Commercial
Washer AN960C10L 100 Commercial
(Current Configuration) Main 369D29999-7 1 HHI

Rotor Balance Kit, consisting
of the following:
Washer 369D29934 10 HHI

Washer 369D29935 10 HHI
Washer AN960C8 100 Commercial
Was her AN 960C 8L 100 Commercial
Screw NAS602-64P 10 Commercial
Nut MS21042L3 10 Commercial
Nut MS21042L08 10 Commercial
MATERIALS
Sealing and coating compound PR- 1436-G, AR Products Research

corrosion inhibitive Class B-2 and Chemical Corp.
(MIL-S-81773, type II-2) 443 San Fernando
Rd., Glendale,
CA 91203
TOOLS AND EQUIPMENT
Balancer/Phazor, Chadwick-Helmuth Model 177

Volt-ohm meter, Simpson 260
NOTICE NO. DN-89.2*
PACE 3 OF 5
FIELD BALANCING PROCEDURE
a.
b.
Remove main rotor blades.
Remove main rotor dampers.

(Refer
(Refer
to Section 7 of HMI-Vol.
to Section 7 of Basic HMI-Vol.

1.)
1.)
I
c. Hook up Phazor. Refer to Chadwick-Helmuth Operation and Service
Instruction Handbook No. 4313 for Helicopter Main Rotor and Tail Rotor Assemblies.
d. Run engine at 103 percent of N2.

e. Record IFS reading and direction (see Figure i).
f. Pl~t IFS reading and direction on balance chart (see Figure 1).
g. Analyze chart for weight location and amount requirements.
h. Install weights as follows (see Figure 2):
1. Engage head of screw, inside lead-lag bolt, with Phillips screwdriver,

then loosen locknut with 1/4-inch wrench.
2. Hold screw inplace with screwdriver while adding or removing flat

washers as required, then reinstall locknut.
d. through i. until reading is 0. 15 IFS, or less.

i. Repeat steps
j. After balance has been established satisfactorily, torque MS21042L08 locknuts

to 20 to 35 inch-pounds or MS21042L3 locknuts to 30 to 60 inch-pounds as applicable.
Coat screw threads, nuts and washers with PR-1436-G sealant. (To prevent
imbalance, do not use excessive amount of sealant.)
NOTE
Intermixing of PN 369D21400-503 and M40452 main rotor blade

damper assemblies in a ship set is not permitted. All dampers
in ship set must be of same type and part number.
k. Reinstall main rotor blades per Section 7 of Basic HMI-Vol. 1.
i. Proceed with blade phasing per Section 7 of Basic HMI-Vol. 1.
1.
m, Proceed with blade tracking per Section 7 of Basic HMI-Vol.
The resultant alteration to the affected helicopters described by the Field Balancing
Procedure in this Notice has been shown to comply with Federal Aviation Regulations
and is FAA Approved,
NOTICE NO. DN-89.2"
PAGE 4 OF 5
60 GRAMS
BLUE
4 40
YEL
SRN
110 3
2 20
12
20 1 20
110
60
11Xi,o
GRAMS
.9 TGT
YO WHITE
,7 5
2
YEL 40 10 ;6
20
40
20
50 GRAMS
3 110
BLUE
,5
20 20
RED
1 1 8
40
20
7 5 RED
O 1
60 20 6
110
CRAMS
40
20
GRN
110
TGT
50 GRAMS
WHITE
HELICOPTER S/N HUB S/N
CLOCK BALANCE WEIGHT AND LOCATION

RUN NO, IFS
ANGLE (1) rm, (2) GREEN (3)YELLOW (4)BLUE (5) WHITE
INITIAL
Figure 1. Main Rotor Hub Balancing Chart

NOTICE NO. DN-89.2*
PAGE 5 OF 5
,IbB
i
i.y
st
;J;
(NOTE 2)
MS21O112LO8
369D29935 MAIN ROTOR HUB BALANCE
NUT
WEIGHT SUPPORT WASHER
(NOTE 1)
AN96OC8, AN96OC8L
WASHERS AS REOUIRED
369021220 TO BALANCE
LEAD- LAG BOLT
369D29934
WASHER
NAS6O2-64P OR -72P OR -76P

SCREW 369021300-501
(NOTE 4) Y PITCH HOUSING
3691\1239 NUT LINK ASSY
llS24665-300 COTTER PIN
i (NOTE 3)
MS21O42L3 LOCKNUT
(NOTE 1)
A-A AN96OC10, AN96OtlOL WASHERS

AS REQUIRED TO BALANCE
SERIAL NO, 0260D AND SUBS
WASHER ,369A122O LEAD LAG BOLT
HS15W
WASHER
J NAS6O3
SCREW
56 OR 64
(NOTE II)
369A1219 NUT
#S24665-300 COTTER PIN
O
i. COAT SCREW THREADS, NUTS AND WASHERS
WITH PR-1436-G, CLASS 8-2 SEALANS, SERIAL NO, 003D THRU 02590
INCH-POUNDS.
2, TORQUE MS21O112L08 LOCKNUT TO 20 TO 35
3. TORQUE MS21042L3 LOCKNUT TO 30 TO 60 INCH-POUNDS,
NUT.
II, DO NOT REMOVE OR DISTURB TORQUE ON 369A1219 3S-
Figure 2. Main Rotor Hub Balancing

43! HUBhe~ Helicopocrs, lac.
REFLRENCESHEET
SERVICE: INFORMATION NOTICES AND LETTERS
Action Reference: When performing 25-hour inspection or performing

maintenance of main rotor blade, refer to Service
Information Notice No. DN-41.1.
HMI Reference: Insert this sheet in 500D Basic HMI Volume II,
Section 2, Table 2-1A Time-Phase Inspections,
Page 2-7.
This reference sheet shall be kept as a part of the manual until

the data is incorporated at the next revision of the Basic HMI
Volume II. (Refer to Service Information Summary, Basic HMI
Volume II, page i.)
C
NOTICE NC DN-91.1k
HUGHE DATE 22 :Julp 1981
S E RV I C E I N FO R MAT I;O M PAGE 1 OF
NOTICE
~Supersedes Service Information
Notice No. nN-91 Da~ed 26 May 1981
MAN DATO RY MAN DATORY MAN DATORY
INSPECTION OF MAIN ROTOR HUB STRAP PACE RETENTION BOLTS

SUBJECT:
AND REPLACEMENT OF BUSHINGS
TIME OF COMPLIANCE: Shall be accomplished within next 100 hours or 30 days

after receipt of parts. Order parts from Mughes Parts
Sales upon receipt,of Notice.
PREFACE: The given inthis Service Information Notice lists pro-

information
cedures inspection of the main rotor hub strap pack retention bolts
for
for general condition and possible corrosion andreppaceement of t~e
associated bushings.
REFERENCE
560D Model 369D Basic HMI-Volume 1; Issued 15 September 1972, Revision No. 4,
1 December 1980
(I) nenotes portion of text added or revised
FORM 9518 (2/81)

HuIlhes Helicopters, Inc. culver city, california 90230
NOTICE NO.
DATE 22
DN-91.~*
July 1981
Onuphr~llcop(m. Ino.
PACE 2 OF 6
PARTS LIST
Nomenclature Part No. gkY Mfr
Bolt~k 884440-08-32 HHI

Nut+ HS4143-6 HHI
Bushing 369021273-3 5 HHI
*If required
TOOLS AND EQUIPMENT
Torque wrench, O to 150 foot pounds
Socket, wrench, 3/4 inch (minimum 3-inches deep)
Micrometer, 3 to 4 inch (with bell caps)
MATERIALS
Tool, threaded bar stock or bolt, 1/2-inch diameter a 6-inches long, 3-inches
of thread minimum
Locknut, 1/2-inch thread
Nut, 1/2-inch thread
Jam nut, 1/2-inch thread (not required if locknut secured with tack weld or
locking compound)
Washer, steel, 1/2-inch ID
Tube, steel, I-inch OD, 0.090/0.150-inch wall x 2.000 inches long. (Ends parallel
within 0.002 inch)
Locking compound, Loctite, Loctite Corp.
Sealing compound, MIL-S-81733, Type II-2, PR1436-G, Class B-t, Products Research
and Chemical Corp.,
Glendale, CA 91209
paint, acrylic lacquer
Sherwin Williems Company, City of Conrmerce, CA
Sterling Lacquer Mfg. Co., St. Louis, MO
Neptha, aliphatic, TT-N-95 or equivalent
Primer, wet zinc chromate, TT-P-1757 or equivalent

Inc. NOTICE NO. DN-91.1~
DATE 22. July 1981
PAGE 3 OF 6
PROCEDURE
a. Remove main rotor blades per Section 7 of Basic HMI-Volume i.
b. Remove hub fairing and fairing support assemblies. (See Figure i.)
c. Remove scissors crank assembly per Section 7 of Basic HMI-Volume i.
CAUTION
Ensure that all main rotor blades are removed before

loosening any bolts. Loosen, replace and torque only
one bolt and bushing at a time to retain clamping force
on the remainder of the strap pack assemblies, Use care
when removing bolt to ensure that bushing does not come
out with bolt.
d. Loosen and remove one nut, one PN 369D21270-5 spacer, one bolt and
one PN 369D21270-3 spacer.
e. Assemble locknut on threaded tool, as shown, using tack weld, jam

nut locking compound.
or Insert tool through strap pack assembly as shown.
(See Figure 2.)
f. Slide new bushing on tool.
NOTE
Identification notch on bushing must be on top side.
g. Install steel washer after bushing and install nut on lower end.
Tighten lower nut, holding top locknut to prevent tool from turning,
h.
until bushing is completely seated in hub and previous bushing has been
new
pressed out. Use 3-inch deep socket to accomplish this operation.
i. Visually inspect removed bolt for corrosion and general condition.

Magnetic or dye penetrant inspect removed bolt for cracks. Replace bolt if
corroded, c~acked or if cad plate is scraped or worn away.
j. Clean ends of bushing (inside hub assembly) and inside diameter

of bushing holes in hub shoes with naptha or equivalent.
k. Measure free length of new or inspected bolt PN 8S4440-08-32.
i. Prepare and apply sealing compound per manufacturers instructions

to interior areas shown, while installing bolt in hub with spacers and nut.
(See Figure 3.) Install bolt with wet zinc chromate primer. 1
NOTICE NO. DN-91.1+
DATE 22 July 1981
PAGE 4 OF 6
m. Retorque nut so that bolt is elongated inch, from free

length (step k. above). Use a torque of 70 ft-lbs as a starting pointfor bolt
stretch.
NOTE
If bolt is inadvertently elongated more than 0.0075 inch,

but not then 0.0090 inch, back off
more nut completely,
remeasure free length of bolt and retorque. If bolt
elongation exceeds 0.0090 inch, discard bolt and use new
bolt.
n. Apply sealing compound to faying surfaces of bolt head, bushing, hub

shoe and nut as shown. (See Figure 3.)
o. Repeat stepsd. through n. for remaining bolts and bushings.
p. Apply a torque stripe with contrasting color acrylic lacquer paint to

head of bolts, spacers end nuts.
NOTE
Torque stripe should be applied such that it can be viewed

during daily walkaround/preflight inspection.
q. Reinstall scissors crank assembly, fairing support and hub fairing.

r. Reinstall main rotor blades.
s. Record compliance with this Service Information Notice in Compliance

WEIGHT AM) BALANCE DATA
FAA/DER APPROVED
NOTICE NO. DN-91.1
Hueho~licopwrrlm.
DATE 22 July 1982
PAGE 5 OF 6
63
w
369021M~-11
FAIRING
369021005-2!
FAIRING SUPFOR;
HSllWIO-08-32
BOLT (TYP 3 PU\CES)
19M1270-J a
SPACER
Figure i. Removal and Inspection of Main Rotor Hub Strap Pack

Retention Bolts and Bushings
NOTICE NO. DN-91.1 nugh~Hllcopbm. inc.
DATE 22 July 1981
PAGE 6 OF 6
TOOL, 172 INCH DIAIYTER X 6.0

INCHES LONG, THREADED BAR
STOCK OR BOLT WITH THREE INUIES
LOCKNUT (TACK WELD, JAn NUT OR
OF THREAD IIINlrWII,
LOCTITE mY BE USED TO SECURE
369921270-5 LOCKNUT)
ALIGN THIS 102186 WITH

O,D, OF 369221279-5 SPACER
/-1 I Y~Rc-HUB AND STRAP PACK ASSOZBLY

369221273 BSC
BUSHING IN HUB
369921273-3 BUSHING
O.H) INCH I,D.

STEEL WASHER
88-942
Figure 2. Removal Tool for Bushing Extraction
(NOTE 1) I ,(NOTE 2)
(NOTE 1)
i, APPLY SEALANT BEFOR INSTALLING BOLT OR
WITH BOLT PARTIALLY IN PLACE. SEAL BETWEEN I Y(NOTE 2)
8USHING AND HUB SHOES, .USE CAUTION WHEN APPLYING
SEALANT THAT IT DOES NOT TOUCH BOLT, AS IT
WILL MKE SUBSEaUENT RW)VAL OF BOLT DIFFICULT,
2, APPLY PR1436-t, CLASS B-l SEALING COIPOUND
TO FAYING SUPFACES,
3, ENSURE THAT BUSHING IS CENTERED

SO THAT SEALANT CAN BE APPLIED
TO BOTH ENDS,
88-$89
Figure 3. Application of Sealing Comgound

NOTICE NC. DN-92
HUGHES
DATE 4 JUNE 1981
SE RVICE IN FOR MA1610N
PAGE 1 OF 6
NOTICE
MAN DATORY I MAN DATORY II I MAN DATORY
SUBJECT: TION/ TREATMENT ONE- WAY LOCK

CORROSION INSPEC
SUPPORT ASSEMBLY, P/N 369A7314 AND 369N2648
MODELS AFFECTED: All 500D Model 369D Helicopters, Serial Nos. 0003D through
1049D
TIME OF COMPLIANCE: Shall be accomplished at the next 100 hour
inspection.
procedure to be used to inspect the magnesium alloy support

link, P/N 369A7314, forgalvanic corrosion resulting from con-
tact with dissimilar metals (steel and brass). Subsequent corro-
sion prevention is included herein.
It is to be noted that
galvanic corrosion has occured at the aft
(lower) ends of the magnesium alloy support links where the
brass pivot bushing (P/N NAS77A8-21P) and steel washer contact
the link. However, the possibility for corrosion also exists
at the forward (upper) end of each link where it contacts the
brass flange bushing (P/N NAS77A6-23P) and a steel washer.

Each of the support links is to be inspected, treated if necessary,
and sealed with a corrosion inhibiting sealing and coating
compound. Procedures are also included for the interchangeable

aluminum support assembly PN 369N2648.
REFERENCE
400D Model 369D Basic HMI-Vol 1, Issued 14 September 1976; Revision No. 4,
1 December 1980.
Customer Service Dep~irtment
FORM 9578 (2/81)

Hughes Helicopters. Inc. culver city, California 90230
NOTICE NO. DN-92
DATE 4 JUNE 1981
PAGE 2 OF 6
MA TERIALS
Sealing compound MIL-S-81733A PR 1436-G Product Research

Class B2 Glendale, Calif.
Chromic acid solution Dow #19 or Dow Chemical Co.

(Ph 2.6 3.4) magne- equivalent
slum touchup
Thinner, acrylic- MIL-T-19544 Prepsol, I. E. DuPont Co.

nitrocellulose
lacquer DuPont 3919 Los Angeles, Calif.
Aluminum oxide cloth
Abrasive paper, P-P-101

silicone carbide,
400 grit (or equivalent
aluminum oxide paper)
a. Remove support links as follows:
i. Remove pilots seat inboard collective

cover or
pitch stick cover
and controls access door from the station 78.5 canted bulkhead.
2. Remove large (central) cyclic stick guard.
3. Position pilots cyclic stick to align holes in uni-loc

support links
with bolt that attaches forward end of uni-loc to
cyclic torque tube;
tighten longitudinal friction.
NOTE
Do not disconnect uni-loc from torque

tube arm or from longitudinal idler bellcrank.
Allow uni-loc to remain suspended at
both ends.
4. Disconnect forward (upper) end of each support link from the seat
structure flanges by removing a cotter pin,~ nut, steel washer,
sleeve bushing, bolt and brass flange bushing.
NOTICE NO. BN-C)2
DATE 4 JUNE 19131
PACE 3 OF 6
5. Disconnect the aft (lower) end of each support link from its uni-
loc trunnion by removing a cotter pin, steel washer, and brass
pivot bu shing.
b. Inspect support links as follows:
aluminum support links for abrasion,

i. Inspect magnesium alloy or
corrosion, pitting, etc.
2. If no abrasion, corrosion, or pitting is evident, seal all contacting

surfaces of the dissimilar metals in accordance with step e, and
reassemble the one-way lock assembly.
3. If the corrosive effects of galvanic action are evident, proceed

through the next steps.
NOTE
Magnesium alloy must be insulated from
contact with dissimilar metals to prevent

galvanic corrosion. All contacting surfaces
must be corrosion treated and coated with
a layer of sealing compound.
Remove corrosion from magnesium alloy support links as follows:

c.
C nv TION
Do not use wirebrush, emery cloth

or steel wool on magnesium surfaces.
1. Wash affected area with solution of niild soap and clean fresh
a
water. Rinse area with clear water and wipe dry; use a clean
soft lintfree cloth.
2. Use thinner on corroded area to remove any grease. Lightly

abrade the surface with aluminum oxide cloth to remove the
corrosion and its by-products.
3, Swab the exposed area for 10 to 30 minutes with chroniic acid
solution.
NOTICE NO. DN-92
DATE 4 JUNE 1981
PACE 4 OF 6
CAUTION
Do not rinse with hot water.
4. Use a clean cloth soaked in clean cold

water; thoroughly rinse
area where chromic acid solution was
applied. Allow area to
air dry.
d. Remove corrosion from aluminum

support links as follows:
CAUTION
Do not steel wool

use or emery cloth on
aluminum surfaces.
i. Remove paint from affected (Refer to Basic

area. H~I-Vol. i,
para 2-67)
2. Using abrasive paper, corrosion and

remove polish affected area.
3. Wash affected with solution of mild

area
soap and water. Rinse
with clean water and wipe
area
dry with clean, soft lintless cloth.
e. Use sealing compound to fill and

seams joints that might trap water.
Seal all contacting surfaces of dissimilar metals as follows:
i. Check that seam joint is clean and free of

or
foreign matter and
moi stur e.
2. Apply sealant with putty knife or similar tool.
3. Force sealant well down into seam or joint to eliminate any air
pockets.
4. Fillet sealant to give joint or seam a smooth appearance.

NOTICE NO. DN-92
DATE 4 JUNE 1981
PAGE 5 OF 6
f. Reassemble support link assemblies and the

one-way lock assembly
into the cyclic control system, as follows:
i. Assemble aft end (farthest from center hole) as follows:
(a) Insert the brass pivot bushing.
(b) Place the assembled bushing and support link on a uni-loc

trunnion, with the bushing flange next to the uni-loc.
(c) Place steel washer on protruding trunnion and secure with

cotter pin.
(d) Ensure that all contacting surfaces between the magnesium

alloy aluminum support link and all dissimilar metals
or are
coated with sealant.
2. Assemble forward end (closest to center hole), as follows:
(a) Place the steel sleeve bushing on the bolt.
(b) Place the brass flange bushing on the assembled bolt and
sleeve. Ensure that the bushing flange is next to the bolt
head.
(c) Align the hole in the forward end of the support link with the
hole in the seat structure flange.
(d) Insert the assembled bolt and bushings through the support
link and through the seat structure flange.
(e) On the threaded end of the protruding bolt. place steel washer
and nut. Secure with cotter pin.
(f) Ensure that all contacting surfaces between the magnesium

alloy or aluminum support link and all dissimilar metals
are coated with sealant.
f. Record compliance with this Service Information Notice in Compliance


NOTICE NO. DN-92
DATE 4 JUNE 1181
PAGE 6 OF 6
_I
SUPPORT
LINK
ONE-WAY
LOCK LONGITUDINALIDLER BELLCRANK
\i
PIVOT
BUSHINGSUPPORT LINK
SLEEVE BUSHING
FLANGE
BUSHING
CYCLIC PITCH
INTERCONNECTING
TORQUE TUBE O SEAT
FLANGE
88-lt57
Figure i. One-Way Lock Control System

NOTICE NC. DN193
E)I
HUGHES DnrE 18 June 1981
SE R~tCE IN FQRIWIATION PAGE 1 OF
R1 OT ICE
MANDATORY C~ ~L II MAN DATO RY e- MAN DATORY
SUBJECT: INSPECTION /MODIFICATION OF BREEZE CORPORATION

INC. HOIST, PN BL-16600-12
MODELS AFFECTED: 500D Model 369D Helicopter equipped with rotorcraft hoist
system.
Shall be accomplished before next operation of rotorcraft

TIME OF COMPLIANCE:
hoist system.

procedures for inspection and modification of Breeze Corpor-
ation Inc. hoist, PN BL-16600-12, which is a component of
the rotorcraft hoist system. This inspection /modification is
to be accomplished in accordance with the instructions given in

the attached Breeze Corporation Inc. Engineering Bulletin
BE B- 1 62-8.
Reference
Breeze Corporation Inc. Engineering Bulletin BEB-162-8.
cutom.r G~NIEC Oepamoen~
FORM 9578 (2/81) Inc.

Hughes Helicopters, Culver city, california 90230
NOTICE NO. DN- 93
DATE 18 June 1981
PAGE 2 OF 2
PROCEDURE
a. Perform
inspection/modification of Breeze CorporationInc.
hoist,
PN BL-16600-12, in accordance with instructions given in attached Breeze
Engineering Bulletin BEB-162-8.
b. Record compliance with this Service Information Notice in Compli-


COYPILLO I IBREUE Ir(C. BEB-162-8 Page 1 of 7
TllrlC9 D.B. UNION, NJ USA
cnEcro3
TTTIl: BL-16600-li! Rescue Hoist
"11Lrci I Safety Inspection and Modification
CODE NO. 08~84
The purpose ofbulletin is to instruct users of the

this
and modi-
BL-16600-12 Rescue Hoist in inspection procedures
minimize the possibility of malfunction
fications intended to
in certain hoist components.
CABLE
i. Reel Cable completely out.
CAUTION
Handle cable carefully. Do not allow cable to
kink. Cable mustbe kept clean during handling,

Do not allow cable to drag over dirty or abrasive
surfaces.
four nuts securing top cover to hoist. Remove

2. Remove
cover.
Hold full out limit switch actuating roller up and

3.
from cable drum. Actuate hoist until
slightly away
inactive turns are unwound from drum.
4. Disconnect all power to hoist.
socket head screw recuring cable end to

5. Remove
cable drum flange.
6. Carefully pull cable through cable guide assembly

and full in limit switch.
the last 15 feet of

7. Vapor degrease approximately
cable measured from the drum anchor end.
red using Dykim Lacquer (color No. DNC)

8. Paint this area
obtainable from Dykim Co., St. Louis, MO.
This area of red cable is to alert the operator that-maximum

NOTE:
cable extension is approaching. td
g. Apply power to hoist.
in until the cable guide assembly moves to the

10. Reel
(motor end) and then reverses
extreme right position
and left one indexing position ofthe shaft
moves
has not
~This operation is not required if the hoist
been operated with the cable removed).
EILII CHINBLS-IILL CHAHCE NOTICL j DITt_L~

BEB-162-8
Page 2
11. Disconnect power to hoist.
12. Thread cable end through full-in limit switch, bellmouth

and cable guide assy.
13. Insert cable endinto cable drum anchor hole. Replace

socket head set and
screw torque to 9 in. Ib.
14. Connect electrical power to hoist.
15. Carefully wind approximately 3 complete wraps onto the

cable ,drum.
16. Disconnect power to hoist.
FULL-OUT LIMIT SWITCH

(Hoist Serial. Numbers up to 117)
Readjust and modify the full-out limit switch as follows:
i. Switch assembly must be positioned on cross bar so as to

allow switch roller to contact grooved surface of drum
immediately adjacent to inactive cable wraps (2 1/2 to
3 1/2 wraps) This may be accomplished by loosening
both sets of socket head screws (A and B,
Fig, 1) in
both collar assemblies. The switch assembly may then
be slid across the bar to the desired position. Tighten
the socket head screws to 4 in. Ib. End clearance in
the assembly must be maintained at .002 to .005 to allow
proper movement of roller (C, Fig.
arm. 1)
2. Wi;throller resting on grooved
portion of drum adjacent
to the proper number of inactive turns
(2 1/2 to 371/2)
loosen socket head screws (A~
Fig. 1) and rotate switch
until it can be heard to actuate. Tighten socket head
screws to 4 in. Ib. Again, end clearance must be .002
to .005 for proper operation. I m
3. Bend end of spring per Fig. i.
4. Check hoist for h,

satisfactory operation.
CAUTION
If after
replacing top cover the two 1/2"
locknuts securing the ffont of the cover are
tightened excessively, the full-out limit switch
adjustment may be affected. Check switch
opera-
tion after is
cover replaced.
BEB-1~2-B
Page 3
FULL-OUT LIMIT SWITCH

~Hdist Serial Nur~bers 118 and up)
the full-out limit switchas follows:

Re-adjust and modify
Switch assembly must be positioned on cross bar so

i.
as to allow switch roller to contac~ arooved surface
of immediately adjacent
drum to inactive cable wraps
(2 1/2 to 3 1/2 wraps) This may be accomplished

(A and B, Fig. 2)
by loosening both socket head screws
in the switch bracket and collar assemblies. The switch

the bar to the de-
assembly may then be slid across
sired position. Tighten socket head screw in switch

bracket (A, Fig. 2) to 9 in. Ih. Torsion spring must
b
be wound 90 to 1200from the free position ~nd then
tightenLt- the-socket.head screw (B, Fig. 2).to 9 in.lb.

The spring is wound by rotating the collar (C, Fig. 2)
in a clockwise direction when viewed from the motor
end of the hoist. .002 to .005 end clearance must be

maintained to permit proper movement for actuator arm.
2. With roller resting on grooved portion of drum adjacent

to the number of inactive turns (2 l/z to 3 1/2)
proper
loosen socket head screw (A, Fig. 2) and rotate switch
bracket until switch can be heard to actuate. Tighten
socket head screw to a torque of 9 in. Ib. End clear-
ance must be .002 to .005 for proper operation.
3. Bend end of spring per Fig. 2.
4. Check hoist for satisfactory operation.
CAIITION
If after replacing top cover the two 1/2" locknuts

securing the front of the cover are tightened excess-
limit switch adjustment may be

ively, the full-out
affected. Check switch operation after cover is re-
placed. I t~
CABLE CUTTER
to be that the shunt wire

i. Inspect cable cutter sure
across the terminals Is cut before the hoist is oo
placedin service. Failure to cut this wire will
prevent the operation of the cutter.

BEB-l62-8
Page 4
HOIST BUMPER
i. Measure thickness of the hoist bumper. If measurement is

less than that shown in Pig, 3, replace bumper.
POST FLIGHT INSPECTION
Perform post flight inspection after each hoist use. If

hoist has not been used, perform at least every 15 days.
(30 days if hoist is removed from aircraft for storage).
ld~-162-8
Page 5
C Bend end of spring

approx. 900 as
shown
Lubricate with
MIL-G-23872 or
equiv. toinsure
free movement of
actuator.
Eouivalent:
FIGURE 1 ESSO-BEACON 325
AMOCO SUPER-MIL
Page 6
II(
Bend end of spring I~e

approx. 900 as
8
shown
MO
w
I I ~C
Lubricate with
MIL-G-23872 or
~P I 1 equiv. to insure
free movement of
actuator.
Equivalcn~:
ESSO-B~ACON 325
Figure f
PJI1OCO SUPER-MLL
BEB-162-8
Page 7
cr_
Fig. 37
NOTICE NO DN-94
HUGHES
""E 25 June 1981
SERVICE INFORMATION
PAGE 1 OF 3
NOTICE
SUBJECT: DEACTIVATION OF MAIN ROTOR BRAKE SYSTEM (IF INSTALLED);

PERIODIC INSPECTION OF TAIL ROTOR DRIVE SHAFT FORWARD
FLEXIBLE COUPLING, PN 369A5401 OR PN 3691--192464
TIME OF COMPLIANCE: PART I Shall be accomplished within next 25 hours of

helicopter ope ration following receipt of this
Notice, if PN 3691-190123 Rotor Brake System is
OF COMPLIANCE: installed
TIME
PART II Shall be accomplished at each 100-hour interval

of helicopter operation, following receipt of
this Notice.
PREFACE: Part I of this Service Information Notice lists a procedure for deactivating
the main rotor brake, if the system is installed on the helicopter.
Part II of this Notice provides instructions for a periodic visual inspection

of the subject tail rotor drive shaft: forward flexible coupling, to ensure
proper condition and operation of the coupling.
Refe rence
500D Model 369D Basic HMI-Vol I(CSP-D-2) Issued 15 September 1976; Revision
No. 4, 1 December 1980
500D Model 369D Basic HMI-Vol II (CSP-D-3) Issued 15 September 1976;
2, 1 November 1978
Revision No.
500D Optional Equipment Instructions for PN 369H90123 Series Rotor Brake
(CSP-006) Issued 1 August 1976; Revised 30 July 1980
FORM 9578 (2/81) Inc.

Hughes Helicopters, culver city, california 90230
NOTICE NO. DN- 94
DATE 25 June 1981
PAGE 2 OF 3
PART I DEACTIVATION OF ROTOR BRAKE SYSTEM
a. Position rotor brake handle at UP position in retainer; secure handle

to retainer with lockwire to prevent brake application (refer to CSP-006).
b. Perform 100-hour inspection of forward flexible coupling, per

Part II of this Notice.
c. Record compliance with Part I and Part II of this Notice in Compli-

PART II 100-HOUR INSPECTION OF FORWARD

FLEXIBLE COUPLING
a. Open tail rotor drive shaft door (Section 2, Basic HMI-Vol

access I).
b. Inspect tail rotor drive shaft forward flexible

coupling as follows:
i. Using mirror and bright light, visually inspect flexible coup-

ling for any indication of cracks, corrosion, deformation or
other physical damage. If any of the above deficiencies are
noted or suspected, -removd -tail rotor drive shaft from heli-
copter and perform closer inspection (Section 9, Basic HMI-

Vol I).
CAUTION
a) Do not disassemble flexible coupling

b) Do not immerse flexible coupling in fluids
or cleaners such magnetic particle,
as
fluorescent penetrant, visible dye, etc.
c) Do not apply corrosion protection fluids

unless coupling has been cleaned with sol-
vent or detergent. Apply any corrosion
protection fluid very sparingly to outside
only.
c. Close tail rotor drive shaft access door.
d. Record compliance with Part II of this~ Notice in Compliance

NOTICE NO. DN-94
DATE 25 June 1981
PAGE 3 OF 3
FAA APPROVED
REFERENCE SHEET
Action Reference: When performing maintenance of tail rotor drive shaft,

refer to Service Information Notide No. DN-94 for peri-
odic check of forward flexible coupling.
HMI Reference: Insert this sheet in HMIIVolume I, Section 9, page 9-27.
incorporated
until the data is at the next revision of HMI-
Volume I. (Refer to Service Information Summary,

HMI-Volume I, page i.)
REFERENCE SHEE T
Action Reference: When performing special 100-hour periodic inspection,

refer to Service Information Notice No. DN-94 for
check of tail rotor drive shaft flexible coupling.
HMI Reference: Insert this sheet in HMI-Volume II, Table 2-3, Section 2,
special inspection, page 2-17.

until the data is
incorporated at the next: revision of HMI-
Volume II.(Refer to Service Information Summary,
HMI-Volume II, page i).
fi~j
NOTICE NC. DN-95
HUGH ES
DATE 7 August 1981
SERVICE IN FORMATION PAGE 1 OF
7
NOTICE
SUBJECT: INSTALLATION OF FAILSAFE DEVICE AT TAIL ROTOR DRIVE SHAFT

FORWARD FLEXIBLE COUPLING, PN 369A5501 OR PN 369H92564;
CHECK OF FLEXIBLE COUPLINGS
MODELS AFFECTED:
PART I- Model 369D Helicopter SerialNo. 0003D thru 0870D; 0872D thru 0875D;
0878D thru 0884D; 0886D thru 0892D; 0894D thru 0902D; 0904D; 0905D;
0907D; 0908D; 0910D thru 0916D; 0918D; 0919D; 0921D thru 0925D;
0928D thru 0935D; 0938D; 0940D thru 0943D; 0947D; 0948D; 0950D thru
0952D; 0955D; 0956D; 0958D; 0960D; 0962D; 0964D; 096513; 0970D; 0974D;
0977D; 0979D; 0985D thru 0987D; 0989D; 0990D; 1000D; 1001D; 1003D; 1005D
PART II- All Model369D Helicopters equipped with Failsafe Device

(PN 369D25530 Coupling Bolt and 369D25531 Socket)
TIME OF COMPLIANCE:
PART I- If PN 369H90123 Series Rotor Brake is installed on helic~opter:

Installation of failsafe device shall be
accomplished within 25 hours
of helicopter operation following receipt of parts, or within 180 days
after date of this Notice, whichever is sooner.. Procure required
parts from your authorized HH Service Center or Distributor upon

receipt of this Notice.
If PN 369H90123 Series Rotor Brake is NOT installed on helicopter:
Installation of failsafe device shall beaccomplished within 100 hours

of helicopter following receipt of parts, or within 180 days after date
of this Notice, whichever is sooner. Procure required parts from
your authorized HH Service Center or Distributor upon receipt of
this Notice.
PART II- Shall be accomplished at intervals specified.
PREFACE: Part I of this Notice provides instructions for installing a failsafe device
to provide an additional drive connection between the main transmission
output shaft and the tail rotor drive shaft at the forward flexible coupling.
The failsafe device consists primarily of a new 369D25530 coupling bolt
FORY 9578 (2/81)

Hughes Helicopters, Inc. Culver city, California 90230
11~61
NOTICE NO. DN-95
I_1ATE 7 August: 1981
PAGE 2 OF 7
PREFACE: to secure the forward flexible coupling to the main transmission output
(Cont) shaft; and a new 369D25531 socket installed between the
connecting
flanges of the forward coupling and the tail rotor drive shaft. The new
coupling bolt incorporates a key which engages a corresponding keyway
in the socket, this providing an alternate drive link if coupling failure
should occur.
Part II of this Notice prescribes checks of the forward flexible coupling,

for all helicopters equipped with the failsafe device.
It is to be noted thathelicopters equipped with the failsafe device

(installed at factory or per this Notice) are NOT subject to special
inspections or requirements of below referenced Hughes Notice
No. DN-94.
Reference
400D Model 369D Basic HMI-Vol I (CSP-D-2) Issued 15 September 1976;

Revision No. 4, 1 December 1480
500D Model 369D Basic HMI-Vol II(CSP-D-3) Issued 15 September 1976;

500D Rotorcraft Flight Manual, issued 8 December 1976; Revised 11 May

1981
500D Optional Equipment Instructions for PN 369H90123 Series Rotor

Brake (CSP-006) Issued 1 August 1976; Revised 30 July 1980
Hughes Service Information Notice No. DN-94, dated 25 June 1981

NOTICE NO. DN-95
DATE 7 August 1981

PAGE 3 of 7
PARTS LIST
Procure parts required from your authorized HH Service Center or Distributor upon
Nom enc lature Part Num be r Qty Mfr
369D24530~ 1 HHI
Bolt, coupling
Socket 369D25531: 1 HHI
Shim 369A5516-9 AR HHI
Washer NAS62 0C41 6L 3 Comme rcial
Washer HS 3 O 6 32 6 HHI
I:A special price of $105. 70 for the PN369D25430 coupling bolt, and $109. 30 for the
PN 369D25531 socket has been established. This pricing will remain in effect
through 31 December 1981.

a:~As required
MATERIAL
Crease MIL-G-81322 Mobil Grease 28 Mobil Oil

Aero shell 22 Shell Oil
or
Grease Lubriplate Fi ske B ro s,

930-AA Toledo, OH
Anti-seize compound MIL-A-907 Commercial
Lockwire MS2 09 9 5C Comme rcial
Primer, zinc chromate TT-P-1757 Commercial
TOOI,S AND EQUIPMENT
Torque wrench 0 to 500 inch-pounds Commercial
Feeler gage Commercial
PART I INSTALLATION OF FAILSAFE DEVICE
a. Remove and inspect tail rotor drive shaft (Section 9, HMI-Vol I).
b. Remove and inspect flexible couplings land disc brake components

if rotor brake is installed) on main and tail rotor transmission gearshafts.
(Refer to Section 9, IIMI-VolI, and CSP-006 Rotor Brake Instructions if
applicable.
NOTE
Retain 369A4516-9 shims for reinstallation.

NOTICE NO. DI\i-95
DATE 7 August 1981
PACE 4 OF 7
c. Install one 0.010-inch shim forward of flexible

coupling on main
transmission output shaft as Figure i.
shown in Coat
coupling splines with
grease and new 369D25530 coupling bolt threads with anti-seize compound
before assembly. Install existing flexible coupling land brake disc compo-
nen~s as applicable) and tighten new coupling bolt to 250 to 300 inch-pounds.
d. Install one 0.010-inch shim aft of flexible coupling on tail rotor

transmission input shaft. Coat coupling splines with grease and coupling bolt
threads with anti-seize compound before assembly. Install coupling and
tighten coupling holt to 250 to 300 inch-pounds.
e. Position new 369D25531 socket on aft face of forward coupling so

that three of the nine holes are indexed to the three nutplates of thecoupling
in such a way tl-iat maximum clearance is obtained between the bolt key and
socket as shown in View B-B. Visually verify proper clearance before
installing tail rotor drive shaft.
f. Reinstall tail rotor drive shaft per HMI-Vol I, except tighten attach
bolts fingertight only at forward coupling and socket. Replace existing
NAS620C416 washers with NAS620C416L washers, 3 places.
g. Obtain 0.010 to 0.020-inch gap between forward flange of tail

rotor drive shaft and aft end of socket, using the following procedure:
1. Back off three attach bolts on forward flange of tail rotor

drive shaft assembly 0. 050 to 0. 100 inch.
2. Push and hold tail rotor output shaft of main rotor

transmission forward (into transmission) to remove
end play. If rotor brake is installed, make certain

that brake pucks do not restrict axial travel of tail rotor
output shaft.
3. Remove end play in tail rotor transmission by applying

force to tail rotor blades in opposite direction of opera-
tional rotation (while still holding tail rotor transmission
output shaft to prevent rotation). Do not push tail rdtor
drive shaft fore or aft.
4. Measure gap between socket and flange of tail rotor drive

shaft (socket flange must be in full contact with flange of
fl,exible coupling).
NOTICE NO. DTJ-94
DATE 7 August 1981
PAGE 5 OF 7
4. Add required number of shims behind flexible coupling at main

transmission end of tail rotor drive shaft, to obtain specified
020 inch.
gap of 0. 010 to 0.
NOTE
a) Shim (0. 010 inch) may be removed from aft

coupling if necessary.
b) If less than specified gap (0. 010 to 0. 020 inch)

exists under minimum shim requirements,
install maximum of one HS306-326 washer on
each of the four tail rotor transmission

mo~nting studs, between gearbox housing and
booth fitting. Apply zinc chromate primer to
both sides of washer at installation.
c) After washer installation, repeat steps g. 1

thru g. 5 a.bove.
h. Complete installation of tail rotor drive shaft assembly, and rotor

disc brake components asapplicsble. (Kefer to HMI-Vol I and CSP-006 as
applicable.
NOTE
a) If rotor brake system was deactivated per
Hughes Notice No. DN-94, remove lockwire
~securing rotor brake handle to retainer.
Perform operational check of rotor brake
system, per CSP-006.
b) Installation of failsafe device (369A2 5430

coupling bolt and 369D25531 socket) lifts the
Irequirements of Hughes Notice No. DN-94.
with Part I of this Notice in Compliance Record

i. Record Compliance
NOTICE NO. DN-95
DATE 7 August 1981

PAGE 6 OF 7
PA.RT II CHECK OF FLEXIBLE COUPLINGS
NOTE
For all 500D helicopters with failsafe device

installed, the tail rotor drive shaft: forward
flexible coupling shall be checked
periodically
as follows:
At Each Pilot Preflight Check:

Rock tail rotor back and forth in
plane of roea-
tion. If blade can move in excess of Q. 75 inch
(1. 93 cm) at the blade tip without rotation of main
rotor blades, check for
proper condition of tail
rotor drive shaft forward
coupling. (Section 9,
Basic HMI-Vol I. Replace coupling as required.
At Each Aircraft/Engine Shutdown:
If thumping rapping is heard from drive train

or
during final revolutions of tail rotor blades,

check tail rotor drive shaft forward flexible
coupling for proper condition. (Section 9, Basic
HMI-VOL I. Replace coupling as required,
At Each Annual 300-Hour
or
Inspection
With tail rotor drive shaft
removed, inspect
flexible couplings per HMI-Vol I. Also visually
inspect forward coupling bolt and socket for
indications of contact. Do not loosen or remove
bolt. If signs of contact are noted, remove
and reinstall socket and/or coupling bolt per
Part I of this Notice.
Reposition socket and/or
bolt so that the maximum clearance is
obtained
between bolt key and socket. (See View B-B,
Figure i. Visually verify proper clearance
before reinstalling tail rotor drive shaft.
FAA APPROVED
NOTICE NO. DN-95
DATE IAugust 1981

PAGE 7 OF 7
MAIN TRANSMISSION
TAIL ROTOR
DRIVE SHAFT
369A5501 OR TAIL ROTOR

369H925611 DRIVE SHAFT
MAIN TRANSMISSION 3691\5516-9 (NOTE)
COUPLING
OUTPUT PINIOfl SHIMS B
_
369825531
SOCKET
O
-t-O--;
II B~ \36915531
SOCKET
3691325530 80LT
O
B-B VIEW
NOTE:
NAS620C416L WASHER REPLACES EXISTING
NAS620CU6 WASHER, 3PLACES,
88-518
Figure i. Installation of failsafe device, tail

rotor drive shaft forward coupling
REFERENCE SHEET
Action Reference: When performing maintenance of tail rotor drive shaft,

refer to Service Information Notice No. DN-95 for
installation of failsafe socket and coupling bolt.
HMI Reference: Insert this sheet in HMI-Vol I, Section 9, page 9-27.

manual until the data is incorporated at the next revi-
sion of HMI-Volume I. (Refer to Service Information
Summary, HMI-Volume I, pagei.)
C;Y.
REFERENCE SHEET
Annual 300-hour Inspection, refer

to Service Information Notice No. DN-95 for

check of failsafe socket and coupling bolts.
engagement
HMI Reference: Insert this sheet in HMI-Volume II, Section 2,

Table 2-2, Annual or 300-hour Inspection.
kept as a part of the

This reference sheet shall be
incorporated at the next
manual until the data is
revision of HMI-Volume II. (Refer to Service ~Informa-
tion Summary, HMI-Volume II, page i.)
O
NOTICE NC. DN-96
HUGHES DaTE 21 AUGUST 1981
"-3
SE RVICE I N FORMATIO N
NOTICE
SUBJECT: ONE-TIME INSPECTION ATTACHMENT HARDWARE FOR STA-STRAP

SECURING ELECTRIC WIRING TO BOOM FAIRING AT STA 138. 50
MODELS AFFECTED: Model 369D Helicopter Serial No. 0003D through 0950D

PREFACE: The information in this Service Information Notice lists

given a procedure
for checking the rivet and washer used to attach the subject sta-strap
assembly at Station 138. 50 on the boom fairing assen?bly, for proper
condition, security of attachment, and for evidence of corrosion.
Field reports indicate that a steel washer may have been installed
inadvertently under the aluminum rivet which can result in dissimilar
metalcorrosion, rivet separation, and possible entry of rivet into the

engine air intake.
Reference
500D Basic HMI-Vol I, Issued 15 September 1976; Revision No. 5, 15 May 1981
Customer Senice Department
FBRM 9578 (2/81)

Hughe~ Helicoptets, Inc. culver city, California 90230
NOTICE NO. DN-96
DATE 21.BUGUST 1981
PAGE 2 of 3
PARTS LIST
Blind rivet, aluminum NAS 1919 B04-02 AR Commercial

or NAS1738B4-2
or NAS 1 39 8 B4- 2
Washer, aluminum AN9 60PD4 L AR Commercial
Strap SSC-2 AR Panduit Corp

or equivalent AR or equivalent
a. Open plenum chamber access door on engine air inlet aft fairing.
(Section 2, Basic HMI Vol I).
b. Install teilporary cover of cardboard or suitable material over

enfiine air intake bell, to prevent entry of foreign objects into engine air
intake.
c. Locate rivet and washer used to attach SSC-2

strap to boom fairing
upper surf ace at Station 138. 50 and i. 20 inches to
right of helicopter center-
line. Strap electric wiring routed
secures
through engine air inlet aft fairing.
d. Using flashlight and mirror, closely check rivet for condition,

security of attachrrient and for
any evidence of corrosion around rivet head.
NOTE
i. If rivet is rriissing or loose, or any corrosion

is noted, replace existing rivet and washer with
new aluminum blind rivet and new aluminum
washer. Do not use existing washer.
2. If rivet ismissing, inspect engine compressor

for damage.
NOTLCE NO. DN-96
DATE 21 AUGUST 1981
PAGE 3 of 3
e. Using metal tool with sharp edge or sharp point, perform hardness
check of existing washer under rivet, to determine whether an aluminum
washer or steel washer is installed.
NOTE
i. Aluminum washer is softer and can be easily

scored or scratched by metal tool. If aluminum
washer is installed, coat scoring or scratches
with zinc chromate primer. No further action
is required.
2. Stainless steel washer can not be scored or
scratched easily by metal tool. Remove rivet

and steelwasher, if installed, and replace with
new aluminum blind rivet and new aluminum
washer.
3. If washer material cannot be determined
positively, remove existing rivet and washer

and replace with new aluminum blind rivet
and new aluminum washer.
f. Check plenum area for any foreign objects or debris; remove
temporary cover froin engine air inlet bell.
g. Close plenum chailber access doors.
h. Record compliance with this Service Information Notice in
FAA/ DER APPROVED 14 August 1981

NOTICE NO. DN-97
HUGHES
DATE 5 OCTOBER 1981
S E RVI C E I N FO R MATI 0 N
PAGE 1 OF 5
NOTICE
SUBJECT: MAIN ROTOR BRAKE SYSTEM, PN 3691-190123 SERIES INSTALLATION
OF MASTER CYLINDER STOP, PN 369D292585
MODELS AFFECTED: All Model 369D Helicopters equipped with subject Main Rotor
Brake System incorporating 369H92 584- 501 or 502 Master
Cylinder Linkage Assembly

operation, or within 180 days after receipt of this Notice,
whichever is sooner. Order parts from your authorized
HH Service Center or Distributor upon receipt of this Notice.
for fabricating and installing a stop device on the rotor brake master
cylinder and the actuating lever, to limit the stroke of the cylinder plunger
the
spring, and prevent possible dislocation of a rubber cup inside
of the spring can
cylinder. Field reports indicate that constant bottoming
dislocate the rubber cup causing blockage of the hydraulic fluid feed holes
The
and preventing brake pucks from disengaging from the brake disc.
re sultant friction can in turn create
heat build up and possible damage to
the brake disc and caliper assembly.
Dimensions and specifications are provided for field fabrication of the
369D292585 Rotor Brake Lever Stop.
Reference
Model 500D Basic HMI Volume I, Issued 15 September 1976; Revision No. 5,
15 May 1981
Model 3691) Optional Equipment Instruction for 3691190143 Rotor Brake, CSP-006,
Issued 1 August 1976; Revised 30 July 1980
FORM 9578 (2/81) Inc.

Hughes Helicopters, culver city, calirornia 90230
NOTICE NO. DN-97
DATE 5 OCTOBER 1981
PAGE 2 OF 5
PARTS LIST
Nomenclature Pa rt No. Qty Mfr
Stop 369D292585 1 Field Fabricate~e

Washer AN9 6 0 51 6L 6 C omm e re ial
Pin, cotter MS24665- 1 7 O 1 C omm e re ial
Spacer NAS 1057T3-075 1 Commercial
Bolt NAS1303-16 1 Commercial
~S,ee Figure 2 for Dimensions and Specifications
TOOLS AND EQUIPMENT
Drill bit No. 10 (0. 190/0. 194 in. dial
MATERIALS
MODIFICATION PROCEDURE
a. Remove linkage cover (Refer to CSP-006).
b. Remove master cylinder assembly and 3691-192829 actuating lever

(Refer to CSP-006).
c. Rework actuating lever by drilling 0. 190/0. 194 inch diameter hole in lever
at dimensions shown in Figure i. Apply zinc chromate primer to reworked area of
lever.
d. Reinstall master cylinder assembly, with new 369D292585 stop, using new
AN960-516L washers and existing nuts and bolts as shown.
e. Install NAS1047T3-075 spacer on actuating lever as shown, using

NAS1303-16 bolt and MS21042-3 nut.
f. Reinstall lever assembly on pin, using existing spring, washer and nut.
Secure with new cotter pin.
g. Position rotor brake handle at down position; check for contact between new
step and spacer; also check for proper engagement of brake pucks and brake disc.
NOTICE NO. DN-97
DATE 5 OCTOBER 1981
PAGE 3 OF 5
h. Perform inspection and operational check of main rotor brake system per
CSP-006.
i. Reinstall linkage cover.
with this Service Information Notice in Compliance Record of

Record compliance
FAA/DER APPROVED 5 October 1981

NOTICE NO. DN-97
DATE 5 OCTOBER 1981
PAGE 4 OF 5
369H9258~-501 NAS13O5-22 BOLT, 2 REOD

369H9258ll-502 AN96O-516L WASHER, 6 REQD
MS210~2-5 NUT, 2 REQD
3690292585 STOP
369H92O18 MAS
CYLINDER
O
369D292585 ST
NAS1669-3L4
JO-BOLTS
369H2508 FRAME
369H92829 ACTUATING LEVER

NAS1303-16 BOLT
I NAS1O57T3-075 SPACER
MS21O112-3 NUT
,630
600
1.000
0.500
0,190
O 0.19q
DIA THRU
369H92829-1 SHOWN
369H92829-2 OPPOSITE
NOTES:
i, ALL DIMENSIONS IN INCHES

2, COAT REWORKED AREA WITH ZINC
CHROMATE PRIMER
88-522
Figure i. Installation of Rotor Brake Master Cylinder Stop Mechanism

NOTICE NO. DN-97
DATE 5 OCTOBER 1981
PAGE 5 OF 5
2,
~CO.1Zi (STO(K RE~) 1.312 .6
t 0,3501
0,600
O
1,21
0,06R,
4 PL
0,344
DIA. THRU, 2 PL
0.348
NOTES:
i, MATERIAL: 0,125 THICK 7075-16 OR T651 AL ALLOY SHEET PER 00-A-25O/12

2, ALTERNATE MATERIAL: 0,125 THICK 2024-T6, T~ OR T3, AL ALLOY SHEET PER
g(JAA-200/9
3, ALL DIMENSIONS IN INCHES
88-521
Figure 2. Field Fabrication 369D292 585 Rotor Brake Lever Stop

REFERENCE SHEET
Action Referenc e: When performing maintenance or inspection of rotor brake
system, refer to Service Information Notice No. DN-97

for installation of master cylinder stop mechanism.
HMI Reference: Insert this sheet in Publications No. CSP-006, Optional Equipment
Instruction for 369H90123 Rotor Brake, page 2-1.

the data is incorporated at the next revision of CSP-006.
NOTICE NO. DN- 99
HUGH ES
S E RVI C E I N FO R MATI 0 N PAGE 1 OF
4
NOTICE
MANDATOR~ MANDATORY MANDATORY
SUBJECT: PERIODIC INSPECTION OF MAIN ROTOR DRIVE SHAFT,

PN 369D25510
TIME OF COMPLIANCE: Shall be accomplished within next 25 hours of operation

for helicopters with 300 or more hours time in service.
Shall beaccomplished at each and every 300-Hour

Periodic Inspection interval
PREFACE: Field reports indicate that cracking has been detected in the spline
teeth at the main transmission end of the main rotor drive shaft. The
information given in this Service Information Notice lists a procedure
for a periodic removal and inspection of the main rotor drive shaft,
including a close visual inspection of the shaft spherical spline teeth
for possible cracks and damage.
The service life of the PN 36.9D25510 main rotor drive shaft is 3410 hours.
Reference
500D Basic HMI-Volume I, Issued 15 September 1976; Revision No. 5, 15 May 1981
500D Basic HMI-Volume II, Issued 15 September 1976; Revision No. 2,
1 November 1978
FORM 9178 (2/81)

Hughes Helicopters, Inc. culver city. California 90230
NOTICE NO. DN-99
PA ~E 2 of 4
TOOLS AND EQUIPMENT
Magnifying Class 5X to 1OX
Magnetic Particle Inspection Kit MIL-I-6868
MATERIALS
Solvent, Cleaning pID1680
PERIODIC INSPECTION OF MAIN ROTOR DRIVE SHAFT
CAUTION
Anytime main iotor drive shaft is removed,

cover opening at top of main rotor hub to
pre-
vent entry of any foreign material into hub,
mast and tran sm i s s ion.
a. Remove main rotor drive shaft (refer to Section 9 of HMI-Vol I).
b. Perform a visual inspection of the shaft spline as follows:
i. Thoroughly clean with cleaning solvent to remove oil, dirt,

etc.
2. Use 5X to 1OX magnifying glass and bright side light (45 O

or
less; downward lighting may not define cracks).
3. Pay particular attention to side of teach) tooth with larger wear

pattern. Hairline cracks appear crescent-shaped and at the
center and bottom of tooth in the root area (see
Figure i).
Also, inspect: neck (shaded area) of spline for cracks.
NOTE
(a) Ifcracking is suspected, perform magnetic

particle inspection of shaft spline and teeth.
(b) If cracking or damage is found, the shaft is

no longer airworthy. Discard drive shaft
and return it to HHI Customer Service
Department.
nclicoptelr. Inc. NOTICE NO. DN-99
PAGE 3 of 4
(c) Inspect replacement drive shaft per

steps b. and c. of this Notice, prior to
installation of shaft on helicopter.
other surfaces of the drive shaft, per Section 9 of

c. Inspect all
HMI Vol I.
NOTE
If surface corrosion or pitting of the shaft surface

is noted, perform field repair of drive shaft per
HMI-Vol I.
d. Remove protective cover and install main rotor drive shaft.
e. Record compliance with this Service Notice in Compliance Record

FAA APPROVED
NOTICE NO. DN-99 Hughe Helicopten. Inc.
PACE 4 of 4
FAIRING
SCREW (5 PLACES)
WASHER (5 PLACESI
EYEBOLT (1 PLACES AS
SHDWN)--~
EXTERNAL
WRENCH I NG
BOLT (7 PLACES)
FAIRING SUPPORT
SPACER (7 PLACES)
DRIVE SHAFT
,Hue
THIN WASHERS
(TYPICAL, 10
PLACES) ROOT AREA (TYP)
SPLINE NECK
NOTE:
PAY PARTICULAR A~ENTION TO

LARGER WEAR PATTERN IMULATED CRACKS
ROOT AE, AT ,ACH ,PLINE
TOOTH. SIMULATED CRACKS SHOWN.
ALSO CHECK SPLINE NECK
(SHADED AREA) FOR CRACKS.
88-541
Figure i. Inspection of Main Rotor Drive Shaft

Spherical Spline
NOTICE NC. DN100
HUGH ES
SERVICE INFORMATION
NOTICE
SUBJECT: RELOCATION OF AUTO REIGNITION CONTROLS AND MODIFICATION OF

SYSTEM FOR FULL-TIME OPERATION
MODELS AFFECTED: 500D Model 369D Helicopters, SerialNo. 0003D through

0949D, 0956D, 0965D, 0977D and 0989D, equipped with
PN 369H90118-513 Automatic Engine Reignition Kit.
TIME OF COMPLIANCE: At owners/operators discretion.
PREFACE: The information given in this Service Information Notice lists procedures
for relocating the auto
reignition controls on the instrument panel and
necessary rewiring, provide full-time operation of the system. The
to
FAA has determined that accomplishment of HEI Service Information

Notice DN-100 is an action which provides an equivalent level of safety
and satisfies the requirement of Airworthiness Directive (AD) 80-24-04.
The authority for this action is granted in paragraph c of the subject AD.
Reference
36)D Pilots Flight Manual, Publication No. CSP-D-I, Reissued 11 May 1981
FAA Airworthiness Directive 80-24-04
,::-t
FORM 9578A (2/81)

NOTICE NO. DN-100
DATE 22 February 1983 nughe~Welicogters. Inc.
PACE 2 OF 7
C
MATERIALS
Aluminum alloy sheet, 2024-T3, Qa-A-240/5, Temp T3.
Primer, catalyzed epoxy, HMS-14-1082
1-1Y-10, Advanced Coatings Chemicals Company, 2213 North

Tyler Avenue, So. Elmonte, CA 91733
U-1201, Sterling Lacquer Mfg. Co., Sunbrite Mfg. Co.,
3150 Brannon Avenue, St. Louis, MO 63139
Paint acrylic lacquer, HMS-15-1083, Color No. 37038 per FED-STD-594.
Advanced Coatings Chemicals Company

Steiling Lacquer Mfg. Co., Sunbrite Mfg. Co.
Scotch Cal Brand Film, 3650
Airmark Company (General Marketing Co.), 211 North Victory,

Burbank, CA 91502
Hesik Company, Inc., 385 Clinton St., Costa Mesa, CA 92626
Rose Name Plate, 4169 Olympic Blvd., Los Angeles, CA C)0063
Switch 882GK15, Cutler Hamn~er (or equivalent)
PROCEDURE
a. Set BATTERY, EXT PWR switch to OFF.
b. Disconnect wires from auto reignition switches as follows:
i. Remove wire no. J501A20 from circuit breaker (CD106-2)

and switch (S11-l) and discard wire.
2. Disconnect wire no. J501AEZO, J502E20, J501I320, 5502A20

and J502D20 at switch (S11).
3. Remove ARM switch (Sl.l) from instrument panel.
4. Remove, wire no. J503D20 and J503EE20 from terminal

board (TR5 02- 13A and 1 3C).
-r
NOTICE NO. DN-100

~B Hughes Helicopters. Inc.
DATE 22 February 1)83
PACE 3 OF 7
5. Remove wire no. J505A20N and J508A20N from stud (E2).
6. Remove wire no. J507AA20 from terminal board (TB502-13E).
7. Remove wire no. E559AC22 from splice (MS25181-1).
c. Remove relays (K304 and K104) and switch (XDS9) form ship.
Remo~e all wires from relays and switch and retain relays and switch for
reuse.
d. Fabricate cover, as required, for hole vacated by switch (see

Figure i).
e. Install cover on instrument panel (see Figure 1).
f. Install plug button on instrument panel (see Figure 1).
g. Paint out lettering at previous auto reignition switch location with

acrylic lacquer.
h. Fabricate plate, as required:
i. Make plate from 0. 062 inch thick aluminum alloy sheet as
shown in Figure 1.
2. Apply one coat HMS-15-1082 primer and dry for 1 to 2 hours.
3. Apply topcoat of HMS-15-1083 acrylic lacquer and air dry

p
4 hours minimum.
i. Install
plate and auto reignition switches (XDS9) (retained above)
and (S11) (PN 882CK15, Cutler Hammer or equivalent) at new location on
instrument panel (see Figure i).
j. Fabricate and install decal on instrument panel (see Figure i).
k. Revise wiring as follows (see Figure 2):
i. Install diode at circuit breaker (CBIO1).
2. Install diodes (CR3 and CR4) on switch (S11).

NOTICE NO. DN-100
4~ Hu9he~ Helic4ptsrs. Inc.
PACE 4 OF 7
3. Install transorb (CR5) on relay (K104).
4. Rewire switches (S1.1 and XT)S9) and relays (K104 and K304)
as shown.
5. Reinstall relays (K104 and K304) in original position.
i. Perform check of modified auto reignition system per instructions

in 369D Pilots Flight Manual, Publication No. CSP-D-1, dated 11 May 1981.
m. compliance with this Service Information

Record Notice in
The resultant alteration to the affected helicopters by the procedure in

this Notice has been shown to comply with Federal Aviation Regulations
and is FAA approved.
NOTICE NO. DN-100
Huehel Helicoptan. Inc.
PACE 5 OF 7
000
O O
o
O o O O 36986416 INSTRUMENT
PANEL ASSEMBLY
O O
O
RE-IOF 27 O
O
COVER (SEE VIEW D-D)
HS1957-2 SCREW
NAS620A6L WASHER
MS210~3-06 NUT
(08 EQUIVALENT)
AUTO RE-ltN
O O
ARMED
Ooooo -IGN~CREMOVE AUTO RE-IGN SWITCHES AND BLACK OUT LETTERING

AND COVER UP HOLES AFTER RELOCATING,
O
14
SS48152 PLUG BUTTON OR EOUIVALENT (CARR FASTENER COMPANY)~
0000
O O
oOOOO
USE EXISTING HOLE IN PANEL USE

6-32 X .50 LG SCREW AilD WASHER
(4 PLACES) 369896:18-105 SWITCH ASSEMBLY REF.
B EXISTING SWITCH MAY BE REWIRED
r 0.218
ILL OIA, HOLES 1N
0.221 PANEL TO USE
RE-IGN
TINHERMAN NUT "U" TYPE ND,
C~23328E-632 OR TAP DRILL
~i I I I ARMED
THREADS FOR 6-32 SCREW
AUTO RE-IGN I I X (REF)
TEST
PLATE
882GK15 SWITCH (CUTLER HA~;EE)
INSTALL OECAL (SEE VIEW E-E)
O
88-511-1
n;
Figure 1. Relocation of Auto Reignition Controls (Sheet 1 of 2)
NOTICE NO, DN1100
DATE 2iFebruary 1983 63) Hughes Hellcaplen. Inc.
PAGE 6 OF 7
(-I
USE EXISTING CLAMP 11 ~--1,125

AND HARUARE
C3 1--, 1.000
I P1, Hdt~ o,,.

I
0.375
MODIFY EXISTING SUPPORT
TO FIT IF REQUIRED
1.12
B-B
~I L
DIA HOLEI
0.175 DIA,
~3" -jl j-
1 PRESS TO
0.
I RESET1,18
0,120,12 1,00
-T
6 POINT GOTHlt
0,130
LETTERS DIA, HOLE
0.193
DIA.I
AUTO RE-IGN
12 POINT GOTHIC ~TEST 0,87

LETTERS
OFIF U~0150 0,03R(TYF 4 PLAtES)
0,88 --1
ZP41Ef!
(FOR 36966416 INSTRUMENT PANEL)
MAKE FROM ALUMINUM ALLOY SHEET, 2024-T3, 13Q-A-250/5, TEMP T-3
0,03 X 1,062 X 1,187, APPLY ONE COAT HMS-15-1082 PRIMER AND DRY
MAKE FROM 3650 SCOTCH CAL BRAND FILM, DLACK BACKGROUND rOR 1 TO 2 HOURS, APPLY TOPCOAT HMS-15-1083 IICRYLIC LACOUER AND
(COLOR NO, 37078) WITII VHITE LETTERS (COLOR NO, 37875) PER blR DRY II HOURS MINIMIIM,
FED-STD-595
E-E D-D
88-511-2
j
Figure i. Relocation of Auto Reignition Controls ISheet 2 of 2)
fl
2
i
I EXISTING HIRES 1N SHIP SHOWN IN BROKEN LINES
P12 (Dll)
U~EI1J Aoo.
E559A22 .34130 SPLICE (AMP.INC)
E559At20
Y XDS18
GEN OUT
WARN LT.
DIODE
MS25036-1492045NILANIMRET
(CRllnP ANI) SOLDER)
f (REF) NO. 2 SLECIING (MIL-1-631

MS17821-4-9 STRAP.WR
MS25181-1
S11 i SPLICE
TEST SW (88261(15)
I+
CB101BUS (REF)
M5
HOUA L----~(REF)
1 (II )METER
E503H20 2
\LV (REF)____ r--1
CR3
J508C20
I-1ffl;
ES,JWO
I (IN4001
PRESS.SU
o
4
(REFI
B_a
tB106 BUS (REF) ~8hl)
E] 5203
h
J501B20
PUSH r0 RESET X
I i (O
TO RtR
-41;-~ TO STARTER
=P
2 i I JUMPERS 20 tA. HIRE K3O1 ~O-,TO STARTER SW (B
2 2
B3
BZI SP G ARMED 5
USE nIL-W-16878/4
TYPE E, OR EQUIVALENT
(PEF)
1
IB1 O
A3
Al I
SP
S2
C NC
:io
NC
J503D20
T8502-13
ICR2
b~H--O
1
SP17
!2
P303
a
O
xl
S1C I
~NO
J503E20 P503C20
-(D
J503820
~-*td 2
a
L --Y E503N20 1
SP18 CR1
iC30il
(NOTE) I SP
L-I___J
E50312Ci S?
r
__
7 kE20 dti~
aJ
82 iG# (REF)
0c1~3
E5S7AD2~y_Aj (REF)( MM"
Jsomc2o
I i: Tfi
N
NOTE: Tti502-13 P19 O
X1
DO NOT RELOCATE RELAYS CR5 (IN6055 TRANSORS) I!
JSO7A20
U Y q O
EPO (P
EXISTING RELAYS r9~Y BE IISED.
(REI?IRE.)
n
J507 E ----i E (REF)
L__L~J tl
K10~
(IIOTE) Y
88-533 O
r
O
Figure 2. VJiring Diagram co

w
NOTICE NC. DN-101
HUGH ES
2
NOTICE
SUBJECT: INSTALLATION OF PN 3691-14237-21 RESISTOR BOARD ASSEMBLY

FOR EASIER, MORE ACCURATE ADJUSTMENT OF TOT INDICATOR
PREFACE: The information given procedure

in this Service Information Notice lists a
for installing a new PN assembly (TB9) which

3691-14237-21 resistor board
incorporates a multiple turn thermocouple lead resistor (R4), as replace-
ment for the existing PN 369H4237 resistor board with an adjustable type
resistor. The new multiple turn resistor allows for easier, more accu-
rate adjustment of the TOT indicator.
It is to be noted that the new PN 3691-14327-21 resistor board assembly

(TB9) is installed on production 500D helicopter SerialNo. 1050D and
subsequent.
Reference
500D Model 369D Basic HMI-Vol I, Issued 15 September 1976; Revision No. 5,
15 May 1981
FORM 9578A (2/81) Inc.

Huehes Helicoptets, culver city, california 90230
NOTICE NO. DN-101
DATE 1
Wughes Helicopters. inc.
February 1982
PAGE 2 OF 2
PART S LIST
N om en c la tu r Part No.
e
aty Mfr
Resistor board assembly (TB9) 369H4237-21 1 HHI
LN STALLATION PROC EDURE
NOTE
Resistor board assembly (TB9) and thermocouple

lead resistor (R4) are mounted on terminals of
TOT indicator.
b. Remove left instrument panel fairing. (Refer to Section 17 of

HMI- VolI.
c. Disconnect thermocouple leads from terminal board TB9 TOT

on
indicator. (Refer to Section 17 of HMI-Vol I.
d. Remove existing terminal board (TB9) from TOT indicator; remove

TOT indicator from instrument panel.
e. Connect TOT thermocouple leads to PN 3691-14237-21

new terminal
board assembly (TB9).
f. Calibrate TOT indicating system, per Section 17 of HMI-Vol I.
g. Reinstall TOT indicator on instrument panel.
h. Connect terminal board

new
assembly (TB9) to TOT indicator
terminal lugs.
i. Reinstall left instrument panel fairing.
The resultant alteration described

by the Installation Procedure in this
Notice has been shown to
comply with applicable Federal Aviation
Regulations and is FAA Approved.
NOTICE NC. DN-102
HUGHES
SE RVI C E I N FO R MATI 0 N PAGE 1 OF 5
NOTICE
MANDATORY MANDATORY a MANDATORY
SUBJECT: INSPECTION OF PN 369A7006-5 TAIL ROTOR CONTROL ROD; REWORK

OF PN 369D290128-11 PARTICLE SEPARATOR FAIRING ASSEMBLY AND
PN 369D290128-31 COVER ASSEMBLY
MODELS AFFECTED: 500D Model 369D Helicopters equipped with PN 3691-190148-507,

-509, -514 or -517 Engine Air Particle Separator Filter
Installation (with APM Filter)

operation, or at next removal of particle separator filter
assembly, whichever is sooner.
PREFACE: Operators in the field have

reported interference between the Station 100. 0
tail rotor control rod assembly and the nutplate installed on the
PN 369D290128-11 particle separator left fairing assembly. The interfer-
ence has been noted only on helicopters equipped with engine particle
sepa-
rator kit installations which incorporate the APM filter assembly.
Part I of this Notice lists a procedure for a one-time inspection of the

Station 100. 0 tail rotor control rod for evidence of chafing and/or inter-
ference with the nutplate installed on the -11 fairing as sembly.
Part II of this notice provides instructions for removal of the nutplate if

interference is noted, and for rework to provide for attachment of the subject
-31 cover assembly. Performance of Part II is recommended, if no inter-
ference is noted between the control rod and fairing nutplate. It is to be
noted that a new PN 369D290128-51. cover assembly is available, which may
be installed in lieu of reworking the existing -31 cover.
Reference
500 Model 369D Basic HMI-Vol 1 (CSP-D-2), Reissued 15 September 1976;

Revision No. 5, 15 May 1981
500 Model 369D HMI Structural Repair Manual, 369D-SRM (CSP-D-6) Issued
15 September 1976
400D Model 369DParticle Separator Filter Installation, Maintenance Instruction
with Parts List (CSP-004) Issued 4 April 1980
FORM OIT8 (2/81) Inc.

Huehes Helicopters, culver city, california 90230
NOTICE NO. DN-102
Hughes Helioopters. Inc.
PAGE 2 OF 5
PARTS LIST
N om enc latur e Part No. Qtr Mfr
Cover As sembly~ 369 D290128 -51 1 HHI
36 9 D2 9 01 28 55 1 HHI
36 9D2901 28 57 1 HHI
~Not required if existing PN 369D290128-31 cover assembly

is reworked per this Notice.
369D290128-55 seal may be field fa~bricated from 3M

Co. No. 9132-B or No. 4508 pressure sensitive tape,
0. 13 in. thick x 1.25 in, width x 1.40 in.
369D290128-57 seal may be field fabricated from 3M

Co. No. 9132-B or No. 4408 pressure sensitive tape,
0. 13 in, thick x 1.25 in, width x 2. 24 in.
TOOLS AND ERUIPMENT
Drill bit No. 1/4 (0. 250 in. diameter)
Drill bit No. 3/32 (0. 0937 in. diameter)
MAT ERIA LS
Abrasive paper, silicon carbide P P 1 01 C omm er cial
Methylethylketon (MEK) TT-M-261 Commercial
Cloth, glass, finished (#181) MIL-C-9084 U. S. Polymeric Chem Inc;
Type VIII Ferro Corp, Cordo Div;
(HMS16-1091) Coast Mfg Supply Co.
Polyester resin with catalyst, MIL- R-7575 Commercial

low pressure laminating Grade B,
Class O
NOTICE NO. DN-102
Hughe. Helicopters, inc. DATE 1 February 1982

PAGE 3 OF 5
PART I ONE-TIME INSPECTION OF STATION 100.0 TAIL ROTOR

CONTROL RLID
a. Remove engine air inlet forward fairings. (Refer to Section 2 of
HMI-VolI.
b. Open plenum chamber access door.
CAUT ION
Installprotective cover in plenum chamber to

prevent foreign materials or objects from entering
engine air inlet.
c. Remove PN 369D290128-31 fairing. (Refer to CSP-004)
d. In plenum chamber, remove hardware securing particle separator

PN 369290128-11 left fairing assembly to tail rotor access door and to for-
ward side of particle separator. (Refe r to C SP 00 4)
e. Remove -11 left fairing.
f. Check tail rotor control rod for evidence of chafing and/or interfer-
ence with nutplate installed on inner wall of -11 fairing assembly.
NOTE
i. If evidence of chafing or interference is noted,
perform Part II of this Notice.
2. If no evidence of interference or chafing is noted,

removal of nutplate and rework of -31 fairing per
Part II of this Notice is recommended.
g. Reinstall PN 369D290128-11 and -31 fairings.
h. Remove protective cover from plenum chamber.
i. Close plenum chamber access door.
j. Install engine air inlet forward fairings.
k. Record compliance with Part I land Part II as applicable) of this
Notice in Compliance Record of helicopter Log Book.

NOTICE NO. DN-102
DATE 1 February 1982 Wughes Helicopter.. Inc.
PAGE 4 OF 5
PART II REWORK OF PN 369D290128-11 FAIRING AND PN 369D290128-31

COVER ASSEMBLIES
a. Drill out rivets and remove nutplate from 369D290128-11 left fairing
ass embly.
b. Using #181 fiberglass and resin, apply one layer of fiberglass on

each side of -11 fairing to patch over nutplate holes. (Refer to Section 2 of
HMI Structural Repair Catalog for fiberglass repair.)
NOTE
The new 369D290128-51 cover assembly

may be
installed in lieu of field rework and buildup of the
existing 369D290128-31 cover assembly.
c. Remove existing -39 seals from -31 cover assembly.
d. Using #181 fiberglass and resin, rework and buildup 369D290128-31

cover assembly per dimensions shown in Figure i. Apply one layer of fiber-
glass to top surface of cover and two layers of fiberglass to bottom surface
as shown.
e. Drill two 0.250 inch diameter holes in reworked -31 cover to match
holes in -11 left fairing.
f. Install new -55 and -57 seals on reworked -31 cover assembly.
g. Reinstall reworked 369D290128-11 left fairing assembly and reworked

369D290128- 31 cover as sembly (or new 51 cover assembly).
NOTICE NO. DN-102
Hughes neliooptero. Inc. DATE 1 February 1982
PAGE 5 OF 5
(NOTE 2)
0.60
I--
s, -31 COVER
(BEFOKE REWORK)
EXISTING
-57 SEAL
-39 SEAL
(REMOVE)
-55 SEAL
EXISTING
-31 COVER
(BEFORE REWORK) I (NOTE
0.61
f- ONE LAYER
181F\BEKGlRSS -31 COVER
-55 SEAL
ITOP) (TYP)
T\NOLAYERS -57SEAL
1B1FIBERGCASS -55 SEAL -41SEAL
(BOTTOM) (TYPI
NOTES:
i. ALL DIMENSIONS IN INCHES.

VIEW A-A
2. DRILL 0. 250 INCH DIAMETER HOLES IN
COVER TO MATCH -IIFAIRING.
3. SHADED AREA DENOTES FIBERGLASS BUILD UP.
BE-540
Figure 1. Rework of 369D290128-31 cover assembly

E)I
HOGHES NOTICE NC. DN-103
SERVICE INFORMATION DATE 10 March 1982
OFi
NOTICE PAGE 1
MODIFICATION KIT PN M50459-404 DOUBLE LAYER ABRA.SION

SUBJECT:
TAPE FOR PN 369D21100-505 AND PN 369D21100-509 MAIN
ROTOR BLADES
MODELS AFFECTED: All 500D Model 369D Helicopters equipped with

PN 36 9D2 1 100 5 04 or PN 369D2 1 100 4 09 Main R otor
Blades
PREFACE: The information. given in this Service Information Notice lists a

procedure for installing a double layer of stainless steel abrasion
tape to the leading edge of the subject main rotor blades inboard
of existing PN 369D2 1 104 or PN 36 9D2 1 105 3 abrasion strips.
Installation of the stainless steel abrasion tape is recommended
for main rotor blades which are subject to a highly abrasive
environment, so that the blade life will not be reduced by erosion.
It is to be noted that the below referenced revision to the 500D

Rotorcraft Flight Manual must be incorporated in the manual when
the helicopter is operated with Main Rotor Blade Abrasion Tape
Kit Part No. M50459-505 installed.
Reference
500D Model 369D Basic HMI-Volume I Reissued 15 September 1976; Revision No. 5,
15 May 1981.
400D Rotorcraft Flight Manual (CSP-D-1) Revised 14 January 1982.
Foam 9578A (2/81)

HuIlhes Helicopters, Inc. culver city, california 90230
Hughes Helicopten. Inc.
NOTICE NO. DN-103
DATE 10 March 1982
PACE 2 of 5
PAR TS LIS T
Nome nclatur e Part No. aty Mfr
Modification E(it Main Rotor M50459-505:::

Blade, Double Layer A.bra-
sion Tape consisting of:
Abrasion Tape M40459-1 10 Field Fabricate

(6.5 in. wide x 0.0027 in.
thick x 12. 00 in, long)
Abrasion Tape M5 045 9 7 d: 5 Field Fabricate
(4.5 in. wide x 0.0027 in.
thick x i. 00 in, long)
:Fabricate from PN 369D21104 stainless steel abrasion

tape as listed
below
MA TER IA. LS
A.brasion tape, stainless steel

(6. 5 in, wide x 0. 0027 in, thick):
30 ft length roll 87-36 9D21104 HHI

or
100 ft length roll 88-36 9D21104 HHI
Solvent aliphatic naphtha TT-N-95 Commercial

(Standard No. 200
Thinner)
Abrasive paper 400 grit Commercial
TOOLS ECZUIPMENT
Heat gun or equivalent
PART I INSTALLATION PROCEDURE

ABRASION TAPE
a. Lightly abrade faying surface of main rotor blade with 400

grit
abrasive paper.
b. Wipe faying surface of blade with TT-N-94 solvent to

remove
grease or dirt film.
Hughes Helicopters, Inc. NOTICE NO. DN-103
DATE 10 March 1982

PAGE 3 of 5
c. Use heat gun or equivalent to warm blade faying surface;
temperature is not to exceed 120"F.
and apply stainless steel abrasion tape to leading

d. Remove backing
of main rotor blade as follows:
edge
blade leading
1. Apply M50459-1 bottom abrasion tape along
or 369D21104-3 abra-
edge, inboard of existing 369D21105
that tape overlap over bottom and
sion strip, as shown, so
is equal. Do not touch adhesive side of tape.

top of blade
Smooth and press abrasion tape into place by

hand, using
2.
heat or equivalent to
gun
maintain te~mperature.
initial installation to
3. Reapply pressure by hand following
the abrasion strip must be free
ensure proper bonding;
of surface wrinkles or air bubbles.
e. Apply a second M50449-1 abrasion tape by wiping surface of

Take
installed bottom strip with solvent and repeating steps c) and d) above.
blade
not to allow solvent to touch
bond line between -1 bottom tape and
care
at surface of blade with inner
aligned top
skin. Outer tape must be evenly
tape, per Figure i, Section A.A..
-1 abrasion strip and existing outboard

Wipe faying surface of upper
f.
i-inch wide strip of M40459-7 abrasion
abrasion strip with solvent; apply a
so that the -7 tape overlaps evenly as shown
tape, per steps c) and d) above,
The -7 tape overlap over bottom
and top of blade is also equal.
in Figure i.
abrasion tape for

g. Check installation M40459-1 and ~50459-7
discrepancies.
ABRASION TA.PE
PAR T II FIELD REPLA.CEMENT pROCEDURE
NOTE
Leading edge tape is to be replaced if damaged,

due to rain dust.
or if excessively pitted
or
remove ~y140459-1 upper

Carefully remove M40459-7 overlap tape;
a.
-1 tape
off tape so as not to affect bonding of bottom
tape by carefully peeling
and surface of blade skin.
NOTICE NO. DN- 103
E~ Hughe.HelieoptbRlnc.
DATE 10 March 1982
PA.GE 4 of 5
b. Wipe surface of -1 bottom tape with TT-N-95 solvent to remove

any adhesive, taking care not to allow solvent to touch bond line between
-1 bottom tape and surface of blade skin.
NOTE
Perform step c) below only if M50459-1 bottom

tape is damaged and is to be replaced.
c. Remove -1 bottom tape and wipe surface of blade skin with solvent
to remove any adhesive; apply -1 bottom
new tape per Part I of this Notice.
d. Apply new M50449-1 upper tape and new M50459-7 overlap tape,
per Part I of this Notice.
WEIGHT AND BA.LANCE DATA
The resultant alteration to the affected Model 500D

helicopters, described
by main rotor blade abrasion tape installation and replacement procedures
per Part I and Part II of this Notice, has been shown to comply with Federal
Aviation Regulations and is FAA Approved.
Hughe. Helicopten. Inc. NOTICE NO. DN-103
DATE 10 March 1982
PACE 5 of 5
30.00 REF
M50459-1
ABRASION TAPE
(TOP LAYER)
A -l~c"50
I.oo
~7 -1 C
M50459-1
ABRASIONTAPE
(BOTTOM LAYER)
369[)21105
369021100-505 OR
OR
369D211053
369[321100-509 ABRASIONSTRIP
MAIN ROTOR BLADE ASSY
7 ABRASION TAPE
-1ABHASIONTAPE
(NOTEI
SECTION A-A
NOTE:
ABRASION TAPE MUST BE ALIGNED

AT TOP SURFACE OF BLADE
88-5328
Figure i. Modification of Main Rotor Blade Double Layer

Abrasion Tape, Kit M50459-505
NOTICE NC. DN-104
HUGHES
DATE 5March1982
SERVICE INFORMATION
PAGE 1 OF 6
NOTICE
SUBJECT: INSTRUMENT CLUSTER 3-PACK CONVERSION -AC TO ROCHESTER
MODELS AFFECTED: 500D Model 369D Helicopter Serial No. 0003D

through 0013D,
0018D through 0025D, 0027D through 0045D, 0047D through
0055D, 0057D through 0059D, 0061D through 0064D, 0066D
through 0069D, 0071D through 0078D, 0080D through 0091D,
0093D through 0097D, 0099D through 0109D, OlllD through
O 147Dthrough 0151D, 0153D through 0156D, 0158D through
through 0181D, 0183D through 0185D, 0188D, 0190D through
0193D, 0196D through 0200D, 0203D through 0206D, 0208D,
0277D, 0287D through 0306D, 0312D through 0321D, 033-1D
0375D through 0394D, 0400D, 0401D, 0403D through 0406D,
0412D through 0417D, 0419D through 0424D, 0429D, 0431D

0507D, 0509D, 0510D, 0512D through 0522D, 0530D through
through 0607D, 0609D through 0614D, 0619D, 0621D through
through 0759D, and 0762D through 0765D.
TIME OF COMPLIANCE: Shall be accomplished at next replacement of instrument

cluster 3-pack assembly.
Foam os7e (nlel) Inc.

Hughes Helicopters, Culver City. California 90230
Notice No. DN-104 Wugheo nelicopters. Inc.
Date 5 March 1982
Page 2 of 6

a procedure for conversion from AC to Rochester instrument
clus ter3-pack assembly. The AC instrument cluster 3-pack
assembly is no longer available from the manufacturer.
Therefore, when replacement becomes necessary, it must
be replaced with a Rochester instrument cluster
3-pack
assembly.
Reference
500 Model 369D Basic HMI Volume i, issued 15 September 1976, Revision
No. 5, 15 May 1981
Inc. Notice No. DN-104
Date 5 March 1982
Page 3 of 6
When ordering, specify Kit No. M30304-507 consisting of the following:
PAR TS LIST
NOMEN CLATUR E PART NO. QTY MFR
Instrument cluster 3-pack 369D296304-21 1 Rochester

assembly
Resistor, R400 RN55C12R1F 1 Commercial

(1/8 W, 12. 1 ohm, 10/o)
Strap MS3367-1 AR Commercial
):;IE required, refer to text
MATERIALS
Sleeving, fiberglass, No. 4, MIL-I-3190, Class HA-1, 0.214 inch ID X

4. O inch.
Solder, aQ-S-571
Trichlorethane 1-1-1, O-T-620C
PROCEDURE
a. Turn off electrical power.
b. Open pilots compartment floor access doors. (R efer to Section 2,

Basic HMI Vol 1.)
c. Locate existing resistor R400 attached to PN 369H4140 wire har-

ness. (See Figure 1.)
d. Unsolder wire D501B20 and D501C20 from resistor R500 and

discard resistor. (See Figure 2.)
NOTE
Perform step e. helicopter serialNo. 0671D

below for
through 0681D, 0683D, 0688D through 0711D, 0714D

through 0721D, 0724D through 0727D, 0732D through
0739D, 0742D through 0748D, 0751D through 0759D and
0762D through 0765D only.
Perform step f. below for all other affected helicopter

serial numbers.
Notice No. DN-104 E~ Hushes HellcopterJ. Inc.
Date 5 March 1982
Page 4 of 6
e. Butt splice wires D501B20 and D501C20 together.
NOTE
Prior to soldering, thoroughly clean surfaces to be

soldered with trichlorethane I-1-I.
WARNING
Provide for adequate ventilation when using trichlorethane

1-].-1.
f. Install new resistor R500. Lap solder wires to resistor, cover
with sleeving and tie.
g. Close pilots compartment floor access doors.
h. Replace instrument cluster 3-pack assembly as follows:
1. Remove instrument panel right side fairing. (Reler to

Section 17, Basic I-IMI Vol 1.)
2. TJnplug connector 54.
3. Kernove and retain hardware attaching instrument cluster

3 -pack as sembly to instrument panel. Remove instrument
cl.uster 3-pack assembly from instrument panel.
4. In stall new instrument cluster 3-pack assembly in instrument
panel with hardwane retained above.
5. Iieconnect connector 54.
6. Keinstall instrument panel right side lairing.
i. Turn on el.ectrical. power and check all instruments for proper

operation.
j. Record compl.iance with this Service Information Notice in Compli-
ance Record of helrcopter Log Book.
WEIGI-IT AND GALANCE T)ATA
The resultant alteration to the affected Model. 369133 helicopters described by

the kit installation instructions in this Notice, has been shown to compl.y
with Federal Aviation Regulations and is FAR Approved.
ORIGaYaL
HL~CEIVEU BY %arP
Notice No. DN-104
~Hughe nalicop~en. Inc. Date 5 March 1982
Page 5 of 6
A
o
EXISTING (R500) CP-5-O,25 RESISTOR

ATTACHED TO 369Hll1ll0 HARNESS,
POST LTS,(REF)
pat~r
I I\REPLACE 369H6417
UTILIII STdRT
CLUSTER WITH
Off
oBog 1
(D 3690296305-21 CLUSTER
ELECTRICAL BOND
Grtr POSLNTI-COII PER BASIC HMI,
YOL 1. SEITIC~ 11
_.- ai
SECTION A-A
88-516
Figure i. ~netturngAt 62urstQr SIPack Conversion

Notice No. DT\T-104 Hughcs nelicoptelr. Inc.
Date 5 March 1982
Page 6 of 6
J4P
r-----~
REV.
WHT CURRENT
A
FUEL E505A22 RELAY
OTY,
OIL
TEMP
AMP
YEL
E506A22
RED
E540C22
RED
0505A20
B
DI I-D501B2O
2
CB 101
1
1(NOTE) 2
R5OO
D501C20
TB 10
151,00"
SHUNTt~Tj K300
I; I
-C~1F-------
METER BLK,
E
D5O1A2O
L__ _1
T- Jgp
3690295305-21 CLUSTER L EXISTING WIRING IN SHIP (REF)
NOTE:
REMOVE RESISTOR R50O AND INSTALL

NEW RESISTOR OR BUTT SPLICE
WIRES 0501820 AND D501C20 TOGETHER,
(REFER TO TEXT)
88-517
Figure 2. Wiring Diagram

NOTICE NC. DN-106
DnrE 29 JUNE 1982

HUGHES
SERVICE INFORMATION
NOTICE
SUBJECT: REWORK OF PN 369A9905-BA.SIC AND PN 369A9905-3 GROUND

HANDLING WHEEL ASSEMBLIES TO A.CCOMMODATE INSTALLATION
OF NEW PN 369D26107 LANDING GEAR SKID FITTINGS
All PN 369A9905-Basic (Aluminum) and PN 369A9905-3
(Steel) Ground Handling Wheel Assemblies
TIME OF COMPLIANCE: At Owners and operators discretion.
PREFACE: Field experience has shown that the PN 369A6107 landing gear skid
fitting for the ground handling wheel assemblies can be bent in service.
A new PN 369D26107 attach fitting has been designed with a larger
and stronger attach pin to preclude bending or breaking under load.

This new improved attach fitting is installed on production Model 400D
helicopter SerialNo. 1210 and subsequent, and may be installed on

earlier helicopters as replacement, when required, for existing
sets of PN 369A6107 skid fittings.
New ground handling wheel assemblies are available to accommodate

the larger attach pin on the new PN 369D26107 skid fittings. The
information given in this Service Information Notice provides

instructions for reworking existing ground handling wheel assemblies
to the new PN 369A9905-501 (aluminum) or PN 369A9905-503 (steel)
configuration, by enlarging the attach pin holes in the wheel base

to accept the larger diameter pin of the new skid fittings.
It is to be noted that the new or reworked ground handling wheel
assemblies (-501 configurations) are NOT to be used if

and -503
early PN 369A6107 skid fittings are installed on the landing gear

skids, since the smaller attach pins will bend under load in the
larger size attach pin holes.
Reference
500D Basic HMI Volume I, Issued 15 January 1982; Revision No. i, 15 March 1982
Foam es7eA (2/81)

NOTICE NO. DN-106
E~ HU9hQ nelicopters. Inc.
DATE 29 JUNE 1982
PACE 2 OF 5
PARTS LIST
Nomenclature aty Mfr
:::Bushing 2 Field Fabricate
:::Required only 369A9905-Basic (aluminum)

for rework of PN
Ground Handling Wheel Assemblies to new PN 369A9905-501
configuration. Field fabricate per specifications, Figure 2.
MA TERIALS
Primer, wet zinc chromate primer TT-P-1757 Commercial
TOOLS AND ERUIPMENT
Drill bit 0.380 inch diameter (#3/8)
Drill bit 0.4219 inch diameter (#29!64)
Ream bit 0.4376/0.4405 inch diameter
REW ORK PROCEDURE
a. For aluminum PN 369A9905-Basic Ground Handling Wheel

Assemblies only: (See DetailA, -401 configuration)
i. Drill and enlarge attach pin holes in wheel base, two places,
to 0.4219 inch diameter.
2. Field fabricate bushings per Figure 2. Ream holes in wheel

base to obtain a fit of -0.0024/+0.0005 inch between hole
and bushing.
3. Reidentify ground handling wheel assemblies as
369A9905-5 01 configuration.
Hughes Welicopters, Inc. NOTICE NO. DN-106
DATE 29 JUNE 1982
PAGE 3 OF 5
b. For steelPN 369A9905-3 ground handling wheel assemblies

only: (See Detail B, -503 configuration)
i. Drill and enlarge existing attach pin holes in wheel base
to 0. 380 inch diameter; coat reworked area with wet zinc
chromate primer.
2. Reidentify ground handling wheel assemblies as 369A9905-403

configuration.
c. Check for proper installation of PN 369D21607

attach fitting pins
in enlarged attach holes in reworked wheel base.
NOTE
Do NOT use 369A9905-501 or -503 ground

PN
handling wheel assemblies, if early PN 369A6107

skid attach fittings are installed on landing gear
skids. (See Preface, Page i.)

NOTICE NO. DN-106
Hughes nelicopterr. Inc.
DATE 29 JUNE 1982
PACE 4 OF 5
~1
LOCK
GROUND HANDLING WHEEL

AND JACK AS
SEMBLY_ ,TOW BAR FITTING
JACK
HANDLEccrr~ KID TUBE
Ij~l/
369[)21607
SKID FITTING
WHEELS LOWERED AND LOCKED
(HELICOPTER RAISEDI FABR IGATED

0. 4400
BUSHING (2 PLCSI (NOTE 2)
(NOTE 1) INCH
0.380 INCH DIA. _
0.380 INCH DIAMETER
12 PLCS) 1 (2 PLCS) ZHOLES ~7 0. 380 1 NCH
~L_ (2 PLCSI
QHOLE (REFI-- F. HOLE (REF)
i- f
-503CONFIGURATION -501CONFIGURATION
D~TAIL O ALUMINUM WHEEL BASE
NOTES:
i. COAT REWORK AREA WITH

WET ZINC CHROMATE PRIMER.
2. INSTALL FABRICATED BUSHING WITH WET

ZINC CHROMATE PRIMER.
88-5518
Figure i. Rework of PN 369A9905 and 369A9905-3

Ground Handling Wheel Assemblies
HughoJnelicOptsrs. Inc. NOTICE NO. DN-106
DATE 29 JUNE 1982
PACE 5 OF 5
I_ 0,890
i
U.410 o.iro
t
C~I[IIES:
1.MATERIAL: 11130 STEEL PER MIL-S-675a OR E~UIV,
2,FINISH: CAD PLATE PER QQ-P-416 TAPE II CLASS 3

IF CAD PLATING FACILITY IS liOT AVAILABLE,
PAINT ALL SURFACES WITH WET ZINC CHRO[IATE PRIMER
TO PREVENT CORROSION,
3. ALL DIMENSIONS IW INCHES,
88-567
Figure 2. Field Fabrication of Bushing for

Aluminum Wheel Assemblies
NOTICE NC DN-107
HUGHES
""E 1 JULY 1982
SERVICE INFORMATION
PAGE 1 OF 11
NOTICE
MAN DATORY I MANDATORY MAN DATORY
SUBJECT: INSTALLATION OF FUSELAGE ATTACH POINTS (PN 369H90070-211/212

SUBASSEMBLIES) FOR ACCESSORY KIT ATTACH FITTINGS
MODELS AFFECTED: 500D Model 369B Helicopter SerialNo. 1127D and subsequent
TIME OF COMPLIANCE: Shall be accomplished in conjunction with installation

attach points.
of accessory kit requiring fuselage
in this Service Information Notice

lists a procedure
for installation of accessory kit
for installing three fuselage hard points
hand side of helicopter.
attach fittings on left hand and/or right
It is to be notedthat the subject PN 3691-190070-211/212 subassemblies

are applicable only to helicopters which do NOT have the hard points
currently installed on the ship.
Reference
Model 400D Basic HMI Volume i, Issued 14 January 1982; Revision No. i,
14 March 1982
Model 400D Structural Repair Manual(369D-SRM), Issued 14 September 1981
FORM 9578 (2/81)

Hughes Helicopters. Inc. culver city, california 90230
NOTICE NO. DN-107 HughecHelicopterr. Inc.
DATE 1 JULY 1982
PAGE 2 OF 11
PAR TS LIST
The fuselage attach points, PN 3691-190070-211 and -212, consist of the items
listed below. The -211 and -212 subassemblies for left hand and hand
are right
attach fitting installations, respectively.
Quantity
Nomenclature Part No. -211 LH -212 RH Mfg
Doubler 369H2401-67 1 1 HHI
Clip 369H3014-47 1 1 Hill
Clip 369H3014-46 1 HHI
Clip 369H3014-45 1 HHI
Clip 3691--13014-43 1 1 HHI
Cover plate 369H90070-71 1 1 HHI
Nutplate NAS6q7A3 1 1 Commercial
Nutplate NAS696A3 6 6 Commercial
Nutplate NAS680A3 3 3 Commercial
Rivet MS20615M4-3 10 Commercial
R ivet MS2 047 OAD4 5 20 20 C omme r cial
Rivet MS2 04 2 7M4 -4 10 C omme r c ial
Rivet MS20427M4-3 10 Commercial
Rivet MS2 04 27M3 6 C omme r cial
Rivet MS2 042 6AD4 4 30 20 C omme rcial
R ivet MS2 042 6AD3 5 5 C ommer cial
Rivet MS2 042 6A3 4 14 15 C omme r cial
Rivet NAS 1738B4-4 20 20 Co mmelcial
Rivet, blind CR3212-4-2 1 1 Cherry Rivet
Screw, nylon 1030-10 32-0104 7 7 Commercial
or
Screw NAS62 3 3 -1 7 1 7 C omme rcial

nughesnelicopters.lnF. NOTICE NO. DN-107
DATE 1 JULY 1982
PACE 3 OF 11
TOOLS EQUIPMENT
Drill bit No. 9 (0. 197 0. 193 in. dial
No. 10 (0. 194 0. 190 in. dial

No. 30 ~0. 1285 in. dial
No. 41 (0. 0960 in, dial
No. 52 (0. 0635 in. dial
Shears, metal cutting
MATE RIALS
Paint, acrylic lacquer MIL-L-81342 Advance Coating

and Chemical
PROCEDURE
a. Remove interior trim panels in crew and passenger compartments

to gain access to work areas inside helicopter (Refer to Section 4, HMI Vol I).
b. Install attach hardware for lower forward acce ss ory attach fitting
as follows:
i. Locate and carefully existing rivet on helicopter skin

remove
at STA 84.86 and WL 45.87,

and existing rivets inside peri-
meter of 369H2401-67 doubler (see Figure I).
2. Mark and drill rivet holes in 369H2401-67 doubler to match
existing rivet hole pattern on helicopter.
3. Cut 369H2408-225 (LH) or 226 (RH) plate, two places, in

order to provide access to buck rivets and install nutplates.
Blend radius on all four corners.
4. Position -67 doubler on exterior skin of helicopter at location

shown. Mark and drill three (3) 0. 194-0. 190 inch diameter
NOTICE NO. DN-107 HugheHelicoptert. Inc.
DATE 1 JULY 1982
PAGE 4 OF 11
holes through -67 doubler, helicopter skin and frame structure
at dimensions shown to match lower forward accessory attach
fitting, or to match holes locations shown in Figure 4. Use
accessory attach fitting as template, if available.
NOTE
When installing all rivets, coat ID of rivet holes

and entire OD of rivets with zinc chromate primer.
5. Mark and drill six rivet holes through -67 doubler, helicopter
skin and frame structure for nutplates as shown; install three
(3) nutplates.
NOTE
If fitting is available, install fitting to nutplates

to check for proper hole alignment; remove
fitting.
6. Mark and drill holes through 369H90070-71 cover plate and

369H2508-225 (LH) or -226 (RH) plate as shown; install -71
cover plate with six (6) rivets as shown.
7. Install three (3) nylon screws as plugs in nutplate attach holes.
8. Prime and paint doubler to match helicopter exterior color

scheme.
c. Install attach hardware for top center accessory attach fitting as
follows: (See Figure 2.)
I. Locate and carefully remove 3691-12508-245 (LH) or -246 (RH)

bracket from helicopter frame structure, to provide access to
install nutplates.
NOTICE NO. DN-107
DATE 1 JULY 1982
PAGE 5 OF 11
NOTE
Displace and/or protect wiring harnesses when

removing rivets and drilling through
369H2508-237 or -238 bracket and helicopter
skin.
2, Locate and carefully existing four (4) rivets in heli-

remove
copter skin and 369H2508-237 (LH) or -238 (RH) bracket.
3. holes through skin and bracket to 0.197 to 0.193 inch

Enlarge
diameter; ensure that holes match holes in top center accessory
attach fitting, if available; or match hole locations shown in
template, if available.
Figure 4. Use fitting as
4. Mark and drill eight (8) rivet holes through skin and -237 or
-238 bracket for nutplates, as shown.
NOTE
When installing all rivets, coat ID of rivet
holes and entire OD of rivets with zinc

chromate primer.
Displace and/or protect wiring harne sse s when
installing rivets in 369H2508-237 or -238 bracket
and helicopter skin.
5. Install nutplates to interior side of 3691-12508-237 or -238
bracket with rivets as shown.
6, If accessory attach fitting is available, install fitting to nutplates

to check for proper hole alignment; remove fitting.
7. Reinstall 3691-12508-245 or 246 bracket to frame structure with

rivets as shown.
8. Install four (4) nylon screws as plugs in nutplate attach holes.
9, Prime and touch up rivets and rework area to match helicopter

exterior color scheme.
NOTICE NO. DN-107 Hughes Hcllccn(cn. Inc.
DATE 1 JULY 1982

PAGE 6 OF 11
d. Install attach hardware for lower aft accessory attach fitting as
follows:
i. Mark fitting attach hole at STA 118.29 and WL 49.51 (see

Figure 3). Carefully drill 0. 063 inch diameter pilot hole
through helicopter skin and 369H3014-41 doubler.
2. Mark and drill 0.063 inch diameter pilot holes for remaining
two fitting attach holes. Use lower aft accessory attach fitting
as template, if available, or drill per hole locations shown in
Figure 4. Ensure that holes match fitting or hole locations
shown in Figure 4.
NOTE
When installing all rivets, coat ID of rivet holes

and entire OD of rivets with aine chromate
p r im e r
Remove and replace existing rivets on helicopter

frame structure, as required, when installing
3691-13014-43, -45 or -46, and -47 clips.
3. Install three clips to frame structure with rivets as shown.
4. Enlarge three (3) pilot holes to 0. 194-0. 190 inch diameter.

Drill through helicopter skin, 3691-13014-41 doubler and
clips.
5. Mark and drill six (6) rivet holes through helicopter skin,
369H3014-41 doubler and clips for nutplates as shown.
6. Install nutplates to helicopter with rivets as shown.
7. If accessory attach fitting is available, install fitting to nut-

plates to check for proper hole alignment; remove fitting.
8. Install three (3) nylon plugs as screws in nutplate attach holes.

E~ HUahe~nelicoptera. Inc. NOTTCE NO. DN-107
DATE 1 JULY 1982
PACE 7 OF 11
9. Prime and touch up rivets and rework area to match helicopter

exterior color scheme.
e. Reinstall interior trim panels in crew and passenger compartments.
The resultant alteration to the affected helicopters described by the attach

points installation procedure in this Notice has been shown to comply with
the applicable Federal Aviation Regulations and is FAA Approved.
369H2508 i+F 0.194
DIA 2 HOLES (TO MATCH
0. 190
PLATE LOWER FORWARD ATTACH FITTING
C~ c~
NAS696A3 NUTPLATE 2 REQD M M H
MS20427M RIVETS 4 REQD

71COVER, mi
PLATE COrM
O 4 r,
LOWER M)RWARD ACCESSORY
rC: O
I/
78. 50
A~ACH FITTING
~t (LH SHOWN: RH OPP)
-i
369H2508
i-
~I
ii
.TRACE OF WL 45.36 rZ
ON CANTED
II i-
i i69H2401-(i OOUBLLR
j 1 REQD M)
N
c.
O
~rwHsos
i ii
-t-
REMOVE EXISTING i i
i;$I
i-
i. RIVET
1ZiL\
R?
i-
i-
3
i
0.91
~TRUE
WL j45.87;
0. 194
OIA HOLE (TO MATCH
36
i
Y-
rZ
1.8?
i
i
369A2516 BRACKET
I
r
0. 190 0
LOWER FORWARD ATTACH FITTING
TRUE 3~
NAS697A3 NUTPLATE 1 REQD 7C ~C i
MS20427M3 RIVETS 2 REQD 369H2401 (YP
450(2PLCS) i i
i I
0.35,,/ j~2.ZDO i (b
TRUE 369H2508
C)
FRAME O
EEPUALSIIACES i DETAILA r,
i
-211 LH SHOWN (P
i -212 RH OPP a
O COVER PLATE i-
i
iis-
"T~
,369H2508-225 PLATE SHOWN
-226 PLATE OPP
C)
t NAS1738B4
MS 20427M4 R I VET MSZ06151~4 RIMT
Rivrrs IRti)lO
1. 25 I
_i 0.60CUT
_t
PLATE
(2 PLCS) RIVET
f 18f- M520615M4MS20427M4
0. 0 RIVET I -t~---- CR3212-42
BLIND RIVET
(2 PLCSI
O MS 20427M4 R IVET
~2 EUUAL
SPACES
~t--0. 30 (2 PLCSI
NAS 171884 MS 20427M4 R IVET C~MS 206158 RIVET
RIVETS 3 RE~1D
88-528A
Figure i. Installation of Attach Hardware for Lower Forward

Accessory
Attach Fitting (LH Shown; RH Opposite)
EXISTING
MS20470AD4 RIVETS
CANTED
369H2508-237BRACKETLH STA
369H2508-238 BRACKET OPP 78.50
90.66
ii 369H2508 FRAME
NAS 173884 RIVET
3REQD
369H2508-237 BRACKET LH
369H2508-238 BRACKET RH
369H2508-245
BRACXET SHOWN
369H2508-246
OPPOSITE /I J-
I
I
I
61.70
TOP CENTER ACCESSORY ATTACH FITTING

a
(LH SHOWN; RH OPP)
I~,
~e
I
a
EXISTING
r
d NAS 173884 RIVET a
MS20470AD4 RIVETS
3REQD
REMOVEEXISTING P
RIVETS 4 PLACES I
a
MS 20426AD4 R IVETS I a
0.197
DIA 4 HOLES MRU SKIN a
369H2508-225 PLATE Y 0.193
NAS696A3 NUTPLATE 4 REUD
MSM426AD3 RIVETS 8 REQD
b~O
DETAIL B n ~-3 t3
-211 LH SHOWN M M W
-212 RH OPPOS ITE
CI
9M
r
OZ
q4
r
88-529A e tj
Figure 2. Installation of Attach Hardware for Top Center Accessory ~D

03
Attach Fitting (LH Shown; RH Opposite) N
I=
369H3000
TR STA.
d a ~z:
121.00 ~bO
i
MMH
25,, 1 0.25 1 m
Z
04
O
118.29 1
0.75
rd
r
~e a
369H3014-47 r
369H3014-45
CLIP 1 RE(ID Cx,NO
0.35
51"
369H3000
i MS 20470AD4 RIVET 4 REQD
i 60 WL50.00
a
I
369H3014-45 CLIP 369H3014 r\
1 REQD SHOWN 0. 190 Q
DIA 3 HOLES (TO MATCH LOWER
369H3014-46CLIP WL 0.194
ATTACHFITTING) NUTPLATE
1 REaD OPPOSITE 51 0.54
30 NAS680A3
09 i i- ~M
3REUD
MSZ0426ADP I
/7~7i (P
RIVET 6 REaD
0.390 C)
r
0. 25 (2 FL)
f
3.061 (D
369H3000
3
0.75 LOWER AFT ACCESSORY ATTACH FITTING
369H3014
ir (LH SHOWN: RH OPP) C)
0.75
2.810
0.390
0.25
MS20470AD4 r
2PL
RIVET-4REPD
(TYP 2 PLACES)
369H3M)9
369H3009
369H3014
369H3014-43
CLIP 1 RE~1D DETAILC-21 LH SHOWN
BL 20.00 -~1ZRHOPPOSITE
124.0
88-530A
Figure 3. Installation of Attach Hardware for Lower Aft Accessory

Attach Fitting (LH Shown; RH Opposite)
Hughes Helicopters. Inc. NOTICE NO. DN-107
DATE 1 JULY 1982
PAGE 11OF11
O 1.
_t
720
0.322-~il 1,1876\I
520
1.510~/
118.29
FOR TOP CENTER FITTING
.51
,1, 080
0,890
..,.i;i 73030
871 Y"
gi
11~
ti
530
CA#T
STA
FOR LOWER AFT FITTING
B 369H9O07O-211 HOLE LOCATIONS SHOWN
(-212 HOLE LOCATIONS OPPOSITE)
FOR LOWER FORWARD FITTING

88-531A
Figure 4. Hole Locations for Fuselage Attach Points

369H90070-211 (LH) or -212 (KH)
HUGHES NOTICE NC. DN-108
SERVICE IN FORMATION 1 July 1982

3
NOTICE PAGE 1OF
SUBJECT: REPLACEMENT OF INTERCOM (ICS) SWITCH AND JACK ASSEMBLY
MODELS AFFECTED: 500 Ilodel 369D -Flelicopters, Serial No. 0003D through 0949D.
TIME OF COMPLIANCE: Shall be accomplished at next replacement of PN 369~92492

or 3691-:92492-11 switch and jack assembly.
PREFACE: The information given in this Service Information Noticelists a procedure

for replacement of PN 369H92492 or 369H92492-11 switch and jack assembly
with PN 3691~92492-21 switch and jack assembly. The Basic and -11 switch
and jack assembly are no longer available as replacement items. Instructions
are ~iven to rework the Basic or -11 switch andjack assembly into an adapter
cable which will accommodate the new -21 switch and jack assembly.
Reference
IPL and B~laintenance Instructions for Integrated Interphone System (ICS) Installation,
Part EQo. 369H90068-11, Publication No. CSP-017, Issued 15 August 1976
FORM 9578 (2/81) Inc.

Hughes Helicopters. culver City, california 90230
NOTICE NO. DN-108
DATE 1 July 1982
PAGE 2 OF 3
PARTS LIST
Switch and jack 369B92492-21 1 HHI

assembly (ICS)
Jack v-92A/U 1 Commercial
REPLACEMENT PROCEDURE
a. Disconnect headphone from switch and jack assembly.
b. Disconnect switch and jack assembly from bulkhead connector and remove
from helicopter.
c. Rework switch and jack assembly into adapter cable as follows (see
Figure 1)
I. Cut cable of switch and jack assembly to desired length and discard
switch
2. Remove insulation from wires in cable and solder wires to new jack.
(Refer to appropriate wiring diagram in Figure 1.)
d. Connect adapter cable to bulkhead connector in helicopter.

e. Connect new switch and jack assembly to adapter cable.
f. Connect headphone to switch and
new jack assembly.
g. Check Intercom System (ICS) for proper operation. (Refer to CSP-017.)
h. Record compliance with this Service Information Notice in Compliance Recore

The resultant alteration to the affected Model 369D

Helicopters, described by the
replacement procedure in this Notice, has been shown to comply with Federal Aviation
Hughes Helicopters. Inc. NOTICE NO. DN-108
DATE 1 July 1982
PACE 3 OF 3
369H92~92 BASIC
SLIDE SWITCH
rJ,
369H921192-11
MATES WITH
369H92~92 BASIC OR-ii SWITCH AND BULKHEAD
JACK ASSEMBLY (BEFORE REWORK) CONNECTOR
369H92~92 BASIC
CUT EXISTING CABLE TO DESIRED LENGTH

BY REMOVING SLIDE SWITCH
INSTALL JACK PER WIRING DIAGRAM

U-92A/U JACK j,,,,,,,,_,,
MATES WITH 369H92~92-21
SWITCH 8 JACK ASSY
ADAPTER CABLE (AFTER REWORK)
1
CAP 8
STOW i 2
CAP& I BLU
STOW
1E
U-92A/U YEL--------I F
BLK 3 I
1 ~----PHONE LO--------BLK A
WHT 4
3 -PHONE HI--------WHT------C--J
r
1 D
RED--~ 5
21 MIC HI--------RED--~--( B
GRN ,,6 i I
1
~----MIC LO--------GRN C
U-92A/U BRN---cl---I 7
WIRING DIAGRAM WIRING DIAGRAM

369H92~92 BASIC 359H92492-11
88-568
Figure i. Rework of Intercom (ICS) Switch and Jack Assembly

Into an Adapter Cable
Hugheo Helicopters, Inc.
REFERENCE SHEET
Action Reference: When replacing intercom (ICS) switch and jack assembly, refer
to Service Information Notice No. DN-108 for rework instructions.
CSP Reference: Insert this sheet in CSP-017, page 2-6.

the data is incorporated at the next scheduled revision of
CSP-017.
IV]cDonnell Douglas NOTiOE NO.: ON-110.1
EN-56
Helicopter Company FN-42
SERVIGE INFORM~STTION NOTICE PAGE 1 of 9
MANDATORY I MANDAToRY- I MANDATORY
Service Information Notice DN-110, dated 24 September 1982.

Supercedes
SUBJECT: Inspection and Modification of PN 369D292028, Aft Passenger Step Assemblies, on

Extended Landing Gear Assemblies; and Inspection and Modification of Aft Landing
Gear Foot Assemblies.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369D, 369E (Serial
No. 0001E thru 0374E) and 3698/88 (Serial No. 0001F thru 00698) Series
helicopters equipped with PN 369D290006 extended landing gear assemblies.
NOTE
Helicopters equipped with 369D292028-5 step assemblies
which are installed with Hi-Shear BNB1100-12-3-5 hardware
are not affected by the requirements of this Notice.
TIME OF COMPLIANCE:
accomplished at each Pilots Pratlgm Check until Part III has been
I
Part II accomplished at the next 100-hour inspection unless Part I1I has
Shall be
been accomplished.
Part III Shall be accomplished anytime discrepancies are noted while performing
Parts I and II or at the next 300-hour/annual inspection, whichever occurs first.
NOTE
a Compliance to Part III of this Notice releases the requirement to
further perform Part I and II of this Notice.
a 369D292028-5 passenger step assemblies along with Hi-Shear
BNB1100-12-3-5 attaching hardware do not have to be modified
per the requirements of this Notice.
PREFACE: Part I of this Service Information Notice lists a procedure for a pilot preflight check of
passenger step assemblies for proper stability and security of attachment. The pilot
check includes a visual examination of the step for obvious cracking, "drooping" or
deformation, plus a load test by stepping on the step to check for deflection,
"sponginess" or noise when weight is applied. The landing gear step assemblies
are to be inspected per Part II of this Notice or modified per Part III, if any foot or
step discrepancies are noted.
Part II of this Notice provides instructions for a visual or dye penetrant inspection of
the step assembly weld area and foot assembly to ensure proper security of
attachment of the step assembly to the foot assembly. Part II of this Notice does not
have to be performed if the landing gear feet and step assemblies have been
modified per the requirements of Part III.
I Denotes portion of text added or revised.
McDonnell Douglas
FORM 9578 (REV 11 187)
Helicopter Company
NIOTICE NO.: DN-110.1*
EN-56
FN-42
PAGE 2 of 9
Part III of this Notice provides a procedure to modify the aft landing gear feet and
step assemblies.
REFERENCE
369D/E HMI Vol.l (CSP-D-2) Revised 01 August 1989

369F/FF HMI Vol.l (CSP-F-2) Revised 01 June 1989
PART I I PILOT PREFLIGHT CHECK OF PASSENGER STEP ASSEMBLY
NOTE
Part I of this Notice is only required to be performed if Part III
has not been accomplished.
WARNING
Extreme care shall be taken when applying weight to the

subject step assembly while performing the following.
a. Visually check passenger step assemblies, on aft extended landing gear assemblies for
obvious deformation, "droop" or deflection. Also apply weight with foot on step
assembly to check for any downward deflection, "sponginess" or noise when weight is
applied.
NOTE
If any of the above step discrepancies are noted, perform
modification of step assembly per Part III below.
PART II 1001HOUR INSPECTION OF AFF PASSENGER STEP ASSEMBLY AND ATT

FOOT ASSEMBLY
TOOLS AND EQUIPMENT
Magnifying glass, 10X minimum Commercial
e Denetrant insDection kit Commercial
NOTE
The 100-hour inspection is not required if modification of the
passenger step and foot assembly has been accomplished per
Part III of this Notice or if 369 D292028-5 step assemblies along
with Hi-Shear BNB1100-12-3-5 attaching hardware are in-
stalled.
NOTICE NO.: DN-110.1*
EN-56
FN-42
PAGE 3 of 9
a. Remove screws and washers securing cover assembly to lower fairing on aft extended
landing gear assemblies; remove cover. (See Figure 1.)
b. apply 84M pound prooi load on stap, approximately one inch from outMsrd end
during inspection.
I
c. Using 10X magnifying glass or dye penetrant inspection, inspect top area of weld where
step is attached to mounting plate for possible cracking or damage Oliew A-A). Removal
of paint is not required.
NOTE
Ifcracking is noted, modify step, inspect foot and install per
Part II1 of this Notice or procure a new (3690292028-5)
passenger step assembly, inspect foot and install per Part III of
this Notice.
d. Remove aft passenger step assemblies and landing gear fairings to perform the
following steps.
e. Remove all Scotchweld adhesive (green in color) from the landing gear foot assembly
and the passenger step ass.embly per Vol. I of the applicable HMI.
f. Using a 10X magnifying glass and bright light, inspect passenger step bolt holes, hole
inside diameters and step mou nting area for cracks. Inspect remainder of foot for cracks.
Replace partswhich are cracked.
g. If light surface corrosion is found, remove, clean and paint/retreat the affected area per
Vol.l of applicable HMI.
h. If no cracking is found, reinstall step assembly. Torque the step assembly mounting
bolts 60 185 in. Ibs.
CAUTION i
JC~UTOH
DO NOT overtorque the mounting bolts as damage can occur to
the strut assembly.
i. Reinstall cover assembly.
NOTICE NO.: DN-llO.l*
EN-56
FN-42
PAGE 4 of 9
j. Record compliance with Part II of this Notice in the Compliance Record section of the
PART III 1 MODIFICATION OF AFT PASSENGER STEP AND FOOT ASSEMBLIES
PARTS LIST
Nomenclature Part No. Source
Bushi plain* Field fabricate 4 Field fabricate
Bolt, HI-Shear"" BNB1100-12-3-5 4 Commercial or
MDHC
Washer"" AN960KD416 4 Commercial or
MDHC
Ca 369H6538-7 A/R MDHC
TOOLS AND MATERIALS

Nomenclature Source
Weldina eauiDment Commercial

Weldi Rod, uminum 4043 Commercial
Aluminum Alloy, 6061-0 (.090 thickness) I Commercial
*Aluminum Alloy Stock, 2024-T4 or T-3 I Commercial
(.4500/.4600 diameter) (12 in, raw stock)
Primer, zinc chromate, TT-P-1757 Commercial, MDHC RM#009222
Top coat, HMS 15-1100, type 2 (flat black) I. Commercial, MDHC RM#009136
*kHi-Shear Tool (BH220-428-M2) MDHC or Commercial
Safety tape, Pressure sensitive (Type B, 3M Co. or Commercial

black~ (16 in. in lenath read.
Adhesive, scotch weld, EC 1838 (MIL- Commercial, MDHC RM#002214
A-52194
Chemical film (Mll-C-5541) I Commercial, Iridite 14-2
Sealant (PR-1436~ I Commercial
Method A only.
"X
Method B only.
a. Remove hardware securing cover assembly to affected landing gear fairing assembly.
(See Figure 1.) Remove cover assembly.
b. Remove hardware securing passenger step to landing gear; remove step assembly.
c. Inspect landing gear foot assemblies per steps f
cracked foot assemblies.
g of PART II of this Notice. Replace I
EN-56
FN-42
PAGE 5 of 9
d. Remove paint, primer, non-slip safety walk tape and chemical surface treatment (Iridite)
from step assembly area to be welded. (Refer to HMI Vol.l.)
e. Heat step assembly to 200 degrees F to break bond on end cap. Remove end cap from
step assembly.
f. Fabricate two gussets (per step assembly) to dimensions shown in Figure 2. Weld
gussets to step and mounting plate as shown. Re-heat treat step assembly to T-62
condition per MlL-H-6088.
EC 1838 or equivalent.
g. Reinstall end cap by bonding with scotch weld
h. Apply exterior surface treatment (iridite) to step assembly; apply primer and paint finish.
Apply non-slip safety tape to step assembly. (Refer to applicable HMI.)
NOTE
Operators have a choice of two different methods to modify the
landing gear foot assemblies.
METHOD A INSTALLATION OF PLAIN BUSHING
i. Ream .322/.329 inch diameter hole through foot assembly at step attachment bolt hole
locations to .4062/.4082 inch diameter.
j. Fabricate bushing (two per step assembly) per the following instructions and Figure 3:
1. Machine stock material to a dimension that will provide .0000/.0005 interferance with
.4062/.4082 inch diameter holes.
2. Ream inside stock material. Inside diameter to be .322/.329 inches in diameter
concentric to O.D. .002).
3. Cut material to a length equal to the outside diameter of foot assembly at the bolt
holes.
4. Contour outer face of bushing to match the contour of the foot assembly (fwd side
only, +.000/-.001).
5. Surface finish of bushing and holes to be 125 RMS or better. Deburr bushing a
maximum of .015 inches.

6. Chemical treat bushing and hole inside diameters per MlL-C-5541.
k. Install bushing with wet zinc-chromate primer.
I.Install step assemblies, bolts, washers and nuts. Torque bolts 60 85 in. Ibs.
m. Proceed to step r.
METHOD B INSTALLATION OF HI-SMEAR BLIND NUT
n. Ream .322/.329 inch diameter holes through foot assembly (2 places) to .391/.397 inch
diameter (forward side only).
o. Countersink hole 100 degrees and minimum depth for flush installation of Hi-Shear
blind nut BNB1100-12-3-5. Apply chemical film per MlL-C-5541 to inside diameter of
holes.
p. Ream .322/.329 inch diameter hole (2 places) in step assembly to .375/.377 inch
diameter. Apply chemical film to hole per MIL-C-5541. Install NAS75-4-003 bushing with
wet zinc chromate primer ~TT-P-1757).
EN-56
FN-42
PAGE 6 of 9
q. Install step assembly using (2) each, NB1100 bolts and AN960KD416
washers
(Hi-Shear BNB1100-12-3-5 includes NB1100 bolt) as shown in Figure 3. Torque bolts
60-85 inch Ibs.
I CAUTION
C*UTION
i
DO NOT over torque the step assembly mounting bolts as
damage can occur to the strut assembly.

r. Seal the nut head on forward side and bolt on aft side of foot assembly. Completely seal
faying surfaces of step assemblies with PR 1436 sealant.
s. Reinstall cover assembly on affected fairing assembly with existing hardware. Trim
cover assembly, as required, to clear gussets.
t. Record compliance with Part I1I of this Notice in the Compliance Record section of the
NOTE
Modification and repair of the passenger step and foot assem-
blies per Part III lifts the requirements to further perform the Part
II inspection requirements of this Notice.
i
WEIGHT AND BALANCE
Weight and balance data not affected.
The resultant alteration to affected models as prescribed by procedures in this Notice has
been shown to comply with Federal Aviation Regulations and is FAA Approved. I
NOTICE NO.: DN-I10.1*
EN-56
FN-42
PAGE 7 of 9
ili
i.
u;kT?~
(NOTE 1)
P3LJI
3690292028 I
j STEP ASSY /i
STEP I
MOUNTING I I I I I I /I
PLATE C~J I GJ II
i
I I
VIM A-A
3690292028 LOWER AFT

STEP ASSY FAIRING
rA ASSEMBLY
NAS6O3-5 SCREW
NOTES: I
AN960PD~OL WASHER
i,
1. CHECK TOP AREA DF WELD WHERE STEP (TYP 6 PLACES)
ATTACHES TO MOUNTING PIATE. USE 1OX I
MAGNIFYING GLASS.
II I
NAS1305-36 BOLT
2. TO OBTAIN ACCESS TO INSPECT WELD FOOT ASSY I MS21O45-5 NUT
I
AREA, REMOVE (6) SCREWS AND I IW96OPDS16 WASHER
WASHERS SECURING COVER TO rV (TYP 2 PLACES)
LOWER FAIRING..
-B
AFICEAR 883698
Figure i. Inspection of Aft Extended Landing Gear Step and Strut Assemblies.
EN-56
FN-42
PAGE 8 of 9
CHAMER
,,,,-ri
780
2S !~\CH
OETRIL O
GUSSET- FABRICATE
FROM 6061-0 ALUM. AL
4.00 X 3.00 X ,090
WELD
CUSSET (WELIMENT) 2 REQD

(NOTE 1)
O
(NOTE 2)
NOTE: (SEE NOTES 3 THRU 6)
1. FABRICATE GUSSETS FROM 6061-0

ALUM AL PER DIMENSION SHOWN,
2. TRIM FAIRING COVER AS REQUIRED DIMENS IONS:(SEE NOTES 3 THRV 6)

TO CLEAR GUSSETS,
A. OUTSIDEDIAME~ERTO PROVIDE.00001.0005
3.FABR ICATE WITH 2024-14 ALUMINUM ALLOY. INTERFERENCE WITH .4062/.4082 D 1AMmR
4. CONTOUR OUTER FACE OF BUSHING TO MATCH HOLES IN LANDING GEAR STRUTS.
STRUT ASSEMBLY MID 5106 ONLY (+.MX)I-. W1).
8. INSIDEDIAMETER TOBE.322/.329DIAMrmR
5. SURFACE FINISH OF BUSHING AND HOLES TO BE
CONCENTRIC TO O.D. WITHIN .002
125 RPM
6. CHEMICAL FILM TREAT BUSHING AND HOLE I,D.S C. LENCTH TO BE EPUAL TO STRUT ASSEMBLY
PER MIL-C -5541. OljTS IDE DIAMETER.
88-5718
Figure 2. Rework of Aft Landing Gear Assemblies.

EN-56
FN-42
PAGE 9 oi 9
BUSHING
ATTACHED DETAIL
WASHER (TWO PLACES)
NUT
BOLT
WASHER L1 M \M WAS HER
BUSHING (NOTE)
(NAS 75-4-003)
HI-SMEAR BLIND NUT

PLAIN BUSHING TTWO PLACESI
ITWO PLACES)
NOTE:
NOT RE9UIREU IF 369[)2920285
STEP IS BEING INSTALLED 88-649
Figure 3. Plain Bushing/i-II-Sheer Blind Nut Rework.

NOTICE NC. DN-111
September 1982
~dl
DnrE 27
HUGHES 6
PAGE 1 OF
S E RVI C E I N FO R MATI O N
NOTICE
MAN DATORY I. MANDATORY MAN DATORY
DRIVE SHAFT
SUBJECT: NEW SHIMMING PROCEDURE FOR TAIL ROTOR
FORWARD FLEXIBLE COUPLING, PN 369A5501 OR 369H92564,
WITH FAILSAFE DEVICE INSTALLED
369D Helicopter SerialNo. 0003D through 1205D

MODELS AFFECTED: 500D Model
TIME OF COMPLIANCE: Shall be accomplished at next 300-Hour Periodic Inspection

Interval, or at next removal of tail rotor drive shalt assem-
bly, whichever is sooner.
instructions
be used, to that minimum
for a revised shimming procedure to ensure
and the main

shims are installed between the forward flexible coupling
transmission shaft, thus precluding bottoming of the coupling and/
output
or coupling bolt on the output shaft.
The information fiivcn in this Notice is to be considered as a part of the

IIMI and will be incorporated at the next scheduled revision of the below
referenced handbooks.
Reference
5001) Model 369D Basic HMI Vol I, Reissued 15 January 1982; Revision No. 1,
15 March 1982
500D Model 369D Basic HMI Vol II, Reissued 1 November 1981; Revision No. 2,
15 May 1982
Instructions for PN 369H90123 Series Rotor Brake (CSP-006)
500D Optional Equipment
Issued 15 May 1982
Service Information Notice No. DN-29. 3, dated 7 June 1982

Hughes
Hughes Service Information Notice No. DN-95, dated 7 August 1981
Foam 8578 (2/81)

Hughes Helicopters, Inc. culver City, california 90230
NOTICE NO. DN-111
PACE 2 OF 6
PARTS LIST
Nom en c latur e Part No. aty Mlr
Shim 0. 010 inch thickness 369~615516-9 AR HHI
Shim 0. 020 inch thickness 369125516-7 AR HHI
Shim 0. 030 inch thickness 369A5516-5 AR HHI
Shim 0. 060 inch thickness 3 6 9A5 5 1 6 3 AR HHI
MA T ERIAL
Grease MIL-G-81322 Mobil Grease 28 Mobil Oil
or
AeroShell 22 Shell Oil
Lubriplate Fisk Bros.

Grease
930-AA Toledo, OH
MIL-A-907 Commercial
Anti-Seize Compound
Lockwire MS20995C Commercial
Zinc Chromate TT-P-1757 Commercial

Primer,
TOOLS AND EQUIPMENT
Torque wrench O to 500 inch-pounds Commercial
Feeler gage Commercial
SHIMMING PROCEDURE FORWARD FLEXIBLE COUPLING
a. Remove and inspect tail rotor drive shaft (Section 9, HMI Vol I).
b. Remove and inspect flexible couplings land disc brake components,

if rotor brake is installed) on main and tail rotor transmission gear shafts.
Vol I, and GSP-006 Rotor Brake Instructions if
(Reler to Section 9, HMI
app lic able).
NOTE
Retain 369A5516 shims for reinstallation.
Install 0. 010 inch shim aft of flexible coupling on tail rotor

c. one
transmission input shaft. Coat coupling splines with grease and coupling
NOTICE NO. DN-111
PAGE 3 OF 6
bolt with anti-seize compound before assembly. Install coupling and tighten
coupling bolt to 250 to 300 inch-pounds.
d. Perform the following to determine shim thickness required at
forward flexible coupling:
CAUTION
Bottom the flexible coupling by holding at the

1. 370 inch OD of coupling (see Figure 1). Do
NOT bottom coupling by pushing on drive shaft

attach flange; doing so may damage coupling,
1. Bottom forward coupling on 369D25125 main transmission

output shaft.
2. Measure gap between end of flexible coupling and shoulder of
output shaft. Add 0. 005 inch to gap measured. This is the

minimum 369A5516 shim thickness required at the forward
coupling, to prevent coupling from bottoming on output shaft.

(See Figure i.)
3. Install minimum 369A5516 shim thickness on main transmis-

sion output shaft.
4. Measure step between aft end of output shaft and shoulder of

flexible coupling, by bottoming coupling against 369A5516
shims. (Refer to CAUTION above.
NOTE
Step between aft end of output shaft and coupling

shoulder must be at least 0.010 inch, to prevent
coupling bolt from bottoming on output shaft.
5. As required, install additional 369A5516 shims to maintain
0.010 inch minimum step.
e. Position new 369D25531 socket on aft face of forward

coupling so
that three of the nine holes are indexed to the three nutplates of the coupling
in such a way that maximum clearance is obtained between the bolt key and
socket as shown in View C-C. Visually verify proper clearance before
installing tail rotor drive shaft.
NOTICE NO. DN-111
PAGE 4 OF 6
I. Rcinstall tail rotor drive shaft per HMI Vol I, except tighten
attach bolts fingertight only at forward coupling and socket.
g. Obtain 0.010 to 0.020-inch gap between forward flange of tail rotor

drive shaft and aft end of soclcet, using the following procedure:
1. Back off three attach bolts on forward flange of tail rotor

drive shaft assembly 0. 040 to 0. 100 inch.
2. Push and hold tail rotor output shaft of main rotor transmis-
sion forward (into transmission) to remove end play. If rotor
brake is installed, make certain that brake pucks do not
restrict axial travel of tail rotor output shaft.
3. Remove end play in tail rotor transmission by applying force

to tail rotor blades inopposite direction of rota- operational
tion (while holding tail rotor transmission output shaft to
still
prevent rotation). Do not push tail rotor drive shaft fore or
aft.
4. Measure gap between socket and flange of tail rotor drive

shaft (socket flange must be in full contact with flange of
flexible coupling).
5. Add required number of shims behind flexible coupling at main

transmission end of tail rotor drive shaft, to obtainspecified
gap of 0. 010 to 0. 020 inch.
NOTE
a) Maintain minimum 0.010 inch step between

coupling shoulder and output shaft. (Refer
tostep d.)
b) Shim (0.010 inch) may be removed from

AFT coupling if necessary.
c) If less than specified gap (0. 010 to 0. 020
inch) exists under minimum shim require-

ments, install maximum of one HS306-326
washer on each of the four tail rotor trans-
mission mounting studs, between gearbox
housing and boom
fitting. Apply zinc
chromate primer to both sides of washer at
installation.
i
NOTICE NO. DN-111
PACE 5 OF 6
d) After washer installation, repeat steps g. 1

through g. 5 above. Also perform rigging
of tail. rotor controls, per Section 8 of
HMI Vol I.
h. Complete installation of tail rotor drive shaft assembly, and rotor

brake components as applicable. (Refer to HMI Vol I and CSP-006 as
applicable.
NOTE
Refer to Service Information Notice No. DN-29.3

for shimming procedure and for check of step on
en gin e -to -t ran smi s sion d rive shaft coup ling s.
i. Record compliance with this Service Information Notice in Com-
The resultant alteration to the affected helicopters described by the shimming

procedure in this Notice has been shown to comply with Federal Aviation
C
NOTICE NO. DN-111
PAGE 6 OF 6
;IAlil TRAIIS[;ISSIOW
..i
i TAIL ROTOR
DRIVE SHAFT
I
I -_I1S
0,010 IIICH
#INIIIUM STEP
(ROTE 3)
O
;iAS620C916L
I(ASHER (3 PLCS)
36965501 OR
36111925(jll
COUPLIIIG
iiAlil TRA;ISIIISSICil
OUTPUT Pll!lOil
F?fil;Ri)
C1UPL~:I.
C-Il TAIL. ROTOR
DRIVE SIIBFT
SOCI:ET (NOTE 1
0 8 3691\5516
SHIIIS
~Ta r
369025530
BOLT
1.370 IIICH OD 369025531
5(19025530 BOLT
C-C
(:IOTS
c3 SOCI;ET
VIEII
;IOT TO SCALE
O
BOTE:
1. ADD 0,1)05 IHCH TO ilEASUREli GAP FOR SHIM THIC#NESS.
2. HOLD COUPLIIJG AT 1.370 OD OIILY, TO BOTTOM COUPLING.

3. ~IIIIIUM 0,010 STEP BETWEEEI AFT EI(D OF OUTPUT SHAFT
AIID SHOULDER OF FORWARD COUPLING,
83-574
Figure i. Shimming procedure for tail rotor drive shaft forward coupling
NOTICE NO. DN-112
~3 19 November 1982
I
c DATE
PAGE 1 OF~1
MBaN f3WTO TPV iZblBFd Dl~iTO R Y nnAlbl ~A70 WY
SUBJECT: INSPECTION LANDING GEAR STRUTS AND FEET
MODELS AFFECTED: All 500D Mcldel 369D Helicopters
q TIME OF COMPLIL\NCE Shall be accomplished at or prior to next 300haur in.pectian.

:i
f i
"j
PREFACE:
C The information given in this Service Information Notice lists a procedure i
for a one time inspection of landing gear (P/N 369DZ6000 and
P/N 369D290006) struts and feet for cracks. Additionally, new torque
values for ABC5244 bolts attaching landing gear feet to struts and pro-
cedures for sealing bolts to prevent corrosion are included.
Reference
500D Model 369D HMI Vol. 1 (CSP-D-2), Reissued 15 January 1.982; Revision No. 1,
15 March 1982.
;Corrosion Control Manual (CSP-A-3), Issued 9 February 1981.
FOR~ 9578 (2/81)

Hughes Helicopte~s. Inc. culver city, california 90230
NOTICE NO. DN-112
PACE 2 OF 5
Material
Primer, zinc chromate, TT-P-1757 Commercial

color Y
MIL-S-81733A PR1436-G Product Research

Sealing compound
(Type II-2) Class B2 Glendale, CA
OR
Pro-Seal 870 Essex Chemical Corp.

Specialty Chemicals Div.
Compton, CA
Duct tape Commercial
Tools and Equipment
Magnifying glass, 10X Commercial
PROCEDURE
a. Remove skid, with feet attached, from struts.
1. Jack up helicopter until landing gear dampers are fully extended

(Section 2, HMI Vol. 1).
2. Remove lower landing gear fairings (Section 5, HMI Vol. 1).
CAUTION
Support skid when removing ABC bolts attaching feet

to struts. Skid and feet may drop from strut when
ABC bolts are removed. Damage to skid and/or posi-
tion Light wiring could occur if skid is not supported.
3. Remove nuts and ABC bolts connecting feet to forward and aft
struts.
4. Carefully lower the skid until the feet are fully disengaged from
the struts.
NOTE
For 369D290006 landing gear, the wire splice adjacent

to the forward cabin entry step should be discon-
nected if necessary to lower the skid. Attach fish
string to wires remaining in strut. For 369D26000
landing gear, sufficient wire slack should be present
to lower the skid and foot assembly without discon-
nectin g wires.
NOTICE NO. DN-112
PAGE 3 OF 5
b. Using 10X glass and bright light, visually check bolt holes in feet and
struts for cracks or corrosion.
1. Remove surface corrosion and treat affected area according to

light
Section 2, HMI Volume 1. If more severe corrosion (ref. Corrosion
Control Manual) is present, replace affected part.
2. Cracks are not permitted in landing gear struts or feet. If any

cracks are noted, replace affected part (Section 6, HMI Volume I).
c. Using 10X glass and bright light, visually check struts and feet for
cracks around and between the foot to strut bolt holes. Replace cracked parts per
Section 6, HMI Volume i.
d. Rem~ove each 369H6006 brace and check bolt holes in strut where brace
attaches for cracks or corrosion, See Figure 1.
1. Pull strut fairing fillet downward against spring tension. Secure

in place with duct tape.
NOTE
For access to forward brace-to-strut attachment, remove
foot support fairings in passengerlcargo compartment.

For access to aft brace-to-strut attachment, open engine
access doors.
2. Remove cotter pin, nut, two washers and bolt attaching 369H6006
brace to strut.
3. Remove cotter pin, nut, bolt, washer and busing attaching inboard
end of 369H6006 brace to 369H2526 fitting. Carefully remove
369H6006 brace.
e. Using flashlight and mirror, inspect bolt holes where 369H6006 brace
attaches to strut, and area of strut covered by clevis of brace for cracks and/or
corrosion
1. If cracks are noted, replace strut (Section 6, HMI Volume 1).
2. Remove surface corrosion and treat affected area according to

light
Section 2, HMI Volume I. If more severe corrosion (ref. Corrosion
Control Manual) is present, replace strut (Section 6, HMI Volume 1).
f. Inspect entire strut for chipped or scratched paint. Check unpainted

areas for loss of corrosion protection. Repaint or seal damaged areas per Section 2,
HMI Volume 1.
g. Reinstall 369H6006 brace.

NOTICE NO. DN-112
PAGE 4 OF 4
C
i. Carefully position outboard clevis of 369H6006 brace over strut at
brace-strut attach holes. Lower inboard clevis of brace over frame
fitting and align holes. Apply zinc chromate primer to holes and
hardware. Install attaching hardware while primer is wet.
attaching
Use new cotter pin.
2. Align outboard end of 369B6006 brace with mating holes in strut.

Apply zinc chromate primer to holes and attaching hardware.
Install attaching hardware while primer is wet. Torque nut 2 to
5 inch-pounds. Install new cotter pin.
3. Remove tape holding fairing fillet down and allow fillet to gently
move upward into position.
h. Reinstall assembled skid and feet on helicopter.
1. Resplice wiring as necessary and remove fish strings. Slide
wiring slack into strut or foot as required while sliding upper

portion of feet into struts.
2. Apply zinc chromate primer to bolt holes, ABC bolts, and nuts.
Install hardware while primer is wet. Torque bolts to 40 to 60

inch-pounds.
3.
instructions.Seal bolts and nuts with sealant mixed according to manufacturers
C
4. Reinstall lower landing gear fairings (Section 6, HMI Vol. 1).
5. Remove supports, lower helicopter, and remove jacks (Section 2,

HMI- Vol. 1).
NOTE
Visual inspection using 10X glass and bright light, of

area not covered by sealant at, around, and between
foot to strut attach bolts for cracks and corrosion is
required at each subsequent 300-hour or annual
inspection. Removal of feet from struts is not required
unless damage is suspected.
i. Record compliance with this Notice in Compliance Record of helicopter

Log Book.
The resultant alteration to the affected helicopters described by the one time
inspection in this Notice has been shown to comply with Federal Aviation
NOTICE NO, DN-112
PAGE 5 OF 5
CENTER BEAM
BONDING
JUMPERCU\MP DAMPER
(NOTE II)
2,00 IN,
369H6006
FRAME SUPPORT BRACE
FITTING ,DAMPER
(NOTE 5)STRUT
FAIRING
4)
BRACE(NOTE
BRACKET
8 PLACES
369H6006
9--
SLOTTED
BUSHING
(NOTE 6)
(NOTE 1)
NOTE 1,2,3,AND 5
STRUT ABC5244 BOLT
(NOTE 5) (TORQUE 40-60 IN. LB.)
(2-5INCH LB TORQUE)
1 FOOT
CABIN ENTRY STEP i
\L
SKID TUBE
NOTE 1,2,3, AND 5
ABC52114 BOLT
(TORQUE 40-60 IN. LB.)
FOOT
NOTES:
1, APPCiZINC CHROMATE PRIMER,COLOR Y TO MATING HOLES
ALL ATTACHING HARDWARE. REASSEMBLE WHILE WET.
2. SEAL AROUND BOLT HEAD AND NUT WITH PRllt36-G SEALANT.
3. NUT IS PROVIDED WITH ABC52114 BOLT.

4, INSPECT ALL BOLT HOLES IN SHADED AREAS FOR CRACKS.
5. INSPECT FOR CRACKS,CHIPPED PAINT OR LOSS

OF CORROSION PROTECTION.
6. EDGE OF BUSHING MUST PROTRUDE 0.010-0.050 INCH BEYOND

OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
88-575
Figure 1. Landing Gear Feet and Strut Inspection

I NOTICE NO. DN-113
13p3UGHi~S Dare 10 January 1983

PAGE 1 OF q
:~IMaSTsCE
nnAsPJ D~OIRFI PMA~ Uk\TBRI rVsAN DATORY
1 SUBJECT: RELOCATION OF ENGINE AIR INLET FILTER BYPASS DOOR AFT PULLEY
CPN 369A8448) AND BRACKET (PN 369A8447), AND PARTICLE SEPARATOR
FILTER (PN 369H90152-3 OR 369D290125-11) GASKET INSPECTION
All 500D Model 369D Series helicopters equipped with

MODELS AFFECTED:
369i190148-503, -505, -507 or -509 Engine Air Particle
Separator Filter Installation.
TIME OF COMPLIANCE: Shall be accomplished when new 369H90150-41 cable assembly

inspection, whichever is
i
is installed or at next annual sooner.
Information given in this Service Information Notice lists procedures for

relocating the Engine Air Inlet Particle Separator Filter bypass door aft
11 pulley (PN 369A8448) and bracket (PN 369A8447), to improve pulley alignment.
Investigation has shown that realignment of: the 369A8448 pulley will reduce
:i the possibility of cable assembly (PN 369B90150-41) fraying, caused by
angle during opening of the
the
filter
:I
swaged end of the cable being pulled at an
bypass door.
Requirements to check the gasket seal on the aft face of the particle separator
i
filter (PN 369H90152-3 or for condition and proper installation,
369D290125-11)
and to check the nine bolts securing the 369D290125-21 mist eliminator
assembly to the aft face of the 369D290125-11 particle separator filter on

:i included.
369H90148-507 and -509 installations are
Reference
5BOD Model 369D Optional Equipment Manual CPS-004, Reissued 4 April 1980.
FORU 8578 (2/81)

NOTICE NO. DN-113
Hughes Helicopten. Inc.
PAGE 2 of 9
MATERIBLS
Adhesive, Epoxy (EA 9314 or equivalent) Hysol Division

Dexter Corp.
Pittsburg, CA
Naphtha, Aliphatic Commercial
Tape, single coated, pressure 3M Company

sensitive vinyl, 1/8" thick
(4408 or equivalent), length and
width as required.
TOOLS AND EQUIPMENT
Drill motor, portable Commercial
Drill, No. 2-Commercial

Countersink, 1000 Commercial
Spatula or wooden tongue depressor Commercial
Protractor Commercial
Die, No. 10-32--Commercial
PROCEDURE
CAUTION
Use care toprevent entry of foreign objects (FOD) into engine

air and engine cooling air inlets. Tape covers of cardboard or
other suitable material over engine inlet and engine cooling
air screens. Do not covers until work is completed and
remove
thoroughly cleaned out of area. After removing

any debris is
covers, verify that area around base of mast, inlet plenum and
entire plenum chamber is free from foreign material.
a. bypass
Pull filter control handle to open filter bypass door
(Section 2, CSP-004).
b.Remove four screws, nuts and washers attaching filter bypass door hinges
to aft engine air inlet fairing. (See Figure 1.)
c. Remove cotter pin, nut, bolt and washers attaching cable assembly to
filter bypass door. Remove door,
NOTE
Step d. applies to 369H90148-503 and -505 installations only.

For 369H90148-507 and -409 installations, continue with step e.
i
NOTICE NO. DN- 113
Hughes nelicopters. Inc. DATE 10 January 1983
PAGE 3 of 9
For 369H90148-503 and -505 installations, visually check the exposed

aft side of 369H90142-3 particle separator filter, using flashlight, to ensure the
0.50-inch wide, soft rubber gasket is in place, undamaged and that deterioration
or flaking of the rubber is not evident. (See Figure 2.) If gasket is not in place,
is damaged or deterioration is evident, replace gasket as follows:
1. Remove and clean particle separator filter (Section 2, CSP-004).
2. Remove damaged seal from aft face of filter. Remove any adhesive
and/or seal remnants from filter aft face using aliphatic naphtha.
3. Cut 0. 50-inch wide pressure sensitive foam tape to length required

to cover area shown in Figure 2. Apply tape to aft face of filter
as shown.
4. Reinstall particle separator filter (Section 2, CSP-004).
e. For 369H90148-507 and -409 assemblies, remove and clean 369D290125-21

mist eliminator (Section 2, CSP-004). Inspect nine bolts attaching mist eliminator
to 369D290125-11 particle separator assembly.
1. Loosen nine bolts attaching mist eleminator assembly to aft side

of particle separator and remove mist eliminator. Bolts should
not bind while being loosened. If binding is noted, use No. 10-32
die to clean threads. Bolts are self retaining and should not come
out of mist eliminator.
2. Check each bolt to ensure that threads adjacent to the unthreaded

shank of the bolts are crimped, or otherwise flattened, as shown
in Figure 3. This thread deformation retains the bolts in the mist
eliminator. Crimp or flatten threads as shown, when necessary.
Use care not to exceed maximum allowable thread deformation.
3. Using a flashlight, check the exposed aft portion of the particle

separator filter assembly to ensure the pressure sensitive tape
seal is in place and undamaged (Figure 4). If seal is not in place,
or if seal is damaged, remove particle separator filter assembly
(Section 2, CSP-004). Remove damaged seal if applicable and clean
area covered by seal with aliphatic naphtha. Apply a strip of
0. 38-inch wide pressure sensitive foam tape as shown in Figure 2.
Reinstall particle separator assembly (Section 2, CSP-004).

NOTICE NO.
ETAD311-ND
10 January 1983
Hughes Helicopters. Inc.
PAGE 4 OF 9
4. Reinstall 369D290125-21 mist eliminator assembly and attach to

aft face of particle separator with nine bolts.
f. Remove nut, bolt, and washers connectingupper pulley (PN 369A8448)

to bracket (PN 369A8447). Remove pulley from bracket. Do not allow bushing
to drop out of pulley.
g. Remove two screws, nut, and washers attaching 369A8447 bracket

to top of aft engine air inlet fairing andremove bracket.
h. Determine location for new 369A8447 bracket attach holes, as shown

in Figure 1, and mark location with soft lead pencil.
i. Drill 0.217 0.229-inch diameter holes at locations marked. Counter-

sink 1000 to 0.43-inch diameter.
j. Using EA9314 epoxy adhesive, or equivalent, mixed according to

manufacturers instructions, fill holes where 369A8447 bracket was removed.
Apply adhesive using spatula or wooden tongue depressor.
k. Attach bracket to fairing using screws, washers, and nuts.
i. With cable seated on top of pulley, installpulley in bracket with bolt,

two washers, nut and new cotter pin. Ensure bushing in pulley is in place.
CAUTION
A serviceable door in
good condition, is necessary
gasket,
at all times. Gasket must be
replaced before deterioriation
occurs. (Flaking or disentigration of the gasket can result
in foreign material entering the engine and cause engine
damage.)
m. Check door gasket (Section 2, CSP-004), then position door inside

fairing and attach cable to door center crank with bolt, two washers, nut and
new cotter pin.
n. Attach door hinges to fairing with four screws, washers, and nuts.
o. Rerig door and check door operation and latching (Section 2, CSP-004).
Door latching mechanism should operate smoothly, without binding.
p. Verify that no gaps exist between door gasket and inlet fairing when
hand pressure is applied to door. If gaps are noted, replace door gasket
(Section 2, CSP-004).
q. Verify that area around base of mast, inlet plenum and entire plenum
chamber is free of debris and other foreign materials. Remove covers taped
over engine inlet and engine cooling air screens.
r. Record compliance wit~h this Notice in compliance section of helicopter

Log Book.
PAGE 5 OF 9
C WEIGHT AND BALANCE DATA
The resultant alteration to the affected helicopters by the procedure in this

Notice has been shown to comply with Federal Aviation Regulations and is
FAA Approved.
C
NOTICE NO. DN- 113 Hughe~ Helicopters. Inc.
DATE 10 Januzis~y 1983
PAGE 6 OF 9
HINGE
B
DOOR OPERATING
AFI CABLE
\1
DOOR CLIP
DOOR GASKET~.
ii D
i.lli y,/
AFT FAIRING
C ~3
DOOR
B 369/\84 7PULLEY
BRACKET
CENTER
CRANK i I i
1 i;
BUSHING
O PLlLLEYINSTALLATION
3691\8448
PULLEY
(NOT~2) I
I-
3691\8447 1,
I
PULLEY I
r
I u,
I
0.29~NCH
II
110 I
3r)~II I
BL. 5.83 RH I
NOTES: /L -I,
i. USE NO. 2 DRILL TO DRILL
11.39
HOLES 0. 217-0.229 INCH
INCH
DIAMETER. COUNTERSINK
FROM TDP OF FAIRING 10n0 To 1. 375
0.43 INCH MINOR DIAMETER.
2. FILL HOLES WITH EA9314 ADHES IVE

OR EQUIVALENT.
VIEW B-B
88574
Figure i. Bracket (PN 369A8447) and Pulley (PN 369A8448) Relocation
i:
PAGE 7 OF 9
RUNTIN6
STRUCTURE
/i
f AFT ENGINE
FAIRING
1j
FIUER
IUB~
FILTER
SCREEN
(TYP1CAL)
PARTICLE FILTER
SEPARATOR
INOTE 2)
GASKET
(NOTE 1)
aoiEr;
1) I~STALL BRSKEI AS SHDWII Oil AFT FACE OF O

369H90152-3 PARTIC~E SE~RWOR FI~TER.
2) WHEII REIIOVEI) (SECTIOII 2,

CSP-OOq),
88-3678
Figure 2. Particle Separator Filter (PN 369H90152-3) Gasket.

C Used With 369H90148-503 and -505 Installations
NOTICE NO. DN- 113 Hughes Helicopters. Inc.
PAGE 8 OF 9
3690290125-21
MIST ELIMINATOR
INOTEZ)
6eO
90"
SECTION VIEW
.160
BOLT TO MEASURE
.170
ACROSS DIAMETER AT
DEFORMED AREA OF THREAD
FLATlENED THREAD AREA (NOTE i)
NOTES:
1) CRIMP OR FLATTEN THREADS

AT DIMENSION SHOWN. DO NOT
EXCEEDE MAXIMUM DIMENSION
MEASURED FROM THREAD NEAREST
UNTHREADED SHANK OF BOLT.
2) CLEAN WHEN REMOVED
(SECTION 2. CSP-004).
.125 MAX.
o,,,,,
O 88-579A
Figure 3. Mist Eliminator (PN 369D290125-21) Bolt Check

j
Hughes Heiicopters. Inc. NOTICE NO. DN-113
PAGE 9 OF 9
GASKET (NaTES 1 ANO 2)
1-0.380
3690290125-11
PARTICLE SEPARATOR ASSEMBLY
MOTES:
1, IIISTALL Ar SHOPII OEI AFT E1OUNTIIG SI!PFPCE OF 3E9C?9~125-ll

PAPTICLE,rEPARP.TOR FILTEP PRIOR TO I~STALLI\TlnFI,
2, PRESSURE SEISITIVE TAPE
3, ALL OIE:ENSIO:IE I~l I?ICHES,

88-372
Figure 4. Particle Separator Assembly (PN 369D290125-11) Seal.

Used With 369H90148-507 and -509 Installations.
j
,mu .n,
NOTICE NO. DN-114
U
i P"T~
i] F ~va s 4
PAGE 1 OF
i~iaAN T)A7Q R P~AN DATO R Y MAN QaTO WY
SUBJECT: MAIN ROTOR TRANSMISSION DRAIN LINE BRACKETRY MODIFICATION I;)
MODELS AFFECTED: 500D Model 369D Series helicopters serial Nos. 3 through 1204.
TIME OF COMPLIANCE: Shall.be accomplished at next 300-hour or annual inspection. I
PREFACE. Information given in this Service Information Notice includes instructions for
the fabrication and installation of a new main rotor transmission oil drain line
support bracket (PN 369D25202-3), and modification of the Fan Bearing

Retainer Mount Assembly (PN 369D25108) to accommodate the new bracket.
!This modification to the oil drain line support bracketry will reduce the
possibility of the bracket contacting the oil cooler blower belt, which can
cause the belt to fray,
Reference
369D HMI Volume 1 (CSP-D-2), Reissued 14 January 1982; Revision 2, 15 August 1982.
j i
j
i
-8 IIIPIBIDe m ~rmasma ~awas
I I g
FORM 9578 (2/81)

NOTICE NO. DN-114
DATE 15 February 1983 4~ nughes Helicopters, Inc.
PAGE 2 OF 4
PARTS LIST
Part No. Qty Mfr

Nomenclatur~
Screw NAS-1096- 3-12 1 Commercial
Washer AN 96 OPD 10 2 Comm ercial
Nut NAS2104 2-3 1 Commercial
MATERIALS
TOOLS AND EQUIPMENT
Motor, portable drill

Drill No. 7
Drill 7/32
PROCEDURE
a. Remove blower cooler access door (Section 2, HMI Vol 1).
b. Remove and retain screw, nut and washer attaching MS25281-6 clamp to
369D 25202 bracket. Retain clamp.
Remove and retain screw, nut and two washers attaching 369D25202
c.
bracket to 369D25108-5 transmission fan mount. Discard bracket.
d. Using 0.06-inch thick aluminum alloy sheet, 0. 50 x 3.50-inches, fabri-

cate new drain line bracket (PN 369D25202-3) as shown in Figure 1.
e. Position fabricated bracket on 369D25108-5 mount as shown in Figure i.

Mark location for new hole inboard of existing hole on mount.
f. Using No. 7 drill, drill hole at position marked on 369D25108-5 in step e.

Drill only through wall of mount marked. Deburr and apply zinc chromate primer
to hole.
g. Install 369D25202-3 bracket on 369D25108-5 mount with 2 screws,

4washers, and 2 nuts. Hardware removed in step c may be reused. Two
washers must be installed on each screw, between bracket and mount.
h. Reinstall clamp on drain line and attach clamp to bracket with hardware
removed in step b. Adjust clamp position to ensure that there are no traps in
drain line.
i. Reinstall blower cooler access door (Section 2, HMI Vol i).

4~ Hughes Helicopters, Inc. NOTICE NO. DN-114
PAGE 3 OF 4
The resultant alteration to the affected helicopters described by the procedure

in this Notice has been shown to comply with Federal Aviation Regulations and is
FAA Approved.
j
NOTICE NO. DN-114
Inc.
DATE 15 February 1983 Hughss Helicopters.
PAGE 4 OF 4
-r
.88
(NOTE 2)
(NOTE 3) 369025202-3
BRACKET
2.25 1 I ,(NOTE 1)
369025108-5
MOUNT 3.?5
I >NOTE 2)
,25
369025202-3
BRACKET
MS25281-6
CLAMP
M/R TRANSMISSION
OIL DRAIN LINE
369025108-5
NOTE:
MOUNT
1) TRIM 0.06-INCH THICK 0,50 x 3.50-INCH
00-A-25O/5 ALLOY SHEET TO DIMENSIONS
SHOWN, APPLY ZINC CHROMATE PRIMER TO
TRIMMED ENDS,
2) DRILL HOLES AT LOCATIONS INDICATED
USING 7/32-I#CH DRILL, DEBURR AND
APPLY ZINC CHROMATE PRIMER 50 HOLES,
3) MARK HOLE LOCATION USING FABRICATED

369025202-3 BRACKET. USE NO,7 DRILL
TO MAKE HOLE; DEBURR AND APPLY
ZINC CHROMATE PRIMER. DRILL THROUGH
ONE WALL OF MOUNT ONLY,
j/
Figure i. Main Rotor Transmission Oil Drain Line Bracket Modification
~I
1~ U~ H ES N(jrlCE N(,. DN- 115

SE P M F~ 6~
PAGE i C)F 2
NOTICE
MAN DATORY MAN DATORY

MANDATORY
"1
SUBJECT: PILOTS COMPARTMENT, CENTER PASSENGER SEAT LAP BELT INSTALLATIO~

CHECK; PREFLIGHT CHECK OF PASSENGER LAP BELT AND SHOULDER STRAP
ADJUSTMENT
B
TIME OF COMPLIANCE: Part I shall be accomplished at next daily inspection aiter
j
receipt of this Notice,
Part II shall be accomplished at each preflieht inspection

when passengers are to be carried. t
PREFACE: Information given provides for a one

in Part I of this Notice time inspection of
the pilots compartment, lap belt assembly
center passenger for proper instal-
lation. If improperly installed, quick release of the lap belt and shoulder strai,
may be impaired.
r edlu
Part II of this Notice lists
strap (non-inertia
a
ohs
preflieht
type)
passengers lap
they d
reel na
properly
check of each
toadjusted
ensure are
belt
so i
that the shoulder strap diagonally crosses the passengers torso.
Reference
5001) Model 369D HMI Vol 1 (CSP-D-2), Reissued 15 January 1982; Revision No. 2,
15 August 1982.
Customer Senrice Department
FORM 95T8 (2/81)

Hughes Helicopters, Inc. Culver City, California 90230
Inc.
NOTICE NO. DN- 115 Hughes Helicopter..
1
PAGE 2 OF 2
PART I PILOT COMPARTMENT, CENTER PASSENGER SEAT

LAP BELT INSTALLATION CHECK
a. Check center passenger lap belt to see that tongue portion is installed
to the right of the seat and that the buckle portion is installed to the left. If
the tongue and buckle portions are reversed, remove and reinstall in correct
positions (Section 4, HMI Vol 1).
b. Record compliance with Part I of this Notice in Compliance Record of
PART II PREFLIGHT CHECK OF PASSENGER SEAT BELT

(NON-INERTIA REEL TYPE) FIT AND ADJUSTMENT
a. Check all but left rear passenger to see that shoulder strap diagonally
crosses the torso and that the buckle, tongue and harness adaptor of the seat
belt assembly are to the passengers left, approximately over the left hip.
b. Check left rear passenger to seethat the shoulder strap diagonally

crosses the torso and that the buckle, tongue and harness adaptor of the seat
belt assembly are to the passengers right, approximately over the right hip.

C
The inspection procedure and resultant alteration to affected helicopters described
by this Notice has been found to comply with Federal Aviation Regulations and is
FAA Approved.
C_
NOTICE NO. DN-117
i-i 14
X .I i
DATE 20 March 1983
i:,B
;P -1
-:;nU;1$ PAGE 1 OF
7
M
~;"!"1P3
f
i:i.Alj i:la-;);:v :~l;.ii Rli:~ i\;:lflli UATO
SUBJECT: INSTALLATION OF 510 OHM RESISTOR IN PN 369D296303, 369D 2963 03- 70 1

AND 369A4245 SERIES FUEL QUANTITY SENDING UNITS
MODELS AFFECTED: 500D Model 369D Series Helicopters Serial No. 0001D through 1116D
with PN 369D296303, 36C3D296303-701or 369A4245 Series Fuel
Quantity Sending Units installed, and all affected parts in spares.
TIME OF COMPLIANCE: Shall be accomplished if fuel low level warning light glows
dimly when known fuel quantity exceeds low level warning
limit, or when affected parts are installed from spares.
PREFACE: The information given in this Service Information Notice provides procedures
foradding a (PN RC07GF411J) to the affected fuel quantity
510 ohm resistor
transmitting units. The resistor will prevent transistor leakage current from
causing the FUEL LOW warning light to glow dimly when the fuel quantity is
above the low level warning point (35 or 70 pounds of fuel as appropriate).
Part I provides procedures for installing the resistor in 369D296303 and
369D296303-701 Fuel Quantity Sending Units. Part II provides procedures
forinstalling the resistor in 369A4245 Series Fuel Quantity SendinZ Units.
The information given in this Service Information Notice is considered to be

p"rt of the HMI and will be incorporated at the next scheduled revision of
the below referenced manual,
Reference
i 500D Model 369D I-IMI Vol. 1 (CSP-D-2), Reissued 15 January 1982; Revision No. 2,
15 August 1982,
C
~ggy
FORM 9578 (2/81)

NOTICE NO. DN-117
DATE 20 March 1983 9~ Hughe~ Helieoptera. Inc.
PAGE 2 OF 7
PART I RESISTOR INSTALLATION, 3691)296303 AND

369D296303-701 FUEL QUANTITY SENDING UNITS
PARTS LIST
Resistor, 410 ohm RC07GF411J Commercial
MATERIALS
Solder, tin alloy Qa-S-571 Commercial

(Composition SN 60WRP 2)
Sealing compound, RTV11 General Electric

silicone
TOOLS
Solder gun Commercial
PROCEDURE
WARNING
Ensure all electrical power is off and helicopter is electrically

grounded while installing resistor.
a. Set helicopter MASTER switch to OFF and remove any external power
source.
b. Remove left fuel cell access door (Section 2, HMI Vol. 1).
c. Disconnect tank unit wire harness at fuel shutoff cable support bracket.
d. Carefully cut and peel enough potting compound from top of tank unit
to expose electrical terminals and circuit board.
e. Using tin alloy solder, solder leads of resistor (PN RC07GF511J) to

tank unit as shown in Figure 1.
f. Fill area where potting compound was removed, ensuring that resistor
installation is covered, using R?V11 sealing compound.
OEIGITAL A; BY AT~
Inc. NOTICE NO. DN-117
Hughes Helicopters.
DATE 20 March 1983
PAGE 3 OF 7
NOTE
hours prior
Allow sealing compound to cure approximately two
in
to completing procedure. The compound will fully cure
48 hours.
g. Reconnect tank unit wire harness.
h. Check fuel quantity indicator for correct reading with a known quantity
of fuel.
i. Perform operational check of FUEL LOW warning light (Section 17, HMI
Vol. 1).
j. Reinstall left fuel cell access door (Section 2, HMI Vol. i).
PART II RESISTOR INSTALLATION, 369A4245 SERIES

FUEL QUANTITY SENDING UNITS
PARTS LIST
RC 07GF 411J Commercial

Resistor, 510 ohm
C MATERIALS
MS 22759 1 34- 22-9 Commercial

Wire, 6-inch length (2)
RNF-100 Commercial
Sleeve, O. 125-inch diameter
RQS-471 Commercial
Solder, tin alloy, rosin core
RQS-471 Commercial
Solder, tin alloy, acid core
MIL-S-8802 Product: Research

Sealing compound
PR1221
alternate
RTV730 Dow Coming
Distilled water Commercial
Sodium bicarbonate (baking soda) Commercial
ORIGtfilB1, fl.; f3Y ATP.

NOTICE NO. DN-117
20 March 1983
B~ #u8hes Helicopters. Inc.
DATE
PAGE 4 OF 7
TOOLS AND EQUIPMENT
Motor, drill Commercial
Drill, No. 25 Commercial
Solder gun Commercial
PROCEDURE
WARNING
Comply with all fuel safety precautions when working in or
around fuel cells. Ifreplacement fuel quantity sending unit

is not available for immediate installation, do not remove
installed unit.
a. Remove fuel quantity sending unit (Section 17, HMI Vol. 1).
b. Using rosin core solder, solder six-inch length of MS22759/34-22-9

wire to each terminal of RC07GF511J resistor; shrink 0.125-inch diameter RNF-
100 sleeve over resistor.
c. Remove strain relief and detach backshell from connector on sending

unit wire harness.
d. Cut wire harness vinyl sleeve near sending unit as shown in Figure 2;
pass one lead and resistor through cut in vinyl sleeve until lead can be mated
with connector.
e. Drill 0.146 0. 152-inch diameter hole in base at approximate position

shown in Figure 2; deburr hole and remove all drill cuttings.
f. Pass resistor lead nearest base through hole; solder lead to bracket
(PN 369A4245-3), using acid core solder. Clean connection thoroughly by
flushing with distilled water with sodium bicarbonate (baking soda) added.
CAUTION
Ensure all areas covered by, and in contact with acid core
solder are thoroughly flushed to neutralize acid.
g. Using rosin core solder, attach opposite lead of resistor to pin D of
sending unit wire harness connector with existing red wire.
h. Reassemble wire harness connector.
1;3Y ATP
I
HuFJhes HelicopPers, Inc. NOTICE NO. DN-117
DATE 20 March 1953
PACE 5 OF 7
C i. Seal around installed wire on both sides of base, and interface of bare
wire to insulation using PR1221 sealing compound. If RTV type sealant was
originally used, RTV730 sealant may be used as alternate. Allow sealing com-
pound to cure for two hours prior to installing unit in helicopter.
Remove temporarily installed sending unit if applicable and reinstall modi-

j.
fied sending unit in helicopter (Section 17, HMI Vol. 1).
k. Check fuel quantity indicator for correct reading with a known quantity
of fuel.
i. Perform operational check of FUEL LOW warning light (Section 17, HMI
Vol. 1).
The resultant alteration to the affected helicopters described by the installation

procedure in this Notice has been shown to comply with Federal Aviation Regula-
tions and is FAA Approved.
NOTICE NO, DN-117 Hughes nelico~tsrcl, Inc.
DATE 20 March 1983
PAGE 6 OF 7
CTOR PLUG
RCO7GF511J
O RESISTOR
O
FLOAT ARM
(NOTE 1.4)
RESISTOR LEAD
TOP
VIEWRED WIRE AND

TRANSISTOR LEAD
INOTE 2)
O
NOTES:
i, CUT AND PEEL AWAY ENOUGH POTIING COMPOUND TO

RESISTOR
EXPOSE TERMINALS AND PRINTED CIRCUIT BOARD.
2. SOLDER RESISTOR LEAD, TRANSISTOR LEAD AND

RED WIRE TOGETHER USING TIN ALLOY SOLDER. .PRINTED CIRCUIT
3. SOLDER APPROXIMATELY 114-INCH OF RESISTOR LEAD II TRACE
TO PRINTED CIRCUIT TRACE,
4,VPON COMPLETING INSTALLATION, FILL AREA WHERE

POTTING COMPOUND WAS REMOVED WITH RTVII (NOTE 3)
SEALANT. ENSURE RESISTOR INSTALLATION IS COVERED.
LEAOI
RESISTOR
bi)
88-584
Figure 1, Resistor Installation 369DZ96303-BSC

and -701 Fuel Quantity Sender
j13
i
llr
Inc. NOTICE NO. DN-B17

Hughes Heliccptets.
DATE 20 March 1983
PAGE 7 OF 7
TO PIN D OF CONNECTER
SENDING UNIT BASE
RC07GF511J RESISTOR
RNF100SLEEVE
M22759134-22-9 W I RE
C~3
a
I
I
I
$I
O
O
CUT EXISTING SLEEVE TO PAS 5

RESISTOR THROUGH
DRILL.125-INCH HOLE
(NOTE 31
369A4245-3 BRACKET
SOLDER JOINT 369A4245-3 BRACKET

AND RES ISTOR LEAD(NOTES 1 AND 21
NOTES:
i. USE ACID CORE SOLDER. WASH THOROUGHLY

W ITH B I CAR BONATE OF SODA AND D I STI LLED
WATER AFTER SOLDERING. I
2. SEAL INTERFACE OF BARE WIRE TO

INSULATION WITH PR1221 SEALANT.
.3. SEAL HOLE AT BOTH S IDES OF BASE

VS INC PR1221SEALANT AFTER RES ISTOR
LEADS ARE SOLDERED TO BRACKET AND
PIN D OF CONNECTOR.
88-588
Figure 2. Resistor Installation 369A4245 Series

Fuel auantity Senders
Ai RIGEIVED BY AT$.
NQTICE NO. DN 118
I
DATE 2 May 1983
z
.bi~:Y i ~s07:CE
~hsil ddid ~9
~?:au PAGE 1 OF
AM CSATO XY
~lil ~?AAN DATO R Y W1AN BAYO W Y """"9
SUBJECT: FUEL VENT SYSTEM HOSE (PN 3691\8131-19) INSPECTION
j
TIME OF COMPLIANCE: Shall be accomplished at the next 300-hour inspection interval,
or six months from date of this Notice, whichever is sooner and
at each subsequent 300-hour inspection interval until affected
hose is replaced with the new PN 369A8131-35 hose."
PREFACE: The information givenin this Service Information Notice provides for a visual
inspection of fuel vent system hose (PN 369A8131-19) for deterioration, and
replacement of hoses found to be defective with fuel vent system hose
(PN 369A8131-35) made of improved materials.
The information given in this Service Information Notice is considered as part of

the HMI and will be incorporated at the next scheduled revision of the below
referenced manuals.
Reference j
j 369D HMI Vol I (CSP-D-2), Reissued 15 January 1982; Revision 2, 15 August 1982. ii
369D HMI Vol II (CSP-D-S), Reissued 1 November 1981; Revision 3, 15 September 1982.
The 300-hour fuel vent system inspection given in HMI Vol II is required regardless
of hose installed.
CI 1
FORM 9578 (2/81)

NOTICE NO. DN-118
~3 Hughes Helicop~era. Inc.
DATE 2 May 1983
PAGE 2 OF 2
panrs LIST
Hose, fuel vent system 369A8131-35 1 HHI
MATERIALS
Lockwire MS 20995H 32 Commercial
PROCEDURE
a. Remove right support fairing,

foot controls access door and fuel vent
cover (Section 2, HMI VolI).
b. Inspect 369A8131-19 fuel vent system hose for signs of deterioration

by pinching or bending hose and looking for surface cracks, visible where hose
is pinched or bent. If any cracks are noted, replace hose with new 369A8131-35
fuel vent system hose (Section 12, HMI Vol I).
NOTE
Replacement of fuel vent system hose PN 369128131-19 with new
PN 369A8131-35 hose deletes the above inspection requirement.
c. Replace fuel vent cover, controls access door and right foot support
fairing (Section 2, HMI Vol I).
d. Record compliance with this Notice in Compliance Record of helicopter

Log Book.
The resultant alteration to the affected helicopters described by the inspection

procedure in this Notice has been shown to comply with Federal Aviation Regula-
tions and is FAA Approved.
NOTICE NO. DN-119.1$
I1
DaTE 23 November 1983
r~qgq
";r1 "f 4
"Supersedes Service Information

Notice DN-119, dated 15 May 1983,
j913AN I?J3Aii9 D~\TOWV ;.;wame~ ~/1AN DBTORY
j SUBJECT: INSTALLATION OF COLLECTIVE STICK SUPPORT BRACKET

REINFORCEMENT STRAP.
MODELS AFFECTED: All 500D Model 369D Series Helicopters,

operation, after receipt of parts.
(1 for installing a collective stick support bracket reinforcement strap to
strengthen the support bracket in the area of attachment by providing a
secondary load path.
Reference
August 1983.
j 500D Model 369D HMI Vol. i. Reissued 15 january 1982, Revision 3, 15
1 I
c Denotes portion of text added or revised.
FOAM 9578 (9/81)

Hu~hes Helicopters, Inc. Culver city, California 90230
ETAD"1.911-ND
NOTICE NO.
23 November
1983~ Ilughes Hslieoars. Inc.
PAGE 2 OF 4
PARTS LIST
NOMENCLATURE PART NO. QUANTITY MANUFACTURER
369ASK806-3 1 HHI
Strap Assembly
369ASK806-9 2 HHI
Spacer
Washer NAS 119 7- 416L AR Commercial
Washer NAS1197-416 AR Commercial
TOOLS AND EQUIPMENT
N OMEN CLAT URE PART NO. QUANTITY MAN UFACTURER
Tool, collective bungee 369D29936 1 HHI

installation
(Commercial Helicopters)
Tool, collective bungee 369A9936 1 HHI

installation
(Military Helicopters)
a. Remove pilots seat cover and controls access door. (Refer to Basic
HMI Vol. 1, Section 2.)
b. Install collective bungee installation tool on collective bungee spring.

(Refer to Basic HMI Vol. i, Section 7.) Use over-center action of collective
stick to load tool.
c. Remove nuts, washers and bolts installed through bungee support

bracket and controls support bracket assembly. Retain washers and discard
bolts and nuts.
j
Inc. NOTICE NO. DN-119.1"
Hughes Helicopters.
PAGE 3 OF 4
NOTL
Insulation on some pi-oduction strap assemblies

PN 369ASK806-3, the entire sti-ap.
covcrs The
insulation material must be removed from each
end of the strap to one inch inboard prior to
installing the strap, To remove this material,
cut the unwanted port.ion from the strap using a
plastic knife or similat instrument. Use care
when cutting the insulating material, If the strap

is scratched or nicketl, it must be replaced.
d.Install strap with new bolts, washers, spacers, nuts and retained
washers, as shown in Figure 1.
e. Ensure that strap is tight with bolts torqued, by shimming with new
washers as required. (See Figure i.)
f. Use over-center action of collective stick to remove load from collective

tool and tool from bungee spring. (Refer to Basic HMI Vol. 1,
bungee remove
Section 7.)
g. Reinstall pilots seat cover and controls access door. (Refer to Basic
HMI Vol. 1, Section 2.)
h, Record compliance with this Service Information Notice in Compliance

The resultant alteration to the affected helicopters described by the installation

procedure of this Notice has been shown to comply with the applicable Federal
AviationRegulations and is FAA-apl>roved.
C
t:ll As
ETAD"1198QHughe. Helicopters.
NOTI~CE NO. DN-119.
23 November
Inc.
PAGE 4 OF 4
-__1
36947339
BUNGEESUPPORT
BRACKET
(REF)
TB
O
III
INBOARD I 1
P~LIO
COLLECTIVE
STICK SOCKET
AS SY
IREF)
;J"LL,
BUNGEE OVER-
CENTER ADJUSTMENT
80LT
(REF)
3691\7339
IREF)
NAS 1304-28 BOLT

MS21042-4 NUT
(NOTE 1)
~Noa a
SHIMWITH
NAS 1197-4161 WAS HER \n
NAS 1197-416 WAS HER
369N2608
AS REQD
3691\7104
FOR SHIMMING
369027304
369ASK806-9~- (NOTE 1) CONTROLS
SPACER 2 REQD -Wut~- SUPPORT
BRACKET
NOTES: ASSY
i. REINSTALL EXISTING WASHERS UNDER

BOLT HEAD AND BETWEEN S PACER ttt~ff- 36945 K806-3
AND NUT. STRAP ASSY 1 REPD
2 EDGE OF BUSHING MUST PROTRUDE

MINIMUM 0. 010 IN. TO MAXIMUM VIEW B-B
0. 080 IN. ABOVE OUTS IDE SURFACE OF
PART AmR NUT IS TIGHTENED. 88-5644
Figure I. Installation of Collective Stick Support Bracket

Reinforcement Strap j
r
NOTICE NC). DN-120
~31
HUG#ES DaiE
31May 1983
SE RVICE IN FOW MATsON PAGE 1 OF_ 5 __~
OT I E
SUBJECT: INSTALLATION AND REPLACEMENT OF PROTECTIVE SLEEVE

(SPEEDI-SLEEVE PN 084957) ON TAIL ROTOR TRANSMISSION
OUTPUT GEARSI-IAFT
MODELS All 500D Model 369D Series

AFFECTED: Helicopters
TIME OF COMPLIANCE: At owners/operators discretion.
PREFACE: Information given in this Service Information Notice provides

pi-oceduies
for installing and replacing a protective sleeve (Speedi-Sleeve PN 084)47)
on the output ~l;earshaft of 3691)25300 or 36C)D25400 series tail rotor trans-
missions. The protective sleeve will prevent gearshaft wear caused the by
gearshalt rubbing against: the output gearshaft cover oil seal lip. It can
also be used to repair minor gearshaft wear caused
by the seal rubbine
against the shaft.
The information given in this Notice is to be considered as part oC the HMI

and will be incorporated at the next scheduled revision of the below
referenced handbooks.
Reference
5001) Model 369D COM (CSP-D-5), Reissued 14

September 1981.
500D Model 369D HMI Volume 1 (CSP-D-2), Reissued 15
January 1182; Revision No. 3,
15 August 1982.
Maintenance Manual and Illustrated Parts List for Four Bladed Tail Rotor
Assembly
(CSP-088), Issued 15 September 1981..
Foam as~en (2/81)

QRIGII~AL A3 R-CEIV D BY ATP. L I

NOTICE NO. DN-120 Hughe~ Welicoptera. Inc.
DATE 31May 1983
PACE 2 of 4
PARTS L~Sr
Part Rtv From
Sl)ccdi-Slccve 084157 1 IIIII
MATI~IIIAI,S
Solvent, dry cleaning PD-680 Commercial
Plastic Steel Devcon A Devcon Corp,

Danvers, MA 01.923
Lockwire CRES
safety wire Commercial
Petroleum jelly VV-P-236 Commercial
TOOLS AND ERUIPMENT
Heat gun orblow dryer Commercial
Pipe/tubing, ].~-inchID Commercial

8-10 inches Icngth
PROCEDURE
a. Remove tail rotor and pitch control assembly (Section 8, I-11~II Vol 1 or
csp-o8s)
b. Drain lubricant from tail rotor transmission (Section 2, NMI Vol 1 or
CSP-088)
c. Remove safety wire, three bolts and washers attaching output gearshaft
cover to housing; remove cover and clam-up shim. Retain all hardware except
safety wire for use at reassembly.
d. Using heat Rut? or blow dryer, heat: output housillg bore to 2740 +250F
(1350 +120C); remove gearshaft and backlash shitn. Iietai~ backlash shim for
use at reassembly.
ORBGrhAL AS RECE1 Vff. U;dED BI AP~.

4~ Hu9hes Helicopters, Inc. NOTICE NO. DN-120
DATE 31May 1983
PAGE 3 of 5
e. Install Speedi-Sleeve as follows: (See Figure 1.)
NOTE
If shaft has been grooved from rubbing against lip of

output gearshaft seal, and depth of groove exceeds
cover
0. 005 inch, shaft must be replaced. (Refer to Part III or

VIII, 3691) COM.) If groove does not exceed 0. 005 inch
depth it may be repaired with Devcon A.
CAUTION
Do not allow any contaminants to enter shaft bearings.

Dust and other contaminants can damage or shorten
the service life of the bearings.
1. Set gearshaft on end, roller bearings down, on hard, clean, level

surface. Wipe away dust and foreign particles from gearshaft using a clean,
lint free cloth, dampened by solvent.
NOTE
If shaft has been grooved by seal lip and groove does

not exceed 0.005 inch depth, fill groove with Devcon A.
2. Apply light coat of Devcon A to shaft area to be covered by sleeve.
3. While Devcon A is wet, put sleeve on shaft, flange down, and

press or tap in place using l~-inch tube or pipe bottomed on flange of sleeve.
Unflanged end of sleeve must be even with outboard end of 1.088 1.090-inch
diameter portion of shaft. Tap end of pipe with hammer or mallet as necessary
to correctly position sleeve on shaft. Wipe any excess Devcon A from shaft
using a clean, lint free cloth.
4. Clip flange of sleeve to notch line and peel from shaft.
f. Replace installed sleeve, if damaged or grooved, as follows and as
shown in Figure 1.
CAUTION
Use care not to cut into or damage gearshaft when

removing damaged sleeve from gearshaft. Do not
allow filings or other contaminants to enter shaft
bearin gs
i. Use file or other suitable instrument to cut through edge of sleeve;

carefully pry cut edge away from shaft.
ORIGII~:A: n~ R:;EI~ In Br ATP.

NOTICE NO. DN-120
DATE 31May1983 ~3! HUBhes Helic~pters. Inc.
PAGE 4 of 5
2. Grasp raised edge with pliers and peel damaged sleeve off shaft.
3. Remove any Devcon residue from shaft using dry cleaning solvent;
dry shaft with clean, lint free cloth.
4. Apply Devcon A to shaft where sleeve is to be installed.
4. Install replacement sleeve on shaft per paragraph e.
g. Reassemble tail rotor transmission.
1. Apply heavy coating of petroleum jelly to roller bearings on end

of gearshaft.
NOTE
If backlash shim removed at disassembly is not

reused, complete reassembly per Section 6,
Part III or VIII, 369D COM.
2. Install backlash shim removed at disassembly, and gearshaft in

housing. Heat output housing bore using heat gun or blow dryer until gear-
shaft bearing retainer assembly fits easily into housing.
3. Install clamp-up shim removed at disassembly and output gearshaft

cover assembly (Section 6, Part III or VIII, 369D COM).
h. Install tail rotor and pitch control assembly (Section 8, HMI Vol 1 or
Section 2, CSP-088).
i. Fill tail rotor transmission with approved lubricant (Section 2, HMI

Vol 1)
j. Record compliance with this Notice in Compliance Record of helicopter

Log Book.
WEIGHT AND BALANCE: DATA
The resultant alteration to affected models as described by procedures given in

this Notice has been shown to comply with Federal Aviation Regulations and is
FAA Approved.
irRIGi I
[)I/ a7.i:
C
9~ Hughec Helicopters. Inc. NOTICE NO. DN-120

DATE 31May 1983
PAGE 5 of 4
i L_ I.0s8 INCH DIA

SLEEVE 1 090 OUTBOARD END
NOTCH LINE
i:3
J
NOTES:
REPAIRABLE
DAMAGED SHAFT UNPAMAFED SHAFT SLEEVEREPLACEMCN_T
i. FILL GROOVED AREA AND i. BOND SLEEVE TO SHAFT i. CVT CO~E OF DAMAGEO SLEEVE
BOND SLEEVE TO SHAFT WITH DEVCON A. WITH FIL.E AND PEEL BACK.
WITH DEVCON A.
2. CLI P FLANGE AND PEEL 2. PEEL SLEEVE FROM SHAFT.
2. CLIP FLANGE AND PEEL FLANGE OFF SHAFT
3. CLEAN WITH PD-680:
FLANGE OFF SHAFT AT AT NOTCH LINE.
DRYWITH CLEAN. LINT FREE
NOTCH LINE.
CLOTH.
4. BOND SLEEVE TO SHAFT

WITH DEVCON A.
5. CLIP FLANGE AND PEEL

FLANGE OFF SHAFT AT
NOTCH LINE.
88-586A
j Figure i. Speedi-Sleeve (PN 084957) Instailatian IReplacement

N(~TICE NO. DN-121
tiTP,
liV;1
DATE 27 June 1983

iPm
i-;l~
j
:Ei~31L?nsl
:i PAGE 1 OF
I
~Zj""
-:~j MAI~I aAl~O FalOARI DATO R\:
:j SUBJECT: BUTTON PLUG lNSTALLATION

AFT CI-IANNEL
MAST SUPPORT STRUCTURE,
i
MODELS AFFECTED: 5000 Model 369D Helicopters Serial No. 1150D and 1185D
through 1204D.
Shall be accomplished at next 300-hour inspection interval

TIME OF COMPLIANCE:
or at next removal of forward eneine air inlet fairing assembly,
whichever is sooner.
PRtF4CE: lli"mrlion eiuo in Lhir Service Inlorniation Nailer. Ijruvidcj a I,rucariure iul-
chcckinff the mast support structure alt channel (PN 36~H3011-17) Cor nu
and such holes when rouncl. When open, hoic

unplugged hole,
allows unfiltepcd air to enter the plenum chatnbcr.
Reference
369D HMI Vol 1 (CSP-D-2), Reissued 15 January 1.182; Revision 2, 15 August 1982.
j j
C
FORM 9518 (2/81)

Hughes Helicopte~s, Inc. Culver City, california 90230
P.3TICE NO, Dlj 121
O HUQhe.Helic~pten. Inc.
DATE 27 June 1983

PAGE 2 of 2
PARTS LIST
Part No, Q_ty Manufacturer

Nomenclature
SS-48155-K1110 1 IIHI
Plu& Button
MATERIALS
Sealant, Silastic I\r,lL-S-8660D RTV-732 Dow Coming
PROCEDURE
Vol I).
a. Ketr~ove left side, forward engine air inlet fairing (Scction 2, HMI
check mast support structure aft channel (PN i6~I13011-17)

b. Visually
left side of channel. II hole has been
rresence of 0,88-inch diameter hole on
~lugged, continue with step e.
CAUTION
the cooling air

Do not allow any foreign objects (FOD) to enter
or engine air inlets. 3ape covers of cardboard or olhcr suitable
material over inlets before ~cginning work. I)o not remove covers
until area has been thoroughly cleaned and a:ll foreign objects
removed.
forward side of
c, If hole is open, install SS-48145-K1110 button plug on
channel to close hole. Cover plug with sealant (RTV-732 or eyuivalent) according
to manufacturers instructions.
debris and other objects:Erom work area; remove

d, Thoroughly clean any
temporarily installed covers.
HMT Vol i).
e. Keinstall left side, forward engine sir inlet I-airirifi (Section 2,
with this Notice in Compliance Record of helicopter

f, Record compliance
log book,
WEIGI~r AND BALANCE DATA
Weight and balance not: af:rectcd.
procedure given in this Notice

The resultant alteration to affected models by the
has been shown to comply with Federal Aviation Regulations and is FAA Approved,
j ~r 7 a_ Ilr,Y ATP
I-,
I
ii
NOTICE NO. DN-122
ii I~"
:1
."-"-~L1C"
;t
~*3
.i
DATE 29 July 1983
3s
ri~ PAGE 1 OF 4
;L,
Inn/~M DATnraib ;:::i~ IWAM i3f\TO~y r-~ MAN DA70~ J
SUBJECT: INSPECTION AND OVERHAUL OF FUEL SHUTOFF VALVE (PN 369A8104-4)
MODELS AFFECTED: All 500D Model 369D Series helicopters.
TIME OF COMPLIANCE: Part I of this Notice shall be accomplished within the next
24 hours of helicopter operation, from the date of this Notice.
Part II of this Notice shall be accomplished if the fuel shutoff

valve does not open and close properly during the inspection
required by Part I of this Notice, or within 6 months from the
(1 date of this Notice.
PREFACE: The activation groove in the fuel shutoff valve ball can become worn from
high
seal drag in the valve. Information given in Part I of this Notice requires a
one-time inspection of the shutoff valve for
proper operation, and placarding
of the fuel shutoff control to leave the shutoff valve
open except in emergency
until Part II of this Notice is accomplished.
Part II lists procedures for overhaul of: fuel shutoff valves (PN 369A8104-5).
Compliance with Part II of this Notice removes the restrictions for using the
fuel shutoff control imposed by Part I of this Notice.
For 6 months from date of this Notice, fuel shutoff valve overhaul kit,
PN 1594-1000, regularly priced $214.52 may be obtained from your Hughes
Service Center or Distributor for $165.34.
References
369DHh4I Volume I (CSP-D-2), Reissued 15 January 1982; Revision 2, 15 August 1982.

Hughes Service Information Notice DN-116, Dated 15 March 1983.
C
Customer Service Department -j
Foam es~s (2/81)

Aj 8~ Air.
NOTICE NO. DN-122 Hughe. Helicepten, Inc.
DATE 29 July 1983
PACE 2 of 4
PART I FUEL SHUTOFF VALVE (PN 369A8104-5) INSPECTION
TOOLS AND SPECIAL EaUIPMENT
Mirror Commercial
a. Ensure all electrical power is off, battery is disconnected, and helicopter

is electrically grounded.
b. Remove left fuel cell access door (Section 2, HMI Vol I),
WARNING
Follow all fuel

handling safety precautions. Fuel vapors are
highly flammable and can result in fire or explosion if

exposed to sparks or open flame..
c. Disconnect powerplant fuel supply tube from fuel shutoff valve

(Section 12, HMI VolI).
d. Ensure fuel shutoff valve control is pushed in. Using mirror, check
ball in fuel shutoff valve to see that valve is fully open.
e. Pull fuel shutoff control on instrument panel full out. Use mirror to
check that valve is completely closed.
f. Push fuel shutoff control in; check valve using mirror to see that valve
is open and unobstructed.
WARNING
If fuel shutoff valve does not open and close fully during
the above checks, the valve must be overhauled per Part II
of this Notice, or replaced prior to further flight.
g. Reattach powerplant fuel supply tube to fuel shutoff valve (Section 12,
HMI VolI).
h. Reinstall left fuel cell access door (Section 2, HMI Vol I).
i. Purge air from low pressure fuel filter housing (Hughes Notice DN-116).
j. Fabricate placard which reads, USE FUEL SHUTOFF VALVE IN

EMERGENCY ONLY; attach placard to instrument panel where it can be easily
seen by the pilot.
k. Record compliance with Part I of this Notice in Compliance Record of

ORIGlhAL A; R~VE;:IID B~ ATP.

i; O Hnghss Ha(icapts. Inc. NOTICE NO. DN-1Z2
DATE 29 July 1983
PAGE 3 of 4
PART II OVERHAUL OF FUEL SHUTOFF VALVE (PN 369A8104-5)
PARTS LIST
Nomenclature Part No. Rty Manufacturer
HHI
Overhaul kit, Fuel 1595-1000 1
shutoff valve
TOOLS AND ERUIPMENT
Electric Pencil or equivalent Commercial
PROCEDURE
a. Ensure all electrical power is off.
WARNING
When defueling helicopter, follow all fuel handling safety

precautions. Ensure all electrical power is off; disconnect
battery; and electrically around helicopter. Open flames
and sparks can cause fire or explosions.
b. Defuel helicopter (Section 2, HMI VolI).
c. Remove fuel shutoff valve from helicopter (Section 12, HMI Vol I).
d. Overhaul fuel shutoff valve according to instructions in PN 1594-1000

Fuel Shutoff Valve Overhaul Kit.
e. Using an electric pencil or equivalent, add the letter "M" at the end of
the Hughes Part No. on the valve body.
f. Reinstall overhauled valve in helicopter (Section 12, HMI Vol I).
CAUTION
Purge air from fuel system prior to next flight. Failure

to purge air from fuel system can result in engine
flameout. (Refer to Hughes Service Information Notice
DN-116.)
g. Refuel helicopter (Section 2, HMI VolI).
h.Check fuel shutoff valve for leaks; check rigging and operation of fuel
shutoff control. (Refer to Section 12, HMI Vol I.)
ORIG"" nl i: f:
~\g BTF
i
NOTICE NO. DN-l2z ~31 HUBhes Hellcopten. Inc.
DATE 29 July 1983
PAGE 4 of 4
with Part II of this Notice in Compliance Record of

i. Record compliance
I~EIGHT AND BALANCE DATA
The resultant alteration to affected models as described by procedures given

Aviation
in Parts I and II of this Notice have been shown to comply with Federal
i,
NOTICE NC) DN-123
-rl! B DATE 28 October 1983

;i, 1it, .i
I
~nrrs MAMDAIORY gaBOnY MAN BATE RY
SUBJECT: BATTERY CASE AND MAIN DC POWER WIRING INSPECTION
MODELS AFFECTED: All 400D Model 369D Series helicopters equipped with Saft
STC SH95850 nickel cadmium batteries and battery cases.
TIME OF COMPLIANCE: Shall be accomplished at or prior to the next 100 hour

periodic inspection interval,
Ci PREFACE: Information
battery case
improved flange
on
in this Notice requires a one-time visual inspection of the
given
affected
has been
models for cracks in the support flanges. An
incorporated on the battery case of all current
production Saft 16146 and 16156-1 batteries. The improved battery case
i
design can be identified by a vertical stiffener that has been added to the
:I flanges on both ends of the battery case,
Additionally, inspection of the main de power wiring for chafing damage

caused by the wiring rubbing against the battery case is required. These
requirements are in addition to the battery inspection required for all 369D
Series helicopters at each 1.00-hour inspection interval, as specified in
Section 2, HMI Volume 2. 1
Reference
500D Model 369D HMI Volume 1 (CSP-D-2), Reissued 15 January 1982; Revision 3,
14 August 1983,
500D Model 369D HMI Volume 2 (CSP-D-3), Reissued 1 November 1982; Revision 3,
15September 1982,
Acceptable Methods, Techniques, and Practices Aircraft Inspection and Repair
(FAA AC No. 43,13-1A).
FORIM 9578 (2/81)

NOTICE NO. DN-123
DATE 28 October 1983 4) ~Ushl Helicopters, Inc. I
PAGE 2 of 3
TOOLS AND EQUIPMENT
Magnifying glass (5x 10x) Commercial
PROCEDURE
a. Ensure all electrical power is off.
b. Remove battery compartment access door (Section 2, HMI Volume 1),
c.Visually inspect battery case support flanges, using 5x 10x magnifi-

cation, for cracks. Pay particular attention to the flange at the connector end
of the battery. Batteries found with cracked flanges are to be corrected by
replacing the battery case with the improved current product battery case.
NOTE
1, Saft America Inc. will replace damaged battery cases
that are under warranty, Call Saft Americas

warranty
administrator for specific instructions (Telephone: (912)
247-2331).
2, Replacement parts for batteries not under warranty can
be obtained from any authorized Saft Order

NP,rotubirtsiD
1723-11, case replacement for PN 16156 batteries, and
PN 18112-3, case replacement for PN 16146-1batteries,
NOTE
Inspection per steps d. and e, below is not required for

369D Series helicopters S/N 1185D and subsequent. Main
de power wiring has been rerouted in these helicopters.
d, Visually inspect main de power wiring from battery connector (P108)

to opposite end terminals for chafing damage or wear. If evidence of damage
or wear is noted, replace wiring (Section 19, HMI Volume 1).
e. routing of main de power wiring to ensure that wiring cannot

Check
rub against battery case or other structure components during helicopter opera-
tion. Reroute and clamp and/or tie wiring as necessary per FAA AC 43. 13-1.A
to prevent wiring from rubbing against battery case or other structure
components.
f. Reinstall battery compartment access door (Section 2, IIMI Volume 1).
g, Record compliance with this Notice in Compliance Record of helicopter

Log Book,
NOTICE NO. DN-123
Hughes Welicopters. Inc. DATE 28 October 1983
PAGE 3 of 3
C WE~GHT AND BALANCE DATA
The resultant alterations to affected models described

as by procedures given
in this Notice have been shown to comply with Federal Aviation Regulations and
are FAA Approved.
C
NOTICE NO. DN-124
DaTE 10 November 1983
S E ~V I 1 C~I1 F~t R f~ PAGE 1 OF
~TB ~E
-d9iapaa~ FAAIU DATO RY sVIAN DATO nY I I

MAN DATO RY
SUBJECT: MAIN TRANSMISSION OIL LINE (PN 369D24709 AND 369D25710) INSPECTION:
AND REPLACEMENT OF MAIN TRANSMISSION OIL LINES (PN 369D24709 AND
369D25710) AND BRACKETRY WITH NEW PN 369D25709-11 AND 369D25710-11
LINES AND BRACKETRY.
MODELS AFFECTED: 500 Model 369D Series Helicopters SerialNo. 0003D through 1288D.
TIME OF COMPLIANCE: Part I Shall beaccomplished at the next 100-hour inspection

and each subsequent 100-hour inspection until Part II of this
Notice is accomplished.
Part II Shall be accomplished at owner/operator discretion, or

at next replacement of main transmission oil lines, whichever
occurs first. Compliance with Part II of this Notice eliminates
Part I 100 hour inspection requirement.
REFACE: PART I The information given in Part I of this Notice provides a required
inspection of the main transmission oil lines (PN 369D25709 and 3691324710)
for chafing damage, which could cause the lines to !leak.
PART II The information given provides procedures

in Part II of this Notice 1
forreplacing (PN
main transmission oil lines 369D25709 and 369D24710) and
bracketry with new oil lines (PN 369D25709-11 and 369D25710-11) and bracketry.
The new installation will reduce the possibility of oillline chafing damage durina
i
1 op eration.
Information given in this Service Information Notice is considered to be part of

II the HMI and will be incorporated in the below referenced manuals at the next
scheduled revision.
Reference
j
369) HMI Volume 1 (CSP-D-2). Reissued 15 January 1982; Revision No. 3, 15 August 1983. :i
369D HMI Volume 2 (CSP-D-3), Reissued 1 November 1981; Revision No. 3, 15 September 1982.
FORM 8578 (2/81)

Hu~hes Helicopters, Inc. Culver city. Cal;lqrnia 90230
NOTICE NO. DN-124 Hughes Helicopters, Inc.
PACE 2 of 8
PART I INSPECTION OF MAIN TRANSMISSION OIL LINES

j
(PN 369D25709 AND 369D25710)
a. Remove sound insulation and main transmission access cover (Section 2,

HMI Vol 1)
b. Visually check entire length of 369D25709 and 369D25710 oil lines for
chafing damage; if noted, perform Part II of this Notice.
NOTE
Black powdery deposits on the aluminum tubes indicate

chafing damage.
c. Visually clamp attached to oil lines for evidence of cushion

check each
wear or deterioration; if noted, remove clamp
and inspect tube under clamp for
chafing damage. If tube is chafed, accomplish Part II of this Notice. If tube is

undamaged install new clamp.
NOTE
Any rubber particles around or on clamp indicates possible

clamp cushion wear or deterioration.
I~und insulatirm and tran.mfsSion access c~ver (6ection i,

HMI Vol
e. Record compliance with Part I of this Notice in Compliance Record of

Hughec Heliooptarr. Inc. NOTICE NO. DN-124
PACE 3 of 8
PART II REPLACEMENT OF MAIN TRANSMISSION OIL LINES

(PN 369D25709 AND 369D2571D) IC~ND BRACKETRY
WITH NEW LINES (PN 3691)25709-11 AND
369D 25710-11) AND BRACKETRY
PARTS LIST
Tube assembly 369D 25709-11 1 Hughes

Tube assembly 369D25710-11 1 Hughes
B racket 36 9D 25701- 3 1 Hughes
Bracket 369D24701-5 1 Hughes
Bracket 369D25701-7 1 Hughes
Washer AN 960KD 4 1 Commercial
Elbow AN833-8D 2 Commercial
Nut AN 924- 8D 2 Commercial
Clamp NAS 1713D 8N 2 Commercial
Clamp HS 418 1A 8N 2 Hughes

Screw NAS1096- 3- 8 4 Commercial
Screw NAS 10 96- 3- 7 2 Commercial
Washer AN960KD10L 8 Commerciall
Washer AN 960-D 1216 4 Commercial
Nut MS 21042- 3 2 Commercial
Rivet MS 20426AD 4 6 Commercial
Rivet MS 20470AD4 11 Commercial
Rivet MS 20470AD 3 2 Commercial
TOOLS AND EQUIPMENT
Drill motor, portable Commercial
Protractor Commercial
MA TERIALS
PROCEDURE
a. Remove sound insulation and transmission access cover (Section 2,

HMI Vol i).
C
NOTICE NO. DN-124 Hughes Helicopters. Inc.
PAGE 4 of 8
b. Drain main transmission lubrication system (Section 2, HMI Vol 1).
c. Remove screws, nuts and washers attaching all clamps holding

369B25709 and 369D25710 tube assemblies. (See Figure 1.)
d. Disconnect 3691)25705-11 hose from AN821-8D elbow connected to

369D 25709 tube assembly.
e. Disconnect 369D25705-21 hose from AN821-8D elbow connected to

369D25710 tube assembly.
f. Disconnect 369D24710 tube assembly from union at oil temperature

sender housing; remove tube assembly fi-om helicoptc~r.
g. Disconnect 369D25709 tube assembly from union at 369DZ3020-i web;

remove tube assembly from helicopter.
h. Drill out rivets attaching brackets (Figure 1) to structure and remove
brackets. Apply zinc chromate primer to holes. Fill holes with MS20426AD4
rivets.
i. Remove clamp securing 3691)292490 heating hose to HS4194-6 standoff on
canted station 124 channel. Remove and relocate standoff as shown in Figure 1
(View A) using MS20470AD3 rivets. Relocate clamp on heater hose and reattach
clamp to standoff.
j. Install 369D25701-3 bracket on 369H3011-17 bracket as shown in

Figure 2, View A.
k. Install 369D24701-5 bracket on 369H3010-73 panel.
i. Position bracket on panel ns shown in Figure 2. Mark lower portion

of panel to match holes in lower portion of bracket; remove bracket.
2. Use No. 30 drill to drill holes in panel at locations marked. Clean

drill cuttings from area and apply zinc chromate primer to holes.
3. Attach bracket to panel using four MSZ0470AD4 rivets.
i. Install 369D25701-7 bracket on 361H3010-9 panel.
i. Mark position for two bracket attach holes on outboard side of

369W3010-9 panel as shown in Figure 2.
2. Use No. 30 drill to drill holes in panel at locations marked. Clean

drill cuttings from area, particularly in plenum; apply zinc
chromate primer to holes.
3. Attach 369D25701-7 bracket to panel using two MS20470AD4 rivets.
j
Huehe, Hcllcnptnrc. Inc. NOTICE NO. DN-24
PACE 5 of 8
m. Install AN833-8D elbow in upper and lower holes of 369D25701-3

bracket, with outboard end of elbow down. Attach each elbow to bracket with
two AN960-D1216 washers and one AN924-8D nut.
n. Connect 369D25705-21 hose assembly to upper AN833-8D elbow outboard

(downward) leg.
o, Connect 369D25705-11 hose assembly to lower AN833-8D elbow outboard

(downward) leg.
p. Install 369D25709-11 tube assembly.
1. Position tube assembly so that upper end mates with inboard end
of lower elbow in 369D25701-3 bracket, and lower end mates with:
open end of union at 369D2302014;Neb. Tube must be centered
between two inboard holes of 3691~25701-5 bracket.
2. Fit upper end of tube over lower elbow; secure to elbow with nut
on tube assembly.
3. Fit lower end of tube over open end of union at 369023020-5 web;
secure tube to union with nut on tube assembly.
4. Place HS4181A8N clamp around tube at 369D25701-5 bracket.

Attach clamp to inboard holes of bracket with two AN960KD10L
washers and two NAS1096-3-8 screws.
5, Place NAS1713D8N clamp on tube at 369D25701-7 bracket. Secure
clamp to forward side of bracket aft leg with NAS1096-3-7 screw,

two AN960KD10L washers and MS21042-3 nut.
q. Install 369D25710-11 tube assembly,
1. Position tube so upper end mates with upper elbow through

369D25701-3 bracket, and lower end mates with open end of tem-
perature sender housing. At 369D25701-5 bracket, tube must be
centered between two outboard holes.
2. Connect tube ends to elbow and union and secure with nuts on
tube ends.
3. Place HS4181A8N clamp around tube at 369D25701-5 bracket; attach

clamp to bracket with two AN960KD10L washers and two
NAS 1096- 3- 8 s crews.
4. Place NAS1713D8N clamp over tube at 369D25701-7 bracket. Attach

clamp to forward side of bracket with NAS1096-3-7 screw, two
AN960KD10L washers and MS 21042- 3 nut.
C
NOTICE NO. DN-124
Hugh~,Helrcoptsn. Inc.
PACE 6 of 8
r. Check to that minimum of 0.25 inch clearance exists between tubes

see
and 369H3011-17 bracket as shown in Figure 2, adjust as required for minimum

clearance.
s. Fill transmission with approved lubricant (Section 2, HMI Vol 1).
t. operate helicopter until lubricant

Start and is circulated through
system (369D Pilots Flight Manual).
u. Check installation for leaks and security.
v. Reinstall sound insulation and transmission access cover (Section 2,

HMI Vol 1).
w. Check main transmission oil level at sight gage (Section 2,

HMI- Vol 1)
x. Record compliance with Part II of this Notice in Compliance Record of

The resultant alteration to the affected helicopters described by Part II of this

Notice has been shown to comply with Federal Aviation Regulations and is FAA
Ap proved.
nelicoptelr. Inc. NOTICE NO. DN-124
PAGE 7 of 8
369[)23024 AFT SECTION CHANNEL

ASSEMBLY (CANTED STATION A _1 ~71.50 HS4194-6STANDOFF
V7V Ii--~ /MS20470AD3RIVET(2)
!I! 219190030 CLAMP

~3_
;Y\
NAS1096-3-7SCRNV
2.
AN960P010LWASHER
i
i 3690292490 HEATING HOSE
1713D30N CLAMP
~61 CLAMP.
(NOTEIBRACKET CLAMP AN821-8D
UNION
CLAMP
a 369025705-21
HOSE
Q
BRACKET
6)
i
(NOTE)
369025705-11
4/9/ HOSE
CLAMP
369[325709
TUBE ASSY
369[)25710
TUBE ASSY
d~x\i O
TEMPERATURE SENSOR
HOUSING
369023020-5
DRILL OUT RIVET ATTACHING WEB
BRACKET AND REMOVE BRACKET.
APPLY WETZINC CHROMATE PRIMER
TO HOLE AND FILL WITH APPROPRIATE
88-583
SIZE SOLID RIVET.
Figure 1. Existing Hardware Removal and Relocation
C
I!" Ci
PICK-UP ZEXISTING ~d Z
RIVETS 990
.50 O ~3 t~
MMH
I!lt 1+1 k -t
CC
m
36902570 m o~
BRACKET co ZO
O c
Ctl
369HMll-17 f cD
369H3009 BRACKET ~z
STATION 124 CANTED FRAME
DR IU TO MATCH 2 PILOT HOLES d C~
N
AND INSTALL 2MSM470AD4RIVETS. Y ~f
DRILL OUT EXISTING RIVETS AND RELOCATE EXISTING

INSTALL MSX)426AD4 PRIOR TO SSC-2M STRAP
INSTALLING 369025701-3 BRACKET. AS SHOWN INSTALL W
AN833-8D ELBOW AN960-D1216
WITH MS 20470AD4
WASHER 4 REQD 369025709-11 1 369H3011-17 BRACKET RIVET ANI) AN960KD3
TUBE ASSY WASHER.
.15
369025710-11
TUBE ASSY
i_
369H3010-73 1
PANEL
Q
,RD25ml~ 5
BRACKET 0.25 4 REPD (D
MINI 4 HOLES. .132,.128 DIA. 99
HS4181A8N CLAMP THRU TO MATCH BRKT.
AN833-8D
ECBOW j lcl NAS1096-3-8 SCREW 4REP1D
AN960KD10L WASHER 4 REQD
.60
WSldd FASTENER
I
C)
1 NASIIUDLIN CLAMP
AN924-8D
NUT
.15 .67
W7aD963)2( O
B
369025705-11 369HU)10-17 TEMP. SENDER a
HOSE ASSY HOUSING
NAS1096-3-7 SCREW 2 REQD PANEL
369025705-21
MS21042-3 NUT 2 REPD
HOSE ASSY 369025701-7 BRACKET C)
AN960KD10L WASHER O REQD
35~
UNION
i
STATION 124 CANTED FRAME ~M \--3690~020-5 WEB
TEMPERATURESENDER HOUSING
MS20470AD4 RIVET. 2 REPD
2 HOLES..132/.128 DIA. THRU TO
TO MATCH BRACKET
VIEW LOOKING AFT.
VIEW LOOKING INBD. L.H,
88-581
Figure 2. Installation of 369D25709-11 and 369D25710-11

Main Transmission Oil Lines
~7 gR161i\Bl BS RECEI\IED BY ATP.

DN-125
i!,as3~:,r I~OTICE NC
DATE 23 r)ece~ber 1983

t~
II~ PAGE I OF 5
-t
WlaNnaTOR~I WIAMDATORII
~lnAi"JDATORYI
INSPECTION AND
MAIN ROTOR SWASHPLATE BEARING, PN 369A7003-3,
i SUBJECT:
POSSIBLE REPLACEMENT
i]
All 400D Model 369D Series helicopters containing any of the

MODELS AFFECTED: uninstalled
following listed assemblies, plus any spare assemblies
on helicopters. Assemblies affected are: 369A7003-3, Swashplate
369D21000 Main Rotor Installation, and
Bearing Assembly,
369D27609-501 Main Rotor Swashplate Installations received between
June 1, 1983 and December 20, 1983.
Swashplate Bearing Assemblies PN 369A7003-3, with 9XXX series

1
serial numbers, or with the blue dot identifier per step g of the
following procedure donot require reinspection per this Notice,
Must be accomplished prior to

to ht following receipt
fur_ther flight,
TIME OF COMPLIANCE:
of this Notice, for affected parts in service.
i installing affected parts from

Shall be accomplished prior to
spares,
i
Shall be accomplished all spares inventory.
j
on
Main Rotor Swashplate
.I
PREFACE: A recent field report indicated that a 369A7003-3
Assembly was found without the ball bearing
given in this Notice provides procedures
cages installed. Information
for a one-time inspection of al
affected 369A7003-3 bearings for missing cages. Subject bearings found

BearingF
and returned
shall be removed from service or spares immediately
cages missing
will be provided by
f
to Hughes Helicopters. Replacement 369A7003-3 bearings
and Distributors.
Hughes through authorized Service Centers
Reference
500D Model 369D HMI Vol. 1 (CPS-D-2),

Reissued 15 January 1982; Revision 3, 15 August
i
1983.
September 1981.
Model 3690 COM (CSPD-5). Keissued ii
i
Customer Senrice Department
Foam ssle (2/81) Hughes Helicopters, Inc. Culver City, California 90230
NOTICE NO. DN-125
DATE 23 December 1983 Hughes Helicopters. Inc.
PACE 2 OF 5
MATERIALS
Fed-Std-15102 Commercial
Lacquer, Blue Acrylic
TT-I-734 Commercial
Isopropyl alcohol
PROCEDURE
from helicopter (Section 7, HMI Vol. 1).

a. Remove main rotor swashplate
NOTE
bearing assembly from swash-

It is not necessary to remove
separate stationary and rotating swashplates

to
plate or
perform the required inspection.
b, Remove four nuts and washers attaching retainer to rotating swashplaf;e,

It may be necessary to move arms of rotating swashplate for access to bolts. (See
Figure 1,)
CAUTION
Do not allow dirt, grit or any foreign material to enter
bearing assembly.
inverted, carefully
c. holding swashplate assembly with bearing
While
surface, ring and seal with a clean lint-
clean exposed bearing assembly snap
with isopropyl alcohol. Do not allow alcohol to enter bearing.
free cloth dampened
seal from swashplate bearing
d, Carefully remove upper snap ring and
2. Note seal orientation so seal can be reinstalled
assembly as shown in Figure
in same position.
that bearing cage is in place

e.Visually check areas under seal to ensure
If cage is not in place, bearing balls will be visible.
as shown in Figure 2,
CAUTION
If bearing present, replace bearing assembly

cage is not
with a
with inspected bearing assembly from spares, or
affected by this Notice. (Refer to
bearing assembly not
of bearing
Part V, 369D-COM for removal and installation
as sembly
shown in Figure 2, carefully clean seal,

f.bearing cage
If is in place as
and snap ring and reinstall seal and snap ring on bearing
snap ring groove,
assembly
NOTICE NO.~DN-125
23 December 198?
Hughes Helicopter.. Inc. ETAD4
PAGE 3 OF
INER
NUT AND
WASHER (4)
RETAINER
SWASHPLATE
BEARING
ASSEMBLY
ROTATING SWASHPLATE
C
L_---Il
RETAINER
BOLT 141
-"2 g
NOTE:
IT IS NOT NECESSARY TO
REMOVE BEARING FROM
SWASHPLATE OR SEPARATE STATIONARY SWASHPLATE
STATIONARY AND ROTATING
SWASHPLA1E TO PERFORM
BEARING INSPECTION.
88-596
Figure i. Main Rotor Swashplate Assembly (Exploded View)
C.
rig By Prr~
NOTICE NO DN-125
DATE 23 December 1983 Hughes Helicopters. Inc.
PAGE 4 OF 5
SNAP RING
BLUE DOT
(NOTE 31
SEAL
BEARING
CAGE GREASE SEAL
(NOTE 2)~ RETA INER
(NOTE 1)
BEARING
ASSEMBLY
NOTES:
i. PART NO. AND SERIAL NO.

ARE INK STAMPED ON GREASE
SEAL RETAINER.
2. IF BEARING CAGE IS MISSING

BALLS WILL BE VISIBLE.
3. AFTER INSPECTION, PLACE

BLUE ACRYLIC LACPUER DOT,
118 INCH DIAMETER, ON SNAP
RING AS SHOWN.
88-595
Figure 2. Main Rotor Swashplate Bearing Inspection
n
r
ii.
NOTICE NO. DN-124
nughe.Helicopters, Inc. DATE 23 December 1983
PAGE 4 OF~ 4
CAUTION
Ensure that seal is flat and smooth after installation, with

seal lip inner diameter contacting inner race of bearing.
g. Using blue acrylic lacquer, place a blue dot, approximately 1/8 inch
diameter, on outer surface of snap ring as shown in Figure 2.
h. Reinstall retainer onrotating swashplate with bolts, washers and nuts.

Torque nuts to 50-70 inch-pounds. (See Figure i.)
i. Reinstall swashplate assembly on helicopter (Section 7, HMI, Vol. i).
j. Record compliance with this Notice in Compliance Record of helicopter

Log Book.
The resultant alteration to affected models from the inspection procedure in this
Notice has been shown to comply with Federal Aviation Regulations and is FAA
Approved.
i
NOTICE NO.
EN-14
HN-193
April
" fPAGE OF10 14891
1
ERRATA
HughesService Information Notice No. DN-126, EN-14, HN-193, dated 9 April 198L;.
Change Page 1 of 7, MODELS AFFECTED, 2, with date of "5/18" or later.....

to read with date of "5/81" or later....
Change Page 2 of 7, step g., Notch 0.265 inch inner diameter x 0.63 inch thick
washer as shown in Figure 1;....
to read: Notch 0.265 inch inner diameter x 0.063 inch thick washer as shown in
Figure i;....
A
DN-126C~
EN-14
i NOTCE NP HN-193
DATE 9 April 1984

csl
PAGE 1 OF 7
*Include
a copy of this Notice
in the Notice file for each

affected model
itan~l Cnlo RY M 6a121DATORYAMDATORY
_
SUBJECT: FUEL SHUT-OFF VALVE CONTROL CABLE (PN 369A8137-503 AND
-603 PULL TEST
MODELS AFFECTED: All 369D, 3693, 369H, 369HE, 369HM and 369HS Series Helicopters
as follows:
1. Having subject cable installed, marked, "Jairen Inc. 16722

1 date of "5/18"
i
PN 110262-15N", with or later, if the swage
is less than 0.50 inch in length.
2. Cables marked as described in I. above, in spares inventory.
NOTE
Affected cables having the swaged end of the cable

housing painted green have been inspected and do
not require reinspection per this Notice.
TIME OF COMPLIANCE: Shall be accomplished within the next 100 hours of helicopter
operation from the date of this Notice for all installed affected
parts. Shall be accomplished prior to installing any affecter
parts from spares inventory.
PREFACE: This Service Information Notice gives procedures for a one time design load
pull test of affected PN 369A8137-503 and -603 Fuel Shut-Off Control Cable
assemblies
Part I gives procedures for testing PN 369A8137-503 assemblies used on 500D
versions of the Mode1~369D helicopter, 36939 369H, 369HE and 369HS Series
helicopters.
Part II gives procedures for testing PN 369A8137-603 assemblies used on 500MD
versions of the model 369D helicopter and 369HM Series helicopters.
Reference
369D HMI Vol. 1 (CSP-D-2), Reissued 15 january

1982; Revision No. 3, 15 August 1983 j
369E Supplement to HMI Vol. 1 (CSP-E-2), Issued 30 November 1983.
Model 500 Basic HMI (CSP-H-2), Reissued 15 September 1981.
Basic HMI Configuration Supplement 14 March 1975
HM (CSP-H-2B), Reissued
Hughes Service Information Notice No. DN-122, dated 29 July 1983.
Hughes Service Information Notice No. EN-9, dated 29 July 1983.
ii Hughes Service Information Notice No. HN-189, dated 29 July 1983.
I___ _
ij
FORM 9578 (2/81)
NOTICE NO. DN-126
EN-14 ~Huglhcss ~lslicolptena, Inc.
HN-193
DATE 9 April 1984
PAGE 2 of 7
PART I. PULL TEST PN369A8137-503 FUEL SHUT-OFF VALVE CONTROL CABLE
TOOLS AND EQUIPMENT
Nomenclature Source
*~FFish Scale (75 pounds capacity or greater) Commercial
MATERIALS
Duct tape (2 inches wide X 12 inches long) Commercial
Safety wire (0.032 inch diameter X 14 inches long) Commercial
Paint, Green lacquer Commercial
""*Washer, Steel (0.265 inch inner diameter X 0.063 inch thick) Commercial
""Since space in aircraft is limited, use scale which achieves

a 50 Pound load with minimum travel.
"*"Washer, may be standard or locally fabricated from

0.063 inch steel stock (any type).
PROCEDURE
a. Remove left instrument panel fairing (Section 17, HMI Vol 1 or

Basic HMI).
b. Remove clamp attaching fuel shut-off cable to bracket on

canopy, or
to back of instrument panel support structure (369E
(See only). Figure i.)
c. Back retaining nut completely off tlireaded
portion of control cable at
back of instrument panel (Figure 1).
d.
Wrap approximately 12 inches of two inch wide duct tape around cable.
casing, approximately 0.05 inch behind instrument panel or
swage, whichever
is further from front of instrument
panel, as shown in Figure 1.
e. Attach one end of safety wire (0(032 inch diameter x 12 inches long)
just behind control cable flange, at front of instru~nent panel.
f. Attach free end of safety wire to fish scale.
g, Notch 0. 265 inch inner diameter x 0.63 inch thick

washer as shown in
Figure 1; place washer over cable between duct
tape and rear of instrument
panel as shown.
WARiNTNC
Cable may separate suddenly

during pull test. Personal
injury can occur~ should the cable separate if person
applying pull test is not securely braced.
ORIG(EIB~ 1"13 WBSEIYfD BY ATP.

NOTICE NO.
~3! HUBhN H)/E~Ptrr Ino. DN-126EN-14
HN-193
DATE 9 April 1984
PAGE 3 of 7
h. securely braced in the left helicopter seat, slowly apply

While
50 pound pull on the safety wire and cable assembly. Do not exceed 50 pound
test load,
NOTE
If cablecasing pulls out of swage, replace cable

assembly (Section 12, HMI Vol 1 or Basic HMI);
return failed cable to HHI, Attn: Warranty and
Repair Administration, with a completed warranty
form
i.Visually inspect swage joint for evidence of partial separation. If

partial separation is evident, replace cable assembly (Section 12, HMI Vol 1 or
Basic HMI); return damaged cable to HHI. (Refer to above Note.)
j. If cable shows no evidence of separation at swage, paint swaged end

of cable housing using green lacquer.
k. Remove safety wire and scale from cable assembly.
i. Remove washer and duct tape from cable at rear of instrument panel.
m. Reinstall retaining nut on threaded portion of control cable at back of

instrument panel,
n. Reinstall clamp which attaches fuel shut-off valve cable to bracket on
canopy or instrument panel support structure.
o. Reinsta11 left instrument panel fairing (Section 17, HMI Vol 1 or
Basic HMI).
NOTE
Part I of Hughes Service Notice DN-122, EN-9 or HN-189

must be reaccomplished if the fuel shut-off valve has not
been overhauled per Part II of the applicable Notice.
p. Inspect fuel shut-off valve per Part I of Hughes Notice No. DN-122,
EN-9 or HN-189, if required.
q. Record compliance with Part I of this Notice in Compliance Record of

helicopter Log Book. r
aEl~;c, h:L ;13 jil,ij~l0 8~ All

NOTICE NO. DN-1Z6
EN-14 4~ Huahe~ Helicopters, Inc.
HN-193
DATE 9 April 1984
PAGE 4 of 7
PART II. PULL TEST FOR PN 369A8137-603 FUEL SHUT-OFF

VALVE
CONTROL CABLE
TOOLS AND EQUIPMEN T
Nomenclature Source
+Fish Scale (75 pounds or greater capacity) tGommercial
+Since space in aircraft is limited, use scale which

achieves a 50 pound load with minimum travel,
Retaining Tool
Locally fabricated
MATERIAL
Duct tape (2 inches wide 12 inches

x long) Commercial
Safety wire (0.032 inch diameter x 14 inches long) Commercial
Steel sheet (0. 188 inch or equivalent) Commercial
Paint, Green lacquer Commercial
PROCEDURE
a. Fabricate retaining tool from 0, 188 inch thick

sheet
or equivalent steel
as shown in Figure 2,
b, Remove cover from right side of horizontal console (Section

17,
HMI Vol 1 or Basic HMI
Configuration Supplement HM).
c. Back securing nut completely off threaded portion of cable

(Figure 2)
d, Wrap 12 inch of two inch wide duct
strip tape around cable housing,
with top of tape two inches above
helicopter floor as shown in Figure 2,
e, Secure one end of safety wire
just behind fl~qnge of control cable
assembly on horizontal console
(Figure 2).
f, Secure free end of safety wire to fish scale.
g; Place slotted end of retaining tool, fabricated in

Step a., on cable at
top of duct tape: stand on tool to secure tool
against helicoptel- floor. (See
Figure 2,)
WARNING
Cable may separate

suddenly during pull test.
Personal injury can occur if person
is not well balanced and
conducting test
prepared for the possible
separation,
"1; i r
ill
i :I$ ~v Aqp
NOTICE NO. DN-12t,
II 4~ Hushe. Hclicnntnrc. Inc. EN-11
HN-193
DATE 9 April 1984
PAGE 5 of 7
h, While stably positioned over horizontal console, slowly apply 40 pound

load to cable. Do not exceed 50 pound test load.
NOTE
If cable casing pulls out: of swage, install new cable

assembly (Section 12, Basic HMI Configuration Supple-
ment HM or llhII Vol 1); return failed cable to tlt-iI,
Attn: Warranty and Repair Administration, with a
completed warranty form.
Visually inspect swage joint fur evidence of partial separation. If

i.
partial separation is evident, replace with new cable assembly (Sectibn 12, HMI
Vol 1 or Basic HMI Configuration Supplement HM); return damaged cable
assembly to HHI. (Refer to the above Note.)
j. If cable shows no evidence of separation, paint swaged end of cable
housing with green lacquer.
k. Remove safety wire and scale.
i. Remove retaining tool and duct tape.
m, Reinstall retaining nut on threaded portion of control cable at under-

side of horizontal console.
n. Reinstallright side horizontal console cover (Section 17, HMI Vol 1 or
Basic HMI. Configuration Supplement Hn/l).
NOTE
Part I of Hughes Service Notice DN-122, EN-9 or

HN-189 must bercaccomplished if the fuel shut-off
valve has not been overhauled per Part II of the
applicable Notice.
o. Inspect fuel shut-off valve per Part I of I-Iughes Notice No. DN-122,
EN-9 or HN-189, if required.
p. Record compliance with Part II of this Notice in Compliance Record of

helicopter Log~Book.
WEIGHT AMD RALANCE DATA
The resultant test of the fuel shut-off valve control cable as described by the
procedures given in this Notice has been shown to comply with Federal Aviation
i
.:~-aeP
NOTICE NO. DN-126 Hu(lhaHdleaptsra. Inc.
EN-14
HN-193
DATE 9 April 1984
PAGE ~6 of 7
i: INSTRUMENT PANEL
(FRONT)
I~ i,;
fr~ i I
RETA INING CLAFViP

(NOTE)
FRONT
OFINSTRUMENT PA~EL
CABLE CASING
.265"
DUCT TAPE
,Ij SWAGE
WASHER NOTCHEDTO
SLIP OVER CABI.E CASING
NOTCHED WASHER
3 THREADS
FLANGE
SAFETY WIRE
SECURINCNIIT
a~a I/
BACK OF
INSTRUMENT
PANEL
NOTE:
CLAMP LOCATED OFi INSTRUMENT

PANEL AFT SIJP~ORT FOR MODEL 169E.
88-600
Figure 1. Pull Test PN 369A8137-503 Fuel Shut-Off Control Cable
OR 1G E s\: Al- AS R1VED BY ATP.

i.
HugheHelrcopters. Inc. NOTICE NO. DN-126
EN-14
HN-193
DATE 9 April 1984
PAGE 7 of 7
C
TO SCALE
SAFETY WIRE
f2~ /INSTRVMENT CONSOLE- TOP

FLANGE.
CURING NUT
THREADS
SWAGE
WRAP A STR IP OF MASKING TAPE
RETAINING TOOL
COMPLETELY AROUND THE CABLE
HOLD TO FLOOR ~--1L AT BOTTOM OF SWAGE
WITH FOOT
(DO NOT CLAMPI I 1 2~ 1 J----DUCTTAPE
o~CAsLECAslNC -II FLOOR
RIGHT SIDE OF AIRCRAFT
.375"
.265"
-T-l II Il_f_
i. I I
_LI T
RADIUS TO
SUIT
RADIUS TO
SUIT
2. 0"
-r1. 875"
.188"
-L I
r
T
O
NOTE:
FABRICATE FROM .IBS" STEEL SHEET

OR EQUIVALENT.
Figure 2. Pull Test PN 369A8137-603 Fuel Shut-Off Valve Control Cable
QSRIGI riML.
h" na
AS Ea IP~e1JE13 iBV ATP.
~s NOTICF~ N( DN-127
EN-15
t:ATE
ERVI~ pl-
12 June 1984
IAGE or-: 4
Isi3 AP! DAT&? RI RnAhfAhf DATO W Y M AN DATE a Y
SUDJECT: REMOVAL OF GRAY COATING FROM PN 369D21700 and 369D21700-3 j

TAIL ROTOR HUBS
jhnODELS AFFECTED: All 500D Model 369D and all 400E Model 369E Series
equipped
.metsySsretpocileH
with 369D292500 Series Four Bladed Tail Rotor Drive
i
PN 369D21700 and 369D21700-3 Tail Rotor Hubs in spares inventory, 1
including those installed in spare 369D292500 Series Four Bladed
Tail Rotor Drive Systems. -i
TIME OF COMPLIANCE: Shall be accomplished at next 100 hour inspection interval, or
at next removal of blades from affected assemblies, whichever
is sooner.
Shall be accomplished for all affected parts in spares inventory

prior to installationon helicopter.
PREFACE: Information given in this Notice provides procedures for removal of gray
coating from bearing lands of PN 369D21700-BSC and 369D21700-3 tail rotor
hub s. If not removed, the material can enter the pitch bearings causing
the bearing action to be stiff.
Reference
Illustrated Parts List and Maintenance Instructions for Four-Bladed Tail Rotor Drive
System (CSP-088), Issued 15 September 1981.
Model 369D COPVI (CSP-D-5), Reissued 15 September 1981. ii
Customer Service De~artment

i
a nsarPn ----sm IP kiB 8941~ YP--.~P a
FORM 8578 (2/81)

Hughes Helicopters, Inc. cuiver city, California 90230
A~ B~ Air.
NOTICE NO. DN-127 neghss Helicoptsn, Inc.
EN-15
DATE 12 June 1984
Page 2 of 4
PARTS LIST
Nomenclature Part Number auantily Source
O-ring 2-025 C873-70 4 HHI
MATERIALS
WARNING
Observe dccal on idler bellcrank, located at

tail rotor transmission (CAUTION: SPRING-
LOADED, DO NOT PUSH) referring to the
inlinebungee assembly. Spring action in
linkage can cause personal injury and/or
parts damage.
CAUTION
Do not allow blade pitch to exceed 30 degrees

from neutral pitch position (blade pitch con-
trol arm movement of approximately one inch)
in either direction, whenever pitch control
links are disconnected. Unrestricted pitch
changes can stretch or bend strap-pack
excessively and cause undetected strap-pack
damage.
NOTE
Mark exact number, location and position of

all items before removal, to prevent balance
problems at reassembly.
a. Remove hardware attaching pitch control links to outboard and inboard

blades (Section 2, CSP-088).
CAUTION
Ensure crush washers and bushings are tagged

sothey can be reinstalled in exact location from
which they were removed.
b. Remove inboard and outboard blades by removing nut, bolt, bushings

and crush washers attaching each blade to hub; remove packing from hub;
discard packing.
c. Cover exposed ends of strap-packs with clean lint free cloth; press
ends of cloth into hub, to prevent debris from entering strap-pack.
P,~ su ATP.
-d
r
e~ ghe Helicopters. Inc.
NOTICE NO. DN-127
EN-15
DATE 12 June 1984
Page 3 of 4
C CAUTION
Protect strap assembly, hub ID and tail rotor

assembly from wool fiber contamination while
removing gray material. Position hub so
debris from removal does not enter tail rotor
assembly. Do not remove any black protective
coating under gray coating. Ensure all wool
fibers are removed from all components before
reassembly.
d. Using 0000 steel wool, remove all gray colored coating from bearing
lands (blade attachment area) on each end of each hub. Wipe area clean using
clean lint free cloth dampened with dry cleaning solvent. Do not allow cleaning
solvent to contact strap-pack.
e.Using clean lint free cloth, wipe inside of each blade root fitting clean,
including bushing hole.
f.
Inspect blade attachment bushings for nicks, scratches or other
damage; replace bushings if damaged. Clean serviceable bushings using clean
cloth dampened with cleaning solvent.
Inspect pitch bearings in each blade per Section 3, Part IX, 369D- COM;
g.
replace damaged pitch bearings (Section 4, Part IX, 369D-COM).
CAUTION
Crush washers and bushings must be reinstalled

in exact location from which they were removed
to ensure proper blade attachment.
h. Install new O-rings on inboard hub, and install inboard blades with
bolts, crush washers, bushings and nuts; torque nuts to 600-650 inch-pounds.
Ensure that crush washers and other hardware reused is reinstalled in same
location from which it was removed.
i. Connect pitch link assemblies to inboard blades hardware removed

using
at disassembly (Section 2, CSP-088).
CAUTION
Crush washers and bushings must be reinstalled

in exact location from which
they were removed
to ensure proper blade attachment.
j. Install new O-rings on outboard hub and install outboard blades with
bolts, crush washers, bushings and nuts; nuts to 600 650 inch-pounds.
torque
Ensure that crush washers and other hardware reused is reinstalled in
same
ioratian Irum which it
uas removed.
w r,
YAf$,
~g Hulhes nalicop~era. Inc.
NOTICE NO. DN-127
EN-14
DATE 12 June 1984
Page 4 of 4
k. Reconnectpitch links to outboard blades using hardware removed at

disassembly (Section 2, CSP-088).
i. Check tail rotor control rigging (Section 2, CSP-088).
m. Check blanace of tail rotor blades using short method (Section 2,

CSP-088)
n. Record compliance with this Notice in Compliance Record of helicopter

Log Book.
The resultant alteration to affected models as described by theprocedure in

this Notice has been shown to comply with Federal Aviation Regulations and is
FAA Approved.
ORIGI~AL A RECEliliD BY ATP,.

NOTICE NO, DN-129
EN-18HN-195
;1 DATE: 27 August 1()84
i i i::
PAGE 1 OF 8
SUBJECT: RIVETING TIP-CAP TO TAIL ROTOR BLADE
MODELS AFFECTED: All 369H, 369HS, 369HE, 369HM, 369D, 369E and OH-6 Series
helicopters having any PN 369A16i3-7, 369A1613-503, 369D21613-11,
369D21613-41, 369D21613-51 or 369D21615 Tail Rotor Blade installed
which has any of the following serial numbers, and any of the
affected parts in spares inventory, as individual blades or as part
of spare tailrotor assemblies.
Serial Serial
Part Number Number Part Number Number
369A1613-503 4148 0233

4842 0365
3 6 9A16 13- 7 3636 3 6 9D 2 1613- 1 1 1379

-41, -41 1766
369D21615 0081 1767
0083 1905
0084 1947
0088 1958
01.01 1968
0141 1975
0142 1976
0143 1982
0144 2021
0145 2022
0146 2027
0147 2038
0148 2039
0149 2040
0150 2042
0151 2043
0152 2054
0153 2045
0154 2064
0155 2075
0146 2104
0157 2108
0158 2218
i:I 0159
0160
2219
2226
Customer Service Dep~rtment

I
FOR~ 9578 (2/81)

Hughes Helicopters, Inc. Culver City. California 90230
A Subsidiary of McDonnell Douglas
NOTICE NO. DN-129
Hughes Helicoptenr, Inc.
EN-18 A Subsidiary of McDonnell Douglas
HN-195
DATE: 27 August 1984
PAGE 2 of 8
S eria% S eri al
3350
369D21613-11, 2244
3351
-41, -51 2251
3352
(continued) 2252
3353
2298
3354
2299
3355
2303
3356
2321
3386
2351
3407
2352
3408
2361
3437
2362
3438
2399
3439
2400
3440
2933
3441
2943
3442
2944
3443
2967
3444
2978
3445
2982
3446
2983
3447
2995
3448
3008
3095 3449
3450
3129
3441
3144
3442
3179
3453
3184
3205 3454
3455
3237
3456
3271.
3476
3337
3543
3338
3548
3339
3636
3341
3642
3342
3657
3343
3648
3344
3659
3345
3660
3346
3347
3661
3348
3662
3349
Hu~hes Helicopters, Inc. NOTICE NO. DN-1.29
A Suhsldlary of Mcnonn~-ll Douglas EN-18
HN-195
DATE: 27 August: 1984
PAGE 3 of 8
S eria~ S eri al
3663 3855
369D 21613-11
3664 3846
-41, -51
3665 3857
(continued)
3666 3858
3667 3859
3668 3860
3697 3861
3698 3862
3701 3863
3702 3864
3705 3875
3706 3876
3746 3877
3793 3878
3795 3881
3804 3882
3805 3883
3806 3884
3807 3885
3808 3886
3809 3887
3810 3888
3811 3890
3812 3896
3813 4066
3837 4107
3838 4108
3839 4113
3840 4114
3841 4115
3842 4116
3843 4117
3844 4118
3845 4129
3846 4134
3847 4135
3848 4136
3849 4137
3840 4138
3851 4141
3852 4142
3853 4159
3854 4187
NOTICE NO. DN-129
EN-18HN-195 Hughes Helicoptets,

A
Inc.
Subsidiary of McDonnell Douglas
PAGE 4 of 8
Seri.al Serial
Part Number Number Part: Number Number
36 9D 21613- Il, 4188 4204

-41, -41 4189 4206
(continu.ed) 4190 4213
4191 4214
4192 4215
4193 4216
4194 4217
4195 4218
4196 4219
4197 4220
4198 4221
4199 4222
4200 4223
4201 4224
4202 4226
4203 4288
4204 4488
NOTICE NO. DN-129
EN-18
ga Hughes Helicopters,
A
Inc.
HN-194
PAGE 4 of 8
TIME OF COMPLIANCE:: Shall be accomplished prior to further flight for all

installed affected blades having more than 100 hours
total time in service. Shall be accomplished within
the next 25 hours of operation for all affected blades
having less than 100 hours total time in service. Shall
be accomplished prior to installation of any affected
blade from spares.
PREFACE: This Service Notice gives procedures for riveting tip cap assemblies
to the affected tail rotor blades. Debonding of the tip cap from the
blade could occur, causing loss of the tip cap during operation of
the helicopter.
Reference
Basic Handbook of Maintenance Instructions (CSP-H-2), Reissued 14 September 1981.

369D HMI Volume 1 (CSP-D-2), Reissued 15 January 1982; Revision 3, 15 August 1983.
C
NOTICE NO. DN-129
EN-1S
HN-195 A Subsidiary of McDonnell Douglas
PAGE 6 of 8
C
PI/IATERIRLS
Nomenclature Spec Source
Rivet, Blind NAS1739B4-2 Commercial
Primer, Zinc Chromate TT-P-1747 Commercial
Epoxy, Clear Commercial
TOOLS AND ERUIPMENT
Nomenclature Source
Drill Motor, Portable Commercial
Countersink 1000 P10, with Commercial

.o
30 N ,
pilot
Rivet Tool, I>neumatic, G-784 or G689 Cherry Rivet Division

1224 E. Warner Ave.
Santa Ana, CA 92707
Phone: (714) 445-5511
and
Pulling Head, H681-4C Cherry Rivet Division
or
Hand Riveter, G-36 Cherry Rivet Division
and
Pulling Head, H615-46 Cherry Rivet Division
j:
NOTICE NO. DN-123
EN-1S
Hughes Helicopters, Inc. HN-194
A Subsldlaryy o( Fni~orlncll Un~lql;ls
DATE: 27 August L9:i-
PAGE 7 of 8
PROCI~DURE
a. Remove blade from helicopter (Section 8, appropriate ref HMI).
evidence
b. Visually inspect tip cap-to-blade bonding for failure. If any
of debonding is~noted, replace blade (Section 8, appropriate ref HMI).
CAUTION
Handle blade carefully. Dents, nicks or scratches

may cause balance problems at reinstallation, or
make blade unserviceable.
With blade on a clean hard surface, measure and mark locations for
c.
rivet holes as shown in Figure i.
d, No. 27 drill, carefully drill holes at locations marked on outboard

Using
and inboard surfaces of blade.
+10 countersink with No. 30 pilot, countersink holes to

e, Using 100
0.035 inch maximum depth.
zinc chromate primer to holes and install NAS1739B4-2 blind rivets

f. Apply
while primer is wet.
Coat installed rivets with clear epoxy.

g.
h. Reinstall blade on helicopter (Section 8, appropriate ref HMI).
i. Check and adjust tail rotor blade balance (Section 8, appropriate ref H~4I).
with this Notice in Compliance Record of helicopter

j. Record compliance
Log Book.
in
The resultant alteration to affected models as described by the procedures
with Federal Aviation Regulations and is
this Notice has been shown to comply
FAA Approved.
NOTICE NO. DN-129
EN-18
HN-195
Hughes Helicoptenr, Inc.
A Subsidiary or McOonnell Douglas
PAGE 8 of 8
n. 69 INCH
ALONG BL.ADE
CONTOUR
I, 0. 38 1 NCH
INCH
n.30
INCH
N3~E
I 0. 25
INCH
n, so INCH
ALONG BLADE
CONTOUR
N3TE
NAS 1739B4-2 R IVET (4 PLACES)
NI)TE:
USE NO. 27 DR i LL AND 100o COUNTERS I NK
WITH NO. 30 PILOT. COUNTERS INK TO
M.9XIMJM 1.035 INCH DEPTH. INSTALL
NAS 173984-2 R IVET. SEAL R IVET W ITH
CLEAR EPOXY.
SR-bnl
Figure 1. Installation Tip Cap-To-Tail Rotor Blade
BY ATP.
ORLGIKRL n3 RECEIVED
NOTICE NO.p HN-197.2u
DN-136.2~e
FN-;t7. 1~
SERVICE 93%dFOIFaO~BTION NOTICE
DATE: March 23,1987
PAGE 1 OF 6
MANDATORY --h-a~ IIIIIIIII MA N DATO R Y I~-II

NIAN DATORY
Service Infarmatian
Notices HN-IS7.1, DN-130.1, EN-
i9.iwnd FN-17 dated 15 April
1986.
S U B +7 F CT INSPECTION OF TAIL ROTOR BLADE LEADING EDGE ABRASION

STRIP BONDING.
MODELS AFFECTED I F5CIRT I and PART II All McDonnell

Douglas Helicopter Company 369 Seri~8 helicopters including
the 369A (OH-LA) which have the following tail rotor blades
installed 569D21606, 369021615-11, -41, -51, 369821615,
369Ai619-7, and 421-(388.
T I ME OF COMP L ~T ANCE PART I of this Natice shall be

accomplished on all helicopters within the nep(t 100 haurs of
helicopter aperation ar three months, whichever comes first.
PART I shall be accamplished an all tail ratar blades and tail
rotar assemblies in spares inventory prior to instillatian an
~s
any helicopter. PART 11 shall be accomplished at each
preflight check (Pilots walkaround check).
P~EFACE I PART I describes procedures far a dye

ot: this Notice I
penetrant and inspection of all tail rotar blades far

tap test
evidence of abrasion strip to blade band tiepar~tion. This
procedure may also be used to canfirm suspected abrasian
separation while performing PART XI af this Notice.
PART fI describes pilot preflight check of the tail

a visual
rotor blade leading edge strip for evidence af
abrasion
possible separation between epoxy band and abrasion strip,
particularly along the abrasion strip to blade bbnd line at
the blade tip. It is ta be noted that a closer check with a
IC~X magnifying shall be perfarmed if any evidence ofband
separation is suspected.
REFERENCES
369D HMI Vol.I (CSP-D-2) Revised 15 June 1985

369F HMI Vol.I (CSP-F-2) Revised 15 April 1986
369H HMI Basic (C8P-H-2) Revised 15 June 1985
Applicable FRA Approved Pilots~Fright Manual
(I) Denotes partian of tewt revised ar added.
Pfoduct Support Department
FORM 8578 (2/01)

NOTICE NO.~ HN-197.2~
DN-130.2Je
FN-17.I~
DCITEl March 23,1987
PCIQE 2 OF b
MCITERICILS
Nomenclature Source
Masking Tape Commercial

CIbrasive paper, silicon carbide (220 grit) Commercial
Dye Penetrant Kit Commercial
(Visible dye, Solvent removable)
TOOLS ANP EPUIPMENT
Magnifying glass (SX and 10X) Commercial

Drill bit, i/B inch Commercial
PERT f Dye P~netrant And Tap Test Inspection
Using a standard 1/8 inch drill bit and a pencil, fabricate a

tapping hammer by taping drill bit to pencil as shown in Figure i.
Drill bit should be minimum of ~iH inches from end of pencil that is
to be held while tapping.
E. Using fabricated tapping hammer, tap test the entire abrasion

the
strip. Hold end of pencil opposite drill bit and tap with shank
r (rounded) end of drill bit. If void indications are noted, remove
blade from service.
NOTE
V~ids are indicated by a dull, dead tone.
Slight tone changes will occur near the tip cap

and along the length of the strip. These should
not be mistaken for voids.
C. Mask area of blade around abrasion strip with masking tape.
CAUTION
Do not usa chemical paint remover to remove
paint from abrasion strip. Chemicals can attack

the abrasion strip to blade banding agent,
D. Using 226 grit abrasive pap~r, sand dry, removing all paint from the
abrasion strip. Ensure abrasion to airfoil bondline is e~posed.
Clean paint dust from blade.
i
NOTICE NO.~
DN-190.2~
EN-I9.2a
FN-17.1+
DATEt March 25,1987
PCI(3E 3 OF b
NOTE
Do not remove masking tape from blade until

completion of dye penetrant
E. Visually check abrasion strip to blade bonding using a iOX

magnifying glass. If bond failure is obvious, remove blade from
service.
F. Dye penetrant according to manufacturers instructions and

inspect,
this Notice, entire abrasion strip to blade bond line, including
abrasion strip bond in blade tip cap area. Apply penetrant using a
small brush or swab to prevent damage to blade paint, and to
minimize clean-up. Allow penetrant to remain on surface of abrasion
strip bondline for five minutes minimum. Use dry lint free cloth or
paper towel to remove excess penetrant. Apply remover to cloth or
lint free towel to remove remaining surface penetrant. Never spray
or flush area of inspection with cleaner. Ensure thorough penetrant
removal from surface before applying developer.
i;:::::
G. Apply a light film of developer on the area of examination.
H. Using a magnifying glass, examine bond ii,, to determine if

SX I
penetrant dye is indicating a bond separation (refer to NOTE which
follows). If any bond separation is noted, remove blade from
servi ce.
NOTE
The epoxy adhesive used to bond abrasion strip

to blade may have porosity voids. The penetrant
will form a circular pattern around voids
resulting from porosity. These circular
patterns do not indicate bond failure. Rond
failure is by penetrant
indicated bleedout from
under the strip, and will appear
abrasion as a
line along the edge of the strip. The ZSX

magnifying glass will lid distinguishing
between porosity voids and bleedout from under
the strip. It may be necessary to wipe
abrasion
off, then reapply the developer to distinguish
between porosity voids and bond separations.
The most positive indication of bond failure
will normally appear during the first one to
i seven minuter following developer application.
NOTICE NO.i HN-197.2~
DN-13Q.2~e
r-i;
EN- i 9. 2+
FN-17. i 3e
DATEI March 23,~987

PCSOE 4 OF b
I. Remove masking tape from blade.
J. Inspect blade for cleanliness and paint damage. Clean and repair
and Basic HMI).
paint damage as necessary (Section 2, HMI Vol.I
NOTE
Do not repaint abrasion strip or abrasion strip

to blade bond line.
K. Check tail rotor balance (Section 8, HMI Vol.T and Basic HMI).
L. Record compliance with Part f of this Notice in Compliance Record

section of the helicopter Log Book.
M. If blade is removed from service because of separation or voids,

notify an Approved MDHC Service Center or Distributor for
are found shall be sent
di~position. Those blades in which voids
an Approved repair station for abrasion strip replacement.
PART II Pilots Preflight Check Procedure
evidence
A. Visually check each tail rotor blade abrasion strip for Any
of bondfailure along the abrasion strip/airfoil bond line. (See
Figure i.)
NOTE
Step B is to be performed only if evidence of
separation along the abrasion strip/airfoil

bond line is suspected.
B. Using a iOX magnifying glass, closely check along abrasion

strip/airfoil bondline and at blade tip for any separation between
epony adhesive and abrasion strip. Any separation between bonding
adhesive and abrasion strip is cause for removal of blade from
service. (See Figure i.) If separation is suspected, but not
confirmed, inspectper PART I 09 this Notice.
MOTE
The epony adhesive used to bond the abrasion

strip to the blade may have porosity v~ids.
Small porosity
~eparation.
voids should not be mistaken for
C.
t
NOTICE NO.:
X~N- i 31.,. 2~e
1.9. 2+
DCSTE:
PCIGE 5
March
23,~9U7E:W-
F"N-- 1. 7. lw
Or-" b
WEIGHT AND BALANCE
W~jglIC ancJ ban.ancr~ noZI
"lh~ ue?;l..lllzi~nl-. ~ltevation tu tl-~e affect~d by thF; anc~--
tim~ intrjp~ctian prrflight pruccdures in

ci3nd thie~j Natict~ b~en ~hawn
to c=amply wi41~ F:~deual Regl.~Xatlance wnd ipj F:~8 8pprnv~d.
C
NOTICE No.: DN-1481
EN-361
FN-25 i

PAGE 6 of 7
Ii~41_1(
UNACCEPTABLE ACCEPTABLE
ANY BULGING oR RAIS[O

SURFACE IN TH 15 AR~*
15 NOT ALLOWED ON THt
UPPER DISK SURIACE
(INSPECT TOTAL
CIRCUMFERENCEI
ORIGINAL
As Received By
ATP
Figure 2, inspection of Upper Web of Output Shaft.

NOTICE NO.: HN-198.1*
DN-131.1*
EN-20.1*
;p;a FN-8.1*
PAGE 1 of 8
SERVICE 1NFOWRnATIBN NOTICE
MAN DATo RY MAN DATo RY 1 I I i I MAN DAToRY
*Supercedes ServiceInformation Notices

HN-198, DN-131, EN-20 and FN-8 Dated 14 November 1984.
SUBJECT: CORROSION REMOVAL AND MAGNETIC RUBBER INSPECTION OF MAIN ROTOR

DRIVE SHAFT I.D.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369 Series helicop-
ters, including the 369A (OH-6A) Series helicopters.
TIME OF COMPLIANCE: This Service Information Notice shall be complied with whenever
corrosion is found or cracks are suspected on inside diameter surfaces of main rotor
drive shaft or if corrosion pits were previously found and an inspection for cracks was
not accomplished at that time.
PREFACE: The information in this Notice provides procedures for removal of corrosion on the
inner surfaces of 369A5500 and 369025510 series main rotor drive shafts and
restoring the protective coating on the I.D. This Notice also provides procedures for
performing a magnetic rubber inspection of the main rotor drive shaft l.D.
NOTE
DYNAMOLD magnetic rubber contains ferromagnetic particles
(colored contrast) which accumulate at any surface
black for
cracks by magnetic attraction, thereby permitting the cracks to
be discerned.
The information given is to be considered as part of the HM1 and will be incorporated
at the next scheduled revision to the below referenced manuals.
REFERENCE
3690/8 HMI Vol.l (CSP-D-2), Revised 15 June 1985

369F/FF HMI Vol.l (CSP-F-2), Revised 15 April 1986
369H Basic HMI (CSP-H-2), Revised 15 June 1985
~I) Denotes portion oi text added or revised.
PARTS LIST
Cork 23420-515-24 1 MDHC

plug
1 Procince Sup!,ori
FORIUI 9578 (2/81)

DN-131.1*
EN-20.1*
FN-8.1*
PAGE 2 of 8
MATERIALS
Nomenclature Source
Sealing compound (Mll-S-7502) Commercial
Epoxy primer Advance Coating and Chemicals

Base (1-1G-69) 1 4343 Temple Blvd.
Catalyst (1-1H-75) I Temple City, CA 91780

Epoxy enamel Advance Coating and Chemicals
White #37875 1 (listed above)
MIL-C-22750
Surface cleaner CTT-C-490) Turco Products, Inc.
P/N WO-1 Wilmington, CA.
1,1,1 Tricloroethane, Commercial
technical inhibited
0-T-620
Cement, polysulfide Product Research

P/Ns 247, 890 or
PR1221B-2
Burbank, CA. C:
Wash, primer Commercial
MIL-C-8514
Adhesive tape Commercial
Dynamold magnetic rubber, kit See list below

P/N MR-502K (1 quart)
Note: shelf-life is 10
months after date received
Domestic and International suppliers of Dynamold magnetic rubber:

Dynamold, Inc. Quality Concepts
2905 Shamrock Ave. 7825 Hillmont
Fort Worth, TX 76107 Houston, TX 77040
817-335-0862
telex: 379-1940 DYNAM Sofratest
39 Bis rue, du D Maurer
Norwest Company 78630 Crgeval, France
5729 Lakeview Dr. NE (3) 975-99.09
Seattle, WA
206-827-9562 Citicorp Air
Singapore
DN-131.1*
EN-20.1*
FN-8.1*
PAGE 3 of 8
Hannah International Matcon

Hongik Bldg. Kwanhoon Dong Singel386
Chongro-Ku, Seoul, Korea 1016 AJ Amsterdam, Holland
733-8234-5 020-238278
Citicorp Air Staveley NDT Technologies

Tel Aviv, Israel Inspection Instruments Division
712 Banbury Ave.
248801
Slough Berks SL1 4LH, England
Slough 0753-76216
Citicorp Air
Moreno 970 of 13 NDT Italiana SAS
1091 Buenos Aires, Argentina viale Monza, 190
32-2809, 34-4097 20128 Milano, Italy
2576089
Citicorp Air
Aerospace Dept. Aviation and Industrial Distributors
Okura Co. Okura Annex 38 39 Church Street
4-1 Ginza 3-Chrome Onehunga, Auckland, New Zealand
chui-ku, Tokyo, Japan 641-403
03-535-3550
Citicorp Air
Candet Melborne, Australia

18 Canso Road
Labratory Supply
Rexdale, Ontario, Canada M9W 4L8
2057 Princes Hwy.
416-243-3456
Clayton, Victoria, Australia
03-543-1155
TOOLS AND EQUIPMENT
Nomenclature Source
Brush, wire or rotary Commercial
Inspection unit, Commercial

magnetic particle"
Cord,l/8 inch x 36 inch (qty. 3) Commercial
Mixing cup, graduated Commercial
"Capable of holding the 369D25510 and 369A5500 main rotor drive shaft securely in a level
(horizontal) position during the inspection and curing period. The magnetic particle inspection
unit must have a coil capacity of 2500 ampere turns (longitudinal field).
DN-131.1*
EN-20.1*
FN-8.1*
PAGE 4 of 8
PROCEDURE
a. Remove main rotor drive shaft (Section 9, applicable HMI).
CAUTION
Care shall be taken not to

removing cork plug.
damage inner bore of drive shaft when
I
b. Using suitable scribe or penknife, carefully remove cork plug from end of drive shaft.
Lightly abrade inner surfaces of shaft using crocus cloth to remove any cork remnants.
c. Degrease entire drive shaft inner diameter (ID), using 1,1,1 trichloroethane.
d. Inspect interior of drive shaft for corrosion with suitable light or borescope~
NOTE
Corrosion will appear as flaking or raised surface areas of drive
shaft ID.
e. Using a fine wire rotary brush or wire brush, remove corrosion and contaminants from
the drive shaft ID.
WARNING
Turco WO-1 will irritate the skin; always use rubber gloves when
handling this material. Wash skin exposed to Turco WO-1
thoroughly with water.
f. Using swab and extension rod, swab ID of drive shaft with Turco WO-1, diluted one part
to four parts water.
rinse drive shaft ID with distilled water and dry with clean compressed air.
g. Thoroughly
h. Using suitable light or borescope, inspect shaft ID for additional corrosion and pitting.
i. If required, locally hone drive shaft ID to remove corrosion using wire or rotary brush.
Blend honed area with existing surrounding area.
j. Verify drive shaft ID does not exceed 1.655 inches. If corrosion removal causes or would
cause shaft ID to exceed 1.655 inches, replace shaft. If any cracks are noted, replace
drive shaft.
DN-131.1*
EN-20.1*
FN-8.1"
PAGE 5 of 8
k. Perform Dynamold magnetic rubber inspection per the following steps:
NOTE
If corrosion is localized to one area of the shaft ID (120 degrees
or less of 1D circumference), only one replicant has to be made.
1. Set up magnetic particle inspection unit to hold driveshaft secure during the inspection
and curing period. Set up coil shot (longitudinal field) at 2500 ampere turns
DC.
ID of drive shaft
2. Place cord through the ID bore and leave ends ha?ging out and plug
by taping gear end closed with cord hanging out.
with stirring
3. Per Dynamold manufacturers instructions, thoroughly mix MR-502K
the rubber liquid. Make sure all
stick mixing all sediment (magnetic particles) into
lumps are mixed into a smooth consistent streak free condition.
4. Pour 10.5 fluid ounces into mixing container and add catalyst per manufac-
(300ML)
turers instructions. Stir this mixture for approximately 30 seconds.
the hub end using
5. Quickly pour the entire 10.5 ounces (300ML) into the 10 bare. Plug
of magnetic rubber will cover
tape, leaving the cord hanging outside. This amount
ID.
120 degrees of circumference over the entire length of the drive shaft
unit with the
6. Immediately place the drive shaft in the magnetic particle inspection
shaft positioned horizontally and secure.
the
7. Begin magnetizing the drive shaft using the coil (longitudinal field) moving along
between
entire length of the drive shaft in approximately four (4) inch increments,
each pulse (1/2 second shot). This should take 35 to 40 seconds.
in a safe area
8. Remove drive shaft from magnetic particle inspection unit and place
after mixture has set up. Ensure drive shaft is not rotated and in same position as it
for approximately 30 minutes or longer
was magnetized and continue curing process
if curing is not completed.
e~3 CAUTION
Dynamold rubber material, when cured, will feel soft and pliable
to the touch and will tear easily if not handled carefully during
removal
9. When mold has cured, remove tape from both ends

of drive shaft. The exposed ends
continue removing
will be indicators of the cure. rate. Using the cord to lift each end,
the mold.
I. If additional replicas are required, repeat steps K-l through K-9.

DN-131.1*
EN-20.1*
FN-8.1*
PAGE 6 of 8
NOTE
Questionable replicant indications shall be carefully packaged
and sent to MDHC for evaiuation. If considerable corrosion is
noted, the drive shaft can be sent to MDHC Warranty and Repair
Department for inspection and interpretation.
If any cracks are noted, scrap and replace shaft (see Figure 1.)
See Figure 2 for location of acceptable machining indications.
m. Clean shaft ID.
n. Apply one coat of wash primer to drive shaft ID according to manufacturers instructions.
CAUTION
Do not allow epoxy primer or epoxy enamel to contact drive. shaft

splines or mounting surfaces.
o. Fill shaft with epoxy primer mixed according to manufacturers instructions to slosh-coat
the shaft ID. Drain primer from shaft. Ensure that shaft ID is completely coated. Allow
primer to dry one hour at room temperature.
p. Apply two coats of white epoxy enamel to drive shaft by filling and draining shaft. Allow
enamel to dry 48 hours at room temperature or let dry 30 minutes at room temperature,
then cure for three hours in oven at 250-275 degrees F.
q. Install cork plug to rotor end of drive shaft by applying a thin coat of adhesive to ID of
shaft end in which cork is to be installed and all cork plug surfaces. Press cork into shaft
until top of cork is flush with top of drive shaft. Allow adhesive to cure according to
manufacturers instructions. Apply a second coat of adhesive to all exposed surfaces of
cork; allow to dry.
r. Reinstall drive shaft in helicopter per applicable HMI, Section 9.
s. Record compliance to this Service Information Notice in the compliance record section
of the helicopter Log Book.
NCTICE No.: HN-1981
3N1311*
EN-201
FN-81
DATE: 30 Ocfaber 1987
PAGE 7 of 8
OL LI-l:*i r ri 102
10 Oli i;ii"ll
020170 030 TOOi CA*CII
i~
s~
:~,il%a
INTLRNIICPICI \IHOL~IS OIO-
N LtY~Tn
;:;i:::
snau cnirii :i i I r
IND CATIONS OF CRACKING

WHEN VIEWED WITH A
1OX MAGNINING GLASS
(UNACCEPTABLE DRIVE SHAFT)
F gure 1 inspection of Main Rotor Drive Shai:.~;:;:; ii,rrete

DN-131.1*
EN-20.1*
FN-8.1*
PAGE 8 of 8
ACCEPTABLE MACHINING
IMARKS (INDICATIONS,
Figure 2. Location of Acceptable Machining Indications.

J
~N-l 32.1*
s-b
-iLi 31 li-i.,
NO~TICE NC? FN-9.1*
1 :X! :1." .J99:9,r151n~p X4
i
HN-1991*
,ji ii
_
oaTE:
1~3=
01 May 1985
~..4
PaGE OF 7
*Supercedes Service Information Notices DN-132,

EN-21 FN-9 and HN-199 dated 6 December 1984.
r\EIANDi~TQ i~Y; I;: R \I
N1 A 1\! DATO Y
SL)GjECT. RIVETING TIP-CAP TO TAIL ROTOR BLADE
MODELS AFFECTED. Part I All 369A (OH-6A), 369D., 369E, 3ti9F, 369H, 369HE, 369HF1,
and 369HS Series Helicopters
having any of the following part
number tail rotor blades installed, with serial numbers not
listed in Hughes Service Information Notices
DN-129, EN-18
and HN-195, dated 27 August 1984, and all such blades
in spares i
inventory.
AFFECTED BLADE PART NOS

i
369A1613-3, -7, -501 and -503
369D21613-BSC
369021613-11, -41 and -51
3691321615369D21606
421-088-850 and -3
Part Ii All
369A, 3690, 3695, 369F, 369H, 369HE, 369HM and
369HS Series Helicopters on which procedures in Part I of this
Notice or Hughes Service Information Notices No.
DN-129, EN-18
and HN-195 are performed, and all
spare tail rotor blades on
which the procedures are performed.
TIME OF COMPLIANCE: Part I shall be accomplished within the next 100 hours of
operation for all affected blades in service.
Shall be accomplished prior to installation of any affected

blade from spares.
Part shall be performed as

II
requi~ed, while performing
Part I of this Notice, or while
performing procedures in
Hughes Service Information Notices No. 0N-129, EN-18 and
HN-195.
PREFACE: Part I of this Notice gives procedures for riveting tip-cap assemblies
to the affected tail rotor blades. Debonding of the
tip-cap from the
blade could occur, causing loss of the tip-cap during operation of the
helicopter.
~:I (I, On.Les port-ion of toxr added or rruijed~
Customer Senice Deptuzment

sl IPI
w
FORM 9518 (2/81)

Hughes Helicoptets, Inc. Culver City. California 30230
A Subsidiary of McDonnell
,a
6 4 ""h~g)
-j
NOTICE NO.
DN-132.1"EN-21,1~
FN-9.13(
HN-199.1*
DATE 01 May 1985
PAGE 2 OF 7
PREFACE: Part II gives procedures for removing FOD from the blade interior,
(Cont.) should removal of the rivets holding the tip-cap be required.
All tail rotor blade assemblies manufactured by Hughes after
21 December 1984, will have the tip-cap riveted to the blade at
the factory.
REFERENCE
Basic Handbook of Maintenance Instructions (CSP-H-2), Reissued

15 September 1981.
3690 HMI Volume I (CSP-D-2), Reissued 15 January 1982; Revision 3,

15 August 1983.
369F HMI Volume 1 (CSP-F-2), Issued 1 March 1984.
Hughes Service Information Notice No. 0N-129, EN-18 and HN-195, Issued
20 November 1984.
j
NOTICE NO. DN-132,1~
EN-21.13(
FN-9 .1*
HN-199 .1k
DATE 1985
~1OFMaY
PART I RIVETING TrP-CAP TO BLADE
MATERIALS
Nomenclature Spec. Source
Rivet, Blind NAS1739B4-2 Commercial

Primer, Zinc Chromate TT-P-1757 Commercial
Epoxy, Clear Commercial
TOOLS AND EQUIPMENT
Nomenclature Source
Drill motor, Portable Commercial

O
Countersink, 100 +1 O, with Commercial
No. 30 Pilot
Rivet Tool, Pneumatic 6700, 6784 or Cherry Rivet Division
G 689 1224 Warner Ave.
Santa Ana, CA 92707
Phone: (7141 115-S5L1
AND
OR
Hand Riveter, 6-36 Cherry Rivet Division
AND
PROCEDURE
a. Remove blade from helicopter (Section 8, appropriate Ref. HMI).
b. Visually inspect tip-cap to blade bonding for failure. If any

evidence of debonding is noted, replace blade (Section 8, appropriate
Ref. HMI).
CAUTION
Handle blade carefully. Dents, nicks or
scratches may cause balance problems at

or.aie blade unservice-
NOTICE NO. DN-132,1*
EN-21,1*
FN-9.1k
HN-199.1"
DATE 01 May 1985

PAGE 4 OF 7
c. With blade on a clean hard surface, measure and mark locations for
rivet holes as shown in Figure 1.
CAUTION
Ensure that locations for rivet holes

are correctly marked.
d. Using No. 30 drill, carefully drill holes at locations marked on

outboard and inboard surfaces of blade.
e. Using 100 _t10 countersink with No. 30 pilot, countersink holes to

0.035 inch maximum depth; carefully openholes to 0.144 inch diameter
using No. 27 drill.
f. Apply zinc chromate primer to holes and install NAS173984-2 rivets

while primer is wet.
NOTE
If it is necessary to installed
remove
rivet for any reason, perform Part II
of this Notice to remove FOD from blade.
g. Coat installed rivets with clear epoxy.
h. Touch-up paint as necessary (Section 2, appropriate Ref. HMI).
CAUTION
Do not use paint strippers when performing

paint touch-up. Bond joints can be damaged.
i. Reinstall blade on helicopter (Section 8, appropriate Ref. H~IJ.
j. Check and adjust tail rotor blade balance (Section 8, appropriate

Ref. HMI).
k. Record compliance with Part I of this Notice in Compliance Record

of Helicopter Log Book.
i
NOTICE NO. DN-132.1"
EN-211"
FN-9.1*
HN-199 1"
DATE 01 May 1985

PAGE 5 OF 7
PAP II REMOVAL OF FOD FROM BLADE INTERIOR
MATERIALS
Nomenclature Spec. Source
Fiberglass Cloth, No. 120 Commercial

Resin, Epoxy 3135A and B Crest Products Corp.
2000-T S. Susan St.
Santa Ana, CA 92704
Phone: (714) 540-9087
OR
Any 2 part (1:1)

Clear epoxy resin
l,l,l-Trichloroethane 0-T-62O Commercial

Emery Cloth Commercial
TOOLS AND EQUIPMENT
Nomenclature Source

Drill, 1/4-inch Commercial
PROCEDURE
a. Drill 0.250 inch diameter hole through tip-cap as shown in

Figure 1.Tip-cap is 3.070 inch thick at thepoint tobe drilled.
b. Remove FOD from blade interior through hole.
CAUTION
Trichloroethane may damage blade paint

finish.
c. Abrade surface surrounding hole using emery cloth; wipe clean

using clean cloth dampened with trichloroethane.
d. Bond two plies of 120 fiberglass cloth over hole with 3135A
and B epoxy resin, or equivalent. Allow epoxy to cure according to
manufacturers instructions.
CAUTION
Do not allow resin to build-up in

hole.
NOTICE NO. DN-132,la
EN-21.1*
FN-9,1J(
HN-199,l~t
DATE 01 May 1985

PAGE 6 OF 7
The resultant alteration to affected models as described

by procedures in
this Notice has been shown to comply with Federal Aviation
Regulations
and is FAA Approved.
j,
NOTICE NO. ON-132.1"
EN-21.1"
FN-9.1*
HN-199.1"
DATE 01 May 1985

PAGE 7 OF 7
r-0.69 INCH
BLADE
_te
0.a INCH
INCH0.38
0.30 i i 0.25
INCH i INCH
NOTE
--i
~----o.solNCH
ALONG BLADE
CONTOUR
NOTE
NAS 173984-2 RIVET(4 PLACES)
NOTE:
USE NO.3n DRILL AND Inno COUNTERS INK
WITH N0.3n PILOT. COUNTERS INK TO
MAXIMUM n.n3j INCH DEPTH. REDRILL HOLE
WITH NO.27 DRILL. APPLY ZINC CHROMATE
PRIMER TO HOLE. INSTALL NAS 173S84-2
R IVET WHILE PRIMER IS WET. SEAL R IVET
WITH CLEAR EPOXY
RIVET INSTALLATION
o.no
INCH.~O
DIA HOLE NOTE
Q$
9
AFTER REMOVAL OF DEER IS SEAL.as

DIA. HOLE W ITH 2 PLIES OF 120 FI BERCLAS S
CLOTH 3135 A&B EPOXY RESIN (CREST
-I
PRODUCTS OR EQUIV) AS SHOWN.
SURFACE PREPARATION: ABRADE SURFACE
WITH EMERY CLOTH AND WI IPE WITH
i. I. 1-TRICHLOROETHANE SOLVENT. HOLE ~OCATION
DO NOT ALLOW RESIN TO BUILD UP IN
.ao oiA HOLE.
NOTE:
FIBERGLASS THIS AREA.
DO NOT PLACE FIBERGLASS CLOTH
OVER OPENING FOR BALANCE WEIGHTS.
1: 88-606
Figure i. Riveting Tip-Cap to Blade; FOD Removal from Blade Interior.
OR)GIKAL Ri R rcEE!rV;.D BY ATP.

DN-133
ii EN-22
~:"I-:Z%-i~
NOTIC:E
DATE
NC. FN-10
18 March 1985
PAGE 1 OF 7
Bj\l DATO RY lan A~ DArrs ~f d AFJ DA~Ta Wi 7
TO: All I,icensees, Service Centers, Distributors, Owners and Operators

of Iiughes Helicopters
SUBT~CT: Cancellation of Warranty
~DELS AFFE~E=D: 500D, 500E, 530F
The attached listing identifies serial rnrmbers 05 aircraft and spare parts
that are suspected of having reached an unauthorized destination.
EFFECTIVE IMMEDIATELY:
i. Hughes Helicopters warranty is VOID on aircraft and components listed

in the attachment.
2. Components are not eligible for overhaul or repair.
3. Notify Hughes HelicoptersProduct Support, Tel: (213) 305-3656, if

any of the listed components are received for overhaul, repair,
inspection or service.
NOTE: Hughes standard warranty will be reinstated an any aircraft

and components listed if utilized in an authorized location.
Z~a ~cLj,
Product Support Tecfn~-lical
Customer Senrice Deprutment

~IPBI ---5---- -1 I ~C- -Q;~-----
FORY 8578 (2/81)

Hughes Helicoptetd, Inc. Culver city. California 90230
Notice No. DN-133
FN-10EN-22 Hughg~
A
Inc.
Date 18March 1985
Page 2 of 7
SERIAL NLTMBER LIST
Helicopter Serial Number
0010F 0044E 0063E 0087E 1119D

0003E 0045E 0064E 0088E 1126D
0017E 0046E 0065E 0089E 1132D
0023E 0047E 0066E 0090E 1133D
0024E 0048E 0067E 0091E 1134D
0026E 0049E 0068E 0092E 1139D
0027E 0050E 0069E 0093E 1140D
0030E 0051E 0070E 0096E 1141D
0031E 0053E 0071E 0097E 1178D
0032E 0054E 0072E 0098E 1179D
0034E 0055E 0073E 0099E 1180D
0035E 0056E 0074E 0100E 1195D
0036E 0057E 0075E 0101E 1196D
0038E 0058E 0076E 0108E 1197D
0040E 0059E 0077E 0116E 1199D
0041E 0060E 0078E 1046D 1202D
0042E 0061E 0079E 1080D 1203D
0043E 0062E 0080E 1085D 1204D
Main Rotor Blade P/N 369D21100

(500D and 500E)
A001 A141 A250 A340 A394

A002 A144 A262 A342 A395
A007 A145 A266 A345 A399
A015 A147 A268 A347 A412
A020 A149 A271 A351 A425
A023 A150 A273 A355 A433
A030 A153 A276 A358 A452
A032 A158 A284 A359 A454
A045 A174 A287 A361 A482
A049 A176 A291 A364 A490
A050 A180 A295 A366 A506
A056 A182 A296 A367 A516
A059 A184 A303 A368 A520
A064 N188 A304 A370 A523
A068 A189 A306 A373 A525
A070 A191 A309 A374 A536
A082 A196 A310 A377 A543
A097 A199 A313 A382 A548
A104 A201 A321 A386 A551
A107 A213 A322 A388 A556
A108 A215 A326 A389 A563
A132 A231 A327 A390 A566
A138 A238 A333 A391 A567
A140 A240 A336 A393 A571
Notice No. DN-133
Inc. EN-22
Hughe Welicoptsrr,
A Subsidiary of McDoonell Douglas FN-10
Date 18 March 1985
SERIAL NUMBER LIST (CONT) Page 3 of 7

(500D and 500E) (Cont)
A572 A695 A780 A885 A970

A574 A697 A781 A886 A973
A577 A698 A782 A891 A977
A578 A700 A784 A893 A979
A580 A701 A786 A898 A984
A581 A703 A787 A900 A985
A588 A704 A791 A902 A987
A590 A706 A793 A903 A988
A591 A707 A795 A905 A995
A604 A708 A797 A906 A997
A605 A712 A798 A907 A998
A606 A714 A800 A908 5544
A607 A715 A801 A909 7139
A608 A716 A803 A910 7220
A609 A719 A808 A911 7331
A611 A720 A811 A912 7476
A613 A723 A818 A913 7530
A617 A724 A820 A914 7533
A619 A725 A821 A919 7563
A622 A727 A823 A922 7568
A627 A729 A826 A927 7625
A628 A730 A827 A931 7634
A632 A731 A828 A932 7718
A633 A733 A829 A933 7720
A635 A735 A830 A937 7722
A638 A737 A835 A938 7767
A642 A738 A837 A940 7874
A645 A739 A839 A942 7884
A647 A740 A840 A943 7885
A649 A741 A842 A944 7919
A656 A744 A844 A945 7925
A661 A746 A845 A946 7929
A662 A750 A853 A948 7930
A666 A754 A854 A951 7932
A673 A755 A857 A952 7948
A676 A756 A860 A953 7959
A677 A757 A861 A9S8 7990
A678 A758 A870 A960 7992
A681 A760 A872 A962 8002
A689 A761 A873 A963 8004
A690 A764 A874 A964 8007
A691 A765 A878 A965 8018
A693 A769 A882 A967 8031
A694 A778 A884 A969 8037
Notice No. DN-133
EN-22
Hu(lhe~ I~c.
FN-10 A Subsidiary of McDonnell Douglas
Date 18 March 1985
Page 4 of 7 SERIAL NUMBER LIST (CONT)

(500D and 500E) (Cont)
8038 8247 8482 B104 B228

8039 8259 8488 B121 B230
8045 8260 8500 B125 B232
8046 8268 8599 B127 B234
8075 8273 8610 B131 B235
8077 8274 8629 B133 B238
8078 8280 8711 B137 B240
8083 8286 8757 B140 B241
8091 8287 8772 B141 B243
8099 8288 B005 B144 B244
8102 8292 B006 B145 B245
8119 8293 BOOB B152 B249
8133 8297 BOll B153 B254
8142 8299 B014 B159 B255
8148 8302 B015 B168 B256
8150 8305 B017 B169 B258
8153 8307 B018 B171 B259
8170 8312 B020 B172 B260
8171 8333 B022 B176 B261
8178
8179
8334
8339
B024
B025
B180
B182
B269B263
8182 8348 B027 B183 B270
8185 8352 B030 B184 B273
8189 8361 B036 B185 B277
8195 8363 B037 B188 B282
8201 8373 B042 B193 B286
8202 8394 B055 B200 B288
8216 8395 B061 B204 B289
8217 8398 B064 B206 B293
8221 8402 B066 B208 B297
8227 8405 B072 B211 B298
8233 8410 B073 B216 B301
8234 8416 B086 B217 B310
8239 8417 B087 B218 B314
8243 8437 BOSS B225 B317
8245 8453 B089 B227 B407

(530F Only)
0036
0053
0057
0058
0059 j;
Notice No. DN-133
I) EN-22
Ilac. FN-10
Date 18 March1985
Pape 5 oi 7
SIRI~LL ~IBEB LIST (CON~)
Main Rotor Hub Assembly P/N 369D21200
1210 1433 1570 1614 1650

1224 1435 1571 1616 1651
1234 1436 1572 1618 1652
1235 1439 1578 1620 1653
1262 1494 1579 1621 1655
1317 1496 1586 1622 1656
1322 1521 1588 1623 1657
1328 1535 1590 1626 1658
1329 1538 1600 1627 1666

1330 1539 1602 1628 1667
1365 1541 1603 1634 1668
1371 1543 1604 1635 1669

1389 1545 1605 1636 1674
1390 1546 1609 1637 1676
1391 1547 1610 1641 1678
1426 1567 1611 1642 1684
1428 1568 1612 1643 1761
1429 1569 1613 1649 1780
1430
Main Rotor Hub Subassembly P/N 369D21201
1073 1510 1721 1767 1809

1148 1534 1724 1770 1811
1153 1547 1726 1777 1813
1340 1557 1727 1778 1815
1378 1559 1744 1;79 1904

1389 1560 1750 1905
1391 1563 1752 1,82 1907

1420 1615 1754 1783 1909
1421 1619 1755 1786 1910
1428 1672 1756 1788 1937
1438 1674 1757 1790 1938

1441 1696 1759 1792 1939
1442 1697 1760 1793 1940
1443 1698 1762 1794 1941

1454 1699 1763 1737 1942
1456 1706 1764 1803 1943
1463 1707 1765 1804 1945
1507 1710 1766 1808 2016

Notice No. DN-133
EN-22 Inc.
Wughe, Helicopte~
FN-10 A Subsidiary ol McDonnel~ Douglas
Date 18 March 1985
Page 6 of 7
SERIAL NUMBER ~IST (CDNT)
Main Rotor Transmission P/N 369D25100
0871 1340 1498 1895 1925

0898 1348 1500 1896 1930
0916 1356 1502 1897 1931
0920 1371 1503 1899 1932
0922 1372 1509 1900 1936
0932 1379 1510 1901 1939
0934 1391 1524 1902 1940
0973 1393 1546 1903 1941
0993 1395 1549 1905 1942
1067 1404 1552 1906 1947
1088 1415 1557 1907 1949
1103 1417 1558 1908 1953
1119 1419 1560 1909 1954
1316 1421 1562 1910 1962
1320 1422 1564 1911 1965
1321 1429 1890 1912 1969
1324 1464 1892 1922 1977
1328 1476 1893 1924 2201
1337 1480 1894
Engine Assembly
CAE833565 CAE834529 CAE835153 CAE835243 CAE835433

CAE834197 CAE~834964 CAE835169 CAE835403 CAE835447
CAE834301 CAE835114 CAF~835193 CAE835420 CAE835463
CAE834509 CAE835129 CAE835211 CAE;835426 CAE835486
Notice No. DN-133
EN-22
Hughel Helicopterr, In~.
FN-10
Date 18 March 1985
Page 7 of 7
SERIAL NUMBER LIST (CONT)
Tail Rotor Transmission P/N 369D25300
0063 1430 1566 1921 1944

0889 1473 1567 1922 1945
1055 1478 1569 1923 1946
1183 1481 1570 1924 1947
1200 1488 1571 1925 1949
1287 1517 1889 1926 1951
1293 1518 1893 1928 1956
1300 1527 1897 1931 1957
1345 1528 1899 1934 1959
1353 1530 1904 1935 1963
1367 1534 1908 1936 1964
1385 1541 1910 1937 1966
1402 1544 1912 1938 1971
1406 1545 1913 1939 1972
1409 1546 1916 1940 1973
1410 1547 1917 1941 1977
1425 1550 1918 1942 1982

1426 1559 1919 1943 1989
FN-11
HN-200
1:1 i""~
Ii~pl
u I.t~
NOTICE NC. DN-134 W
i
1;;- ._"\.1.7
A-111~49 EN-23
ii
.j
\-I I
aUI B DATE
18 March 1985
It ii PAGE 1 OF1
r~ Ai~i
~iii R M AN BaT8 R V r\daBsal DATO R Y
TO: All Owners and Operators of Hughes Helicopters

i
i SUBJECT: Non-Airworthy Clutch Assemblies
Models Affected: All 500HS, 500HE, 500HM, 500D, 500E and 530F Model Hughes
;i Helicopters,
Hughes Helicopters Manufacturing and Inspection Departments have determined

i
that two (2) clutch assemblies P/N 36965350-21 Clutch Assemblies, serial i
numbers 6674 and 6678 may have been illegally introduced into service. As a j:
co~sequence of this possibility, it is requested that owners and operators
of Hughes Model 500 Helicopters examine any of the subject assemblies
received since 11 December 1984 to look fo+ serial numbers 6674 and 6678,
these assemblies must be considered as not airworthy and should be immediately
i returned to Hughes Helicopters. ,i
1 law~t
I i
i
Foam a57e (2/81)

Hughes Helicopten, Inc. Culver City, california 90230
HN-201
NOTICE IJC? DN-135
lil ,I :1 w na i~ ~a DATE 7 August 1985
C PAGE I c_~F 2
G ~Y iVIAN Dda~PO H\J M AN DATO RY

.-1
2
EXIT WARNING DECAL P/N 369[)24043
i
SUBJECT:
MODELS AFFECTED: All Model 369H, 369HE, 369HM, 369HS, 369A (OH-6) and 369D
~Ij (Serial No. 06040 and prior).
TIME OF COMPLIANCE: This Service Information Notice shall be complied with at or

i prior to the next 300 hour or annual inspection after rece;ipt
of decals. i
PREFACE: Pilots and operators of Hughes helicopters are reminded of the importance 1
of properly briefing passengers on how to avoid undue hazards while theyre
around helicopters. It is recommended that the precautions gi\ren by the
FAA in Advisory Circular AC-91-32, SAFETY IN AND AROUND HELICOPTERS
(attached), should be read and conveyed to al~ flight and nonflight per-
sonnel and passengers as applicable.
In keeping with this awareness of passenger safety, Hughes Helicopters has

produced a warning placard to be applied on the inside of each front door
and on the interior panel visible to passengers in the back seat. These
warnings will act as a reminder of the pilots briefing about movement
around the helicopter. These placards will be made available at a special
price of $5.00 for four (4) decals until 8 November 1985.
PARTS LIST
Decal, Exit Warning 369024043 4 required Manufacturer, Huahes
PROCEDURE
Per manufacturers in~tructions, apply exit warning decals at four (4) locations
i shown on Figure i.
i Custorrer Service Deplutment

--c-
--,_ IllglWIIWls~L9
1
FORM 8578 (2/81)

Hughes Helicopters, Inc. Culver City. California 90230
SUbS dialv ot McDonnell Dougias
BPR~S. i
ii.;
73_ijj j- I?
li-_.::
i
1
AT P
DATE 1 July 1985

PAGE 2 of 2
u1
i:I
O
DANGER
WHEN EXITING. WALK AWAY FROM THt
HfllCOPTIR. KL~P Hli~Ol i\ND HL40 LOW.

00 NOT WALK TO THt RLAR.
Figure i. Exit Warning Decal Locations

)(C NO: 91-32
~4DVISORY
CIRCULAR
DEPARTMENT Of TRBNSPDRTATID#
FLDERAL AVIATION ADMINISTRATION
SUBIICT: SAFETY IN AM) AROUND HFLICOPTERS
i. PURPOSE. advisory circular provides suggestions to improve helicopter

This
safety by means of acquaintlng non-flight crew personnel and passengers with
the precautions and procedures necessary to avoid undue hazards.
2. GENERAL. People have been injured, some fatally in helicopter accidents

which would not have oocurred had they been informed of the proper method
of boarding or deplaning. A properly briefed passenger should never be
endangered by a spinning tail rotor, yet some have lost their lives because
they were not told the proper way to approach or depart the aircraft. The
simplest method of avoiding accidents of this sort is to have the rotors
stopped before passengers are bearded or allowed to depart. Because this
action is not always practicable, and to realize the vast and unique capa-
bilities of the helicopter, it is often necessary to take on passengers
or to deplane them i~Jhile the engine and rotors are at, or close to, opera-
tional settings. Therefore, if accidents are to be avoided, it is essential
that all persons associated with helicopter operations including passengers,
be made aware of all possible hazards, and instructed as to how they can
be avoided.
3. NON-FLIGHT CREW PERSONNEL. Persons directly involved with enplaning or de-

planing passengerS, aircraft servicing, rigging or hooking up of external
loads, etc., should be instructed as to their duties.. It would be
difficult if not impossible to cover each and every type of operation or
non-flight crew training matter related to helicopters. A few of the
more obvious and cormnon are covered below:
a. Ramp attendants and aircraft servicing personnel. These personnel

should be instructed as to their specific duties, and the proper method
of fulfilling them. In addition, the ramp attendant should be taught to:
(1) Keep passengers and unauthorized persons out of the helicopter

landing and takeoff area.
C Initioted by: FS-442

AC 91- 32 7 May 71
(2) Brief passengers on the best way approach

to and board a
helicopter with its rotors turning. (see 4a)
b. External load Rigger training is possibly one of the most

riggers.
difficult and continually changing problems of the helicopter
external load operator. A poorly rigged cargo net, light standard, or
load pallet could result in a serious and costly accident. It is
imperative that all riggers be thoroughly trained to meet the needs

of each individual external load operation. Since rigging require-
ments may vary several times in a single day, proper training is of
the utmost importance to safe operations.
c. External load hook-up men.
(1) Know lifting capability of the helicopters involved.

the Since
some operators have models of helicopters that have almost iden-
tical physical characteristics but with different liftingcapa-
bilities, this knowledge is essential. For example, a hook-up
man may be working with a turbo-supercharged helicopter on a
high altitude project and without any warning a non-supercharged

helicopter, which looks exactly the same to the ground crew, comes
to a hover to pick up a load. It does not take a vivid imagina-
tion to see what could happenif the hook-up man connects a load
far too heavy for th~ non-supercharged helicopter to lift.
...ii
(2) Know the pilots. The safest plan would be to standardize all
pilots insofar as in which sling loads are picked up
the manner
and released. pilot standardization, the hook-up man

Without
should learn the technique used by each pilot. Does he come in
fast or slow, high or low? Does he try to lift the load off
with a combination of collective and cyclic? The hook-up man
should specifically demand standardization on the pilot techni-
que for any sort of emergency occurring while he is beneath the
helicopter.
(3) Know the cargo. Many carried via sling are very fragile,
items
others can take a beating. The hook-up man should always know
when a hazardous article is involved, and the nature of the
hazard; such as explosives, radio active materials, toxic chemi-
cals. In addition to knowing this, he should be familiar with
the types of protective gear or clothing or actions that are neces-
sary for his and the operations safety.
4. PASSENGERS. The term passenger used throughout this circular refers to

all non-flight crew personnel that ride in helicopters, and is not limited
to the fare-paying customer. All persons that board a helicopter while
its rotors are spinning should be instructed as to the safest means of
doing so. Naturally, if the pilot is at the controls, he could not

possibly conduce a boarding briefing. Therefore, the individual who
i
?:tdl.
Page 2
7 May 71 AC 92-32
arranged for the passenger flight or assigned as the ramp attendant

shoi~ld accomplish this:,task.~ The exact procedures may vary slightly
from one helicoptermodel to another, but in general the following
should suffice:
a. Boardin
(1) Stay away from the rear of thehelicopter.

(2) Crouch low before getting under the main rotor.
(3) Approach from the side or front, butnever out of the pilots
line of vision.
(4) Hold firmly to hats and loose articles.
(5) Never reach up or dart after a hat or other object that might
be blown off or away.
(6) Protect eyes by shielding with a hand or by squinting.
(7) If suddenly blinded by dust or a blowing object STOP CROUCH
LOWER OR BETTER YET SIT DOWN AND AWAIT HELP.
(8) NEVER GROPE OR FEEL YOUR WAY TOWARD OR AWAY FROM THE HELICOPTER.
b. Pre-takeoff briefing. Since few helicopters carry cabin

attendants,
this briefing must be made by the pilot. The type of
operation will
dictate what sort of briefing is necessary. Passengers should al-
ways be briefed on:
(1) Overwater flights. The location and use of flotation gear and
other survival
equipment that might be on board. How and when
to abandon ship should a ditching be necessary.
(2) Flights over rough or isolated terrain. All occupants should

be told where maps and survival gearare located.
(3) Emergency instructions. In the event of an emergency each

passenger should be instructed as to what actions and precau-
tions take.
to Such as the body position for best spinal pro-
tection against a high vertical impact landing (erect with
back firmly against the seat back). When and how to exit after
landing.
c. Pre-landing br Lef ing The nature~of the landing area will determine
what the passengers need to be told. A few items to consider are;
(1) If a hill,
on depart downhill. If this involves walking around
the helicopter to avoid the area of lowest rotor clearance,
always go around the front, NEVER THE REAR.
(2) Repetition of the basic instructions shown in 4a.
Page 3
AC 91- 32 7 May 71
5. SAFETI AROUND HELZ_COPTERS. The material appearing in Appendix 1 was
taken from the June 1970 issue of R~TORNEWS, a publication of the

Helicopter Association of America.
Acting Director
Flight Standards Service
Page 4
7 May 71 ~C 91- 32
Appenciix 1
Page i
8. Do not touch bubble or aFy. of the moving parts

SAFETY AROUND HELICOPTERS (tail rotor linkage, etc.).
b.A
9. Keep helispot clear of loose articles water bags,
i. Approach or leave machine in a crouching manner
(for extra clearance from main rotor). groundsheets, empty cans, etc.
2. Approach or leave on the down slope side (to avoid

main rotor).
10. Keep cooking fires well clear of helispot.
86
3. Approach or leave in pilots field of vision (to avoid 11. Loading assistants should always be supplied with
tall rotor). plastic eye shields.
12. After hooking

up cargo sling, move forward and to
side signal pilot (lo avoid entanglement and
to
4. Carry tools horizontally, below waist level (never getting struck, with loaded sling).
upright or over shoulder). ----I
-C-
r ~--2_
wind
13. When directing machine for landing, stand with back

to wind with arms outstretched toward landing pad.
5. Hold onto hard hat when approaching or leaving
machine, unless chin straps are used.
i ii. When directing pilot by radio, give no landing in-

structions that require acknowledgement as pilot
will have both hands busy.
6. Fasten seal belt on entering helicopter and leave it
buckled until pilot signals you to get out.
15. When moving larger crews:
(a) Brief them on salely as above.
7. if leavingmachine at the hover, get out and off in (b) Keep them together and well back at side of
landing zone (this gives the pilot a chance in the
one smooth, unhurried motion. either
event he has to land suddenly during
landing or take-off).
Ic) Have them face away Irom machine during land-
ingand take-oil
(d) Have each man look alter his own perscnal gear.
le) Have men paired oil snd ready to gel aooard, as
soon as pilot gives tne signal
Page I
ORIGIKAL R L:~ REECEIV~il- D BY ATP.

Ej U6 E-~ E~ EN-24DN-136
Suq ~Ls
i
NOTICE NO
FN-12
Si4 Or~
DATE 7 August 1985
;B
PAGE 1 OF 6
M Iq j~ CATO RY IV]PISad D~O R Y W1AN DATO R V
SUBJECT: Replacement of Main Rotor Cooling Installation Bracket from

369D25701-3 to 369D25701-11,
MODELS AFFECTED: 530F Model 369F Serial No. 0001F through 0014F, Model 3693
Serial No. 0001E through 0024E, 0026Ethrough 0109E, 0112E
through 0114E, OllbE, 0124E, 0125E, 0130E through 0134E.
Model 369D Serial No. 0003D
through 1308E,
TIME OF COMPLIANCE: This Service Notice shall be

complied with during the
next 300 hours of operation or at the next annual
inspection
PREFACE: This Service Information Notice contains all

required information for
owners/operators of Hughes Helicopters to fabricate and install the
369D25701-11 Cooling Installation Bracket which
replaces the 369D25701-3
bracket.
Reference
369D HIM Volume I (CSP-D-2) Rev. 41 15 January 1985,

369D PFM (CSP-D-1) Rev. 20 January 1984,
369E HMI Volume I (CSP-E-2), Issued 30 November
1983,
3693 Pilots Flight Manual (CSP-E-1), Issued 23
November 1982.
369F HMI Volume I (CSP-F-2), Issued 01 March
1984.
369F Pilots Flight Manual (CSP-F-1), Issued 29
July 1983,
PARTS LIST
Nomenclature Part No. Rty. Source
Bracket 369B25701-11 1 Hughes

Rivet MS 20426AD 4 4
or Commercial
Rivet, Cherry-Max ~CR3213-4-2 4 Commercial
*OpfioniEquivaion~
Customer Service Deptlnment

1.!7bG ilifli, AS Culver City, California 90230
REcsiv~a By ATP. A Subsidiary of McDonnell Douglas

DN-136
Notice No. EN-24
FN-12
Date: 7 August 1985
Page 2 of 6
TOOLS AND EaUIPMENT
Nomenclature Source

MATERIALS
Lubricant (12 U.S, Pts) MIL-L-7808 Commercial

Primer, zinc chromate I
TT-P-1757 Commercial
*Steel, 301 sheet condition A MIL-S-5059 Commercial

Size .040 thick x 2.50 x 3.75
*Only required when field fabricating the -11 bracket.
PROCEDURE
A. Remove sound insulation and transmission access cover (Section 2,

HMI Vol i).
B. Drain main transmission lubrication system (Section 2, HMI Vol 1).
C. Disconnect 369D25705-11 hose from AN833-8D elbow connected to

D. Disconnect 369D25705-21 hose from AN833-8D elbow connected to

E. Disconnect 369D25709-11 tube assembly from the 369D25701-3 bracket.
F. Disconnect 369D25710-11 tube assembly from the 369D25701-3 bracket

and loosen HS4181A8N clamp attaching tube assembly to 369D25701-5
bracket.
G. Remove AN924-8D nuts from 369D25701-3 bracket.
H. Drill out rivets attaching the 369D25701-3 bracket to structure and

remove bracket. Apply zinc chromate to holes.
I. Fabricate 369D25701-11 bracket per figure 1. (Optional)
J. Install 369D25701-11 bracket on 369H3011-17 bracket as shown in

Figure 2, view A.
DN-136
""i"
:~r::
Date: 7 August 1984
Page 3 of 6
PROCEDURE (CONT)
K, Install AN833-8D elbow in upper and lower holes of 369D25701-11 bracket,

with outboard end of elbow down. Attach each elbow to bracket with
two AN960-D1216 washers and one AN924-8D nut.
L. Connect 369D25705 -21 hose assembly to upper AN833-8D elbow outboard

(downward) leg.
M. Connect 369D25705-11 hose assembly to lower AN833-8D elbow outboard

(downward) Leg.
N. Attach 369D25709-11 tube assembly, as follows:
1. Position tube assembly so that upper end mates with inboard end of
lower elbow in 369D25701-11 brqcket,
2. Fit upper end of tube over lower elbow; secure to elbow with nut on
tube assembly,
O. Attach 369D25710-11 tube assembly, as follows:
i. Position tube assembly so upper end mates with upper elbow through
369D 25701-11 bracket.
2. Connect tube ends to elbow and union and secure with nuts on tube
ends.
3, Tighten clamp attaching tube assembly to 369D25701-5 bracket.
P. Fill transmission with approved lubricant (Section 2, HMI Vol 1),
Q. Start and operate helicopter until lubricant is circulated through

the system, Check installation for leaks and security,
R. Reinstall sound insulation and transmission access cover (Section 2,

HMI Vol i).
S. Check main transmission oil level at sight gage (Section 2, HMI Vol I).
Add oil, if required.
T. Record compliance with this notice in Compliance Record of helicopter

log book.

DN-136
Notice No. EN-24
FN-12
Date: 7 August 1985
Page: 4 of b
The resultant alteration to the affected helicopters described in this Service

FAA Approved.
ORgi;,-
DN-136
Notice No. EN-24
FN-12
Date: 7 August 1985
Page 5 of 6
0. 13. R TYP
2.00
1.00
0. 50 -~--c-1 I I I ,0. 13210.

AID821
HOLE
THRU 4 PLACES
1
O t0.62
0. 62
i. 0.13 R TYP
1. 25
M
1 0.78 DIA
URHTELOH
2 PLACES
L12. 0.62
k a
IJ ~_-r
0.62
-11 BRACKET
88-613
(TO BE MADE OUT OF 301 SHEET STEEL CONDITION A PER IfIL-S-5059)
Figure 1. 369D25701-11 Fabrication Diagram.
~Cs
DN-136
Notice No. EN-24
FN-12
Date: 7 August 1985
Page 6 of 6
AN833-8D ELBOW AN960-D1216

WASHER (REFI 3691)25709-11
TUBE ASSY(REF)
369025710-11
TUBE ASSY(REF)
369[325701-5 BRACKET
AN833-8D
HS4181A8N CLAMP
ELBOW
~lil
4N924-8D
~NUT REF)
369025705-11
HOSE ASSYIREFI
369Li25705-21
HOSE ASSY (REF)
SjATION 124 CANTED FRAME
VIEW IOOKING AFT
DRILL OUT EXISTING RIVETS AND INSTALL

MS20426AD4 RIVETS 14 PLACES)
ICR3211-4-2 CHERRY-MAX RIVETS MAY ALSO BE USEDI
.50
369025701-11 BRACKET
t!
(REPLACEMENT OF -t
U
0,
j69H3nll-17--------lt tl i t
BRACKET
h\-bl?
Figure 2. 369D25701-11 Bracket Installation Drawing.
ORIGI~AL p13 R~PC!;I-n

tU BY. ALe,
DN-137
EN-25
NOTICE NO.
FN-13
C=(IAHLP3LI Al~Y
PAGE 1 OF 2
SERVI%E INFORMATION NQTICE
MANDATORYI IMAN DATO 8 Y I~nAN DATORY

r
I I I
SUBJECT: TAIL ROTOR BELLCRAM( INSPECTION P/N 369D27514 369D27515
MODELS AFFECTED: All Model 369D, 3693, 369F and 369FF helicopters with
bellcrank 3691)27514 (two-bladed) or 369D27515 (four-bladed)
parts installed and all spares in stock.
TIME OF COMPLIANCE: All owners and operators shall comply with this Service
Information Notice within the next 100 hours of operation

or three months, whichever occurs first.
PREFACE: This Service Information Notice gives procedures for inspecting the
thickness of the ear at the clevis end of the tail rotor bellcrank.
~Improper thickness may cause failure and loss df control of the tail
rotor during helicopter operation.
Reference
369D/E Basic (CSP-D-2) Reissued 15 Jan 1982; Revised 15 June 1985

HMI
369F Basic HMI (CSP-F-8) Issued 01 March 1984; Revised 15 August 1985
CSP-088 (Four-bladed Tail Rotor Opt. Eqpt. Man.) Reissued 15 Jan 1985
Tools and Equipment

Nomenclature Source
Caliper Conrmercial
Procedure
A. Remove tail rotor push rod from be3.lcrank per Section 8, HMI Vol 1.
B. Using caliper, meastge thicknc,as of the ears at the clevis end of tail
rotor bellcrank as shown in figure i.
C, Minimum thickness shall be .065inches, If minimum thickness is not found

at points shown in Figure i, replace bellcrank,
f D. Reinstall tail rotor plJ8~ rod and bolt per Section 8 of Vol. 1 in HMI.
E. Record compliance to this SerJice Information Notice in the appropriate

sectl.on of the Helicopter Log Book.
FORM 9678 2/81)

MCDONNELL DOUC~LAS
HELICOPTER COMC~NV
DN-137
EN-25
Notice No, FN-13
Date 20 December 1985
Page 2 of 2
Weight and Balance
The resultant alteration to the affected helicopters described in this Notice

has been shown to comply with Federal Aviation Regulations and is FAA Approved,
065 BOTH SIDES.TOP ISEE NO1II)
.065 BOTH SIDES, BOTTOM
NOTES:
1. MINIMUM THICKNESS SHALL BE.WS. WHEN MEASURING

THE AREAS SHOWN, AVOID PLACING CALIPER ON INSIDE AND
OUTSIDE RADII OF BELLCRANK TO ENSURE PROPER READING.
2 ALL DIMENSIONS SHOWN IN INCHES.
Figure lo Tail Rotor Bellcrank Inspection
88-619
DN-138
EN-26
NOTICE NO
"-3~ "9" FN-14
PAGE 1 OF 1
~a\lE j 1
F~ R Itn
AT i g) N i ti
4F
i,e
MAN DATORY :~-1-:: MANDATORY WIAN DATO RY
SUBJECT: FARGO AUXILIARY FUEL TANKS P/N A1066-1082
Fj
MODELS AFFECTED:
All Model
Auxiliary
369D,
Fuel Tank
3693 and 369FF Helicopters with Fargo
(P/N A1066-1082, serial numbersl0l
j
through 220) installed and all spares in stock, :Ij
TIME OF COMPLIANCE: Per attached Service Information Notice. i

procedures for inspection and repair of Fargo Manufacturing Company
auxiliary fuel tank, P/N AW1066-1082. The inspection, repair and
owner compliance is to be accomplished in accordance with the
instructions given in the attached Fargo Service Notice No, 2,
Reference
Fargo Manufacturing Co, Service Notice No.2 Revision No. i, Dated

30 December 1985.
Procedure
A. Perform inspection/repair of Fargo auxiliary fuel tank, P/N AW1066-1082,

in accordance with instructions
given in attached Fargo Service Notice No.2.
B, Record compliance with this Service Information Notice in the

Compliance
Record section the the helicopter
log book.
C:
"rilriiicr Supjlult iepnrtillc~oi
Fonm 0578 (2!91)

DESIGNERS g FABRICATORS OF PRECISION METAI PRODUCTS
TELEPHONE~ 489-2200
COMPANY
FARGO SERVICE NOTICE NUMBER 2 Revision No.l

30 December 1985
SUBJECT: Leaks in Fargo Auxiliary Fuel Tanks
BAC~GROUND: Leaks have been reported in Fargo Auxiliary

Fuel Tanks. An investigation of those leaks
reported indicates that insufficient contact
of the tank bottom with the cabin floor can
cause these leaks to develop. Specifically,
if the spacer blocks located on the underside
of the tank do not rest firmly on the lateral
upright that-section stiffener) of the cabin
floor, leaks can develop with continued service.
If there is a gap between the right and/or

left stainless steel mounting plates and the
tank security strap and this gap is closed
by torquing the attaching bolts and nuts
without the use of shims, the tank can be
deformed such that leaks may develop during
service.
FAA APPRO~AL: The technical aspects of this notice are FAA

approved.
MODELS
AFFECTEDr All Fargo Awciliary Fuel Tanks, Model
Number AW1066-1082
SERIAL NUMBERS
AFFECTED Serial Numbers 101 through 220
DATE: February 28, 1986
PREFACE: This notice is in two parts. Part I gives

procedures for inspection and repair (if
required). Part
requests 11 owner acknowl-
edgement of completionof Part I, and feed-
back regarding the evidence of: (1) fuel tank
leaks and (2) proper spacer block-to-floor
support contact.
page 1 of 6
PART I INSPECTION AND REPAIR
C
A. Remove the auxiliary fuel tank from the heli-
copter.
B. With tank filled with fuel, visually inspect the

tank for any evidence of a fuel leak.
If a fuel leak is found:

(1) Remove all fuel from the tank and field
repair per AC 43.13-1A or return to
Fargo for repair.
NOTE: Refer to Part II, Step C,

for further instructions
for returning tanks for repair
(2) Install the repaired tank in accor-

dance with Fargo Installation Manual
102, revised (Incorporating
the remainder of Part I of this
notice).
If no leak is found, proceed to step C.
C. Visually inspect the fuel tank spacer blocks

for evidence of wear, surface rubbing or chaffing.
D. Visually inspect ehe lateral upright floor

stiffener that-section) for any evidence of
surface wear. At the points where the
spacer
blocks bear upon the Lateral upright, there
should be some indication of surface contact.
E. Cut a 3/4" wide inspection slot in the front

of the tank cleat at each of
spacer the two
blocks, These slots must be deep
enough to
expose the bottom of the two spacer blocks.
See Figure i, Detail
i, page 6 of 6,
F. Reinstall tank in the aircraft.
G. Inspect at the newly cut inspection slots

to ensure that the two spacer blocks are resting
firmly on the floor stiffeners.
H. i. If there is no space between the blocks

and the floor stiffener, record
compliance
with Part I of this notice in the Helicopter
Log Book, and proceed to Part II.
j_
page 2 of 6
~jrtrtir
2, If is any space between the bottom of

there
a spacer block and the floor stiffener,
repair steps I through M must be performed.
See Figure i, Detail 2, Page 6 of 6,
I. Machine two (2) separate spacers from aluminum

that: will:
(1) Fill the space between the bottom of

the spacer blocks and the floor stiffener,
and
(2) Provide a .020" to .032" vertical clearance

between each tank mounting bracket (P/~
A-1080, item 2) and ii;s mating mounting
plate (P/N A-1081, items 19 and 20). See
Details on Page 6 of this notice.
3. Remove the paint from the bottom of the spacer

blocks under the auxiliary fuel tank.
K. With a two (2) part epoxy glue suitable for

metal-to-metal bonding, glue the new spacers
to the bottcan of the old spacer blocks.
L. After the glue has cured, install the tank in

the aircraft.
Sl, ~f there are gapsright and/or left

between the
stainless steel mounting plates and tank security
strap, these gaps must be shimmed so no prelo~ding
or stressing of the tank occurs.
All plastic upholstery must be returned to its
proper place before placing tank in position.
O. Refer to the Fargo Auxiliary Jet Fuel Systeci

Installation Manual 102 for installation procedures.
P. When installing the Fargo Auxiliary Fuel Systen, all

work performed must be in accordance with the
Federal Aviation AC 43.13-2A,
Acceptable Methods, Techniques, ani Practices
Aircraft Alterations.
a. Record compliance with Part I of this notice in the

Helicopter Log Book.
Ilote: Weight and balance are not affecteu 5Y this

repair.
C
page 3 of 6
PART II OWNER COMPLIANCE
j
Owners are requested to reply directly
to Fargo providing the following information
on these sheets, Reply to be sent to:
Fargo Manufacturing
2750 Elston Avenue
N.
Chicago, Illinois, 60647
A. Please enter Tank Serial Numbert
B. Was Part I of this notice complied with?
Please Check One: YES
NO
C. Was there any evidence of a fuel leak in the
auxiliary fuel tank?
NO
NOTE; Ovners advised Mat .ny Fargo

are
Auxiliary Fuel Tank found to have

leak as a result of compliance with
this notice, will be repaired by
Fargo. The expense for this repair
will be borne by Fargo provided:
(1) Owner agrees to pay freight to
and from Fargo
(2) This notice is complied with by
~ebruary 28, 1986 and
(3) If it is necessary to send the
tank to Fargo, please remove thF
bottom red frangiable fitting,
Fargo Kit Part tA-1040 and the
aluminum assembled fuel cell cover,
Fargo Kit Part ~AW-1062. Cover tank
openings before shipping.
D. Did the inspection specified by Part I, Step G
reveal a space between the spacer block(s) and
the floor stiffener3
NO
Please Check One: BOTH
LEFT ONLY
RIGIIT ONLY
4 of 6
page
~QAG17
C E, Did the inspection specified by Part I, Steps

C and D reveal any evidence of surface-to-
surface contact such as rubbing, chaffing or
wear marks3
Please Check One YES
NO
If YES, which one(s)3
Please Check as Appropriate:
Both Spacer Blocks
Left Spacer Block
Right Spacer Block
Floor Stiffener Both Spacers
Floor Stiffener Left Spacer
Floor Stiffener Right Spacer
N ame
Address
City State Zip Cocie
C
page 5 of 6
NOPE:
The spacer blocks in the "U" channel on
the bottom of the fuel tank must rest
firmly on the lateral upright floor
stiffener (see detail below).
required vertical clearance between
The
j
bracket P.N, A-1080, and plate, P.N~
A-1081 is .020" to .032" before the
mounting bolts are tightened.
r I~RACKFT A-1080
A-1081
Any space Leteen tank

security strap and
mounting plate must be
n~
shimmed so that no stresE
is put on tank when
b
s,., YI mounting bolts are
~LIUC tightened,
FI
s
II
C
\U
~p,
IZ~F4 1/P
FUEL TA~JK, FRO~JT VIEW
i I I _I I
FWD "iI Cut 3/4"wide slots at each

spacer block location.
Fuel Tank
DE-TAIL 3
End View
Firewall
Tanl: cleat; with spacer

If airspace exists
when tank is Dlaced
CarfSa Floor
in position use
additional ~Dacer shims
to insure that tank rests LLateral uDrl~J7t
firmly on the unripSIC
floor stiffner.
DETAI~ 2
FIGUFIE I
na~e r; nt h
6
DN-139
EN-27 .l;t
:i41:" NOIICE NC?
FN-15 .Ift
DA" 18 M""h 1986
~-IOhl NOTICE
PAGE Of-
5
iF~ WIAPIUAIOR~ i\iiAi\j U14iOnY T)ilAPIICinTOX\I

"Supercedes Service Information Notices DN-139~
EN-27 and FN-15 dated 10 February 1986.
SUBJECT: COOLING FAN PULLEYS P/N 369D25620, 369D25622, 369D25622-3 and

369D25624 INSPECTION.
MODELS AFFECTED: Part I All 369E, 369F and 369FF Helicopters with serial
i numbers listed below:
0040E thru 0156E 0009F thru 0044F
:I 0158E thru 0177E

0183E thru 0186E
a
All 369D, 369E, 369F and 369FF Helicopters that have had
pulleys installed which were received from spares on or
after January 1, 1984 and before January i, 1986.
C: Part
Part
II
I.
to
All
All
affected helicopters
pulleys in spares with
December 31, 1985.
and
marked
spares listed
dates of
in
January i,
1984
All pulleys marked January 1, 1986 or later and/or marked

with a blue dot or stripe are not subject to this Notice.
TIME OF COMPLIANCE: p,,t I shall be accomplished within the next 25 hours

of operation.
Part II shall be accomplished within the next 100 hours
of operation.
Shall be accomplished prior to installation of any affected
pulley assemblies from spares. it
PREFACE: McDonnell Douglas Helicopter Company (MDHC) has established that a quantity
of non-conforming cooling fan pulleys have been introduced into service.
j These suspect pulleys do not mesh properly with the cooling fan belt which
can cause excessive belt wear and premature belt replacement, Some pulleys
were also found to have extremely sharp tooth edges further causing
excessive belt wear. ~ffected pulleys shalt be inspected using a new fan
belt. If found to not properly mesh with the new fan belt, the pulleys and
the old fan belt shall be replaced.
Part I of this Notice describes procedures for visually inspecting affected
helicopters and those helicopters with affected spares installed for excessive
1 cooling fan belt wear.
j Part
of
II
affected
of this Notice
provides procedures for a more thorough inspection
helicopters and spare pulleys. Also, procedures for returning
non-complying parts to approved ~IDHC Service Centers and Distributors i
are explained.
\r
DN-1391"
EN-27.1"
Notice No. FN-15.1*
Date: 18 March 1986
Page 2 of 5
REFERENCE
369D and 3693 HMI Vol. 1 (CSP-D-2) Revised 15 June 1985.

369F/FF HMI Vol. 1 (CSP-F-2) Revised 15 August 1985.
PARTS LIST
Part No. Nomenclature Qty. Source
369D25623 Belt, drive 1 MDHC

*369D25620 Pulley Assy 1 MDHC
J(369D25622 Pulley Assy 1 MDHC
*369D25622-3 Pulley Assy 1 MDHC
JE369D25624 Pulley Assy 1 MDHC
If required
REPAIR MATERIALS
Material Specificat, ion Source
,rAbrasive paper, silicon P-P-101 Commercial

carbide, grade 320 (grit),
wet or dry
*Primer, catalyzed epoxy MIL-P-23377B Commercial

(yellow)
If required.
PART I PROCEDURE
A. Gain access to the cooling blower assembly and visually inspect fan
belt for excessive wear per Section 9 of applicable HMI Vol. 1.
NOTE
Signs of excessive wear include frayed belts showing white

fibers, extremely worn belt teeth and heavy amounts of debris
in the of the smaller
area pulley.
B. If there are no signs of excessive wear to the fan belt then proceed
to Part II of this Notice within the next 75 hours of operation.
C. If there are signs of excessive belt then proceed

wear to Part II of
this Notice immediately or before further helicopter operation.
f/
DN-139. 1*
Notice No. EN-27.1j(
FN-15. ld(
Date: 18 March 1986

Page 3 of 5
PART II PROCEDURE
A. Disassemble cooling blower assembly as required to gain access to
pulley drive assemblies per Section 9 of applicable KMI Vol. I.

Remove pulley assemblies.
B. Using a new fan belt, perform inspection of pulleys by loosely

wrapping drive belt around the pulley assemblies as shown in Figure i.
C. Figure 1 depicts acceptable and unacceptable meshing between the

drive belt and pulley assemblies. Those smaller pulleys which are
found to be acceptable shall be further inspected for having too
sharp of teeth edges. The teeth on the smaller pulleys shall have
edges which feel smooth when touched.
D. All pulleys found to be UNACCEPTABLE shall be returned to an approved

MDHC Service Center or Distributor for replacement.
Those small pulleys found to mesh properly with the fan belt and
E.
yet have unacceptable teeth edges shall be further inspected and
reworked per the following steps:
1) Measure O.D. of pulley from the tops of the pulley teeth

as shown in figure 1,
Dimension ~1
O,D. from the bottoms of fhe pulley teeth grooves as

2) Measure
shown in figure 1.
Dimension ~2
3) Subtract "Dimension 2" from "Dimension 1"
Dimension ~3
4) Divide "Dimension 3" by 2.

Dimension ~4 ~3/2
Note Dimension ~4 shall .078; If Dimension ~4
not be less than
is less than .078, Approved MDHC
return pulley to an
Service Center or Distributor for a replacement part.

If Dimension ~4 is .078 or greater, rework pulley per the
following steps:
a) Mark retaining ring for proper placement during reinstallation.
b) Adequately support retaining ring and carefully press pulley

out of ring.
c) Using abrasive paper, smooth edges of the teeth to obtain a
corner radius of ,020 to .030.
Note Surface smoothness shall be that which is obtained using

silicon carbide 320 grit paper. However, 120 grit abrasive
paper may be used initially as long as the final finish
has been obtained using 320 grit abrasive paper.
Notice No. DN-139.1"
EN-27.15
FN-15.lk
Date: 18 Plarch 1986
Page 4 of 5
PART II PROCEDURE CONT.
d) Sniooth old stake point on pulley (4 places).
e) With same side facing pulley teeth, reinstall retaining ring

and stake at four places half way in between old stake points.
f) Using yellow primer paint, mark pulley as shown in Figure 1.
F. Those larger pulleys found to mesh properly with fan belt shall shall
be marked using yellow primer paint as shown in Figure i.
G. Using a new fan belt and acceptable pulley assemblies, reassemble

cooling blower assembly per Section 9 of applicable HMI Vol. I except
as noted below.
NOTE
The out in paragraph 9-45, step w

torque value currently called
of the 369F HMI Vol. inch-pounds is incorrect. When
I of 95-110
installing pulley in blower assembly, tighten pulley nut to
160-190 inch-pounds plus drag torque.
H. Record compliance of this Service Information Notice in the Compliance

Record of helicopter Log Rook.
WEIGHT AND BALANCE
Weight and balancenot affected.
I
The resultant alteration to affected models as described by procedures
in this Notice has been shown to comply with Federal Aviation Regulations
and is FAA Approved.
td) Denotes portion of text added or revised.

DN-139 .Ix
Notice No. EN-27.1*
FN-15.1*
Date: 18 hlarch 1986

Page 5 of 5
"TH
DlhliNllOhlll
Y UIIC(IPBBLL
MLLOW PRIM~R DIMINII~NI?
.OZO-.09D
CORN~R RIIOIUI
1~i
saazi
Figure 1. Cooling Pan Assembly Pulley Inspection/Kewark

FN-16
EN-28
NOTICE NC7
DN-140
IL~OUGILAS ,,r, HN-203
15 April 1986
PAGE OF 2
SERVICIE INFORMATION NOTICE
SUBJECT: OIL TANK FILLER NOZZLE STRAINER ASSEMBLY P/N 369D28318
MODELS AFFECTED: All Model 369B, 369HE, 369HM, 369HS, 3698 (OH-6), 369D,
3693, 369F and 369FF helicopters that do not have strainer
assembly (P/N 369D28318) installed.
TIME OF COMPLIANCE: This Service Information Notice shall be complied with

at Owners/Operators discretion.
PREFACE: With the advent of plastic oil containers which have screw-off caps and
plastic or aluminum seals on the filler neck, there have been cases of
seal debris finding its way into the oil tank. Therefore, in keeping with
its awareness of safe helicopter operation, McDonnell Douglas Helicopter
Company has produced an oil strainer which can be easily installed into
the filler neck of the oil tank.
REFERENCE
Basic HMI, CSP-H-2, Reissued 15 September 1981,

Basic HMI, CSP-D-2, Reissued 15 January 1982; Revision 5, 15 June 1985.
Basic MII, CSP-F-2, Issued 1 March 1984; Revision 1 15 August 1985.
PARTS LIST
Strainer Assembly, Oil 369D28318 1 McDonnell Douglas

Tank Filler Nozzle Helicopter Company
PROCEDURE
a. Remove oil tank assembly from helicopter (Vol, 1, Section 13, appropriate HMI).
b. Insert oil strainer (PJN 369U28318) into filler neck of oil tank as shown
in figure i,
c. Install oil. tank assembly into helicopter (Vol. i, Section 13, appropriate HMI).
FORM 957BA (2/81)

Notice No. FN-16
EN-28
DN-140
HN-203
Date: 15 April 1986
Page 2 of 2
PROCEDURE (CONT.)
d. Record compliance to this Notice in helicopter Log Book.
The resultant alteration to affected models as described by procedures in

this Notice has been shown to comply with Federal Aviation Regulations and
is FAA Approved.
"k-
i----:
9~ ii
i
j\\ 3
C
f
I
a STRAI
"~i
ti
8 o
a O
\a, m
o
m I/ V\\
m o
o
B
a Q)
L
Figure i. Oil Strainer Assentbly (P/N 369D28318) Installation.
Notice No. HN-202
.S*? ".4 DN-141
-"i~"Yd zsa :,tsuii;i~c/
Y
F.N-29
.~-iig 1 i-~
i FN-18
I;~:
i I ;;".jr" Y
Date: 15 May 1986
i;"" i n a i~;a
Page 1 of 3
I)
REMOVAL OF SEAT BELT ASSEMBLIES MANUFACTURED BY THE EON CORPORATION
SUBJECT:
MODELS AFFECTED: All 369 Series Helicopters equipped with seat belt assemblies
and all Spares Inventories manufactured by the Eon Corporation.
TIME OF COMPLIANCE: This Service Information Notice shall be accomplished

PRIOR to the next flight.
PREFACE: NcDonnell Douglas Helicopter Company (EII)HC) has determined that the buckle
assembly used on various seat belt assemblies manufactured by Eon Corporation
may inadvertantly open. As a result, those operators with helicopters equipped
with Eon Corp. seat belts that are listed in the attached table shall replace
those seat belts with the appropriate acceptable repiacement/alternate.
The problem component of the belt assemblies is the Eon Corp. "hir:h lift latch"
buckle assembly. It is distinguishable from other Eon Corp. buckle assemblies
in that it requires the releasing lever to be raised to approximately the
90 degree (vertical) position before the 3atching tongue normally releases,
Other Eon Corp. buckle assemblies have not been found to have disengaged
inadvertant ly,
REFERENCE
3698 Basic HMI Vol,I (CSP-H-2) Revised 15 June 1985
369D/E Basic HMI Vol,I (CSF-D-2) revised 15 June 1985
369F Basic HIII Vol,I (CSP-F-2) Revised 15 April 1986
PROCEDURE
A. Remove Seat bel.t assemblies manufacrured by Eon Corporation as listed
in the attached table andreplace with listed acceptable

alternate per Section 4 of applicable t~MI Vol.I,
C, NOTE
Seat belt assembly part numbers are found on cloth labfls

sewn to webbing,
HN-202
Notice No.
DN-141
EN-29
FN-18
Date: 15 May 1986

Page 2 of 3
PROCEDURE (CONT.)
B. Seat belt assemblies removed in accordance with this Notice will be
replaced free of charge until 31 August 1986. Seat belt assemblies will
be made available at list price after 31 August 1986 for those
helicopters or belt assemblies not covered by the standard ~DHC Warranty.
Operator/owners shall order replacement seat belt assemblies from the
nearest Approved MDHC Service Center/Distributor. Service Centers/
Distributors will obtain replacement seat belt assemblies from Warranty
and Repair at MDHC, Culver City, CA. All discrepant seat belts will be
returned to the Service Center/Distributor upon receipt of the replacement
belts.
C. Record compliance to this Notice in the Compliance Record section of

WEIGHT AND BALANCE

j
The resultant alteration to affected models described by procedures in this
FAA Approved.
r fl
TABLE
SEAT POSITION TYPE REMOVE (See Note 3) REPLACEMENT I ACCEPTABLE ALTERNATE

(See Note 1)
Pilot Lap Belt with 369B6512-503 1 36986512-19 or i 36986541-29 or
Go-Pilot Dual Shoulder I 1 3 69H6 512- 501 369116 54 1-503

Harness (See Note 2)
Lap Belt Having 369B6541-503 1 369H6541-29 or 369B6512-19 or
Single Shoulder 36986541-503 369B6512-501 when
I I Strap with (See Note 2) used with

Inertia Reel 369B6514-9 or
j- 369H6514-11
Rear Passenger Lap Belt Having 369B6541-501 369B6541-501 36986511-3
Single Shoulder (See Note 2) or
Strap with 369B6541-27

Inertia Reel
Lap Belt Having 36986511-501 369B6511-3 369B6541-501

Shoulder (See Note 2) or
Single
369116541-27
Strap
_
I Front Center Lap Belt Having 36986511-503 369B6511-31 1 369f16541-29 or
Single Shoulder 369B6541-503

Strap (See Note 2)
Lap Belt Having 369B6541-503 369B6541-29 or 369B6511-31
Single Shoulder 369116541-503

Strap with (See Note 2)
Inertia Reel
da e
Note 1 Interchanging from one type seat belt to another alternate installation shown
for position above (seat
the seat belt vs seat belt and shoulder strap/harness) Wr (O
i
is approved as long as the entire seat belt restraint system including hardware o
is Lnterchanged (Per MDHC IPC).

wC
Note 2 Manufactured by other than Eon Corporation (369116541-501 369B6541-503). M rj ~d
r 2: 2:
i \O
Note 3 Belt assemblies manufactured by the Eon Corporation Only. O3Nr hi
Notice No. HN-205
~1" lu~ DN-142
:r?ni~
EN-30
~N-14
Date: 20 May 1986

Page 1 of 1
INC, ALTIMETERS (MDHC Part No. 369D24174, 349B4505

SUBJECT: UNITED INSTRUMENTS,
and 369890124)
3698, 369HE, 369HM, 369HS, 369A (OH-6A), 369D,

I~ MODELS AFFECTED: All Model
369F and with United

369E, 369FF helicopters Instruments, Inc.
Series 5934 altimeters per attached Service Bulletin installed.
1
TIME OF COMPLIANCE: p,r attached United Instruments, Inc. Service Bulletin No.2, :li
PREFACE: McDonnell Dougl;s Helicdpter Company (MDHC) has learned from United
Instruments, Inc. that numerous 5934 Series altimeters manufactured

t
from approximately February 1985 through February 1986 are subject j
1
to an inspection and possible modification per the attached Service
Bulletin.
I
REFERENCE
i United Instruments, Inc. Service Bulletin No.2, February 24, 1986
PROCEDURE
A. Owners and/or Users of United Instruments, Inc. 5934 Series Altimeters

shall perform inspection/modification to affected altimeters per the
attached Service Bulletin.
1
B. Record comp~liance to this Service Information Notice in the Compliance
~edord section of the helicopter Log Book.
C1
alNrreC IN~bTRUMENTB, INC.
B~s 3826 Camotare Avenue, Wichits, Kansas 67226 Phone: (3rB) 8868203
CABLE CbbE: VNITEDINST Service Bull etJ n No, 2

February 24, 1988
SERVICE BULLETIN
TO; Owner and/or User of United Instruments, Inc. 5934 Series AltSmeters.
TITLE: Setting knob locking mechanism Inspection/ModSfIcation
PURPOSE: Check for possible dlsengagement of setting knob locking

mechanism during barometric a4iustment,
EFFECTIVITY: Part number 5934 series altimeters with serial numbers listed
below that were manufactured from approximately February 1985 through
February 1986,
S/N
60461 through ~C999

C 7C000 through 7C999
80000 through 80999
90000 through 90999
OD000 through 0D999
1D000 through 1D999
2D000 through 20869
GENERAL: The normal operation of the barometric setting knob mechanism is

to drive both the barometric dial and the mechanism assembly (altitude
pointers) simultaneously when entering barometric pressure settings.
DESCRIPTION: Improper function of the locking stud (P/N 34-1-27) may allow
the adjustment stem (P/N 34-1-5) to slide outward by more than Its normal
end-play of appoximatcly 0.01 inch, causing a disengagement of the
barometric gears which would allow the barometric dial to turn
independently from the mechanism assembly (aitit;ude pointers) as the
barometric knob is turned.
CORRECTIVE ACTION: Replace with new corrected locking stud (P/N 34-1-27).
rUENTIFICATION: Instruments modified will be identified with a yellow dot,

approximately 0.25~nch diameter in the lower half area on the rear side of
Page 1 of 3
C
Service Bulletin No, 2
February 24, l986
the case and letter "M" approximately one-eighth inch high will be metal
stamped on the nameplate preceding. the name "Alt~Smeter".
COMPLIANCE AND HANDLING INSTRUCT~ON:
I. I u rrently I nstal led i n A i re raf t
Prior to next flight check to see if the barometric gear disengages

from.the mechanism assembly by gently pulling the barometric knob outwarp
and rotate the barometric knob. If the altitude pointers do not move
simultaneously with the barometric dial, remove the instrument from the
aircraft for modification by the manufacturer.
If the barometric setting knob.functionr satisfactorily, use of thc:

instrument may continue until the next regular scheduled inspection not to
exceed 120 days from the issue date of this service bulletin at which time
the instrument should be removed from service and sent to the altimeter
manufacturer for warranty modification.
2. Instruments Other Than Currently Installed in ASrcraft:
Return all affected instruments to the altimerer manufacturer for

warranty no later than July 1, 1986.
3. When returning the instruments to the altimeter manufacturer, each

instrument should be adequately wrapped packaged in a container no
and
smaller than 8" x 8" x 8" to protect from damage, and sent by United Parcel
Service (UPS).
CREDIT ~NFORMA7ION:
1. Removal and Installation: F;or an instrument already installed in an

aircraft falling within the affected serial numbers, the actual charges
incurred for removal and reinstallation Ito include required check for
Static Sylem leaks) will be reimbursed in the amount of a maximum of $40.00
far a single engine aircraft and $65.00 for a twin engine aircraft. A
completed claim form must be Submitted to be eligible for reimbursement.
2. freight: Ship by United Parcel Service (UPS) freight collect to:
United ~nstruments, Inc.

3625 Comotara Avenue
Wichita, Kansas 67226
Page 2 of 3
3625 Comoters Avenue, Wichits, Kansas 67228 Phane: (318) 885-9203
UNltED INBtRUMENTIB, INI1.
f
fELEX NO. 417481
CABLECObE: UNI~EDLNST
Service Bulletin No. 2
february 24, 1986
CLAIM FORM
OWNER NAME ADDRESS
ACFT MAKE MODEL SERIAL 9
ALT P/N AtT S/N REMOVED; S/H INSTALLED
DATE COMPLETED CERTIFIED MECH.
FBO NAME CERT, NO,
FBO ADDRESS
DO NOT WRITE BELOW THIS LINE
Page 3 of 3
I~I ~6p
NOTICE NO. HN-206.1*

DN-143.1*~
EN-31.1+
DATE: 28 November 1986
PAGE 1 of 8
SEWVICE INFOW~WATION NOYI@E
MAN DATE 8Y MAN DATQ 8 V -4--~P.
*Supersedes Notice HN-206, DN-14

26 August 1986
SUBJECT: INSTALLATION OF FAILSAFE DEVICE AT TAIL ROTOR DRIVE SHAFT AFT

FLEXIBLE COUPLING, P/N 369A5501 or 369B25643 AND INSPECTION OF FLEXIBLE
COUPLINGS.
MODELS AFFECTED: PART I All Model 36911, 369HE, 3691181, 369118, 369A (OH-6A), 369D and
369E (S/N 0001E thru 0134 E) Series helicopters with Bendix couplings
installed in the tail rotor drive system.
PART II-All Model 36911, 369HE, 3691181, 369118, 369A (OH-6A), 3691) and
3693 Series helicopters with failsafe couplings installed (P/N 369D25530
Coupling and 369D25531 Socket).
JT?ME OF COMPLIANCEt
PART I Installation of failsafe device shall be accomplished within 100 hours of operation or
within 60 days of the effective date of this notice, whichever is sooner. Procure
required parts from an Approved MDHC Service Center or Distributor. MDHC advises I
prompt adherence to the time of compliance as defined by this Notice.
PART II- Shall beaccomplished at intervals specified, All 369H/HE/HM/HS and 369A (OH-6A)
model helicopters should accomplish this notice in conjunction with Service Information
Notice HN-173.1 if the forward tail rotor coupling failsafe device has not been
inst alled.
PREFACE: Part 1 of this Notice provides instructions for installing a failsafe device to provide an
additional drive connection between the tail rotor drive shaft and the tail rotor
transmission at the aft flexible coupling. The failsafe device consists primarily of a
new 3691125530 coupling bolt to secure the aft flexible coupling to the tail rotor drive
shaft and a new 369D25531 socket installed between the connecting: flanges of the aft
coupling and the tail rotor transmission. The new coupling bolt incorporates a key
which engages a corresponding keyway in the socket, thus providing an alternate drive
link if coupling failure should occur.
Part II of this Notice prescribes checks of the aft flexible coupling for all helicopters
with the failsafe device installed.
(I)Denotes portion of text added or revised.
FORM 8578 (2/81)

NOTICE NO. HN-206.1
DN-143.1
EN-31.1
PAGE 2 of 8
REFERENCE
369D Basic HMI-Vol I(CSP-D-P) Rt~vised 15 June 1985

369D Basic HMI-Vol II (CSP-D-3) Revised 15 May 1985
369E Supplement to HMI (CSP-E-2) Issued 30 Nov 1983
369E Basic HMI-Vol I(CSP-D-2) Revised 15 June 1985
369E Basic HMI-Vol II (CSP-E-3) Issued 15 Feb 1984
3698 Basic HMI (CSP-H-O) Revised 15 June 1985
36911 HMI Appendix B (CSP-H-4) Revised 15 Jan 1982
369D/E/F SRM (CSP-DEF-6) Reissued 15 November 1984
PARTS LIST
Distributor upon receipt of

Procure parts required from your authorized MDHC Service Center or
this Notice.
Nomenclature Part Number QTY Mfr
Bolt, Coupling 369D25530* 1 MDHC
Socket 369D25531* 1 MDHC
Shim 369A5516-9 AR MDHC
Washer NAS620C416L 3 Commercial
Washer HS306-326 4** MDHC
Stud MS51992A803-14 4 Commercial
Lockring MS51997103 4 Commercial
for the 369D25531 socket

*A special price of $131.52 for the 369I325530 coupling bolt, and b179.49
has been established. This pricing will remain in effect through 31 January 1987.
**As required/HS306-326H (ALTERNATE)

c~
NOTICE NO. HN-206.1

DN-143.1
EN-31.1
DATE: 28 November
PAGE 3 of 8
MATERIAL
Grease MIL-G-81322 Mobil Grease 28 Mobii Oil

Aeroshell 22 Shell Oil
or Lubriplate Fiske Bros,

Grease 930-AA Toiedo, OH
Anti-seize compound MIL-A-90? Commercial
Lockwire MS20995C Commercial
Tools and Equipment
Torque wrench 0 to 500 inch-pounds Commercial
Commercial
Wrench P/N R1105W MDHC Spares or Rosan*
Adapter P/N SM101-18
*Rosan Products
P.O. Box 25225
Santa Ana, CA 92799
(213) 628-6191
(714) 250-8800
PART I PROCEDURE INSTALLATION OF FAILSAFE DEVICE ON AFT COUPLING
A. Remove tail rotor gearbox and drive shaft per Section 9, Pare. 9-67, of HMI Vol. I. Remove
tail rotor gearbox from drive shaft,
B. Remove and inspect for corrosion and damage the tail rotor gearbox coupling per Section 9,
Pare. 9-77, of HMI Vol. I.
C. Lubricate tail rotor gearbox input shaft splines with Lubriplate 930AA or MIL-G-81322
grease.
NOTICE NO. HN-206.1
DN-143,1
EN-31.1
PAGE 4 of 8
D. Install coupling onto gearbox input shaft.

shaft with anti-seiae
E. Coat threads of coupling bolt (P/N 369D25530) and gearbox input
compound and installbolt. Torque bolt to 250 to 300 inch pounds.
and tail rotor drive shaft
Install aft socket (P/N 369D25531) between tail rotor gearbox
as
F.
80 to 100 inch pounds.
shown in Figure i. Torque aft coupling tail rotor bolts to
Pars 9-10 of HMI Vol. I,

G. Shim forward coupling; to minimum shim requirements per Section 9(
(369D/E). Shim per HN-181 (36911 Series and 369A (OH-6A)).
9, Pare. 9-70 of HMI Vol. I.

ii. Install forward socket (P/N 369D25531) per Section
CAUTION
When the tail rotor gearbox and driveshaft

reinstalling
do not compress the forward coupling as damage to the
coupling could result.
NOTE
If the tail rotor gearbox does not bottom on the tailboom

flange and there is no gap on the forward coupling,- then
install one washer (P/N H5306-326 or HS306-326H) on each
mounting stud prior to installation of t/r gearbox.
Pare. 9-70 of HMI Vol. i. Check for

I. Install tail rotor gearbox and drive shaft per Section 9,
clearance (.010 to.020 inch) between tail rotor drive shaft coupling and tail rotor output
is not obtained, install or subtract additional shims
shaft of main transmission, If clearance
per Pare. 9-10.
NOTE
If gap Is less than .010 Inch, remove tail rotor gearbox

and driveshaft and install(l) each washer (P/N HS306-326
or HS306-326H) on each tailboom mounting
stud.
J. Repeat Step 3.
from each of the four tail rotor gearbox
K. Verify that a minimum of (1) one thread protrudes
studs per the following
mounting studs. If less than one thread is showing, replace mounting
steps:
of
1) Remove tail rotor gearbox and driveshaPt per Section 9, Pars. 9-67
HMI Vol. I.
NOTICE NO. HN-206..
DN-143.1
EN-31.1
DATE: 28 November
PAGE 5 of 8
2) Using Rosan wrench (P/N R1105W) and removal tool (P/N SM101 -18) remove
existing studs as shown in Figure 2.
3) Install MS51992A803 -14 studs.
4) Repeat Step J.
Part I of this Notice in the Compliance Record section of the

L. Record compliance with
PART II INSPECTION OF FLEXIBLE COUPLINGS
NOTE
For all helicopters with failsafe device installed,

the tail rotor drive shaft forward and aft flexible
couplings shall be checked periodically as follows:
At EBCh Pil,t Preflie~ht Check~
Rock tail rotor back and forth in plane of rotation.

If blade can move in excess of 0.75 inch (1.93 cm)
at the blade tip without rotation of main rotor blades,
check for proper condition of tail rotor drive shaft
forward and aft flexible couplings. (Section 9,
Basic HMI, Vol. I), Replace coupling as required before
further flight.
At each Aircraft/Engine Shutdown:
If thumping or rapping is heard from drive train during

final revolutions of tail rotor blades, check tail rotor
drive shaft forward and aft flexible couplings for proper
condition. (Section 9, Basic HMI Vol. I). Replace
coupling as required before further flight.
At each Annual or 300-Ho_ur Inspection:
With tail rotor drive shaft removed, Inspect flexible

couplings per Section 9 HMI Vol. I. Also visually inspect
forward and aft coupling bolts and sockets for indications
of contact. Do not loosen or remove bolt. If signs of
NOTICE NO. HN-206.1
DN-143.1
EN-31.1
PAGE 6 of 8
contact are noted, remove and reinstall socket and/or
coupling bolt sothat maximum clearance is obtained be-

tween bolt key and socket. (See View B-B, Figure I.)
Visually verify proper clearance before reinstalling tail
rotor drive shaft.

The resultant alteration to affected models described by procedures in this Notice has been shown
to comply with Federal Aviation Regulations and is FAA Approved.

1~
NOTICE NO. HN-206.1

DN-143.1
EN-31.1
DATE: 28 November 198C
PAGE 7 of 8
3694\5501 OR
(NOTE) 369H92564 369025531
COUPLING SOCKET
TAIL ROTOR GEARBOX
TAIL ROTOR
INPUT SHAFT
DRIVE SHAFT
369025530
BOLT
o O
-t-O---,
369025531
SOCK~T
L~cB 369A5416-9
SHIMS
369[)25530
BOLT
VIEW B-B
NOTE:
NAS620C416L WASHER REPLACES EXISTING
NAS620C416 WASHER, 3 PLACES
Figure i. Installation of Failsafe Device, Aft Tail Rotor Coupling

NOTICE NO. HN-206.1
DN-143.1
EN-31.1
PAGE 8 of 8
STEPI S1EPZ STEP3

BACI( OUT STUD OR INSERT COUAPSE AND REMOVE LOC~RING
MIIl. OR DR1U OUT INNER SERRATIONS
STUD
LOCKRING
IOOJ1
Figure 2. Stud and Insert Typical Replacement

REFERENCE SHEET
SERVICE INFORMATION AND NOTICES AND LETTERS
Action Reference: When performing; maintenance of tail rotor drive shaft, refer to Service
Information Notice No. HN-2i)6.1, DN-143.1 and EN-3r.l for installation of
failsafe socket and coupling bolt.
HMI Reference: Insert this sheet in HMI Vol. i, in the front of Section 9.
This reference sheet shall be kept as a part of the manual until the data is
incorporated at the next revision of HMI Vol. I. (Refer to Service
Information Summary, HMI Vol. I Page i.)
C
REFERENCE SHEET
Action Reference: When performing Annual or 300-hour Inspection, refer to Service

Information Notice HN-206.1, DN-143.1, and EN-31.1 for engagement check
of failsafe socket and coupling bolts.
HMI Reference: Insert this sheet in HMI Vol. II, Section 2, Table 2-2 for 3693[) and 369E
Models and HMI Appendix B, Annual or 300-hour Inspection.
This reference sheet shall be kept as part of the manual until the data is
incorporated at the next revision to the HMI Vol. II and Appendix B. (Refer
to Service Information Summs~v, HMI Vol. II, Page i.)
C:
I
NOTCE NO.I UN-145:e
EN-33
FN-22
SERVICE gNFORWIAVION MOTICE DClfEI ~9 April 1987

PAQE 1 OF 9
MAN IDATO RY MAN DATO RY MAN DATO RY
SUBJE CT FABRICATTON AND INSTALLATION OF 36913crE:5704 OIL FLEX-

LINE HUSE ASSEI*1BLIES IN THE MAIN TRANSMISSION C001-Il\lG
INSTALLATION (F"/N
MOr)tCS FCTtD All 369D, 3648, S6StF and S69FF
helicopters that have rigid oil lines installed in the main

transmission ail cooling system.
T I Mt OF COMFCL I F~NCE This Service Information Notice

shall be accomplished within helicopter
the next 100 hours of
operation or when the 369D257~9 or 363D2~710 tctbe assemblies

need replacing, whichever occurs first. Compliance to this
Service Information Notice will satisfy the requirements and
compliance to EN-10 dated ~O November ~983, DN-124 dated 10
November 1983 and dated 7 August ~985.
FFFr ~CE This Service Information required

Notice contains all
information owners/operators
for Douglas of McDonnell
Helicopter Company (MDHC) Model 5(:,(:, helicopters to fabricate
and install or 969DZ57r~4-21 oil hoses
which replace the and ~69D257103 tube assemblies and
3h9D2570S hose assemblies,
REFERENCE
369D HMI Vol. I (CSP-D-2) Revised 15 June ~985

369E HMI Vol. I (CSP-E-2) Revised 3O Nov 1983
369F MMII Vol. I (CSr-F-2) Revised 19 Apr 1986
369U PFM (CSP-D-1) Revised 2~ Jan 1994
3h4E PFM (CSP-E-1) Revised 11 July 1984
369F PFM (CSP-FF-1) Issued 25 Oct 1985
EN-10/DN-124 Dated tO November 1985
Dated 07 August 1985
FORM 9579 (2/81)

SWCf30AINEL& ePOUOLW4ia
:i
NOTICE NO,I DN-145
EN-33
FN-1;22
DATEl;bS Flpril 1987
PCIOE 2 OF 9
PCSRTS LIST
Part No. Namenclature Qty. Source
Hose Assembly 1~
Hose Assembly 1 or 2~ MDHCw~
MS21266-2N Grommet A/F;; Commercial
AN743-~2 Bracket 1 MDHC
AN960KD~OL Washer 9 Commercial
MS21919WDF~2 Clamp 3 Commercial
NAS1713D30N Clamp Commercial
MS219199DFll Clamp 4 Commercial
N~81303-3 Bolt 1 Commercial
MS21042-3 Nut 5 Commercial
NAS1096-3-7 Screw 2 Commercial
MS20470A~4 Rivet 4 Commercial
NASi303-4 Bolt 2 Commercial
PARTS LIST (H~se Fabrication)w~
AE701-8 Hose A/F Aeroquip Corp.

Jackson, MI.
AE138-16 Abrasion Sleeve n/R
816-8D Fitting 4
I.D. Tag 2 Commercial
OR (Alternate)
156-8 Hose A/R Stratof 1 e:~ inc.

Fort Worth, TX.
2645-22 Chafe Gua;d ~/R
676-8D Fitting 4
I.D. Tag 2 Commercial
w3b3F/FF Series helicopters require (2) -11 hose assemblies; ShSD/E

Series helicapters require (1) -11 and (1) -21 hose assembly.
+~369D"5704-11 and -21 hose assemblies can be procured from MDHC or
~abricated per Step A and Figure 1.

NOTfeE NO.I DN-145
EN-33
DATE1 c,s FiprilFN-22~587

P8(3E S C3F E~
ME~TERIALS
Primer, zinc chromate TT-P--1757 Commercial

Lctbricant (12 U.S. Fts) MIL-L-78r~8 Commercial
Epoxylite 202 or N/A Commercial or
equivalent Epoxylite Corp.

Fl Monte, CA.
PROCEDURE
A. Procure reqilired hose assemblies from an Approved MDHC Service
Center, Distributor or fabricate required hose assemblies per the
following steps and Figure 1:
NOTE
Hose, abrasion sleeve and end Cittings are to

be from the same manufacturer, Do not
1 interchange parts.
1) Cut hose material to required length allowing for installation of

end ~ittings.
2) Cut abrasion sleeves to required length.
3) Install and position abrasion sleeves an hose assemblies.
4) I17stall end Fittings per manuSacturers instructions.
5) Proof pressure test each hose assembly to 200 P.S.I.G. for two
minutes minimum, five minutes ma::imum as shown in Figure 1A
6) Identify each hose assembly with complete part number- and af
assembly using metal identification tag or equivalent.
E(. Fietnove sound insulation and transmission access cover (Sectian 2,

HMI Vol. i).
C. Drain main transmission and oil cooler lubrication system iSection

2, HMI Vol. i).
D. Disconnect and remove 369D25705-11 and -21 hose assemblies,

(--13 on 369F/FF models;) and 369D2571(:,-11 tltbe
assemblies and all associated hardware as shown in Figure 2.
NOTICE NO.I DN-14~i
EN-33
FN-22
DCITE1 09 April 1987
PCIOE 4 OF 9
E. Remove or -11 bracket and install MSZ0470AD4 rivets in

holes or cutoff bracket and debur all
sharp edges to prevent
possible damage to 9le~:-hose installation and-surrounding area (See
Figure 2).
F. Remove 369D257r:,1-5 and -7 and fill holes with epoxy

compound or cutoff brackets and debuv- all sharp edges to prevent
possible damage to flex-line installation and surrounding area.
G. Using #6
drill, drill .204 inch diameter holes in two places as
shown in
Figure 3. Apply zinc chromate primer to holes and
surrounding area.
i-i. Install MSZ1266-2N grommet and position MS21919WDFll clamps loosely

around applicable hose assemblies as shown in Figure 3.
I. Attach 369D25764 hose assemblies to ~N 837-8D elbows.
J. Attach (369~, E, F/FF=) hose assembly to S69D2J7O6valv

housing.
i:::. Attach (3C~9F/FF) to 369D25706 valve housing or
569U257(~4-21 (Sh9nl E) to connector port located on web.
L. Fosition abrasion sleeves so that no unshielded hose contacts

buli::heads using NASi713D3(:,N and MS2.1919WDI-12 clamps.
M. Complete installation and tighten all clamps as shown in Finure 3
N. Fill transmission with approved lubricant ISection 2, HMI Vol,
O. Startengine and operate until lubricant has circulated thrcic.~gh the

entire oil cooling system (refer to applicable Pilots Flight
Manual). Check installation for leaks and security.
P. Reinstall sound installation and transmission access covers (Section

2 of applicable WMI Vol. i)
B. Check main transmission oil level at sight gage (Section 2, WMI Vol.
I). Add approved oil, if required.
H. Record compliance with this N~tice in the applicable section of the

C---
~r: NOTrCE NO.I DN-145
EM-33
FW-22
DCltE: 09 April ~987
j
PAGE J OF 9
WEIGHT ClWD BCILANCE
Changed Weight:
WEIGHT (LBS.) ~RM (INCH) MOMENT(INCH LBS.)
+1.a2 Station ~2h.2 +~54
The resultant alteration to af~ected models as described by procedures

in this notice has been shown to comply with Federal Aviation
Hegulations and is FAA Approved.
C:
NOtICE NOli DN-~45
EN-33
FN-22
DATEI 03 April 1987
PCIOE b OF g
816-81) FITTING, 2 REQD

(888 NOTE a
701-8 HOSE (588 NOTE 2)
AE138-16 ABRASION SLEEVE

(SEE NOTES 1 AND 2)
37. O (-11) ASSEMBLY
8.0
40.0 1-211 LENGTH
AU DIMENSIONS SHOWN IN INCHES.
NOTES:
i. EACH HOSE ASSY IS TO HAVE AN 8 INCH LONG

ABRASION SLEEVE LOOSELY FITTED OVER THE HOSE.
THIS WILL BE POSITIONED IN NEXT ASSY.
2 HOSE, ABRASION SLEEVE AND HOSE FITTINGS IN COMBINATION

MUST BE FROM THE SAME MANUFACTURER.
88-63nA
Figure i. Oil Flex Line Fabrieati~n.

NOTIeE NO.:
EN-33
DPTEI 09 AprilFN-2219e7
PAGE 7 OF 9
AIR GAUGE
AIR SOURCE
36908704-11/-21
HOSE ASSY
HOLDING FIXTURE FOR

WATER (H201
OR STODDARD SOLVENT
PROOF PRESSURE TESTING
(COMMERCIAL AVAILABLE NON-CORROSIVE) OF HOSE ASSY (PIPICAL)
88-629
Figure 1A. Huse Assembly ProaSS Pressure Set-Up.

z
DRILL OUT AND REPLACE 0~ O
CJ--(
MISTING RIVETS m m
~7
(MS~DQOA D414 PEACES m
03
-rl G
r r
OIO
9 -rl
r_ D
f 67a
iTi -t -t -r
1 Y-------l-- r
a
BRACKET -t
-C
O O c-ZTr -rlmz
9 c
369H3009 03 PJ ~i P
~ti
r STATION 124 CANTED FRAME
rt
C3 369025709-11
r TUBE ASSY
r 1 369025710-11
TUBE ASSY 369H3010-73
17
O PANEL
r _I II I 1 3690257013
1 BRACKET
In
rt I I III II 1 369025706
L TEMP. SENDER
r
r
HOUSING
m 369HM10-17
rt
r PANEL
369025705-11
3 HOSE ASSY
369025705-21
m HOSE ASSY 3691323020-5 WEB
369025701-7 BRACKET
STATION 124 CANTED FRAME
rt
7?
m TEMPERATURE
3 SENDER HOUSING
r
VIEW LOOKING AFT. I VIEW LOOKING INBD. L.H,
f7 88-6b
NOTICE NO.r DN-~45
EN-33
DATE: 09 AprilFN-2214E37
PAGE 9 OF 9
396025704-21 (369DIE1
WEB (REFI
369025706 HOUSING
TEMP SENDER (REF)
AU DIMENSIONS SHOWN IN INCHES.
MS21266-2N I --cl I Cc2n

GROMMET I I I (TYP) t.l8(PIP) DETAIL- A
3690/2
369025704-11 HOSE AS SY (3690,E. F, FF)
369[)25704-11 1369FIFR
C I I ~i( ~(SEE DETAIL AFOR 3690/E)
MS21919WDR2 CLAMP (2 REQD)
DRILL .204 DIA. HOLE 51303-3 BOLT
(2 101 WASHER
AN 837-80
MS21042-3 NUT
ELBOW
4. 0~
(REF) MS21919WDn2 CLAMP
51096-3-7 SCREW
101 WASHER PREQD
MS21919WDFll CLAMP 4 REQD I lMS21042-3 NUT
NAS1303-4 BOLT 2 REQD IAN743-12 BRACKET
AN960KDIOL WASHER 4 REQD
MS21042-3 NUT 2 REPD I( 369[3 257(14-11
NAS17UD30N CLAMPI ~HOSEASSY
NAS1096-3-7 SCREW 369023020-5
AN96nKDIOLWASHER WEB (REFI
(2 REQD)
MS21n42- NUT
3690292490 (REF)
AN815-80~ UNION
NAS617-8PACKING IAEFI
VIEW LOOKING AFT I ltBd
APPX. POS ITION OF ABRASION SLEEVES.
LOCATE SLEEVES SO MAT NO UNSHIELDED
HOSE CONTACTSBULKHEADS.
USE CLAMPS TO SECURE SLEEVES AS SHOWN.
369D25708HOUSiN6
VIEW LOOKING INBD. LH. 369D25706HOUSING
VALVE (REFI
TEMP SENDER IREF)
1369FIFF SHOWN,
SEE DETAII A FOR 3690/5)
58-6228
Figure 3. Main Rotar Cooling Fle>: Line Installation.

McDonnell Douglas NOTICENO-
EN-34.1*
Helicopter Company
DATE: loseptember 1992
SERVICE INFORMATION NOTICE ~G, ,,f 3
FN-23, dated 18
Supersedes Servioe
February 1987.
Information Notices HN-208. DN-146, EN-94 and
I
SUBJECT: Daily Preflight Examination of Main Rotor Blade Leading Edge Abrasion
Strip Bonding.
MODELS AFFECTED: Ah McDonnell Douglas Helicopter Company (MDHC) Model 369
Series helicopters, including the 369A (OH-6A), and 500N Series helicopters
equipped with 369A1100-503, 369A1100-505, 369A1100-507,
369D21100-505, 369A21100-509, 369D21100-513, 369D21100-515,
369D21100-516, 3693~21102, 369D21102-501 and 369D21102-503 main
rotor blades.
TIME OF COMPLIANCE: This Service Information Notice shall be complied with

check.
immediately upon receipt and is considered part of the pilots preflight
PREFACE: The information given in this Notice lists criteria for examining the leading
edge abrasion strip bonding on the main rotor blades prior to each flight.
Abrasion strips with excessive bonding separation may separate from the
main rotor blade which could result in serious balance problems. To ensure I
safehelicopter operation, MDHC is requiring all affected operators to per-
form the following examination of the main rotor blade leading edge abrasion
strip for adequate bonding.
PROCEDURE
a. During the pilots preflight check of the helicopter, perform a visual inspection of the
main rotor blade leading edge abrasion strip bonding. Any blisters, bubbling or lifting
of the abrasion strip indicates a void. Voids not closer than .5 inch to any outside edge
of the abrasion strip, which do not exceed 1.5 inches square in size and which are no
closer than one inch to any other voids are acceptable. Also, there cannot be more than
three voids on either the top or bottom of 36 inch long abrasion strip surface or more
than two voids on either the top or the bottom abrasion strip surface of an 18 inch
section of abrasion strip.
b. Record all voids noting size and location in the helicopter Log Book and check each
void prior to each flight for growth and acceptance criteria.
McDonnell Douglas
FORM 9578 (REV 11187)
Helicopter Company
NOTICE NO.:.^.,HN-208.1*
DN-146.1*
EN-34.1*
FN-23.1*
NN-002
DATE: 10Septemberl99a
PAGE 2 of 3
c. Those blades which do not meet criteria given in Step A of this Notice shall be re-
moved from service. Contact an Approved MDHC Service Center concerning the
other
disposition of those blades still covered by warranty. The abrasion strip on
blades can be replaced in accordance with FAA approved MDHC data. MDHC recog-
nizes only those repair stations listed below.
WEIGHT AND BAU~NCE: N/A.

POINTS OF CONTACT:
For further information, local MDHC Field Service Representative (refer
contact your
to the latest revision of the Product Support handbook for address
and telephone
numbers) or contact the Field Service Department at MDHC, Mesa, Arizona.

Telephone: 1-800-445-1516 or (602) 891-6342.
Approval: The engineering design aspects of this notice have been shown
FAA to
I comply with applicable Federal Aviation Regulations, and are FAA approved.
MDHC approved main rotor blade repair stations
Inc. Composite Technology, Inc.

Composite~chnology,
111 Val Dervin Parkway East Coast Division
Stockton, CA95206 2407 Schirra Place

(209) 983-8490 High Point, NC 27263
FAX.: (209) 983-8419 (919) 885-2400
TELEX: 359435 COM TECH STO FAX.: (919) 885-2492
Composite ~chnics, Inc. BH Pacific PTY, Ltd.

10724 Goodnight Lane P.O. Box 138
Dallas, Texas 75220 Hamilton Central
(214) 556-0744 Queensland 4007 Australia
FAX.: (214) 556-0781 (61)7 268-4077
(800) 588-0744 FAX: (61)7 268-7815
Composite Technology Canada LTD. Rotor Blades, Inc.

69 Durand Road P.O. Box 3689
Winnepeg, Manitoba RW 3T1, Canada Bristol, TN 37625

(204) 661-6412 (615) 538-5151
FAX.: (204) 661-9218 FAX: (615) 538-8469
NOTICENQ.: HN-208.1*
DN-146.1*
EN-34.1*
FN-23.1C
NN-002

PAGE 3 of 3
MDHC approved main rotor blade repair stations
Rotor Blades Inc.

Composite Technology, Ltd.
1514 East Scotts Avenue Box 589
Thruxton Airfield
Thruxton, Andover Stdckton, CA 95205
Hampshire SP11 8PW England (209) 466-0725
(44) 264-773361 FAX: (209)466-3148
FAX.: (44) 264-773980
Rotor Blades (NZ) LTD

6/11 Markedo Place
PO. Box 673
Papakura, New Zealand
(64) 9-298-1655
FAX.: (64) 9-298-1655
EN-35.1*
FN-24.1*
PAGE 1 of 6
SERV3C% INFORMATI~N NOTICE
MANDATORY I I MAN DATO RY MAN DATo RY
This Service Information Notice supercedes Notice DN-147,

EN-35 and FN-24, dated 23 April 1987.
I
SUBJECT: ONE-TIME INSPECTION OF MAIN TRANSMISSION TAIL ROTOR OUTPUT DRIVE
PINION SHAFT (P/N 369D25125-BSC and 369D25125-11).
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 3690, 369E and
369F/FF Series helicopters with 369025100-BSC or -501 main transmission assem-
blies installed.
TIME OF COMPLIANCE: Those helicopters with the following listed main rotor transmission
assemblies shall accomplish this Notice within the next 25 hours of helicopter
operation:
Main Transmission Serial Numbers:

1989
1 992 and 1993
1998 thru 2000
2002 thru 2082
2084 and 2085
100 hours of
All other helicopters shall accomplish this Notice within the next
operation or at the next annual inspection, whichever occurs first.
main transmission tail rotor output drive pinion shafts in Spares inven-
All subject
tories shall comply with this Notice before installation.
NOTE
369D25125-11 pinions with the letter "T after the serial number
and those pinions with serial number 8790 and subsequent
(8790 through 2999) do not have to comply with this Notice.
it is recommended that compliance with Notice DN-148.1/EN-
36.1/FN-25.1 be accomplished in conjunction with this Notice, if
not previously accomplished.
drive pinion
PREFACE: Recently there have been reported instances of the 369D25125 output
shafts fracturing. As a result, MDHC is requiring the of
following inspection the output
shown in Figure
pinion shaft. Parts which do not have the undercut and shotpeening
1 may be returned to MDHC for rework if a magnetic particle inspection
of the part
shows no indications of cracking.
I) Denotes portion of text added or revised.
Prcciuct Support
FORM 9578 j2i811 DQBiiGL~rS

i-j-,--:;iC;3 P7:Er7
EN-35.1
FN-24.1*
PAGE 2 of 6
REFERENCE
3690/8 HMI Vol.l (CSP-D-2) Revised 15 June 1985

369F/FF HMI Vol.l (CSP-F-2) Revised 15 April 1986
389DEF COM (CSP-DEF-5) Revised 15 March 1985
PARTS LIST
O-Ring MS29561-014 2 MDHC
MS29561-013 2 MDHC
O-Ring
MS29561-022 1 MDHC
O-Ring
MS29561-235 1 MDHC
O-Ring
1 MS29561-437 1 MDHC
O-Ring
Lockwasher SL61 W-11F 1 MDHC
sleeve 99187 AR MDHC

Speedi
3690251 82-3 1 MDHC
Seal, oil
Filter ACA388F90 AR MDHC
MATERIAL
Nomenclature Source
Emery Cloth, fine Commercial
Carborundum Stone or Commercial
Arkansas, extra fine

Primer, Epoxy (MIL-P-23377, Type 1) Commercial
Procedure
a. Remove main rotor transmission per applicable HM!, Vol.l, Section 9.
b. Disassemble main rotor transmission per Part I, Section 2 of COM.

EN-35.1*
FN-24.1*
DATE: 30 Octcber 1987
PAGE 3 of 6
c. Visually inspect the output pinion gearshaft for the following inspection criteria/discre-
pancies:
1. Identify and record shaft serial number. If shaft serial number is contained in the list
below, return shaft to MDHC for disposition:
T/R Output Drive Pinion Shaft Serial Numbers:

1474 thru 1502
1504 thru 1 547
1549 thru 1561
1563 and 1564
1566;
2. Verify pinion has an undercut style fillet radius as shown in Figure 1.
3. Perform magnetic particle inspection, per MIL-I-6868, or dye penetrant inspection, per
MIL-I-25135, grade 4 or better, to verify fillet radius area and I.D. of shaft do not show
indications of cracking.
I
NOTE
Parts which do not have the undercut shown in Figure 1 may be
returned to MDHC for rework if a magnetic particle or dye
penetrant inspection of does not show any crack
the part
indications. Parts which show indications of cracking during
magnetic particle inspection shall be returned to MDHC for
disposition.
4. Scratches, tooling marks, corrosion or other surface defects in the fillet radius (inboard
bearing journal). The fillet radius surface finish shall not exceed RMS 63. Verily ares
specified in Figure 1 is shot peened.
I
NOTE
RMS is a standard used shops for measuring
by machine
machined metal surfaces. RMS comparators can be obtained at
machine shop supply facilities.
A shot peened surface exhibits an orange peel appearance

when viewed with a 10X magnifying glass.
5. Indications of corrosion or rough surface finish on the I.D. of the shaft and/or lack of
cadmium plating. The surface finish of the shaft l.D. shall not exceed RMS 125.
6. Scratches, tooling marks, corrosion or other surface defects which exceed the
serviceable dimensions shown in Figure 1.
NOTE
Those shafts which do not meet the criteria listed above, may be
returned to MDHC for dispoition or reworked per the following
instructions:
NOTICE NO.: DN-1J~.1*
EN-35."
FN-24.1"
PAGE 4 of 6
d. Aework those parts which have scratches, tooling marks, corrosion or other minor
surface defects in the fillet radius per the following steps if a magnetic particle inspection
of the part shows no indications of cracks:
1. Position pinion on a lathe or equivalent rotating fixture.

fillet radius as it is turned by hand on the rotating
2. Polish out defects in the pinion
fixture.
E~J CAUTION
Fine emery cloth and extra fine hand stone are the only approved
method for the above procedure. I.D. finish requirements and
sen/iceable dimensions shall comply to this Notice and to Figure
1 of this Notice and to Part I, Section 3 of the COM. Parts which
do not comply can be returned to MDHC for evaluation or
warranty consideration if applicable.
NOTE
tongue depressai for
U5e fine Emery cloth wrapped around a
polishing. Extra-fine Arkansas or carborundum stone may be

d
used provided the diameter matches radius.
e Surface corrosion and/or corrosion pits, which can be removed

without excessive honing (not greater than .005 inch), on the I.D.
of the shaft should
may be removed and blended out. The I.D.
be coated with epoxy primer (MIL-I-23377, Type 1) following
rework or if the I.D. is not cadmium plated and no corrosion is
found. The magnetic particle inspection of the part for crack
indications should be performed prior to the application of the
primer coat.
e. Magnetic particle inspect pinion, per MIL-I-6868, if not already performed.

via the
Reidentify acceptable output pinions with a "T" after the pinion serial number,
f.
vibroscribe process, and by etching ink stamp the serial number and the
shown in Figure 1.
letter "T as
I
Part I, Section 6 of COM.
g. Reassemble main transmission per
h. Reinstall main transmission into helicopter per Section 9 of applicable HMI Vol.l.
i. Record compliance to this Service Information Notice in the Compliance Record Section
NOTICE NO.: DN-tj7.1*
EN-35.1*
FN-24.1*
PAGE 5 of 6
C:
NOTICE NO.: DN-147.1+
EN-35.1+
FN-24.t
PAGE 6 of 6
22424 MINIMUM DIAMEIER OVER I. 9696 MAXIMUM DIAMETER

1. 8(3 MAXIMUM INOTE IB1
TWCIO. 096 DIAMETER PINS I. ~U7 MINIMUM DIAMETER
DIAMETER INOlE 1)
I
INcllE 61 1.11720 MINIMUM DIAMETER L 1791 MINIMUM
(NOTI 2) DIAMETER OVER TWO
n. 060 DIAMETER PINS
.i~.... ........_,!~.... _L
INOTF 7AI
Ur
c~
I (NOTE 41
,I,
~f- i;i
i
(NOTE 5)
1.06 R TANGENT
TO SHOULDERI
Nons:
mnS INCH.
I. CONCENTRIC WITH "A" DIAMETER WITHIN n.
n.n35-0.035 P\\\ 2. CI,NCENIRIC WITH "A. DIAMETER WITHIN 0.001 INCH.
MIrIML)M O.O~tO I j I I ALL UIMI NSIONS IN INCHt S.
L~S
UNDtRCUI 4. SIIRFACE FINISH SHALL NOT ~XCEtD RMS L
SURFACE FINISH SHALL NUT EXCEED RMS 6~

O rl. SURFACE AREA, EXCEPT THE DRIVE SIDE
UNDERCUT FILLET RADI~S DF VERIFY THAT UNDERCUT FILLET
IHt CLAH TEETH.
RADIIIE SHOWN IN DETAIL "BIS SHOT PEENED.
IA. VIRRO(TRIRE THF LETTER 7"FOLIOWINC THE

FXISIINC SERIAL NUMBER.
IR. tlrnlNC INK STAMP IHF SERIAL NUMBER FROM

Ih Ft)lLOWID RY THI LflTER 7"ON THIS DIAMETER.
A. cno ,lallNe SHOULD BE EVIDENT OVER THIS

AREA.
49-M6C
Figure 1. Output Drive Pinion GearShaft Inspection.

NOTICE NO.: DN-148.1R
EN-36.1*
FN-25.1*
SERVleE INF~RMATION NOT1CE
MANDATORY MANDATORYI MANDATORY
*This Notice supercedes Service Information Notices DN-148, EN-36 and FN-25, dated 23 April
1987 and DN-105, dated 26 May 1932. 1
SUBJECT: INSPECTION OF MAIN TRANSMISSION OUTPUT SHAFT ASSEMBLY RING GEAR
CARRIER (P/N 369D25132-BSC or -5).
I
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369D, 3698 and
369F/FF Series helicopters equipped with 369D25100-BSC, -501 or -503 main
transmission assemblies. Ail Spares 369D25100-BSC, -501 or -503 main ttansmis-
sion assemblies. All Spares 369D25132-BSC or -5 main transmission output shaft
assemblies.
NOTE
Main transmission assemblies (369025100-505) are not affected
by this Notice. All 369D25132-3 Spares main transmission out-
put shafts are not affected by this Notice.
Owners/Operators are advised to replace all 369D25132-BSC

and -5output shafts at the earliest convenient date with the
369D25132-3 output shaft which will eliminate the necessity to
perform the following periodic inspection. Those 369025100-
BSC, -501 and -503 transmissions will be reidentified as a -505
when the 369D25132-3 output shaft assembly is installed and
the output pinion noule and input gear noule are reworked per
COM, Part I, Section 5.
TIME OF COMPLIANCE:
NOTE
If theperiodic visual inspection per DN-148, EN-36 and FN-25
has already been complied with, the following periodic visual
inspection does not have to be complied with again at 100
hours.
It is recommended that compliance with Notice DN-147.1/EN-

35.1/FN-24.1 be accomplished in conjunction with this Notice if
not previously accomplished.
Periodic Visual Inspection Shall be accomplished within the next 100 hours of
helicopter operation and at each subsequent 300 hours of helicopter operation or if
any of the following conditions exist: 1) metal particles found in the transmission;
I, Denotes portion of text added or revised.
FORMB578(2/81)
_I1:4fYLF~r9:LY
EN-36.1*
FN-25.1*
PAGE 2 of 7
2) excessive noise vibration in the main transmission; 3) vibration in the aircraft

or
that can not be reduced or eliminated by ordinary main rotor blade tracking and
balancing procedures. Helicopters that have transmission assemblies installed with
less than 200 hours total time on the output shaft do not have to comply with this
Notice until the next 300 hour or annual inspection, whichever occurs first.
PREFACE: This Notice lists a procedure for periodic visual inspection

a of the main transmission
output shaft assembly to check for possible cracks in the lower welded disk,
particularly in the area of the electron beam weld which attaches the lower disk to the
output shaft; and in the upper disk, in the area ofpotential electron beam
impingement directly in line with the welded area.~The visual inspection is to be
performed by disassembly of the transmission, and repeated at the interval specified
until the 369D25132-3 output shaft is installed into the transmission.
It is to be noted that the time between overhaul CTBO) interval for the 369[325100-
BSC, -501, -503 and -505 transmission assemblies are 3000 hours.
REFERENCES
369D/E HMI Vo~.l (CSP-D-2) Revised 15 June 1985 C

369DEF COM, Part I (CSP-DEF-5) Revised 15 March 1985
PARTS LIST
O-Ring 5-488-047-071 1 MDHC
O-Ring MS29561-264 1 MDMC
Washer SL61W-15F AR MDHC
Filter ACA388F90 AR MDHC

NOT1CE NO.: DN-148.1"
EN-36.1*
FN-25.1*
PAGE 3 of 7
TOOLS AND EQUIPMENT
Nomenclature Source
10X Magnifying Glass Commercial
Dye Penetrant Kit (MIL-I-25135) Commercial
PERIODIC VISUAL INSPECTION
a. Remove main transmission assembly (1, Fig.l) from helicopter (Section 9, HM! Vol.l).
b. Remove lubrication pump assembly (2, Fig.l), tail rotor drive assembly (3, Fig.l) and
main rotor drive assembly (5, Fig.l) from main transmission (COM, Part I, Section 2).
c. Inspect output drive shaft per the following:

1. Inspect the upper surface of shaft for bulging or raised surfaces in the area noted in
Figure 2.
NOTE
Any shafts with bulging or raised surfaces in this area shall be
rejected for service and returned to MDHC.

If any indication of cracking is noted~in step 2 or 3 below (see
Figure 3), discard shaft and install 31j9D25132-3 shaft.
a Those shafts which have questionable indications shall be sent
to MDHC Warranty and Repair for interpretation.
2. Using a 10X magnifying glass, visually inspect upper surface of shaft for indications
of cracks in the area noted in Figure 3.
3. Perform dye penetrant inspection, per MIL-I-25135, on upper and lower disk surfaces
allowing dye penetrant to remain on disk surfaces for a minimum of five minutes.Us-
ing a 10X magnifying glass, visually inspect both surfaces for indications of cracks.
d. Operators with 369D25100-BSC transmission assemblies shall rework the 369D25164-
13 output pinion noule and the 369825165 input gear noule per COM, Part 1, Section
e. Reassemble main transmission (COM, Part I, Section 6) and reinstall transmission in
helicopter (HMI Vol.i, Section 9).

f. If a 369[)25132-3 output shaft has been installed in the transmission assembly, then,
using a reidentify main -transmission aSsembly as 369025100-505 on the
vibro-pencil,
transmission ID plate..
g. Record compliance with this Notice in the Compliance Record Section of the helicopter
Log Book.
EN-36.1*
FN-25.1*
PACE 4 of 7
EN-36.1*
FN-25. i"
PAGE 5 of 7
SEE SEE
CAUTION CAUTION
BELOW BELOW
AREA OF 5
INSPECTION
,i\ 2
tt
t_
-3
i
1 MAINTRANSMISSION
E, 2 IUBE PUMP
3 TAIL ROTOR DRIVE
4 OUTPUT PINION NOZZLE
S MAIN ROTOR DRIVE
DO NOT REMOVE INPUT

DRIVE ASSEMBLY
CAUTION: OUTPUT PINION NOZZLE ASSEMBLIES (4) MUST

BE REMOVED BEFORE REMOVING MAIN ROTOR DRIVE ASSEMBLY (51.
IDENTIFY NOZZLE ASSEMBLIES (4) TO REINSTALL EACH NOZZLE IN
SAME LOCATION
Figure 1. Main Transmission Major Components. 88-633

I
NOTICE NO,I HN-197,2+

DN-130.2*
EN-19.2e
ILN-i7.ir
DATEI March 23,1987
PAGE b OF b
x~lu.;
-r ii
a,
~*f"ilM:"*:
"i: c r:C
";:ae~ l.i;
i;
SHOWN *8OVI: UN8ONDING O~IPOXY *OHIIIVI 1NO I8RI8lON STRIP

WITH SEPIRI~ION B~NV(IN IBRISION STRIP ANO
*IR~Oll IURT*CI. BL*OIUNCCIPT~SLI ~OR SIRVICI.
IHOWN RIGHT: UNBONDIO RNO DIPPLAC,D ABRASION ETRIP

BL1Dt TIP; S~PARITION BINltlN ~BR*IION
ETRIPIAIRIOIL SURPICL ~LONO BONO LINI.
BLAOI UNI\CCIPTABLI ~OR SIRVIC~.
PINCII IL--onlu sir 118 INCHI
npr
MIN( INCH
TIPPING TOoL ~OR RBICITION
88-170-21
Figure i, Inspnction of Til Rotor Blade nbrasion 8trip

i
EN-36.1*
FN-25.1*
PAGE 7 of 7
Y
u
hr 6 JI
kJ
~J hJ41)
Ca" t
I t
tli
:C i:
4
INOTF 21
B B L3 umll
C
(NOTL ii)
;ii
@p ~:i
:::;e
MAIN TRANSMISSION OUTIUT SHAFT

IIPIER DISK SURFACE
a/ MAIN TRANSMISSION OUTPUT SHAFT
LOWER DISK SURFACE
NOTES:
i. PAY PARTICULAR ATTENTION ~OH CRACKS IN AREA Ot ELECTRON HIAM WELD

WHICH ATTACHES LOWER DISK TO OUTPUT SI1AFT ISHADID AREA P6001.
2. PAY PARTICULAR ATlENTION TOR CRACKING, OR CHIPPINC IN I:LAT SLIHIACE
OF DISKS. SIMI)IATED CRACK IROPAGATION AND CtIIIPIN(; IS SHOWN.
88-562A
Figure 3. Periodic Inspection of Transmission Output Shaft.
NOTICE NO.: HN-209*
nN-~49*
EN-37
FN-26
DATE: 15 Sept. 1987
iS F ~r:i i= E I i~i;= O Ti,L; ~ig; O N ~i PAGE 1 of 4
Ti E
MANDATORY MANDIL~TORY ?I*-a

MAN DATORY
"Supercedes Service Information Notices

HN-194 DN-128, Dated 09 July 1984.
SUBJECT: 369A8010 ENGINE O1L PRESSURE AND TORQUE TUBING PULL TEST.
ters including the 369A (OH-6A) Series helicopter.
TIME OF COMPLIANCE: The requirements of this Notice shali be
accomplished within the next
100 hours of helicopter operation, if it has not already been
complied with, and any
time the 369A8010 oil lines and related firewall fittings are removed and reinstalled
or
replaced
CAUTION
In addition, this Notice shall be complied with anytime there are
indications of oil leaks around the 369A8010 oil tubing at the
firewall fittings.
PREFACE: Procedures in this Notice describe an inspection of two

nylon tubes used as oil
pressure and torque pressure lines for proper swaging of the tube assemblies
connected to the firewall fittings. If not properly swaged, the tubes can
pull out of the
fittings, causing loss of engine oil which may result in damage to the and engine
surrounding components.
REFERENCES
369H Basic HMI (CSP-H-2) Revised 15 June 1985

369D/E HMI Voi.l (CSP-D-2) Revised 15 June 1985
Applicable Pilots Flight Manual (for helicopter operation)
TOOLS AND EQUIPMENT
Nomenclature Source
Duct tape (2 inch wide) Commercial
Cord (30 Ib. test min.) Commercial

two to three feet long
Spring scale, short body Commercial
25 Ib. min.
I
FORM 9578 (2/81)
.3?C"tGbr3~
NOTICE NO.: HN-209*
DN-149*
EN-37
FN-26
DATE: 15 Sept. 1987
PAGE 2 of 4
PROCEDURE
a. Release and prop open filter bypass door or plenum chamber access door.
CAUTION
Use care to prevent entry of foreign objects (FOD) into engine
air inlet. Install cover over engine air inlet. Do not remove cover
until work is completed and any debris or other materials are
thoroughly cleaned out of the area. After removing the cover,
verify that area around base of mast, inlet plenum and entire
plenum chamber is free from foreign material.
b. Wrap duct tape around oil pressure tube, approximately one inch in front of bulkhead
fittings. (See Figure 1.)
NOTE
Before performing the following step, it may be necessary to
practice tieing the rolling hitch, as shown in Figure 1, using one
hand.The rolling hitch is used to attach the cord to the tube
assemblies while performing the pull tests.
c. Tie a small loop in one end of a two to three foot length of cord. Tie opposite end of cord
around oil pressure tube using a rolling hitch; slide rolling hitch down tube until it rests
on duct tape; tighten hitch. (See Figure 1.)
d. Using a short body length spring scale (capacity 0-25 Ib.), attach hook on scale to loop
in free end of cord. Apply 15-20 Ibs. straight pull, using cord, on oil
pressure tube for
approximately 15 seconds. If tube pulls partially or completely out of fitting, replace
fitting. Remove scale and cord from tube assembly.
e. Repeat steps B through D for torque pressure tube assembly.
f. Remove FOD cover installed over engine air inlet. Verify that area around base of mast,
inlet plenum and entire plenum chamber is free of debris and other foreign materials.
g. Start and operate helicopter at ground idle for two minutes minimum.
h. Shutdown helicopter. After rotor blades have stopped turning, check oil pressure and
torque pressure tubing at the firewall fittings for any indications of leakage. Replace
fitting(s) if any leakage is noted. (Section 17 of applicable HMI).
i. Close filter bypass door and chamber access door.
j. Record compliance to this Service information Notice in the Compliance Record Section
NOTICE NO.: HN-209*
DN-14SX
EN-37
FN-26
DATE: 15 Sept. 1987
PAGE 3 of 4
i
NOTICE NO.: HN-209*
DN-1 49*
EN-37
FN-26
DATE: 15 Sept. 1987
PAGE 4 of 4
Z~-- PLWUM CHCMBLR

PAN
ii
I~
DUCT TAPE (NOTE 1)
NYLON TUBING
FIREWALLFITTING,
FORWARD SIDE
UNION AND NUT
ROLLING
FIREWALL FITlINC,
HITCH
AFISIDE
CORROSION RES ISTANT

S~EL TUBE
INOTE 21
O FIRENALL (TYPICALI
NOTES:
1. WRAP TUBE AT LEAST ONCE WITH TWO

INCH WIDE DUCT TAR APPROXIMATELY
O ONE INCH FROM FlnlNG.
2. SLIM HITCH DOWN TUBE UNTIL lT

RESTS ON DUCT TAPE.
88605
Figure 1. oil and Tbrque Pressure Tubing Pull Test Inspection.

NOTICE NO.: HN-210
DN-150
EN-38
FN-27
iC3 -~2
DATE: 15 Sept. 1987
~PI1; Oj=11~3ai3@N N671r P"GE 1 of 5

1Li
MANDATORY MANDAToRY 4 -s~--I- MAN DATO RY
*This Notice supercedes Ser~ico infor~-r,atisn Lett~rs, HL-92, DL-60 and EL-11, dated 15
July 1985.
SUBJECT: START PUMP LVIRE ROUTING END FUEL UUANTITY SENDER INSPECTION.
MODELS AFFECTED: All McDonnel! Co~glas Heliccpter Company (MDHC) 369A (OH-6A),
369H, 369HE, 369HM, 3691--3S, 369U and 3E9E Series helicopters. In addition, all
3698/88 Series helicopters equipped with internal start pumps.
TIME OF COMPLIANCE: This Service Information Notice shall be accomplished within the next
25 hours of helicopter operation or at the ne;ct removal 05 the fuel start pump or fuel
quantity sender unit, whichever occurs first and at each subsequent removal of the
start pump from the fuel cell.
PREFACE: There have been recent incidents where the fuel tank start pump wiring interfered with
the 369A4245 fuel float after the sl~trt pump and fuel quantity sending unit had been
replaced in the field. This interference can result in erroneous fuel quantity indica-
tions. To prevent this situation, the fuel pump wiring shall be wrapped around or
tie-wrapped to the fuel inlet hose per the HMI. This Notice provides for an inspection
to be performed to ensure proper start pump wire routing and fuel quantity sender
unit operation.
WEFERENCE
369D/E HMI Vol.l (CSP-0-2) Revised 15 June 1985

369H Basic HMI (CSP-W-2) Revised 15 June 1985
Service Information Notice (HN-185) Issued 15 March 1983
PROCEDURE
~NBRE\38NG
Use ail necessaiy precautions consistent withsafe practice

when working in or around fuel cells.
CBUYIOPd
Care shall be taken not to da;nag~ fuel float arm or low fuel level
warning contact ~Fring ~i:ile ai::con!?fis~ing this Notice.
a. Ensure all electric Fewer is off.
?rjcil.:-t -!117I)-.2
FORM 9578 (2/81)

NOTICE NO.: HN-210
DN-150
EN-38
FN-27
DATE: 15 Sept. 1987
PAGE 2 of 5
PROCEDURE CONT.
b. Remove left fuel cell access cover per applicable HMI, Section 12.
c. Disconnect start pump electrical harness from access cover. (See Figure 1.)
d. Ensure that electrical harness is wrapped around fuel inlet hose
preventing any
interference with the fuel quantity float arm as shown in Figure 1.
e. Inspect fuel float arm and low level warning contact spring for damage. Replace any
damaged parts as necessary.
CAUTION
Do not reinstall any current configuration float assembly that
shows indications that attempts have been made to adjust fuel
level indications by bending fuel float arm. (See Figure 2.)
f. Connect start pump electrical harness to access cover.
g. Install left fuel cell access cover per Section 12 of applicable HMI. Turn access cover
clockwise and slide as far aft as possible.
h. Bleed fuel system as necessary per HN-185 for 369H Series helicopters and Section 12
of HMI for 369D and 3696 Series helicopters.
i. Perform an operational check of the fuel quantity transmitter and indicator per the
following instructions:
NOTE
This operational check is not for accura~y of the fuel quantity
indicating system but rather for proper functioning of the fuel
float arm.
1. With fuel cell fuel, set main power switch to EXT PWR (24 to 28.5 VDC). Fuel gage
should read FULL.
2. Begin defueling fuel cell per Section 2 of applicable HMI. Observe movement of fuel
gage.
3. Continue draining fuel cell until empty. Note point at which, if any, indicator ceases to
show decreasing fuel quantity. Verify proper operation of FUEL LOW warning light. If
gages and warning lights function properly until fuel cell is empty, proceed to Step j.
4. If fuel float interference is experienced, loosen (5) sensor attach bolts and rotate
sensor clockwise as far as possible and tighten. If float is still interferred with, loosen
fuel cell access cover and slide access cover aft as far as possible and turn
clockwise. One or both of these actions should free the float arm. If float arm is still
interferred with, disconnect electrical power, remove sensor unit and verify start
pump wiring does not interfere with fuel float arm.
5. When fuel float arm is free from any interference, tighten all bolts and recheck
operation of fuel quantity sending unit per Step i, (1) through (3).
NOTICE NO.: HN-210
DN-150
EN-38
FN-27
i/
DATE: 15 Sept. 1987
PAGE 3 of 5
PROCEDURE CONT.
j. Ensure fuel system is properly serviced per HN-185 for 369H Series helicopters and
Section 2 of HMI, Vol.l for 369D, 369E and 369F/FF Series helicopters.
k. Record compliance to this Service Information Notice in the Compliance Record Section
NOTICE NO.: HN-210
DN-150
EN-SB
FN-27
DATE: 15 Sept, 1987
PAGE 4 of 5
12
LEFT FUEL CELL COVER
B
P
E
7 1
POWER PLANT
SUPPLY TUBE
FUEL CELL (TOP)
WRAP AROUND FUEL INLET HOSE

TO PREVENT INTERRRPJCE
WITH FLOAT
FUEL INLET HOSE
START PUMP
FITTING
(O-RING)
MOUNTING PAO
%:,_ FUEL CELL (BOTTOM)
~,:;..,O-RING
LOCKWIRE
O
START PUMP AND HOSE FUEL CELL GRAIN VALVE
88-b1j
Figure 1, Fuel Start Pump Wire Routing Inspection,

NOTICE NO.: HN-210
DN-150
EN-38
FN-27
DATE: 15 Sept. 1987
PAGE 5 of 5
O EI~LYCONI(CURATIIE
FULL POSITION I ~j9 I
/I^b
la. 06 RCt~:: I
e- 1 \I
9.11 -7
8.99
ti~
EMPTY POSITION
L25
SPRIN~ CONTACT
POSITION
CONFIGURATICN
FULL POS ITION
35,0
0 I 1 i.-
54(1
i~o
10. 05
R
ia 11
EMPN POSIT1~
Figure 2. Fuel Float Arm Assembly Inspection.

NOTICE NO.: DN-151
EN-39
FN-28
DATE: !O Oct. 1987
IPr( 1~ PAGE 1 of 4
SER?I?CE NOT1CE
MANDATORY ~P" ~IIANDATORY I

MAN DATo RY
SU&JECT: INSPECTION OF TAIL ROTOR TRANSMISSION MOUNTING STUDS.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369D, 369E and
369F/FF Series Helicopters.
TIME OF: COMPLIANCE:

PART I Shall be accomplished prior to next flight.
PART ii Shall be accomplished during each pilots preflight check of the
helicopter.
PART III Shall be accomplished within the next 25 hours of helicopter
operation.
PART IV-- At each subsequent 100 hours of helicopter operation following compli-
ance to PART III of this Notice.
PREFACE: There have been several reported instances where some or all tail rotor transmission
mounting studs have failed due to indications of bending fatigue. in some cases, a
considerable loss of the mounting studs clamping force has occurred which allows
C prohibitive amounts of vibrating motion of the tail rotor transmission relative to the tail
boom casting. As a result, the following four-part service information notice has been
developed to ensure the proper integrity of the tail rotor transmission mounting
studs.
REFERENCES
369D/E HMI Vol. I (CSP-D-2) Revised 15 June 1985

3698/88 HMI Vol.l (CSP-F-2)Revised 15 April 1986
369D/E/F/FF SRM (CSP-DEF-6) Revised 15 Nov 1984
PART I. INITIAL INSPECTION
WARNING
If there are any indications of movement, wear or fretting while

performing steps a. and b. of Part I of this Notice, perform Part
III of this Notice before the next flight.
a. On 369D/E helicopters, visually examine the security of the tail rotor transmission attach-
ment to the tailboom fitting for any indications of relative motion or fretting products
be-
tween the transmission and tailboom casting.
On 3s9F/FF helicopters, visually examine the security of the tailboom extension to
FORM 8578 (2/81)

NOTICE NO.: DN-151
EN-39
FN-28
DATE: 10 Oct. 1987
PAGE 2 of 4
tailboom attachment for any indications of relative motion or fretting products between
these attachments.
b. Inspect each mounting stud and attaching hardware for movement, wear or fretting.
NOTE
If the attach joint issecure, a one-time flight, not to
visually
exceed three hours in duration, is allowed to enable operators
to move affected helicopters to a facility where the following
torque check can be performed.
c. On369D/E helicopters, verify the torque of the tail rotor transmission to tailboom m9unt-
ing studs is 75195 inch-pounds on each of the four nuts.
On 369F/FF helicopters, verify the torque of the tailboom extension to the tailboom mount-
ing studs is 75-95 inch-pounds on each of the four mounting nuts.
d. If it can be established that the tail rotor transmission or tailboom extension Is se-
safely
cureiy attached to the tailboom mounting studs and faying surface, apply torque stripe
paint line across the faying surfaces of each nut and transmission fiange or tailboom ex-
tension flange and also across the tailboom casting pad and the adjacent transmission
case or tailboom extension.
e. Record compliance with Part I of this Notice in the Compliance Record Section of the heli- C-
copter Logbook.
PART II. PILOTS PREFLIGHT CHECK
CAUTION
If any indications of cracks appear on torque paint stripping,

perform PART III before further flight.
a. Examine tail rotor transmission installation for security by checking the torque stripes for
movement of the transmission (cracks in the torque paint), fretting products, gaRping be-
tween the faying surfaces and/or rotation of the nuts and studs.
PART III. REMOVAL AND REINSTALLATION OF TAIL ROTOR TRANSMISSION.
a. Remove tail rotor transmission from helicopter, Section 9, HMI Vol.l.

b. On 369F/FF Series helicopters, remove tailboom extension, Section 5, HMI Vol. i.
NOTICE NO.: DN-151
EN-39
FN-28
DATE: 10 Oct. 1987
PAGE 3 of 4
c. Remove all paint and sealant from mating surfaces.
NOTE
Remove excessive sealant, as required, from transmission to
gain clean mounting surfaces. Ensure that no gap in sealant
coverage exists around the transmission bearing cover assem-
bly.
CAUTION
Use care not to remove the anodize coatings.

d. Visually examine mounting studs for damage or deformation. Replace damaged
the or
deformed stud per Section 3 of the Structural Repair Manual (CSP-DEF-6).
e. Apply zinc chromate primer in holes, on faying surfaces and on the grip area of the
mounting studs and install tail rotor transmission (Section 9, HMI Vol.l) or tailboom exten-
sion (Section 5, HMI Vol. I) while primer is still wet.
NOTE
C: e Note the drag torque

transmission in the
for each nut and its locationon the
helicopter for later use.
Torque nuts 75-95 inch-pounds while zinc chromate is still wet.
f. Torque nuts 75-95 inch-pounds plus drag torque.

g. Apply torque stripe paint per Part I of this Notice.
h. Between two (2) and ten (10) hours of helicopter operation (to allow parts to seat), check
the torque of each mounting nut as follows:
1. Using drag torque previously measured and noted in the Logbook, apply a torque
the
load of 95 rt3 inch-pounds plus the noted drag torque (noted for each individual nut)
to each mounting nut of the transmission.
i. Reapply torque strip paint per step d., Part I, of this Notice.
j. Record compliance with Part III of this Notice in the Compliance Record Section of the he-
licopter Logbook.
PART IV REPETITIVE INSPECTION (100 hour)

a. Check the torque of each tail rotor transmission mounting nut and tailboom extension
mounting nut (369F/FF only) as follows:

of
1. Using drag torque previously measured and noted in Logbook, apply a torque load
95 inch-pounds plus the noted drag torque (noted for each individual nut) to
each mounting nut on the transmission.
b. Reapply torque stripe paint per step d., Part: i, of this Notice.
NOTICE NO.: DN-151
EN-39
FN-28
DATE: 19 Oct. 1987
PAGE 4 of 4
c. Record compliance to Part IV of this Notice in the Compliance Record section of the heli-
copter Logbook.
ii/1;,3 ~_-:n n: Douglaj o:
EN-41
Heiicoptfr Company FN-30
_SERVICE INFORMATION NOTICE PAGE 1 of 3
SUBJECT: REPLACEMENT OF 369A8442-BASlC LATCH ASSEMBLY ON THE PARTICLE SEP-

ARATOR BYPASS DOOR.
ters including the 369A (OH-6A) Series helicopter.
TIME OF COMPLIANCE: The requirements of this Notice shall be accomplished at the next
annual inspection or the next time the particle separator filter by pass door is
removed, whichever occurs first.
PREFACE: MDHC has recieved reports of the latches on the engine inlets filter bypass door
fracturing and allowing the latch portion of the assembly to fall into the plenum
chamber which in turn could result in damage to the engine. A new and improved
latch assembly has been introduced to prevent future occurences of this problem.
MDHC is requiring operators to replace the existing latch assembly with the
improved design per the instructions given in this Notice.
REFERENCES
Optional Equipment Manual (CSP-004) Re-issued 15 Jan. 1985

Illustrated Optional; Accessories (CSP-H-8) Re-issued 01 Sept. 1978
PARTS LIST
Latch Assembly 369A8442-3 2 MDHC
Screw MS24693C279X 4 Commercial
Washer AN960KD10L 4 Commercial
MS24693C277, MS24693C280 MS24693C281 may be used as alternates.
1 Product Support Department
h/lcDonnell Douglas
Uh l;rh r rr\ m h hi
NO.: Ht\i-213
DN-152
EN-41
FN-30
PAGE 2 of 3
PROCEDURE
CAUTION
Use care to prevent entry of foreign objects (FOD) into engine
air inlet. Install FOD cover over engine air inlet. Do not remove
cover until work is
completed and any debris is thoroughly
cleaned out of the area. After removing cover, verify that area
around base of mast, inlet plenum and entire plenum chamber
is free from foreign material.
a. Disconnect 369A8439 link assemblies from 369A8442-BSC latch assemblies. (See

Figure i.)
b. Remove 369A8442-BSC latch assembly. (two places)
c. Install 369A8442-3 latch assembly in two places on bypass door.
d. Attach 369A8439 link assemblies to 369A8442-3 latch assemblies.
e. Remove FOD cover installed over engine air inlet. Verify that area around base of mast,
inlet plenum and entire plenum chamber is free of debris and other foreign objects.
f. Record compliance to this Notice in the compliance record section of the helicopter log
book.
NO.: HN-213
DN-152
EN-41
FN-30
PAGE 3 of 3
sA~S
II/ Yf~
/J~o
MS24693CnP SCREW
C (2 PLACESI
369A&439
LINK ASSY IREF)
I:
i
369A8M2-3
LATCH ASSY
II I
(2 REPDI
AN960PO 101 WASHER

(2 PLACES)
01 I
MS210a;-3 NUT
O FILTER BYPASS
DOOR INSTALLATION (2 PLACES)
88-632
Figure 1. Installation of 369A8442-3 Latch Assemblies.

McDonnell Douglas "OT" NO.:
EN-cl.2
Melicopaer Company FN-32.2*
DATE: 21 April 1989
PAGE 1 of 4
SE1WVIGIE BNFg4RM~ION
supercedes Service Intcrmation Notices HN-212, DN-153, EN-43 and FN-32, dated 13 November 1987; and
HN-212.1, DN-153.1, EN-43.1 and FN-32.1, dated 03 March 1989. HN-212.1, DN-153.1, EN-43.1 and
FN-32.1 were cancelled prior to publication end distribution to Owners, Operators and Service Centers.
MANDATORY i MANDATORY -----------------~sl MANDATORY
EJECT: ONE-TIME INSPECTION AND REPLACEMENT OF TAIL ROTOR FORK BOLT

(369A1 602).
ODELS AFIFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369A (OH-6A) and
369H Series helicopters. All 369D, 3698 and 369F/FF Series helicopters equipped
with uninscribgd or 369A1 E302-BSC tail rotor fork bolts. All tail rotor fork bolts and tail
rotor assemblies in Spares inventories.
NOTE
Helicopters equipped with 369A1602-3 tail rotor fork bolts and a
MS21206C4 washer and all Spares Inventories that have been
purged of uninscribed bolts are not affected by the require-
ments of this Notice.
ME OF COMPLIANCE: Part r of this Service information Notice shall be accomplished within

the next 25 hours of operation. in addition, Part I of this Notice shall be accomplished
on all tail rater fork bolts and tail rotor assemblies in Spares inventories prior to being
installed onto helicopters. Compliance to Part I is essential to ensure the continued
airworthiness of all 369 Series helicopters.
Part II shall be accomplished at the next 300 hour or annual inspection or at the next
disassembly of the tail rotor assembly, whichever occurs first.
REFACE: Part I The possibility exists that some 369A1602 tail rotor fork bolts, manufactured
between April 8, 1986 and August 28, 1986, did not receive proper processing at the
manufacturer. Inadequate processing of these bolts can result in cracking and
eventual bolt failure. This Notice provides instructions to identify and replace those
uninscribed bolts with properly inscribed bolts.
Part II MDHC has developed an improved tail rotor fork bolt (369A1602-3). MDHC
I
requires that all operators replace the 369A1602 (BSC) with the improved 369A1602-
3 bolt to provide greater resistance to corrosion and a MS21206C4 to provide proper
seating of the bolt head shank radius.
REFERENCE
369H Basic HMI (CSP-H-2) Revised 15 January 1989

369D/E HMI Vol.l (CSP-D-2) Revised 01 March 1989
I
3698/88 HMI Vol.l (CSP-F-2) Revised 15 April 1986
369H Comp. Overhaul Man (CSP-H-5) Revised 15 March 1982
369DEF Comp. Overhaul Man (CSP-DEF-5) Revised 06 March 1989 11
(I) Denotes portian of text added or revised.

Support Department
NlcDonnell Douglas
FORM 9R78 (REV 11187)
Helicopter Company
DN-153.2*
EN-43.2*
FN-32.2*
DATE: 21 April 1989
PAGE 2 of 4
PARTS LIST
Bolt, T/R Fork 369A1602-3 1* MDHC
Washer MS21206C4 1" MDHC or
Commercial
Two required on a four-bladed tail rotor assembly.
TOOLS AND EQUIPMENT
Nomenclature Source
Socket, 12 point spline Commercial

01#evird
bolt size
PART I INSPECTION PROCEDURE
a. Visually inspect all Spares inventories and tail rotor fork bolts installed on helicopters
and tail rotor assemblies for proper inscription on the head of the bolt (see Figure 1).
NOTE
Uninscribed tail rotor fork bolts on helicopters shall be replaced,
proceed to Part II.
e Remove all uninscribed tail rotor fork bolts from Spares inven-
tories and scrap those fork bolts.
b. Record compliance to Part I of this Service Information Notice in the Compliance Record
PART II TAIL ROTOR FORK BOLT REPLACEMENT
a. Remove tail rotor fork bolts from affected helicopters as follows: I

NOTII=E NO.: HN-212.2*
DN-153.2*
EN-43.2*
FN-32.2*
DATE: 21 April 1989
PAGE 3 of 4
When the blade and hub assembly is removed from the

I
ter, and at all times when the pitch control links are disconnelcted,
DO NOT allow blade pitch to exceed 30 degrees from neutral
position (see Figure 1). This is equal to blade pitch control
movement of approximately one inch in either direction. Unre-
stricted rotation of blades on hub can excessively bend or st:retch
strap pack assembly and cause undetected damage to tail rotor
assembly when reassembled.
(8 Do not remove hub-to-drive fork hinge bolt to remove tail rotor
assembly. Damage to strap pack may occur.
I
NOTE
To prevent tail rotor balance problems, at reassembly of parts
and hardware, mark exact number, locations and positions lof all
items before removal for correct reinstallation.
1. Remove tail rotor assembly (Basic HMI and HMI Vol.l, Sectioln 8). Removal of pitch
control assembly is not required.
2. Disassemble tail rotor assembly into major assemblies (HMI Appendix C and
Component Overhaul Manual, Part VII).
3. Remove fork bolt and NAS6X0C-416L washer (if installed) I(HMI Appendix C and
NOTE
Contact an Approved MDHC Service Center or Distributor for
disposition of removed bolt.
CAUTION
A MS21206C4 washer must be installed with a 369A16023 tail
rotor fork bolt.
Install a 369A1602-3 fork bolt along with a MS21206C4 washer with the countersunk
4.
side towards the bolt head and reassemble hub and fork unit (HMI Appendix C and
I
5. Perform testing balancing procedures (HMI Appendix C,
and Part VIII and Compo-
nent Overhaul Manual, Part VII).
b. Record compliance with Part II of this Notice in the Compliance Record section of the

WEIGHT AND BALANCE
)The resultant alteration to affected models as by procedures in

described this Notice has been
DN-l 53.2*
EN-43.2*
FN-32.2*
DATE: 21 April 1989
PAGE 4 of 4
CHORDLINE
(NEUTRAL PITCH)
(SEE
CAU11bN;\r
NO INSCRIPTION
ON BOLT HEAD
BOLT HEAD
O
SUSPECT BOLT CORRECTLY PROCESSED
(SCRAP) BOLT
CAUTION:
DO NOT ALLOW BLADE PITCH TRAVEL TO EXCEED LIMITS SHOWN.

ROTATING THE BLADES TO EXCESS IVE PITCH ANGLES MAY RESULT BLADE TRAVEL LIMITS WIIH
IN UNDETECTED DAMAGE TO TENSION-TORSION STRAP ASSEMBLY. PITCH LINKS DISCONNEC1ED
886281\
Figure 1. Inspection of Tail Rotor Fork Bolt.

McDonnell Douglas "~I"
EN-44*
FN-33*
January 1988
SERVICE ]NFBRMATION NOTICE PAGE 1 of 9
MANDATORY. I -r L MANDATORYI, I
,RIIANDATORY
*This Notice supercedes Service Information Notices: DN-2.3, dated 3 February 1981; DN-77.1,
dated 1 February 1982 and HN-204, dated 20 May 1986.
SUBJECT: MAIN ROTOR HUB ASSEMBLY STRAP PACK LAMINATION INSPECTION AND
TRI-FLOW WASH PROCEDURE OF THE MAIN ROTOR HUB ASSEMBLY AND
STRAP PACK LAMINATES.
MODELS AFFECTED: PART I All McDonnell Douglas Helicopter Company (MDHC) 369 Series
PART II All helicopters contained in Part I which operate over or around marine and
other corrosive environments.
TIME OF COMPLIANCE: PART I shall be accomplished within the next 100 hours of operation or
90 days, whichever occurs first, and at each subsequent 100 hours of operation for
all 369D, 369E and 3698/88 series helicopters; and 300 hours of operation or nine
months, whichever occurs first, and at each subsequent annual inspection for all
369H and 369A (OH-6A) series helicopters. In addition, if two laminates have failed
in any one leg or tongue area of any strap assembly, the inspection shall be
performed at 25 hours of operation or 30 days, whichever occurs first, and at each
subsequent 25 hours of operation for 369D, 369E and 3698/88 series helicopters
and 100 hours of operation or 90 days, whichever occurs first, and at each
subsequent 100 hours of operation for all 369H and 369A (OH-6A) series helicopters.
NOTE
PART I shall be considered as part of the HMI and will be
incorporated into the applicable section of that manual at the
next scheduled revision to the HMI.
PART II shall be accomplished daily, prior to engine shut down following the last
flight of the whenever helicopter operation has taken place over or around salt
day,
water environments and other environments found to be corrosive to components of
the main rotor hub assembly.
PREFACE: The information given in Part I of this Notice provides an inspection of the main rotor
strap pack assemblies and adjacent shims. Previously issued Service Information
Notices concerning the inspection of main rotor strap packs have been incorporated
into this Notice.
C
McDonnell Douglas
FORM 9578 (REV 11187)
Helicopter Company
NOTICE NO.: HN-214*
DN-1 54*
EN-44*
FN-33*
PAGE 2 of 9
PREFACE CONT.
If a assembly or strap assembly (other than new parts in storage) are subjected
hub
to extended periods of non-use, whether installed on the helicopter or not, the strap
assembly should be inspected critically for corrosion and pitting due to corrosion
before being returned to service. If corrosion is found on the strap pack assemblies,
contact MDHC for disposition.
It is acceptable to operate helicopter with a hub assembly having a strap pack with
a
up to two failed laminates in any one leg of the strap assembly (see Figure 1). When
a laminate in the strap assembly fails, the remaining laminates pick up and carry the
load. This increased load causes slightly more elongation in the remaining laminates
of that leg thus shifting the mass of the rotor system. Anytime a vibration develops or
there is an increase in vibration level over a short period of time, the main rotor strap
pack assembly should be inspected for cracked or failed laminates per Part I of this
Notice.
Part II of this Notice provides a wash/rinse procedure to help prevent main rotor hub
component corrosion on helicopters operating in marine and other environments
found corrosive to helicopter components.
REFERENCE

369D/E HMIVol.l (CSP-D-2) Revised 15 June 1985
TOOLS AND EQUIPMENT
Nomenclature Source
10X Maanifvina Glass Commercial
i
NOTICE NO.: HN-214*
DN-1 54*
EN-44*
FN-33*
PAGE 3 of 9
MATERIALS
Nomenclature Source
Tri-Flow Lubricant Commercial or
Costa Mesa Lubricant

P.O. Box 125
Olive Branch, MI 38654
or
Break Free Break Free Corp.

10359 Lynwood Ave.
Santa Anna, CA 92705
Zip Wax Commercial or
Turtle Wax, Inc.

5655 West 73rd Street,
Chicago, IL 60638
PART I I INSPECTION PROCEDURE
NOTE
Conduct inspection indoors, if possible, or in a shaded area to
eliminate glare of sun or bright outdoor light. To facilitate
inspection, field fabricate and use plastic tool as shown in Figure
a Used main rotor hub assemblies in storage shall be inspected

per the requirements of PART I of this Notice.
CAUTION
Figures 1 thru 3
depict the main rotor hub and
strap pack
assembly disassembled for clarity of location and area to be
inspected for cracks. Under no circumstances should the strap

pack or main rotor hub assembly ever be disassembled in the
field. MDHC and MDHC Approved Licensees are the only
approved repair stations for main rotor hub assembly overhaul.
a. Remove main rotor blades per Section 7 of applicable Basic or Vol. I HMI.
b. Trim teflon from edges of laminates as shown in Figure 2.
c. Field fabricate plastic tool per Figure 1. Run plastic tool in both directions along each
laminate, feeling for a "catch" from a crack on a single laminate.
NOTICE NO.: HN-214*
DN-154*
EN-44*
FN-33*
PAGE 4 of 9
PART I PROCEDURE CONT.
d. Using light and mirror, visually inspect each of the four (369H, 369A/OH-6A) or five
a
(369D,E,F/FF) main rotor strap pack assemblies for evidence of cracks or breaks in
strap pack laminates in the areas of the outboard shoes and pitch housing assemblies.
Each strap pack assembly consists of 15 (369H, 369A/OH6A) or 16 (369D,E.F/FF)
corrosion resistant steel strap laminates. (See Figure 1.)
e. Using a 10X magnifying glass, visually inspect the edge of strap pack laminates on both
sides at outboard end of blade pitch housing (area between outboard shoes) (See
Figure 1, Item 6.)
CAUTION
A laminate has failed: a) If a crack is found in tongue area of the
laminate or b) if a crack is found in both legs (lead and lag) of the
same laminate.
a A strap pack is to be rejected (hub must be returned for

overhaul): a) if three or more laminates in a single strap pack
have failed, as defined above or b) if three or more laminates in
a single strap pack are cracked in the same leg (lead or lag) or c)
if one laminate is cracked at the outboard end (area between
outboard shoes, see Figure I, Item 6). A single gap in any one
strap pack assembly is allowed. Two or more gaps in the same
strap pack requires main rotor hub replacement, (See Figure 2).
NOTE
a Do not pry at strap pack assemblies with sharp or hard edged

tools. If edges become nicked or laminates get scratched,
additional cracking can occur thus causing hub replacement.
Where accessible, ends of acceptable cracked or broken lami-
nates should be taped to prevent scratching and damaging of
adjacent laminates. (Refer to applicable HMI, Vol.l.)
f. Visually inspect strap pack assemblies for evidence of corrosion. If corrosion is found on
strap pack laminates contact MDHC service department for disposition.

g. Using a blunt-nosed wooden or phenolic pin (pencil size with 1/16 inch radius point),
probe at the upper and lower strap laminations at the outboard ends of the blade pitch
housings for evidence of laminate failure. A failed laminate, either at the lead or lag end
of the strap pack, will move away from the other laminates. If the adjacent upper and
lower laminates remain in tension under the probing operation, no laminate failures have
occurred. Refer to Step E Caution for gap limitations.
i
NOTICE NO.: HN-214*
DN-154*
EN-44*
FN-33*
CDATE: 5January
15
8891
of 9
PART I PROCEDURE CONT.
NOTE
Laminate failures are defined in Step E, refer to the CAUTION.
h. Inspect upper (369[321271-5), lower
(369D21271-7) and center (369621271-3) lami-
nates for cracks and breaks. (See Figure 3.)
NOTE
Cracks, breaks or other noticeable damage to the lamina-
te/shims require main rotor hub overhaul/replacement.
i. Install main rotor blades per Section 7 of applicable HMI.
j. Perform tracking of main rotor blades per Section 7 of applicable HMI,Vol.l.
CAUTION
The maximum allowable balance weight per pitch case housing
on the main rotor hub assembly is 150 grams.
k. Record location of all cracked/broken laminates in helicopter Log Book

icluding strap
serial number, blade color, leg (lead or lag) and laminate position, if possible
numbering
from the top down.
I. Record compliance to Part I of this Notice in the Compliance Record section of the
PART II I
TRI-FLOW WASH PROCEDURE
NOTE
Perform Step A below prior to engine shutdown, following the
last flight of the day if possible. When the rotor system stops
turning, the laminates of the strap pack assembly spread apart
slightly. Contaminates collected on the edges of the strap pack
assembly can enter the area between the laminates as they
spread apart. If the rotor continues turning until the contami-
nates are washed away, centrifugal force will keep the laminates
compressed and not allow the corrosive su bstances to enter the
area between the laminates.
a. Bring engine to grou nd idle (64-65 percent N1); set SCAV AIR to ON. (Refer to applicable
Pilots Flight Manual.)
I wanalac I
Use extreme caution when working around turning rotor blades.
Stay low and remain on right side of helicopter to avoid the tail
C rotor blades.
NOTICE NO.: HN-214*
DN-154*
EN-44*
FN-33*
DATE: 15
PAGE
January
6 of 9
1988
C
b. Spray fine fresh water mist on main rotor blades.
PART II PROCEDURE CONT.
c. Direct strong stream of clean and fresh water

a into main rotor hub and control system
surrounding the main rotor hub assembly.
d. Spray entire main rotor hub assembly with Tri-Flow (or Break Free as an alternate)
Lubricant.
e. Shutdown engine. (Refer to applicable Pilots Flight Manual.) When main rotor blades
stop turning, spray strap packs with additional Tri-Flow Lubricant.
NOTE
Lift main rotor blades to separate strap pack laminates and
spray Tri-Flow Lubricant directly in between the individual
laminates.
f. Perform engine water wash. (Refer to Section 2 of applicable HMI).

g. Wash main rotor blades with Zip Wax or equivalent, mixed per manufacturers instruc-
tions.
h. Record compliance to Part II of this Notice in the Compliance Record section of the
L
NOTICE NO.: HN-214*
DN-1 54*
EN-44*
FN-33*
C DATE: 15
PAGE
January
7 of 9
1988
O
LAC LEC 1 -f
LAMINATE HAS FAILED IF CRACKS OCCUR
ON 8OTH LEAD ANO LAC LEGS OF SAME
LAMINATE.
0.250
LEAD LEC
PROBE
O
LAMINATE HAS FAILED IF CRACK OCCURS
IN TONGUE OF LAMINATE ISHADED AREA
SHOWN BEYOND JOINT OF STRAP PACK
LEGS).
PUSTICI
TOOL
6.00
I VZ INCH IRER 4.00
O
NYO LAMINATE FAILURES AS DEFINED IN i
AND/OR O ARE ALLOWED IN EACH STRAPPACK
ASSEMBLY. ITOTAL OF TEN LAMINATE FAILURES
PER HUB ASSEMBLY.)
~-Lmi I cO.OY1-O. In
RILD FABRICATION INSPECTION TOOLS
NOTE:
ALL DIMENSIONS IN INCHES.
STRAP PACK IS REJECTED IF THREE OR MORE

LAMINATES IN SAME PACK HAVE FAILED AS
DEFINED I N ANDIOR OABOVE.
O O r)
0//0
/I
L G3 STRIP PACK IS REJECTED IF THREE OR MORE
LAMINATES IN SAME PACK ARE CRACKED IN
I THE LEG (~AD OR UG).
CAUTION: I /FAILED LAMINATE IF CRACK

IS FOUND ON EITHER EDGE
DO NOT DISASSEMBLE STRAP PACK
OF LAMINATE.
ASSEMBLY- LAMINATIONS ARE
ONE LAMINATE I S FAILED.
SHOWN SEPARATED ONLY TO DEPICT
POSSIBLECRACKLOCAIIONS.
O FI.BUH
REMOVE
NOTE:
ANY CRACK IN LAMINATE IS CONSIOI~ZD 14 BREAK.
THE LAMINATE HIS NOT FAILED
BOTH LEAD AND LAG LEGS ARE CRACKED, CRACK I11
IS LOCATED IN TONGUE AREA OF LAMINATE, OR iS
UNDER SHOES (SEE DETAIL 61.
Figure i. Main Rotor Hub Strap Pack Assembly Inspection.

NOTICE NO.: HN-214*
DN-1 54*

PAGE 8 of 9
ALL LAMINATES STRAIGHT.

NO GAPS.
DETAIL 1 ACCEPTABLE
ALL LAMINATES STRAIGHT. SINGLE C;AP

EXISTING ADJACENT TO EITHER SHOE.
DETAIL 2 ACCEPTABLE
NOTE:
WHITE TEFLON MAY APPEAR WRINKLED AND EXTEND PAST END OF LAMINATES
PREVENTING CLEAR VIEW OF LAMINATES. WHEN THI S OCCURS, LOOK ALONG
EITHER SIDE IN AREA A-A OR B-B IDETAIL 3).
A A
ALL LAMINATES STRAIGHT. SINGLE GAP

EX ISTING ANYPLACE WITHIN LAMINATES.
C/
DETAIL 3
ACCEPTABLE B
REMOVE EXCESS TERON THIS AREA.
Figure 2. Strap Pack Inspection and Preparation.
L
NOTICE NO.: HN-214*
DN-154*
EN-44"
MZ-i
P*G. 9dB
Ie
1
ii.
L
i L
IAMINATE
396021271-)
LP~MINI\TE
5
I
a
LAMINAIE
CAUTION
Do not disassemble strap pack or hub assembly. Hub assembly
is shown separated only for clarification of location of possible
C cracks and damage.
NOTE:Model 369D,E,F/FF shown; Model 369H, 369A/OH-6A is

similar.
Fiaure 3. Main Rotor HubLaminate Insr>ection.

I\flcoonnell Douglas NOTICE NO.:
ML-t55~EN-45
Helicopter Company PAGE 1 of 3
SE~VICE IMFORMATION NOTICE
SUBJECT: MAIN ROTOR BLADE UPPER AND LOWER TRAILING EDGE WEIGHT REWORK.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369D and 369E
Series helicopters with 369D21100-505, -509, -511, -513 or 421-086 main rotor
blades that have upper and lower external trailing edge weights installed.
TIME OF COMPLIANCE: The requirements of this Notice shall be accomplished within the next
100 hours of helicopter operation or 90 days, whichever occurs first.
PREFACE: An incident was reported of an operator finding the main rotor blade upper external
trailing edge weight, PN 369D21106, partially debonded. When this situation occurs,
these main rotor blades may be reworked in the field by re-bonding and the applying
two rivets to both the upper and lower trailing edge external weights.
REFERENCE
369D/E HMI Vol.l (CSP-D-2) Revised 15 June 1985
PARTS LIST
Nomenclature Part No. Oty. Source
Rivet MS20470AD3 A/R MDHC or
Commercial
MATERIALS
Nomenclature Source
*Naptha, Aliphatic (TT-N-95, Type II) Commercial
Emery Cloth, Fine (No. 200-300 grit) Commercial
Adhesive, two-part epoxy (EA9330-3) Commercial or
Dexter Corp., Hysol Division

Pittsburg, CA 91745
Primer, Zinc-chromate ~TT-P-1757) Commercial
Use best comparable grade material when conformity of available materials of same type with
listed Specification No. cannot be determined.
McDonnell Douglas
FORM 9578 (AEV 11187)
Helicopter Company
NOIICE NO.: DN-155
EN-45
PAGE 2 of 3
TOOLS AND EQUIPMENT
Nomenclature Source
Drill, 1/4 inch drive Commercial
Drill Bit, #40 Commercial
PROCEDURE
a. Inspect upper and lower main rotor blade external trailing edge weights for proper
bonding.
NOTE
a If all upper and lower external trailing edge weights are properly
bonded, proceed to Step C. If there are any indications of
looseness or debonding, perform Step B.
a Perform Steps C, D and E before applying adhesive to bonding

surfaces.
b. Bond upper and lower external trailing edge weight as required, per the following:
1. Carefully remove loose or partially debonded weight from affected main rotor blades.
2. Abrade bonding surfaces using #200-300 grit emery cloth and clean bonding
surfaces with clean cloth and naphtha solution.
3. Mix epoxy adhesive, per manufacturers instructions, and apply to bonding surfaces.
4. Properly position weight onto affected blades by aligning holes in weights to existing
rivets on blade, (see figure 1), and apply light pressure to weights until epoxy has set.
5. Let epoxy adhesive cure per manufacturers instructions.

c. Per Figure 1, mark locations of rivets to be installed.
d. Using drill and #40 bit, carefully drill holes at marked locations.
e. Debur and clean debris from holes.
f. Coat all exposed surfaces with zinc-chromate primer.

g. Install rivets.
h. Record compliance to this Notice in the Compliance Record section of the helicopter log
book.
WEIGHT AND BALANCE

Weight and balance is not affected.
NOTICE NO.: DN-155
EN-45
PAGE 3 of 3
MS20470AD3
RIVET (2 PLS)
6.312
(REF)
EXISTING EXISTING
BLADE EXISTING BLADE
RIVET BLADE RIVET
RIVET
1. 58 (REF)
.75
9.25
369021106 UPPER
EXTERNAL TRAILING
EDGE WEIGHT
NOTE: POS ITION WEIGHT ONTO BLADE

369021106
LOWER EXTER NAL IONE EACH ON UPPER 4ND LOWER SURF~CE
TRAILING EDGE WEIGHT BY ALIGNING CENTER OF HOLES I F\1 IG re I
TO EXISTING RIVETS ON BLADE
VIEW A A
(ROTATED 900~
ss-e!9
Figure i. Main Rotor Blade Trailing Edge Rework.
MANDATORY __
MANDATORY MANDATORY
NOTICE NO: HN-215.2*

McDonne/l Doug/as f3( DN-156.2EN-46.2*~aJ
Helicopter Systems ~Le FN-34.2*
NN-010
SERVICE IN FORMATION NOTICE DATE: 11 APRTL 1997

PAGE 1 OF 4
*Supercedes Service Information Notices HN-215.1, DN-156.1, EN-46.1 and FN-34.1,

dated 14 October 1988.
OVERRUNNING CLUTCH OUTER RACE INSPECTION

1. PLANMNG INFOR3MATION:
A. Aircraft Affected: All McDonnell Douglas Helicopter Systems (MDHS) 3698

(OH-6A), 369H, 369D, 3693, 369FF and 500N Series Helicopters. All spares
inventories of 369A5350-11, -21, -31 and -41 Overrunning Clutch Sub-Assem-
blies.
B. Assemblv/ComDonents Affected by this Notice: Overrunning Clutch Assemblies

(P/N 369A5350-603) and Overrunning Clutch sub-assemblies (P/N 369A5350-11,
-21, -31 and -41) which contain Overrunning Clutch Outer Race, P/N
369A5352-BSC, serial numbers 0692 thru 0927.
C. Reason: MDHS has determined that some races may have been improperly
outer
processed during manufacturing. Therefore, all clutch assemblies with
369A5352-BSC, serial numbers 0692 thru 0927 outer races will have to be replaced
and removed from service. Failure to comply with the requirements of this Notice
may result in loss of engine drive to the rotor system which may result in an engine
overspeed condition and/or a forced landing situation.
D. Description: Procedures in this Notice provide owners and operators with

information to inspect and, if necessary, replace the outer race of the 369A5350
overrunning clutch assembly.
E. FAA A~Droval: The technical design asp~cts of this Service Bulletin are FAA
Approved.
F. ManDower: One half manhour to inspect aircraft records. ILvo manhours to inspect
overrunning clutch subassembly, plus two manhours to remove and replace outer
race, if required.
G. Time of Compliance: The requirements of this Notice shall be accomplished within

the next 50 hours of helicopter operation or by 31 July 1997, whichever occurs first.
All spares inventories shall comply with the inspection requirements of this Notice
prior to installation into a helicopter or within 30 days of the date of this Notice,

MANUAlOnY MANDATOnY MANUATORY
NN-010DN-156.2*
EN-46.2*
FN-34.2*
McDonne~ Doug/as
Helicopter Systems
DATE: IIAPRIL 1997

SERVICE INFORMATION NOTICE i
PAGE 2 OF 4
NOTE
Outer races with serial numbers 0692 thru 0927 should be removed from service
regardless of heat treat number. 369A5352-BSC outer race assemblies with
these serial numbers that have been inspected and returned to service as a re-
sult of HN-215.1, DN-156.1, EN-46.1 and FN-34.1 are affected by the require-
ments of this Notice and must be removed.
369A5352-5 overrunning clutch outer race assemblies are not affected by this
Notice.
H. Interchangeabilitv: The 369A5352-5 outer race, together with the W1593-018
wave washer, replaces the 369A5352-BSC outer race.
I. Material/Part Availability: Contact MDHS Warranty and Repair Department.
Outer Race 369A5352-5 A/R MDHS
Wave Washer W1593-018 A/R MDHS
J. Parts Policy: If during the inspection portion of this Notice, operators find an outer
race (369A5352-BSC) with an affected serial number, remove the part and notify
MDHS Warranty and Repair Department. MDHS Warranty and Repair will
exchange the affected part for a new outer race and an overrunning clutch assembly
overhaul kit (99-369A5350-603) at no cost to the operator or customer. This offer
expires 31 July 1997. This parts exchange policy is for the purpose of complying
with this Service Information Notice and in no way affects any other MDHS parts
exchange policy, either past or future.
K. Tooling~: Pliers, Snap-ring (TRUARC) #7 Tip and a torque wrench (0-500 In. Ibs.).
These tools are commercially available.
L. WeiPht and Balance: N/A
M. Electrical Load Data: N/A
N. Other Publications Affected: N/A
2. ACCOMPLISWRIENT INSTRUCTIONS:
NOTE
It is not necessary to remove coupling from overrunning clutch to perform this
inspection.
A. to determine what serial number outer race
Inspect aircraft records
(369A5352-BSC) is installed in the overrunning clutch assembly.
B. If 369A5352-BSC outer race serial number cannot be determined through aircraft
records, remove overrunning clutch sub-assembly per instructions contained in the
2/
NOT~CE NO: EN-215.2*

McDonne/l DN-156.2*
Douglas
Helicopter Systems EN-46.2*FN-34.2*
NN-010
SERVICE IN FORMATION NOTICE DATE: 11 APRIL 1997

PAGE 3 OF 4
Handbook of Maintenance Instructions (CSP-HMI-8, Section 63-10-00 for
369D/E/FF/500N) or (CSP-H-8, Section 9 for 369H).
C. Inspect outer race and record serial number of outer race in Log Book.
NOTE
Serial numbers clearly vibroscribed on outer surface of the outer race on af-
are
fected parts. (See Figure 1.)

D. If the outer race serial number is not 0692 thru 0927, proceed to step F If the outer
race serial number is 0692 thru 0927, proceed to step E.
E. Replace outer race of overrunning clutch assembly per Part CSP-COM-5

(369D/E/F/500N) or Basic HMI, Appendix C (369B).
F. Reinstall clutch sub-assembly into clutch housing per CSP-HMI-8, Section
63-10-00 (369D/E/FF/500N) or Section 9 of HMI (36911).
CAUTION
Ensure that clutch sub-assembly retaining ring is installed WITH BEVELED

SIDE OUTWARD.
G. Check clutch oil level per the applicable HMI.
3. DISPOSITION OF PARTS REMOVED: RETURN TO MDHS.
Record compliance to this Service Bulletin in the Compliance Record section of
POINTS OF CONTACT: assistance, contact your local MDHS Field Service

For further
Representative (refer to the Business Development and Customer Support handbook
for address and telephone numbers) or contact the Field Service Department at
MDHS, Mesa, Arizona. Telephone: 1-800-388-3378 or (602) 891-6342. DATAFAX:
(602) 891-6782.
3
1YlnlYYHI VnT

DN-156.2*
EN-46.2*
McDonnell Doug/as
FN-34.2* Helicopfer Systems
NN-010
DATE: 1IAPRIL 1997

SERVICE INFORMATION NOTICE
PAGE 4 OF 4
B-
RETAINING RING
SERIAL NUMBER LOCATION
rcleROSCRlBED)
(BNELED SIDE OUMIARD)
CLUTCH SUBASSEMBLY I ENGINEPOWERAND

liB 1 ACCESSORYGEARBOX
ENGINE SHP~
FIREWALL SEAL
CLUTCH HOUSING
8&751
i
Figure i. Inspection of Overrunning Clutch Assembly Outer Race.
i2~cli3)onnell Douglas NoncE NO.: HN-216
DN-157
bj"elicopt~er C~7mp;anyFN-35
DATE: 05 April 1989
E i 3~ E I N Fe~ R i4%-ir g N ~I e~V II E PAGE 1 of 2
MANDATORY MANDATORY
FMANDATORY--
SUBJECT: ONE-TIME INSPECTION OF THE ENGINE TO TRANSMISSION DRIVESHAFT COU-
PLINGS- 369H5660.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369H Series heli-
copters, including the 369A (OH-6A) Series helicopter, 3690, 369E and 369F/FF
Series helicopters and all 369H5660 couplings in Spares inventories.
TIME OF COMPLIANCE: The requirements of this Service Information Notice shall be accom-
plished within the next 100 hours of helicopter operation or the next time the main
rotor transmission access panel is removed, whichever occurs first. Spares inven-
tories shall be inspected within the next 30 days or prior to installation into a
helicopter, whichever occurs first.
PREFACE: MDHC inspection personnel have detected small cracks in the spline of the 369H5660
engine to transmission driveshaft couplings which could lead to part failure. As some
of these parts were introduced into service before MDHC became aware of the
problem, operators are requiredto perform the following one-time inspection to
verify that none of the couplings listed below remain in service or are contained in
Spares inventories.
REFERENCE
Basic HMI (CSP-H-2) Revised 14 March 1988

PROCEDURE
a. Remove main rotor transmission access panel per the applicable HMI.
b. If any of the serial numbered couplings listed below are installed, remove and install a
serviceable coupling per the applicable HMI. Verify that all Spares inventories do not
contain any of the following engine to transmission driveshaft couplings.
Coupling Serial Numbers:

5200 thru 5309
NOTE
Return allengine to transmission
couplings listed above to
MDHC Warranty and Repair Department for a replacement
coupling.
NlcDonnell Douglas
FORM 9ri78 (REV 11187)
Helicopter Company
NOTICE NO.: HN-216
DN-157
EN-47
FN-35
DATE: 05 April 1989
PAGE 2 of 2
c. Record compliance to this Service Information Notice in the Compliance Record section
FAA APPROVED.
k:cDonn~JI iaougi;ls
I/.fii:;,pier 6::~c,,:,:,af,il HMICE NO.: HN-217.1
DN-1 58.1.
DATE: 21 July 1989

PAGE 1 of 8
X1 i~! I:II; iUiBY ~ihur p-- i~

IWIAWU~o;%BWZ!
SUBJECT: INSPECTION AND REWORK OF MAIN AND TAIL ROTOR CONTROL TUBES
MODELS
369A7007, 369A7009, 369A7011 AND 369A7012).
AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369 Series helicop-
ters, including the 369A (OH-6A) Series helicopters.
(PNS
I]
TIME OF COMPLIANCE: PART 1 of this NOTICE, the inspection of the control tube, shall be
accomplished within the next 25 hours of helicopter operation and at each subse-
the requirements of PART II are
quent 100 hours of helicopter operation until
accomplished.
PART II of this NOTICE, the rework procedure to install the sleeve, shall be
annual
accomplished within the next 600 hours of helicopter operation or at the next
i inspection performed after 30 October 1989, whichever occurs first.
All spares inventories shall comply with PART I and PART II of this Notice prior to
installation into a helicopter or within 180 days from the date of this Notice, whichever
occurs first.
PREFACE: MDHC have revealed internal and external cracks in the vertical Tunnel-
inspections
Routed main and tail rotor control tubes. Therefore, MDHC is reauirina all operators
ot affected helicopters to perform the following inspection and install reinforcing
sleeves to each end of the control tubes. There have been no reported failures of the
control tubes.
REFERENCE
369D/E HMI Vol. I (CSP-D-2) Revised 01 March 1989
3698/88 HMI Vol. I (CSP-F-2) Revised 01 June 1989 a
i REPLACEMENT POLICY: The following policy is applicable for replacement of subject control
;f tubes found to be defective.
1 A. Aircraft Under Warranty (within two years of aircraft delivery):
i. MDHC will provide, Free Of Charge, Control Tube Rework Sleeves and Epoxy
Ad hesive.
are rejected per PART I of this Notice, MDHC will provide on
2. For tubes that
exchange (free of charge), a serviceable control tube with sleeve
modjf~ation
applied. completed
A Service and Operations Report (SOR, form 853A) must
the control tube specifing the serial number of the aircraft from
accompany
which the control tube was removed. Control tubes damaged by obvious
misuse, neligence, or accident will not be replaced free of charge.
3. MDHC will pay shipping charges one-way.
B. Aircraft Beyond Warranty (more than two years since aircraft delivery):
1. MDHC will provide, Free Of Charge, Control Tube Rework Sleeves and Epoxy
Adhesive.
2. For tubes that are rejected per PART I of this Notice, MDHC will sell, on
exchanan a serviceable control tube with steeve modification applied at a cost
of 306.bb USD. A completed Service and Operations Report (8OR, form 853A)
must accompany the control tube specifing the serial number of the
aircraft from which the control tube was removed.
NlcDonnell Douglas
NOTICE NO.: HN-217.1
DN-1 58. 1
EN-48.1
FN-36.1
DATE: 21 July 1989
PAGE 2 of 8
3. MDHC will pay shipping charges one-way.
PARTS LIST
Sleeve (for 369A7007) 369 02701 3-1 or 2

369027013-2 2
Sleeve (for 369A7009) 369 02701 3- 1 or 2

369027013-2 2
MDHC No Charge
or Field Fabricated
Sleeve (for 369A7011) 369027013-3 or 2
369027013-4 2
Sleeve (for 369A7012) 369027013-5 2
Rivet MS20470AD3-15 4
DN-1 58.1
EN-48.1
FN36.1
DATE: 21 July 1989
PAGE 3 of 8
MATERIAL
Primer, tinc chromate (RM009222) MDHC
-P-1757~ (MIL-P-8585) I Commercial (Refer to HMI
Paint (top coat Flat Black) (RM006581) MDHC
Commercial (Refer to HMI
Paint Stripper MDHC
Commercial (Refer to HM
M.E.K. or equivalent (R M008922) MDHC
-M-261~ Commercial (Refer to HML
Cloth, oil and lint free (RM003505) MDHC
Commercial (Refer to HMI
Epoxy Adhesive (RM012080) MDHC No Charge
EA9330.3 Dexter corporation

Hysol Division
Pittsbura, CA. 94565
isuprupyi Alcohol tHMU10721) MDHC
-1-735~ i Commercial (Refer to HM!
ii
Contact Cement (RM000685) I MDHC

Alternate material. GRIP) EC1300L Commercial (Refer to HMI
Chemical Film (RMO1 2007) MDHC
(Iridite or Al-coat) (MIL-C-5541) Allied-Kelite Products Division
(Required if sleeve is field Fabricated) 2400 E. Devon Ave

Des Plaines, IL
TOOLS AND EQUIPMENT

Nomenclature Source
Kit, d netrant MIL-I-25135 Commercial Z o Test Kit

Drift Punch 3/32 inch diameter
Caliper (0-1 inch)

Drill Motor, portable Commercial
#40 Drill
PART I -INSPECTION PROCEDURE
a. Remove 369A7007, 369A7009, 369A7011 and 369A7012 control tubes as follows:

(refer to figure 1.)
1. Align blue blade to right side of aircraft.
DN-l 58. 1
EN-48. 1
FN-36. 1
DATE: 21 July 1989
PAGE 4 of 8
2. Remove bolts from top of tubes.

3. Remove double boot from the 11 and 09 tubes (ref. view A).
All tubes will be removed through the double hole.
4. Move blue blade pitch housing down as far as it will go. This will allow the tubes to
go past the housing.
5. Remove bolts from bottom of 11 and 09 tubes.
6. Move cyclic controls so that the 12 tube moves to its highest point (ref. view
B).
Place 09 tube to the far right and lower out of the way. Lower 11 tube to the left side
of center beam. This will allow 11 tube to angle
up through the double hole.
7. Remove bolt from bottom of 12 tube and lower to of aircraft and
belly angle up
through the double hole (ref. view C).
8. Remove bolts from bottom of 07 tube and lower to the belly of aircraft, then angle up
through the double hole (ref. view D).
9. Move 09 tube io the other side of center beam and angle up through the double hole.
To install tubes just reverse sequence (ref. view E).
b. Using paint stripper (refer to HMI), remove paint approximately six inches back from end
of each tube (tapered area of tube).
c. Dye penetrant inspect external surface of stripped area for cracks. Cracks are indicated
by heavy bleed out. It may be necessary to wipe off and reapply the developer to
distinguish between surface defects caused during swaging operation. Light penetrant
indications are not cause for rejection. Control tubes that are cracked must be removed
from service.
d. Ifno cracks are found and Part II will not be at this

accomplished time, inspected control
tubes can be painted and reinstalled.
e. Record compliance to PART I of this Service Information Notice in the Compliance

Record section of the helicopter Log Book.
PART II REWORK PROCEDURE

a. Perform Part I prior to installing sleeve. If control tube was reinstalled after
performing
PART I, reinspection per PART I is required. All four control tubes are to be reworked
during this procedure.
t~lrYwnrcj
CAUTION
~MMhlLhJ3
If control tube is not accurately measured, flight controls will
require rerigging.
b. Measure and record length of control tubes for reinstaliing rod ends and to prevent j
rerigging after control tube reinstallation.
ISOTICE NO.: HN-217.1
DN-158.1
EN-48.1
FN-36. 1
DATE: 21 July 1989
PAGE 5 of 8
c. Remove rod ends (MS20470AD3 Rivet must be removed from fixed end). When
removing rivet, drill out rivet head and punch out the remainder of the rivet with a drift
punch.
CAUTION
Drilled out rivet may damage threads upon rod end removal.
Visually Inspect control tube threads for damage from rivet and
rod end removal. Replace damaged control tubes. Drilled rod
ends are match drilled to each control tube and must be rein-
stalled into control tube end from which it is removed.
d. Measure outside diameter of control tube end and select sleeve per table in figure 2.
e. Temporarily install sleeve onto control tubes per figure 2. Align sleeve and control tube
witness hole. If sleeve protrudes past end of control tube, trim end of sleeve flush (0.000
inch) or back (0.080 inch) from end of tube.
f. Thoroughly clean end of control tube and interior surfaces of sleeve with lint free cloth
and MEK, or equivalent.
y. Mix epoxy adhesive per manufacturers instructions.
h. Plug end of control tube to prevent adhesive from entering threads.
CAUTION
Bond integrity is dependent on clean surfaces.
i. Bond sleeve to control tube per figure 2. Apply adhesive to both surfaces and install
sleeve. Align witness/rivet hole in sleeve and tube.
j. Remove excessive adhesive with lint free cloth moistened with MEK, or equivalent. Do not
saturate the cleaning cloth. Remove adhesive from witness holes.
k. Repeat procedure for ends of each control tube.
i. Allow to cure for 24 hours at minimum ambient temperature of 68 degrees F (alternate

cure 4 hours at 115 140 degrees Fl.
CAUTION
Do not use Heat Gun. Use of heat lamp is acceptable.

m. Install rod ends into end from which it was removed.
n. On fixed rod end, align witness/rivet hole in sleeve and tube with rivet hole in rod end.
Drill (#40) thru opposite end of sleeve.
o. Rivet fixed end with MS20470AD3-15 rivet.

DN-1 58.1
EN-48.1
FN-36.1
DATE: 21 July 1989
PAGE 6 of 8
p. Adjust each control tube to its previously measured length.

q. Paint control tube ends with primer. Paint adjustable end of control tube flat black.
CAUTION
Do not vibro-mark or impression stamp the control tubes.
r. Reidentify, with permanent ink, the control tubes that have been reworked as indicated
below;
Old Part Number New Rework Part Number
369A7007 369A7007-5
369A7009 369A7009-5
369A7011 369A7011-5
369A7012 369A7012-5
s. Rework control tube boots per Figure 1, View F.
t. Reinstall control tubes and boots in reverse order listed in Part I. Reinstall trimmed boots
with vertical seam facing aft. If control tubes have not been accurately measured, flight
controls will require rerigging.
u. Check flight controls for interference or binding.
v. Record compliance to this Service Information Notice in the Compliance Record section
WEIGHT AND BALANCE

Weight and Balance not affected.
The resultant alteration to affected models prescribed by procedures in

as this Notice has been
DN-1 58.1
EN-48.1
FN-36.1
DATE: 21 July 1989
PAGE 7 of 8
JOUBLE 9001
16961009 1 II II Inl\ooualE BOOT

r69Amo7~1111 1111 HOLE
169AIOll
~6PAfOlZ
j69A1012
)WAIOII
16961007
369Alm9
:IIEW LOOKING FORWARD VION LOOKING FORWARD

VIEWA VIEW B
YOLEdI
3_
50UBlE BOOT DOUBLE BOOT
3bPA1001
,!69A102, j~iFii7
HOLE
1I I
169A1009 369Am09
VIEW LOOKING FORWARD VIEW LOOKING FORWARD

VIEWC
SEWNSEAMS SEWNSEAMS
JMJBLE BOOT
50-.50
NOIE I
169AlaW
I SINGLE Bm
-----------I DOUBLE BOOT
VIEW F
NOTES (Boot Rework):

1.Trim boots below horizontal seam
2. Clean inside and outside of vertical seam and top of

boot with clean cloth dampened with isopropyl alcohol.
YInW UW)Y;~U: FORW~LRD CAUTION Do not use solvents or petroleum based

VIEWE cleaning fluids on vinyl boots.
3. Coat both sides of vertical seam with contact cement.
4.Apply thin coat of contact cement. along trimmed
edge and 1/8 to 1/ 4 inch down inside and outside sur-
faces of boots to prevent fraying.
Figure i. Control Tube Removal and Boot Rework

ON-1 58.1
EN-48. 1
FN-36. 1
DATE: 21 July 1989
PAGE 8 of 8
0.097
DIA
CONTROL
TUBE SLEEVE
0.102
i 0.340
A 0.750
DIA DIA
I_0.720
0.080
0.000
0.910
j
D IMENS ION Td BLE
SLEEVE NO. DIM A TUBE O.D.
ROD NO.
369027013
-1 .540-.445 .501-.530
369A7007 NOTES:
369A7009 1. Material
2 .510-.515 .470- .500
2024-T351 or-T4
-3 1 .590-.595 i .551-.580
(QQA 225/6) Bar
or Round Stock
369A7[111
2. Break sharp edges
-4 .560- .565 .520-.550
0.005 0.015 inch
3. Surface finish
369A 71112 -5 .570 .575 .530 .560 125 RMS
4. Chemical Film
per Mll-C-5541
5. Tolerance
+0.010 inch
Figure 2. Sleeve Fabrication and Installation

j
NlcDonnell Douglas NOTICE NO:
EN49
Helicopter Company FN-37
DATE: 12 June 1989
PAGE of 2
aSER~llg=% s BVI F~RBVIATION 1
MAN DATO MANDATORY ~JIANDBTORY
SUBJECT: ONE-TIME INSPECTION OF AEROQUIP HOSES (P/Ns 369A8352, 369H8306,

369H8025, 369H8024-5 and 369028651).
MODEL AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369 Series helicop-
ters, including the 369A (OH-6A), except as noted below, and all Aeroquip hoses in
Spares Inventories.
NOTE
369E, Serial Number 0280E and subsequent; and 369F/FF,
Serial Number 0056F and subsequent helicopters are not
affected by the requirements of this Notice.
TIME OF COMPLIANCE: All affected helicopters shall be inspected per the requirements of this
Notice at the next 100 hour inspection. All Spares inventories shall be inspected per
the requirements of this Notice before installation onto a helicopter or no later than
from the date of this Notice.
j 60 days
PREFACE: Aeroquip Corporation has advised MDHC of problems on certain hoses manufac-
tured by Aeroquip. Aeroquip has traced the
problem particular group of hoses
to a
and hose material identified with "cure dates" 2Q84 thru 3Q87. These hoses have
had a problem with leaking, seepage and failure.
Although no incidences have been reported by operators of MDHC helicopters, all

operators are required to inspect their aircraft to verify that hoses identified with cure
dates 2Q84 thru 3Q87 are not installed. Those operators who find any discrepant
hoses will have those hoses replaced at no charge.
REFERENCE
369H Basici HMI (CSP-H-2) Revised 14 March 1988

PROCEDURE
a. On 369H, D and affected 369E Series aircraft, gain access to the engine compartment
and inspect the 369A8352 and 369H8306 oil hoses for the proper cure date number.
Refer to sample identification tag information shown at the end of this Notice.
b. On affected aircraft equipped with an airframe mounted anti-ice fuel filter, inspect the
369)-18024-5 and 369H8025 fuel hoses for proper cure date number.
McDonnell Douglas
FORM 9i7D (REV 11/87)
Helicopter Company
NOTICE NO.: HN-218
DN-1 59
EN-49
FN-37
DATE: 12 June 1989
PAGE 2 of 2
PROCEDURE CONT.
NOTE
All hoses identified with cure dates 2Q84 thru 3(3)87 shall be
removed from service and returned to MDHC for replacement
hoses which will be provided free of charge.
c. On 369F/FF Series aircraft, gain access to the engine compartment and inspect the
369D28651 oil hose for proper cure date number. Refer to sample identification tag
information at the end of this Notice.
NOTE
All hose identified with cure dates of 2~3184 thru 3Q87 shall be
removed from service and returned to MDHC for replacement
hoses which will be provided free of charge.
d. Inspect and purge ail Spares Inventories of Aeroquip hose assemblies indentified with
cure dates 2Q84 thru 3Q87.
e. Record compliance to this Service Information Notice in the Compliance Record section
SAMPLE IDENTIFICATION TAG INFORMATION:
The affected hose assemblies have CRES I.D. band that is etched with identification information
including, but not limited to:
Manufacturers Name Location
Aeroquip Part Number
Customer Part Number
Assembly Date
Cure Date
Proof Test Date
Hose Manufacturers Federal Code
Operating Pressure (Optional)
a typical I.D. band would look like:
Aeroquip- ACM
AE707050-1
369D28651
A4Q85
2(3184 or CD2Q84
PT 10-&4
50556
60 psi
McDonP)elS NOTCE NO.:
DATE: 19 June 1989
HediccPptes sCnmpany/ PAGE 1 of 4
M A N DATO RY~IC-- -C1 III ~--s MANDATORYPCIP-~-I CC- ---4-P~ MANDATORY
SUBJECT: ONE-TIME INSPECTION OF FOUR-BLADED TAIL ROTOR HUBS (PN 369D21700-3).
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369D and 369E
Series helicopters equipped with four-bladed tail rotor assemblies.
TIME OF COMPLIANCE: Helicopters equipped with four-bladed tail rotor assemblies that
contain hub serial numbers 196 thru 251 shall accomplish the requirements of this
Notice within the next 10 hours of helicopter operation or at the next disassembly of
the tail rotor assembly, whichever occurs first.
All other helicopters equipped with four-bladed tail rotor assemblies shall accom-
plish the requirements of this Notice within the next 100 hours of helicopter operation
or at the next disassembly of the tail rotor assembly, whichever occurs first.
Spates Inventories shall be inspected per the requirements of this Notice prior to
installation onto a helicopter or 90 days from date of Notice.
PREFACE: MDHC had one four-bladed tail rotor hub returned from service which had fatigue
cracks. MDHC has determined that the cracks are a result of electrical arcing caused
by poor anode contact during the Tiodize coating process during manufacture.
Therefore, MDHC is requiring the following inspection of the tail rotor hub assembly.
REFERENCE

OPT. EQUIPMENT MANUAL (CSP-088) Revised 19 June 1989
HUB REPLACEMENT POLICY: MDHC will replace free of charge any hub that is;,found
unserviceable due to the conditions described in this Notice. Return parts to the
MDHC Warranty and Repair Department along with a completed Service and
Operations Report (SOR, form 853A).
PROCEDURE
a. Remove blades from the four-bladed tail rotor assembly per the applicable HMI/CSP-
088.
NOTE
Record the exact location, number and type of existing hardware
for use in reinstallation. Hardware must be reinstalled in the
exact same location when reassembling the tail rotor blade
asse m bly.
Avoid bending or damaging strap pack. Scratches or nicks on
strap laminates may make strap pack unserviceable.

McDonnell Douglas
FORM 9578 (REV 11187)
Helicopter Company
NOTICE NO.: DN-160
EN-50
DATE: 19 June 1989
PAGE 2 of 4
b. Visually inspect inside and outside diameter of hub from each end inboard .50 inch for
indications of a foreign material on the surfaces (having the appearance of corrosion or
corrosion products), pitting of the surface and/or small pock-type spots where melting
and puddling of the surface metal has occured.
NOTE
Any of these conditions subject for rejection of the hub
are
unless the foreign material and pitting can be removed per Step
(9 The area where the outboard bearing contacts the O.D. surface
of the hub may have small dimples which have the appearance
of a pit. This is where softer material has worn away and is not to
be misconstrued as pitting and is not cause for rejection. Fitting,
if existing, will be associated with foreign material on the surface
and will be isolated to the end face surface las shown in Figure
1) or inside surface (normally within .25 inch from the outboard
end) of the hub.
c. Perform a dye penetrant visual inspection of the outer surfaces of the hub for cracks from
the tip inboard 1.00 inch. Apply the dye penetrant per the manufacturers instructions
with a clean dry QTIP or equivalent.
CAUTION
Protect the exposed strap pack ends by placing a plastic bag over
the strap assy which extends at least 1.00 inch inside the end of
the hub. Secure the bag with a rubber band, wire tie or plastic tie
wrap and work it down inside the end of the hub opening. Stuff
each end of the hub with a clean rag to prevent the cleaner,
penetrant or developer solution from getting on the strap assem-
bly.
d. If the contaminant is only on the O.D. remove foreign material or minor pitting from the
O.D. of hub using a 400 grit or finer abrasive paper or cloth.
CAUTION
Do not remove Tiodize coating in the bearing area.
e. If there are indications of pitting not corrected by Step d. or indications of cracking,

replace hub with a serviceable hub per the HMI/CSP-088.
f. Reinstall tail rotor blades onto helicopter per the applicable HMI/CSP-088.
NOTICE NO.: DN-160
EN-50
DATE: 19 June 1989
PAGE 3 of 4
CAUTION
Reinstall blades, bushings, crushwashers and other attaching

hardware in the exact same location it was removed. This will aid
in dynamic balancing of the tail rotor assembly.
g. Perform tail rotor balancing per instructions contained in the HMI.
h. Record compliance of this Service Information Notice in the Compliance Record section
The resultant alteration to the affected models as described by the procedures in this Notice
has been shown to comply with Federal Aviation Regulations and is FAA Approved.
NOTICE NO.: DN-160
EN-50
DATE: 19 June 1989
PAGE 4 oi 4
END FACE
(BOTH ENDS)
HUB
CRITICAL AREA
TO INSPECT,
(1.0. 80.0.,
BOTH ENDS)
CAUTION SHOES NOT TO 8E REMOVED FROM

STRAP PACK. AVOID DAMAGING STRAP PACK.
SCRATCHES OR NICKS ON STRAP LAMINATES
MAY MAKE STRAP PACK UNSERVICEABLE.
88-648
Figure 1. Inspection of Four-Bladed Tail Rotor Hubs.

~cDonnell Douglas
FN-38
Heiic~i-ipier Compa~y DATE: 10 July 1989
PAGE 1 of 4
MANDATORY I I I MANDATORY MANDATORY
SUBJECT: ONEITIME INSPECTION OF TAIL ROTOR TRANSMISSION OUTPUT SHAFT

DUPLU( BEARINGS (P/N 369025420).
HELICOPTER MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC)

3690, 369E and 369F/FF series helicopters with 369025400 tail rotor assemblies
installed.
NOTE
Only those helicopters equipped with 369025400 tail rotor
transmissions (two-bladed) are affected by the requirements of ij
this Notice.
SPARES INVENTORIES AFFECTED: All 369025400 tail rotor transmissions placed into Spares
Inventories prior to 01 March 1989.
All 369025420 bearings manufactured by the Fafnir Bearing Company and placed
into Spares Inventories prior to 01 March 1989.
NOTE
Fafnir bearings are sold in a box which contains an inspection-
/approval date. Fafnir bearings dated 01 March 1989 or later are
not affected by the requirement~ of this Notice.
TIME OF COMPLIANCE: Aircraft The requirements of this Service Information Notice shall be
accomplished within the next 300 hours of helicopter operation or at the next annual
inspection, whichever occurs first. Operators whose helicopters are experiencing
excessive tail rotor vibration shall accomplish this Notice immediately.
Spares Inventories IAll affected parts and assemblies in Spares Inventories shall be
inspected per the requirements of this Notice before assembly/installation and in no
case later than 60 days from the date of this Notice.
PREFACE: MDHC recently found 369025420 bearings manufactured by the Fafnir Bearing
Company allowed axial play in the output shaft of the tail rotor transmission due to
the bearing being out of tolerance. The possibility exists that some out of tolerance
bearings may have been installed onto helicopters presently in service. Therefore,
operators have to perform the following one-time inspection to check the tail rotor
transmission for axial play in the output shaft.
McDonneli Douglas
FORM 9.578(REV 11187)
Helicopter Company
NOTICE NO.: DN-161 i
EN-51
FN-38
DATE: 10 July 1989
PAGE 2 of 4
REFERENCE

369FF HMI Vol.l (CSP-F-2) Revised 01 June 1989
Component Overhaul Man. (CSP-DEF-5) Revised 06 March 1989
TOOLS AND EQUIPMENT
Nomenclature Source
Dial Indicator Commercial
PROCEDURE
NOTE
Operators can either remove the tail rotor transmission per the
HMI and inspect for axial play per the COM or they can attach a
dial indicator to the tail rotor transmission to inspect for axial
play similar to the configuration shown in Figure 1.
a. Attach dial indicator to the tail rotor transmission with the probe of the dial indicator
a
contacting the fork inboard vertical face as shown in Figure 1 or remove tail rotor
assembly from the output shaft of the tail rotor transmission per Section 8 of the HMI.
CAUTION
Do not clamp-up to the body of the tail rotor breather assembly as

damage to the breather assembly could occur. Clamp-up should
only be made to the hex base of the breather assembly.
b. Disconnect tail rotor pitch control links at the pitch control end.
CAUTION
Do not allow blade pitch travel to exceed 30 degrees travel in

either direction. Rotating the blades to excessive pitch angles
when pitch links are disconnected may result in undetected
damage to the strap pack.
NOTE
Improper clamp-up can result in excessive axial play in the
output shaft.
NOTICE NO.: DN-161
EN-51
FN-38
DATE: 10 July 1989
PAGE 3 of 4
c. Verify the tail rotor transmission output shaft has no axial play.
NOTE
Ifoutput shaft has axial play, ensure the tail rotor transmission
output shaft has proper clamp-up (shimming of.001-.003 inch)
per Part ill, Section 6 of the Component Overhaul Manual
Remove and replace duplex bearings which
those 369025420
are found to be out of tolerance causing play in the tail rotor
axial
transmission output shaft and return to MDHC Waranty and
Repair Department for replacement.
d. If removed, install tail rotor assembly onto helicopter per Section 8 of HMI.
e. if the tail rotor assembly has been removed, perform tail rotor balancing per Section 8
of the HMI.
f. Record compliance to this Service Information Notice in the Compliance Record section
g. Verify all tail rotor transmission assemblies in Spares Inventories have no output shaft
axial play per Component Overhaul Manual.
h. Return all 369D25420 bearings dated prior to 01 March 1989 manufactured by Fafnir
Bearing Company to MDHC Waranty and Repair Department for a replacement.
NOTE
369D25420 bearings with a date of March Oi, 1989 or later are
approved for service.
The resultant alteration to affected models as described by procedures in this notice has been
NOTICE NO.: DN-161
EN-51
FN-38
DATE: 10 July 1989
PAGE 4 of 4
C-CLAMP BASE
TAIL ROTOR
TRANSMISSION
DIAL INDICATOR
j
e
NOTE:
TAIL ROTOR FORK
THIS ILLUSTRATION DEPICTS A SAMPLE CLAMP-UP CONFIGURATION
OF A DIAL INDICATOR TO MEASURE TAIL ROTOR AXIAL PLAY. OPER-
ATORS ARE ALLOWED TO CLAMP-UP TO ANOTHER LOCATION ON THE
TRANSMISSION BASE AS LONG AS ACCURATE TAIL ROTOR AXIAL PLAY
CAN BE MEASURED. CLAMP-UP SHOULD BE MADE TO HEX PORTION
ONLY OF BREATHER CA P AS SEMBLY.
88-647
Figure 1. Tail Rotor Transmission Output Shaft Inspection.

NO"CE NO.: DN-162
McDonnell Douglas EN-52
FN-40
Helicopter Company
M AN DATO RY- I MANDATORY M AN DATO RY
SUBJ ECT: ONE-TIME INSPECTION OF EMERGENCY AND UTILITY FLOAT SKID TUBE EXTEN-
SION ASSEMBLIES.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 3690, 369E and
369F/FF Series helicopters with emergency or utility floats installed.
NOTE
Utlity floats are only approved for use on the 3690 and 369E
Series helicopters.
100 hours of helicopter operation.
PREFACE: MDHC has received reports of fractures in the float skid tube extensions as a result of
corrosion and/or wear on the Skid tube extensions assemblies in combination with
wave action on ocean waters or ground handling loads.
As a result of this experience, operators are required to perform the following

one-time inspection of the skid tube extensions. Operators who find their skid
extensions damaged are req~ired to rework skid tube extensions per modification
instructions in CSP-002 (utlity floats) and CSP-025 (emergency floats). Copies of
CSP-002 and CSP-025 will be provided with this Notice. It should be noted that utility
floats are only certified on the 3690 and 369E series helicopters.
REFERENCE
Utlity Floats Manual (CSP-002) Reissued 12 June 1989

Emergency Floats Mgnual (CSP-025) Reissued 12 June 1989
PROCEDURE
a. Gain access to emergency and utility float skid tube extension assemblies.
b. Remove the skid extension tubes and inspect for internal corrosion.The area to be
inspected is from the attach point aft to the bend in the tube.
NOTE
Light surface corrosion can be removed and touched up per
instructions in the HMI.
Wear should not exceed 20% of the wall thickness of the tube.
c. Inspect emergency and utility float skid tube extensions for any signs of cracking,
corrosion and/or wear. Remove light corrosion per instructions in the HMI.
I-roduct Support Department
IWcDonnell Douglas
Melicopter Company
NOTICE NO.: DN-162
EN-52
FN-40
DATE: 30 June 1989
PAGE 2 of 2
ii
NOTE
Replace those skid tube extension assemblies found to have
or excessive wear per INSTALLA-
cracks, excessive corrosion
TION OF SKID TUBE EXTENSIONS instructions found in CSP-
002 (utility) and CSP-025 (emergency) optional equipment in-
stallation instructions.
Refer to CSP-OO2 and CSP-025 Illustrated Parts List for current
configuration emergency and utility float skid tube extension
asse m bl ies.
d. Record compliance to this Notice in the Compliance Record section of the helicopter
Log Book.
FAA APPROVED
McDonnell Douglas NOTICE NO.: HN-220
DN-1 63
Helicopter Company EN-53
FN-41
PAGE 1 of 3
MANDATORY I-I MANDATORY MANDATORY
SUBJECT: ONE-TIME INSPECTION OF 369A5358 LOCKWASHER IN THE OVERRUNNING

CLUTCH ASSEMBLY AND INSPECTION OF ENGINE OUTPUT DRIVE SPLINES.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369A (OH-6A),
369H series,~ 369D, 369E, serial No. 0001E thru 0368E and 369F/FF, serial No.
0001F thru 0067FF, series helicopters.
TIME OF COMPLIANCE: The requirements of this Service Information Notice shall be accom-
plished within the next 300 hours of helicopter operation or the next time the
overrunning clutch sub-assembly is removed from the helicopter, whichever occurs
first.
PREFACE: Several 369A5358 overrunning clutch lockwashers have been found cracked in
service. As cracking may occur during the crimping operation at installation, MDHC
is requiring operators to perform the following inspection to ensure the subject
lockwasher is not cracked.
,I Additionally, e~cessive wear hae been detected an the Allisan engine output drkis
splines on some helicopters. Therefore, anytime the overrunning clutch sub-
assembly is removed from the helicopter, the splines on the overrunning clutch and
the output spline in the engine should be inspected for wear. Wear in the engine
output splines can be detected by feeling for a "step" inside the splines. Operators
are required to contact Allison for a disposition if any "step" in the area is
felt/observed.
REFERENCE

369H COM (CSP-H-5) Revised 15 July 1989
369D/E/FF COM (CSP-DEFd) Revised 29 September 1989
PROCEDURE
a. Remove overrunning clutch subassembly per HMI to gain access to 369A5358

lockwasher.
NOTE
DO NOT remove iockwasher unless cracks are observed when
performing the following step.
NlcDonnell Douglas
FORM 9578 (REV 11 187)
Helicopter Company
NOTICE NO.: HN-220
DN-1 63
1-\
EN63
FN-41
PAGE 2 of 3
b. Using a suitable light and a 10X magnifying glass, inspect lockwasher crimped area as
shown in Figure 1 for any indications of cracking. Replace cracked lockwashers per the
applicable COM.
NOTE
Pay particular attention to the crimped portions of the lock-
washer.
c. Check the splines of the overrunning clutch for wear per the COM.
d. Check the engine output drive splines using a sharp point scribe lightly feel for a
"step" in the spline length (see Figure 1) where the clutch input drive splines mesh with
the engine output drive splines.
NOTE
If a "step" is observed or felt using sharp point scribe, contact
a
Allison Gas Turbine Division of General Motors Corporation for
disposition at (317) 230-2720.
e. If a "step" is not felt/observed install overrunning clutch sub-assembly per applicable

HMI.
NOTE
e Verify overrunning clutch assembly has been properly serviced.
e Verify clutch input and output drive splines have been properly
lubricated before installation.
f. Record compliance to this Service information Notice In the Compliance Record section
NOTICE NO.: HN-220
DN-1 63
EN-53
j FN-41
PAGE 3 of 3
NO STEP ALLOWED IN THE AREA WHERE

THE CLUTCH INPUT DRIVE SPLINES
alESH WITH THE ENGINE OUTPUT DRIVE
5 PLINES IF STEP" CAN BE FELT WITH
A SCRIBE.
ENGINE OUTPUT
DRIVESPLINES
CLU[CII CLUICII
~OUTER
INNER a RACE
RACE
j
OUTWT DRIVE INPUT DRIVE
M832428/
1-141PACKING INSPECT AREA OF CR IMP 169A5358
IN SLOTS IN 369A5357 OR 369A5365
AND 369A5352 AS SHOWN.
49-071-1
Figure i. Inspection of Overrunning Clutch Assembly and Engine Output Drive Splines.
NlcDonnell Douglas o:
HDNN:~B:.I
EN-54.1*
Heijcop2er dCon?pan~ FN-44.1*
DATE: 04 May 1990
PAGE 1 of 3
~1BPIDATOHY hllANe)~r;TORY j~ilbaNDAfOM1(
Supercedes Service Information Notices DN-164, EN-54 and FN-44, dated 27 October 1989.
SUBJECT: CONVERSION TO 369A5350-41 OVERRUNNING CLUTCH SUB-ASSEMBLIES.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369H Series, 369D, 369E
(0001E thru 0324E) and 369~FF (0001~ thru 0065FF) Series helicopters equipped with
cargo hooks, including the 369A (OH-6A) Series helicopter that do not have a 369A5350-41
overrunning clutch sub-assembly or 369A5350-605 clutch assembly installed.
NOTE
The primary reason for re-issuing this Notice is to include the 369H
and 369A Series helicopters and to make a change to the time of
compliance section of this Notice. This revision also splits the Notice
into two parts: PART I contains a procedure to modify the clutch
sub-assembly and PART II reidentifies the clutch housing to indicate
369A5350-605.
TIME OF COMPLIANCE: PART I Operators of 369 Series helicopters equipped with cargo hook
assemblies shall comply with PART I of this Notice within the next 300 hoursf* of helicopter
cargo hook operation.
XRTo establish TIME OF COMPLIANCE, either clutch total time with hook installed may be
used, or a separate and permanent log of external load (cargo hook) operating time
(take-off to landing which involves external load operations) may be used. The log must
meet requirements of FAR 91.173.
PART II Shall be accomplished at the next removal of the engine. I

PR EFAC E: Field reports indicate that some operators utilizing cargo hooks are experiencing chipping of
the sprag elements in 369A5350-31 overrunning clutch sub-slssemblies. Increased fre-
quency of full power lifts causing component defle-~tions are believed to be the cause of this
chipping of the sprag elements. The applicable Component Overhaul Manuals contain
instructions for upgrading existing overrunning clutch sub-assemblies to the 369A5350-41
configuration which is adapted to handle increased loads.
REFERENCE

369D/E HMIVol.l CSF)-DP) Revised 01 August 1989
369F/FF HMI Vol.I
(CSP-F-2) Revised 01 June 1989
369D/E/F COM (CSP-DEF-5) Revised 29 September 1989
Product Support Depar!nier7r
McDonnell Douglas
FOAM 9578 (REV 11187)
Helicopter Company
NOTICE NO.: HN-222
DN-164.1*
EN-54.1*
FN-44.1*
DATE: 04 May 1990
PAGE 2 of 3
PART I MODIFICATION OF OVERRUNNING CLUTCH SUBIASSEMBLY I
PARTS LIST
Inner race 369A5353-3 1 MDHC
Nut, bearing retainer 369A5365-3 1 MDHC
Sprag 369D25351 If MDHC
Seal kit 99-369A5350-603 1 MDHC
R
Not required if converting from a 369A5350-31 to 369A5350-41 overrunning clutch sub-assembly and
the sprag assembly meets the inspection criteria called out in the Component Overhaul Manual.
PROCEDURE
a. Remove overrunning clutch sub-assembly per Section 9 of applicable HMI.
b. Rework overrunning clutch sub-assembly to convert it to the 369A5350-41 configuration per
instructions contained in the applicable Component Overhaul Manuals.
NOTE
The various items needed to convert to a -41 clutch from the various
configurations are shown in the applicable Component Overhaul
Manual and parts list contained in this Notice.
c. Ensure that the overrunning clutch sub-assembly has been properly serviced and the
output and
input splines have been coated with grease per the applicable HMI.
NOTE
Add 30cc of lubricating oil (Mll-L-23699) to 369A5350-41 overrun-
ning clutch sub-assemblies as existing HMls give instructions to add
45cc of lubricating oil to the earlier configuration clutch sub-
assemblies during assembly.
d. Re-identify the overrunning clutch sub-assembly to the 369A5350-41 configuration by vibro-

scribing or impression stamping on the existing sub-assembly data plate.
e. Install the overrunning clutch sub-assembly which has been upgraded to the 369A5350-41
config uration.
f. After installation, verify oil level is acceptable per the applicable HMI.
9 Record compliance to PART I of this Service Information Notice in the

Compliance Record sectian
I
NOTICE NO.: HN-222
DN-1 64.1*
EN-54.1*
FN-44.1*
DATE: 04 May 1990
PAGE 3 of 3
PART II RE-IDENTIFICATION OF CLUTCH ASSEMBLY
a. Verify that PART I of this Service Information Notice has been accomplished.
b. Re-identify the overrunning clutch to a 369A5350-605 configuration by vibro-scribing or impression
stamping on the existing clutch assembly data plate at the next removal of the engine.
NOTE
The clutch assembly data plate is located on the outside of the
369A5351-5 housing and is accessible only with the engine removed.
The 369A5350-41 clutch sub-assemblyis a component of the
369A5350-605 clutch assembly. The 369A5350-11, -21 and -31
clutch sub-assemblies are components of the 369A5351-603 clutch
assembly.
c. Record compliance to PART II of this Service Information Notice in the Compliance Record and
Component Log sections of the helicopter Log Book.
WEIGHT AND BALANCE

NlcDonnell Douglas NOTICE NO.: HN-221
Helicdpter Company DN-1 65

EN65
FN-43
SERVICE INFORMATION NQTICE DATE: 27 October 1989
PAGE 1 of 2
MANDATORY I MANDATORY -I MANDATORY
SU BJ ECT: INSTALLATION OF OIL FLOW RESTRICTING DEVICES INTO THE ENGINE OIL AND
TORQUE PRESSURE SENSING SYSTEMS.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369A (OH-6A),
369H Series, 369D, 369E (Serial No. 00018 thru 03048) and 36988 (Serial No.
0001F thru 00598) helicopters not equipped with oil flow restricting devices in the
engine oil and torque pressure sensing lines.
NOTE
Only those 369 Series helicopters equipped with direct sensing
torque and oil pressure line systems are affected by the
requirements of this Notice.
100 hours of helicopter operation or 90 days, whichever occurs first.
PREFACE: Federal Aviation Administration rules CAR 6.606(b) and 6.613 require the installation
of a restriction device at the pressure source of engine oil and torque sensing
systems to restrict oil flow ~in the event of a system failure. Due to this requirement,
operators are required to install restricting devices (snubbers) in those engine oil
and torque pressure sensing systems which do not already contain restricting
devices. Parts required to comply with this Notice can be obtained, free of charge,
from the MDHC Warranty and Repair Department.
REFERENCE
ApplicablePilots Flight Manual (for helicopter operation)

3698/88 HMI Vol.l (CSP-F-2) Revised 01 June 1989
McDonnell Douglas
FORM 9578 (REV 11 187)
Helicopter Company
NOTICE NO.: HN-221
DN-1 65
EN-55
FN43
PAGE 2 of 2
PARTS UST
Reducer 359028410 1 MDHC
Packing, O-ring NASG17-4 2 MDHC or Commercial
Snubber 398-003 1 MDHC or Commercial
Reducer AN919-OJ 1 MDHC or Commercial
Packing, O-ring NASG17-3 2 MDHC or Commercial
Snubber 5702-001 1 MDHC or Commercial
PROCEDURE
a. Open and secure engine access doors.
b. Disconnect the 369A8010 engine oil pressure and torque pressure sensing lines from
the connecting ports located on the engine and remove existing hardware.
c. Install NAS617-4 packing, 398-003 snubber, NAS617-4 packing and 369D28410

reducer into oil pressure sensing port. Reconnect oil pressure sensing line to reducer.
d. InstallNAS617-3 packing, 5702-0D1 snubber, NAS6173 packing and AN919-OJ

reducer on torque pressure sensing port on engine. Reconnect torque pressure
sensing line to reducer.

e. Start and operate helicopter at ground idle for two minutes minimum per applicable
PFM.
f. Bleed air from engine oil pressure and torque pressure sensing lines per Section 13,
Vol.l of the HMI.
g. Shutdown helicopter per applicable PFM. After rotor blades have stopped turning,
check oil and torque pressure sensing lines and associated connection ports for
security and any evidence of leakage. If any leakage is noted, repeat steps a thru f.
h. Close and secure engine compartment access doors.
i. Record compliance to this Service Information Notice in the Compliance Record section
McC)~nnpll Donglas ~E
FN-45.1*
~-1 ~7
DATE: 14 March 1990
PAGE 1 of 6
5 i IC E i kf ~t
A ki iii?;i Pl D R~
Supercedes Service Information Notices DN-166, EN-57 and FN-45, dated 12 December 1989.
SUBJECT: One-time Inspection and Replacement of Air Industries MS21250-04036 Bolts AND
Verification of Proper Installation of All MS21250-O4036 Bolts in Main Transmission.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369D, 369E (Serial No.
0001E thru 0352E) and 369F/FF (Serial No. 0001F thru 0067FF) Series helicopters.
SPARES INVENTORIES AFFECTED: All spare MS21250-04036 Bolts delivered from MDHC or
purchased direct from Air Industries since August 1988. All spare main transmissions
delivered prior to September 1989 shall be inspected per the requirements of this Notice.
CAUTION
If it cannot be determined when the MS21250-04036 Air Industries bolts were

purchased, those Air Industries bolts shall be replaced.
To identify a -04038 bolt, the length is ETON(See).Figure

1
2.887 +/-.010 inch. I
TIME OF COMPLIANCE: The requirements of this Notice shall be accomplished within the next 300
hours of helicopter operation, the next annual inspection, or the next time the transmission
is removed, whichever occurs first.
PR EFAC E: MDHC has determined that some bolts manufactured by Air Industries and delivered since
August 1988 may not meet industry standards. Theref~re, MDHC is requiring operators to
perform the following one-time inspection and/or replacement of these suspect bolts.
In addition to replacing bolts manufactured by Air Industries, all 369D, 369E and 369F/FF
operators required to inspect main rotor output driveshaft bearing assembly bolt
are
installations for proper thread protrusion through the nut end of the bolt.
Failure to comply with the requirements of this Notice could result in severe damage to the
main transmission.
NOTE
After installation, bolts shall protrude through .the nut for a length
I
equivalent to two full threads (0.071 inch minimum), including the
chamfer.
e If necessary, replace bolts with hn821250-04038 bolts. The maximum

bolt protrusion from the nut end is four (4) threads.
Bolts manufactured by Air Industries that have drilled (safety-wire

holes) heads are acceptable.
I~lcDonnell Douglas
FORM 9578 (REV 11/87)
HelicopS~r eompany
EN-57.1*
FN-45.1*
DATE: 14 March 1990
PAGE 2 oi 6
REFERENCE
369D/E HMI Vol. I (CSP-D-2) Revised 01 August 1989

369FIFF HMI Vol. I (CSP-F-2) Revised 01 June 1989
Component Overhaul Manual, (CSP-DEF-5) Revised 29 September 1989
SPECIAL WARRANTY POLICY: The following listed aircraft and transmissions are eligible for these
special warranty considerations:
a. MDHC will provide, free of charge, replacement o-rings, bolts and nuts.
b. MDHC will provide 15 hours of labor credit to remove, disassemble, inspect, reassemble and
reinstall the main transmission. This work must be performed at an MDHC Approved Service
Center or International Distributor.
NOTE
For further warranty information contact the MDHC Warranty and
Repair Department Administrator.
AIRCRAFT ELIGIBLE FOR SPECIAL WARRANTY CONSIDERATION
Xmsn Ser. A/C Ser. I I XmsnSer.# A/CSer.# I I XmsnSer.# A/C Ser.

1744 0237E 1 1 1087 0319E I 1 1329 0341E
1714 0281E I 1 2104 0320E I 1 2222-0011 0343E
2094 0282E 1 1 1811 0321E I 1 2222-0036 0344E
1759 0293E 1 1 1802 0322E 1 1 2222-0035 0346E
1628 0298E 1 1686 03238 1 1 2222-0016 0347E
2113 0301E I 1 1818 0324E 1 1607 0349E
1814 0303E I 1 1663 0325E 1 1 1667 0350E
1676 0304E 1 1671 0326E 1 1 2222-0015 0351E
3659 0305E I 1 1813 0327E 1 1 2222-0028 0352E
1797 0306E I 1 1826 0328E 1 1 1809 0057FF
2109 0307E I 1 2222-0009 0329E I 1 1807 0058FF
1657 0308E I 1 1328 1 0330E I 1 1812 0059FF
1661 0309E I 1 1820 0331E I 1 1658 0060FF
1787 0310E I 1 2222-0029 0332E 1 1 1804 0061FF
2117 0311E I 1 2222-0012 0333E 1 1 1794 0062FF
1819 0312E I 1 2222-0013 0334E 1 2222-0022 0063FF
1646 0313E I 1 2222-0019 0335E 1 1 2222-0027 0064FF
1709 0314E I 1 1704 0336E 1 1 1716 0065FF
2132 0315E I 1 2222-0010 0337E 1 1 1652 0066FF
1810 0316E I 1 2222-0026 0338E 1 1 1709 0067FF
1776 0317E I 1 2222-0025 0339E
1815 0318E I 1 2222-0014 0340E
EN-57.1*
FN-45.1*
DATE: 14 March 1990
PAGE 3 of 6
ADDITIONAL TRANSMISSIONS ELIGIBLE FOR SPECIAL WARRANTY CONSIDERATION
Xmsn I I Xmsn IIXmsn I I Xmsn IIXmsn I I Xmsn IIXmsn I I Xmsn

Ser. IISer. i I Ser. IISer. IISer. I I Ser. I I Ser. I I Ser.
U0712 110376 110737W 111313 111567 1 11756 1 11994 1 178-0095
U1261 110384 110738 111317 111575 1 11757 1 12000 1 178-0099
U1468 110409 110776 111330 1 11592 1 11770 1 12003 1 1106-0030
0142 ii 0445 110793 111335 1 11611 1 11793 1 12004 1 1127-0075
0165 1 10447 110843 111347 1 11620 1 11799 1 12008 1 12222-0002
0169 1 10450 110849 111364 1 11637 1 11800 1 12009 1 12222-0003
0171 1 10451 110868 111385 1 11641 1 11801 1 12048 1 12222-0004
0194 110455 110893 i 11387 1 11662 1 11803 1 12059 1 12222-0005
0201 110535 110906 111401 1 11677 1 11816 112063 1 12222-0006
0202 110541 110939 1 11424 111687 1 11817 112067 1 12222-0007
0207 110556 110992 111425 111689 1 11821 1 12077 1 12222-0008
0216 I I 0607 111024 1 11427 1 11698 1 11822 1 12121 1 12222-0021
0260 1 10610 111027 1 11438 111701 1 11823 1 12124 2222-0023
0276 110660 1 11030 111458 1 11707 1 11824 112125 1 12222-0030
0294 1 10662 (11058 (11460 1 11715 1 11825 112129 1 12222-0032
0307 1 10668 111065 111;477 1717 1933 113662 1 12222-0033
0321 I I 0686 111082 111514 1 11718 1 11934 113674 112222-0039
0326 1 10713W 111106 1 11528 1 11727 1 (1943 1 1460005 112222-0042
0343 110719 111240 111530 1 11733 1 11969 1 1470058 1 12222-0043
0360 1 10733 111292 111555 i 11751 1 11991 1 118-0079 )12222-0044
2222-0045
2222-0055
2222-0079
SPARE PARTS REQUIREMEN%

PARTS LIST
O-Ring 5-488-047-071 1 MDHC
O-Ring MS29561-0 14 2 MDHC or Commercial
O-Ring MS29561-016 2 MDHC or Commercial


Filter ACA388F90 A/R MDHC
Bolt MS21 250-04038 4 MDHC
Nut MS21042L4 or H14-4 A/R MDHC or Commercial
Washer NAS620C416L or NAS620C416 A/R MDHC or Commercial
AN960C416L or AN960C416
EN-57.1*
FN-45.1*
DATE: 14 March 1990
PAGE 4 of 6
PROCEDURE
a. Remove main rotor transmission per HMI Vol i.

b. Disassemble tail rotor drive assembly, two nozzles and main rotor drive assembly (Ref. CSP-
DEF-5)
c. Inspect 1\11821250-04036 bolt head inscriptions for unacceptable bolt head markings (refer to
Figure 2). Replace unacceptable bolts with M521250-04038. Deform and sciap unaccepta6ie bolts
to prevent bolts from re-entering service. I
NOTE
To identify a -04038 bolt, the length is 2.887 +/-.010 inch. (Refer to Figure 1.) I
IWP~ANINOGNI RAWI
The following bolt protrusion inspection must be accomplished on all
main transmissions.
d. Inspect bolts for proper thread protrusion through the H14-4 nuts. If proper thread protrusion
cannot be obtained, replace bolts with MS21250-04038 bolts.
NOTE
Bolts must protrude through the nut for a length equivalent to two full
threads (0.071 inch minimum), including the chamfer. Thread protru-
sion must not exceed four (4) threads. The H14-4 nut may be installed
without a washer.
To prevent possible disiocation of clamp-up shims on main rotor

output drive assembly, remove unacceptable bolts individually.
e. Install acceptable MS21250-04038 bolts, washers and nuts (Ref. GSP-DEFd). Torque bolts 50-70
inch-pounds. Verify that bolts protrude through the nut for a length equivalent to two full threads
(0.071 inch minimum), including the chamfer. If more than 4 threads protrude through the nut, add
r;JAS620C416L or NAS620C416 (or acceptable alternate per Parts Li~t) washer(s) under the nut as
required.
NOTE
If any washers other than those called out in Step E have been
installed, replace those washers at the next disassembly of the main
transmission.
f. Reassemble main rotor drive assembly, two noules and tail rotor drive assembly
(Ref. CSP-DEFd).
g. Apply a white dot to the main transmission data plate to indicate the transmission has been
inspected and reworked per the requirements of this Notice.
h. Install main rotor transri~ission (Ref. applicable HMI).
i. Record compliance to this Notice in the Compliance Record Section of the helicopter Log Book.
EN-57.1*
FN-45.1*
DATE: 14 March 1990
PAGE 5 of 6
_,.i;ap~3
e MS 21250-04036 BOLT (NOTE)

o
20002C4WASHER
I
369025174 COVER DEBRIS
j
I-i c:
/I
PIN X~.010
M521250-04036
MS 21250-04038
2.762 . 887
NOTE:FOR REPLACEMENT ORDER

MS21250-04038 BOLT
t TLOBar
PR~TUS ION
0.071 INCH MINIMUM
ALL DIMENSIONS SHOWN IN INCHES

O
JNAS620C416L OR AN960C416L
OR NAS620C416 OR AN960C416
WASHER (AS REQUIRED)
14-4 NUT 88-652
Figure 1. Inspection/Replacement of Main Transmission
Output Driveshaft Bearing Assembly Bolts.

NOTICE NO.: DN-166.1
EN-571-
FN15.1
DATE: 14 March 1990
PAGE 6 of 6
A C CE PTA BLE
a D
UNACCEPTABLE
Figure. 2. InspectioniDefinition of Bolt Heads
ORIGINAL
As Received By
ATP
McDolnizii z-7oug1,75 NOTICE NO:
FN-46
j.i~SCOL)fi-?: COTI~S3nW onTE: 14 March 1990
PAGE 1 of 5
ONEITIME CHECK/PERIODIC INSPECTION/REPLACEMENT

OF TAIL ROTOR SWASHPLATE BEARING SET I
SUMMARY: MRC Corporation has determined that all tail rotor swashplate bearing sets (P/N
369021832) with black seals (except those bearings shipped from MDHC after March 1,
1990) shall be inspected periodically for indications of roughness (similar to a rachet feeling
1
when the tail rotor assembly is rotated).
PURPOSE: The purpose of this Notice is to perform a one-time check to verify what bearings are
installed by the color of the tail rotor swashplate bearing seals and further inspect those
bearing sets with black seals for roughness.
i
TIME OF COMPLIANCE: PART I
accomplished prior
ONE-TIME CHECK
to the next flight. (May be
The requirements
performed by a pilot.)
of PART I shall be
i
PART II PERIODIC INSPECTION AIRCRAFT WITH BLACK SEALS The requirements
of PART II of this Notice shall be accomplished within the next ten (10) hours of helicoDter
operation and each subsequent ten (10) hours of operation until the tail rotor swash~late
bearing sets have been replaced with acceptable bearing sets provided by MDHC. In no
case, shall bearings with black seals (within the unacceptable serial number range) remain
in service more than 300 hours since installation or after 3uly 1, 1990, whichever occurs first.
SPARES INVENTORIES All 369021832 tail rotor swashplate bearings that have black
seals with a serial number in the identified range of unacceptable serial numbers and pitch
control assemblies (P/N 369021800 and 369021820) that have bearings with black seals
installed shall be returned to MDHC Warranty and Repair Department for replacement
bearings.
The following 369D2183: tail rotor swashplate bearing serial numbers shall be removed
from Spares inv6ntories and returned to MDHC Warran;y and Repair Dept.:
059150-0001 thru 059150-0692 and
059150-0734 thru 059150-0742
MDHC will be issuing a limited number of tail rotor

swashplate bearings that have black
seals. These bearings are and will be marked and tagged verifying they are
acceptable
acceptable. Operators who receive these bearings and who receive bearings from MDHC
after March 1, 1990 should make an entry in the Component Historical Record section and
the Compliance Record section of the helicopter Log Book to record the serial number of
the tail rotor swashplate bearing. Helicopters with these bearings installed do not have to
further comply with the requirements of this Notice. Later bearings will have yellow and
green seals and are acceptable. Bearings with yellow or green seals do not have to be
inspected per PART II of this Notice.
MODELS AFFECTED: All MDHC 3690, 369E and 369F/FF Series helicopters.
ASSEMBLY/COMPONENTS TO BE INSPECTED AND CORRECTED: All 369021600 and

369021610 Series tail rotor assemblies and all 369021800 and 369021820 Series pitch
McDonnell Douglas
FOHM 9578 (HEV 11107)
Helicopter Company
NOTICE NO.: DN-167
EN-58
FN-46
DATE: 14 March 1990
PAGE 2 of 5
control assemblies. (Tail rotor swashplate bearing serial number is not visible when installed
in swashplate housing.) Tail rotor assemblies, pitch control assemblies and tail rotor
swashplate bearings shipped after September 14, 1989 and prior to February 28, 1990, are
suspect and subject to the inspection requirements of this Notice.
REFERENCE PUBLICATIONS: (Use the manuals listed below or any later revisions.)
369D/E/F COM (CSP-DEFd) Revised 29 September 1989

369D/E HMI Vol.l (CSP-DQ) Revised 01 August 1989
369F/FF #MI Vol.l (CSP-F-2) Revised 01 June 1989
SUPPLY/PARTS AND WARRANTY DISPOSITION:
PARTS LIST
Bearing set, tail rotor 369D21832 1 MDHC (no charge)

swashplate (A/R)
Swage ring 369 D21 805 1 MDHC (no charge)

(A/R)
Lockwasher MS172209 1 MDHC (no charge)
(AJR)
Lockwasher HS1551S238 1 MDHC (no charge)
AJR
LABOR ALLOWANCE: MDHC will reimburse operators a labor allowance of two (2) hours for
replacement of the bearing if the work Is performed at a MDHC Approved Service Center or
Distributor.
SPECIAL TOOLS/JIGS AND FIXTURES REQUIRED. Refer to the Component Overhaul Manual for
required tooling to remove and install the tail rotor pitch control
bearing set.
PART I ONE-TIME CHECK
a. Check tail rotor swashplate bearing assembly to determine which color bearing seal is installed.
(Refer to Figure 1)
NOTE
a Bearing seal can be observed by looking into the outboard end of the
T/R swashplate bearing assembly.
If necessary, clean the face of the bearing seal with a dry cotton swab
(Q-Tip) so that bearing seal color can be determined.
NOTICE NO.: DN-167
EN-58
FN-46
DATE: 14 March 1990
PAGE 3 of 5
b. If the bearings installed have green or yellow seals, no further inspection is required. Proceed to the
Recording and Cdmpliance section of this Notice.
c. If thebearings installed have black seals, immediately contact MDHC Field Service Dept. and
provide A/C serial number and time since tail rotor swashplate bearing was installed. Bearings with
black seals shall be inspected per the requirements of PART II.
PART II P ERIO DIC I NSPECTION/REP LACEMENT OF TAIL ROTO R SWASHP LATE

BEARING ASSEMBLIES
a. Disconnect outboard end of beilcrank (refer to Figure 2).

b. Disconnect dust boot from inboard end of pitch control assembly. CThis will allow rotation of tail
rotor swashplate housing.)
c. Whileapplying a down load on top of the housing by hand, slowly rotate pitch control housing to
verify smoothness of operation. Bearing must rotate smoothly and without roughness to be
acceptable.
NOTE
A slight feeling of grit in the grease, with smooth areas in between, is
considered acceptable for continuing an additional ten hours of
operation. If the gritty feeling is continuous, replace the bearings.
d. Ifroughness occurs, replace tail rotor swashplate bearing before further flight with an acceptable
bearing set provided by MDHC per the Component Overhaul Manual.lf an acceptable black seal
bearing has been installed apply a white dot (approximately 1/8 inch dia.) on.the outside face of the
housing as shown in Figure 1 per the applicable Handbook of Maintenance Instructions.
e. Install and lockwire dust boot on inboard end of pitch control housing.
f. Service the tail rotor swashplate pivot bearing assembly with acceptable grease per the Handbook
of Maintenance Instructions.
Reconnect bellcrank to outboard end of pitch control assembly per the Handbook of Maintenance
g.
Instructions.
WEIGHT AND BALANCE. N/A.
RECORDING AND COMPLIANCE: Record compliance to this Service Information Notice in the
Compliance Record section of the helicopter Log Book.
POINTS OF CONTACT: For further information contact your local MDHC Field Service Representative
(refer to the latest revision of the Marketing and Product Support handbook for address and
.telephone numbers) or contact the Field Service Department at MDHC, Mesa, Arizona.
Telephone: 1-800-445-1516 or (602) 891-6342.
This Service Information Notice has been shown to comply with Federal Aviation Regulations and is
FAA Approved.
NOTICE NO.: DN-167
EN-58
FN-46
DATE: 14 March 1990
PAGE 4 of 5
NOTE 1
NOTE 1
t
NOTE 2 1
NOTE 2
TWO BLADED T/R FOUR BLADED T/R
NOTES:
L VERIFY BEARING SEAL IS GREEN OR YELLOW. BEARINGS WITH
BLACK SEALS SHALL BE REMOVED AND REPLACED OR SUBJECTED
TO THE IO-HOUR RECURRING INSPECTION.
2 APPLY A WHITE DOT TO PITCH CONTROL HOUS INGS WITH
ACCEPTABLE BEARING WITH BLACK SEALS AS SHOWN.
N88-656-1
Figure 1. Inspection of Tail Rotor Assembly.

NOTICE NO.: DN-167
EN-58
FN-46
DATE: 14 March 1990
PAGE 5 of 5
I
__*
O t
--i CE~
VIEW FROM O1~BD END THROUGH TM

NOTE:
TWO OR FOUR BLADED SWASHPLATE TO
ENSURE WASHER IS INSTALLED
SEE COLOR OF BEARING SEAL.
ON INSTALLATION
GREEN SEAL.NMT DEPART. HYATT-
BLACK SEAL.MRC BEARINGS -REPLACE BOLT TO BE REMOVED TO PERFORM

OR GOOD IF IDENTIFIED
INSPECTION(PARTII)
AS ACCEPTABLE
YELLOW SEAL.MRC BEARINGS -GOOD
*e
O) \Y \Y \r L.-L
__
N88-656-2
Figure 2. Inspection of Tail Rotor Assembly.

McDonne~Douglas NOTICE NO.:
HN-2 3DN-1 68
EN69
Helicopter ~ampar?kr DATE: 15 June 1990
FN-47
PAGE 1 of 3
MAl\lh3~60RY I\dlANDAlOaY ~9ANYj4TORY
ONEITIME REPLACEMENT OF POLYCARBONATE

COVER ASSEMBLIES (369A9817)
l SUMMARY: McDonnell Douglas Helicopter Company (MDHC) has received reports that some
369A9817 polycarbonate cover assemblies were found cracked by visual inspection.
~7
CAUTION
Complete failure of the cover assembly could result in severe FOD damage to the
engine.
PURPOSE: It is the purpose of this Notice to replace all polycarbonate cover assemblies with aluminum
cover assemblies.
MODELS AFFECTED: All (MDHC) 369 Series helicopter equipped with 369A9817(BSC) polycarbonate
engine air filter overboard cover assemblies.
TIME OF COMPLIANCE: The requirements of this Notice shall be accomplished within 90 days after
receiving or fabricating parts. If needed, parts should be ordered immediately after
receiving this Notice.
ASSEMBLY/CO MPON ENTS TO BE INSPECTED AND CORRECTED: 369A9817, cover assem-
bly, engine air filter overboard cover assembly; Qty. per helicopter (1).
369# IPC (CSP-H-7) Revised 17 March 1989
3690 IPC (CSP-D4I Revised 17 February 1989
3690/00 IPC (CSP-E/F-4) Revised 16 June 1989
PARTS UST
1. Cover assembly, engine 369A9817-11 1 1 MDHC (Warranty and Re-

air filter overboard vent pair Department) or field
fabricate using items 2 thru
4 listed below.
2. Cover 369A9817-5 1 Field fabricate per Figure 1.
McDonnell Douglas
FORM 9578 (REV 11187)
Helicopter Company
NOTICE NO.: HN-223
DN-1 68
EN-59
FN-47
DATE: 15 June 1990
PAGE 2 of 3
PARTS UST
3. Nutplate MS21o76-L3 8 Commercial or MDHC (Nut-

plates from polycarbonate
covers can be used on alu-
minum cover assemblies.)
4. Rivet MS2o426A3 A/R Commercial or MDHC
SPECIAL TOOLS/JIGS AND FIXTURES REQUIRED. N/A.
AIRCRAFT INSPECTION AND CORRECTION PROCEDURES:
tcaui~l
CAUTION
Use care to avoid dropping screws, washers or other foreign matenal into the
engine air intake when performing the following steps. Severe FOD could occur.
a. Cover engine air inlet with a suitable cover to prevent foreign objects from entering the engine.
b. Remove the 369A9817 cover assembly from the engine air inlet fairing (See Figure 1 for location).
C. Verify which type of ~over assembly is installed.
NOTE
369A9817(BSC) assemblies are polycarbonate and 369A9817-
cover
11 cover assemblies ate aluminum.
d. Discard polycarbonate cover assemblies and procure a 369A9817-11 cover assembly from MDHC
Warranty and Repair Dept. or field fabricate a 369A9817-11 cover assembly per instructions in
Figure 1.
NOTE
Nutplates may be removed from polycarbonate covet assemblies
and reused for fabricating an aluminum cover assembly.
e. Prime and paint covet assembly accordingly.
f. Install aluminum cover assembly using existing screws and washers.
RECORDING AND COMPLIANCE:

Record compliance to this Service Information Notice in the Compliance Record Section of
POINTS OF CONTACT:
For further information contact your local MDHC Field Service Representative (refer to the
latest revision to the Marketing and Product Support handbook for address and telephone
numbers) or contact the Fiela Service Department at MDHC, Mesa, Arizona. Telephone:
1-800-445-1516 or (602) 891-6342.
NOTICE NO.: HN-223
DN-1 68
EN69
FN-47
DATE: 15 June 1990
PAGE 3 of 3
FAR SIDE
(SEE NOTE U
3.562
L 781
tTYP) 2UR~YP)
(L35 L781
(RER
3.781
G~=
F
d/
COMR
5.781O 7.562
3BM~n-LI co\rm asEMsa

3250014
MS2l076-u NOTPLATE
RRSIDO
(SEE NOTE 2) M52042~3 RIMT
(2 REPO) 8 PUm
N(m5r
tlNK STAMP PART NO. ON BACK SIM AND
WASHER
PAINT FRONT SIM TO MATCH HELICOPIER
SCRMI 2 COMR ASSEMBLY TO BE FABRICATED OUT
OF 2024-73 ALUMINUM AUOY, 3040 INCH THICK 88-655
3. AU DIMENSIONS ARE IN INCHES
Figure 1. Fabrication of 369A9817-11 Cover Assembly.

N"CE HO.:
McDonnell Douglas DN-169
42 -NH/
EN-60
Welicopter Company ~:,,,_,,

FN-48
PAGE 1 of 3
EWANDBTORY pU-U MANDATORY
SUBJECT: ONE-TIME REPLACEMENT OF TAIL ROTOR BLADE PITCH ARM BOLT ATTACHING
NUTS.
MODELS AFFECTED: Al McDonnell Douglas Helicopter Company (MDHC) 369 Series he(ico~
ters, equipped with metal tail rotor blades.
300 hours of helicopter operation or at the next annual inspection, whichever occurs
first.
PREFACE: MDHC installation requirements were recently revised to lower the installation torque
of the tail rotor pitch link nuts. Therefore, MDHC is requiring operators to replace the
subject MS17826-4 nuts. MDHC will provide operators with replacement nuts, free
of charge. Contact a MDHC Approved Service Center or Distributor for replacement
nuts.
PARTS LIST
Nomenclature I Part No. Oty. Source
Nut MS17826-4 A/R MDHC
REFERENCE

369088 COM (CSP-DEF-5) Revised 29 September 1989
PROCEDURE
CAUTION
Carefully secure the hex porbon of the pitch arm holt while removing and
installing nut
a. Remove nuts at pitch control assembly and nuts at tail rotor blade pitch arm attachments.
(Refer to Figure 1.)
Product Support Depart;nent
McDonnell Douglas
FORM 9578 (REV 11187)
Helicopter Company
NOTICE NO.: HN-224
DN-1 69
EN-60
FN-48
DATE: 15 June 1990
PAGE 2 of 3
b. install MS17826-4 nuts. Torque tail rotor blade nuts to 50

new 60 inch~pounds. Torque
nuts at pitch control assembly to 30 40 inchlpounds.
CAUTION
DO NOT exceed 60 inch-pounds torque on the tail rotor blade nuts or 40

inch-pounds on the pitch control assembly nuts.
6. Without exceeding torque limits, align cotter pin hole at the outboard and inboard ends of
the pitch arm and install cotter pin.
NOTE
Apply MlL-P-8585 zinc chromate primer to cotter pin during
installation.
d. Record compliance to this Service Information Notice in the Compliance Record section of
WEIGHT AND BALANCE
Weight and balance are not affected.
NOTICE NO.: HN-224
DN-1 69
EN-60
FN48
DATE: 15 June 1990
PAGE 3 of 3
PITCH
CONTROL
ARM
PITCH ARM BOLT
TORQUE PITCH CONTROL

i ASSY. NUT IPIN MS 17826-4)
1
1 30-40 IN. LBS. (ALL BLADES)
TORQUE TIR BLADE NUT

PITCH
(PIN MS 17B26-4)
CONTROL
5060 IN. LBS.(ALL BU\DESI 88-651
LINK
Figure i. Replacement of Tail Rotor Pitch Linje Nuts.

McDonnell Douglas "O""
EN-61.1*
Helicopter Company DATE:. 15
FN-49. 1"
May 1991
PAGE 1 of 2
SERVICE INFORMATION NOVICE
Supercedes Service Information Notices HN-225, DN-170, EN-61 and FN-49, dated 25 July 1990.
ONEITIME TORQUE CHECK AND INSPECTION OF MAIN ROTOR BLADES
SUMMARY: McDonnell Douglas Helicopter Company (MDHC) has determined that the torque on some
main rotor blade root fitting bolts do not meet MDHC manufacturing specifications. These
bolts provide an additional degree of safety due to the clamping load of the bolts providing
additional friction in the bolted joint. The reason for reissuing tkis notice is that some of the
part numbers were added or revised and the time of compTiance had a minor change.
PURPOSE: It is the purpose of this Service Information Notice to verify/check the torque of the main rotor
blade rootfitting bolts and to inspect the root fitting bond lines for integrity.
MODELS AFFECTED: All MDHC 369 Series helicopters with any of the following main rotor blades
installed:
369A1100-505 and -601

369021100613 and -515
369D21102(BSC) and -501
NOTE
Helicopters that have previously accomplished the inspection
requirements of this Notice are not affected.
hours of helicopter operation, the next time the main rotor blades are removed or no later
than June 30, 1991, whichever occurs first.
ASSEMBLY/COMPONENTS TO BE INSPECTED AND CORRECTED: 369A1100-505, 369A1100-

601, 369D21100-513, 369021100-515, 369021102(BSC) and 369[321102601.

369D/E/F/FF HMI (CSP-Hhill-2) Issued 31 October 1990 I
a. Visually examine the root fitting bond lines for integrity. All M/R blades that exhibit bond line
separation shall be removed from service.
NOTE
Contact a MDHC Field Service Representative for disposition of any
M/R blade that appears to have separation in the area of the root
fitting bond lines.
Product Suppo~t Department
NlcDonnell Douglas
FonM 9578 (AEV 11187)
Helicopter Company
DN-1 70.1*
EN-61.1*
FN-49.1*
DATE: 15 May 1991
PAGE 2 of 2
a. If no separation is observed, apply a torque of 60-65 inch pounds to each root fitting attach I
bolt on all main rotor blades.
NOTE
The 60-65 inch pound torque requirement includes a nominal
value to account for run-on torque.
b. Apply a white dot to the underneath side of acceptable main rotor blades in the area of the
root fitting bolts/nuts.
Record compliance to this Service Information Notice in the

Compliance Record
POINTS OF CONTACT:
For further information contact your local MDHC Field Service

Representative (refer
to the latest revision of the Marketing and Product
Support handbook for address
and telephone numbers) or contact the Field Service-Department at MDHC, Mesa,
Arizona. Telephone: 1-800-445-1516 or (602) 891-6342.
Theinspection procedures in this Notice have been shown to comply with Federal Aviation
""C "O: DN-171.1/
McDonnell Douglas EN-62.1
FN-50.1
Helicopter Company

Supersedes Service Information Notices DN-171, EN-62 and FN-50, dated 25 July 1990. 1
ONE-TIME INSPECTION OF 369[)25623 OIL COOLER BLdWER BELT
SUMMARY: The Gates Rubber Company, which bought out Uniroyal and is currently the sole I
source manufacturer of the 369D25623 oil cooling blower fan belt, has indicated to
McDonnell Douglas Helicopter Company that blower assembly belts found in
service out in the field with green labels were not manufactured by Gates. These I
belts are not authorized for use on MDHC 369 Series helicopters.
PURPOSE: The purpose of this revision to the original Service Information Notice is to provide
operators with additional information which will aid operators in identifying accept-
able and non-acceptable blower belts.
CAUTION
Unacceptable belts can track improperly and damage other components of

the cooling fan assembly.
MODELS AFFECTED: All MDHC 3690, 3696 and 369F/FF Series helicopters.
100 hours of helicopter operation, the next time the main transmission cover
assembly is removed or no later than June 30, 1991 whichever occurs first. I
ASSEMBLY/CO MPON ENTS TO BE INSPECTED AN D CORRECTED: 369 D25623 oil cooler

blower belts.

(I pombn of ten added w revised. I
I~cl)onnell Douglas
FORM 9578 (REV 11187) Helicopter CornFany
EN-62.1
FN-50.1
PAGE 2 of 3
SUPPLY/PARTS:
PARTS LIST
Nomenclature Part No. Qty. I Source
Blower belt 369D25623 AJR MDHC
NOTE
The main transmission oil cooler blower belt identification
markings can be inspected by removing the inspection plug on
the main transmission cover and viewing the identification
markings using flashlight.
a
a. Gain access to the oil cooling blower assembly.
b. Inspect oil cooler blower belt as follows:

1. Acceptable blower belts are identified by white PN 369D25623 followed by a
three-digit code (see sample shown in Figure 1) with 3/16 to 1/4 inch high lettering
along with some other numbering. In order to be acceptable the three digit code
must be present.
2. Blower belts identified with green part numbers and letters (refer to Figure 1) or belts
without three-digit codes immediately after the part number must be replaced with
acceptable belts per instructions contained in the appropriate Maintenance Manu-
als.
3. Remove unacceptable blower belts from Spares Inventories. Return unacceptable
belts to MDHC Warranty and Repair Department for warranty consideration/re place-
ment.
Record compliance to this Service Information Notice in the Compliance Record

POINTS OF CONTACT:
For further information contact your local MDHC Field Service Representative (refer
to the latest revision of the Product Support handbook for address and telephone I
Telephone: 1-800-445-1516 or (602) 891-6342.
The requirements of this notice have been shown to comply with Federal Aviation Regulations
and are FAA Approved.
EN-62.1
FNdO.l
PAGE 3 of 3
369025623 904 HA1634 3 89
THREE-D IGIT MANUFACTURERS CODE MUST BE

PRESENT
WHITE MARKINGS ACCEPTABLE
M"d" In
UUf~ 369935668 1
3691)25623
369925623
j~ ~leB: 369925623,
3~21623
GREEN MARKINGS UNACCEPTABLE
33-662
Figure 1. Inspection of Oil Cooler Blower Belt.

McDonnell~ouglas "0: HN-226.1
1.27-ND/~ yr
EN-63.1
Helicop~? DATE: 04 September 1990FN-51.1

PAOE tofa
SERVICE NOTI@E
MANDATORY-- 1 3---------~- --MANDATORY-- --1- ---I M A N DAiO RY
ON EIT1MEJ NSTALI;ATION OF 369D2405413WaRNING DECALS

IN THE ENGINE COMPARTMENT AREA
SUMMARY: Proper and safe maintenance in the engine bay area is critical. The applicable
maintenance manuals should be used at all times.
I WARNING I
Failure toproperly install, align and torque fuel, oil and air
tubes/lines and fittings could result in engine damage/fail-
ure.
PURPOSE: The purpose of this Notice is to install 36913240543 warning decais in the engine
compartment which will help alert maintenance personnel of the importance to
properly reinstall any fuel, oil or air tubes that have been removed or disconnected.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369, including the
369A (OH-6A) Series helicopters not equipped with 369D24054-3 warning decals.
TIME OFCOMPUANCE: requirements of this Notice shall be accomplished within the next
The
100 hours of helicopter operation after receipt of parts or no later than June 30,
1991, whichever occurs first. Order parts immediately after receipt of this Notice. I
ASSEMBLY/COMPONENTS TO BE INSPECTED AND CORRECTED: 369024054-3 engine
bay area warning decals.
SUPPLY/PARTS:
PARTS LIST
Decal, warning 1 369024054-3 A/R MDHC
AIRCRAFT INSPECTION AMD CORRECTION PROCEDURES:

Proc?iict Sl.lppoil Dc;partn:enl
McDonnell Douglas
F;ORM 9.578(REV 11187)
Helicopter Company
DN-1 72.1
EN-63.1
FN-51.1
DATE: 04 September 1990 j
PAGE 2 of 3
a. Gain access to inside of the engine compartment.

b. Verifythat 369024054-3 warning decals are installed shown in Figure 1. If
as warning
decals are installed, no further action is required.
c. Ensure surface where decals are going to be installed is clean and free of oil
installation. Install warning decals at locations shown in Figure 1.
,li,,,
I
d. Secure engine access doors.

POINTS OF CONTACT:
For further information contact your local MDHC Field Service

Representative (refer
to the latest revision of the Product Support handbook for address and
telephone
Telephone: 1-800-445-1516 or (602) 891-6342.
The resultant alteration to affected models as prescribed

by procedures in this Notice has
been shown to comply with Federal Aviation Regulations and is FAA
Approved.
DN-1 72.1
EN-63.1
FNbl.l
PAGE 3 of 3
369[)24054-3 2 REQD, 1EACH SIDE

LOCATE ~PPROX. AS SHOWN
BETWEEN STIFFENING RIBS ON
INS IDE OF 369022034 DOOR
/wARNING WL
I FAILURE TO PROPERLY IIS9LL ALIW.
AnO TOROVE FUQ Ok 1WO AIR TUBES
1 I 34 50
REF
OTAn,
110 rITTInOS COULO RESULT In
il
I I
FAILURL. RLFfR THL
I
LWGIWE 1
APPLICABLE MIIUAL TOR PROPER

369024054-3 (PEF)
AnO TOROUE
STA
Uf. 50
REF
88-6606
Decal Installation.
Figure 1 EnSi"B Compartment Warning
lVicDonnell Douglas
Heliropter Comioany
Ik$FQRBb~l PAGE 1 of 2
MA N DATO RYlsll ---PlsMANDATOHY- I MANDATORY
INSPECTION OF LEAD-LAG LINK ATTACH NUTS
SUMMARY: A field report indicated that cracking of the 369A1219 nut,

attaching the lead-lag
links, has occurred due to stress corrosion.
PURPOSE: The purpose of this notice is to check all main rotor

lead-lag link attachment nuts for
integrity.
MODELS AFFECTED: All McDonnetl Douglas Helicopter Company (MDHC) 369 Series helicop-
ters, including the 369A (OH-6A) Series helicopter.
TIME OF COMPLIANCE:
Part I Shall be accomplished prior to the next flight.

Part II Shall be accomplished at each daily preflight check.
ASSEMBLY/COMPONENTS TO BE CHECKED 369A1219 Lead-lag link attachment nuts.
369D/E HMIVol.l (CSP-D-2) Revised 01 August 1989
369F/FF HMIVol.l (CSP-F-2) Revised 01 June 1989
SUPP LY/PARTS:
PARTS LIST
Lead-lag link attach 369A1219 A/R MDHC

nut
PART I-ONE-TIME INITIAL INSPECTION
a. Visually inspect all lead-lag link attachment nuts for cracks.

McDonhell Douglas
FORM 9578 (REV 11/87)
Helicopter Company
NOTICE NO.: HN-227
DN-1 73
EN-64
FN-52
PAGE 2 of 2
CAUTION
Main rotor hub assemblies found to have cracked nuts at the lead-lag link
bolts shall be removed from service and replaced before further flight and
shall be returned to MDHC Warranty and Repair Department for repair.
PART II DAILY PREFLIGHT CHECK
a. Visually check all lead-lag link attach nuts (P/N 369A1219) for cracks at each daily preflight
check.
CAUTION
Main rotor hub assemblies found to have cracked nuts at the lead-lag link
bolts shall be removed from service and replaced before further flight, and
shall be returned to MDHC Warranty and Repair Department for repair.
Record compliance to Part I this Service Information Notice in the Compliance

POINTS OF CONTACT:
For further information contact your local MDHC Field Service Representative
(refer
to the latest revision of the Customer Support handbook for address and telephone
Telephone: 1-800-445-1516 or (602) 891-6342.
Theinspection requirement of this Notice has been shown to comply with Federal Aviation
DN-1 74
n/]cDonneil Douglas EiV-65
FN63
Helicopter Company ~7j""b""""

SERVICE IN FOI~MATION NOTICE

INSPECTION OF T/R INPUT GEARSHAFT (P/N 369[)25434) IN THE T/R GEARBOX
UMMARY: A field report indicated that the 369D25434 T/R

input gearshaft was found to have
chipped gear teeth. As a result, MDHC investigation has revealed that some of the
subject gears may not meet minimum hardness requirements. Suspect gears have
been found to have come from the same lot of 65 serialized gears which are listed
below (see assembly/components to be inspected and corrected).
URPOSE: The purpose of this Notice is to verify the serial number of the T/R input gear installed
in all aircraft and remove from service those suspect serial number T/R input gears.
MODELS AFFECTED: Ail McDonnell Douglas Helicopter Company (MDHC) 369D/E/F/FF Series
helicopters.
ME OF COMPLIANCE: The requirements of this Notice shall be accomplished within the next
300 hours of helicopter operation (See the following note).
NOTE
If the serial number of the gearshaft
is unknown, then the tail
rotor gearbox must be disassembled within 300 hours of
helicopter operation for verification of serial number.
EMBLY/COMPONENTS TO BE INSPECTED AND CORRECTED: 369D25434 T/R Input

Gearshaft, serial numbers 0569 thru 0633.
369D/E/FF COM (CSP-DEFd) Revised 29 September 1989
SUPPLY/PARTS:
PARTS LIST
Nomenclature I Part No. Qty. Source
T/R Input Gearshaft 369D25434 A/R MDHC Warranty and

Assembly, T/R Gear- Repair Dept.
box
Packing 2-152-47-071 A/R MDHC Warraty and

2-032-47-071 (oDtion) I I Re
Product Support Dcpartinent
fllJcDonnell Douglas
FORM 9578 (REV 11/87)
Helicopter Company
NOTICE NO.: DN-174
EN65
FN-53
pnoE
PARTS LIST
Shim 369 D2541 4 A/R MDHC Warranty and

Repair Dept.
Shim 369D25416 A/R MDHC Warranty and
Repair Dept.
Shim 369025436 A/R MDHC Warranty and
Re De
WARRANTY DISPOSITION: MDHC will provide a labor allowance of 2.8 hours to remove and
reinstall the tail rotor transmission. A labor allowance of 4 hours will be provided for
the removal and replacement of the 369025434 gearshaft.
All labor shall be performed at a MDHC Approved Service Center at that Service
Centers standard labor rate.
a. Research helicopter/aircraft records (log book or component overhaul log card) to

determine if any of the following serial number T/R gearshaft assemblies are installed. If it
cannot be determined what serial number gearshaft is installed, remove the T/R gearbox
assembly per CSP-HMI-2 and disassemble per the COM for the T/R gearbox as required
to gain access to the gearshaft serial number.
b. Remove the following serial number gearshafts from service and return to MDHC Warranty
and Repair Department for an acceptable replacement gearshaft.
Serial Number Gearshafts: 0569 thru 0633.
NOTE
Gearshafts should be returned to MDHC Warranty and Repair
Department accompanied by a SOR requesting labor.

NOTICE NO.: DN-174
EN-65
FNd3
pnoE 30~3
j
RECORDING AND COMPUANCE:
Record T/R gearshaft serial number and record compliance to this Service Informa-
tion Notice in the Compliance Record section of the helicopter Log Book.
POINTS OF CONTACT:
to the latest revision of the MD500 Customer Support handbook for address and
telephone numbers) or contact the Field Service Department at MDHC, Mesa,
Arizona. Telephone: 1-800-445-1516 or (602) 891-6342. For Warranty issues,
contact the MDHC Warranty and Repair Department at (602)891-8565,
The resultant alteration to affected models as described by procedures in this Notice have
been shown to comply with Federal Aviation Regulations and is FAA Approved.
"OT)CE n0.:
IVlcDonnellDouglas HN-2 8EN-6
DN-175
Helicopter Company ~",","b""""

MANDATORY MANDATORY
ONE-nME ~OF 369H8407
ENGINE BLEED AIR TUBE FLEXIBLE AREA
SUMMARY: McDonnell Douglas Helicopter Company (MDHC) has received field reports indicating that
some 369H8407 bleed air tubes have developed a leak in the flexible section of the tube
assembly. The effect of a leak in this tube will give operators high temperature indications
CTOT) and low power indications.
PURPOSE: The purpose of this Notice is to inspect all helicopters for possible leaks in the flexible portion
of the engine bleed air tube.
MODELS AFFECTED: All (MDHC) 369H Series helicopters, including the 369A (OH-6A) Series helicop-
ter, 369D and 369E Series helicopters.
hours of helicopter operation from the date of this Notice or at the next annual inspection,
NOTE
The requirements of this Notice should be accomplished whenever
low power or high TOT is suspected.
ASSEMBLY/COMPONENTS TO BE INSPECTED: 369H8407 tube assembly, compressor air bleed.

369H Opt. Equip. (CSP-H-3) Issued 15 October 1982
369D/E HMI Vol.l (CSP-DP) Revised 01 August 1989
SUPPLY/PARTS: Normal warranty policy applies when obtaining parts to accomplish this Notice.
PARTS LIST
Tube assembly Com- 369H8407 *A/R MDHC

air bleeb
A quantity of (1) is required per helicopter, if necessary.
Product Support Departrnen!
NfcDonnell Douglas
FonM 9578 (HEV 11/87)
Helicopter Company
NOTICE NO.: HN-228
DN-1 75
EN-66
PAGE 2 of 2
MATERIALS
Nomenclature Source
Soapiwater solution Commercial
IWARNIN61WARNING
Failure to
properly install, align, and torque fuel, oil and air
tubes and
fittings could result In an engine failure. Refer to the
applicable manual for installation and torque procedures.
a. Gain access to the engine compartment.
b. Using the applicable Pilots Flight Manual, operate engine at ground idle.
I WARNING
WIRNINO I
Avoid contact with

engine exhaust and engine bleed air as
engine operating temperatures could cause severe burning.
Use suitable ear protection when performing maintenance
around operating engines.
c. Apply Snoop (or equivalent soap/water solution) over the ftexible portion of the 369H8407 bleed air
tube assembly.
NOTE
Any leaksin the compressor air bleed tube assembly flexible area
should become apparent when the soap/water solution or snoop is
appled to the compressor air bleed tube assembly.
d. Replace those tube assemblies which exhibit leaking per applicable maintenance manual.
WEIGHTAND BALANCE. N/A.

Record compliance to this Service Information Notice in the Compliance Record section of
POINTS OF CONTACT:
For further information contact your local MDHC Field Service Representative (refer to the
latest revision of the Product S~upport handbook for address and telephone numbers) or
contact the Field Service Department at MDHC, Mesa, Arizona. Telephone: 1 -800-445-1516
or (602) 891-6342.
Alterations to affected models as described by procedures in this Notice have been shown to
comply
with Federal Aviation Regulations and is FAA-~proved.
McDonnell Douglas
EN-67
Helicopter Company DATE: 21 November 1990FN-54

PAGE 1 of 2
IPI~FBRMATION NOTICE

ONEITIME REINSTAUATION OF THE 369A1602~3
TAIL ROTOR FORK BOLT
SUMMARY: To ensure proper clamp-up of the tail rotor hub and fork, the 369A1602(BSC) and
-3 fork bolt should be installed using the elongation method only.
NOTE
HN-212.2, DN-153.2, EN-43.2 and FN-32.2, dated 21 April
1939, required operators to replace the 369A1602(BSC) bolt
with a 369A1602-3 tail rotor fork bolt.
PURPOSE: The purpose of this Service Information Notice is to require operators to install the tail
rotor fork bolt using the elongation method rather than the previously used
torque
method.
MODELS AFFECTED: All McDonnell Douglas Helicopter Company (MDHC) 369 Series
helicop-
ters, including the 369A (OH-6A) Series helicopter that have had the tail rotor fork
bolt retorqued using the alternate torque method (140-160 in.lbs.).
NOTE
If it can be verified that the 369A1602-3 tail rotor fork bolt was
last installed using the elongation method, those helicopters
do not have ~o accomplish the requirements of this Notice.
300 hours of helicopter operation from the date of this Notice, at the next annual
inspection, or at the next disassembly of the tail rotor fork assembly, whichever
occurs first.
ASSEMIBLY/CORnPONENT~ TO BE INSPECTED AND CORRECTED: 369A1602-3 tail rotor

fork bolt.
369D/E/F COM (CSP-DEF-5) Revised 17 September 1990
R/lcDonnell Dougfas
FbnM 9578 (REV 11187)
Nt~ilicopter Company
NOTICE NO.: HN-229
DN-1 76
EN-67
FN-54
PAGE 2 of 2
PARTS LIST
Fork bolt, tail rotor *369A1602-3 A/R MDHC Warranty and

Re De nt
Boltsexceeding .012 inch elongation will be replaced through MDHC Warranty and Repair
Department.
TOOLS AND EQUIPMENT
:nnicrometer (4-inch) Commercial

a. Remove cotter pin from nut end of fork bolt.
b. Loosen nut far enough to become free of the chamfered washer.
c. Using a micrometer, measure length of fork bolt with zero torque applied.
d. Torque nut to elongate bolt .008 to .011 inch, and install cotter pin.
~1
CAUTION
If fork bolt elongation exceeds .012 inch, replacement of fork bolt is required.

POINTS OF CONTACT:
to the latest revision of the Product Support handbook for address and telephone
Telephone: 1-800-445-1516 or (602) 891-6342.
McDonnell Douglas NOTICE 110.:
EN-68.1*
Helicopter Company FN-55.1*
DATE: 01 March 1991
SERVICE INFORMATION NOTICE PAGE 1 of 5
Supercedes ~HN-230,DN-177, EN-68 and FN65, dated 21 November 1990.
PREIFUGHT CHECK AND

ONEITIME INSPECTION OF TAIL ROTOR BLADES
SUMMARY: Due to a failure of a fitting, McDonnell Douglas Helicopter

tail rotor blade root
Company (MDHC) is requiring operators to perform an inspection of all aluminum
tail rotor blades to ensure that no crack exists in the tail rotor blade root fitting and
that the tail rotor blade root fitting has proper wall thickness. Thin wall thickness in
the tail rotor blade root fitting can lead to tail rotor blade failure.
PURPOSE: The purpose of this Notice is to provide operators with procedures on how to
perform a daily pre-flight check of the tail rotor blades and instructions on how to use
the MDHC provided tools to inspect the tail rotor blade root fitting area for proper
wall thickness. This revision to this notice is being issued to allow operators
additional time to comply with the requirements of this notice. I
MODELS AFFECTED: All NIDHC 369 Series helicopters equipped with affected tail rotor blades.
All tail rotor blades and tail rotor assemblies in Spares Inventories. All affected tail
rotor blades are listed in the following table.
AFFECTED TAIL ROTOR BLADE ASSEMBLIES
Part Number Blade Serial Numbers
369A1613 tall dash numbers) Prior to 7959
3691)21613 tall clash numbers) Prior to 6482
369D21615 tall dash numbers) Prior to 1358
369D21606 tall dash numbers) Prior to 0538
421-088 tall dash numbers Prior to 0218
New 369 Series helicopters delivered on 01 September 1990 and thereafter and all
tail rotor assemblies or tail rotor blades delivered thereafter were factory inspected
and meet MDHC specifications.
Tail rotor blades with yellow dots applied to the aft edge of the root fitting and those
above the affected serial number range have been inspected for proper root fitting
McDonnell Douglas
FORM 9578 (REV 11 187)
Helicopter Company
DN-1 77.1*
EN-68.1*
FN-55.1*
DAfE: 01 March 1991
PAGE 2 of 5
wall thickness and do not have to comply with the requirements of this Notice.
(II PO(tiM Of added or ~evlsed. I

TIME OF COMPLIANCE: PART I Daily Pre-Flight Check Shall be accomplished at the initial
I
pre-flight check before the first flight of each day after receipt of this Notice until the
requirements of PART II have been accomplished.
PART II Onelnme Inspection of Tail Rotor Blade Shall be accomplished within

the next 100 hours of helicopter operation after receiptof tools but no later than 01
June 1991.The tools will become available approximately February 1991. Tools to
perform PART II can be loaned from a MDHC Field Service Representative, an
Approved MDHC Service Center or the IMDHC Warranty and Repair Department.
1
SUPPLY/PARTS:
PARTS LIST
Inspection tool 369D21633-1-40201 1 MDHC
(Part 1)
Inspection tool 369 D21 633-1 -40201 1 MDHC
(Part 2)
Crush washer 369H5309 A/R MDHC Warranty and
Repair Dept.
O-ring 2-122(=873-70 A/R MDHC Warranty and

Re De
AIRCRAFT CHECK/INSPECTION AND CORRECTION PROCEDURES:
PART I DAILY PREIFLIGHT CHECK OF TAIL ROTOR BLADE
both sides of each tail rotor blade in the area detailed in Figure 1, Detail A,
a. Visually check
for any indications of cracking.
b. Tail rotor blades having indications of cracking shall be removed from service and returned
to MDHC for further inspection and warranty consideration.
NOTICE NO.: HN-230.1"
DN-1 77.1*
EN-68.1*
FN65.1*
DATE: 01 March 1991
PAGE 3 of 5
install acceptable tail rotor blades per the applicable maintenance manual.
c. As required,
PART II I ONE~TIME INSPECTION OF TAIL ROTOR BLADE ROOT FITTING

MDHC Field Service
a. Procureinspection tooling from an Approved MDHC Service Center, a
Representative or the MDHC Warranty and Repair Department.

NOTE
Ensure tail rotor blades, crush washers and bushings are
marked so they can be reinstalled in the exact location and
orientation from which they were removed.
b. Remove tail rotor blades per the applicable maintenance manual.
CAUTION
DO NOT attempt to force the inspection tool to install the retention bolt.
c. With HS610C6244R375X375 bushing (Qty. 1) (369A1624-BSC root fitting) or 369H5308

bushings (Qty. 2) and 359H5309 crush washers (369A1624-3 root fitting) installed, ensure
there are no foreign objects inside the bore of the tail rotor blade root fitting. With root fitting
vertical, inboard end up, insert the 369D21633-1-40201 Part 1 inspection tool into the I.D.
of the root fitting. Align root fitting strap retention holes with tool hole. (See Figure 1, Detail
B.) Attempt to install the retention bolt through the root fitting and tool holes.
NOTE
Tail rotor blade is acceptable if tail rotor blade retention bolt
cannot be inserted thru toot fitting and inspection tool (Part 1)
holes. Unacceptable tail rotor blades shall be removed from
service and returned to MDHC Warranty and Repair Depart-
ment for further inspection and warranty consideration.
d. With HS610C6244R375X375 bushing (Qty.l) (369A1624-BSC root fitting) or 369H5308
bushings (Qty.2) and 369H5309 crush washers (369A1624-3 root fitting) installed, position
the 369D21633-1-40201 Part 2 inspection tool (tab end outboard) over one side of the root
fitting. Align the holes in the inspection tool with the blade attach holes in the root fitting.
For the 369A1624-BSC root fitting, use washers on each side of the root fitting (equal
amounts) to center the inspection tool on the root fitting (See Figure 1, Detail C.). Attempt
to install the retention bolt through the tool and the root fitting. (See the following
CAUTION.)
NOTICE NO.: HN-230.1+
DN-1 77.1*
EN-68.1*
FN-55.1*
DATE: 01 March 1991
PAGE 4 of 5
CAUTION
DO NOT attempt to bend or force the inspection tool to install the

retention holt.
NOTE
Tail rotor blade is acceptable when the tail rotor blade attach-
ment bolt cannot be inserted thru the root fitting holes and both
sides of the inspection tool (Part 2). Unacceptable tail rotor
blades shall be removed from service and returned to MDHC
Warranty and Repair Department forfurther inspection and
warranty consideration.
e. Repeat step d. with the inspection tool positioned on opposite side of blade.
CAUTION
Tail rotor blades, crush washers and bushings must be reinstalled in the
exact location and orientation from which they were removed to ensure
proper blade attachment.
f. Apply a yellow dot to acceptable tail rotor blades on the trailing edge of the root fitting
approximately 1/2 inch outboard from the bushing. (See Figure 1, Detail A.)
g. Install acceptable tail rotor blades per the applicable maintenance manual.
h. Verify the tail rotor assembly is correctly balanced per the applicable maintenance manual.
HELICOPTER WEIGHT AND BALANCE. N/A.
Record compliance to PART II of this Service Information Notice in the Compliance

POINTS OF CONTACT:
For further information or loan of inspection tools contact your local MDHC Field
Service Representative (refer to the latest revision of the Product Support handbook
for address and telephone numbers) or contact the Field Service Department at
MDHC, Rnesa, Arizona. Telephone: 1-800-445-1516 or (602) 891-6342.
The resultant inspection/check to affected models as described by the procedures in this No-
tice has been shown to comply with Federal Aviation Regulations and is FAA Approved.
NOnCE NO.: HN-230.1*
DN-1 77.1*
EN-68.1*
FN-55. 1"
DATE: 01 March 1991
PAGE 5 of 5
SPECIFIC AREAS (BOTH SIDESI

SHOWN CVTAWAY
CRACKS MIGHT INITIATE
FOR CLARITY
AFTER INSPECTION
PER PART II
APPLY A YELLOW DOT
TO ACCEPTABLE BLADES
TAB END
OFTOOL RETENTION BOLT
I
cC~i 7
GENERAL AREA TO BE
INSPECTED fOR CRACKS
IBOTH SIDES. BOTH BLADESI
DETAIL C
36902163?-1-40201 PART 2 INSPECTION TOOL

f IINSPECT BOTH SIDES, EACH BLADD
(SEE NOTE 1)
DETAIL A
I~
~--G"--7
369~2183-1-40201 PART 1
INSPECTION TOOL RETENTION BOLT
BUSHING
SHOWN CUTAWAY
FOR CLARITY
NOTEI
FOR 369A16H-BSC ROOT FI~INC O
ISINGLE BUSHING ON ONE SIDE)
USE WASHERS ON EACH SIDE OF
ROOT FITTING TO CENTER THE INSPECTION
TOOL ON THE FITTING (I- .W INCH). DETAIL B
88-666
Figure 1. Inspection of Tail Rotor Blade Root Fitting.

McDonnell Douglas E
Helicopter Company
SERVICE INFORMATION NOTICE PAGE 1 of 3
ONEITIME REWORK OF MAIN ROTOR TRANSMISSION

OIL COOLING FAN MOUNTING BRACKET
SUBBMARY: The oil cooling fan mounting bracket is subject to galvanic corrosion. The following
measures can be taken to
help prevent the occurrence of galvanic corrosion.
PURPOSE: It is the purpose of this Service Information Notice to provide operators with a
procedure to rework 369D25827(BSC) and 369H5613(BSC), -11 or -21 oil cooling
fan mounting brackets by adding a drain hole at the bottom of the bracket, replacing
steel washers with aluminum washers, adding a .12 inch radius fillet and
applying
sealant around bolt heads and open insert holes in the bracket.
MODELS AFFECTED: All McDonnelr Douglas Helicopter Company (M6HC) 369 Series helicop-
ters equipped with belt driven oil cooling fan assemblies that are not
equipped with
369025627-3 (369D/E/F/FF) or 369H5613-31 (3691-1 series) oil cooling fan mounting
brackets.
TIM~ OF COMPUANCE: The requirements of this Notice shall be accomplished within the next
300 hours of helicopter operation.
ASGEMBLY/COMPONENTS TO BE REWORKED: 369D25627(BSC) (369D/E/F/FF) or

369H5613(BSC, -11 or -21) (369H Series), oil cooling fan bracket.
AND WARRANTY DISPOSITION:
PARTS LIST
Washer, aluminum AN960KD416L 4 Commercial or
MDHC
Sealant (PR1221) MIL-8-8802 A/R Product Research

5454 San Fernando
Rd.
Glendale, CA 91209
Douglas
FOFIM 9578 (HEV 1 1/87)
Helicopter Company
NOTICE NO.: HN-231
DN-1 78
EN-69
FN-56
PAGE 2 of 3
a. Gain access to oil cooling blower assembly using the applicable maintenance manual.
b. Disassemble blower assembly and remove applicable 369D25627 or 369H5613 brackets.
Drill a .250 dia. hole in bracket at location shown in Figure 1, view A.
NOTE
Note the difference in hole location between the 369D25627
(369D/E/FF) and the 369H5613 (369H Series) brackets.
c. Add .12 inch radius to locations shown in Figure 1, view C-C.
d. Treat exposed magnesium with chromic acid solution per the applicable maintenance
manual.
e. Touch-up paint with zinc chromate primer.

f. Reinstall 369D25627 or 369H5613 bracket using aluminum washers in place of steel
washers. Apply PR1221 sealant across joint faying surfaces after assembly.
g. Apply sealant around bolt holes and the open insert holes in the fan bracket shown in
Figure 1, view B-B.
h. Complete installation of the cooling fan assembly per the applicable maintenance manual.
j

POINTS OF CONTACT:
to the latest revision of the Product Support handbook for address and telephone
Telephone: 1-800-445-1516 or (602) 891-6342.
shown to comply with Federal Aviation Reguations and is FAA Approved.
NOTICE NO.: HN-231
DN-1 78
EN-69
FN-56
PAGE 3 of 3
~31111))_
d
1iI
:Bij ~1:Itl ii
;e
lr
.495
1- 1.75
PIN ~69H5613
R. 12 VIEW A
12 RADIVS
GRILL HOLE
~3 .2500IA
VIEW C-C
.620
f I- 1. 75-1 PIN 369025627

369 DIEIFIFF
B
AP LYSEALANT OTHESE
SIIRFACES
(4LOCATIONS)
MOVNTINC
BRACKET
NOTE: DIMENS ION SHOWN IN INCHES SECTION B-B
R8-643A
Figure i. Rework of Oil Cooling Fan Mounting Bracket.

NOTICE NO.: HN-232
McDonnell Douglas DN-179EN-70

PNd?
Helicopter Company DATE: 27 SEPTEMBER1991
PAGE 1 OF 5
ONE-TIME ADDITION OF RIVETS TO TAIL ROTOR

ABRASION STRIP
SUMMARY: McDonnell Douglas Helicopter Company (MDHC) has developed and

approved procedure to rivet abrasion strips to the tail rotor blade which
a
provides a secondary failsafe method of attachment of the abrasion strip.

Helicopters that are equipped with tail rotor blades that have abrasions
strips riveted are no longer subject to HN-197.2, DN-130.2, EN-19.2 or
FN-17.1 dated MARCH 23, 1987. Tail rotor blade abrasion strips should
still be inspected for security at the normal inspection intenrals (pilots
preflight daily check and the 100/300 hour annual inspection) per the
applicable HMI.
PURPOSE: To provide a secondary failsafe method of attachment of the tail rotor blade
abrasion strip.
MODELS AFFECTED: helicopters equipped with 421-088, 369A1613-7,

~P11 369 Series
369A1613-503, 369A1613-505, 369D21606, 369D21613-11,
369D21613-31, 369D21613-41, 369D21613-51, 369D21615 and
369D21615-21 tail rotor blades. Tail rotor blades that do not have abrasion
strips are not affected by the requirements of this Notice.
TIME OF COMPLIANCE: PART I of this Service Information Notice shall be
accomplished within the next 25 hours of helicopter operation after receipt of
this Notice and every subsequent 100 hours not to exceed 300 hours until
the requirements of PART II have been accomplished.
PART n shah be accomphshed within the next 300 hours of helicopter

operation.

369D/E/F/FF HMI (CSP-HMI-8) Revised 10 May 1991
AIRCRAFT INSPECTION AND/OR REWORK PROCEDURE:
PART I TAIL ROTOR BLADE ABRASION STRIP INSPECTION

a. Use a 10X magnifjing glass to inspect abrasion strip/airfoil bond line for debonding. If
abrasion strip debonding is suspected but cannot be confirmed by visual inspection,
remove blades and perform dye penetrant and tap test inspection per the applicable
Nlce)onnell Douglas
FORM 9578 (REV 11187)
Helicopter Company
NOTICE NO.: HN-232
DN-179
EN-70
FN-67
DATE: 27 SEPTEMBER1991
PAGE 2 OF 6
maintenance manual to assure abrasion strip is secure. If debonding has occurred

remove blade from service.
b. Record compliance to PART I of this Notice in the Compliance Record section of the
~ART II TAIL ROTOR BLADE ABRASION STRIP RIVETING
PARTSISUPPLIES
Rivet CR2545-4-1, Bulbed Cherry- 2(per Cherry Textron

lock Unisink Head or blade) 1224 E. Warner Ave.
CR3555-4-1, Cherrymax Santa Anna, CA 92707
Unisink Head Rivets, (714) 545-5511 or
Commercial
Drill bit Cobalt No. 27 1 Commercial
Riveter, Pulling Head For Bulbed Cherrylock use 1 Cherry Textron

Unisink Head (preferred) or 1224 E. Warner Ave.
CTSK Head Santa Anna, CA 92707
For Cherrymax Rivets use (714) 545-5511
Cherrymax Head (Refer to or Commercial
current Cherry Rivet catalog)
Fiberglass cloth, No. 120 Commercial

Resin, Epoxy Spec. 3135A and B or any 2 A/R Commercial or
part (1:1) Clear epoxy resin Great Products Corp.
2000-T S. Susan St.
Santa Ana, CA 92704
(714) 540-9087
1,1,1 Trichloroethane Spec. 0-T-620 A/R Commercial
Emery Cloth 4/R Commercial
luMo~l
CAUTION
DO NOT ATTEMPT TO PERFORM THIS PROCEDURE WITH THE TAIL RO-

TOR BLADES INSTALLED ON THE HELICOPTER. FAILURE TO COMPLY
WITH THIS CAUTION MAY RESULT IN DEFECTIVE RIVET INSTALLA-
TION AND POSSIBLE BLADE DAMAGE.
CAUTION
It is important to locate rivet holesexactly as specified in the following steps.

Failure to do so may affect structural integrity of the tail rotor blades.
NOTICE NO.: HN-232
DN-179
EN-70
FN-57
bATE: 27 SEPTEMBER1991
PAGEIOF 5
CAUTION
When performing the following step, drill bits should be equipped with drill
stops to prevent them from going through both sides of the blade.
a. Remove the tail rotor blades from helicopter per the applicable maintenance manual.
b. Carefi~lly secure the tail rotor blade in a suitable holding fixture.
c. hTsing a No. 27 Cobalt drill, drill holes (DIA. .143/.146) at the locations shown on
Figure 1. (Light center punch prior to drilling is allowed.)
fc*uT;o~
CAUTION
DO NOT exceed countersink depth of.Oll inch when performing the following
step as damage to the abrasion strip will result.
d. Hand deburr holes using 100 degree countersink.
NOTE
It is recommended that practice rivet installation be made (using an equiva-

a
lent thickness sheet stock, .046 inch) to check rivet gun for proper adjustment.
e. Apply zinc chromate primer to holes and install CR2545-4-1 or CR3555-4-1 rivets in
locations shown in Figure 1 while the zinc chromate primer is still wet.
CAUTION
Installed rivet stems may be deburred using a file. Do not remove material from
locking collar.
f. Inspect installed rivets in accordance with Cherry rivet catalog. (If rivet installation is
satisfactory, proceed to step j. below.)
CAUTION
During removal of defective rivet observe the following:
Do not damage or enlarge rivet hole.
Do not drive or force rivet stem from hole.
Do not remove rivets common to tip cap.
g. Remove defsetive rivets as follows:

NOTICE NO.: HN-232
DN-119
EN-70
FlY-b7
P~CEIOF 6
(1) Carefully grind off locking collar and upper portion of rivet head.
(2) Carefi~lly push center stem through rivet sleeve.
(3) Using a drill stop, drill through rivet sleeve using care to prevent hole enlarge-
ment.
(4) Push remainingrivet sleeve through hole.

(5) Inspect hole in abrasion strip. If defective, consult MDHC Field Senrice Depart-
ment.
h. Remove FOD from interior of tail rotor blade as follows:
(1) Drill 0.250 inch diameter hole through tip-cap as shown in Figure 1.
(2) Remove FOD from blade interior through hole (there is space at tip cap end for de-
bris to pass aft of spar).
(3) Return to step e. above and install new rivet(s).
CAUTION
Excessive use oftrichloroethane may damage blade paint finish.

(4) Abrade surface surrounding .250 inch diameter hole using emery cloth; wipe
clean using clean cloth dampened with trichloroethane.
(5) Bond two plies of 120 fiberglass cloth over hole with 3135A and B epoxy resin, or
equivalent. Allow epoxy resin to cure according to manufacturers instructions.
Ic~
CAUTION
Do not allow resin to build up in hole.

i. Repeat inspection of abrasion strip.
j. Install tail rotor blades per the applicable maintenance manual.
k. Perform tail rotor balancing per the applicable maintenance manual.
i. Record compliance to PART II of this Notice in the Compliance Record section of the
WEIGHT AND BALANCE: N/A.
POINTS OF CONTACT:
For further information, contact your local MDHC Field Service
Representative (refer to the latest revision of the Product Support handbook
for address and telephone numbers) or contact the Field Service
Department at MDHC, Mesa Arizona. Telephone: 1-800-445-1516 or (602)
891-6342.
The resultant alterations to affected models as described by the procedures in this Notice
NOTICE NO.: HN-232
DN-179
EN-70
FN67
PAGE 5 OF 5
NOTE:
Ic-.60 NOTE FIBERGLASS THIS AREA.
0.250 INCH
I DDNOTPLACEFIBEROLASS
CLOTH OVER OPENING FOR
C- .30
DIAHOLE I BALANCE WEIGHTS.
.143/.148 DIA HOLE CSK 10CP
o o INSTAU(SEE DETAIL B)
----8--- CR2545-4-1 RIVETS.2REQD
(ONE EACH SIDE)
HOLE LOCATION .51t.03

i i .30t.00
AFTER REMOVAL OF DEBRIS SEAL.250

DIA HOLE WITH 2 PLIES OF 120 FIBERGLASS
CLOTH A 3135AEJg EPOXY RESIN (CREST
PRODUCTS OR EQUIV) AS SHOWN.
1/
SURFACE PREPARATION: ABRADE SURFACE
wrm EMERY CLOTH AND WIPE WTTH
1,1.1-TRICHLORORHANE SOLVENT. O
DO NOT ALLOW RESIN TO BUILD UP IN
.250 DIA HOLE. l.16t.03
.2&.03 ALONG CONTOUR

(BOM SIDES)
O ABRASION STRIP
J
0~1 BLADE SKIN
"O~s
DETAIL B
LOOKING DOWN
NOTE: DIMENSIONS SHOWN IN INCHES.
88-667
Figure 1. Addition of Rivets to Tail Rotor Abrasion Strip, FOD Removal from Blade Interior.
1
NOTICE NO.: HN-233
McBonnell Douglas
FN-59
P-ieiicopter ~Compana/ DATE: 17 January 1992
PAGE 1 of 2
MANDATORY--UI- I--MANDATORY
INSPECTION OF OVERRUNNING CLUTCH OUTER RACE
SUMMARY: At a inspection, an operator detected cracks in the root of eight

300-hour
splines on the 369A5352 overrunning clutch outer race. The part had a total
of 2219 hours in service. MDHC is requiring all operators to inspect all
overrunning clutch outer races that were processed in the same lot as that
of the cracked part.
PURPOSE: To ensure that all of the below listed serial number overrunning clutch outer
races (369A5352) are inspected for cracks.
MODELS AFFECTED: Ah MDHC 369 Series helicopters, including the 369A (OH-6A),
equipped with overrunning clutch assemblies that have any serial number
2840 through 2976 outer races installed.
TIME OP= COMPLIANCE: Affected helicopters shall accomplish the requirements of this
notice within the next 300 hours of helicopter operation or the next time the
overrunning clutch is disassembled, whichever occurs first. Helicopters
equipped with cargo hooks must accomplish repetitive inspections at
intervals not to exceed 300 hours of helicopter operation. Ah affected
overrunning clutch outer races are to be retired at next overhaul.
ASSEMBLY/COMPONENTS AFFECTED BY THIS NOTICE: 369A5352 overrunning clutch

assembly outer race: serial numbers 2840 through 2976.
REFERENCE PUBLICATIONS:
369D/E/F/FF HMI (CSP-HMI-2) Revised 09 September 1991
369H COM (CSP-H-5) Revised 01 April 1990
369D/E/F/FF COM (CSP-COM-5) Issued 17 August 1991
a. overrunning clutch assembly per applicable HMI.

Remove
b. Disassemble overrunning clutch assembly per the applicable COM.
NOTE
Serial number of outer race is vibroscribed on outer diameter surface near the
part number.
c. Magnetic particle inspect 369A5352 serial numbers 2840
outer race through 2976 per
MIL-STD-1949. Check for cracks in the root of the splines.
n/lcDonnell Douglas
FORM 9578 (REV 11187)
Helicopt~r Company
NOTICE NO.: HN-233
DN-lsO
EN-72
FN-59
PAGE 2 of 2
d. If cracking is detected, replace outer race.
e. Assemble overrunning clutch assembly with servicable components per the applicable
COM.
f. Install overrunning clutch assembly per the applicable HMI.
Record compliance to this Service Information Notice in the Compliance
WEIGHT AND BALANCE:
POINTS OF CONTACT:
RRpresentative (refer to the latest revision of the Product Support handbook
for address and telephone numbers) or contact the Field Service
Department at MDHC, Mesa Arizona. Telephone: 1-800-445-1516 or (602)
891-6342.
The resultantinspection to affected models as described by the procedures in this Notice

J V/ C L/SP~ P ~1 tl d 30uglas
Helicopter Company
DATE: 10 Sepfember r992
PAGE 1 OF 4
InformsCon NoQoes HN-234 DN-181, EN-73 and FN-BO, dated 17

JanuEw 1
INSPECTION/REWORK OF FUEL VENT SYSTEM
SUMMARY: A McDonnell Douglas Helicopter Company (MDHC) investigation has

revealed that an int~nal component of the 369HS108 fuel vent line
emergency shutoff valve (rollover valve) is subject to possible degradation
over time. As a result, it is possible for the aircraf2 fuel vent system to
become obstructed resulting in potential erroneous fuel level indications on
the fuel gauge. This possible obstruction occurs when the weight
cockpit
component of the valve assembly slides down the shaft that it is mounted
on and becomes lodged in the vent tube opening, subsequently closing the
valve (see Figure i). Therefore, MDHC is requiring operators to perform an

inspection of the fuel vent system and eventual replacement of the fuel vent
emergency shutoff valve assembly with an acceptable confrguration.
I
PURPOSE: To ensure the proper operation of the fuel vent line emergency shutoff valve.
MODELS AFFECTED: Ah MDHC 369H Series, 369D, 3693 (Serial No. 0001E thru
0B03E) and 369F or 369FF (Serial No. 0003 thru 0091) Series Helicopters
equipped with 369H8108, 369H8108-501 or 369H8108-503 fuel vent line
emergency shutoff valves are affected by the requirements of this Notice.
TIME OF COMPLIANCE: CONDITION I Helicoptere with less than 2400 hours are
not affected by the requirements of PART I of this Service Information
Notice unless e~Pperiencing one of the conditions listed below (items 1 thru 3).
Helicopters wi~h more than 2400 hours shall accomplish the requirements of
PART I within the ne~t 100 hours of operation after receipt of Notice and at
each subsequent 100 hours not to e~tceed 600 hours until the requirements of
II: have been accomplished.
PAItT I shall also be accompiished on any aircraft if any Of the following

conditions errist:
i. Erroneous fuel indications are suspected.
(1I)Denotes portion of text added or revised.
McDonnell Douglas
FORM 9578 (REV 11/87)
Helicopter Company
NOTICE NO.: FIN-234.1L
EN-73.1*
FN-60.1+
PAGE 2 OF 4
NOTE
actual
It is the responsibility of the pilot to have an accurate understanding of the
fuel level and fuel consumption rate during operation of their individual aircraft.
Never Iighfas a
2. Rapidair displacement when the fuel cap is

occurs
removed within five minutes after operation of the aircraft.

3. Fuel quantity indication does not decrease at normal rate
below 250 Ibs.
NOIE The 100/300 hour fuel vent inspection requirements in the mainte-
nance manual remain in effect.
CONDITIONII Helicopterswith less than 2400 hours shall accomplish the

with more than
requirements of PAI~T II at 3000 hours of operation. Helicoptera
600 hours of
2400 hours of operation shall accomplish PAItT II within the nerrt
operation.
ASSEMBLY/COMPONENTS PSFECTED BY THIS NOTICE: 869HB108, 369H8108-501

and 369HS10S-503 fuel vent-line emergency shutoff valves.
I 369D/E/1F/FF HMI (CSP-HMI-1) Revised 24 August 1992
PAI~rSISUPrrrmES
Part No. Qty. Source
Nomenclature
1 MDHC
Fuel vent line emergency shutoff 1369113103-505
valve
Approved rework facilities,
I
36911310351, 1
Reworlred fuel vent line emer-
369113103-50151 contact MDHC for approved
gency shutoffvaive
or
369113103-50314 sources

PART I FUEL VENT LINE EMERGENCY SIIUTOFF VALVE INSPECTION
a. Remove the vent tube emergency valve assembly per the applicable maintenance
manual.
Valve should be open when
b. Inspect vent tube emergency shutoff valve for condition.
vertical position.
held vertical. Valve should be closed when held in the 45 deg. fkom
NOTICE NO,: -HN-234.1*
I)N-lsl.l*
EN-73.1*
FN-60.1*
PAGE 3 OF 4
that valve is
While held in the 45 deg. position blow in the valve assembly and check
closed. Valve shall open when returned to the 25 deg. position from the 45 deg.
reworked
position. Replace obstructed assemblies with a 369H8108-505 assembly or
369HS 50 I
NOTE -Do not use compressed air to blow into vent tube.
tube opening
c. Holding the vent tube in an upright position (0 deg. vertical), inspect
shown in Figure 1 using a pen-light. Ensure tube is not obstructed. Replace any
369HS10S-501M
obstructed vent/tube assemblies with
or 369H8108-503M vent/tube assembly.
a 369H8108-505, 369H8108M,
I
NOTE
369H8108-505 fuel vent line emergency shutoff valves have an improved valve
to slide
weight attachment design which will not allow the weight assembly
from ob-
down the shaft that it is mounted on thus preventing the valve weight
structing the fuel vent system (see Figure 1). The 369H8108M,
369HS10S-501M and 369H8108-503M have been modified to incorporate the
improved weight attachment design.
I
d. Install fuel vent emergency shutoff valve assembly per the applicable maintenance
i manual.
section of the
e. Record compliance to PART I of this Notice in the compliance record
PART II FUEL VENT LINE EMERGENCY SHUTOFF VALVE
REPLACEMENT
shutoff
a. Remove 369H8108, 369H8108-501 or 369B8108-503 fuel vent line emergency
valve from affected helicopters per the applicable maintenance manual.
b. Install a 369HS10S-505, 369HS10SM, 369H8108-501M or 369H8108-503M fi~el vent I
line emergency shutoff valve per the applicable maintenance manual.
c. Record compliance to PART II in the compliance record section of the helicopter Log
Book.
POINTS OF CONTACT:
For further information, contact your local MDHC Field Service Representative (refer
to the latest revision of the Product Support handbook for address
and telephone
numbers) or contact the Field Service Department at MDHC, Mesa Arizona. Telephone:
1-800-445-1516 or (602) 891-6342.
FAA Approval: The design

with the applicable Federal Aviation Regulations, and are FAA approved.
cmnpb
I
NOTICE NO.: HN-234.1,
i
DN-181.1
EN-73.1+
FN-60.1,
DATE: 10 september 1992
PAGE 4 OF 4
389H8108-505 OBSTRUCTED VALVE

(NEW PART) (SLIPPED WEIGHT)
OVERTICAL(OPEN)
ENSURE THIS
AREA IS CLEAR
28(0009) OFOBSTRUCTION
UP
45 (CLOSED)
I
OPENINGI TO BE VIBNIED
WTR PEN-LIGHT TO
NCf
88-688
Figure i. Inspection/Re~orlr of Fuel Vent System.

McDorsnilll Douglas H~-235
~bN- 182
Nelicopter Company EN-74FN-61
DATE: 20 MARCH 1992
PAGE 1 OF 8
ONE-TIME INSPECTION/RW_ORK OF ENGINE AIR

MANDATORY
SUMMARY: McDonnell Douglas Helicopter Company (MDHC) investigation has revealed

that it is possible for unsecured or worn hardware in the engine plenum
area to fall into the engine inlet causing engine compressor damage. As a
result, MDHC is requiring all operators to check the cable, latches, hinges,
hardware, etc., and to inspect the entire inlet plenum area for serviceability
and security. In addition to this special inspection, MDHC would also like
to stress the importance of conducting a thorough check of this area during
the required daily/preflight.
MDHC is also requiring operators to replace the mist eliminator access

door attaching hardware and to inspect and replace the particle separator
bypass door latch hardware or replace the plenum chamber door access
receptacles.to prevent foreign object damage (FOD) fiom entering the
engine inlet and possibly damaging the engine compressor or other engine
components.
PURPOSE: To prevent possible FOD to the engine compressor.
MODELS AFFECTED: All MDHC 369 series helicopters.

TIME OF COMPLIANCE: The requirements of this Notice shall be accomplished within
the next 300 hours of helicopter operation. Subsequent/repetitive inspections
of the engine inlet area will be covered by the apphcable HMIs.
ASSEMBLY/COMPONENTS AFFECTED BY THIS NOTICE: Ah of the components and

assemblies located in the engine air inlet plenum area.
369D/E/F/FF HMI (CSP-HMI-P) Revised 20 January 199%
369D/E/F/FF IPC (CSP-IPC-8) Revised 09 September 1991
PARTS/SUPPLIES
Nomenclature Part No, Qty. Source
Cotter Pin IMS24665-151 1 Commercial or MDHC
.032 2024-T3 AL Alloy Stoclr RM 000560 (raw material See Pig. 2 1 Commercial or MDHC
Per Q&-A-250/4 code)
Nutplate MS21060L3 2 Commercial or MDHC
Rivet MS20426AD3-4 4 1 Commercial or MDHC
hllcDonnell Douglas
FORM 9578 (REV 11187)
Helicopaer &ompany
NOTICE NO.: HN-235
DN-182
EN-74
FN-61
DATE: 20 MAaCH 1992
PAGE 2 OF 8
PARTS/SUPPLIES
Rivet MS20426AD3-5 8 1 Commercial or MDHC
Screw MS24693-C273 2 Commercial or MDHC
Washer NAS1169-10C 2 Commercial or MDHC
Receptacle 212-12A 2 Camloc Fasteners

601 Route 46 West
Hasbrouck Heieghts,
NJ 07604
(201)288-8300
or MDHC

NOTE
Inspection and/or rework procedures are dependent on the helicopter configura-

tion. Only comply with those requirements applicable to the helicopter being in-
spected/reworked.
CAUTION
AVOID FOD. Cover engine compressor inlet prior to working in plenum cham-
ber. Vacuum all FOD debris out ofpIenum chamber before removing protective
cover from engine inlet bell. Severe damage to engine may result from entry of
foreign objects.
FOR HELICOPTERS EQUIPPED \I~ITH PARTICLE

SEPARATOR BYPASS DOOR (FIG.1)
P/N 36982099 369[429[b134
a. Remove particle separator bypass door per the applicable maintenance manual.
b. Inspect all latches, hinges, hardware, etc., for serviceability and security. Remove and
replace any unserviceable components.
c. Remove and inspect the bypass door latch and replace the latch retention cotter pin
located inside the attach cable "U" clamp (see Figure i).
d. Replace the 369A8442-3 latch assembly if any of the following limits are exceeded:
If cotter pin hole in the stem of the latch is elongated more than .080 inch in length.
NOTICE NO.: HN-235
DN-182 t
EN-74
FN-61
DATE: 20 MARCH 1992
PAGE 3 OF 8
If cotterpin has worn into the surface of the cable attach "U" clip more than 1/2 the
thickness of the clip (.025 inch deep).
If the latch engagement faying surface is worn more that .050 inch below the original
surface.
e. Complete installation of particle separator bypass door.
FOR HELICOPTERS EQUIPPED WITH PLENUM CHAMBER

ACCESS DOOR (FIG.2)
P/N 369H2080
a. Remove two 26B16-1 encapsulated receptacles and replace with 212-12A receptacles.
(Refer to Figure 2.)
NOTE
Some doors may already have the 212-12A receptacles installed.
b. Inspect fixed-wing fastener stud for serviceability and security paying particular
attention to cross pin on stud and associated lockwasher (see Figure 2). Remove and
replace any unserviceable components.
F~R HELICOPTERS EQUIPPED WI~TH MIST ELIMINATOR

ACCESS DOOR (FIG.3)
P/N 369D298270
NOTE
MDHC 3693 (Serial No. 04453 and subsequent) and 369F/FF (Serial No.
0084FF and subsequent) Series helicopters have the nutplates installed and are
not affected by the following procedure.
a. Remove mist eliminator door per the maintenance manual.

b. Remove the two 2700-7 studs, 2600-LW lockwashers and 26B16-1 receptacles (Ref.
CSP-IPC-4, Section 71-10-10).
c. Field fabricate two nutplate assemblies as shown in Figure 3.
d. Install nutplate assemblies onto bottom side of 369D290272 frame assembly making
sure to center nutplate assembly over existing hole in frame assembly as shown in
Figure 3.
e. Complete installation of mist eliminator accessdoor using MS24693-C273 screw and
NAS1169-10C washer (two each required).
NOTICE NO.: HN-235
DN-ZS2
EN-74
FN-61
DATE: 20 MARCH 1992
PAGE 4 OF 8
FOR ALL HELICOPTERS (FIG. 4)
a. Remove any unused clamps, clips, brackets or other hardware from the engine inlet
plenum area.
b. Remove three clips shown in Figure 4 (clips are bonded and covered with (1) layer of
glass cloth). Carefully cut glass cloth around edges of clip and then remove clips. Trim
cut edges of glass cloth.
c. inspect entire inlet plenum area hardware, hinges, cables, latches, etc., for serviceabil-
ity and security. Remove and replace any unserviceable components.
Record compliance to this Service Information Notice in the Compliance
WEIGHT AND BALANCE: NiA.
POINTS OF CONTACT:
Representative (refer to the latest revision of the Product Support handbook
for address and telephone numbers~ or contact the Field Service
Department at MDHC, Mesa, Arizona. Telephone: 1-800-445-1516 or (602)
ii
891-6342.
The resultant inspections/alterations to affected models as described

by the procedures
in this Notice have been shown to comply with Federal Aviation Regulations and are
FAA P,pproved.
NOTICE NO.: HN-235
DN-1S2 f
EN-74
FN-61
DATE: 20 MARCH 1992
PAGE 5 OF 8
DOOR OPERATING
AFTCABLE re r/0
DOOR CLIP
DOOR GASKET
j3,-~ QP ~,i
/..4iP LINK
II
9 i
DOORCENTER
-7 B~
CRANK
I
AFT FAIRING
1 CLIP MOUNTING
PLATE
LATCH ASSY
lll~j i I LAMINATED SHIM/

J
CLIP
COTTER PIN
O 36846442-3
EMBLY
88-683A
Figure 1. Particle Separator Bypass Door Latch Cotter Pin Installation.

NOTICE NO,: HN-235
DN-1S2
EN-74
FN-61
DATE: 20 MARCH 1992
PAGE 6 OF 8
<I
I -I IIO
o
i
FIXED-WING FASTENER
O
O
26R16-1 RECEPTACLE
(REPLACE WITH 21 2-12A RECEPTACLE)
STUD WlTH CROSSPIN o
ji
LOCKWASHER
26R16-1 RECEWACLE
(REPLACE WITH 212-12A RECEPTACLE)
212SERIES ENCAPSULATED
26R18 SERIES
RECEPTACLES
88-670
Figure 2. Plenum Chamber Access Door Inspection/Rework.

NOTICE NO.: HN-235
DN-~82
EN-74
FN-61
DATE: 20 MARCH 1992
PAGE 7 OF 8
MS24693-C273 SCREW
NAS1169-10C WASHER
4
eis
MS2042BAD3-5 2024-73 .032 THK
RIVETASSY ALALLOY SHT
PER QQ-A-25014
,I 1
II I
IC---- 1.125~
DEBUR EDGES
it
NVIPLATEASSY
i i
TO BE INSTALLED 1.30j
1( EDGE
i
r i
r
3690290272
FRAME ASSY
PICi< UP D(ISTINO HOLES
j
MS 21060L3 NUTPLATE 1 REQD
.250~70 DIA HOLE
3/32" DIA HOLE

COUNTERSUNK
MS20428 AD~-4 RIVET 2 REQD

FLUSH OPP SIDE
Q
NUTPLATE FABRICATION
O
Z
NUTPLATE ASSY 2 REQ"D
NOTE: DIMENSIONS SHOWN IN INCHES.
88-669
Figure 8. Replacement of Mist Eliminator Door Attaching Hardware.

NOTICE NO.: HN-235
DN-1S% !r
EN-74
FN-61
DATE: 20 MARCH 1992
PAGE 8 OF 8
c~t
j:
REMOVE MESE
THREE CLIPS
88-671
Figure 4. Removal of Clips and Other Hardware From Plenum Chamber,

~7"E": DN-183.2*
McDonnell Douglas EN-75.2*
FN-62.2*
I-Jelicopter Compaj7Y 2?JANUARY1993
PAGE 1 of 3
SEWVICE INFORMPal-ION Ngl3"$geE
MANDATORYtek I)--PI II~ -II MANDATORY MAFIDATORY
Supersedes Service Information Notices DN-183.1, EN-75.1 and FN-62.1, dated 26 August 1992. 1
The revision deletes the blade removal and inspection requirements of PART I. The 369D21100-515 and
369D21102-501 main rotor blades must be inspected per the requirements of DN-51.6, EN-42.4 and
FN-31.4, dated 27 January 1993.
MAIN ROTOR BLADE REPLACEMENT
SUMMARY: The requirements of PART I have been deleted.
PART II of this notice provides instructions to remove the 369D21100-515 and

369D21102-501 main rotor blades and send them to MDHC for rework to 369D21100-516A
and 369D21102-503A and/or replace them with 369D21100-516, 369D21100-516A or
369D21100-517 (if available) and 369D21102-503, 369D21102-503A or 3693321102-517 (if I
available) main rotor blades, as applicable.
PURPOSE: To prevent the possibility of a main rotor blade root fitting crack.
IWPIRNIWGIWARNING
If sudden, unusual or excessive vibrations should occur during flight, a precautionary I
landing must be made. No further flights shall be attempted until the cause of the
vibration has been identified and corrected.
MODELS AFFECTED: All 369D, 3693 and 369F/FF series helicopters equipped with 369D21100-515
or 369D21102-501 series main rotor blades.
TIME OF COMPLIANCE: PAItT I has been deleted.
PART II shall be accomplished within 600 hours of main rotor blade operation from the
original issue date of this notice (20 May 1992) or no later than June 30, 1993.
ASSENIBLY/COMPONENTS AFFECTED BY THIS NOTICE: All 369D21100-515 and

369D21102-501 main rotor blades.
(I)Denotes portion of text added or revised.
NlcDonnell Douglas
FORM 9578 (HEV 11/87)
Helicopter Company
NOTICENO.: DN-183.2*
EN-75.2*
FN-62.2*
PAGE 2 of 3
369D/E/F/FF HMI (CSP-HMI-2) Revised 20 January 1992
REPLACEMENT PARTS
Nomenclature Part No. &ty. Source
Main Rotor Blade 369D21100-516 or A/R MDHC

369D21100-516A
Main Rotor Blade 369D21102-503 or A/R MDHC

369D21102-503A

PART I The requirements of PART I have been deleted.
PART II ReworWReplacement of Main Rotor Blades

I
a. Remove all 369D21100-515 (369D/E) and 369D21102-501 (369F/FF) main rotor blades per the
HMI.
b. Install 369D21100-516A, 369D21100-516, 369D21100-517 (if available) (369D/E) or

369D21102-503A, 369D21102-503, 369D21102-517 (if available) (369F/FF) main rotor blades
per the HMI.
c. Send removed M/R blades to MDHC for rework to the 369D21100-516A or 369D21102-503A
configuration, as applicable, following the procedures outlined below:
i. Inspect M/R blades for serviceability per the HMI (section 62-10-00, pages 601-610 and
801-810 and all applicable Service Information Notices.
NOTE: MDHC WILL NOT REWORK ANY UNSERVICEABLE M/R BLADES OR BLADES
WITH NON-STANDARD REPAIRS OR ALTERATIONS WITHOUT THE PROPER
APPROVAL DOCUMENTS. ALL HISTORICAL RECORDS MUST BE SENT WITH EACH
BLADE FOR MDHC TO PERFORM THE REWORK.
2. Send affected M/R blades to be reworked to MDHC, Mesa. The proper address is 5000 E.
McDowell Road, Mesa, AZ 85205. Attention: Mr. Richard Head, Warranty and Repair
Department.
3. Upon receiving M/R blades, MDHC will perform a receiving inspection of each blade. On
blades that do not pass the inspection, the customer will be contacted for disposition of the
blade.
d. MDHC is offering operators two options for rework. There will be no charge to the operator for
the main rotor blade rework.
OPTION #1: MDHC, Mesa, Arjzbna, for rework. The operator will pay
Send M/R blades to
shipping charges to Mesa per MDHC standard warranty policy. MDHC will rework blades and
ship them back to the operator. MDHC will pay shipping charges from Mesa back to the
NOTICENO.: DN-183.2*
EN-75.2*
FN-62,2*
PAGE 3 of 3
they Mesa. MDHC will credit 4.0 hours labor to

shipped to
operator, the same way were
remove, install and track the

main rotor blades. This work must be performed by an
authorized MDHC Service Center.
will pay
OPTION #2: Send M/R blades to MDHC, Mesa, Arizona, for rework. The operator
While the blades being
shipping charges to Mesa per MDHC standard warranty policy.
are
loaner blades until the reworked blades are returned

reworked in Mesa, MDHC will schedule
to the operator. MDHC will pay for shipping the
loaner blades and the operators will not be
labor to remove, install and track the
charged for the flight time. MDHC will credit 4.0 hours
loaner main rotor blades. MDHC will pay charges for the reworked blades from Mesa
shipping
and track the reworked main
back to the operator (same way) and 4.0 hours labor to install
rotor blades. This work must be performed by an
authorized MDHC Service Center.
NOTE: Blades will be reidentified to 369D21100 -516A and

369D21102-503A respectively.
PART II of this Notice in the compliance record section of the
e. Record compliance with
POINTS OF CONTACT:
(refer to the
For further information, contact your local MDHC Field Service Representative
revision of the Product Support handbook for address and telephone
numbers) or
latest
contact the Field Service Department at MDHC, Mesa Arizona. Telephone: 1-800-388-6342 I
or (602) 891-6342.
have been shown to comply with the

FAA Approval: The design engineering aspects of this Notice
:L.C~ NOTICENO.: HN-236
DN-1S44i
EN-77
1~
,Yei,cc-?p 3~iC;^m
V1~13
PN-63
NN-005
DATE: 10 MARCH 1994
PAGE 1 OF 4
fVIANDATORY MAND~-TORY MANDATQRY

aPlss~Yq
I I
FOUR-WAV TRIM SWITCH REPLACEMENT PROGRAM
PLANNING INFOR1MATION:
A. Aircraft Affected: All McDonnell Douglas Helicopter Systems (MDHS) 369/500 Se-
ries helicopters with Guardian Electric A218-100646-03 four-way trim switches
installed in the cyclic grip.
B. Assembly/Components Affected by this Notice: A218-100646-03 prior to Rev. "D",

four-way trim switches and A218-966714-02 and 369D27133-501 grip assemblies.
C. Reason: MDHS has received and investigated reports from operators in the field
that some four-way cyclic trim switches were sticking during operation. This
condition could cause an uncommanded directional travel in the cyclic control sys-
tem which can be overcome by the pilot. The forces will increase by approximately
30 pounds in this direction, therefore creating an increase in pilot workload. How-
ever, the helicopter will still respond normally to all inputs by the pilot. Therefore, I
MDHS is requiring operators to replace those affected switches with switches that
have been upgraded to a Rev. "D" configuration.
D. Description: Procedures in this notice require operators to replace affected four-way

trim switches with switches that have been upgraded by Guardian to a Rev. "D"
configuration. Upgraded A218-100646-03 switches can be readily identified by the
green colored epoxy added to the four tabs at tlie bottom of the switch and Rev. "D"
stamped on the bottom of the mounting bracket of the switch (see Figure i).
CAUTION
Procedures described in this Notice only approved means of compliance

are the
to therequirements of this Notice.Operators who elect to make their own modi-
fications of the trim switch, should assure that they comply with FAA require-
ments regarding parts and aircraft modifications. Any unapproved means of
compliance to the requirements of this Notice will result in the voiding of any
helicopter warranties by MDHS. 1
E. A~Droval: The design engineering aspects of this notice have been shown to comply
with the applicable Federal Aviation Regulations and are FAA approved. .j
F. Man~ower: One and a half man-hours will be required to remove and replace each
cyclic trim switch.
G. Time of Compliance: The requirements of this notice shall be complied within the
the next 100 hours of helicopter operation or one year, whichever occurs first.
L-mmerciai Customer Support
I r P 1 I
Gousi~s
5i/sle~77s
WOTICENO.: HN-236
DN-184
EN-77
FN-63
NN-OOS
DATE: 10 MARCH 1994

PAGE 2 OF 4
H. Interchangeability: See Compliance Record section of this notice.
I. I~laterial/Part Availability:
Nomenclature Part No. Qty, Source
Four-way Trim Switch A218-100646-03 (Rev. "D") 1 MDHS Warranty and Repair
(No Charge)
MATERIAL
Nomenclature/Speclf ication Source
Sealing compound (MIL-S-7502) Product Research

5454 San Fernando Rd.
Glendale, CA 91209
Solder, tin alloy, rosin core (QQ-S-571) Commercial

(Composition SN60WPR2)
Strap, tie (MS3367-*-*) (size optional) Thomas Betts

Los Angeles, CA
J, Warranty Policy: MDHS will provide, free ofcharge, A218-100646-03 Rev. "D"
switches to replace A218-100646-03 switches (previous to Rev. "D"). If the work is
performed at a MDHS Approved Service Center, MDHS will allow 1.5 hours labor
per each switch that has to be replaced. This policy is contingent upon MDHS re-
ceiving the affected switches within 30 days of receipt of the new -03 Rev. "D"
switch. Failure to return the affected switch will result in a billing at full list price
and no labor allowance.
Affected switches shall be returned to MDHS Warranty and Repair Department.

K, Tooling: Soldering iron or gun.
L, Weierht and Balance: Not affected.
M, Electrical Load Data: Not affected.
N, Other Publications Affected: NIA

NOTICENO.: HN-238
DN-184
EN-77
FN-63
NN-005
DATE: 10 MARCH 1994
PAGE 3 OF 4
A. Remove affected A218-100646-03 switches per instructions contained in the Hand-

book of Maintenance Instructions (CSP-HMI-2).
B. Install an A218-100646-03, marked with Rev. "D" on its mounting bracket, per
instructions contained in the Handbook of Maintenance Instructions (CSP-HMI-2).
NOTE: A218-100646-03 switches marked with Rev. "D" will also have
green epoxy
over the four tabs at the base of the switch (see Figure i).
3. IDENTIFICATION: Not affected.
A. Operators must return all affected switches to MDHS in order to receive credit for
replacement switches and labor allowance credit. Return all affected parts to
MDHS Warranty and Repair Department. NOTE: Affected operators can receive
replacement switches prior to returning the affected switches.
A. Record compliance of this Service Information Notice in the compliance record sec-
tion of the helicopter Log Book. NOTE: If cyclic controls are subsequently removed
from the aircraft they should be identified as complying with the requirements of
this notice. When installing new/different controls, verify that those cyclic controls
have complied with the requirements of this notice or are not affected by the re-
quirements of this notice.
A. For further assistance, contact your local MDHS Field Service Representative (refer
telephone numbers) or contact the Field Service Department at MDHS, Mesa, Ari-
zona. Telephone: 1-800-388-3378 or (602) 891-6343. For Commercial Warranty
and Repair issues, contact the MDHS Warranty and Repair Department at (602)
891-8565.
NOTICENO.: HN-236
DN-184
EN-77
FN-63
NN-005
DATE: 10 MARCH 1994

PAGE 4 OF 4
23 LmER D
STAMPED IN THIS LOCATION
C~a
C]e
ROTATED 180"
~3.
LIGHT GREEN EPOXI

(4 PLACES)
88-878
Figure i. Four-way Trim Switch.

NOTICENO.: DN-185
EN-78
FN-64
i,
I,IC*T;~E DATE: 23 SEPTEMBER 1994
PAGE 1 OF 3
LOCKWASHER INSPECTION
1. PLANNING
A. Aircraft Affected: All McDonnell Douglas Helicopter Systems 369D, 3693 and
369F/FF series helicopters.
B. Assemb iv/Components Affected by this Notice: 3 69D2 180 O and 3 69 D2 1820 Pitch
Control assemblies and all MS172209 Lockwashers.
C. Reason: MDHS received a report that a MS172209 lockwashers failed in service.

MDHS investigation revealed that some washers appear to have a flaw at the inner
tang inside radius. Failure of this tang could allow the nut to back off, losing clamp
up and thereby causing eventual disengagement of the assembly resulting in
virtual loss of tail rotor control.
D. Description: Procedures in this Notice require operators to inspect all MS172209

lockwashers in spares inventories and to apply a torque stripe to installed tail rotor
swashplate and locknut to periodically inspect those assemblies for possible
locknut rotation.
E. FAA Approval: The design engineering aspects of this Notice have been shown to
comply with the applicable Federal Aviation Regulations, and are FAA Approved.
F. Time of Compliance: Lockwashers in spares inventories must be inspected per the

requirements of this Notice before being installed onto a helicopter. Operators in
the field must perform a torque check of installed lockwashers and apply slippage
marks to tail rotor swashplate and locknut per the requirements Part Il of this
Notice within the next 25 hours of helicopter operation and they must be inspected
per Part III of this notice for locknut rotation at each subsequent 100 hours of
operation
G. Material/Part Availability:
Lockwasher MS172209 AIR Commercial or MDHS

NOTICENO.: DN-185
EN-78
FN-64

PAGE 2 OF 3
MATERIAL
Nomenclature/Specification I, Source
Torque Seal Commercial
H. Warranty Policy: Same as normal MDHS airframe and spares warranties.

I. Tooling: No special tooling required.
J. Weight and Balance: N/A.
K. Electrical Load Data: N/A.
L. Other Publications Affected: None.
2. PART I INSPECTION OF LOCKWASHERS IN SPARES INVENTORIES
A. Using a 5X or 10X magnifying glass, inspect all MS172209 lockwashers in spares

inventories for an unacceptable condition as shown in Figure 1. Scrap unacceptable
lockwashers.
3. PART II INSPECTION OF LOCKWASHER AND APPLICATION OF

TORQ.UE STRIPE
A. Remove tail rotor and pitch control assembly from tail rotor gear box.
assembly
Using holding fixture, (item 4, table 501, CSP-COM-5, 64-30-00) and without
bending lock tab of lockwasher away from nut, check torque of locknut (use
minimum value of 550 inch pounds) to ensure that torque on nut is within specific
limits. If nut does not move after applying torque, continue with step B. If locknut
moves during application of torque, remove locknut and discard lockwasher. Install
new lockwasher and torque nut to 550-600 inch pounds per CSP-COM-5, Section
64-30-00.
B. Clean surface of locknut and swashplate (fig. 1) with an alcohol dampened cloth to
remove any excess grease from surface. Avoid
getting alcohol in bearing.
C. Apply 0.125 inch wide torque strip, using Torque Seal or equivalent product to the
surface as shown in Figure i. Do not allow Torque Seal to get into swashplate
splines
D. Reassemble parts and install on tail rotor gear box per CSP-HMI-2, Section
64-30-00.
4. PART III PERIODIC 100 HOUR INSPECTIONOF TORQ.UE STRIPE
A. Inspect torque stripe for any sign of slippage at each 100-hour interval of helicopter
operation. If necessary, reassemble the tail rotor swashplate assembly using a new/
acceptable tang washer.
NOTICENO.: DN-185
EN-78
FN-64
PAGE 3 OF 3
A. Scrap all unacceptable lockwashers.
6. COMPLLANCE RECORD:
Notice in the
A. Record compliance to the requirements of this Service Information
Compliance Record section of the helicopter Log Book.
POINTS OF CONTACT: For further assistance, contact your local MDHS Field Service
and Customer
Representative (refer to the latest revision of the Business Development
or contact the Field Service
Support handbook for address and telephone numbers)
Department at MDHS, Mesa Arizona. Telephone: 1-800-388-3378 or (602) 891-6342.
DATAFAX: (602)891-6782.
TORQUE STRIPE
I
LOCATIONS
w
I
ACCEPTABLE
UNACCEPTABLE
88-680
Figure 1. Tang Washer Inspection and Application of Torque Stripe.

NOTICE NO.: HN-237
DN-186
EN-79
FN-65
NN-007
PAGE 1 OF 6
ill
FIREWALL FUEL FITTING MODIFICATION
All McDonnell Douglas Helicopter Systems (MDHS) 369 and 500N Series helicop-
ters equipped with 369A8100-503, -505, --507, -509, -511, -703 and -705 fuel sys-
tem installations are affected by the requiremc-~;l?:3 of this Notice.
B. Assemblies/ComDonents Affected by this Notic::,

Any of the above 369A8100 fuel system instal- itooss which are not configured as
shown in Figure 1.
C. Reason:
MDHS has received reports from the freld of :e station 124 firewall fuel fitting in-
terfering with the landing gear brace. As a re alt, there is a possibility of the fuel
fitting becoming damaged, thus creating a po-ential for fuel leakage. Therefore,
MDHS is requiring all operators to modify th;: ir aircraft according to procedures
contained in this Notice.
D. Description:
Operators are required AN837-8D elbow at station 124.00 and
to install an remove
the drain valve from the engine fuel pump filter housing.
E. Approval:
The design engineering aspects of this notice have been shown to comply with the
F. Manpower:
Approximately 2.5 man-hours are required to perform this notice if it is accom-
plished in conjunction with the next 300 hourlannual inspection.

G. Time of Compliance:
The requirements of this notice shall be accomplished within the next 300 hours of
operation or at the next annual inspection of the helicopter, whichever occurs first.
H. Interchang~:eabilitv: N/A.
NOTICENO.: HN-237
DN-186
EN-79
FN-65
NN-007

PAGE 2 OF 6
Nut AN924-8D 1 Commercial
Laminated Washer 1-285079-4346 1 Commercial
Washer AN960KD1216 2 Commercial
Elbow AN837-8D 1 Commercial
Plug AN814-4DL 1 Commercial
Packing M529512-04 1 Commercial
Lockwire (0.032" die.) MS20995N32 (RM000571) A/R Commercial
J. Warranty Policy:
None.
K. Tooling:
No special tooling required.
L. Weight and Balance:
Not affected.
Not affected.
The CSP-IPC-4 and CSP-H-7 (IPCs) will be revised at a future date to reflect the
revised configuration of the firewall fuel fitting described in this notice.
2. ACCOMPLISHMENTINSII~C_TIC)NS:
NOTE
The helicopter must be de-fueled before performing the requirements of this no-
tice.
NOTICENO.: HN-237
DN-186
EN-79
FN-65
NN-007
PAGE 3 OF 6
GNI RAW/
Ensure that the aircraft is adequately grounded when purging the fuel system.
Failure toproperly install. align and torque fuel, oil and air fittings and tubes
could result in engine power surges, flameout, or leakage.
Air entering the airframe fuel supply lines may cause a power reduction or
flameout. Fuel system vacuum leak check and fuel air bleed procedures must be
performed after opening the fuel system for any reason, prior to releasing the
helicopter for flight.
A. Refer to HMI Vol. I, Section 28-00-00 for access to fittings. This will require loosen-
ing the lacing supporting the fuel cell.
B. If installed, remove the following parts from the 369A8100-503, -505, -507, -509,
-511, -703 and -705 fuel system installations: (see Figure 2)
MS24393D8 union, qty. 1

AN924-8 nut, qty.3
MS295i 2-08 packing, qty.2
369H8103 fitting, qty. 1
369D28099 drain valve, qty. 1 or 2
CAV-170-H4 drain valve, qty. 1 or 2
369A8010-85 tygon tubing
MS29512-04 packing, qty. 1 or 2
TY-25M ty-rap
AN837-8D elbow, qty. 1
MS24394D8 elbow, qty.l
AN814-4DL plug, qty.l
AN939-8D elbow, qty.l
6151-0250 tee, qty. 1
C. InstallAN924-8D (nut), (2) AN960KD1216 (washers), H85079-4346 (laminated

washer) and AN837-8D (elbow) as shown in Figure 1.
D. Ensure that AN837-8D is clocked 12" to 16" (25" to 29" for fuel systems equipped
with anti-ice fuel filter installations) inboard as shown in Figure i.
NOTE: ~85079-4346 shim thickness may be adjusted to obtain proper elbow
orientation.
NOTICENO.: HN-237
DN- 186
EN-79
FN-65
NN-007

PAGE 4 OF 6
E. Reassemble fuel cell lacing per the HMI Vol. I, Section 28-00-00.
E Re-install hoses to the AN837-8D fitting (see Figure i). Torque hoses per the HMI-
CSP-2, Vol. I, Section 28-00-00.
G. Install AN814-4DL plug, MS29512-04 packing and MS20995N32 lockwire to en-

gine fuel pump housing 369A8100-507 configurations only at location shown in
Figure i.
H. Re-fuel aircraft per servicing instructions contained in the Handbook of Mainte-

nance Instructions (HMI).
~WPIRNINOGNI RAWI
Fuel/vapor discharged during bleeding is a fire hazard. Prevent fuel vapor accu-
mulation, ignition and fire. Perform work in an open, well ventilated area away
from all potential ignition sources. Attach helicopter to an approved electrical
ground. Wear approved eye protection.
I. Perform a vacuum check of the fuel system line and components to ensure no en-
gine or airframe fuel system leaks are present.

J. Bleed air from fuel system per instructions contained in the HMI.
3. IDENTIFICATION:
A. Not affected.

A. Scrap.
A. Record compliance to this Service Information Notice in the compliance record sec-
tion of the helicopter Log Book.
A. For further assistance, contact your local MDHS Field Service Representative (refer
telephone numbers) or contact the Field Service Department at MDHS, Mesa, Ari-
zona. Telephone: 1-800-388-3378 (602) 891-6342. For Commercial Warranty is-
or
sues, contact the MDHS Warranty and Repair Department at (602) 891-8565.
NOTICENO.: HN-237
DN-186
EN-79
FN-65
NN-007
PAGE 5 OF 6
FUEL PUMP
FILTER HOUSING
LOCATION OF OPTIONAL ANTI-ICE
FUEL FILTER. WHEN INSTALLED,
RE-ROUTE DRAIN LINE AS SHOWN.
i
1 AN814-40L PLUG
i
12" 16"
MS29512-04 PACKING
(SEE NOTE) MS20995N32 LOCKWIRE
AN897-BD
ii AN924-8D
NUT
ELBOW
I i i
TYGON TUBING AN980KD1216
AN960KD1216
(.375 OD X .062 WALL) I
WASHER
WASHER
STA
124.07
HS5079-4340
N-25M TYRAP
LAMINATED WASHER
(ADJUST THICKNESS TO OBTAIN
PROPER ELBOW ORIENTATION)
SECTION A-A
NOTE:
AVC EQUIPPED WITH ANTI-ICE FUEL
FILTER INSTALLATIONS MUST CLOCK LBL 8.45 88-677-1
THE FTTTINO TO 25 29.
Figure i. Firewall Fuel Fitting Modification (Installation).

NOTICENO.: HN-237
DN-186
EN-79
FN-65
NN-007

PAGE 6 OF 6
ANes7-8o ELBOW (1) OR P

MS24394DB ELBOW (1)
AN924-8 NUT (2) FUEL PUMP FILTER HOUSING
M529512-08 PACKING (2)
MS24393DB UNION (1) sssDneoss DRAIN VALVE(I) OR

AN924-8 NUT (2) CAV-170H-4 DRAIN VALVE (1)
ANOG0KD 1215 WASHER MS29512-04 PACKING (1)
(1)
3891\8100-3 PIGON TUBING
PIRAP
ANaa-eo ELBOW (1)

OR
6151-0250TEE(1) 359H8103 FITTING (1)
MS29512-04 PACKING (1)
3s9Dn8099 DRAIN VALVE (1)
OR
CAV-110 H4 DRAIN VALVE(1)
OR
AN814-4DL PLUG (1)
8&677-2A
Figure 2. Firewall Fuel Fitting Modification (Removal).

NOTICENO.: HN-238
DN-L87
EN-80
FN-66
DATE: 26 OCTOBER 1994
PAGE 1 OF 4
MANDATORY: MANDATORY
IMANDATORY
TAIL ROTOR BLADE ABRASION STRIP MODIFICATION
PLANNING INFORMATION:
A. Aircraft Affected: All McDonnell Douglas Helicopter Systems (MDHS) 369 Series
helicopters that are equipped with tail rotor blades (two or four bladed) listed in
Paragraph B. All tail rotor blades listed in Paragraph B in spares inventories.
B. Assemblies Affected by this Notice: 369A1613-7, 369A1613-503,
369A1613-505,
369A1613-509, 369D21606, 369D21606-509, 369D21613-11, 369D21613-31,
369D21613-41, 3693~21613-51, 369D21613-71, 369D21615, 369D21615-21,
369D21615-41 and 421-088 tail rotor blade assemblies.
C. Reason: MDHS has received reports of tail rotor blade abrasion strips debonding
during operation. Separation of an abrasion strip could cause loss of the tail rotor
gear box due to an out-of-balance condition. Therefore operators are required to
comply with the requirements of this notice to ensure safe helicopter operation.
D. Description: This notice requires operators to modify the tail rotor blades by
applying 304 stainless steel tape (.0027 inch thick) over the inboard end of the
abrasion strips. This notice also requires that existing tail rotor blades be replaced
with tail rotor blades equipped with the new design abrasion strips within a
required amount of time.
E. FAA A~DDroval: The design engineering aspects of this Notice have been shown to
comply with the applicable Federal Aviation Regulations, and are FAA Approved.
F, Time of Compliance: NOTE: The requirements of HN-232, DN-179, EN-70 and

FN-57 (applying rivets to the tail rotor blade) must be accomplished before
performing this notice.
PART I: The requirements of this notice shall be accomplished within the next 25
hours of helicopter operation and at each subsequent 100 hours of helicopter
operation until PART II of the Notice has been accomplished. NOTE: It may be
necessary to replace the tape more frequently depending on the environment in
which the helicopter is being operated.
PART II: The requirements of PART Ii shall be accomplished within 1000 hours of
tail rotor blade operation upon receipt of this Notice.
~cC7r=nr;ei! ocugi~s
~ysten;s
NOTICENO.: HN-238
DN-1SI
EN-80
FN-66

PAGE 2 OF 4
G. Material/Part Availability:
MATERIAL
Nomenclature/Specification Source
304 Stainless Steel Tape (.0027 inch thickness) MDHS or Teledyne Rodney Metals
87-369D21104 30ft. (800-325- 1455)
Abrasive Paper (400 grit) Commercial
Naphtha, alphabetic Commercial
H. Warranty Policy: MDHS will provide tape free of charge through our Service
Center/Distributor network for the initial installation. Additionally, MDHS will
provide 1/2 hour labor per blade for the initial installation of the tape, provided the
work is performed by an Approved MDHS Service Center.
I. Tooling: No special tooling required.
J, Weight and Balance: NIA
ACCOMPLISHMENT INSTRUCTIONS:
PART I: Abrasion Strip Inspection and Modification

A. Inspect the tail rotor blade leading edge abrasion strip per PARTI of HN-197.2,
DN-130.2, EN-19.2 and FN-19.2. If blade is removed from service because of
separation or voids, notify an Approved MDHS Service Center or Distributor for
disposition. Those blades in which voids are found shall be sent to an Approved
repair station for abrasion strip replacement. If one blade is removed due to voids
in the abrasion strip, the corresponding blade(s) will also have to be replaced.
Proceed to PART II. If blades are equipped with the new and improved abrasion
strips they must be installed in ship sets.
B, Lightly abrade faying surface of tail rotor blade in the area where the tape is to be
installed with 400 grit abrasive paper (see Figure 1).
C, Wipe faying surface of blade with solvent to eliminate grease and dirt film.
D. Use heat gun or equivalent to warm blade faying surface. Temperature must not
exceed 120 deg. F.
E. Remove backing and apply stainless steel abrasion tape to leading edge of tail rotor
blade as shown in Figure I. Apply tape so it overlaps each side of blade equally.
Tape should overlap the inboard end of abrasion strip .5 in. .03 at the leading
edge of the blade.
E Smooth and press tape into place by hand.
G. Re-apply pressure by hand following initial installation to ensure proper bonding.
Abrasion tape must be free of surface wrinkles or air bubbles.
NOTICENO.: HN-fL38
I)N-llJ7
EN-80
FN-66
PAGE 3 OF 4
H. Check tail rotor balance per the requirements of the HMI after installation of tape.
PART II: Replacement of Tail Rotor Blade or Tail Rotor Blade Abrasion
Strip
A. Contact MDHS authorized MDHS blade repair facility for installation of new
or an
style abrasion strip. NOTE: The requirements of this Notice are not required on tail
rotor blades with new design abrasion strip (see Figure 1).
B. Install tail rotor blade

equipped with a new design abrasion strip per the
requirements of the HMI. NOTE: New tail rotor blades must be installed in
shipsets.
C. Check tail rotor balance per the requirements of the HMI after installation of tail
rotor blades.
COMPLIANCE RECORD:
A. Record compliance to this Service Information Notice in the Compliance Record

Representative (refer to the latest revision of the Business Development and Customer
Support handbook for address and telephone numbers) or contact the Field Service
Department at MDHS, Mesa Arizona. Telephone: 1-800-388-3378 or (602) 891-6342.
DATAFAX: (602)891-6782.
NCIPICE NO.: HN-LSL)
DN-1(17
EN-80
FN-Rfi

PAGE 4 OF 4
so IN.
ilN
i
1.o01N.
OLD STYLE ~BRASION STRIP
1 L
NEW IBAPSION STRIP
NOTES:
i. SPIST*INLEGSSTEELNIPESHILLBE*PPUa): 112-INCHTOTIILROTORBUDE.
2. *PPCY TI~E E)UALLY TO BOTH SIDEI OF BUOE 81-(111
Figure i. Application of Steel Tape to Tail Rotor Blade.

NOTICENO.: HN-239
McDonneil Dougias DN-1SS
18-NE/
FN-67
Helicopt~r Systems NN-O0S

SERVICE 1N FORMBTION NOJICE
PAGE 1 OF 5
MANDATORY MANDATORY
MANDATORY
MAIN ROTOR BLADE ROOT END INSPECTION
I WP~NINO GNIRAWI
Failure to comply with the requirement of this Notice may
result in separation of the main rotor blade from the
helicopter during operation.
Douglas Helicopter Systems (MDHS) 369 and

A. Aircraft Affected: All McDonnell
500N series helicopters.
369Al100- BSC thru
B. AssemblviComDonents Affected by this Noticer All
369A1100-601, 369A1100-603, 369D21100-BSC thru
369A1100-507,
rotor blades.
369D21100-517 and 369D21102-BSC thru 369D21102-517 main
load operators in the
C. Reason: Due to reports that MDHS has received from sling
all main rotor blades for cracking
field, MDHS is requiring all operators to inspect
and the doubler at
and bonding separation between the lower surface root fitting
this Notice, concentrate
the inboard end. Specifically, the inspections contained
in
on the most outboard root fitting

attachment b;olt. The inspections required by this
rotor blade inspections
Notice are to be accomplished in conjunction with main
as referenced in paragraph D.
below.
already required
D. Reference Inspections:
main rotor blades

i. Handbook of Maintenance Instructions daily inspection of all
for cracks.
rotor blade root end fitting for

2. Pilot Flight Manual daily preflight check of main
chordwise cracks.
5X to 10X
3. Handbook of Maintenance instructions 100 hour inspection using a
magnifying glass inspecting root fittings for cracks.

rotor blade
4. FAA Airworthiness Directive 95-03-13 100 hour inspection of main
root fitting lug and doublers adjacent to root fitting.
McDonnell Douglas
FCRM 9578 (RE/ ;194) Helicopter Systems
NOTICENO.: EIN-239
DN- 188
EN-81
FN-67
NN-008

PAGE 2 OF 5
E. Description:
PART I ONE-TIME INSPECTION:

PART I of this Notice contains a one-time visual inspection of the main rotor blade
root end for chordwise cracks and paint/sealant
cracking between the lower root end
fitting and the doubler. PART I is to be performed with the main rotor blade
installed and raised off of the droop stop.
PART II REPETITIVE 100-HOUR INSPECTION:

PART II of this Notice is a repetitive 100 hour inspection of main rotor blades for
chordwise cracks and separation between the lower root end fitting and doubler.
PART II of this Notice is to be performed with the main rotor blades removed.
F. FAA ApT~roval: The design engineering aspects of this Notice have been shown to
comply withthe applicable Federal Aviation Regulations, and are FAA Approved.
PART I of this Notice shall be accomplishedwithin the next 10 hours of helicopter

operabion. Note: the requirements of PART I only have to be accompl$hed once.
Q:
PART II of this Notice shall be accomplished at the next scheduled 100 hour in-
spection and at each subsequent 100 hours of helicopter operation.
H. Warranty Policy: N/A.
j
NOTICENO,: HN-239
DN-188
EN-81
FN-67
NN-008
PAGE 3 OF 5
PART I ONE-TIME INSPECTION
A. With the main rotor blade lifted off of the droop stop, observe the area shown in
Figure 1 for any indications of chordwise cracking emitting from the root fitting
edge on the blade doubler and skin. Cracking can travel toward both the leading
and trailing edges of the blade. NOTE: Based on field reports, chordwise cracking is
most likely to be found in line with the outermost bolt. If any chordwise cracking is
noted, the blade is unserviceable. Operators should contact their local Field Service
Representative for disposition of unserviceable blades. If no cracking is noted,
proceed to Step 2. B.
B. With the main rotor blade lifted off the droop stop, inspect for missing or cracked
adhesive/paint at the root end to doubler bonding line in the area shown in
Figure 1. If there is any missing or cracked adhesive/paint in the root end fitting to
doubler bond line, proceed to Step 3. If no cracking is evident, further operation is
allowed
PART II REPETITIVE INSPECTION
A. Remove main rotor blade.
B. Using a magnifying glass, inspect the area shown in Figure 1 for any
10X
indications of chordwise cracking emitting from the root fitting edge on the blade
doubler and skin. Cracking can travel toward both the leading and trailing edges of
the blade. NOTE: Based on field reports, chordwise cracking is most likely to be
found in line with the outermost bolt. If any chordwise cracking is noted, the blade
is unsenriceable. Operators should contact their local Field Senrice Representative
for disposition of unserviceable blade. If no cracking is noted, proceed to Step 3.C.
C. Inspect blade for missing or cracked adhesive/paint at the root end fitting to doubler
bonding line in the area shown in Figure i. If there is any missing or cracked
adhesive/paint, proceed to step 3.D. If no cracking is evident, skip step 3.D. thru
3.F.
C~3
CAUTION
DO NOT use any feeler gauges, knives, plastic wedges, etc., when performing
the following step.
D. Loosen but DO NOT remove the root end fitting outboard bolt and nut.
E. Using a piece of Mylar/viewfoil (stapled to this Notice), attempt to

.004 inch thick
insert the corner of the Mylar in between the lower root fitting and the doubler
surface in the area shown in Figure i. If Mylar can be inserted, contact a MDHS
Field Service Representative for disposition of the blade. If the Mylar can be
NOTICE NO.; BN-239
DN-188
EN-81
FN-67
NN-008

PAGE 4 OF 5
inserted .10 inch or greater, remove the blade from service. NOTE: Measurement of
insertion is from the edge of the root fitting. If the Myiar cannot be inserted, the
blade is serviceable, proceed to step 3.F.
cnu~rlow
Correct torque application to the outboard root fitting

attach bolt is important to maintaining continued blade
serviceability.
F. Ensure that a minimum run-on drag torque of 3.5 inch
pounds can be achieved
when re-torquing the outboard nut. If the minimum drag torque cannot be
achieved, the self-locking nut must be replaced with a serviceable nut. Apply a
torque of 60-65 inch pounds to the outboard nut.
4. DISPOSITION OF PARTS REMOVED: Contact a MDHS Field Senrice

Representative for disposition of unserviceable blades.
A. Record compliance to this Service Information Notice in the Compliance Record
Representative (refer to the latest revision of the Business Development and Customer
Support handbook for address and telephone numbers) or contactthe Commercial
Field Service Department at MDHS, Mesa Arizona. Telephone: 1-800-388-3378 or
(602) 891-6342. DATAFAX: (602)891-6782.
IIRE~TOQEINSPECTED.
THE ROOT END FITIINO
TO DOUQLER B(1NO UNE
is 10 BE INSPECTED FOR
MISSINGORCR~CKING
*DHESIVEIP*INT
SEEFIGURE2FOR
mMPLEOFCRACKS
NTHEBONDLINEIWD~
I\cHORDWISECW\CK
1NTHEOOUBLER
Figure 1. Main Rotor Blade Root Fitting Inspection.
ORIGINAL
As Received By
ATP
NOTICE NO.: AN-239
DN-188
EN-81
FN-87
NN-008
PAGE 5 OF 5
cw\cKs IN inE
BONDLINE
CHORDWISE
CRI\CK
868$8
Figure 2. Example of Main Rotor Blade Root End Cracking.
ORIGINAL
As Received By
ATP
MANDATORY MANDATORY
MANDATORY
r McDonnell Douglas f3~

HelicOPter Systems i~i--

NOTICE NO:
DATE:
DN-189
EN-82
IOJANUARY1997
PAGE 1 OF 3
MAIN ROTOR TRANSMISSION COMPONENT INSPECTION (369D25127-11)

1. PLANNING IMFORMATION:
k Aircraft Affected: All McDonnellDouglas Helicopter Systems (MDHS) 369D, 3693,
369FF and 500N Series Helicopters that have 369D25100 Main Rotor
Transmissions installed.
B. Assemblv/Comnonents Affected by this Notice: 369D25100 Main Rotor
Transmissions that contain 369D25127-11 Output Drive Gears with the following
serial numbers:
S/N 005570-0646 thru and including S/N 005570-0765

S/N 005570-0876 thru and including S/N 005570-0998
C. Reason: An initial MDHS investigation of a commercial cargo hook operators

369D25127-11 output drive gear which experienced a premature gear tooth
fracture while operating during "sling-load" operations.
Based on the results of this investigation, MDHS is requiring operators of aircraft

described in 1.A. to determine what serial number 369D25127-11 output drive gear
is currently installed in their 369D25100 main rotor transmission.
If the operators
aircraft records do not indicate what serial number output drive gear is installed,
and be
then the operator must either: (1) contact MDHS Field Senrice Department
prepared to provide the installed 369D25100 main transmission serial number,
or
the S51HL liquid level plug for viewing access in order to determine
(2) remove
output drive gear serial number.
Failure to perform the requirements of this Notice may result in gear tooth spalling
or tooth fiacture of the 369D25127-11 output
drive gear. This could eventually lead
to perform a
to transmission "chip light" illumination which requires operators
landing as soon as possible.
with
D. Description: Procedures in this Bulletin provide owners and operators
information to inspect their main rotor transmissions and, if required, replace the
369D25127-11 output drive gear.
FAA
E. FAA A~jDroval: The technical design aspects of this Service Bulletin are
Approved.
F. ManDower: Refer to Warranty Policy.
G. Time of Compliance for 369D25127-11 Output Gear redacement:
(1) For helicopters equipped with cargo hook assemblies that maintain a separate
permanent log of actual hook time: Within the next 25 hours of logged hook time or
whichever first.
400 hours of helicopter operation after receipt of this Notice, comes
not maintain
(2) For helicopters equipped with cargo hook assemblies that do
a
separate permanent log of actual hook time: k Within the next 25 hours of
MANDATORY MANDATORY
MANDATORY
MANDATORY
MANDATORY MANDATORY I
NOTICE NO: DN-189

EN-82 McDonnell Douglas
FN-69
NN-009 Helicopter Systems i~--
:ETAD3
PAGE 2 OF
10 JANUARY 1997
helicopter operation aRer receipt of this Notice; or, B. Immediately
begin
maintaining a permanent log of actual hook time and comply with the
of G.(1) above.
requirements
(3) For helicopters not equipped with

cargo hook assemblies: Within the next 400
hours of helicopter operation aRer
H. Interchangeabilitv: None
I. MateriaVPartAvailabilitv: Contact MDHS Field Service Department.
Output Drive Gear 369D25127-11 1 MDHS
J. Warranty Policy: Replacement Output Drive Gears will be provided at a prorated

price based on hours used on the original output gear since the last TBO.
(Transmissions will not be overhauled at MDHS unless
specifically requested by the
owner; then MDHS will charge for labor and materials above and
beyond the
Output Gear removal and replacement.)
MDHS will provide credit equivalent of ten

(10) labor hours for transmission
removal and reinstallation. Please contact MDHS
Warranty Administration if a
I
loaner transmission is required.
K. Toolinrr: No special tooling required.
L. Wei~ht and Balance: NIA
M. Electrical Load Data: N/A

N. Other Publications Affected: N/A
k Inspect aircraft records to determine what serial number

output drive gear
(369D25127-11) is installed in the main rotor transmission.
B. If369D25127-l1 Output Drive Gear serial
number determination cannot be made
via aircraft records, contact MDHS Field Service
Department with transmission
serial number or, using a bright
light, view thru the open liquid level plug port to
determine serial number of Output Gear. NOTE:
Serial number is located on the
back surface of the gear.
C. Ifit is determined that the
Output Gear Drive installed is among the serial
numbers listed, and the time of
compliance requirements of 1.G.(1), 1.G.(2) or
1.G.(3) are satisfied, then the gear must be replaced with
one that has a serial
number that falls outside the
suspect range of serial numbers.
3. DISPOSITION OF PARTBREMOVED: RETURN TO MDHS.
MANDATORY MANDATORY
MANDATORY
MANDATORY I MANDATORY MANDATORY
r
__
NOTICE NO: DN-ISS

McDonnel/ Doug/as f3i EN-82
Helicopter Systems ;3L$"- FN-69
NN-009
SERVICE INFORMATION NOTICE DATE: 10 JANUARY 1997

PAGE 3 OF 3
4. COMPLLANCE RECORD:
the helicopter Log.Book.
POINTS OF CONTACT: For further assistance, contact your local MDHS Field Senrice
Representative (refer to the Business Development and Customer Support handbook
telephone numbers) or contact the Field Senice Department at
for address and
MDHS, Mesa, Arizona. Telephone: 1-800-388-3378 or (602) 891-6342. DATAFAX:
(602) 891-6782.
L._.. MANDATORY MANDATORY

NOTICE NO: DN-190
McDonnell Douglas /3( EN-83FN-70

Helicopter Systems ~e NN-O11
SERVICE IN FORMATION NOTICE DATE: 25 JULY 1997

PAGE 1 OF 5
OVERRUNNING CLUTCH INSPECTION

A. Aircraft Affected: All McDonnell Douglas Helicopter Systems (MDHS) Model 369D,
3693, 369FF and 500N Series Helicopters.
B. Assemblv/ComDonents Affected by this Notice: Overrunning Clutch Assemblies

(P/N 369F5450-501).
C. Time of Compliance: This Notice shall be accomplished as follows:
For helicopters with less than 100 hours of operation with the affected
3691"5450-501 clutch assembly: After the initial 100 hours of operation and at
each subsequent 100 hours of operation.
For helicopters with more than 100 hours of operation with the affected
369F5450-501 clutch assembly: Within the next 25 hours of helicopter operation
and at each subsequent 100 hours of operation.
D, Reason: To ensure the proper operation of the overrunning clutch assembly.

Failure to accomplish the requirements of this Notice may result excessive vibration
and wear of clutch components and possible loss of power to the helicopter drive
system.
E. Description: Procedures in this Notice provide owners and operators with

information to inspect and, if necessary, replace the overrunning clutch assembly.
F. FAA The technical design aspects of this Service Bulletin are FAA
Approved.
G. ManDower: 2.0 man-hours to perform the inspection of the clutch. 14.0 man-hours
if the overrunning clutch assembly has to be replaced.
H. Material/Part Availability: Contact MDHS Warranty and Repair Department.
PARTS/SUPPLIES REQUIRED FOR REPLACING

A 369F5450-501 CLUTCH ASSEMBLY
Nomenclature Part No. &ty. Source
Ovenunning Clutch 369F545e501 1 MDHS

Assembly

r"
NOTICE NO: DN-190
FN-70EN-83 McDonnell Douglas

NN-O11 He/icopter Sysfems
DATE:2SJCTLY199i
PAGE 2 OF 5
PARTS/SUPPLIES REQUIRED FOR REPLACING

A 369F5450-1 CLUTCH SUB-ASSEMBLY
Ovenunning Clutch 36935450-1 1 MDHS

Assembly
PARTS/SUPPLIES REQUIRED WHEN REPLACING A 369F5450-501 WITH

A NEW 369A5350-605 CLUTCH ASSEMBLY
Nomenclature Part No. Qty Source
Overrunning Clutch 369A535e605 1 MDHS

Assembly
Coupling 369H5660 1 -I MDHS
Coupling Bolt 369115528 1 MDHS
Shims 369A5526 2 MDHS
Bolt NAS11OA-4 4 MDHS
Washer AN960KD416L 4 MDHS
Seal Assembly 1 369A8005-503 1 MDHS
Packing NAS1593-017 or 1 MDHS

M83248/1-017 (Alternate)
I. Parts Policy: MDHS will provide a replacement 369F5450-1, -501 or a new

369A5350-605 clutch assembly and hardware as required. Return worn/spun
369F5450-1 or -501 clutch assemblies to MDHS Warranty and Repair Department.
Refer to the parts request form at the end of this Bulletin.
J. Weierht and Balance: 369F5450-501 7.98 Ibs. 369A5350-605 5.38 Ibs.
K. Electrical Load Data: N/A
L. Other Publications Affected: NIA
2. ACCOMPLISHMENT INSTRUCTIONS: REFER TO FIGURE 1.
k Gain access to the overrunning clutch.

B. Remove 369F5450-1 overrunning clutch su~-assembly from housing (Ref.
CSP-HMI-8, Section 63-10-00).
C. Inspect clutch as follows:
1). Visually inspect 369F5460-1 retainer, 369F5461-1 carrier and 369F5451-1
housing at MS16556-801 pin and shoulder for indications of wear from exces-
sive spinning.
MANDATORY MANDATORY i MANDATORY

MANDATORY MANDATORY MA N DATO RY
NOTICE NO: DN-190

EN-83
McDonneN Doug/as nv-ro
Helicopfer Sysfems NN-O11
SERVICE 1NFORMATION NOTICE DATE: 25 JCnv 1997

PAGE 3 OF 5
NOTE
369F5461-1 carrier slot may not be in line with the slot in the 369F5460-1 re-
tainer. As long as no wear is observed on the carrier or 369F5451-1 housing,
this relative movement is acceptable.
2). Condition A: existence of either of the two following
If inspection reveals
situations, the 369F5450-501 clutch assembly is to be replaced with serviceable
369F5450-501 or a new/serviceable 369A5350-605 clutch assembly (Ref.
CSP-HMI-8, Section 63-10-00).
1. 369F5451-1 clutch housing wear and/or MS16556-801 pin damage.

2. 369F5461-1 carrier wear.
Condition B: If inspection reveals existence of only the following situation,

with no damaee to the 369F5451-1 clutch housing~ and MS16556-801 pin. the
currently installed 369F5450-1 clutch sub-assembly is to be replaced with a
serviceable 369F5450-1 clutch sub-assembly.
1. Yielded material in the 369F5460-1 retainer outside diameter slotted area
which interfaces with the MS16556-801 pin in the 369F5451-1 housing

NOTE
Installation of a new/serviceable 369A5350-605 or serviceable 369F5450-501

assembly requires removal of the engine.
clutch
3). Record aircraft serial number, clutch serial number, run time on clutch and date
of inspection.
D. If no wear, indication of spinning or pin damage is observed, reinstall 369F5450-1
overrunning clutch sub-assembly into 369F5451-1 housing.
E. Upon reaching 100 hours of additional operation time, return to step 2.A. and
proceed accordingly.
3. DISPOSITION OF PARTS REMOVED: RETURN TO MDHS.
POINTS OF CONTACT: For further contact your local MDHS Field Service
assistance,
Representative (refer to the "At Your Service" handbook for address and telephone
numbers) or contact the Field Service Department at MDHS, Mesa, Arizona.
Telephone: 1-800-38&3378 or (602) 891-8342. DATAFAX: (602) 891-6782.
L MANDATORY MANDATORY I MANDATORY

NOTICE NO: DN-190
EN-83 j
FN-70 McDonnell Douglas f~K
NN-O11 Helicopter Systems li~L
DATE:2Smnr1997
PAGE 4 OF 5
NO CARRIER WEAR FROM U(CESSIVE

ROTATION/ SPINNING ALLOWED
(PM369F5461-1)
NO RETAINER ROTATION
ALLOWED (PIN 369F5460-1)
INSPECT HOUSING
FOR WEAR
INSPECT RETAINER SLOT I (P/N 369F5451-1)
FOR INDICATIONS OF: YIELDED
MATERIAL 8 INTERFACE
WITH PIN IN HOUSING.
INSPECT PIN FOR ANY

BENDING OR BREAKAGE
88-752
Figure i. Inspection of Overrunning Clutch Assembly.

NOTICE NO: DN-190

EN-83
McDonnel/ Doug/as FN-70
Helicopfer Systems NN-O11
SERVICE IN FO RMATION NOTICE DATE: 25 JULY 1997

PAGE 5 OF 5
OVERRUNNING CLUTCH INSPECTION
PARTS IC~QUEST FORM: Please fill in the following information and return to MDHS
Aircraft Ser. No.
Aircraft Total Time
Date
Part Ser. No. (ifrequired)
Ship to:
MANDATORY MANDATORY
SL
Brisbane, CA 94005 (800)227-4610
MD Helicopters Inc.
3691) Series
SERVICE LETTER
1) Applicable AD
2) Part Kit (1)
DL-72.1 Exchange program-main rotor 1)

10/08/2003 blade,contd.-remove this 2)
letter from your files one 3)
year after the issue date 4) None Found
SL369D-87.2 Customer request for original 1)

09/06/2000 aircraft records 2)
3)
4) None Found
SL369D-108 SERVICE NOTICE. LETTER AND 1)

02/13/1998 BULLETIN DESIGNATIONS 2)
3)
4) NONE FOUND
SL369D-109 INTERCHANGEABILITY OF MAIN 1)

10/19/1998 ROTOR BLADES 2)
3)
4)NONE FOUND
SL369D- 110 TBO TIME EXTENSION CONDITIONS 1)

10/19/1998 FOR 369025100 MAIN ROTOR 2) 369025100
TRANSMISSION 3)
4) NONE FOUND
SL369D-111 R1 MD helicopters model 369/500N/ 1)

05/15/2001 600N torque event/retirement 2)
index number explanation 3)
4) None Found
HU 0203 SI SL
1) Applicable AD
2) Part Kit (1)
SL369D-112 Transfer of ownership of light 1)

02/19/1999 helicopter line 2)
4) None Found
SL369D-113 Required inspections and 1)

08/16/1999 critical inspection areas 2)
3)
4) None Found
SL369D-114 Availability of Federal 1)

05/23/2000 Aviation Administration 2)
airworthiness directives 3)
affecting MD helicopters 4) None Found
SL369D-115 R1 Availability of federal 1)

06/05/2000 aviation administration 2)
supplemental type certificates 3)
for MD helicopters 4) None Found
SL369D-116 New standard warranty 1)

03/02/2001 statement 2)
4) None Found
SL369D-117 Availability of MDHI 1)

09/17/2003 publications in electronic 2)
format 3)
4) None Found
SL369D-118 Certain helicopters not 1)

03/31/2004 eligible for FAA certificate 2)
of aiworthiness 3)
4) None Found
End of Index
HU 0203 SI SL
DL-72.1*
EL-23. I*
FL-14.1*
SERVICE LETTER
PAGE 1 OF 1
Supersedes Service Letters DL-72, EL-23, and FL-14, dated 10 February 1988.
TO: ALL OWNERS AND OPERATORS OF MD HELICOPTERS INC. (MDHI) 369D, 3693 AND
369F/FF SERIES HELICOPTERS.
EXCHANGE PROGRAM MAIN ROTOR BLADE ELASTOMERIC

DAMPERS
The Damper Exchange Program is rescinded in its entirety and this Service Letter is canceled for
all models.
Remove this letter from your files one year after the issue date.
Copyright 1999-2001 by MD Helicopters inc. This document may be reproduced and distributed prouided no fee is choged, the
HL-113~* i
EL-383*
FL-31~2*
SERVICE LETTER DATE: 06 SEPTEMBER 2000
PAGE 1 OF 1
EL-38.1 and FL-31.1, dated 15

*Supercedes Senrice Information Notices HL-113.1, DL-87.1,
September 1989.
TO: ALL OWNERS AND OPERATORS OF MD HELICOPTERS
369 SERIES HELICOPTERS.
I
CUSTOMER REQUESTS FOR ORIGINAL AIRCRAFT RECORDS
contacted by many customers over the
The MD Helicopters Field Service Depa~tment has been
years requesting copies
of original aircraft records. In general, these requests are to replace a
Due the extensive time required to locate and
document which has been lost or destroyed. to
duplicate these records, it is necessary for MD Helicopters to charge a nominal fee of $250.00 (U.S.
these documents. Requests for helicopter records must
funds) for the retrieval and reproduction of
Field Service Department (refer to address
be made in writing and sent to the MD Helicopters
will be sent C.O.D. to the requester.
listed below). If the records are available, copies
Address records requests to:
MD Helicopters inc.
4555 E. McDowell Road
Mesa, Arizona 85215-9734
ATTN: Field Service Supervisor

Phone: 1-800-388-3378
Datafax: (480) 346-6813

I
This document may be reproduced an& distributed provided no fee is charged,

CoWright 1999-2000 by MD Helicopters Inc. notice is included.
the text is Mt modi~iOd, cnd this copyn~ht
SL369H-131 SL369D-1o~J
SL369E-60
.ainMenuNOTPiG SL500N-005 SL369F-53SL600N-001
13 FEBRUARY 1998
SERVICE LETTERDATE:
SERVICE NOTICE, LETTER AND BULLETIN DESIGNATIONS

Light Helicopter Division Technical Publications has restructured service information documents
in anticipation of document electronic access and transmittal. The service document letterhead has
changed to reflect the current document designation. Blue Border Service Information Notices
(optional compliance) will be replaced by Technical Bulletin letterhead and Red Border Service
Information Notices (mandatory compliance) will be replaced by Service Bulletin letterhead.
Document identification by the compliance requirements must be used and not the paper or border
color; since, color information in a document can not be verified with local printing capabilities
using black and white fax, dot matrix or laser printers for service documents transmitted
electronically.
Older documents have been scanned and in some cases the format rearranged to match the
current format; however the document technical content has remained the same.
Individual divider tabs are available for Service Bulletins, Technical Bulletins and Service Letters
and will be mailed with this letter and can also be ordered separately.
1. SERVICE INFORMATION DO_CUMENT DESI_GNATION

Service Bulletins are service documents containing technical procedures, generally affect
aircraft safety or performance, requires urgent attention by the operator, requires mandatory
compliance and/or requires a record of accomplishment, and are issued for;
a special inspections/checks required to maintain the aircraft and/or components in safe
operating condition (such as; special inspections/checks to detect a flaw or manufacturing
error which could be one-time or performed until corrective action can be taken).
a reduction of existing life limits or establishment of first time life limits for components.
providing instructions and authority for inspection, repair, alteration, and/or rework of the
helicopter and/or its components.
a providing instructions and authority for retrofit of the helicopter or its components by
modifving existing and/or incorporating new components.
Technical Bulletins are service documents containing technical procedures, not safety
related, no comn,liance reauirement (completed at owner/operator option), requires a record of
accomplishment only when instructed, and are issued for;
providing instructions and authority for inspection, repair, alteration, and/or rework of the
helicopter and/or its components.
providing instructions and authority for retrofit of the helicopter or its components by
modifying existing and/or incorporating new components.
Service Letters are information documents which do not have a compliance requirement and
are issued for;
a discussing field problems and highlight information already or scheduled to be incorporated
in existing documentation.
a notifying operators of interchangeable or future spare part numbers of equipment which
have no effect on aircraft safety, performance, maintainability and reliability.
a providing preliminary information of an impending Service Bulletin or Technical Bulletin.
a notifying operators of available or forthcoming modifications.
notifying operators of changes in material finishes, protective coatings, etc.
Copyright 1997 by McDonnell Douglas Helicopter Systems.
This doclrment may be reprod~ced cmd clistrib~Lted pmvided no fee is
charged, the tert is not modified, and this copyright notice is included.
SL369H-131 SL369D-108
SL364E-60 SL369F-53
SL500N-005 SL600N-001
Main Menu NO TAG

DATE: 13 FEBRUARY 1998
PACE 2 OF 2 SERVICE LETTER
2. SERVICE INFORMATION NUMBERING EXPLANATION
The e~sting document numbering will remain as originally published to ensure traceability
and verification of compliance; however, as the document is superseded by either a
revision/reissue, its numbering will change to conform with c~u;rent service document
numbering. Service document numbering and type designation, during revision/reissue, will be
based on the information designation criteria defined on the previous page.
NOTE: The document designation (SB, TB, SL) and the helicopter model designation are currently
being used in the numbering prefix.
SERVICE BULLETIN I SERVICE INFORMATION NOTICE

HELICOPTER MODEL DESIGNATION SERVICE DOCUMENT
FAA New SE Old SIN
369A (OH-6A) S8369H- HN-
369HIHEIHMIHS S8369H- HN-
3690 SB369a- DN-
3695 583695- EN-
369F/FF 583695- FN-

500N S8500N- NN-
600N SBGOON- N/A
TECHNICAL BULLETIN I SERVICE INFORMATION NOTICE

HELICOPTER ML)DEL OESIONATION SERVICE OOCUMENT I t
FAA New SE Old SIN
369A (OH-6A) TB3tiSH- HN-
369HIHERIMIHS TB369H- HN-
3691) TB369D- ON-

3695 fB369E- EN-
369F/FF TB369F- FN-
500N T8500N- NN-

600N fBGOON- N/A
SERVICE LETTER /SERVICE INFORMATION LETTER

HELICOPTER MODEL DESIGNATION SERVICE DOCUMENT
FAA New SL Old SIL
369A (OH-6A) SL369H- HL-
369H/HE/HM/HS 5L369H- HL-

3690 5L369P DL-
3695 SL369E- EL-
369WF;F SL369F FL-
500N SLSOON- NL-
600N SLGOON- N/A
Copyright 1997 by McDonneEI Douglas Helicopter SysZems.

This document mccy be reproduced and distributedprovided no fee is
charged, the tert is not modi~ied, and this copyrightnotice is included.
SL369D-109 SL369E-061
SL600N-004
McDonnell Douglas Helicopfe~ Systems

OCTOBER 1998
SERVICE LETTER DATE:PAGE 911
1 OF
Supersedes Service Information Letters DL-23.2, dated 01 March 1984, DL-98, EL-49, and
FL-43, dated 19 December 1991.
INTERCHANGEABILITY OF MAIN ROTOR BLADES
3693[)21100 Main Rotor Blades
Operators should take note that 369D21100-513, -515, -516, -517, -519, -521 and -523 main
rotor blade assemblies may be intermixed in any combination. The 369D21100-505 and -509
are only interchangeable with other -505 and -509 main rotor blades.
369D21102 Main Rotor Blades
369D21102-BSC, -501, -503, -517, -519, -521 and -523 main rotor blade assemblies may be
intermixed in any combination.
NOTE: Main rotor blades with the 2.20 inch cord abrasion strip can be intermixed with blades
having the 3.00 inch cord abrasion strip.
latest revision of the fAt Your Service" handbook for address and telephone numbers) or contact
the Field Service Department at MDHS, Mesa, Arizona. Telephone 1-800-388-3378 or (602)
891-6342. DATAFAX: (602) 891-6782.
SL389D-110j SL369E-062
SL369F-055 SL500N-007

OCTOBER 1998
SERVICE LETTER DATE:PAGE 911
1 OF
TBO TIME EXTENSION CONDITIONS FOR

36913)25100 MAIN ROTOR TRANSMISSION
i. Aircraft Affected:
All McDonnell Douglas Helicopter Systems (MDHS) 369D, 3693, 369FF and 520N Series
Helicopters equipped with 369D25100 main rotor transmissions.
k Assemblv/Corm~,onents Affected By This Notice:
Main Rotor Transmission, P/N 369D25100
The component overhaul time for the 369D25100 main rotor transmission can now be
extended from the recommended 3000 hour interval to a mandatory 4000 hour overhaul if
the following conditions are met:
1. The transmission is operated with Mobil Oil SHC626 since the last overhaul.
2. The transmission has not accumulated more that 750 hours of cargo hook operation
time since the last overhaul.
The Handbook of Maintenance Instructions (CSP-HMI-8, Section 05-10-00) will be

reflect this change.
updated to
the Field Service Department at MDHS, Mesa, Arizona. Telephone 1-800-388-3378 or (602)
891-6342. DATAFAX: (602) 891-6782.
SL369~1[-132R1* SL369D-ErlR1*\(
SL369E-063R1* SL369F-OB6R1"
SL500N-00SR1* SL600N-0051e1"
SERVICE LETTEB DATE:

PAGE 1 OF 2
15 MAY 2001
Supersedes Service Letters SL369H-132, SL369D-lll, SL369E-063, SL369F-056,

SL500N-008, SL600N-005, dated 11 January 1999.
MD HELICOPTERS MODEL 369/500N/600N

TORQUE EVENT/RETIREMENT INDEX NUMBER EXPLANATION
MD Helicopters,Inc. (MDHI) is currently establishing a new approach to tracking certain

retirement lives and inspection intervals of various helicopter components. This is being
implemented to ensure safe operation of the helicopter within the widest range of helicopter
usage.
Components are assigned retirement lives based on flight test, fatigue test and field
experience. This Life is based on a flight spectrum that is representative of maneuvers a
particular model helicopter is expected to see. A flight spectrum defines flight maneuvers and I
a percentage of time performing these maneuvers. Each maneuver produces
different loads.
The number of times these loads are applied has a cumulative effect ~on component lives.
The MDHI flight spectrum is FAA approved and represents our knowledge of helicopter usage. I
This spectrum is conservative in its representation. However, helicopter usage has changed
since we first established our helicopter spectrum. Some operators have reported exceeding the
estimated average amount of high stress maneuvers in our flight spectrum. This can result in
reduced service life or early failure of components. Because of this, MDHI reevaluated the
manner of establishing limited lives which currently considers
I
Flight and fatigue testing have determined that a "rorque Event" (TE) accelerates fatigue
damage on certain components. A Torque Event is defined as the transition to a hoverfrom
forward flight or any external lift operation. For this definition of TE, forward flight is
considered to be flight at any airspeed in any direction after attaining transitional lift. A flight
that has a takeoff and a landing is one (1) TE. Hover taxi with no external lift will typically
result in no TEs. For sling operators, each load will count as two (2) TE (pick-up and
drop-off). For example, if an operator takes off and moves six (6) sling loads then lands, this
would total twelve (12) Torque Events (thirteen (13) if the helicopter drops off the last load and
then flies to another landing area). An external lift can either be on the cargo hook, external
hoist or in externalbaskets. An autorotation from forward flight to a landing or a hover is one
(1) TE. In order to account for a greater number of Torque Events than what was represented
in our original FAA approved flight spectrum, we are asking owners and operators to record
the number of Torque Events that their helicopters experience. The number of Torque Events
should be entered into the helicopter Log Book. For each flight, the pilot should maintain a
count of TEs performed. At the end of each day, the number of TEs should be added to the
accumulated number of TEs in the helicopter log or equivalent record.
This document may be reproduced and distributed provided fee is charged, the
CoWright 1999-2001 by MD Helicopters Inc. no
text is not modified,and this copyright notice is included.

SL369H-182R1*
S~369E-063R1* S1;389F-056R1*
SE500N-008R1* SL600N-005R1*
DATE: 15 MAY 2001 SERVICE LE%rE[R

PAGE 2 OF 2
Components affected by TEs will no longer have retirement lives or inspection intervals based
solely on TIS. Components that are effected by Torque Events will have an inspection interval
based on TE or be assigned a maximum Retirement Index Number (RIN). This RIN
corresponds to the maximum allowed fatigue damage resulting from Torque Events and
accumulated flight hours. The RIN is an adjustment factor times flight hours plus another
adjustment factor times TE, or RIN (Adjustment factor one x flight hours)
I factor two x TE). For example, if factor one
hours equal 1,190 hours with 12,800 TE, RIM
160 and adjustment factor two
(Adjustment
24 and flight
(160 r, 1,190) (24 x 12,800) 497,600 RIN.
The RIN system accounts for flight hours and TEs and results in equal conservatism being
applied to alloperators. A new component will begin with an accumulated RIN of zero that
will be increased as TEs and TIS occur. The operator will record the number of TEs, TIS and
increase the number of RlINs accordingly. When the maximum number of hours or the
maximum number of RIN is reached (whichever occurs f~rst), the component will be removed
from service.
For components that have inspections intervals based on TE, the inspection interval will occur
at a set TE interval.
Refer to the latest revision of CSP-HMI-8 or CSP-H-4, Section 04-00-00, Table 1

Airworthiness Limitations Component Mandatory Replacement Schedule for component life
limits, retirement index number formulas and inspection interval requirements.
the Field Service Department at MDHI, Mesa, Arizona. Telephone 1-800-388-3378 or (480)
346-6387. DATAI"AX: (480) 346-6813.
SL369H-133 SL369D-112
SL369E-064 SL369F-057
SL500N-009 SL600N-006
MeDonnell Douglas Helicopter Systems

FEBRUARY 1999
SERVICE LETIER DATE:PAGE 911
1 OF
TRANSFER OF OWNERSHIP OF LIGHT HELICOPTER LINE
In February of 1998, McDonnell Douglas Helicopter Company (MDHC), an indirect subsidiary

of The Boeing Company, announced they were going to sell the commercial helicopter
manufacturing business. During the ensuing months, MDHC received and evaluated several
offers from other companys interested in purchasing our commercial helicopter product lines.
In January 1999, MDHC and MD Helicopters Inc., (MDHI) an indirect subsidl~trv of RDM
Holding, Inc., signed an agreement on an asset purchase ofBoeings MD500, MDGOON~ and
MD Explorer~ series of light helicopter product lines.
MD Helicopters Inc., has stated that it will initially operate from existing Boeing facilities at
Mesa, Arizona. MDHC will continue to provide technical and engineering support under
contract to MD Helicopters.
Current MDHC will remain in their current positions in support of the light
employees
helicopter program for up to 120 days. Following that period, MDHC will be under an
agreement to provide various support (parts and technical) for two years, followed by an
additional three years of technical support on an as needed basis. With the transition period,
followed by the support agreements, we fully expect production, spares support, field support
and technical publications efforts will be unintemrpted.
In regards to certification and production issues, both H3WE (MD369/500N/600N series) and
H1SNM (MD900) Type Certificates (TCs) have been transferred to MDHI. This sales contract
action requires MDHC to terminate the use of Production Certificate No. 410, which was in
continuous use since the 1960s. MDHI intends to make application for their own PC, however
that process could take upwards of six months. Therefore, MDHI has licensed back the rights
of the TCs to MDHC who has already received a new Production Certificate No. 714NM.
Please be aware that this new Production Certificate Number (714NM) will be evident on
various documents to include sales orders and helicopter airframe data plates in the near
future as newly manufactured parts and helicopters are built and delivered. Components,
parts and helicopters manufactured before February 19, 1999 are identified by the old PC
number (410) and should be considered totally acceptable.
MD Helicopters can be contacted at (602)891-8014, FAX (602)891-8018, MD Helicopters can

also be located on the Internet at www.mdhelicopters.com:
the Field Service Department at MDHS, Mesa,~Arizona. Telephone 1-800-388-3378 or (602)
891-6342. DATAFAX: (602) 891-6782.
SL369I~-134 SL369D-113/
SL369E-065 SL369F-058
SL500N-010 SL600N-007
SERVICE LETTER DATE:

PAGE
16 AUGUST 1999
1 OF 2
REQUIRED INSPECTIONS AND CRITICAL INSPECTION AREAS
This Service Letter is issued to advise owners/operators of the importance of performing the
published inspections and checks at the designated intervals. It is also to advise
owners/operators of critical areas of the main rotor blade and lead lag links for helicopters
which average more than six Torque Events (TE) per hour. Service Letter 369B-132,
369D-111, 3693-063, 369F-056, 500N-008, 600N-005, dated 11 January 1999, or later
revision explains Torque Event/Retirement Index Number and recommends recording Torque
Events on all helicopters,
Owners/operators should review and perform all the required inspections and checks at the
required intervals published in the Airworthiness Limitations Section, Continued
Airworthiness Section, Service Information Notices/Service Bulletins, Airworthiness Directives
and Rotorcraft Flight Manual. The inspections/checks and intervals are critical for safe flight
and continued ainvorthiness.
MD Helicopters Inc. (MDHI) wishes to emphasize the critical areas of the main rotor blade and
lead-lag links for helicopters that average more than six Torque Events per hour (Refer to
Figure 1). These areas are already included in the pilot preflight and maintenance inspections,
but become more critical for helicopters which average more than six Torque Events per hour.
For further assistance, contact your local IMDHI Field Service Representative (refer to the
or (602) 891-6342. DATAFAX: (602) 891-6782.
Copyright 1999 by MD Helicopters Inc. This document may be reprorlncecl and distributed providect no fee is chaged the text is not

SL369H-134 SL369D-113
SL369E-065 SL369F-058
SL500N-010 SL600N-007
DATE:
PAGE 2 OF 2
16 AUGUST 1999
SERVICE LETTER
CRACK
~a C) CRACK
II MAIN ROTOR BLADE UPPER AND LOWER

~I ROOT FITS~ING AND LEAD-LAG LINK LUG
CRITICAL INSPECTION AREA
AREAS TO BE INSPECTED.
ROOT END FITTING-TO-DOUBLER
BOND LINE FOR MISSING OR
CRACKING ADHESIVVPAINT.
CRACK
CRACK ,I,: ~1 ~I.I

CRACK
O O
INSPECT THIS AREA FOR CRACKS

APPEARING FROM UNDER THE ROOT
FITTING (LEADING AND TRAILING EDGE)
MAIN ROTOR BLADE LOWER SIDE
~II (ROTATED)
Figure 1, Main Rotor Blade and Lead-Lag Link Critical Areas
Copyr~oht 1999 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the text is not
modified, and this copyr~lrt notice is included.
SL369H-135 SL369D-114/
SL369E-066 SL369F-059
SL500N-011 SL600N-008

PAGE 1 OF 1
23 MAY 2000
Supersedes and cancels Service Information Letters HL-71.12, DL-30.12, EL-8.6 and FL-25.4,
dated 07 April 1995.
AVAILABILITY OF FEDERAL AVIATION ADMINISTRATION

AIRWORTHINESS DIRECTIVES AFFECTING MD HELICOPTERS
TO: ALL OWNERS AND OPERATORS OF MD HELICOPTERS.
Federal Aviation Administration Airworthiness Directives affecting MD helicopters can be

viewed and printed from the Internet at: "http://av-info.faa.govr.
If Internet access is not available, owners and operators can contact the Federal Aviation
Administration for information on obtaining paper or microfiche copies at the following
address.
U.S. Department of Transportation

Federal Aviation Administration
Regulatory Support Division
Airworthiness Program Branch, AFS-610
P.O. Box 26460
Oklahoma City, OK 7~125-0460
FAX 405 -954-4104
Inc. This document may be reproduced and distributed provided no fee is charged, the
Copyright 1999-2000 by MD Helicopters
text is not modiFed, and this copyright notice is inclLLded.
SL369H-136R1 SL369D-115R1
SL369E-067R1 SL369F-060R1
SL500N-012R1 SL600N-009R1
SERVICE LETTER DATE: 26 JUNE 2000

PAGE 1 OF I
Information Letters SL369H-136, SL369D-115, SL369E-067, SL369F-060,

Supersedes
SL500N-012, .s erd aecirneS
and SL600N-009, dated 05 June 2000. Revision 1 is issued to correct the Internet I
AVAILABI1ITY OF FEDERAL AVIATION ADMINISTRATION
SUPPLEMENTAL TYPE CERTIFICATES FOR MD HELICOPTERS
for MD
A Listing of Federal Aviation Administration Supplemental Type Certificates
Helicopters can viewed and printed from the Intenet at:
."mth.tluafedeb I
If Internet access is not available, owners and operators can contact the Federal Aviation
Administration for information on obtaining paper or microfiche copies at the following
address.
U.S. Department of Transportation

Federal Aviation Administration
Regulatory Support Division
Airworthiness Program Branch, AFS-B10
P.O. Box 26460
Oklahoma City, OK 73125-0460
FAX 405-954-4104
listing provides a summary of FAA Supplemental Type Certificates (STC) for optional
kit
The
items applicable to MD helicopters. Contact the STC holder to obtain a copy of a particular
STC.
the
Copyright 1999-2000 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged,
SL369H- 137 SL369D- 116
SL369E-068 SL369F-061
SL500N-014 SL600N-010

PAGE 1 OF 1
02 MARCH 2001
Supersedes Service Letters DL-69, EL-20 and FL-10, dated 27 May 1987, DL-88.1, EL-39.1
and FL-32.1, dated 15 September 1989, and NL-002, dated 1 June 1994.
SUBJECT: NEW STANDARD WARRANTY STATEMENT
The purpose of this letter is to inform all owners and operators of the new standard
helicopter warranty of 2 years or 2,000 hours, prorated and a spare parts warranty of 12
months ~or 1,000 hours of operation. This warranty applies to new helicopters and parts
and does not supercede or replace erristing warranties. The new warranty is fully
described in the revised Warranty Exchange Program Information pamphlet
(CSP-A-8), dated 1 November 2000, or later. Other changes included in the Warranty
Exchange Program Information pamphlet include:
Addition of the 600N Component Exchange Program.
Comprehensive Proration Schedule.
Improved Labor Allowance Chart.
Updated contact information.
Copyri~ht 1999-2000 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged,
the tQt is not modi~ied, and this copyrtght notice is included.
SL500N-016 SI,600N-012
SERVICE LETTER
PAGE 1 OF 1
AVAILABILITY OF MDHI PUBLICATIONS IN ELECTRONIC FORMAT
MD Helicopters, Inc. has received numerous requests for electronic technical manuals. In an
effort to provide owners and operators with the most up-to-date information, MDHI is pleased
to announce that Technical Manuals and Rotorcraft Flight Manuals for all MDHI model
helicopters are available electronically on the MDHI website http~www. mdhelicopters.com. In
addition, and in order to promote safety and reduce incidents, MDHI will provide e-mail
notification of Service Bulletins and changes to Technical Manuals or Rotorcraft Flight
Manuals. To register and obtain a password for this service go to http~www. mdhelicopters.com/
pubs/etmhome.htm There is no charge to register for either the e-mail notification service or
access to the on-line electronic format Technical and Rotorcraft Flight Manuals.
MDHI plans to continue offering manuals in conventional print formats. Printed versions,
which include updates, can be obtained by contacting the MDHI Publications Order Desk.
Subscription service fees apply for conventional printed manuals.
On-line availability of MDHI helicopters Technical Manuals gives maintenance personnel
timely access to up-to-date information which can be printed locally as needed. The on-line
publications are in AdobeB AcrobatB PDF format with embedded hyper-links, but retain the
look of the original paper manuals content. The move to on-line document distribution
eliminates the administrative task in updating publications. The electronic update notification
service will notify registered users via e-mail of new or revised MDHI Technical Manuals,
Rotorcraft Flight Manuals, Service Bulletins, Service Letters, Technical Bulletins and
applicable FAA Airworthiness Directives.
Other publications currently available at the MD Helicopters, Inc. website are: Service
Bulletins, Service Letters, Technical Bulletins, FAA Airworthiness Directives, Overhaul
Manuals, Illustrated Parts Catalogs, Part Price Lists, Publication Indexes, Publication Order
Forms, Logbook Forms, Service Operations Reports, Publication Change Requests,
Rotorcraft Technical Descriptions, Marketing Brochures, Warranty Exchange Book, Training
Center Brochure, Service Center Listing, Distributor Listing and Contact numbers for
Customer Support, Customer Training and Marketing personnel.
CD-ROM Electronic Technical Manuals (ETM) for MDHI model helicopters are also available
from two companies, Aircraft Technical Publishers (ATP) and Avantext. Both companies
develop, market, sell and support their own versions of a CD-ROM ETM. If CD-ROM
subscriptions are required, they must be purchased directly from these companies.
Aircraft Technical Publishers (ATP) Avantext
Aircraft Technical Publishers (ATP) Avantext, Inc

101 South Hill Drive 340 Morgantown Road
Brisbane, CA 94005-9966 Reading, PA 19611
To order by phone, please call: To order by phone, please call:

800-227-4610 (US Canada) 800-998-8857 (US Canada)
415-330-9500 (Worldwide) 610-796-2383 (Worldwide)
For more information or for ordering online: For more information or for ordering online:
http:~www. atp. com http:~www. avantext. com
Copyri~ht 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed provided no /ee is charged,
the te3ct is not modified, and this copyright ,lotice is included.
S E RVI C E L ETTE R
DATE: 31 MARCH 2004
PAGE 1 OF 1
SUBJECT: CERTAIN HELICOPTERS NOT ELIGIBLE FOR FAA CERTIFICATE OF

AIRWORTHINESS
MODELS AFFECTED: Model 369D, 3693, 369Fn"F Helicopters
Recently, MD Helicopters, Inc. has seen Export Certificates of Airworthiness issued by a Foreign
CAA on two helicopters serial numbers listed on the HSWEl~pe Certificate Data Sheet Note 4e)
"not eligible for an FAA Certificate of Airworthiness" list. This event has prompted MDHI to
provide the following clarification in regards to this list.
The list was intended to highlight the fact that helicopter serial numbers on this list did not
receive an initial FAA Certificate of Airworthiness due to some major deviation from the FAA
Design. helicopters were never intended for civil operations and were sold to
These derivative
United States and Foreign Governments i Military that do not require a FAA Certificate of
Airworthiness Unique (non-FAA approved) military or customer furnished parts, wiring and
modifications were installed in these helicopters. Simply removing and replacing certain parts on
these helicopters will not make them eligible for a FAA Certifieste ofAirworthiness Many of
these helicopters were operated outside the surveillance of a Civil Airworthiness Authority, may
not have received adequate maintenance and may have been flown outside the FAA approved RFM
limitations and exposed to a night spectrum beyond what has been approved by the FAA. Spare
and used parts used on these helicopters should be considered "suspect" until fully inspected to
determine its service history and current sirwarthiness condition before installation on a civil
helicopter
Parts or components used on these helicopters which are returned to MDHI for repair or overhaul
will be segregated and tagged so that these parts are returned only to the owner operator who
shipped them to MDHI. These parts or components will not he put into an exchange pool where
they would migrate into the civil neet nor will they receive FAA approval documents.
The Data plates on these helicopters are different than those helicopters issued a Standard
Airworthiness Certificate. The "Not Eligible" helicopter data plates renect the name and location
of the manufacturer and a serial number; hut, do not show the FAA model desibllation, the 1Lpe
Certificate number nor a Production Certificate Number.
Potential buyers of helicopters on this list should validate that these helicopters would meet the
airworthiness standards of the country in which they intend to operate. MDHI Service Centers
should refer potential buyers of these helicopters to call MDHI Customer Support Division for
verification prior to entering into a contract to purchase or refurbish helicopters on the
nan-eligible list.
For further information in regards to this letter, contact Roger Carlin, Manager, CertiT~cation
Department (480) 346-6231 or E-MH11 rogerearlin@mdhelicopters.com.
Copyny(( IOYI-Z00n by MD Hriicup(rr. in. This daci~n,r,if moy ~e n,,d dislri8u~eliymlidul1 no(re is rllorb~
la~ i~l is ,lol niodQad, n~ld this mpy~h( ia
TB
Brisbane, CA 94005 (800)227-4610
MD Helicopters Inc.
369[1 Series
TECHNICAL BULLETIN
1) Applicable AD
2) Part Kit (1)
aIssue Date Issue Description 4) Compliance Time
DN-12 Installation of modified 1)

11/18/1977 (rotor brake handle) trim 2) 369026524-25
cover panel assembly 3)369[)26524-26
4)See Issue
DN-16 Rewrork of turbine outlet 1)
02/01/1978 temperature (TOT) indicator, 2) See Issue
PN 369A4521-53 and torque 3)
pressure indicater,contd. 4)See Issue
DN-17 Installation-engine compressor 1)

02/06/1978 water wash kit, PN 369H92537 2)See Issue
4) See Issue
DN-18 Removal of capacitor-voltage 1)

02/06/1978 regulator, "AAE or LSI model 2) V47ZA7
VR204; installation of 3) MS25036- 102
varistor-landing light, contd. 4) See Issue
~N-20 Replacement of plenum wall 1)

06/06/1978 fittings-torque pressure gage 2) See Issue
tubing engine oil pressure 3)
gage tubing 4)See Issue
DN-24 Field inspection corrosion 1)

07/05/1978 repai.r-main rotor drive shaft, 2)See Issue
PN 369025510 3)
4) Recommended
HU 0203 SI TN
1) Applicable AD
2) Part Kit (1)
DN-36 Installation of air baffle, 1)

11/14/1978 seal and cover assemblies- 2) See Issue
transmission compartment 3)
4) See Issue
TB369D-002 Cyclic grip modification 1)

06/01/1999 2) See Issue
4) Optional
TB369D-003 Main transmission lubrication 1)

04/09/2001 pump modification 2) See issue
4)0ptional
TB369D-004 Cylic trim actuator housing 1)
06/12/2001 replacement or modification 2)See Issue
4) Optional
End of Index
1)2/24/2004 Copyright Aircraft Technical Publishers Page 2 of 2

HU 0203 SI TN
DN-12
TECHNICAL BULLETIN DATE: 1BNOVEMBER194a

PAGE 1 OF 2
INSTALLATION OF MODIFIED (ROTOR BRAKE HANDLE) TRIM

COVER PANEL ASSEMBLY
1. Models Affected:
All 500D Model 369D helicopters equipped with left rotor brake installation PN
369B90123-31 or right rotor brake installation PN 369B90123-32
A. Preface:
The information given in this Service Information Notice provides a procedure for
installation of a modified trim cover panel for helicopters equipped with a rotor brake. It
has been found that with the rotor brake installed, ambient (hot or cold) air is allowed to
exit through the brake handle and handle retainer trim panel cutouts causing discomfort to
the pilot. Installation of the modified trim cover panel will eliminate air passage through
the brake handle and brake handle retainer (stowage clip) cutouts.
The modified trim panel cover will be provided by Hughes Helicopters; contact your Hughes
Service Center or Distributor.
B, Time of Compliance:
At owners and operators discretion
C. Weieht and Balance:
D. Reference Publications:
Hughes 500D Helicopter Model 369D Basic HMI Volume 1; Revision No. 15 November 1977
Trim cover panel assembly (LH 369D26524-25 (modified) 1 HH

brake handle only)
Trim cover panel assembly (RH 369[)26524-26 (modified) 1 HH

brake handle only)
E. TOOLS AND EQUIPMENT
No special tools or equipment required.

2. PROCEDURE
NOTE: The following procedure is applicable for either left or right rotor brake handle installation.
(1). Remove existing (rotor brake handle) trim cover panel; retain attaching hardware.
(2). Carefully trim modified panel to match existing panel.
Copyr~ht 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the
te~ctis not modified, and this copyright notice is included.
DN- ~2
DATE: 18 NOVEMBER 1977 TECHNICAL BULLETIN

PAGE 2 OF 2
(3). Locate and drill screw attach holes in modified panel.
(4). Slide modified trim panel boot over brake handle, align screw holes and check panel for
fit. If required, remove panel and make minor trim adjustments.
(5). Install panel if removed; secure panel with attaching hardware.

(6). Push panel boot aft on brake handle approximately 2 inches; secure boot fastener tape.
Copyright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed prouided no fee is charged, the
tert is not modified, and this copyright notice is included.
ori-ls
TECHNICAL BULLETIN DATE: 1FEBRUARY1BII

PAGE 1 OF 4
REWORK OF TURBINE OUTLET TEMPERATURE (TOT)

INDICATOR, PN 369A4521-5; AND TORQUE PRESSURE
INDICATOR, PN 369H4526-5
A. Models Affected:
500D Model 369D Helicopter Serial No. 0003D thru 0212D, 0214D thru 0225D and 022711
thru 0229D.
Allsubject TOT and Torque Pressure Indicators in Spares Inventory for Model 369D
Helicopter
B. Preface:
The information given in this Service Information Notice provides instructions for optional
rework of the PN 369A4521-5 TOT indicator to the current 369A4521-7 configuration, and
the PN 3691-14526-5 Torque Pressure indicator to the current 369H4526-7 configuration, to
allow the usage of higher TOT temperatures at 320 horsepower or less, so that operators
may have an additional advantage on hot day conditions.
Certification of the Model 369D helicopter was performed at a maximum continuous power
setting of 779" C, and the helicopter is fully capable of operating continuously at that power
setting.
The engine manufacturer, however, specifies that if the engine is operated continuously at
74.3 PSI torque pressure (320 HP) or less, the maximum TOT is 755"C. The torque
pressure indicator is therefore marked with a blue dot at 74.3 PSI and the TOT indicator
with a yellow are from 755"C to 8100 C.
For continuous power in excess of 74.3 PSI but not exceeding 81.3 PSI,. the maximum TOT
is 738"C. The TOT indicator is thus also marked with a blue dot at 7380 C.
It is to be noted that if the engine is operated in excess of the above values, the engine
warranty will not be honored by DDA. The new TOT and torquepressure data are
incorporated in the below referenced revision to the Model 369DRotorcraft Flight Manual
C. Time of Corm,liance:
D. FAG G~Droval:
FAA APPROVED
E. Weicrht and Balance:
Copyright I999-2001 by MD Helicopters inc. This document may be reproduced and distributed prooided no fee is charged, the
DATE: 1FEBRUAKY1978 TECHNICAL BULLETIN
PAGE 2 OF 4
F. Reference Publications:
Model 369D Basic HMI-Vol i, Issued 15 September 1976; Revision No. 1, 15 November
1977
Model 369B FAA Approved Rotorcraft Flight Manual, Revised 1 February 1978 Detroit
Diesel Allison Engine Operation and Maintenance Manual, 10W2
MATERIAL
Nomenclature Source
Paint, red (FED-STD-595) No. 11136 Commercial
Paint, white (FED-STD-595) No. 17875 Commercial
Paint, blue (FED-STD695) No. 15123 Commercial
Paint, green (FED-STD-595) No. 14260 Commercial
Paint, black (FED-STD-595) No. 37078 Commercial
2. PART I REWORK PROCEDURE FOR TORQUE PRESSURE INDICATOR
(1). Rework PN 369H4526-5 torque pressure indicator to the 369H4526-7 configuration as

follows: (See Figure 1.
(a). Clean and wipe dry the glass face of indicator; apply a 0.06 inch diameter blue dot
on glass face of torque pressure indicator at 74.3 PSI as shown.
(b). Apply a 0.06 inch wide white slippage mark on glass face and indicator housing at
three oclock position as shown.
(c). Reidentify instrument with PN 369H4526-7.
(2). Record rework of PN 369H4526-5 torque pressure indicator to 369H4526-7 configura-

tion in Components Record of helicopter Log Book.
3. PART II REWORK PROCEDURE FOR TOT INDICATOR
NOTE: The TOT indicator is hermetically sealed and must be evacuated and protected by trained
personnel. If the instrument is unsealed by any facility other than an Insco-approved repair
station, the vendor warranty is automatically voided.
(1). As applicable, remove TOT indicator from helicopter. (Refer to Basic HMI-Vol i.
(2). Rework PN 369A4521-5 TOT indicator to the 369A4521-7 configuration as follows:

(See Figure 1.
(a). Using soldering iron, soften solder bond at center of instrument. Peel off strap and
retain. Remove screws from case and remove instrument from case.
(b). Re-mark indicator dial to extend green are from existing 738"C to 7550 C; width of
green are is 0. 100 inch.
(c). Apply a 0.06 inch diameter blue dot on indicator dial at 7380 C.
DN-16
TECHNICAL BULLETIN DATE: 1 FEBRUARY 1978

PAGE 3 OF 4
ADD BLUE
100
wr lr rrs PS1~ fi. 10
no
so
40(12
TOIOU(
SLIPPAGE MARI(
10
nl
so 20
4030
RNMRI( OF 364426-5
TORQUE: PRESSURI INDICATOR
AOD BUCI: WTTO

OBSCURE MISTING RED
WT AT 860C
ADD RED WT
lo ii
O(TEND GRW ARC

FROM 134 C tO 7~OC
ADO BLUE
AT ~OC XX~
REWORK OC 344421-5
TOT INDICATOR
BB-Z#A
Figure I. Rework of TOT Indicator and Torque Pressure Indicator
CoWright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the
tert is not modified,and this copyright notice is included.
DN-l~
DATE: 1 FEBRUARY 1978 TECHNICAL BULLETIN

PAGE 4 OF 4
(d). Apply a 0.06 inch diameter red dot on indicator dial at 8430 C as shown.
(e). Apply a 0.06 inch diameter (or larger) black dot to obscure existing red dot on dial at
860" C.
(3). Check TOT indicator as follows:
(a). Red line at 8100C
(b). Yellow are from 755"C to 8100C
(c). Green are from 360"C to 755"C
(d). Red dot at 8430C (refer to DDA Engine Operation and Maintenance Manual)
(e). Blue dot at 7380C
(4). Insert instrument in case and secure with existing screws and strap. Apply solder bond
at center of instrument.
(a). Reidentify instrument with PN 369A4521-7.
(5). Reinstall TOT indicator, per Basic HMI-Vol 1.
(6). Perform calibration check of TOT indicating system, per Basic HMI-Vol 1..
(7). Record rework of PN 369A4521-5 TOT indicator to 369A4521-7 configuration in

Copyright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed prooided no fee is charged, the
tezt is not moditied, and this copyright notice is included.
o~-lu
TECHNICAL BULLETIN DATE: 6 FEBRUAW 1978

PAGE 1 OF 6
INSTALLATION ENGINE COMPRESSOR WATER WASH KIT,

PN 369H92537
A. Models Affected:
500D Model 369D Series Helicopter Serial No. 0003D thru 0089D
B. Preface:
The information given in this Service Information Notice lists procedures for optional
installation of an engine compressor water wash kit on the above affected 369D Series
helicopters. The kit is designed to provide a quick, convenient method for removing any
contaminants or corrosive air particles (smoke, fumes, salt water air, etc.) from
compressor
components, and to help ensure optimum performance and service life of the engine.
Detailed information to operating procedures, equipment, water availability and flow

cover
requirements are provided
in the attached below referenced Detroit Diesel Allison
Commercial Service Letter and subsequent revisions. The DDA Service Letter, reprinted as
part of this Notice, also provides an abbreviated check list for performing the engine water
wash.
C. Time of Com~liance:
At Owners and Operators discretion.

D. Reference Publications:
369D Basic HMI, Issued 15 September 1976; Revision No. i, 15 November 1977 Detroit
Diesel Allison Commercial Service Letter 250-C18 CSL-69; 250-C20 CSL-1020, dated 25
dune 1973; Revision No. 1, 17 January 1975 or subsequent revisions.FORM 9578A (REV
11/87)
Hose 369H304&5 1 HH
Hose 369H3048-3 1 HH
Support 369H3047 1 HH
Cap and lanyard assy 369H3046 1 HH
Spray assy 369H3042 1 HH
Washer AN960PD71 6L 2 ICommercial
Nut AN924-4D 2 ICommercial
Copvright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the
DN-17

PAGE 2 OF 6
REPLACEMENT PARTS/SUPPLIES (Cont.)

Hose elbow AN848-4D 1 Commercial
Hose adapter AN807-4D 1 Commercial
Clamp AN737TW22 4 ICommercial
Grommet MS35489-11 1 Commercial
Clamp MS25281-4 1 Commercial
Nut MS21 042-3 1 Commercial
Rivet NAS1 39884-2 6 Commercial

(alternate: MS20615-3M5)
Rivet NAS1 738M4-2 8 Commercial
Screw NAS632-3-3 2 ICommercial
TOOLS AND EQUIPMENT
Nomenclature Source
Drill mdtor portable Commercial
Drill bit No. 29/64 (0.4531 in, dia.) Commercial
Drill bit No. 8 Commercial
Drill bit No. 30 Commercial
Flycutter or equivalent Commercial
Gun, rivet Commercial
MATERIAL
Nomenclature Source
Silicone adhesive/sealant (RTV732 or equivalent) Dow Coming or Commercial
Zinc chromate primer Commercial
2. INSTALLATION INSTRUCTIONS WATER WASH KIT
(1). Perform the following, per HMI, to gain access to work area:
(a). In aft compartment, remove seat assemblies, LH bulkhead trim, access cover and
insulation; gearbox access cover.
(b). Remove engine air inlet forward fairings; open plenum chamber access door.
CoWright 1999-200I by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged the
te~tis not moditied, and this copyright notice is included.
nN-l?
TECHNICAL BULLETIN DATE: 6FEBRUAKY1878

PAGE 3 OF 6
Install temporary cover of cardboard or suitable. material over engine air intake.
CAUTION
(c). Remove engine air shield screen or engine air inlet screen, as applicable; remove
access cover from mast support structure panel.
(d). Open LH engine compartment access door.
(2). Position 369H3047 support on Station 137.50 lower section ring at dimensions shown in
Figure i, view E-E. Mark and drill rivet holes and install support with six
NAS1398B4-2 rivets. Install rivets with zinc chromate primer.
(3). Drill No. 8 hole in ring assembly as shown; locate from existing hole in support.
(4). Install AN807-4D hose adapter in support with hardware as shown; install lanyard clip
in No. 8 hole with hardware as shown. Install 369H3046 cap onhose adapter.
(5). Drill or cut 29/64 (0.4531 inch diameter) hole in firewall assembly at dimensions shown
in view A-A. Position and install AN848-4D hose elbow. in firewall with hardware as
shown.
(6). Cut hole for MS35489-11 grommet in forward wall of plenum chamber per dimensions
shown; install grommet with silicone sealant.
(7). Position 369H3042 spray assembly on inner side of plenum chamber forward wall as
shown in Figure i, view B-B, with tube inserted forward through grommet. Mark and
drill rivet holes and install spray assembly with eight NAS1738M4-2 rivets. Install
rivets with zinc chromate primer.
(8). Install 369B3048-5 hose on spray assembly tube and on hose elbow at firewall; secure
hose at each end with AN737TW22 clamps.
(9). Mark and drill No. 8 hole in 369H3024 channel and install MS25281-4 clamp with
hardware as shown. Secure -5 hose with clamp.
(10). Install 369H3048-3 hose on hose elbow at aft side of firewall, and on hose adapter at
forward side of lower section ring. Secure hose at each end with AN737TW22 clamps.
(11). Check installation of water wash kit for discrepancies.
(12). Carefully check and/or vacuum the plenum chamber for any foreign objects or debris.
Remove protective cover from engine air intake.
NOTE: Spray kit using 369113042 nozzle requires 60 pounds PSI to establish water flow rate of one
quart in 9 to 10 seconds. A bypass valve or equivalent installed at source hose connection
is recommended, in order to relieve pressure and facilitate disconnection at hose adapter.
(13). Perform operational check of water wash kit installation; refer to attachment Detroit
Diesel Allison Commercial Service Letter for operating procedures and check list.
(14). Reinstall removed components and assemblies; install and secure access covers and
doors.
(15). Record installation of 369B92537 engine compressor water wash kit in Components
tQt is not modified, and this copyright notice is included.
DN-17

PAGE 4 OF 6
su sa
521.01 rn.n
hpD j
j
MS3Y(P-~1
apR CROMWIIREQ
TYPICAL (W NQI SRIT)
WL
Q16 5000
060
,J\ i
PJ
(mlTE II
C.L. ENGINE
HOCEFOI
cRommr
ANnnm2
CUMPZREP ANII~JD HOSE III
ANP60PO11Y NASHEN
LArL
ANlL)-AD NUT
3)1)(301-5 HOSE
3616306 CAP AWD

yyy \I(y UHYARD ASSEMBLY
ANIOI~D HOSE ADAPTLR
j
ANWOPD116L IBASHEP
Oj
ANIRIWn CLAMP
ZRLQ
MIBI-NI NUT
1
NOTES:
L. SEALWIM SIL~CONE SEALANT.
An SLCTION ASSEMBLY
FUSMCE STRUCNRE
5616306-5 HOSE
ANn7m22 CLAMP
?1
I-ZY~l
Figure i.. Installation Engine Compressor Water Wash hit, PN 3691192537

(sheet 1 of 3)
CoWright 1999-200I by ML) Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the
DN-17

PAGE 5 OF 6
1QBO
/~IRWCU IdSY
st
zo.a,
WLYI.DD
.IP
I.m
%3
IRAQ
WLlOO)
C. C. I]IIGINE
o.a,

AFT SECTION
NISI~UI-2 RIVn
MFD HUD FAR SIDE ~69n30U SPRAY ASSEMBLY
6
i
NOTE: II~)
ALTERNATE MS20615-I) RIVETMAY
BE USED IN PUCE OF NAS17~M1-2.
t--UD-2
Figure 1. Installation- Engine Compressor Water Wash Kit, PN 3991192537

(sheet 2 of 3)
Copyright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed
prooided no fee is charged, the
DN-17

PAGE 6 OF 6
aoo
t--
i. I
~liL
m
IHElASSEMILY, ENGINE
AFI SECTION
RING ASSEMIYIOYYER
e-e QIP~
SECT. SfA Ut.~ P(O. E) DIAMLE
azoc
NAS6D-3-3 SCREW
WL
ANPdQPDIOLWAS(ORZREa
3150
MS210Q3 NUt
3693011 REF
a#
aw,
LTACOLTEV)R
NAS139111)-b2
FR~I L
369306 6 RQO
;I BL
s.a
L STA
12bm
3691309 SUPPORT
CANT DD
Q !99
~NO. O DIA nOLL LOCATE FROM 31193011
R.lOl
SCREW
AHQdaPDIP. WASIIER
Elf Mszlou-~ NuT
M-ZY)-)
Figure i, Installation- Engine Compressor Water Wash Kit, PN 369H92537

(sheet 3 of 3)
Copyright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed prouided no fee is charged, the
test is not modified, and this copyright notice is included.
TECHNICAL BULLETIN DATE: BFEBRUAI~T1978
PAGE 1 OF 4
REMOVAL OF CAPACITOR VOLTAGE REGULATOR, "AAE OR

LSI MODEL VR204; INSTALLATION OF VARISTOR LANDING;
LIGHT RELAY, PN MS24166D1
A. Models Affected:
500D Model 369D Helicopter Serial No. 0003D thru 0249D All Subject Voltage Regulators
in spares at date of this notice.
B. Preface:
The information given in this Service Information Notice lists a procedure for removal of
the 8 ~Lfd capacitor (C5) incorporated in the subject Model VR204 voltage regulator to
reduce EMI. The C5 is paralleled by a 1 CLfd capacitor which accomplishes the same
function. Since failure of the C5 capacitor due to voltage spikes has been reported, removal
of this capacitor is recommended to ensure the operating reliability of the voltage regulator.
Installation of a varistor on the landing light relay is also recommended to help prevent
failure of other components of the voltage regulator, and other installed avionics.
*(AAE) Aircraft Appliance and Equipment, Div of Aerospace Div; (LSI) Lear Siegler, Inc.
C. Time of Compliance:
At owners and operators discretion.
D. Weig~ht and Balance:
E, Reference Publications:
500D HMI Vol I Issued 15 September 1976; Revision No. 1, 15 November 1977
Varistor V47ZA7 1 General Electric
Terminal MS25036-1 02 2 ICommercial
DN;IB
DATE: BFEBRUARY1978 TECHNICAL BULLETIN

PAGE 2 OF 4
2. VOLTAGE REGULATOR REMOVAL OF C5 CAPACITOR
NOTE: Applicable to voltage regulator in spares or installed on 500D Model Helicopter Serial No.
0003D thru 0249D.
(1). Check that all electrical power is OFF.
(2). Gain access to voltage regulator and disconnect electrical connector. (Refer to HMI Vol
(3). Remove hardware securing regulator to support and lift out regulator.
(4). Remove cover from regulator: remove four screws, spacers and nuts securing upper circuit
board of regulator. (See Figure i.
(5). Remove capacitor C5 as shown; clip wire leads as close as possible to circuit board.
(6). f. Reinstall upper circuit board and cover.
(7). Using ink stamp, add "MOD 5C" on vendor nameplate to indicate modified voltage
regulator.
(8). Reinstall voltage regulator and attach electrical connector.
(9). Perform an operational check of the voltage regulator and make adjustments as
necessary. (Refer to HMI Vol I).
3. LANDING LIGHT RELAY INSTALLATION OF VARISTOR
NOTE: Applicable to 500D Model 369D Helicopter Serial No. 0003D thru 0149D only.
(2). Disconnect wiring leads from X1 and X2 on relay (See Figure 2). Disconnect relay panel
369H2502-66 located on lower support of instrument panel assembly. (Refer to HMI
Vol I).
(3). Crimp terminal to each lead of variator (trim varistor leads as close as practical to body
of resistor).
(4). Install varistor leads to relay terminals as shown in Figure 2; connect wire leads at XI
and X2.
(5). Reinstall relay panel.
Copyright 1999-2001 by MD Nelicopters Inc. This document may be reproduced and distributed prooided no fee is charged, the
tert is not modified and this copyright notice is included.
DN- 18

PAGE 3 OF 4
uRRa
lclla
~LIO
M YIASIILR
MDIOOI
Q1 REmM Q
CArAtlTQRONLI o
OIQR 0
M
llOQ)
)12
Y
~To
SrAQR
u
o
i. 01 UIACIIDR MAV IE IOB(lfTliP~

nw, R-lDRMD, IQDYV 10) e~.
UIWM~ fJO~ OR~aP. dua. vlpm;-
lorvo, RRllOIwRIJIRHR(lO.
t eO~M CM QMIW.
ADN1S-1
Figure i. Installation of Varistor Landing Light Relay
Copyright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributedprovided no fee is charged, the
tert is not modified and this copyright notice is included.
DNI1S

PAGE 4 OF 4
K1D1
Al A2
li~
I--- IANDINC LIGHT

VARISRR
V4nAI RBAY
X2 L
ADN18-2
Figure 2. Installation of Varistor Landing Light Relay
te~t is not modified, and this copyright notice is included.
oN-no
TECHNICAL BULLETIN DATE: BJUNE1978

PAGE 1 OF 3
REPLACEMENT OF PLENUM WALL FITTINGS TORQUE

PRESSURE GAGE TUBING
AND ENGINE OIL PRESSURE GAGE TUBING
A. Models Affected:
500D Model 369D Helicopter Serial No. 0003D thru 0232D
B. Preface:
Field reports indicate that breakage and damage to the reducer installed on the plenum
chamber pan firing has occurred during normal service or removal and installation of the
engine oil pressure line. Installation of new type fittings is recommended for both the
torque pressure gage and the engine oil pressure gage lines, to facilitate removal and
installation of the tube assemblies and preclude possible breakage or failure of the fittings.
C. Time of Compliance:
D. Weieht and Balance:
E. Reference Publications:
500D Basic HMI-Volume I, Issued 15 September 1976; Revision No. i, 15 November 1977
Union ASI 2-3XH2BZ-SS-T 2 HH
tezt is not modified, and this copyright notice is included.
nn-zo
DATE: 6JZn~YE1478 TECHNICAL BULLETIN

PAGE 2 OF 3
2. PROCEDURE
(2). Remove left forward engine air intake rafting, and left aft bulkhead access cover in
cargo compartment. Refer to Basic HMI-Vol I.
(3). Open LH engine compartment access door.
(4). Disconnect pressure line nuts at forward and aft sides of both plenum chamber pan
fittings. Cap pressure lines. Refer to Basic HMI-Vol.I.
(5). Remove existing fittings (reducers and unions) from plenum chamber pan.
(6). Install new ASI 2-3XH2BZ-SS-T fittings at plenum chamber pan, as shown in Figure
(7). Uncap lines and connect forward and aft sections of engine oil pressure and torque
pressure gage lines to new fittings.
(8). Check installation of new fittings for discrepancies.
(9). Perform pressure and leak test of both lines between engine and gages at 200 psi.
(10). Bleed and service oil pressure lines, per Basic HMI-Vol I.
(11). Close engine compartment access door. Reinstall aft bulkhead access cover and engine
air intake rafting.
Copyright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed prouided no fee is charged the
text is not modified, and this copyn~ht notice is included.
DN-20
TECHNICAL BULLETIN DATE: 6 JUNE 1978

PAGE 3 OF 3
~r i
i!
ii
PI
i.i
NYLON NBE OR
k IUNSERC
STED. TUBE
COLLAR HOTtl
PLPIVM CHAMBER
PAN
UNION AND NVI
O
TYPICAL Z PLACES AT CRES STLEL TUBE
RD(UM CHAMBER PAN
ij/ m,aJclNr CONNECTlON,
HOTL:
INSTALL COLLAR WITH TAPER DOWNWARD 8

AS SHOWN 10 FIT INTO UNION.
Qb3
Figure i. Replacement of Plenum Wall Fittings Torque Pressure Gage Tubing and
Engine Oil Pressure Gage ~bing
tent is not modified and this copyright notice is included.
DN-2~
TECHNICAL BULLETIN DATE; SJUI;Y1978

PAGE 1 OF 3
FIELD INSPECTION AND CORROSION REPAIR MAIN ROTOR

DRIVE SHAFT, PN 369D25510
A. Models Affected:
All 500D Model 369D Series Helicopters

B. Preface:
The information given in this Senrice Information Notice lists a procedure for field repair of
the main rotor drive shaft, if evidence of corrosion pitting through the original phosphate
coating on the drive shaft is noted.
C. Time of Comdliance:
At owners and operators discretion; recommended whenever subject main rotor drive shaft
is removed from helicopter
D. Weieht and Balance:
E. Reference Publications:
500D Basic HMI- Vol I, Issued 15 September 1976; Revision No. 1, 15 November 1977
MATERIAL
Nomenclature Source
1,1,1 Trichloroethane (0-T-620) Commercial
Surface Cleaner (TT-C-490 or MIL-C-10578, Type II) I Turco Products Inc.

Wilmington, CA
Crocus Cloth (P-C-458) Commercial
Primer, Zinc Chromate (MIL-P-8585) W.P Fuller 3 Co.

Los Angeles, CA
Oil Preservative (VV-L-800) Commercial
Sealing Compound (MIL-S-7502) PR1221 or EP711 Product Research

Burbank, CA or
Coast ProSeal
Compton, CA
tQt is not modified,and this copyright notice is included.
DN-a(
DATE: SJULY1978 TECHNICAL BULLETIN

PAGE 2 OF 3
2. PROCEDURE
(1). Remove main rotor drive shaft, per Basic HMI-Vol I.
(2). Inspect all surfaces of drive shaft for dents, nicks, scratches and evidence of
deformation. Inspect splines on end of drive shaft for excessive wear. (Refer to Basic
HMI-VolI.
(3). Inspect all external surfaces of shaft for corrosion. Remove corrosion as follows:
(a). Degrease corroded area of drive shaft with clean cloth saturated in trichloroethane.
3 1 Surface cleaner irritates hands on repeated exposure. Rubber gloves

I WARNING I should be worm.
(b). Swab shaft exterior with diluted solution of surface cleaner (mix one part Turco #1
with four parts water). Keep wet with solution for ten minutes, or until corrosion
appears to be removed, Wipe, clean and inspect, and repeat as necessary until there
is no further evidence of corrosion.
(c). Rinse with water and dry thoroughly with compressed air.
Exercise care when removing pits to ensure that shot peening is not completely
GrrmmYYmJ penetrated. Also, remove only minimum material necessary to remove pits. Minimum
wall thickness of 0. 1775 inch must be maintained.
(d). Lightly abrade corroded surface with crocus cloth to remove pits. If pit removal
exceeds depth of O. 0012-inch in Area 1 or O. 0008-inch in Area 2 (See Figure i),
shaft is unserviceable and must be replaced.
(e). Repeat 1 through 3 above.
(f). Spray two coats of zinc chromate primer on shaft exterior. Do not prime spline teeth
or mounting surface.
(4). Apply preservative oil to spline teeth.
(5). Immediately reinstall main rotor drive shaft, per Basic HMI.
(6). Apply a 0.06-inch bead of sealing compound around interface of hub and drive shaft.
NOTE: Main rotor drive shafts on early Model 500D helicopters have a recessed area at the top of
the drive shaft ID to accommodate phasing tool. This recess is no longer required and should
be filled to prevent water accumulation and possible corrosion. Clean the recessed area
(shaft ID and cork plug) of any dirt, debris, water, etc, and fill recess flush to top of shaft with
sealing compound. On late Model 500D helicopters, the cork plug is installed flush with top
of shaft to eliminate the recessed area.
CoWright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged the
tezt is not modified, and this copyright notice is included.
DN-24
TECHNICAL BULLETIN DATE: 5 JULY 1978

PAGE 3 OF 3
I
1. I INCHES
1 E~j:
1INCHES
54 IE1CHES
I: MAXIMUM PLT OEPTH Omll-INCH.

I I
I
2: MAXIMUM PII DEPTH RUKIB-INCH.

AREA 1
I
MAXIMUM PIT DEPTH h0020-~NCH.
AREA CHECK TEETH BY MEASURING ACRUSS

IWO O.IOB-INCH-DIAMETER PINS
PUCED IN OPPOSITE INTER-TOOTH
GROOVES. MEASURED DIMENSION
SHOULD BE A MINIMUM OF 2.268
INCHES.
88-24,
Figure i. Inspection and Repair Main Rotor Drive Shaft
te~cr is not modified, and this copyright notice is included.
nrr-ss
TECHNICAL BULLETIN
DATE: 14 NOVEMBER 1978
PAGE 1 OF 6
INSTALLATION OF AIR BAFFLE, SEAL AND COVER

ASSEMBLIES TRANSMISSION COMPARTMENT
A. Models Affected
500D Model 369D Helicopter Serial No. 0003D through 0333D.
B. Time of Compliance
At owners and operators discretion.
C. Preface
The information given in this Service Information Notice lists a procedure for field
installation of air baffles and seals and cover assemblies in the upper section of the aft
transmission compartment to prevent entry of plenum air and moisture into the cabin
area.
D. Reference
500D Basic HMI-Volume I, Issued 15 September 1976; Revision No. i, 15 November 1977.
Hughes Service Information Notice No. DN-IB, dated 18 November 1977.

E. Weieht And Balance
Changed Weight:
Weight (Ibs): +1.5
Arm (inch): Station 110.2
Moment (inch- Ibs): +169
Copyright 1999-2001 by ML) Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the
DN-36
TECHNICAL BULLETIN
PAGE 2 OF 6
A. Parts. SuaPlies. and Materials
Aft Baffle Assembly, Upper 369D26541-19 1 HH

Aft Baffle Assembly, Lower 369D26542 1 HH
Air Seal Assembly, LH Aft 369D26543-11 1 HH
Air Seal Assembly, RH- Aft 369D26543-21 1 HH

Cover Assembly, LH 80-369 D26545-11 1 HH
Cover Assembly, RH 80-369D26545-21 1 HH

Nut MS21 042L3 4 Commercial
Trim Cover Panel Assembly 369D26524-25 1 HH

(LH Rotor Brake Handle (Modified)
Assembly)
*Trim Cover Panel Assembly 369D26524-26 1 HH

(RH Rotor Brake Handle (Modified)
Assembly)
*Not applicable if presently installed on helicopter, per Hughes Notice No. DN-12.
DN-38
TECHNICAL BULLETIN
PAGE 3 OF 6
MATERIAL
Nomenclature Source
Sealing Compound, EP711 Coast ProSeal, Compton, CA
Caulking Compound, PR1221 Product Research, Burbank, CA
Seal, Sponge Rubber, DE-41 Armstrong Cork Co., Lancaster, PA
B. Installation Procedure
(1). Remove engine air inlet forward fairings. (Refer to Basic HMI Vol I.)
(2). Remove PN 369D25640 cooling fan inlet screw.
(3). Remove aft compartment interior trim panels and blower access door.
(4). Install PN 369D26541-19 upper baffle assembly as follows:
(a). Position baffle between main transmission and mast support structure; align four
attach holes in baffle with existing holes in structure. (See Figure 1.)
(b). Install baffle with screws, washers and nuts; seal screw heads with sealant.
(5). Install PN 369D26542 lower baffle assembly as follows:
NOTE: During installation of lower bame, disconnect heater duct at forward attach point and
insert duct through 2.00-inch diameter hole in baffle.
(a). Secure lower baffle to upper baffle with two screws and washers at matching
nutplates in upper baffle.
(b). Disconnect 5/8-inch diameter drain tube at mast support base and insert tube
through hole in baffle. Safetywire drain tube to structure.
(6). Reinstall PN 369D22070 blower access door.
(7). Position and install PN 369D26543-11 and -21 seal assemblies at lower baffle and
blower access door as shown. Install seal assemblies with screws and washers at
matching clipnuts on lower baffle and on blower access door.
NOTE: If excessive gap (0.06 or more) exists between structure and rubber extrusion on seals, fill
gap by bon~2ing strip of adhesive-backed gasket to structure, (See Detail A.)
(8). Position PN 369D26545-11 and -21 cover assembliesas shown; align cover attach holes
with existing fairing attach nutplates. Temporarily secure cover assemblies with screws
and washers, 5 places each.
(9). Check installation ofbaffles, seals and cover assemblies for discrepancies.
(10). Using caulking compound, seal all gaps between fuselage structure and baffle, seal and
cover assemblies.
(11). Remove screws securing cover assemblies; reinstall engine air inlet forward fairings.
tQt is not modified,and this copyr~ht notice is included.
DN-3B
TECHNICAL BULLETIN
PAGE 4 OF 6
(12). Reinstall aft compartment trim.
(13). For helicopters equipped with Rotor Brake Kit, perform the following:
NOTE: Not applicable if modified rotor brake handle trim cover panel has already been installed,
per Hughes Notice No. DN-12.
(a). Carefully trim modified trim cover panel assembly (for LH or RH rotor brake handle
assembly); locate and drill screw attach holes in modified panel.
(b). Slide modified trim panel boot over brake handle; align screw holes and check panel
for fit. As required, remove panel and make minor trim adjustments.
(c). Install panel, if removed; secure panel with attaching hardware.
(d). Push panel boot aft on brake handle approximately two inches; secure boot with
fastener tape.
text is not moditied, and this copyright notice is included.
DN-36
TECHNICAL BULLETIN
PAGE 5 OF 6
uPo~aul19a*mr IHIP I1RKNR~

O
EXTRUSION
349026643 SEAL
CI CASRT 36902~61139
GAP (NOTE 31 BACRE
(N~,E II
)69026643-21 SEAL
NAS603-l SCREW 14)
ANP60PDIOL WASHER 10 1
I (L H SHOWN)
B INOTl
365021342841112 369026Z43-11SEAL
(L H SHO\VN)
3690220104002360008 361022010
ACCESS DOOR
NAS~B-) SCREW
21 COVER
AWP60PDOL WASHER
I-II OPWSIIE)
369026962 BAFN
M9D2swjll SEAL #AS(03-I SCREW In
ANP(DPD 10C WASHER In
FAIRING PLAIE
cNoa n vim 8-B
(NOW 1) r
ii L)
7;\ 1WD21025
IAIRINC~
VIEW DD
ITYPICAL IOTH SIDES)
ZI~ 369126641-19 RAFFLE
NAS603-t SCREW (4)
VIEW CC AN9~60PWL WASHER (4
MSZIDIZU NUI II)
rrm~
NOWS:
L. DURING 1NSTALLATION OF 369026342 RAFFLE. DISCONNECT

ANO INSERT HEAWR DUCT THRU HOLE IN RAFFLE.
2. ACTLR 369026642 IAFFLE IS INSTALLED. DISCONNECT AND
ROUTL DRAIN TUBE MRU HOLE iN BAFRE.
i. IF EXCESSIVE GAP (a06 X 1.QDOR MORE) EXISTS 8ETWEEN
STRUCTURE AND RUIIIICR EXIENSION ON SEALSFILL CAP BV
BONOING STRIP OF ~DHESIM-BACIQD CASKET TO STRUCTURE.
I NO. 10 SCREW HOLE IN FAIRING ON SHIPS. DO HOT USE THIS
HOLE TO INSTALL COVER OR FAIRING.
5. TRIM PIATE AS REPUIRED m CLEAR SCREW HEAD.
88-281-2
Figure 1, Installation of Air Baffle, Seal and Cover Assemblies (Sheet 1 of 2)
DN-36
TECHNICAL BULLETIN
PAGE 6 OF 6
16)026~0) CASKET
M90~6(1-U CASYLI
-8-
IHOlt I),
-e c~slrrr
SUPPORT STRUCNRE
)(902HlL 19 BATN
-1 CASKET
UCASKET-, I~ P 36nDmD FRMM IwSn
~W)Tt d) ~Non M, BYnt
CUIILD STATIOW
COIIER
a
M)TE lr INOR 21
nc~nloucr
IMr
(WOL
LICASl;tT I
I -IStM
lCOVIR
-11 S(AL
II
5,
1)(012 9)
j jl ACCESS
2 .7/ I
DOOR
Inonu
-LPO1Sm L.
n
Iwo~
~U, -Phrxn
WIOZ(bQ ~ACN
~P02aW MSN
crcor n CANTED
C wr
ACCESS MYWI
-11 SEAL ASYMIY
-II SEAL ASSEMILY LU6
VIEW L001(IWO MRWARD
NOIES:
I MOLD ALOWO STR1ICNRL AID WX;GLE OII*DDDIOACCfSS DOOR. INSIDE CO(mWI TO MATCH MRRSAE )ARCL.
L TRIM IUILID ALO)IO CANTED STA. IUOIOCLLM STROCTLIRAL fORWADD RAWCC 10 MATCH 3(W)~d4 UFRE.
COMPOIDNTS. UURAWCt TO SIRUCIIIIL RRR DOIDINO IEM
IS Q Y INCH. I. OPTIOHALD,SD INCH WIDTH CUIOUTTOR ROTMI )RAIIL (21 GOWIROL).
MOLD W)Tnm EWD ALOIIG DPPElI OUISI# COIROUR QI ~OZaBO I. rmLE(S) MATCH CLIP MITS II DOOR.
ACCESS O01. RIM )OTTOM EI1D 10 SECDDE M)IIMWM OIILRUP 1.
mQE(S) MATCH CLIP NUTS IN W#IEMU URLE.
Of aso INCH.
88-281-1
Figure 1, Installation of Air Baffle, Seal and Cover Assemblies (Sheet 2 of 2)
TB369H-002 TB369D-002
TB369E-002 TB369F-002
TB500N-002 TB600N-003
TECHNICAL BULLETIN DATE:

PAGE 1 OF 5
01 JUNE 1999
CYCLIC GRIP MODIFICATION

All MD Helicopters, Inc. (MDHI) 369B, 369HE, 369HM, 369HS, 369D, 3693, 369F/FF,
500N and 600N series helicopters.
Pilot/Go-Pilot Cyclic Grip Assemblies (369D27133 and 369H7833)
C. Reason:
To allow to install the improved A218-101117-00 cyclic trim switch.
operators
D. Description:
Procedures in this Bulletin provide owners and operators with information to install the
A218-101117-00 cyclic trim switch. The modifications necessary to install the
A218-101117-00 cyclic trim switch may be performed using the instructions and tooling in
this Technical Bulletin or the cyclic stick may be sent to the authorized Service Center
listed below for modification.
E. Time of Compliance
Customer option: at the discretion of the owner/operator.

F. FAA Ar>Drovalt
ManPower:
Three (3) man-hours.
None
I. Authorized Service Centers:
Re-Wing Aviation Inc.

275 Durley Avenue
Camarillo Airport
Camarillo, CA 93010
Phone: (805) 484-0556
Fax: (805) 388-9906
J. MateriaVPart Availability:
Commercial sources.
REPLACEMENT PARTS/SUPPLIESTTOOLS
Switch A218-101117-00 1 Guardian Electric

(iteml)
QQ-S-571 (composition A/R Commercial

(item 2) Solder, tin alloy, rosin
core SN60WRP2)
Copyri,oht 1999 by !MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the text is not
moditied, and this copyright notice is included.
TB369H-002 TB369D-002
TB369E-002 TB369F-002
TB500N-002 TB600N-003
DATE: 01 JLn\$E 1999 TECHNICAL BULLETIN

PAGE 2 OF 5
R E PLACEM ENT PARTS/SU PPLI ESTTOO LS (Cont.)

(item 3) Potting Compound Mll-S-8802 890 A/R Coast Proseal, Compton, CA.
Mll-S-8516 3C-3007 A/R Churchill Chemical Corp. L.A.

Class II CA.
PR1422 A/R Product Research

A 1/2 Type I I 2919 Empire Ave.
Burbank, CA 91504
RTV 730 A/R Dow Coming

Type I, Class 3 Midland, MI.
(item 4) Isopropyl Alcohol TT-I-735 A/R Commercial
(item 5) Lubricating Oil A/R Commercial
(item 6) Tie Strap MS3367 (size optional) A/R Commercial
(item 7) Modification Tool RBT28477-1 1 Red Barn Machine

4681 isabelle St.
Eugene, OR 97402
(541) 344-9953
FAX: (541)344-3863
(item 8) 1/2 Drill Press 1 Commercial

(1000 rpm or less)
(item 9) Small Hand Drill Motor 1 Commercial
(item 10) Small Tap Handle 1 Commercial
(item 11)Setscrew AN565D632H4 1 Commercial
K. Warranty Policy:
NIA
L. Weieht and Balance:
N/A
M, Electrical Load Data:
N/A
Illustrated Parts Catalog (CSP-IPC-4)
Copyright 1999 by !MD Helicopters Inc. This document may be reproduced and distributed provided no fee is char~ed, the text is not
modified and this c0pynght notice is included.
TM
TB369H-002 TB369D-002
TB369E-002 TB369F-002
TB500N-002 TB600N-003

PAGE 3 OF 5
01 JUNE 1999
Refer to Figure 1
Refer to the following manuals for cyclic switch removal/instailation:
CSP-H-2, Section 7 (369H series)

CSP-HMI-2, Section 67-10-20 (369D/E/FF/500N and 600N)
(1). Remove cyclic stick from helicopter per CSP-H-8 and CSP-HMI-2.
(2). Remove clamp and/or tie straps at bottom of cyclic stick assembly.
removed serrated end first
(3). Remove pivot pin holding trigger switch (S101). The pin is
while holding the grip in the normal position. Carefully pull switch from grip approxi-
mately 2 inches (50.8 mm).
(4). Remove trim switch cap by pulling cap off.
the 2 screws securing the
(5). Remove potting compound from top of grip assembly exposing
trim switch. Remove (2) screws. Carefully remove trim switch (S107).
hook switch (S4) if installed.

(6). Tag, identify and unsolder wires from switch (S107) and
from stick feeding wires out.
(7). Remove screw at the base of grip and carefully remove grip
at the bottom of grip
(8). Install grip into fixture RBT 28477 (Figure 1, -1). Route wires
over flat on fixture.
to secure the grip to fixture

(9). Install "T" pin (-19) into hole for trigger switch pivot pin
RBT 28477 (-1).
set screw. Ensure
(10). Install arbor (-11) along with sleeve (-9) into fixture (-1) and tighten
sleeve (-9) is firm atop fixture (-1) and set screw is against flat. Sleeve (-9) should be
below of grip.
approximately 5/16" (0.3125) (7.9375 MM) top
wire
(11). If needed, piece of 0.032 (0.8128 MM) safety wire and hook any remaining
use a
inside the grip assembly and pull the wires down to prevent any damage when modify-
ing the grip.
(12). Put 1 drop of lubricating oil (item 5) on top of arbor.
(13). With a 1000 RPM less drill press (item 8), place the cutter assembly (-7) in the chuck
or
and then slowly feed the cutter into the grip. Release for a moment and feed again until
the cutter stops cutting.
from fixture.
(14). Remove cutter (-7) from drill press and arbor (-11), sleeve (-9)
top of grip to cut keyway. Use #22 drill bit at 1000 RPR/I. Drill
(15). Install drill guide (-5) on
1/2" (0.5) (12.7000 MM) deep, remove drill guide.

drill
(16). Install a bushing into the fixture (-1). With a small hand drill motor;(item 9)
#36
with a #36 bit through to the 1" (25.40 MM) hole.
6132" thread in grip for set

(17). Install bushing #27 in the fixture (-1), and tap by hand a
screw.
(18). Remove grip from fixture (-1).
prouidecl fee is chorged, the text is not

1999 by M13 Helicopters Inc. This document may be reproduced ancE distributeoI no
Copyright
modified, and this cop~vright notice is included.
TB369H-002 TB369D-002
TB369E-002 TB369F-002
TB500N-002 TB600N-003
DATE: 01 JUNE 1999 TECHNICAL BULLETIN

PAGE 4 OF 5
(19). Re-solder wires to new cyclic switch (A218-101117-00) and hook switch (S4) if installed
using solder (2).
(20). Clean grip, wiring and switches with alcohol (item 4).
(21). Remove identification tags from wires.
(22). Carefully position switches to their approrrimate location within the grip.
NOTE: Ensure that switches are correctly positioned with any applicable keyway, pin hole, etc., for
proper alignment of mating parts.
(23). Install attaching hardware securing switches onto grip. New trim switch is secured with
one set screw (item 11) installed in tapped hole (Step 17). Original two set screw holes
are filled with sealing compound (item 3).
(24). Install trigger and trigger attach pin.
(25). Install cyclic trim switch cap.
(26). Reinstall grip on stick tube, pull wiring down through stick and secure with clamp.
(27). Reinstall cyclic stick per (CSP-H-2) or (CSP-HMI-2).
Cydic trim actuators should be operated only momentarily to prevent damage to the
CAUTION
equipment.
(28). Check switch operation and wiring continuity.
Example: Trim left, cyclic stick should move left. Repeat in all four directions (right, left,
forward and aft).
(29). Apply sealing compound (item 3) to all screw holes and insert holes.
(30). Secure wiring to stick with nylon straps (item 6) and/or previously removed clamp.
(31). Record compliance to the Technical Bulletin in the Compliance Record section of the
891-6342. DATAFAX: (602) 891-6782.
modif~ed, and this copyright notice is included.
TB369H-002 T8369D-002
TB3sBF-OOZ
TB500N-002 TB600N-00S
TECHNICAL BULLETIN
-19
6/32 tap
1(8-"
JJ
#27 bushing
b drill bit
#36 bushing#36
Grip Shown Installed Fixture with Assooiated Tools

Figure 1. on
ORIGINAL
As Received By
ATP
ies is charged. the all is not

1999 by MD H~iiropt.rr Ini. ThiP docum~nl moJ be "podueod and dirlri(ut~dpmvid.d no
CopynSh~
modified.and dir opmgh~ noiice is incluBd
TB369D-003
Pt TB369E-003
TB369F-005 TB500N-003
TB600N-005
TECHNICAL BULLETIN DATE: 09 APRIL 2001

PAGE 1 OF 5
MAIN TRANSMISSION LUBRICATION PUMP MODIFICATION
Al Model 369D, 3693, 369FF, 500N, and 600N Helicopters equipped with Main
Transmission Assembly, P/N 369F5100-503, -505.
B. Assemblv/Com~onents Affected By This Notice:
Main Transmission Assembly (P/N 369F5100-503, -505), Lubrication Pump (P/N

369F5135-1, -3).
C. Reason:
The settings for the main transmission lubrication pump differential pressure indicator and
filter bypass valve are too low for the required oil flow. This condition may result in
premature differential pressure indication (button pop) with relatively clean filters.
D. Descri-otion:
This Bulletin provides operators with information pertaining to installation of a new filter
bypass valve and differential pressure indicator in the main transmission lubrication pump.
E. FAA A~roval
The technical design aspects of this Service Bulletin are FAA Approved.
F.
4 Man-hours.
Customer option, at operators discretion, if repeated instances of differential pressure

indicator actuations occur with a relatively clean filter installed in the lubrication pump.
H. Interchaneeabilitv:
The modified lubrication pump (P/N 369B5135-5) is one-way interchangeable with

previous versions of the lubrication pump (P/N 369F5135-1, -3).
The parts listed below are included in Howden Airdynamics, Inc., Kit P/N H26090. Contact
MDHI Warranty and Repair Dept.
Element, Filter H22990 1 MDHI
Valve, Filter Bypass H24996 1 MDHI
Copyright 1999-2000 by MD Helicopters Inc. This document may be reproduced and distributed providod no fee is charged, the
text is not modt~ied, and this copyright notice is included.
TB369D-003TB369F-005 TB369E-003TB500N-003
TB600N-005
DATE: 09 APRIL 2001 TECHNICAL BULLETIN

PAGE 2 OF 5

Indicator, Differential Pressure H25074 I 1 MDHI
Plate, Identification H26089 1 MDHI
Ring, Retaining I P15035A 1 MDHI or Commercial
O-Ring M83248/1-016 2 MDHI or Commercial
O-Ring M83248/1-017 1 MDHI or Commercial
C-Ring M83248/1-028 1 MDHI or Commercial
C-Ring M83248/1-140 1 MDHI or Commercial
*Petrolatum (petroleum jelly) W-P-236 I AR Commercial

Mll-G-6032
*Solvent:
Alcohol, Isopropyl AR Commercial
Cleaner Desoclean 45 AR DeSoto Aerospace

Coatings, Inc.
1608 Fourth Street
Berkeley, CA 94710
*Adhesive (epoxy) EA9330.3 AR Hysol Division

Dexter Corporation
P.O. Box 312
Pittsburg, CA
*Not part of Kit.
J. Warranty Policy:
If kits are ordered from MDHI Warranty Department prior to 31 December 2001, kits will
be provided at no cost to the operator. After 31 December 2001., parts should be ordered
through MDHI Parts Sales at the published price.
K
Toolin~
MDHI will coordinate the field use of a special tool (P/N EIT10628) required for modification
of the lubrication pump.
L. Weierht and Balance
NIA
NIA
Illustrated Parts Catalog CSP-IPC-4.
Copyrght 1999-2000 by MD Helicopters Inc. This document may be reproduced and distributed provided no fee is charged, the
text is not mocEifred, and this copyright notice is included.
TB369D-003 TB369E-003
TB369F-005 TB500N-003
TB600N-005

PAGE 3 OF 5
09 APRIL 2001
A. Prer,aration Instructions
(1). Remove sound insulation, transmission access covers and baMe to gain access to
lubrication pump on right side of main transmission.
B. Modification Instructions
(Ref. Figure 1)
(1). Break safety wire and unscrew and remove filter bowl from lube pump housing. Remove
and discard O-ring.
(2). Remove and discard filter element and two O-rings.
(3). Remove filter bypass valve and O-ring from pump housing using special tool (P/N
HT10628).
(a). Hold hex portion of special tool, with ball lever at 90" to tool axis, and rotate cylindeP
(between lever and hex) CW until snug.
(b). Rotate cylinder approlrimately 270" CCW.
(c). Carefully install collet end of special tool into receiving end of pump bypass valve.
(d). Support special tool and rotate ball lever 90" CW.
(e). Support special tool and swivel ball lever 90" until its axis is in line with hex and
cylindrical portions of tool.
(f). Pull special tool and filter bypass valve outward, along tool axis and away from
pump body.
(g). Discard O-ring. Return special tool and removed filter bypass valve to MDHI (Ref.
3. Disposition of Parts Removed).
(4). Lubricate new M83248/1-028 O-ring with petrolatum and install onto new filter
bypass valve.
(5). Install filter bypass valve into pump housing.
(6). Remove and discard retaining ring holding differential pressure indicator in filter bowl.
(7). Remove and discard differential pressure indicator and O-ring.
(8). Lubricate new M83248/1-017 O-ring and install onto new differential pressure
indicator.
(9). Install differential pressure indicator into filter bowl and secure with new retaining
ring.
(10). Lubricate two new M83248/1-016 O-rings and install them into new filter element.
(11). Insert filter element over differential pressure indicator boss within filter bowl.
(12). Install new M83248/1-140 O-ring onto filter bowl.
(13). Screw filter bowl with filter element into pump housing until hand tight.
This document may be reproduced and distributedprovided fee is c~rged, the

Copyright 1999-2000 by MD Helicopters Inc. no
tert is not modi.fed, and this copyright notice is included.

TB369D-003TB369F-005
TB600N-005
DATE: 09 APRIL 2001 TECHNICAL BULLETIN

PAGE 4 OF 5
(14). Use i-inch (25.4 mm) socket on hex located at back end of filter bowl to secure filter
bowl to pump housing. Torque filter bowl to 75-100 in-lbs (8.474-11.298 N.m). Safety
wire filter bowl.
(15). Wipe outer cylindrical surface of pump housing body with solvent.
(16). Affix identification plate to the cleaned surface of pump housing body.
(17). Seal outside edges of identification plate with adhesive mixed according to container
instructions.
(18). Reidentify P/N 369F5100-503 main transmission as as P/N 369F5100-503M, as

follows.
(a). Locate nameplate bonded to left side of main transmission housing.
03). Scribe?M" in close prolrimity to "-503" dash number.
(19). Reidentify P/N 369F5100-505 main transmission as as P/N 369B5100-507, as follows.
(a). Locate nameplate bonded to left side of main transmission housing.

Cb). Cross-out existing dash number and scribe -507" in close proximity to "369F5100"
base number.
C. ComPletion Instructions
(1). Reinstall baffle, transmission access covers and sound insulation.
3. DISPOSITION OF PARTS REMOVED
Return special tool (P/N HT10628) used for filter bypass valve removal and removed filter
bypass valve to MDHI Field Service Department. If tool and removed valve are not received
within five days of removal, customer will be billed for tool and valve.
Scrap all other parts removed from lubrication pump.
Record compliance to this Technical Bulletin in the Compliance Record section of the
For further assistance, contact your local MDHI Field Senrice Representative (refer to the
or (480) 346-6387. DATAFAX: (480) 346-6813.
TB369D-003 TB369E-003
TB369F-005 TB500N-003
TB600N-005
TECHNICAL BULLETIN DATE: 09 APRIL 2001

PAGE 5 OF 5
O
MIR TRANSMISSION-VIEW ROTATED
O-RING
(M83248/1-140)
FILTER BYPASS VALVE
j J
O-RINGY
31882431-823
RETAINING RING
O-RING
NOTE, (M83248/1-017)
PUMP HOUSING
(REF)
FILTER BOWL
(REF)
O-RING DIFFERENTIAL PRESSURE
(M83248/1-01 6) 1 INDICATOR
O-RING
(M83248(1-016)
ELEMENT~
FILTW
O
LUBRICATION PUIPVIMT ROTATED
NOTE:
LOCATE IDENTIFI~ATION PLATE ON CYUNDICAL
SURFACE OF PUMP HOUSING. 88-781
Figure 1. Lubrication Pump Modification
This document may be reproduced and distributed provided no fee is charged, the
CoWright 1999-2000 by MD Helicopters Inc.
TB369H-003 TB369D-004\f
TB369E-004 TB369F-006
TECH NICAL BU LLETI N DATE: 12 JUNE 2001

PAGE 1 OF 6
CYCLIC TR(M ACTUATOR MOUSING REPLACEMENT OR

MODIFICATION
1 PLAN NING INFORIVIATION
All Model 369HME/HM/HS~/E/FF series helicopters equipped with a lateral cyclic trim
actuator assembly and/or longitudinal cyclic trim actuator assembly listed in Paragraph
1.B.
B. Assembly/Components Affected By This Notice:
LateralCyclic Trim Actuator Assembly (P/N 369A7170-5, -7, -9)

Longitudinal Cyclic Trim Actuator Assembly (P/N 369A7171-5, -7,-9, -11)
C. Reason:
Removal and instailation of the hardware ;st the lower end of the lateral and longitudinal
cyclic trim actuators is difficult because of t~he location of the nut and cotter pin.
Complying with this Bulletin will facilitate ease of removal and installation of the lateral
and longitudinal cyclic trim actuators.
D. Description:
replacement or modification of the lateral and longitudinal cyclic trim actuator housings.
Modification consists of installing a nutplate on the housing, eliminating the need to use
the washer, nut and cotter pin on the lower end. Replacement housings have the nutplate
installed.
E. Time of Compliance
Customer option, at owner/6perator)s discretion.

F, FAA Approval:
G. fvIanD_ower:
Six (6) man-hours.
H. Interchancfeabilitv:
None
Contact MDHI parts Sales Dept.
Housing, Support (Longitudinal) 80-369A7119-5 1 MDHI
Housing, Support (Lateral) 80-369A711 0-6 1 MDHI
Copyright 1999-2001 by MI, Helicopters Inc. This decrement m4y be reproduced and distributed provided no jee is chnrged, the
lert is not modifLed, and this copyright notice is included.
TE~369H-003
TB369E-004
~B389D-004
TB369F-006 -~as-
DATE: 12 JUNE 2001 TECHNICAL BULLETIN
PAGE 2 OF 6

Nutplate NAS1474A4 2 1 MDHI or Commercial
Rivet IMS20426AD3-7 4 1 MDHI or Commercial
Bushing (Longitudinal) MHS626-4-250 1 MDHI
Bushing (Lateral) MHS626-4-293 1 MDHI
Bushing (Longitudinai and Lateral) MHS626-4-440 2 IMDH)
Dye Penetrant Kit 1 M1L-I-25135 I A/R Commercial
Fluorescent dye ASTM E1417 A/R Commercial
Epoxy primer MIL-P-8558, T1, CL C2 A/R Deft Inc.

17451 Von Karman Ave
Irvine, CA 92614
(800) 544-3338
J. Warranty Policy:
N/A
E. Toolin~
N/A
L. Wei~ht and Raiance:
N/A
N/A
Basic Handbook of Maintenance Instructions Basic Handbook of

Maintenance Instructions (CSP-H-8)
2.. ACGOMPLISHMENT INS1HUCTIONS
A. PreParation Irrstructions
(1). Remove cyclic trim actl;.zators from helicopter Section 67-10-00, Cyclic
Trim Actuator Removal ol CSP-H-2, Section 7, Cyclic Trim Actuator Remova.l) and
discard cotter pin, nut and washer (under nut) wizen disconneet:in~ lower end of
actuator
(2). Remove actuatcr from housing (CSP-XMI-2, Sedion 67-lb-00, Cyclic Thin Actuator
(Motor/Gear Drive Mechanism) Replacement or CSP-il-8, Section 7, Cyclic Trim
Actuator (Motor/Gear Drive Mechanism) Replacement).
Copyright 1~99-2001 by ~1D Helicopters Inc. This cocumPnt may be reproduced and d~stributed provided no fee is char~bd, the
2ert is not modifie~ and this coi~Yibht notice is included
TB369H-003 TB369D-004
TB369E-004 TB369F-006
TECHNICAL
(3). Replace housing with new housing ~which includes nutplate holes) as follows or modify
housing per step 2.B., Modification instructions.
(a). Install nutplate on new housing with two rivets.
03). Replace housing (CSP-HMI-8, Section 67-10-00, Cyclic Trim Actuator Housing or
Trim ~be Replacement or CSP-H-2, Section 7, Cyclic Trim Actuator Housing or
Trim Tube Replacement).

(c). Proceed to step 2.C., Completion Instructions.
B. Modification Instructions
(Ref. Figure 1)
(1). Remove both bushings from housing.
shown for longitudinal actuator. Machine opposite side of housing
(2). Machine housing as
for lateral actuator.
CRef. Figure 2)
holes in housing
(3). Locate and drill two 0.0980 inch (2.489 mm) nutplate installation
using #40 drill. Back countersink holes at inside surface of lug usir~ #40 piloted back
counter sink.
(4). Finish machined surfaces to 125 II~MS.
!5). Perform a in accordance with MIL-I-25135 or fluorescent

dye penetrant inspection
inspection in accordance with ASTM E1417 for cracks in reworked surfaces.
(6). Chemically treat exposed magnesium (CSP-A-3, Section 5, Magnesium).

(7). Apply epoxy primer to reworked surface per manufacturers instructions.
inch (6.35 mm) for
NOTE: If original bus~ing is serviceable, it may be cut down to a length of 0.250
and reinstalled.
longitudinal actuator and 0.293 inch (7.44 mm) for lateral actuator
MHS626-4-250 Qongitudinal) MHS621i-4-293 (lateral)
(8). Install reworked or new or
bushing in housing on nutplate side.

(9). Install new MHS626-4-440 bushing in housing on bolt head side.
(10). Install nutplate on housing with two rivets.
C. Completion Instructions
(1). Install actuator on housing (CSP-HMI-8, Section 67-10-00, Cyclic Trim Actuator
(MotorlGear Drive Mechanism) Replacement or CSP-H-2, Section 7, Cyclic Trim
Actuator (MotorlGear Drive Mechanism) Replacement).
(2). Install cyclic trim actuators in helicopter (CSP-HMI-8, Section 67-10-00, Cyclic Trim
Actuator Installation or CSP-H-8, Section 7, Cyclic Trim Actuator Installation).
3. DISPOSITION OF PARTS REMOVED
Scrap
Record compliance to this Technical Bulletin in the Compliance Record section of the helicopter
Log Book.
fee is charged, the
by MD Helicopters Inc. This document may be reprod~ced and distributed provided no
Copyrig~t 1999-2001 tert is not modiFed, and this copyright -notice is inclLlded.
TB369H-003 TB369D-004
TB389E-004 TB369F-006
DATE: 12 JUNE 2001 TECHMICAL BULLETIN

FAOF 4 OF 6
5. PQINTS OF CONTACT
latest revision of the ~At Your Service" handbook for address and telephone numbers) or contact
346-638i. DATAFAX (486:, 346-6813.
1,099- 2001 by MD H~icopters inc. This doci~ment mcry be reproduced ur.d di~-triblctcd provided no fee is charged, the
tert Is not modified. ond this copyright notice i~ inclLccled.
TB369H-003 TB369D-004
TB369E-004 TB369F-006
TECHNICAL BULLETIN DATE: 12 JUNE 2001

PAGE ~5 OF 6
0.88 10.40 IN.

(9.7 1 10.2 MM)
0.03 1 0.06 IN.
~I
(0.8 11.5 MM)
0.3745 1 0.37551#.(9.5121 9.538 MM)2 HOLES IN UNE.
G- 0.375 IN. R
(9.53 MM)
0.570 IEl. i 0.1971N. R

(14.48 MM) (4.75 MM)
O
25
0.08 IN. --ff

(2.0 MM)
J 1~- 0301N.
0/.6 MM)
NOTE: LONGITUDINALACTUATOR
SHOWN, LATERALACTUATOR
IS OPPOSITE.
88-788
Figure i. Machining of Actuator Housing
Copyright 1999-2001 by MD Helicopters Inc. This document may be reproduced and distrib~tedprooided no fee is charged, the
text is nor modified,and this copyright notice is included
TB389H-003 TH369D-0~
TB369E-004 TB369F-006
DATE: 12 JUNE 2001 TECHNICALL BULLETIM

P,4%E 6 OF 0
MS20426A03-7 RIVET (2 REQD)

(MFG HD FAR SIDE)
NAS1474A4
NUTPLATE
200
LATERALACTUATOR SHOWN
MHS626-4-250 BUSHINCI
(LoNGITuolNALACTvAToR)
MHS626-4-293 BUSHING
(LATERAL ACTUATOR)
UHS626~4-440 BUSHING
NAS11W-210 SOLT(1 REQD)REF.

AN460PD416L WASHER (1 REQD)
88-787
Figure 2. Reworh of Actuator Housing
Comlrighr 19P9-200~ by MD se2ic~ptcrs II~. This ~y be reprodcLced 071CZ no:re is cha.rged, the
ter: is no: modiFed, ~nd this ccpyri~ht notice isincluded.
ADs
Brisbane, CA 94005 (800)227-4610

3690 Series
ADS
AD Number
Effective Date Issue Description
70-16-07 TO PREVENT FAILURE OF THE MAIN

08/08/70 ROTOR BLADE
Recurring
77-05-03 TO PREVENT BINDING OF THE TAIL

03/07/77 ROTOR CONTROL SYSTEM AND
DAMAGE TO THE TAIL ROTOR
OUTPUT SHAFT
77-19-03 TO PREVENT FAILURE OF THE MAIN

09/27/77 ROTOR RETENTION STRAPS WHICH
Recurring CAN RESULT IN LOSS OF A MAIN

ROTOR BLADE
77-21-04 TO PREVENT FAILURE OF THE

11/23/77 ROTOR DRIVE OVERRUNING CLUTCH
AND SHAFT ASSEMBLY, WHICH CAN
RESULT IN LOSS OF, CONTD.
78-20-03 TO PREVENT HYDRAULIC FLUID

11/07/79 FROM ENTERING THE ENGINE AFTER
A SEAL FAILURE OF THE CHADWICK
HYDRAULIC MOTOR, CONTD.
78-26-04 TO PREVENT FAILURE OF TAIL

12/27/78 ROTOR HUB ASSEMBLY
Recurring

HU 0203 SI AD
AD Number
79-10-09 TO PREVENT FAILURE OF THE TAIL

05/17/79 ROTOR PITCH CONTROL ASSEMBLY,
Recurring WHICH COULD RESULT IN LOSS OF
TAIL ROTOR CONTROL
80-24-04 TO PREVENT THE POSSIBILITY OF

12/04/80 MIDDLE FRONT SEAR OCCUPANT
ACCIDENTALLY DEACTIVATING THE
AUTOMATIC ENGINE, CONTD.
80-25-01 TO PREVENT POSSIBLE FATIGUE

12/04/80 FAILURE OF THE HUGHES COUPLING
IN THE TAIL ROTOR DRIVE SHAFT
AND LOSS OF TAIL ROTOR POWER
81-26-01 R1 TO PREVENT FAILURE OF THE MAIN

10/31/90 ROTOR DRIVE SHAFT, P/N
Recurring 369025510, WHICH COULD RESULT

IN THE LOSS OF THE HELICOPTER
82-01-08 TO PREVENT LOSS OF CONTROL OF

01/07/81 ENGINE POWER DUE TO CONTROL
ROD FAILURE
82-14-01 TO PROVIDE EARLY WARNING OF

07/30/82 AUXILIARY FUEL TRANSFER PUMP
MALFUNCTION AND THE ASSOCIATED
DECREASE IN USABLE, CONTD.

08/23/82 OUTPUT GEARSHAFT ASSEMBLY, P/N
Recurring 369025132
84-01-02 R1 TO PREVENT POSSIBLE LOSS OF

04/09/84 CONTROL OF ROTOR SYSTEM IN
FLIGHT
HU 0203 SI AD
AD Number
84-11-01 TO PREVENT INTERFERENCE OR

05/31/84 BINDING AND POSSIBLE LOSS OF
LONGITUDINAL CYCLIC CONTROL
IN FLIGHT
84-12-01 R1 TO DETECT UNAPPROVED BLADES

10/24/84 AND PREVENT POSSIBLE ROTOR
BLADE FAILURE IN FLIGHT
86-01-04 TO PREVENT THE LOSS OF A TAIL

02/14/86 ROTOR BLADE TIP CAP IN FLIGHT
AND SUBSEQUENT LOSS OF TAIL
ROTOR CONTROL
86-20-07 TO PREVENT FAILURE OF THE TAIL

10/24/86 ROTOR (T/R) DRIVE SHAFT SYSTEM
Recurring AND SUBSEQUENT LOSS OF T/R
CONTROL
87-18-11 TO PREVENT POSSIBLE LOSS OF

09/01/87 TAIL ROTOR CONTROL
87-18-12 R1 TO PREVENT POSSIBLE LOSS OF

01/15/88 POWER TO THE MAIN ROTOR
Recurring
88-17-09 R1 TO PREVENT FAILURE OF THE TAIL

12/26/89 ROTOR TRANSMISSION MOUNTING
Recurring STUDS (P/N MS51992A803-13 OR

-14) ON MDHC MODEL 369. CONTD.
89-02-01 R1 C2 TO PREVENT FAILURE OF THE MAIN

07/19/90 ROTOR BLADE RETENTION STRAPS
Recurring WHICH COULD RESULT IN THE LOSS

OF A MAIN ROTOR BLADE
HU 0203 SI AD
AD Number
89-20-02 TO PREVENT FATIGUE FAILURE OF

10/16/89 FOUR-BLADED TAIL ROTOR HUBS
WHICH COULD RESULT IN LOSS OF
CONTROL OF THE HELICOPTER

12/04/89 THE CONTROL TUBES WHICH COULD
Recurring RESULT IN LOSS OF CONTROL OF

THE HELICOPTER
90-01-08 TO PREVENT POSSIBLE FAILURE OF

02/05/90 THE ENGINE-TO-TRANSMISSION
DRIVESHAFT COUPLING, WHICH
COULD RESULT IN LOSS, CONTD.
90-12-03 TO PREVENT TAIL ROTOR

06/22/90 MALFUNCTION, WHICH COULD
Recurring RESULT IN LOSS OF CONTROL AND
POSSIBLE LOSS, CONTD.
90-19-02 TO PREVENT AN OVERRUNNING

10/05/90 CLUTCH ASSEMBLY FAILURE, WHICH
Recurring MAY RESULT IN THE LOSS OF

ENGINE POWER TO THE MAIN ROTOR
90-24-07 TO PREVENT POSSIBLE FAILURE OF

12/10/90 THE MAIN ROTOR TRANSMISSION
DRIVE ASSEMBLY, WHICH COULD
RESULT IN LOSS, CONTD.
91-08-02 TO DETECT OR PREVENT CRACKS IN

05/03/91 THE TAIL ROTOR BLADE ROOT
Recurring FITTING
93-07-10 TO PREVENT HAZARDOUS YAW

07/06/93 OSCILLATIONS DURING DESCENTS,
CONTROL OF THE HELICOPTER
HU 0203 SI AD
AD Number
93-18-05 TO PREVENT ERRONEOUSLY HIGH

12/21/93 INFLIGHT FUEL QUANTITY
Recurri ng INDICATIONS DUE TO A BLOCKED
FUEL VENT LINE IN THE ASSY
94-18-08 TO PREVENT THE LOSS OF

09/27/94 ABRASION STRIPS, SEPARATION OF
THE TAIL ROTOR, AND SUBSEQUENT
LOSS OF CONTROL OF HELICOPTER

12/13/94 INNER TANG OF THE PITCH
Recurring CONTROL ASSEMBLY LOCKWASHER

(LOCKWASHER), LOSS OF,CONTD.
95-03-11 TO PREVENT LOSS OF THE

03/01/95 ABRASION STRIP, SEPARATION OF
Recurri ng A TAIL ROTOR BLADE, SEPARATION
OF THE TAIL ROTOR,CONTD.
95-03-13 TO PREVENT FAILURE OF A M/R

03/21/95 BLADE ASSEMBLY OR A M/R HUB
Recurri ng LEAD-LAG LINK ASSEMBLY, LOSS
OF A M/R BLADE,CONTD.
96-10-09 TO PREVENT FAILURE OF A MAIN

05/29/96 ROTOR BLADE (BLADE) RESULTING
Recurring IN SEPARATION OF THE BLADE AND
SUBSEQUENT LOSS OF, CONTD.

08/04/97 TRANSMISSION OUTPUT DRIVE GEAR
(GEAR), PART NUMBER P/N
369025127-11, WHICH,CONTD.

05/06/98 OVERRUNNING CLUTCH ASSEMBLY
OUTER RACE, WHICH COULD RESULT
IN LOSS OF ENGINE DRIVE,CONTD.

HU 0203 SI AD
AD Number
98-15-26 TO DETECT CRACKS THAT COULD

08/03/98 LEAD TO FAILURE OF THE BLADE
Recurring SUBSEQUENT LOSS OF CONTROL OF

THE HELICOPTER, BEFORE,CONTD.
98-21-12 TO DETECT WEAR OF OTHER CLUTCH

10/22/98 COMPONENTS, EXCESSIVE
Recurring VIBRATION WHICH COULD LEAD TO
FAILURE OF THE,CONTD.
99-04-12 To prevent failure of the

03/23/99 spline teeth in each input
shaft coupling assy (coupling
assy), loss of drive,contd.
99-13-09 To prevent failure of the fork

08/04/99 assy, P/N 369021701-21, which
Recurring can result in loss of a tail
rotor blade and,contd.
99-20-12 To prevent failure of a

11/04/99 bracket, loss of cooling of
engine oil and transmission
oil, and a subsequent,contd.
2000-08-22 To prevent an erroneous TOT
05/22/00 indication, damage to critical
Recurring engine components, loss of
engine power, and a,contd.
2000-25-52 To detect a void in the
02/06/01 bonding that could result in
a crack due to corrosion pits
on the blade spar,contd.
2002-13-05 R1 To prevent loss of the tail
02/25/03 rotor gearbox due to attaching
bolts of inadequate grip
length and subsequent,contd.
HU 0203 SI AD
AD Number
2003-08-51 C To prevent a tail rotor blade

07/17/03 pitch horn (pitch horn) from
separating from the tail rotor
blade, leading to an,contd.
2003-24-01 To prevent fatigue cracking of

12/10/03 the blade, blade failure, and
Recurring subsequent loss of control of
the helicopter
End of Index
HU 0203 SI AD
Brisbane. CA 94005 (800)227-4610
MD Helicopters Inc.
3691) Series
ADS
Serial# Tach.Time Total Time N Number Date Researched
Hours
AD Number Issue Description Date of At Method of One Next Authori zed
Effective Date Compliance Compliance Comp Compliance Time Recurring Comp.Due Signature
70-16-07 TO PREVENT FAILURE OF THE MAIN I I I I I
08/08/1970 ROTOR BLADE
Recurring
77-05-03 TO PREVENT BINDING OF THE TAIL I I I I I I

03/07/1977 ROTOR CONTROL SYSTEM AND
DAMAGE TO THE TAIL ROTOR
OUTPUT SHAFT
77-19-03 TO PREVENT FAILURE OF ME MAIN I I I I I I I

09/27/1977 ROTOR RETENTION STRAPS WHICH
Recurring CAN RESULT IN LOSS OF A MAIN

ROTOR BLADE
77-21-04 TO PREVENT FAILURE OF THE I I I i I I

11/23/1977 ROTOR DRIVE OVERRUNING CLUTCH
AND SHAFT ASSEMBLY. WHICH CAN
RESULT IN LOSS OF. CONTD.
78-20-03 TO PREVENT HYDRAULIC FLUID I I I I I

11/07/1979 FROM ENTERING ME ENGINE AFTER
A SEAL FAILURE OF THE CHADWICK
HYDRAULIC MOTOR. CONTD.
78-26-04 TO PREVENT FAILURE OF TAIL j 1 I I I I I

_
12/27/1978 ROTOR HUB ASSEMBLY
Recurring
79-1009 TO PREVENT FAILURE OF THE TAIL I I__~ I I I I

_ __ ~___
05/17/1979 ROTOR PITCH CONTROL ASSEMBLY.
Recurring WHICH COULD RESULT IN LOSS OF

TAIL ROTOR CONTROL
HU 0203 SI AD
Hours
Effective Date Compliance Compl lance Comp Compli ance Time Recurring Comp.Due Signature
80-24-04 TO PREVENT THE POSSIBILIPI OF I I I I I I I

12/04/1980 MIDDLE FRONT SEAR OCCUPANT
ACCIDENTALLY DEACTIVATING ME
AUTOMATIC ENGINE. CONTD.
80-25-01 TO PREVENT POSSIBLE FATIGUE I I I I I I I

12/04/1980 FAILURE OF THE HUGHES COUPLING
IN ME TAIL ROTOR DRIVE SHAFT
AND LOSS OF TAIL ROTOR POWER
81-26-01 R1 TO PREVENT FAILURE OF ME MAIN I I I I I

10/31/1990 ROTOR DRIVE SHAFT. P/N
Recurring 369025510. WHICH COULD RESULT

IN THE LOSS OF THE HELICOPTER
82-01-08 TO PREVENT LOSS OF CONTROL OF I I I I I

01/07/1981 ENGINE POWER DUE TO CONTROL
ROD FAILURE
82-14-01 TO PROVIDE EARLY WARNING OF I I I I I I I

07/30/1982 AUXILIARY FUEL TRANSFER PUMP
MALFUNCTION AND THE ASSOCIATED
DECREASE IN USABLE. CONTD.
82-17-01 TO PREVENT FAILURE OF THE I I I I I I I

08/23/1982 OUTPUT GEARSHAFT ASSEMBLY. P/N
Recurring 369[325132
84-01-02 R1 TO PREVENT POSSIBLE LOSS OF I I I I I

04/09/1984 CONTROL OF ROTOR SYSTEM IN
FLIGHT
84-11-01 TO PREVENT INTERFERENCE OR I I I I I I I

05/31/1984 BINDING AND POSSIBLE LOSS OF
LONGITUDINAL CYCLIC CONTROL
IN FLIGHT
84-12-01 R1 TO DETECT UNAPPROVED BLADES j I ___________

I /____~_ i I
10/24/1984 AND PREVENT POSSIBLE ROTOR
BLADE FAILURE IN FLIGHT
HU 0203 SI AD
Hours
86-01-04 TO PREVENT THE LOSS OF ATAIL I I j I I I I

02/14/1986 ROTOR BLADE TIP CAP IN FLIGHT
AND SUBSEQUENT LOSS OF TAIL
ROTOR CONTROL
86-20-07 TO PREVENT FAILURE OF THE TAIL I I I I I I

10/24/1986 ROTOR (T/R) DRIVE SHAFT SYSTEM
Recurring AND SVBSEOUENT LOSS OF T/R

CONTROL
87-18-11 TO PREVENT POSSIBLE LOSS OF I I I I I I I

09/01/1987 TAIL ROTOR CONTROL
87-18-12 R1 TO PREVENT POSSIBLE LOSS OF I I I I

01/15/1988 POWER TO THE MAIN ROTOR
Recurring
88-17-09 R1 TO PREVENT FAILURE OF THE TAIL I I I I I I

12/26/1989 ROTOR TRANSMISSION MOUNTING
Recurring STUDS (P/N MS51992A803-13 OR

-14) ON MDHC MODEL 369. CONTD.
89-02-01 R1 C2 TO PREVENT FAILURE OF ME MAIN I I I I I I

07/19/1990 ROTOR BLADE RETENTION STRAPS
Recurring WHICH COULD RESULT IN ME LOSS

OF A MAIN ROTOR BLADE
89-20-02 TO PREVENT FATIGUE FAILURE OF I I I I I I

10/16/1989 FOUR-BLADED TAIL ROTOR HUBS
CONTROL OF ME HELICOPTER

12/04/1989 ME CONTROL TUBES WHICH COULD
Recurring RESULT IN LOSS OF CONTROL OF

THE HELICOPTER
90-01-08 TO PREVENT POSSIBLE FAILURE OF I __

j I 1 I I I
02/05/1990 ME ENGINE-TO-TRANSMISSION
DRI\IESW\FT COUPLING. WHICH
COULD RESULT IN LOSS. CONTD.
HU 0203 SI AD
Hours
90-12-03 TO PREVENT TAIL ROTOR I I I I I I

06/22/1990 MALFUNCTION, WHICH COULD
Recurring RESULT IN LOSS OF CONTROL AND
POSSIBLE LOSS. CONTD.
90-19-02 TO PREVENT AN OVERRUNNING I I j I I I I

10/05/1990 CLUTCH ASSEMBLY FAILURE. WHICH
Recurring MAY RESULT IN THE LOSS OF

ENGINE POWER TO THE MAIN ROTOR
90-24-07 TO PREVENT POSSIBLE FAILURE OF I I I I I I

12/10/1990 THE MAIN ROTOR TRANSMISSION
DRIVE ASSEMBLY. WHICH COULD
RESULT IN LOSS. COFF~D.
91-08-02 TO DETECT OR PREVENT CRACKS IN I I I I I I

05/03/1991 THE TAIL ROTOR BLADE ROOT
Recurring FITTING
93-07-10 TO PREVENT HAZARDOUS YAW I I j I I I I

07/06/1993 OSCILLATIONS DURING DESCENTS.
CONTROL OF ME HELICOPTER
93-18-05 TO PREVENT ERRONEOUSLY HIGH I I I I I I I

12/21/1993 INFLIGHT FUEL QUANTITY
Recurring INDICATIONS DUE TO A BLOCKED

FUEL VENT LINE IN THE ASSY
94-18-08 TO PREVENT THE LOSS OF I I j I I I I

09/27/1994 ABRASION STRIPS. SEPARATION OF
THE TAIL ROTOR. AND SUBSEOUENT
LOSS OF CONTROL OF HELICOPTER
94-24-04 TO PREVENT FAILURE OF THE I I 1 I I I I

12/13/1994 INNER TANG OF THE PITCH
Recurring CONTROL ASSEMBLY LOCKWASHER

(LOCKGIASHER). LOSS OF,CONTD.
95-03-11 TO PREVENT LOSS OF ME j j I_~ I I I I

_
03/01/1995 ABRASION STRIP, SEPARATION OF

Recurring A TAIL ROTOR BLADE. SEPARATION
OF ME TAIL ROTOR,CONTD.
HU 0203 SI AD
Hours
Effective Date Compliance Compl lance Comp Compli ance Time Recurring Comp.Due Signature
95-03-13 TO PREVENT FAILURE OF A M/R I I I I I I

03/21/1995 BLADE ASSEMBLY OR A M/R HUB
Recurring LEAD-LAG LINK ASSEMBLY. LOSS

OF A M/R BLADE.CONTD.
96-10-09 TO PREVENT FAILURE OF AMAIN j I j I I I

05/29/1996 ROTOR BLADE (BW)E) RESULTING
Recurring IN SEPARATION OF ME BLADE AND
SUBSEOUENT LOSS OF, CONTD.
97-15-08 TO PREVENT FAILURE OF THE I I j I I I

08/04/1997 TRANSMISSION OUTPUT DRIVE GEAR
((;EAR). PART NUMBER P/N
369025127-11. WHICH.CONTD.
98-09-02 TO PREVENT FAILURE OF THE I I I I I I I

05/06/1998 OVERRUNNING CLUTCH ASSEMBLY
OUTER RACE. WHICH COULD RESULT
IN LOSS OF ENGINE DRIVE.CONTD.
98-15-26 TO DETECT CRACKS THAT COULD I I I I I I I

08/03/1998 LEAD TO FAILURE OF ME BLADE
Recurring SUBSEQUENT LOSS OF CONTROL OF

ME HELICOPTER. BEFORE.CONTD.
98-21-12 TO DETECT WEAR OF OTHER CLUTCH I I I I I I I

10/22/1998 COMPONENTS. EXCESSIVE
Recurring VIBRATION WHICH COULD LEAD TO
FAILURE OF THE.COFCTD.
99-04-12 To prevent failure of the j I I I I

03/23/1999 spline teeth in each input
shaft coupling assy (coupling
assy). loss of drive.contd.
99-13-09 To prevent failure of the fork I I I I I I I

08/04/1999 assy. P/N 369021701-21, which
Recurring can result in loss of a tail
rotor blade and.contd.
99-20-12 To prevent failure of a I I I_ I I I

11/04/1999 bracket. loss of cooling of
engine oil and transmission
oil. and a subsequent.contd.
HU 0203 SI AD
Hours
2000-08-22 To prevent an erroneous TOT I I I I I I I

05/22/2000 indication. damage to critical
Recurring engine components. loss of
engine power. and a.contd.
2000-25-52 To detect a void in the I I I I I I I

02/06/2001 bonding that could result in
a crack due to corrosion pits

on the blade spar.contd.
2002-13-05 R1 To prevent loss of the tail I I I I I I

02/25/2003 rotor gearbox due to attaching
bolts of inadequate grip
length and subsequent.contd.
2003-08-51 C To prevent a tail rotor blade I I I I I I

07/17/2003 pitch horn (pitch horn) from
separating from the tail rotor
blade. leading to an.contd.
2003-24-01 To prevent fatigue cracking of I I I I I

12/10/2003 the blade, blade failure. and
Recurring subsequent loss of control of

the helicopter
End of Index
HU 0203 SI AD
70-16-07 HUGHES: Amendment 39-1059. Applies to Model 369
Series helicopters, certificated in all

categories, which incorporate PIN 369A1100 and P/N
369A1100-501 main rotor blade serial numbers listed in Hughes Service Information Notice
No. HN-8, dated November 19, 1969, or later FAA approved revision and serial numbers listed
in OH-6A Information Notice Numbers, 120, 120A, and 1206 dated October 24, 1969;
November 5, 1969; and December 19, 1969, respectively.
Compliance required as indicated:
To prevent failure of the main rotor blade P/N 369A1100 and P/N 369A1100-501
accomplish the following or an equivalent inspection procedure approved by the Chief, Aircraft
Engineering Division, FAA Western Region:
Within 25 hours time in service after the effective date of this AD, unless already
accomplished, determine the identification notation on the blade top and bottom doublers in
accordance with the procedures in Part I a, b, and c of Hughes Service Information Notice No.
HN-8, dated November 19, 1969, or later FAA approved revision.
(a) For blades displaying "PR-12" ink stamps or blades lacking ink stamps below
the part number on either of the doublers:
(1) Inspect prior to fu rther flight in accordance with Part i d of Hughes Service
Information Notice No. HN-8, above.
(2) If indications of cracks or doubler peeling or separation are found, remove
the blade from service prior to further flight.
(3) If indications of cracks or doubler peeling or separation are not found,

repeat the inspection required under (1) above, at periods not to exceed 25 hours time in
service from the last inspection until the blades are removed from service as specified in (4),
below.
(4) Remove from service prior to the accumulation of 100 hours time in
service from the effective date of this AD.
(b) Blades displaying ink stamp letters and numerals other than "PR-12" below the
part number on both doublers may be returned to service with no further inspection, following
refinishing and identification per Hughes Service Information Notice No. HN-8, dated
November 19, 1969, or later FAA approved revision.
This amendment becomes effective August 8, 1970.
MCDONNELL DOUGLAS HELICOPTER COMPANY

77-05-03 HUGHES HELICOPTERS: Amendment 39-2845. Applies
toHughes Model 3691) helicopters Serial No. 0003 through 0049, certificated in all categories,
that were manufactured without protective boots on the tail rotor output shaft.
Compliance required as indicated unless already accomplished.
To prevent binding of the tail rotor control system and damage to the tail rotor output
shaft, accomplish the following:
(a) Within 30 calenderdays from the effective date of this AD, disassemble the tail
rotor control assembly, install Hughes PIN 369021806 rotating boot and Hughes P/N
369021807 stationary boot, and reassemble in accordance with Hughes Handbook of
Maintenance Instruction.
(b) Equivalent replacement parts may be used when approved by the Chief, Aircraft
Engineering Division, FAA Western Region.
(c) Special flight permits may be issued in accordance with 21.197 and 21.199 to
operate helicopters to a base for the accomplishment of the installation required by this AD.
This amendment becomes effective March 7, 1977.
MCDONNELL DOL/GLAS HELICOPT~ER COMPANY

77-1 9-03 HUGHES HELICOPTERS: Amendment 39-3038. Applies
to Hughes Model 3690 helicopters, certificated in all categories, which have PIN 369021200
main rotor hub serial numbers 0001 through 0178 installed.
Compliance required as indicated.
To prevent failure of the main rotor retention straps which can result in loss of a main
rotor blade accomplish the following:
A. Before fu rther flight after the effective date of the AD, visually inspect the lead leg
of each main rotor retention strap pack, P/N 369021210, at the inboard ends to determine if
two adjacent metallic anti-fretting laminates PIN 369021271-5, -51, -53 or -55, have been
installed on the upper side of the lead leg of any strap pack.
(1) If two adjacent metallic anti-fretting laminates have been installed, visually
inspect to determine if one or both are cracked or have been broken off where they extend
from the hub.
(i) If no anti-fretting laminate is found cracked or broken, repeat the

inspections in (1), above, repetitive inspection
attirnes in service notto exceed 25 hours. This
can be discontinued when the main rotor hub, PIN 369021200, has been replaced by a
serviceable hub having only one anti-fretting laminate on the upper side of the lead leg of each
main rotor strap pack.
If any anti-fretting laminate is found cracked or broken, further

(ii)
visually inspect the main rotor retention strap laminates adjacent to the anti-fretting laminates.
(a) If any strap laminate is broken or cracked, replace the main

rotor hub, P/N 369021200, before further flight.
If no strap laminate is cracked

(b) or broken, replace the main
rotor hub, P/N 369021200, within ten hours time in service.
(2) inspection reveals that only one metallic anti-fretting laminate has
If the
been installed on the upper lead leg of each strap pack no further action is required by this AD.
This amendment becomes effective September 27, 1977, for all persons except those
to whom it was made effective by telegram dated August 12, 1977, which contained this
amendment.
MCDONNELL DOLIGLAS HELICOPT~ER COMPANY

to Hughes Model 369 (YOH-GA), 369A(OH-6A), D, H, HE, HM and HS helicopters, certificated
in all categories.
To prevent failure of the rotor drive overrunning clutch and shaft assembly, which can
result in loss of power to the rotor main transmission, accomplish the following:
receipt of this telegram, unless already

Within the next 10 hours time in service after
accomplished in the last 25 hours time in service, visually inspect the overrunning clutch
assembly PIN 369A5350-11, drive shaft bearing P/N 369A5361 and bearing seal P/N
369A5368 for proper operation, lubrication and condition per affected Hughes Service
Information Notices DN-9 (for Model 3690) or HN. 118 (Model 369A (YOH-GA), 369A,
(OH-6A), H, HE, HM and HS)) both dated August 29, 1977 or later FAA-approved revisions as
follows:
(a) Remove assembly P/N 369A5350-11, per Hughes Basic

overrunning clutch
Handbook of Maintenance Instructions (HMI).
(b) Visually inspect overrunning clutch assembly, PIN 369A5350-11, bearing, PIN
369A5361, and bearing seal, PIN 369A5368, for adequate lubrication, condition, and proper
operation perthe applicable sections and paragraphs of Hughes Component Overhaul Manual.
(c) Remove clutch retainer (P/N 369A5356 or 369A5366) to expose ball bearing (P/N
369A5361).
(d) Inspect bearing for condition. If the bearing is found dry of lubricant or rough,
replace it with new bearing and report the finding to the local FAA General Aviation District
Office along with completed Malfunction or Defect Report Form 8330-2.
(e) bearing is not found dry of lubricant or rough, using solvent and brush,
If
thoroughly remove existing grease from both bearing and retainer. Do not use compressed
air to remove grease from ball bearing.
Thorough flushing of bearing and retainer of all existing grease is necessary to

NOTE:
prevent possible mixing of dissimilar greases when bearing is repacked with Aeroshell 22 or
Mobil 28.
(f) If bearing is found in satisfactory condition, the repack bearing 50% to capacity
with Aeroshell 22 or Mobil 28 grease only by packing open side of bearing level without forcing
grease through bearing cage.
MCDONNELL DOUGLAS COMPANY

(g) Fill void of retainer 50% full with grease; reinstall retainer. Flat side of retainer
faces unit; bevel side is out.
NOTE: Some clutch assemblies may have suffix letter "T" following serial number.
(h) Add suffix letter "G" to serial number on ID plate of subassembly (after suffix
letter T" if applicable).
(i) Coat clutch splines with Aeroshell 22 or Mobii 28 grease; carefully insert clutch
subassembly into housing and secure with retaining ring.
O) Check clutch oil level per basic HMI.
(k) coupling, main transmission drive

Reinstall the serviceable component, clutch
shaft and other removed corn ponents per referenced Hughes Basic Handbook of Maintenance
Instruction.
(1) Record compliance with this airworthiness directive in compliance record

of helicopter log book.
This amendment becomes effective November 23, 1977, for all persons except those
to whom it was made effective by telegram dated August 31, 1977 which contained this
amendment.
MCDONNELL DOUGLAS HELICOP~ER COMPANY

78-20-03 HUGHES: Amendment 39-3307 as amended by
Amendment 39-3599. Applies to Hughes Model 369D and 369H helicopters which have either
the C-500 aerial spray system, STC No. SH~ 84NW or the Chadwick C-500 fire suppression
kit, STC No. SH567NW installed.
To prevent hydraulic fluid from entering the engine after a seal failure of the Chadwick
hydraulic motor, accomplish the following:
Within the next 100 hours time in service or days, whichever comes first, after the
30
effective date of this AD, install a drain line on the engine mounting flange, Chadwick PIN
500-60405-1, in accordance with Chadwick Service Bulletin 500-78-02 dated September 1,
1 978, or later FAA approved revisions, or in a manner approved by the Chief, Engineering and
Manufacturing Branch, FAA Northwest Region.
To prevent possible fatigue cracking of the helicopter undercarriage, accomplish the

following: Within the next 50 hours flying time or six months, whichever comes first, after the
effective date of this amended AD, install a doubler, P/N 500-60487-1, and grommet, PIN
AN931-7-1, in accordance with Chadwick Service Bulletin 500-79-01 dated September 27,
1979, or later FAA approved revisions, or in a manner approved by the Chief, Engineering and
Manufacturing Branch, FAA Northwest Region.
The manufacturers specifications and procedures identified and described in this

directive are incorporated herein and made a part hereof pursuant to 5 U.S.C. 552(a)(1).
All persons affected by this directive who have not already received these documents
from the manufacturer may obtain copies upon request to Chadwick Inc., 1 1969 SW Herman
Road, Sherwood, Oregon 97140. These documents may also be examined at FAA Northwest
Region, 9010 East Marginal Way South, Seattle, Washington 98108.
Amendment 39-3307 became effective November 2, 1978.
This Amendment 39-3599 becomes effective November 7, 1979.
MCDONNELL DOUGLAS HELICOP;rER COMPANY

to Hughes Model 269C, Serial Number 0004 through 0716, and Models 269A, 269A-1, and
2698 certificated in all categories, equipped with LTS Tail Rotor Assembly P/N 269A6034,
including Military Model TH-55A equipped with LTS Tail Rotor Assembly P/N 269A6034,
equipped with Tail Rotor Hub Assembly Part No. 369A1725 or Tail Rotor Hub Assembly Part
No. 369A1725-5, Serial No. 001 through 862.
Also, applies to Hughes Model 3691-1, 369HM, 369HS, 369HE and 369D, Serial
Numbers 0001D through 032413 and 0331D through 0333D certificated in all categories,
Rotor Hub Assembly Part
equipped Assembly Part No. 369A1725 or Tail
with Tail Rotor Hub
No. 369A1725-5, Serial No. 001 through 862 or Tail Rotor Hub Assembly Part No.
369A~725-501.
To prevent failure of Tail Rotor Hub Assembly, Hughes P/N 369A1725, 369A1725-5,
Serial No. 001 through 862 and 369A1725-501, which could result in a loss of the rotorcraft,
(a) Within 100 hours time in service or six months after the effective date of this AD,
whichever occurs sooner, unless already accomplished, inspect the tail rotor hub for cracks,
corrosion or damage and rework the tail rotor hub in accordance with Part II Hub
other
Inspection and Rework Paragraphs a through h of the following FAA approved Hughes Service
Information Notices:
(1) Hughes Model 269 Series Helicopter use Hughes Service Information
For
Notice No. N-153, dated September 1, 1978.
(2) Hughes Model 369H Series Helicopter

For use Hughes Service
Information Notice No. HN-128.1, dated December 8, 1978.
(3) For Hughes Model 3690 Series Helicopter use Hughes Service
Information Notice No. DN-27.1, dated December 8, 1978.
NOTE: Hughes Service Information Notices of the above listed dates are the only
versions of S.I.N.s suitable for compliance with this AD.
(b) Remove all cracked hubs from san/ice prior to further flight and replace with like
serviceable part. If replacement part has part number suffix identification SP, no further action
is required by this AD. If replaced with part number hub affected by this AD, revert to the
inspection requirements of Paragraph (c).
MCDONNELL DOUGIAS HELICOPTER COMPANY

(c) Reinspect the tail rotor hub with a 10 power magnifying glass at each annual
inspection or 300 additional hours time in service since the last inspection, whichever occurs
earlier. pits, corrosion or other damage is found, inspect
If cracks, and rework, per the
instructions of Paragraphs (a) and (b).
(d) repairs may

Equivalent inspection procedures and be used when approved by
the Chief, Aircraft Engineering Division, FAA Western Region.
This amendment becomes effective December 27, 19781
MCDONNELL DOUGLAS HELICOP7-ER COMPANY

79-~ 0-09 HUGHES HELICOPTERS: Amendment 39-3466. Applies
toHughes Model 3690 Helicopters certificated in all categories, except Serial Numbers 0409
and subsequent.
To prevent failure of the tail rotor pitch control assembly, which could result in loss of
tail rotor control, accomplish the following:
(a) Before further Right after the effective date of this AD, check the 369021803-3
locknut and tang washer P/N MS 172209 or HS1551 S238 ofthe tail rotor pitch control assembly
PIN 369021800 as follows:
Pull back the non-rotating boot P/N 369021806 from the tail rotor pitch control
assembly P/N 369021800 and check the locknut and tang washer by hand for looseness.
(1) If the locknut or tang washer is loose, remove and replace the tail rotor
pitch control assembly with a serviceable assembly with a white dot on the locknut, before
further flight.
(2) If either the locknut tang washer is not loose, repeat the check for
or
looseness of the locknut or tang washer before each engine start-up. See (c) below for
termination action.
The checks required by this AD may be performed by the pilot.
NOTE 1: requirements regarding the listing of compliance and method of

For the
compliance with this AD in the helicopters permanent maintenance record, see FAR 91.173.
(b) Forthe operators that have previously complied with Hughes Service Information
Notice DN-37, dated December 1, 1978, the following applies:
(1) Ifthe tail rotor pitch coritrol assem bly was repaired d ue to looseness of the
locknut or tang washer, repeat the checks in (a) above and remove and replace the tail rotor
pitch control assembly within 150 hours time in service after the receipt of the airmail letter
dated April 9, 1979.
(2) For the tail rotor pitch control assemblies for which records of repair are
not known, see (b)(l) above.
(3) pitch control assemblies which were repaired per DN-37

For the tail rotor
with no looseness of the locknut or tang washer, the requirements of this AD do not apply.
MCDONNELL DOUGLAS HELICOPTFR COMPANY

NOTE 2: pitch control assemblies which have loose locknut or tang washers
The
must be overhauled per the Hughes Model 3690 Helicopter Basic Handbook of Maintenance
Instructions and DN-37, dated December 1, 1978, before return to service.
(c) For those assemblies which do not have loose tang washers orlocknuts, per
paragraph (a)(2) above, within ~00 hours of time in service from the receipt of the airmail letter
dated April 9, 1979, accomplish DN-37.
(d) Equivalent checks and repairs may be used when approved bythe Chief, Aircraft
Engineering Division, FAA Western Region.
This amendment becomes effective May 17, 1979, as to all persons except those
persons to whom it was made immediately effective by the airmail letter dated April 9, 1979,
which contained this amendment.
MCDONNELL DOL/GLAS HELICOP77SR COMPANY

80-24-04 L~uoLIEstluLw2enas; Amendment393979 Appliesto
Model 369 Series Helicopters, certified in all categories, equipped with Automatic Engine
Reignition System.
Compliance is required as indicated unless already accomplished.
the
To prevent the possibility of the midd le front seat occu pant accidentally deactivating
Automatic Engine Reignition System and also from blocking the crews view of the automatic
reignition "ARMED" and "RE-IGN" advisory lights, accomplish the following:
(a) Within thirty (30) consecutive calendar days or prior to flight in falling and/or
install a placard in
blowing snow, whichever comes first, after the effective date of this AD,
view of the pilot
close proximity to the Automatic Engine Reignition Arming switch and in plain
which states "Middle front seat is not to be occupied during flight in falling and/or blowing snow"
or equivalent words.
may be issued in accordance with FAR 21.197

and .199
(b) Special flight permits
to operate aircraft to a base for the accomplishment of modification required this AD.
(c) Alternative inspections, modifications or other actions which provide an

and
equivalent level of safety may be used when approved by the Chief, Engineering
Manufacturing Branch, FAA Western Region.
This amendment becomes effective December 4, 1980.
MCDONNELL DOUGLAS HEIICOPTER COMPANY

80-25-0 HUOHES HELICOPTERS: Amendment3P3980. Appliesta
Model 369 Series Helicopters certified in all categories.
Compliance is required as indicated unless already accomplished.
To prevent possible fatigue failure of the Hughes couplings in the tail rotor drive shaft
and loss of tail rotor power, accomplish the following:
(a) Within 25 hours time in service from the effective date of this AD, inspect the fore
and aft tail rotor drive shaft couplings to determine the serial numbers of the installed
couplings. The serial number is on the Bendix part number decal.
(b) For those helicopters with the following couplings installed, prior to further flight,
remove couplings from service and label couplings "Unairworthy." Hughes
Part No.
369H92564, serial numbers 0883U, 0932U, 0933U, 0935U, 0940U, 0950U, 0957U, 0961U,
0971U; and for Hughes Part No. 369A5501, serial numbers 10670U and 10672U. Replace
removed coupling with like serviceable part.
(c) Installation of any coupling listed in paragraph (b) will render the helicopter
unaiMlorthy.
(d) Report the serial number of each suspect coupling listed in paragraph (b) found
as a result of the inspection of paragraph (a) to the Chief, Engineering and Manufacturing
Branch, FAA, Western Region, P.O. Box 92007, World Way Postal Center, Los Angeles,
California 90009. Negative reports are not necessary. Reporting approved by Office of
Management and Budget, OMB No. 041F10174.
(e) Special flight permits may be issued in accordance with FAR 21.197 and 21.199
to operate helicopters to a base for the accomplishment of inspections required by this AD.
(f) Alternative inspections, modifications or other actions which provide an
equivalent level of safety may be used when approved by the Chief, Engineering and
Manufacturing Branch, FAA Western Region.
This amendment becomes effective December 4, 1980.
MCDONNELL DOUGLAS HELICOP7-ER COMPANY

81-26-0~ R~ MCDONNELL DOUGLAS HELICOPTER
COMPANV (MDHC): Amendment 39-4275 as revised by Amendment 39-6689. Docket

No. 89-ASW-43.
Applicability: All Model 369 series helicopters equipped with main rotor drive shaft, part
number (P/N) 369025510, certificated in any category.
Compliance: Required as indicated, unless already accomplished.
prevent failure of the main rotor drive shaft, PIN 369D25510, which could result in
To
the loss of the helicopter, accomplish the following:
(a) Prior to the accumulation of 300 hours total time in service on the P/N
369025510 drive shaft, or within the next 25 hours additional time in service from December
17, 1 981 for the Model 3690 or from the effective date of this amended AD for Models 369E
and F (whichever occurs later), and thereafter at repetitive intervals not to exceed 300 hours
additional time in service since the last such inspection:
(1) Visually inspect the spherical spline and adjacent shaft area of the drive shaft,
P/N 369025510, in accordance with the instructions contained in Hughes Service Information
Notices (SIN) DN-99, dated November 30, 1981; FN-4, dated July 29, 1983; or MDHC SIN
EN-4, dated April 29, 1983, as applicable.
(2) Replace cracked parts with like serviceable part prior to return to service and
continue to inspect at 300-hour intervals.
NOTE: Drive shaft retirement is established at 3,410 hours time in service.
(3) Drive shaft retirement is established at 3,410 hours time in service for Models
369F and FF, and 5,020 hours time in service for Models 369D and E.
(b) Special flight permits may be issued in accordance with FAR 21.197 and 21.199
to operate aircraft to a base for the accomplishment of inspections or modifications required
by this AD.
(c) compliance, which provides an equivalent level of

An alternative method of
safety, may be used when approved by the Manager, Los Angeles Aircraft Certification Office,
ANM-100L, FAA, Northwest Mountain Region, 3229 East Spring Street, Long Beach, California
90806-2425; telephone (213) 988-5200.
repair and inspection procedures shall be done in accordance with Hughes Service
The
Information Notices (SIN) DN-99, dated November 30, 1981, incorporated by reference
MCDONNEIL DOUGL4S HEIICOPTER COMPANY

(See 46 FR 60807, December 14, 1981); FN-4, dated July 29, 1983; or MDHC SIN EN-4,
dated April 29, 1983, as applicable. This incorporation by reference was approved by the
Director of the Federal Register in accordance with 5 U.S.C. 552(6) and 1 CFR Part 51.
Copies may be obtained from McDonneil Douglas Helicopter Company,
5000 E. McDowell Road, Attention: Publications Department, MS 5431P 213, Mesa, Arizona
85205. Copies may be inspected at the Regional Rules Docket, Office of the Assistant Chief
Counsel, Federal Aviation Administration, 4400 Blue Mound Road, Room 158, Bldg. 38, Fort
Worth, Texas, or at the Office of the Federal Register, 1100 L Street, NW., Room 8301,
Washington, DC.
Airworthiness Directive 81-26-01 R1 revises AD 81-26-01 Amendment 39-4275 (46 FR

60807, December 14, 1981).
AD 81-26-01 R~) becomes effective October 31, 1990.

This amendment (39-6689), on
FOR FURTHER INFORMATION CONTACT:
Mr. Roy McKinnon, ANM-143L, Los Angeles Aircraft Certification Office, 3229 East Spring
Street, Long Beach, California 90806-2425; telephone (213) 988-5247.
MCDONNELL DOUGLAS HELICaPTER COMPANY

HUGHES HELICOPTERS: Amendment 39-4292. Appliesto
Model 369 Series helicopters, certificated in all categories.
Compliance required as indicated, unless already accomplished.
accomplish the
To prevent loss of control of engine power due to control rod failure,
following:
(a) Within 25 hours additional time in service after the effective date of this AD,
remove PIN 369A7706-3 RPM Governor Lever Control Rod and replace
with P/N 369A7706-5
RPM Governor Lever Control Rod.
NOTE: Hughes Helicopters Notice No. DN-87 and HN-169, dated May 15, 1981,
refers to this subject.
(b) Special flight permits may be issued in accordance with FAR 21.1 97 and 21.199
to operate helicopters to a base for the accomplishment of inspections or
modifications
required by this AD.
(c) Alternative inspections, modifications or other actions which provide an
equivalent level of safety may be used when approved by the Chief, Engineering and
Manufacturing Branch, FAA Western-Pacific Region.
This amendment becomes effective January 7, 1982.

82- f 4-01 tlUrt~Es;Am8ndment34441)2. AppiiestotheHughesModel
369 Helicopters with Chadwick C-20 Auxiliary Fuel System installed per Supplemental Type
Certification SH129WE. Compliance is required as indicated, to provide early warning of
fuel.
auxiliary fuel transfer pump malfunction and the associated decrease in usable auxiliary
Accomplish the following, unless already accomplished:
1. Within 30 days after the effective date of this AD, install placard in accordance
a
with Chadwick Service Bulletin 20-81-01 dated October 6, 1981, or FAA approved equivalent
usable auxiliary fuel to half the amount in the auxiliary tanks at takeoff.
limiting
2. Within 300 hours time-in-service or 6 months from the effective date of this AD,
whichever occurs Monitoring Kit in accordance with Chadwick

first, install the C-20-FM Flow
Service Bulletin 20-81-01 dated October 6, 1981, or FAA approved equivalent. The placard
installed per item 1 above may be removed, provided the revised Flight Manual Supplement,
the
Chadwick Auxiliary Fuel System C-20, dated October 21, 1981, is incorporated into
Rotorcraft Flight Manual.
3. Alternate modifications or other actions which provide an equivalent level of

FAA
safety may be used when approved by the Chief, Seattle Area Aircraft Certification Office,
Northwest Mountain Region.
may be issued in accordance with Federal

Aviation
4. Special flight permits
for the
Regulation Part 21, Sections 21.197 and 21.199, to operate each helicopter to a base
accomplishment of the modification required by this AD.
This amendment becomes effective July 30, 1982.
MCDONNELL DOUGLAS HELICOPT~ER COMPANY

82-~ 7-0~ HUGHES HELICOPTERS. INC.: Amendment 39-4433.
to Model 3690 helicopters certificated in categories, equipped

all with main
Applies
transmission part number 369025100 basic configuration.
Compliance is required as indicated, unless already accomplished.
To prevent failure of the output gearshaft assembly, P/N 369D25132, accomplish the
following:
(A) Within 100 hours time in service after the effective date ofthis AD, and thereafter
at intervals not to exceed 300 hours time in service, until such time as the ultrasonic inspection
of this AD is accomplished, conduct visual inspection for cracks in the
of paragraph (8) a
transmission output shaft in accordance with instructions in Part I entitled "Periodic Visual
Inspection" of Hughes Service Information Notice No. DN-105 dated May 25, 1982,
thereinafter referred to as DN-105), or FAA approved equivalent.
(8) The visual inspections required by paragraph (A) of this AD may be discontinued
by conducting a one-time ultrasonic inspection of the electron beam weld area of

the
transmission output shaft in accordance with the instructions of Part II entitled "Ultrasonic
Inspection" of DN-105, or FAA approved equivalent. This inspection must be accomplished no
later than the next overhaul or major disassembly of the transmission.
(C) if cracks are found as a inspections required by paragraph (A)

result of the visual
of this AD or an unacceptable electron beam weld is found as a result of ultrasonic inspection
of paragraph (B) of this AD, before further flight replace the output gearshaft assembly with a
like assembly which has been inspected and found to be acceptable in the electron beam weld
area in accordance with the ultrasonic inspection technique described herein.
(D) Output gearshaft assemblies ultrasonically inspected and found to have

acceptable electron beam welds in the transmission output shaft are to be identified in
accordance with Figure 2 of DN-105, or FAA approved equivalent.
(8) Special flight permits may be issued in accordance with Parts 21.197 and 21.199
to operate aircraft to a base for the accomplishment of inspections required by this AD.
(F) Altemativeinspections, modifications, or other actions which provide an

equivalent level of safety may be used when approved by the Chief, Western Aircraft
Certification Field Office, FAA, Northwest Mountain Region, Hawthorne, California.
This amendment becomes effective August 23, 1982.
MCDONNELL DOUGUIS HELICOPirER COMPANY

84-01-02 R1 HUGHES HELICOPTERS. INC. (HUGHES
HELICOPTERSI: Amendment 39-4831. Applies to Hughes Helicopters, Inc., Model 369
series including Army YOH-GA, and OH6A helicopters certificated in all categories.
Compliance is required prior to further flight, unless already accomplished.
To prevent possible loss of control of rotor system in flight, accomplish the following:
Hughes Helicopters, Inc., Model 369 (Army YOH-6A), 369A(Army OH-6A) D, E, H,

For
HE, HM, and HS helicopters with swashplate bearing assembly P/N 369/1\7003-3 installed
after June i, 1983;
(a) Comply with paragraphs A through J of procedures section of Hughes

Helicopters, Inc., Mandatory Service Information Notices DN-125, EN-12, and HN-191, as
applicable, all dated December 23, 1983, or FAA approved equivalent. Model 369 series are
to comply with Mandatory Service Information Notice HN-191 or FAA approved equivalent.
(b) Replace deficient swashplate bearing assembly with serviceable unit.
(c) Swashplate bearing assembly P/N 369A7003-3 with positively identified serial
numbers 9000 through 9999 or with a l/&inch-diameter blue dot on the outer surface of the
need not be reinspected.
snap ring has been determined to contain the ball bearing cage and
(d) Only subject bearing assembly positively identified as being S/Ns 9000-9999 or
bearing assemblies with blue dot on the outer surface of snap ring or FAA approved equivalent
bearing assemblies approved by the Manager, Western Aircraft Certification Office may be
used as replacement swashplate bearing assemblies.
inspections, modifications, or other actions which provide an equivalent level

Altemative
of safety may be used when approved by the Manager, Western Aircraft Certification Office,
Hawthorne, California.
This amendment becomes effective April 9, 1984, as to all persons except those
persons to whom it was made immediately effective by priority mail AD 84-01-02, issued
January 10, 1984, which contained this amendment.
MCDONNELL DOUGLAS HELICCIPTER COMPANY

84-11-01 HUGHES HELICOPTERS, INC.. (HUGHES
369E helicopters
HELICOPTERS~: Amendment 39-4870. Applies to certain Model 369D and
certificated in all categories.
Compliance is required within 1 0 hours time in service after the effective date of this AD,
unless already accomplished.
binding and possible loss of longitudinal cyclic control flight,

in
To prevent interference or
110871D only, and Model 3696

ForHughes Helicopters, Inc., Model 369D, Serial No.
0036E, and 00386 through
Helicopters, Serial Nos. 0001E through 00276, 00296 through
369A7011, and doubler PIN
0043E, with longitudinal mixer control rod Part Number (PIN)
369D22509-51 installed.
PART I of Hughes
(a) Comply with procedures a., b., and d. through k. under
Notice EN-13 or equivalent procedures
Helicopters, Inc., Mandatory Service Information
approved under paragraph (c) of this AD.
NOTE: Procedure c. under PART I concerns an inspection for proper number of

rivets in PIN 369I322509-21. Compliance with this procedure and installation of rivets are
recommended.
If the control rod is damaged or control rod clearance is less than 0.21 inch, while
(b)
with
performing procedures f. or g. under PART I or approved equivalent procedures, comply
method approved
PART II of Mandatory Service information Noti~ EN-13 or an equivalent
under paragraph (c) of this AD.
(c) Alternative inspections, modifications, or other actions which provide an

Aircraft
equivalent level of safety may be used when approved by the Manager, Western
Certification Office, Hawthome, California.
Aviation
(d) Special flight permits may be issued in accordance with Federal
base in order to comply with
Regulations 21.197 and 21.199 to ferry aircraft to a maintenance
the requirements of this AD.
This amendment becomes effective May 31, 1984.
MCDONNELL DOUGLAS HELICOP7ER COMPANY

R~ HUGHES HELICOPTERS. INC.. (HUGHES
HELICOPTERS~: Amendment 39-4877 as amended by Amendment 39-4937. Applies

to
Model 369D and 369E helicopters certificated in all categories.
Compliance is required prior to further flight, unless already accomplished.
To detect unapproved blades and prevent possible rotor blade failure in flight,
with main rotor blades

Hughes Helicopters, Inc., Model 3690 and 3696 helicopters
For
installed which have been procured from any source.
(a) verify that the main rotor blades are of the proper
To Part Number (PIN)
369021100 internal configuration, comply with the following:
(1) A coin tap test or equivalent test shall be used to identify the number of
ribs in each blade. Carefully tap along the length of the blade, aff of the spar, from the tip end,
the number of ribs in the
using heavy coin; e.g., U.S. quarter, half dollar, or equivalent. Note
a
has 20 ribs, 1.5 inches
blade by the difference in sound. The proper PIN 369021100 blade
369A1100 series blade has
apart, beginning 1.5 inches from the blade tip. The unapproved
only four ribs, beginning 3 inches from the blade tip.
(2) unapproved blade also has a painted over, flush plug installed to fill
The
a 0.218- to 0.224-inch-diameter hole required
in the trailing edge inboard end of all 369A1 1 00
series blades. There is no such hole in the proper P/N 369021100 blades. Inspect the blade
for a filled hole in the trailing edge inboard end.
(b) If a blade has four ribs and a filled hole, an improper blade is installed. Replace
with an airworthy proper P/N 369021100 blade prior to further flight.
(c) Alternative inspections, modifications, or provide an

other actions which
level of safety to this AD may be used when approved by the Manager, Western
equivalent
Aircraft Certification Office, Hawthorne, California. The procedure specified in Hughes Service
Information Letter DL-57 or EL-5, dated February 10, 1984, is an alternative.
NOTE: Hughes Service Information Letter No. DL-57 or EL-5 dated February 10,
1984, pertains to identification of improper blades.
Amendment 39-4877 became effective June 11, 1984.
This Amendment 39-4937 becomes effective October 24, 1984.

86-01-04 HUGHES HELICOPTERS. INC. IHuahpo Helicaoten):
Amendment 39-5187. Applies to Model 369 series helicopters including military Models YOH-
6A and OH-6A, certificated in any category, equipped with tail rotor blades Part Numbers (P/N)
369A1613-3,- 7, -561, and -503, Serial Numbers (S/N) 6928 and prior; PINs 369021613-11,
41, and -51, SINs 5144 and prior; PIN 369021606, SINs 0077 and prior; P/N 369021815,
S/Ns 0480 and prior; and PINs 421-088-BSC and -3, all serial numbers.
date
Compliance is required within the next 100 hours time in service after the effective
of this AD, unless already accomplished.
the loss of tail rotor blade tip cap in flight and subsequent loss of tail rotor
To prevent a
control, accomplish the following:
(a) Remove, inspect, and modify blades in accordance with paragraphs a through
of Hughes Service Information Notices ~SIN) DN-~ 32.1, EN-
g, Part I "PROCEDURE" section
21.1, FN-9. 1, HN-199.1 dated May 1, 1985, or S1Ns DN-129, EN-18, and HN-195 dated
August 27, 1984.
An alternate method of compliance which provides an equivalent level of safety

(b)
approved by the Manager of the Western Aircraft Certification Office,
may be used when
Hawthorne, California.
(c) Special flight permits may be issued in accordance with FAR Sections 21.197
and 21.199 to ferry aircraft to a maintenance base in order to comply with the requirements of
this AD.
The manufacturers specifications and procedures identified and described in this

directive are incorporated herein and made a part hereof pursuant to 5 U.S.C. 552(a)(1). All
received these documents from the
persons affected by this directive who have not already
manufacturer may obtain copies upon request to McDonnell Douglas Helicopter Company,
Centinela Avenue and Teale Street, Culver City, California 90230. These documents also may
be examined at the FAA, Southwest Region, Room 158, Building 38, 4400 Blue Mound Road,
Fort Worth, Texas 76106, or at the Western Aircraft Certification Office, 15000 Aviation
Boulevard, Hawthome, California 90250.
This amendment supersedes Amendment 39-4940 (49 FR 43046; October 26, 1984),
AD 84-18-08.
This amendment becomes effective February 14, 1986.
MCDONNELL DaUGLAS HELICOPTER COMPANY

86-20-07 MCDONNELL DOUGLAS HELICOPTER COMPANY
(Huahes Helicopters. Inc.): Amendment 39-5422. Applies to Model 369, 369A, 3690, 3695,
369H, 369HE, 369HM, and 369HS helicopters, including military Models YOH-GA and OH-6A,
certificated in any category, equipped with tail rotor drive shaft flexible couplings, Part Number
(P/N) 369A5501 or 369H92564.
Compliance required as indicated unless already accomplished.
To prevent failure of the tail rotor (TIR) drive shaft system and subsequent loss of nR
control, accomplish the following:
Within 100 hours time in service after the effective date of this AD, install aft
(a)
with
coupling failsafe device (P/Ns 369025530 bolt and 369025531 socket) in accordance
Part I of the applicable Service Information Notices (SIN) DN-143, HN-206, or EN-31, each
dated August 26, 1 986. Installation of the failsafe device on military Models YOH-GA orOH-GA
helicopters in civil use shall be accomplished in accordance with Part I of SIN HN-206. ~S1LEr
The failsafe device required by paragraph (a) will be installed before delivery on all applicable
Model 369E helicopters, Serial Number 0135E, and subsequent.
(b) Within 100 hours time in service aftertHe effective date of this AD, install forward
with
coupling failsafe device (PINs 369025530 bolt and 369025531 socket) in accordance
Part I of SIN DN-95, dated August 7, 1981, or Part ill, HN-173, dated November 2, 1981, as
applicabie. Installation of the coupling failsafe device on military Models YOH-GA or OH-6A
helicopters shall be accomplished in accordance with Part III of SIR HN-173.
For all helicopters with tail rotor driveshaft flexible coupling failsafe devices
(c)
installed, the nR drive shaft forward and aff flexible couplings shall be checked as follows:
(At Each Prefliaht Check: Check for TIR backlash or looseness by rocking
the nR back and forth in its plane of rotation. The blade should not move in excess of 0.75
inch (1.93cm) at the blade tip without rotation of the main rotor blades.
(2) At Each Aircraft/Engine Shutdown: if thumping or rapping is heard from

the nR drive trainduring final revolutions of the nR, check the nR to assure that the T/R
blade does not move in excess of 0.75 inch (1.93cm) at the blade tip without rotation of main
rotor blades.
The checks required by this AD may be performed by the pilot and must be
(d)
recorded in accordance with FAR Section 91.173.

(e) required by paragraph (c), the tail rotor blade tip movement
If during the checks
either or
exceeds the specified limits, prior to further flight, inspect and replace, as necessary,
both fore and aft tail rotor drive shaft couplings.
(f)Rotorcraft may be ferried in accordance with the provisions of FAR Sections

and
21.197 and 21.199 to a base where the modifications and inspections of paragraphs (a)
(b) of this AD can be accomplished.
An alternate method of compliance which provides an equivalent

level of safety
(g~
Western Aircraft Certification Office, P.O. sox 92007,
may be approved by the Manager,
Worldway Postal Center, Los Angeles, California 90009-2007.
be done in accordance with applicable parts of MDHC SINs DN-

The procedure shall
dated August 7, 1981;
143, HN-206, EN-31, all dated August 26, 1986; MDHC SIN DN-95,
reference was approved
MDHC SIN HN-173, dated November 2, 1981. The incorporation by
552(a) and 1 CFR
by the Director of the FEDERAL REGISTER in accordance with 5 U.S.C.
Part 51. Copies may be obtained from McDonnell Douglas Helicopter Company, Centinela
Avenue and Teal Street, Culver City, California 90230. These documents may be examined
at the Office of the Regional Counsel, Federal Aviation Administration, Southwest Region,
the Western
Room 158, Building 38, 4400 Blue Mound Road, Fort Worth, Texas 76101,
or the Office of
Aircraft Certification Office, 15000 Aviation Boulevard, Hawthome, California,
D.C.
the FEDERAL REGISTER, 1100 L Street, NW., Room 8401, Washington,
Amendment 39-4186 (46 FR 40868), AD 81-17-02, as

This amendment supersedes
amended by Amendment 39-4221 (46 FR 46566), AD 81-17-02R1.
This amendment becomes effective October 24, 1986.
MCDLINNELL DOUGIAS HELICOPT~ER COMPANY

87-1 8-1~ MCDONNELL DOUGLAS HELICOPTER COMPANY
Model 3690, E,
(MDHC) (Huahes Helicooters. Inc.): Amendment 39-5678. Applies to all
main transmission
F, and 65 helicopters, certificated in any category, equipped with MDHC
(P/N 369025100-BSC or- 501) which has tail rotor output drive pinion shaft (P/N 369D25125-
BSC or -11) installed.
Compliance is required as indicated, unless previously accomplished.
To prevent possible loss of tail rotor control, accomplish the following:
Within the next 25 hours time-in-service after the effective date of this AD,
(a)
the main transmission tail rotor
perform a one-time magnetic particle and visual inspection on
with the following
output drive pinion shaft (P/N 369025125-660 or -11) on helicopters
in paragraphs (c)
serialized main rotor transmission in accordance with procedures detailed
through (f) of this AD.
TRANSMISSION SERIAL NUMBER

1989
1992 and 1993
through 2000
1998
2002 through 2082
2084 and 2085
the
If the tail rotor output drive pinion shaft serial number is contained in the list below, remove
shaft from sen/ice prior to further flight.
TAIL ROTOR OUTPUT DRIVE

PINION SHAFT SERIAL NUMBERS
1474 through 1502
1504 through 1547
1549 through 1561
1563 and 1564
1566
Within the next 100 hours time-in-service after the effective date AD, of this
(b)
main transmission tail rotor
perform a one-time magnetic particle and visual inspection on the
with
output drive pinion shaft (P/N 369D25125-BSC or -11) on all affected helicopters
transmission serial numbers other than those listed above in accordance with procedures
detailed in paragraphs (c) through (f) of this AD.

(c) Verify that the tail rotor output drive pinion shaft has an undercut style fillet radius
as shown in Figure 1 of MDHC Mandatory SIN DN-147/EN-35/FN-24, dated April 23, 1987, or
FAA-approved equivalent. Remove parts which do not have the undercut from service prior
to further flight.
NOTE: output drive pinion shafts removed from service in accordance

Tail rotor
with paragraph (c) may be returned to MDHC for rework if a magnetic particle inspection of the
part does not show any crack indications.
(d) Performmagnetic particle inspection of the tail rotor output drive pinion shaft.
a
Remove parts which show indications of cracking found during magnetic particle inspection
from service prior to further flight.
(e) Inspect the tail rotor output drive pinion shafts for scratches, tooling marks,
corrosion, or other minor surface defects in the fillet radius or elsewhere on the shaft in
accordance with paragraphs c. (4), c. (5), and c. (6) of MDHC Mandatory SIN DN-1471EN-
35/FN-24, dated April 23, 1987. Prior to further flight, rework discrepant shafts that show no
indication of cracks in accordance with procedures stated in paragraph d. of M DHC Mandatory
SIN DN-147/EN-351FN-24, dated April 23, 1987.
(f) Special flight permits may be issued in accordance with FAR Sections 21.197
and 21.199 to ferry aircraft to a maintenance base in order to comply with the requirements of
this AD.
The procedure shall be done in accordance with MDHC SIN DN-147/EN-35/FN-24,

datedApril 23, 1987. This incorporation by reference was approved by the Director of-the
Federal Register in accordance with 5 U.S.C. 552 (a) (1),
Copies may be obtained from MDHC, 500 E. McDowell Road, Mesa, Arizona. Copies
Southwest Region, 4400 Blue
may be inspected at the Office of the Regional Counsel, FAA,
Mound Road, Fort Worth, Texas, or at the Office of the Federal Register, 1 100 L. Street, NW.,
Room 8401, Washington, D.C.
This amendment becomes effective September 1, 1987.
MCDaNNELL DOI/GLAS HELICOP~ER COMPANY

87-18-~2 Ri McDONNELL DOUGLAS HELICOPTER
COMPANY (MDHCI (Huahes Helicopter. Inc.~: Amendment 39-5700 by as amended

amendment 39-5800. Applies to all Model 3690, 369E, 369F, and 369FF helicopters,
certificated in any category, incorporating main rotor transmission output shaft assembly ring
gear carriers (P/N 369D25132-BSC or -5) in main transmission assemblies P/N 369D25100-
BSC, -501 or-503.
Compliance is required as indicated unless previously accomplished.
To prevent possible loss of power to the main rotor, accomplish the following:
(a) helicopters with metal particles found in the main transmission, excessive
For
noise or vibration experienced in the main transmission, or vibrations felt in the aircraft that
cannot be reduced or eliminated by ordinary main rotor blade tracking and balancing
procedures, accomplish the inspection of paragraph (d) ofthis AD prior to further flight afterthe
effective date of this AD and thereafter at intervals not to exceed 300 hours time in service from
the last inspection.
(b) helicopters that have main transmission assemblies installed with less than
For
200 hours time in service on the output shaft assembly ring gear carrier on the effective date
of this AD, accomplish the inspection of paragraph (d) of this AD prior to accumulating 300
hours time in service and thereafter at intervals not to exceed 300 hours time in service from
the last inspection.
For helicopters that have main transmission assemblies installed with more than
(c)
200 hours time in service output shaft assembly ring gear carrier on the effective date
on the
of this AD, accomplish the inspection of paragraph (d) of this AD within the next 100 hours time
in service after the effective date of this AD and, thereafter, at intervals not to exceed 300
hours time in service from the last inspection.
(d) Performdye penetrant and visual inspection on the affected ring gear carriers
a
in accordance with the procedures detailed in paragraphs a through g of the "Periodic Visual
Inspection" section of McDonnell Douglas Helicopter Company Mandatory Service Information
Notice (SIN) DN-148.1/EN-36. 1/FN-25. 1 dated October 30, 1987. Remove from service prior
to further flight:"
(1) OutPut shafts with any bulging or raised surface in the area being
inspected on the upper disc surface (see Figure 2 in referenced SIN).
(2) OutPut shafts with any crack indication in the area being inspected on the
lower and upper disc surfaces (see Figure 3 in referenced SIN).

(e) When the main rotor transmission output shaft assembly ring gear carrier P/N
369025132-3 is installed and the main transmission assembly is reidentified as PIN
369025100-505, repetitive inspections are no longer required.
(f) Alternative inspections, modifications, or other actions which provide an

equivalent level of safety may be used when approved by the Manager, Western Aircraft
Certification Office, Hawthorne, California.
(g) Special flight permits may be issued i n accordance with FAR section s 21 1 97 and
21.199 to ferry aircraft to a maintenance base in order to comply with the requirements of this
AD.
The procedure shall be done in accordance with MDHC Mandatory Service Information
Notice DN-148. 1lEN-36. 1/FN-25. 1, dated October 30, 1987. This incorporation by reference
was approved by the Director of the Federal Register in accordance
with 5 U.S.C. 552(a) and
1 CFR Part 51. Copies may be obtained from McDonnell Douglas Helicopter Company, 500
E. McDowell Road, Mesa, Arizona 85205. Copies may be inspected at the Office of the
Regional Counsel, FAA, Southwest Region, 4400 Blue Mound Road, Fort Worth, Texas, or at
the Office of the Federal Register, 1 100 L Street, NW., Room 8401, Washington, D.C.
This amendment 39-5800 amends Amendment 39-5700 (52 FR 33228; September 2,

1987), AD 87-18-12.
This amendment 39-5800 becomes effective January 15, 1988.
MCDONNELL DOI/GLAS HELICOP~ER COMPANY

88-47-09 R~ MCDONNELL DOUGLAS HELICOPTER
COMPANY (MDHC~ (HUGHES HELICOPTERS. INC.): Amendment 39-5964 as revised
by Amendment 39-6400. Docket No. 88dSW-24.
Applicability: Model 3690, E, F, and FFhelicopters, certificated in any category, which

have tail rotor transmission/tail boom extension mounting studs, Part Number (PIN)
MS51992A803-13 or -14, installed.
(a) To prevent failure of the tail rotor mounting studs (P/N

transmission
MS51992A803-13 or -14) on MDHC Model 369 D/E helicopters, accomplish the following:
Prior to further flight after the effective date of this AD, conduct an initial
inspection of the tail rotor transmission attachment to the tail boom casting for any indications
parts in accordance with MDHC Service Information Notice
of relative motion between the
(SIN) DN-1511EN-39/FN-28, Part I, paragraphs a, b, c, d, and e, dated October 10, 1987.
(2) Within the next 25 hours time in san/ice after the effective date of this
amended AD, and at intervals not to exceed 25 hours time in service from the last check,
conduct a check for security in accordance with MDHC SIN DN-151/EN-39/FN-28, Part II,
a, dated October 10, 1987. The checks required by this paragraph may
be
paragraph
performed by the pilot and must be recorded in accordance with FAR Section 43.9.
(3) If there are indications of relative motion between the tail rotor
transmission and the tail boom casting found by the inspection and check of paragraphs (a)(l
and (a)(2), prior to further flight, remove the tail rotortransmission and replace all four mounting
studs in accordance with MDHC SIN DN-1511EN-39/FN-28, Part III, paragraphs a thru j, dated
October 10, 1987.
(4) At intervals not to exceed 100 hours time in service from the last
inspection after the effective date of this AD, conduct repetitive inspections of the torque of
each mounting nut and reapply torque stripe paint in accordance with MDHC SIN DN-~ 51/EN-
39/FN-28, Part IV, paragraphs a and b, dated October 10, 1987.
(b) Toprevent failure of the tail boom extension mounting studs (PIN MS51992A803-
13 or -14) on MDHC Model 369 FIFF helicopters, accomplish the following:
(1) Prior to further flight after the effective date of this AD, conduct an initial
inspection casting for any indications

of the tail boom extension attachment to the tail boom
of relative motion between the parts in accordance with MDHC SIN DN-151/EN-391FN-28, Part
i, paragraphs a, b, c, d, and e, dated October 10, 1987.
(2) Within the next 25 hours time in service after the effective date of this
amended AD, and at intervals not to exceed 25 hours time in service from the last check,
conduct a check of the tail boom extension installation for security in accordance with MDHC

SIN DN-151/EN-39/FN-28, Part II,paragraph a, dated October 10, 1987. The checks required
bythis paragraph may be performed by the pilot and must be recorded in accordance with FAR
Section 43.9.
(3) If there are products between the
indications of relative motion of fretting
tail boom casting and the tail boom extension found by the above inspections or checks, prior
to further flight, remove tail boom extension and replace all four studs in accordance with
MDHC SIN DN-1511EN-391FN-28, Part III, paragraphs b thru j, dated October 10, 1987.
(4) At intervals not to exceed 100 hours time in service from the last
inspection after the effective date of this AD, conduct repetitive inspections of the torque of
each mounting nut and torque stripe paint in accordance with MDHC SIN DN-1SI/EN-
reapply
391FN-28, Part IV, paragraphs a and b, dated October 10, 1987.
(c) An alternate means of compliance which provides an equivalent level of safety

Aircraft Certification Office, P.O. Box
may be used when approved by the Manager, Western
92007, Worldway Postal Center, Los Angeles, CA 90009-2007.
In accordance with Sections 21.197 and 21.199, the helicopters may be flown
(d)
to a base where compliance may be accomplished.
These inspections and check procedures shall be done in accordance with MDHC
Mandatory SIN DN-151/EN-391FN-28, dated October 10, 1987. This incorporation by

reference was approved by the Director of the Federal Register in accordance with 5 U.S.C.
552(a) and 1 CFR Part 51. Copies may be obtained from MDHC Technical Publications,
Building 543/D214, McDonnell Douglas Helicopter Company, 5000 E. McDowell Road, Mesa,
Arizona 85205-9797, telephone (602) 891-6484. A copy may also be inspected at the Office
of the Assistant Chief Counsel, Federal Aviation Administration, 4400 Blue Mound Road,
Room 158, Building 38, Fort Worth, Texas, or at the Office of the Federal Register, 1100 L
Street NW, Room 8401, Washington, D.C.
This AD revises Amendment 39-5964 (53 FR 30023; August 10, 1988), AD 88-17-09,
which became effective on August 24, 1988.
This amendment (39-6400, AD 88-17-09 R1 becomes effective on December 26, 1 989.

CORRECTION
89-02-01 R1 C2 MCDONNELL DOUGLAS
HELICOPTER COMPANY (HUGHES HELICOPTERS. INC): Amendment 39-6051 as

revised by Amendment 39-6341. Docket No. 88-ASW-43.
Applicability: Model 3690, E, F, and FF helicopters, certificated in any category,

with main rotor hub retention straps having Part Number (P/N) 369D21210-BSC or -501
installed.
(a)Within the next 100 hours time in service and thereafter at intervals not to
exceed 100 hours time in service from the last inspection, conduct inspections of the main
rotor blade retention strap assemblies (P/N) 369D21210-BSC, or -501 in accordance with
paragraphs a, c, b, d, e, g, i, j, and I of Part I, Inspection Procedures, in McDonnell
Douglas Helicopter Company Service Information Notice (SIN) DN-154 (3690), EN-44
(369E) or FN-33 (369F and 369FF), dated January 15, 1988.
(b) If, as a result of an inspection in paragraph (a) above, two strap pack
laminates are determined to have failed in any one leg or tongue area of any strap
assembly (faiiure being defined in the applicable S1N under CAUTION following paragraph
e of Part IInspection Procedures), conduct the repetitive inspections of all strap packs
required in paragraph (a) above and thereafter at intervals not to exceed 25 hours time in
service.
(c) For Model 3690 hub assemblies (P/N 369021200) which were subject to
inspections under AD 77-15-09 R1 at intervals of 25 hours because of two strap pack
laminate failures, conduct the inspections required by this AD within 25 hours time in
service from the last inspection made in accordance with AD 77-15-09 R1, and thereafter
at intervals not to exceed 25 hours time in service.
(d) For Model 369D hub assemblies (P/N 369021200) which were subject to
inspections under AD 77-19-04 (retention straps with P/N 369021210-BSC) at intervals of
25 hours, conduct the inspections required by this AD within 25 hours time in service from
the last made in accordance with AD 77-19-04, and thereafter at intervals not to
inspection
exceed 25 hours time in service.
(e) For Model 3690 hub assemblies, P/N 369021200, which were subject to
inspections under AD 81-10-08 (retention straps with P/N 369021210-501, S/N 8531
through 9135) at intervals of 25 hours time in service, conduct the inspections required by
this AD within 25 hours time in service from the last inspection made in accordance with
AD 81-10-08, and thereafter at intervals not to exceed 25 hours time in service.
(f) Replace the hub assembly, P/N 369D21200, with a serviceable assembly
89-02-01 R1 C2
prior to further flight if, as a result of the inspection required by paragraph
(a), (b), (c), (d),
or (e) above, a strap pack, P/N 369021210-880 or -501, is rejected
(using the rejection
criteria in the applicable SIN under CAUTION
following paragraph e of Part I Inspection
Procedures).
(g) For strap packs which contain observed

damage but are not rejected by the
criteria of paragraph (f)
(1) Record in the maintenance record (Ref. Section

43.9) the locations of
observed cracks, fractures, or corrosion in each
strap laminate in a manner which
includes--
(i) Blade color;

(ii) Strap part numbers and serial number;
(iii) Laminate number (top being number
one);
(iv) Leg location (lead or lag); and
(v) Tongue location (The tongue location is
not the same as the outboard end).
NO~: Strap packs containing cracks in outboard end locations are rejected by the
criteria of
paragraph (f).
(2) Record for each strap pack
(i) The number of laminate failures;

(ii) The number of laminates cracked in the
same leg; and
(iii) The number of gaps.
Airworthiness Directive 89-02-01 superseded the

following:
AD 77-15-09, Amendment 39-2978 (42 FR
37806; July 25, 1977) as
amended by AD 77-15-09 R1, Amendment 39-3952
(45 FR 70848; October 27, 1980)
which was effective October 30, 1 980.
AD 77-19-04, Amendment 39-3039 FR (42 46923; September 19, 1977), as
amended by AD 77-19-04 R1, Amendment 39-3597 (44 FR 61936; October
29, 1979)
which was effective November 1, 1979.
AD 81-10-08, Amendment 39-4144
(46 FR 33225; June 29, 1981) which was
effective June 30, 1981, to all persons to those to whom it was made
except immediately
effective by priority letter AD 81-10-08 issued
May 5, 1981.
Amendment 39-6341 revises Amendment 39-6051
(54 FR 105; January 4,
1989), AD 89-02-01 ,which becomes effective on February 2, 1989.
Amendment 39-6341, AD 89-02-01 R1, became effective
on October 27,
1989.
A correction to reflect a change to paragraph (d) became effective on July 19,
1990.
89-02-01 R1 C2

This correction is issued to reflect ADs previously superseded by AD 89-02-
Ol,which were inadvertently omitted from AD 89-02-01 R1.
FOR FURTHER INFORMAIION CONTACT: Mr. Sol Davis, Aerospace Engineer,

Airframe Branch, ANM-123L, Northwest Mountain Region, Los Angeles Aircraft
Certification Office, 3229 E. Spring Street, Long Beach, California 90806-2425, telephone
(213) 988-5233.
89-02-01 R1 C2
(MDHCI: Amendment 39-6324. (Docket No. 89-ASW-32)
Applicability: Model 3690 and E helicopters, certificated in any category, with hubs of
four-bladed tail rotors, Part Number (P/N) 369021700-3 installed.
rotor hubs which could result in loss of

prevent fatigue failure of four-bladed tail
To
control of the helicopter, accomplish the following:
(a) Within 1 0 hours time in service after the effective date of this AD, remove each
installed on a
tail rotor hub, (P/N) 369021700-3, with serial numbers 196 through 251,
helicopter and visually inspect for electrical are burns and dye penetrant inspect for cracks.
result of this inspection, replace the hub with a
If arcing burns or cracks are observed as a
serviceable unit prior to further flight.
NOTE: McDonnell Douglas Helicopter Company Service Information Notices DN-160
and EN-50 pertain to this inspection.
(b) Within 100 hours time in service after the effective date of this AD, remove each
tail rotor hub, (PIN) 369021700-3, with serial numbers from 1 through 195, and visually inspect
for electrical are burns and penetrant inspect for cracks. If are burns or cracks are
dye
observed as a result of this inspection, replace the hub with a serviceable unit prior to further
flight.
(c) helicopter, visually inspect each four-bladed tail rotor hub,

Priorto installation in a
are burns
(P/N) 369D21700-3, serial numbers 1 through 251, in spares inventory for electrical
of this
and dye penetrant inspect for cracks. If are burns or cracks are observed as a result
inspection, reject the hub.
(d) inspections required by paragraphs (a) and (b) in

Enter the results of the above
the aircraft log and report cracks or are burns to the Los Angeles FAA Aircraft Certification
Office within 10 days of the inspection. Include in the report the helicopter model and
serial
total hours of
number, hub part number, hub serial number, vendor identification (if possible),
service for the hub, the location of any cracks and are burns, and the geographical location
(city, state) of the helicopter at the time of inspection.
(e) inspections of paragraph (c) on hub spares, when are

Report the results of the
burns or cracks are found, to the Los Angeles FAA Aircraft Certification Office within 10 days
of the inspection. Include the date of the inspection, hub part number, hub serial number,

vendor identification (if possible), total hours in service (if previously used, or zero hours if
new), the location of are burns andlor cracks, and the geographical location of the inspection.
NOTE: All new hubs (zero service life) which are rejected should be returned to MDHC
for further inspection and evaluation.
(f) The reporting requirements of this regulation have been approved by the Office
of Management and Budget under OMB No. 2120-0056.
(g) In accordance with FARSections 21.1 97 and 21 .199, the helicopter may be flown
to a base where compliance with the AD may be accomplished.
(h) An alternate method of compliance with this AD which provides an equivalent

level of safety may be used if approved by the Manager, Los Angeles Aircraft Certification
Office, FAA, 3229 E. Spring Street, Long Beach, California.
ihis amendment (39-6324, AD 89-20-02) becomes effective on October 16, 1989.
MCDONNELL DOL/GLAS HELICOP~ER COMPANY

(MDHC~: Amendment 39-6392. Docket No. 89-ASW-26.
Applicability: Model 369 series

helicopters, certificated in any category, with main rotor
collective tube, P/N 369A7009-BSC; longitudinal control tube, P/N 369A7011-BSC; lateral
control tube, P/N 369A7012-BSC; and tail rotor control tube, P/N 369A7007-BSC.
prevent fatigue failure of the control tubes which could result

To in loss of control of the
helicopter, accomplish the following:
(a) Within 25 hours time in service after the effective date of this AD, and at intervals
of 1 00 hours time in service until the
requirements of paragraph (c) are accomplished, remove
and inspect for cracks the swaged ends of each main rotor collective control tube (P/N
369A7009-BSC), longitudinal control tube (PIN 369A7011-BSC), lateral control tube
(P/N 369A7012-BSC), and each tail rotor control tube (PIN 369A7007-BSC) installed on a
helicopter. If external cracks are observed as a result of this inspection, replace the control
tube with a serviceable unit prior to further flight.
NOTE: PART I of MDHC Service Information Notice DN-~ 58. EN-48. 1, FN-36. 1, and
HN-217.1 pertains to this AD.
(b) Prior to installation,

inspect for cracks the swaged ends of each main rotor
collective control tube (PIN 369A7009-BSC), longitudinal control tube (PIN 369A7011-BSC),
lateral control tu be (PIN 369A70 4 2-BSC), and tail rotor control tube (P/N 369A7007-BSC) from
spares inventory. Reject control tubes found to be cracked as a result of this inspection.
(c) Within 600 hours time in service after the effective date of this AD remove and
inspect each main rotor collective control tube (P/N 369A7009-BSC), longitudinal control tube
(P/N 369A701 1-BSC), lateral control tube (P/N 369A7012-BSC), and tail rotor control tube (P/N
369A7007-BSC) in accordance with the requirements of paragraph (a). Replace cracked tubes
with BASIC (BSC) part numbers with the corresponding FAA-approved -5 configuration.
Modify remaining BASIC (BSC) tubes to the corresponding FAA-approved -5 configuration

before reinstallation.
NOTE: PART II of MDHC Service Information Notice DN-158, EN-48, FN-36 or HN-21 7
pertains to rework and reinstallation procedures.
(d) In accordance with FARSections 21.1 97 and 21.1 99, the helicopter may be flown
MCDONNELL DOIIGLAS HELICOPT~ER COMPANY

(e) An alternate method of compliance with this AD which provides an equivalent
level of safety may be used if approved by the Manager, Los Angeles Aircraft Certification
Office, FAA, 3229 E. Spring Street, Long Beach, California.
This amendment (39-6392, AD 89-23-14) becomes effective on December 4, 1989.

(MDHC): Amendment 39-6456. Docket No. 89-ASW-10.
Applicability: Model 369 series helicopters (including Models YOH-6A and OH-6A)
certificated in any category.
To prevent possible failure of the engine-to-transmission driveshaft coupling, which

could result in loss of control of the helicopter, accomplish the following:
(a) Within the next 25 hours time in service or within 120

days after the effective
date of the AD, whichever occurs first, inspect the couplings, MDHC Part Number (P/N)
369H5660, to determine serial numbers.
(b) Replace any couplings, PIN 369H5660, which have serial numbers in the range
from 5200 through 5309, with airworthy parts.
(c) Record compliance with paragraph (a) of this AD in the AD compliance record
and in the maintenance record of the helicopter log book. This record must include the serial
numbers of any deficient couplings found during compliance with this AD.
NOTE: MDHC Service Information Notices HN-216, DN-157, EN-47, FN-35, dated
April 5, 1989, pertain to this subject.
(d) In accordance with FAR Sections 21.197 and 2 1.199, flight is permitted to a base
where the requirements of this AD may be
accomplished.
(e) An alternate method of compliance or adjustment of the compliance time which
provides an equivalent level of safety, may be used if approved by the Manager, Los Angeles
Aircraft Certification Office, ANM-100L, FAA, 3229 East Spring Street, Long Beach, California
90806-2425.
NOTE: Unairworthy couplings removed from service and in spares inventory

should be marked unairworthy. Unairworthy couplings should be purged from spares inventory
in accordance with MDHC SIN HN-216, DN-157, EN-47, FN-35, dated April 5, 1989.
This amendment (39-6456, AD 90-01-08) becomes effective on February 5, 1990.
Mr.Roy McKinnon, Aerospace Engineer, ANM-143L, FAA, Northwest Mountain Region, Los
Angeles Aircraft Certification Office, 3229 East Spring Street, Long Beach, California
90806-2425; telephone (213) 988-5247.
MCDONNELL DOUGLAS HELICaPTER COMPANY

90-1 2-03 MCDONNELL DOUGLAS HELICOPTER COMPANY
(MDHC~: Amendment 39-6618. Docket No. 90-ASW-21.
Applicability: Model 369D, E, F, and FF helicopter, certificated in any category.
Compliance is required as indicated, unless already accomplished.
To prevent tail rotor malfunction, which could result in loss of control and possible loss
of the helicopter, accomplish the following:
(a) VVithin the next 10 hours time in service after the effective date of this AD, check
swashplate bearing assembly to determine the color (green, yellow, or black) of
the tail rotor
the bearing seal, P/N 369021832. The check required by this paragraph may be performed
by a pilot. The bearing seal can be observed by looking into the outboard end of the T/R
swashplate bearing assembly. If necessary, clean the face of the bearing seal so that the color
can be determined.
NOTE: Part I of MDHC Service Information Notice DN-167, EN-58, and FN-46
pertains to this one-time check.
(b) If thebearings have green or yellow seals, record the seal color in the logbook
together with the record of compliance with this AD, and no further action is required.
(c) Forbearings with black seals which have a serial number in the range of
059150-0001 through 059150-0692, or 059150-0734 through 059150-0742, or which have
unidentified serial numbers, conduct the following inspections within the next 10 hours time
in service, and thereafter at intervals not to exceed 10 hours time in service from the last
inspection until the bearing is replaced:
(1) Disconnect the outboard end of the bellcrank.

(2) Disconnect the dust boot from the inboard end of the pitch assembly. This
will allow rotation of the tail rotor swashplate housing.
(3) While applying a down load on top of the housing by hand, slowly rotate
the pitch control housing to verify smoothness ofoperation. The bearing must rotate smoothly
and without roughness to be acceptable. A slight feeling of grit in the grease, with smooth
areas in between, is considered acceptable for an additional 10 hours time in service. If the
gritty feeling is continuous, replace the bearings.

(4) If the roughness is beyond that allowed in paragraph (c)(3) or if the gritty
feeling is continuous, replace the tail rotor swashplate bearing with an airworthy bearing before
further flight.
(5) Install and lockwire the dust boot on the inboard end of the pitch control
housing.
MCDCNNELL DOUGLAS HELICOP~ER COMPANY

(6) Service the tail rotor swashplate pivot bearing assembly with an
acceptable grease as specified in the Handbook of Maintenance Instructions.

(7) Reconnect the bellcrank to the outboard end of the pitch control assembly
as specified in the Handbook of Maintenance Instructions.
(8) If an acceptable black seal bearing (i.e., a bearing having a serial number
exclusive of the specified unacceptable ranges) is installed or has been installed as a
replacement, apply a white paint dot on the outside face of the housing and record this action
in the helicopter log book.
(9) Record compliance in the helicopter log book, together with the serial
number of the newly installed bearing.
NOTE: Part II of MDHC Service Information Notice DN-167, En-58, and FN-46
pertains to this inspection procedure.
Replace any bearings with black seals which have any serial number in the range
(d)
of 059150-0001 through 059150-0692 or 0591 50-0734 through 059150-0742, or which have
unidentified serial numbers as follows:
bearings which have 290 or more hours time

For in service on the
effective date of this AD, replace the beanng with an airworthy part within the next 10 hours
time in service.
(2) For bearings which have less than 290 hours time in service on the
effective date of this AD, replace the bearing with an airworthy part before the accumulation
of 300 hours time in service.
(e) Prior to the installation of new or replacement bearing sets, P/N 369D21832;
pitch control assemblies, P/N 369021800 or 369021820 series; or tail rotor assemblies, P/N
369D21600 or swashplate bearing seal and
369021610 series, determine the color of the
record in the logbook. If a bearing set has a black seal, install only parts that are verified to
have serial numbers other than those listed in paragraph (c).
(f) In accordance with FAR Sections 21 1 97 and 21 1 99, the helicopter may be flown
to a base where compliance with this AD may be accomplished.
(g) An alternate method of compliance or adjustment of the compliance time which
provides an equivalent level of safety may be used if approved by the Manager, Los Angeles
Aircraft Certification Office, FAA, 3229 E. Spring Street, Long Beach, California.
This amendment (39-6618, AD 90-12-03) becomes effective on June 22, 1990.
FOR FURTHER INFORMATION CONTACT: Mr. Sol Davis, FAA, Los Angeles Aircraft
Certification Office, 3229 E. Spring Street, Long Beach, California 90806-2425;
telephone (213) 988-5233.

90-~ 9-02 McDONNELL DOUGI~AS HELICOPTER COMPANY
(MDHC~: Amendment 39-6718. Docket No. 89ASW-Q4.
that
Appiicability: All Model 369 series helicopters, certified in all categories, are
equipped with a cargo hook. Compliance: Required as indicated, unless already

accomplished.
To prevent an overrunning clutch assembly failure, which may result in the loss of
engine power to the main rotor, accomplish the following:
(a) Within the next 300 hours time in service after the effective date of this AD or at
the next annual inspection, whichever occurs first, accomplish the following:
(1) Remove overrunning clutch assembly, part number (P/N) 369A5350-BSC,

-601, or -603, if installed.
~2) Install the overrunning clutch subassembly, P/N 369A5350-41, in the
clutch assembly, PIN 369A5350-BSC, -601, or -603, whichever is installed, or replace clutch
assemblies with P/N 369A5350-605.
NOTE: Clutch subassembly, PIN 369A5350-31, can be converted to PIN
369A5350-41, in accordance with MDHC Service Information Notice (SIN) No. DN-164,
EN-54, and FN-44, dated October 27, 1989. Clutch assemblies, P/N 369A5350-BSC, -601,
or -603, can be reidentified as a -605 clutch assembly after installation of clutch subassembly,
PIN 369A5350-41.
inspect
(b) the assembly, PIN369A5350-605 or PIN
overrunning clutch
369A5350-BSC, -601, or -603 with PIN 369A5350-41 subassembly, at intervals not to exceed
300 hours time in service or at annual inspections, whichever occurs first, for condition of the
race inner clutch, PIN 369A5353-3, the race outer clutch, P/N 369A5352,
and the sprag
assembly, P/N 369025351.
Replace sprag assemblies, PIN 369025351 and P/N 369A5364, with an

(c)
airworthy part on or before attaining 1,800 hours total time in service.
NOTE: The Manufacturers Handbook of Maintenance Instruction and the

Component Overhaul Manual pertain to the removal, identification, and installation of these
assemblies.
(d) Special flight permits may be issued in accordance with FAR Sections 21.197
and 21.1 99 to operate helicopters to a base for the accomplishment of inspections required by
this AD.
MCDONNELL DOUGL9S COMPANY

(e) Alternative inspections, modifications, or other actions which provide an
equivalent level of safety may be used when approved by the Manager, Los Angeles Aircraft
Certification Office, ANM-100L, FAA, Northwest Mountain Region, 3229 East Spring Street,
Long Beach, California 90806-2425.
(f) For the purpose of establishing the "time in service" specified in this AD, either
the clutch total time with hook attached may be used, or a separate and permanent log of
external loadoperating time (take-off to landing on a flight which involves external load
operations) may be used; this log must meet the requirements of FAR Section 91.173.
Airworthiness Directive 90-19-02 supersedes AD 81-07-10, Amendment 39-4077, as
revised by Amendment 39-4266.
This amendment (39-6716, AD 90-19-02) becomes effective on October 5, 1990.
Mr. Roy McKinnon, AN M-143L, Northwest Mountain Region, Los Angeles Aircraft Certification
Office, 3229 East Spring Street, Long Beach, California 90806-2425; telephone (213) 988-
5247.
MCDONNELL DOUGLAS NELICOPTER COMPANY

(MDHC):
Amendment 39-6784. Docket Number 90-ASW-10.
Appiicability: All MDHC Model 3690, 369E, and 369F/FF series helicopters certificated
in any category.
Compliance: Required as indicated, unless previously accomplished.
To prevent possible failure of the main rotor transmission drive assembly, which could
result in loss of control of the helicopter, accomplish the following:
(a) Within the next 300 hours time in service after the effective date of the AD or at
the next annual inspection orthe next time the transmission is removed, whichever occurs first,
after the main rotor transmission is removed inspect the MS21250-04036 bolts which retain
the debris cover, P/N 369025174. Remove any bolts with the head inscription shown as
unacceptable in Figure i, and replace with MS21250-04038 bolts, which have a length of
2.887 plus/minus 0.010 inch.
NOTE: MDHC Service Information Notice (SIN) DN-166.1, EN-57. 1, and SIN FN-45. 1,
dated March 14, 1990, or later revisions pertain to this subject.
(b) Inspect the thread protrusion of all bolts. Remove any bolt which does not
inch
protrude through the H14-4 nut for a length equivalent to two full threads (0.071
minimum), including the chamfer. Replace removed bolts with MS21250-04038 bolts. Torque
the bolts to 50-70 inch pounds. Verify that the bolts protrude through the nut for a length
equivalent to two full threads (0.071 inch minimumj, including the chamfer. If more than four
threads protrude through the nut, add AN960C416t or AN960C416 washers under the nut as
required. Remove and reinstall parts in accordance with the manufacturers instructions.
white dot to the main transmission data plate to indicate that the
(c) Apply a
transmission has been inspected and reworked in accordance with the manufacturers
instructions, and record compliance with this AD in the rotorcraft log book.
(d) In accordance with FAR Sections 21.1 97 and 2 1 1 99, flight is permitted to a base
where the requirements of this AD may be accomplished.
(e) An alternate method of compliance or adjustment of the compliance time which
provides an equivalent level of safety, may be used when approved by the Manager, Los
Angeles Aircraft Certification Office, ANM-100L, FAA, Northwest Mountain Region, 3229 East
Spring Street, Long Beach, California 90806-2425.
MCDONNELL DOL/GLAS HELICOPT~ER COMPANY

This amendment (396784, AD 90-24-07) becomes effective on December 10, 1990.
FOR FVRTHER INFORMATION CONTACT:
Mr. Roy McKinnon, Aerospace Engineer, ANM-143L, Northwest Mountain Region, Los
Angeles Aircraft Certification Office, 3229 East Spring Street, Long Beach, California 90806-
2425, telephone (213) 988-8247.
ACCEPTABLE
UNACCEPTABLE
Figurel. InspeRionlDsfinition of 8011 Heads.
MCDONNELL WUGIAS HELICOPTER COMPANY

91-08-02 mllONNELLOOUGL15HELiCOPTER
COMPANY (MDHC) (HUGHES): Amendment 39~963. Docket No. 90-ASW-53.
Applicability: All MDHC Model 369 series helicopters, certificated in any category.
To detect prevent cracks in the tail rotor blade root fitting, which could result in tail
or
rotor blade failure and subsequent loss of the tail rotor blade, accomplish the following:
(a) Within 8 hours time in service after the effective date of this AD, or upon
installing replacement tail rotor blades, determine if any aluminum tail rotor blades are installed
which--
(1) Have any of the following part numbers (P/Ns) and serial numbers (S/Ns):
(i) P/N 369A1613 tall dash numbers) with S/N less than 7959,
(ii) P/N 369021613 tall dash numbers) with S/N less than 6482,
(iii) P/N 369021615 tall dash numbers) with S/N less than 1358,
(iv) P/N 369021606 tall dash numbers) with S/N less than 0538,
(v) P/N 421-088 tall dash numbers) with S/N less than 0218; and
(2) Do not have a yellow dot applied to the aft (trailing) edge of the root fitting.
(b) Record the tail rotor blade P/Ns and S-Ns from the determinations of paragraph
(a) in the aircraft log.
NOTE: Only tail rotor blades which meet the criteria of paragraphs (a)(l) and
(a)(2) are affected by the remaining inspections of this AD.
(c) Within 8 hours time in service, after the effective date of this AD and, thereafter,
prior to the first flight of each day, conduct a check of each tail rotor blade that fits the criteria
outlined in paragraph (a). Visually check both sides of the tail rotor fitting for cracks in the area
shown in Figure 1, Detail A. Replace any cracked blades with airworthy parts before further
flight.

(d) Within 100 hours time in service, after the effective date of this AD unless
previously accomplished, for the blades that fit the criteria outlined in paragraph (a),
accomplish the following checks and inspections:
(1) Conduct a visual check for cracks in accordance with the instructions of
paragraph (c).
(2) Conduct a dimensional inspection of the tail rotor blade fitting as follows:
(i) blades, crush washers, and bushings so they

Mark the tail rotor can be
reinstalled in the exact location and orientation from which they are removed.
(ii) Remove the tail rotor blades in accordance with the applicable maintenance
manual.
NOTE: CAUTION: Do not remove the feathering bearings.
(iii) With HS610C6244R375X375 bushing (Qty. 1) (369A1624-BSC root fitting) or

369H5308 bushings (Qty. 2) and 369H5309 crush washers (369A1624-3 root fitting~ installed,
ensure there are no foreign objects inside the bore of the tail rotor blade root fitting. With root
fitting vertical, inboard end up, insert the 369D21633-1-40201 Part 1 inspection tool into the
inner diameter (I.D.) of the root fitting. Align root fitting strap retention holes with tool hole. (See
Figure 1, Detail B.) Attempt to install the retention bolt through the root fitting and tool holes.
The tail rotor blade is airworthy if the tail rotor blade retention bolt cannot be inserted through
the root fitting and inspection tool (Part 1) holes.
(iv) With HS610C6244R375X375 bushing (Qty. 1) (369A1624-BSC root fitting) or

369H5308 bushings (Qty. 2) and 369H5309 crush washers (369A1624-3 root fitting) installed,
position the 369021633-1-40201 Part 2 inspection tool (tab end outboard) over one side of the
root fitting. Align the holes in the inspection tool with the blade attach holes in the root fitting.
For the 369A1624-BSC root fitting, use washers on each side of the root fitting (equal
amounts) to center the inspection tool on the root fitting (See Figure 1, Detail C). Attempt to
install the retention bolt through the tool and the root fitting. Do not attempt to bend or force the
inspection tool to install the retention bolt. The tail rotor blade is airworthy when the tail rotor
blade attachment bolt cannot be inserted through the root fitting holes and both sides of the
inspection tool (Part 2).
(v) Repeat step (iv) with the inspection tool positioned on the opposite side of the
blade.
(vi) Replace unairworthy blades with ainnrorthy blades. Replacement blades must
comply with this AD.
(vii) Install tail rotor blades, crush washers and bushings in the exact location and
orientation from which they were removed to ensure proper blade attachment.
91-08-02
(viii) Apply a yellow dot to airworthy tail rotor blades on the trailing edge of the root
fitting approximately one-half inch outboard from the bushing. (See Figure 1, Detail A.) Record
compliance by part number and serial number in the helicopter log book.
(ix) Install airworthy tail rotor blades in accordance with the applicable maintenance
manual.
(x) Verify that the tail rotor assembly is correctly balanced in accordance with the
applicable maintenance manual.
NOTE: MDHC SIN Nos. HN-230.1, DN-~77.1, EN-68.1, and FN-55.1, dated
March 1, 1991, pertain to these inspections. A copy of the service bulletins may be obtained
from MDHC Technical Publications, Building 543/D214, McDonnell Douglas Helicopter
Company, 5000 E. McDonnell Road, Mesa, Arizona 85205-9797, telephone (602) 891-6342.
The MDHC local field service representative or the field service department has inspection
tools available for loan and requests that unairworthy tail rotor blades be removed from service
and returned to the MDHC Warranty and Repair Department.
(e) 21.199, the helicopter maybe flown

In accordance with FAR sections 21.197 and
(f) The checks of this AD may be accomplished by a trained pilot.
(g) An alternate method of compliance or adjustment of the compliance times, which

provides an equivalent level of safety, may be approved by the Manager, Los Angeles Aircraft
Certification Office, FAA, 3229 E. Spring Street, Long Beach, California.
This Amendment (39-6963, 91-08-02) becomes effective on May 3, 1991.
Mr. Sol Davis, Ai3rospace Engineer, Airframe Branch, ANM-123L, Northwest Mountain Region,
Los Angeles Aircraft Certification Office, 3229 E. Spring Street, Long Beach, California
90806-2425; telephone (213) 988-5233.
91 68-02
of Tail Rotor Blade Root
Figure 1 Inspection
Fitting.
SPECIFIC AREAS 180111 SIDES1 SHOWN CUTAWAY

CRACKS MIGHT INITIATE i
FOR CLARITY
AFTER INSPECTION
PE4 Crb
APPLY A YNOE: D0T
ct TO ACCEPTABLE BLADES
TAB ENO
r RETENTION BOLT
OF TOOL
GENERAL AREA 10 BE
INSPECTED FOR CRACKS
(BOTH SIDES. BOTH BUOES)
DETAIL C
~690t163f1-40a31 PART Z INSFECTIONIOOL

f (INSPECT BOTH SIDES. EACH 8UDO
(SLE NOTE LI
DETAIL A
I, 1
-----J
30902163?-1-a3701 PART 1
RETENTION 801:
INSPEtTIDNfO(jC
BUSHING
SHOWN tUfXWAY
fOR CLARITY
Haril
IOR Ibin Ib2d~SSC ROOT FlfTINC O
ISINCLE BUSHING ON OM SIDf)
UTE ;vASnERS ON EACH SIDE OF
ROOT FlnlHC TO CENTER ~r INSPECTION
TOOC PN 1)4 FITTIHC (I- .W INCH).
DETAIL B
COMPANY
91-0802
MCDONNELL DOUGLAS HELICOPTER
t~
93 -0711 O MCOONNELL OoUGLPIS HELICOPTER
COMPANY AND HUGHES HELICOPTERS, INC.: Amendment 39-8542. Docket

Number 92-ASW-42.
Applicability: Model 369D, 369E, 369F, 369HE and 369HS series helicopters,
equipped with Gajon Associates, LTD. ~Viking Helicopters Limited) Supplemental Type
Certificate (STC) No. SH1134EA external cargo container kit (baggage pod), with or
without the auxiliary fuel system, certificated in any category.
Compliance: Required within 10 days or 25 hours time-in-service, whichever

occurs first, after the effective date of this AD, unless accomplished previously.
Toprevent hazardous yaw oscillations during descents, which could result in

loss of control of the helicopter, accomplish the following:
(a) Install a durable placard on the instrument panel as close as is practical to
the airspeed indicator and that is legible to the pilot that reads:
BAGGAGE POD INSTALLED
-90 KlAS IN POWERED DESCENT (r1000 fpm) OR IN AUTOROTATION

V,,
following statement into
Insert the the Operating Limitations Section of the
(b)
flight manual supplement for the baggage pod:
AIRSPEED LIMITS
V,, is 90 KIAS in moderate rates of powered descent (greater than 1,000 fpm)
or in autorotation with baggage pod installed.
(c) Insert the following statement into the Emergency and Malfunction
Procedures Section of the flight manual supplement for the baggage pod:
ENGINE FAILURE AT HIGH CRUISE SPEED
NOTE: speeds in excess of 90 KIAS in stabilized moderate descents

At
(greater than 1,000 fpm) or in autorotation, the lateral directional handling of the
helicopter is degraded. Yaw oscillation may occur and persist, and there is a tendency
for the pilot to overcontrol.
(1) Adjust collective pitch according to altitude and airspeed to
maintain rotor speed between 410 and 508 RPM.
(2) Apply pedal pressure as necessary to control aircraft yaw.

(3)Adjust cyclic controlnecessary to reduce airspeed to 90 K1AS
as or
less as collective is lowered and stabilized autorotation is achieved.
NOTE: See basic rotorcraft flight manual for recommended minimum rate
of descent and maximum glide distance power-off speeds.
(d) Compliance with Paragraphs (b) and (c) above may be accomplished by
attaching a copy of the appropriate AD paragraphs to the Operating Limitations Section
and Emergency Procedure Section of the flight manual supplement.
(e) An alternative method of compliance or adjustment of the compliance

time, which provides an the
acceptable level of safety, may be used when approved by
Manager, New York Aircraft Certification Office, FAA, 181 South Franklin Avenue, room
202, Valley Stream, New York. Operators shall submit their requests through an FAA
Principal Maintenance Inspector, who may concur or comment and then send it to the
Manager, New York Aircraft Certification Office.
NOTE: Information concerning the existence of approved alternative

methods of compliance with this AD, if any, may be obtained from the Manager, New
York Aircraft Certification Office.
(f) Special flight permits may be issued in accordance with FAR 21.197 and
21.199 to operate the helicopter to a location where the requirements of this AD can
be accomplished.
(g) This amendment becomes effective on July 6, 1993.

Mr. Sol Maroof, Aerospace Engineer, ANE-172, FAA, New York Aircraft Certification
Office, 181 South Franklin Avenue, room 202, Valley Stream, New York, telephone
(516) 791-6220.
93-07-10
93-18-05 .CDON..LLOOUGLI\S IICLICOPTER
COMPANY AND HUGHES HELICOPTERS, INC.: Amendment 39-8690. Docket

Number 92-ASW-33.
Applicability: Model 369D, 369E (Serial No. 0001E thru 0508E), 369F (Serial
No. 0003 thru 0091), 369FF (Serial No. 0003 thru 0091), and 369H series helicopters,
equipped with fuel vent line emergency shutoff valve assemblies, part number (P/N)
369H8108, 369H8108-501 or 369H8108-503, certificated in any category.
Compliance: Helicopters with less than 2,400 hours time-in-service on the

effective date of this AD shall be inspected on or before attaining 2,500 hours
time-in-service, and thereafter, at an interval not to exceed 100 hours time-in-service
from the last inspection an improved fuel vent line emergency shutoff valve
until
assembly (assembly) is installed in accordance with paragraph (d) of this AD.
Helicopters with 2,400 hours or more time-in-service on the effective date of this AD
shall be inspected in accordance with this AD within the next 100 hours time-in-sen/ice,
and thereafter, at an interval not to exceed 100 hours time-in-service from the last
inspection until an improved assembly is installed in accordance with paragraph (d) of
this AD.
To prevent erroneously high inflight fuel quantity indications due to a blocked fuel
vent line in the assembly, accomplish the following:
(a) Remove the assembly from the helicopter as required by the appropriate
Model 369 maintenance manual.
(b) Inspectthe fuel vent line emergency shutoff valve (valve) in accordance
with Part I, Fuel ~ent Line Emergency Shutoff Valve Inspection, of McDonnell Douglas
Helicopter Company Service Information Notice HN-234, DN-181, EN-73, FN-60, dated
January 17, 1992.
(c) If the inspections conducted in accordance with the requirements of

paragraph (b) uncover an incorrectly closed or obstructed valve, before further flight
install an airworthy assembly in accordance with the appropriate Model 369
maintenance manual.
(d) Install assembly, P/N 369H8108-505 or higher dash number, as follows,

unless already accomplished:
(1) For helicopters with 2,400 hours or more time-in-service on the

effective date of this AD, install the assembly on or before attaining the next 600 hours
time-in-service.

(2) For helicopters with less than 2,400 hours time-in-service on the
effective date of this AD, install the assembly before attaining 3,000 hours time-in-
service.
(e) An alternative method of compliance or adjustment of the compliance

time, which provides an acceptable level of safety, may be used when approved by
the Manager, Propulsion Branch, Los Angeles Aircraft Certification Office, 3229 E.
Spring Street, Long Beach, California 90806-2425. Operators shall submit their
requests through an FAA Principal Maintenance Inspector, who may concur or
comment and then send it to the Manager, Propulsion Branch, Los Angeles Aircraft
Certification Office.
NOTE: Information concerning the existence of approved alternative

methods of compliance with this AD, if any, may be obtained from the Manager,
Propulsion Branch, Los Angeles Aircraft Certification Office.
(f) Special flight permits may be issued in accordance with FAR 21.197 and
21.199 to operate the helicopter to a location where the requirements of this AD can be
accomplished.
(g) The inspection shall be done in accordance with MDHC Service

Information Notice HN-234, DN-181, EN-73, FN-60, dated January 17, 1992. This
incorporation by reference was approved by the Director of the Federal Register in
accordance with 5 U.S.C. 552(a) and 1 CFR Part 51. Copies may be obtained from
McDonnell Douglas Helicopter Company, 5000 East McDowell Road, Mesa, Arizona
85205-9797, Attention: Field Service Department. Copies may be inspected at the FAA,
Office of the Assistant Chief Counsel, 4400 Blue Mound Road, bldg 3B, room 158, Fort
Worth, Texas; or at the Office of the Federal Register, 800 North Capitol Street, NW.,
suite 700, Washington, DC.
(h) This amendment becomes effective December 21, 1993.

Mr. Bruce Conze, Aerospace Engineer, Propulsion Branch, Los Angeles Aircraft
Certification Office, ANM-143L, FAA, Northwest Mountain Region, 3229 E. Spring
Street, Long Beach, California 90806-2425, telephone (310) 988-5261, fax (310) 988-
521 0.
93-1 8-05
94-1 8-08 MCDONNELL DOUGLAS HELICOPTER COMPANY
(MDHC) AND HUGHESHELICOPTERS, INC.: Amendment 39-9021. Docket Number

93-SW-03-AD. Supersedes Priority Letter AD 92-22-14, issued October 16, 1992, and AD
92-02-15, Amendment 39-8151.
Applicability: Model 369, 369A (OH-6A), 3690, E, F, FF, H, HE, HS, and HM series
helicopters, equipped with the following tail rotor blades with bonded tail rotor abrasion strips
(abrasion strips) installed, but without abrasion strip rivets (rivets) installed as described in
paragraph (c) of this AD: part numbers (P/N) 421-088; 369P11613-7, -503, -505; 359021606,
369021613-11, -31, -41, -51; 369021615, -21; 369A1613-3M; and any of these P/N with
or a
suffix (such as the letters "M" or "M-STC") added to the dash numbers, certificated in any
category.
Compliance: Required as indicated, unless accomplished previously.
To prevent the loss of abrasion strips, separation of the tail rotor, and subsequent loss
of control of the helicopter, accomplish the following:
(a) Before the first flight of each day, until two rivets are installed as required by
paragraph (c) of this AD, visually check each abrasion strip for any evidence of debonding
along the entire abrasion strip bond line. This visual check may be pe~ormed by the
owner/operator holding at least a private pilot certificate and must be entered into the aircraft
records showing compliance with this AD in accordance with sections 43.11 and 91.417
(a)(2)(v) of the Federal Aviation Regulations.
(b) performance of the visual check required by paragraph (a) results

If in
evidence of debonding, conduct the following inspections before further flight:
(1) Remove the tail rotor blade from the helicopter, and perform a dye-
penetrant and a tap-test inspection in accordance with the applicable helicopter maintenance
manual to ensure that the abrasion strip is secure.
NOTE: MDHC Service Information Notice HN-197.2, DN-130.2, EN-19.2, and

FN-17. 1, dated March 23, 1987, contains additional information on the inspections required
by paragraph (b).
(2) Ifdebonding is confirmed, remove the tail rotor blade from service and
replace it with an airworthy blade, which has been modified by the installation of rivets.
(c) Within 25 hours time-in-service or on or before 7 calendar days after the

effective date of this AD, whichever comes first:
MCDONNELL DOUGLAS HELICOPTER COMPANY (MDHC) AND HUGHES HELICOPTERS, INC.

Inspect the tail rotor blades in accordance with paragraph (b)(l) of this
(1)
AD, and if no evidence of debonding exists, install rivets in accordance with Part II of MDHC
Service Information Notice (SIN) HN-232, DN-179, EN-70 and FN-57, dated September 27,
1991.
(2) If evidence of debonding exists, remove the blade from service and
replace it with an airworthy blade, which has been modified by the installation of rivets, prior
to further flight.
(d) strip rivets in accordance with MDHC SIN HN-232,

Installation of the abrasion
DN-179, EN-70, and FN-57, dated September 27, 1991, constitutes a terminating action for
the requirements of this AD.
(e) An alternative method of compliance or adjustment of the compliance time that

provides an acceptable level of safety may be used when approved by the Manager, Los
Angeles Aircraft Certification Office, FAA, Northwest Mountain Region, 3229 E. Spring
Street, Long Beach, California 90806-2425. Operators shall submit their requests through an
FAA Principal Maintenance Inspector, who may concur or comment and then send it to the
Manager, Los Angeles Aircraft Certification Office.
NOTE: Information concerning the existence ofapproved alternative methods of
compliance with this AD, if any, may be obtained from the Manager, Los Angeles Aircraft
(9 Special flight permits may be issued in accordance with sections 21.197 and
21.199 of the Federal Aviation Regulations (14 CFR 21.1 97 and 21.199) to operate the
helicopter to a location where the requirements of this AD can be accomplished, provided
there is no evidence of debonding of the abrasion strip at any point along the entire abrasion
strip bond line of the tail rotor blades.
(9) inspection, removal, modification, and replacement, if necessary, shall be

The
done in accordance with McDonnell Douglas Helicopter Corporation (MDHC) SIN HN-232,
DN-179, EN-70, and FN-57, dated September 27, 1991. This incorporation by reference was
previously approved by the Director of the Federal Register in accordance with 5 U.S.C.
552(8) and 1 CFR Part 51. Copies may be obtained from MDHC Technical Publications,
Bldg. 530/B111, 5000 E. McDowell Road, Mesa, Arizona 85205-9797. Copies may be
inspected at the FAA, Office of the Assistant Chief Counsel, 2601 Meacham Boulevard,
Room 663, Fort Worth, Texas; or at the Office of the Federal Register, 800 North Capitol
Street, NW., suite 700, Washington, DC.
(h) This amendment becomes effective on September 27, 1994.
FOR FURTHER INFORMATION CONTACT: Mr. Brent Bandley, Aerospace Engineer,

Airframe Branch, ANM-123L, FAA, Northwest Mountain Region, Los Angeles Aircraft
(310) 988-5237, fax (310) 988-5210.
94-18-08
MCDONNELL DOUGLAS HELICOPTER COMPANY (MDHC) AND HUGHES HELICOPTERS, INC.
94-24-04 MCDONNELL DOUGLAS HELICOPTER SYSTEMS
(MDHS) AND HUGHES HELICOPTERS, INC. (HUGHES): Amendment 39-9077. Docket No.
94-SW-1 3-AD.
Applicability: Model 3690, E, F, and FF series helicopters with pitch control

assembly, part number (P/N) 369021800 or P/N 369D21820, installed, certificated in any
category.
To failure of the inner tang of the pitch control assembly iockwasher

prevent
(lockwasher), loss of the locknut, disengagement of the pitch control assembly, loss of tail
rotor control, and subsequent loss of control of the helicopter, accomplish the following:
(a) Within 25 hours time-in-service or 90 calendar days after the effective date of
this AD, whichever occurs first, remove the tail rotor (T/R) assembly and pitch control
assembly from the T/R gearbox in accordance with the applicable maintenance manual.
the lockwasher, P/N MS172209, for dents in either side of the inner
(b) Inspect
No.
tang inside radius as shown in Figure 1 of MDHS Service Information Notice (SIN)
DN-185, EN-78, and FN-64, dated September 23, 1994, using a 5x or higher magnifying
glass.
(c) Apply a 0.125 inch-wide torque stripe to the surface of the locknut and
swashplate in accordance with paragraph B and C of Part II of MDHS SIN No. DN-185, EN-78,
and FN-64, dated September 23, 1994, and reinstall the T/R assembly and pitch control
assembly into the T/R gearbox in accordance with the applicable maintenance manual.
(d) Inspect the torque stripe for slippage at intervals not to exceed 100 hours time-
In-service. If any slippage is detected, replace the lockwasher with an airworthy lockwasher in
accordance with the applicable maintenance manual. Reapply the 0.125 inch-wide torque
stripe to the surface of the locknut and swashplate.
(e) An alternative method of compliance or adjustment of the compliance time that

angeles Aircraft Certification Office, FAA. Operators shall submit their requests through an
NOTE: Information concerning the existence of approved alternative methods of

with this AD, if any, may be obtained from the Los Angeles Aircraft Certification
compliance
Office.
MCDONNELL DOUGLAS HELICOPTER SYSTEMS

(f) Special flight permits may be issued in accordance with sections 21.197 and
21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate the
helicopter to a location where the requirements of this AD can be accomplished.
(g) The inspections shall be done in accordance with McDonnell Douglas

Helicopter Systems Service Information Notice No. DN-185, EN-78, and FN-64, dated
September 23, 1994. This incorporation by reference was approved by the Director of the
Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR Part 51. Copies may be
obtained from McDonnell Douglas Helicopter Systems, Technical Publications, Bldg.
543/B111, 5000 E. McDowell Road, Mesa, Arizona 85205-9797. Copies may be inspected at
the FAA, Office of the Assistant Chief Counsel, 2601 Meacham Blvd., Room 663, Fort Worth,
Texas; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite 700,
Washington, DC.
(h) This amendment becomes effective on December 13, 1994.
FOR FURTHER INFORMATION CONTACT: Mr. Brent Bandley, Aerospace Engineer,

Airframe Branch, ANM-123L, Northwest Mountain Region, FAA, Los Angeles Aircraft
(310) 988-5237, fax (310) 988-5210.
94-24-04
95-03-1 1 .EOONNELLOOUGU5
HUGHES HELICOPTERS, INC.: Amendment 39-9147. Docket No. 94-SW-21-AD.
Applicability: Model 369, OH-6A, and YOH-6A series helicopters, with tail rotor blade
assemblies, part number (P/N) 369A1613-7, 369A1613-503, 369A1613-505, 369A1613-509,
369021606, 369021606-509, 369021613-11, 369D21613-31, 369021613-41, 369D21613-
51, 369D21613-71, 369021615, 369D21615-21, 369D21615-41, or 421-088, installed,
To prevent loss of the abrasion strip, separation of a tail rotor blade, separation of the
tail rotor gearbox, and subsequent loss of control of the helicopter, accompiishthe following:
(a) Within 25 hours time-in-service (TIS) or 90 calendar days, whichever occurs

first, and thereafter, at intervals not to exceed 100 hours TIS, inspect the tail rotor blade
abrasion strip for debonding from the tail rotor blade. Prior to conducting the repetitive
inspections, remove any abrasion tape from the tail rotor blade.
(1) inspection reveals debonding, replace the tail rotor blade with an
If the
airworthy blade that has been modified by an installation of rivets, and install 304 stainless
steel abrasion tape (.0027-inch thick) over the inboard end of the abrasion strip in
accordance with steps B through H of Part I of the Accomplishment Instructions of McDonnell
Douglas Helicopter Systems Service Information Notice (SIN) HN-238, DN-187, EN-80, FN-66,
dated October 26, 1994.
(2) If the inspection reveals no debonding, install 304 stainless steel

abrasion tape (.0027-inch thick) over the inboard end of the abrasion strip in accordance with
steps B through H of Part I of the Accomplishment Instructions of McDonnell Douglas
Helicopter Systems SIN HN-238, DN-187, EN-80, FN-66, dated October 26, 1994.
(b) Within 1,000 hours TIS after the effective date of this AD, replace the affected
tail rotor blades in shipsets with tail rotor blades that contain the new-design abrasion strips
in accordance with Part II of the Accomplishment Instructions of SIN HN-238, DN-187, EN-
80, r=N-66, dated October 26, 1994. Once the new-design abrasion strips are installed on the
tail rotor blades, the tail rotor assembly P/N changes as follows:
MCDONNELL DOUGLAS HELICOPTER SYSTEMS AND HUGHES HELICOPTERS, INC.

Old Tail Rotor Assembly Number New Tail Rotor Assembly Number
369A1613-7 369A1613-11
369A1613-503 369A1613-507
369A1613-505 369A1613-507
369A 1613-509 369A 1613-507
369021 606 369 021 606-51 1
369021 606-509 369021 606-511
369D21613-11 369021613-11N
369021613-31 36902161 3-31N
369021613-41 36902161 3-61
369021613-51 369021613-61
369021613-71 369021613-61
369021615 369021615-N
369021615-21 369021615-31
369021615-41 36902161 5-31
421-088 421-088-11
(c) Installation of tail rotor blades with new-design abrasion

strips installed in
accordance with Part II of the Accomplishment Instructions of SIN HN-238, DN-187, EN-80,
FN-66, dated October 26, 1994, constitutes a terminating action for the requirements of this
AD.
(d) An altemative method of compliance or adjustment of the compliance time that
Angeles Aircraft Certification Office, FAA. Operators shall submit their requests through an
NOTE: Information concerning the existence of approved alternative methods of

compliance with this AD, if any, may be obtained from the Los Angeles Aircraft Certification
Office.
(e) Special flight permits may be issued in accordance with sections 21.197 and
helicopter to a location where the requirements of this AD can be accomplished, provided
there is no evidence of debonding of the abrasion strip at any point along the entire abrasion
strip bond line of the tail rotor blades.
95-03-11
(f) The modification and replacement shall be done in accordance with McDonnell
Douglas Helicopter Systems Service Information Notice HN-238, DN-187, EN-80, FN-66,
dated October 26, 1994. This incorporation by reference was approved by the Director of the
Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR Part 51. Copies may be
obtained from McDonnell Douglas Helicopter Systems, Technical Publications, Bldg.
530/B111, 5000 E. McDowell Road, Mesa, Arizona 85205-9797. Copies may be inspected at
the FAA, Office of the Assistant Chief Counsel, 2601 Meacham Blvd., Room 663, Fort
Worth, Texas; or at the Office of the Federal Register, 800 North Capitol Street NW., suite
700, Washington, DC.
(g) This amendment becomes effective on March 1, 1995.

Mr. Brent Bandley, Aerospace Engineer, Los Angeles Aircraft Certification Office, FAA,
Transport Airplane Directorate, 3960 Paramount Blvd., Lakewood, California 90712,
telephone (310) 627-5237, fax (310) 627-5210.
95-03-11
95-03-1 3 MCOT~NELL OOUOL~S HEUCO~ER SYSTEMS *NO
HUGHES HELICOPTERS, INC.: Amendment 39-9149. Docket No. 94-SW-05-AD.

Supersedes AD 91-17-04, Amendment 39-3003.
Applicability: Model 369 and OH-6A series helicopters, with any of the following parts
installed: (1) Main rotor (M/R) blade assembly (blade assembly), part number (P/N)
369A1100-BSC, -501, -503, -505, -601, or -603; 369D21100-BSC, -503, -505, -507, -509,
_511, -513, or -515; 369021102-BSC or -501; or (2) M/R hub lead-lag link assembly (lead-lag
link assembly), P/N 369A1203-BSC, -3, or -11; 369H1203-BSC, -11, -21, or -31, certificated in
any category.
To prevent failure of a M/R blade assembly or a M/R hub lead-lag link assembly, loss
of a M/R blade, and subsequent loss of control of the helicopter, accomplish the following:
(a) Within 25 hours time-in-service (TIS) after the effective date of this AD, and
thereafter at intervals not to exceed 100 hours TIS from the last inspection, remove each
blade assembly from the helicopter and accomplish the following:
(1) Inspect the attachment lugs of the M/R blade root fittings (root fittings)
and the M/R lead-lag links (links) for cracks and the lug bushings (bushings) for looseness.
Conduct the inspections in accordance with paragraph (b) of Part I of McDonnell Douglas
Helicopter Company Service Information Notice HN-211.4, DN-51.6, EN-42.4, FN-31.4 (SIN),
dated January 27, 1993.
(2) Visually inspect the following for cracks--
(i) The root fittings around the blade attachment lugs; and,
(ii) The M/R blade doubler and blade skin adjacent to the root fittings.
(3) Mark the root fittings and bushings with slippage marks in accordance
with paragraph (e) of Part I of the SIN, dated January 27, 1993, if the slippage marks are
degraded or missing.
(4) Replace any M/R blades or links found to be cracked or to have loose
bushings with airworthy parts before further flight.
(b) Within 25 hours TIS after compliance with the requirements of paragraph (a) of
this AD, and thereafter at intervals not to exceed 25 hours TIS from the last inspection,
accomplish the following without removing the M/R blade:

(1) Visually inspect the fittings and links
root for cracks or loose bushings in
accordance with Part II of the SIN, dated January 27, 1993.
(2) Replace any M/R blades or links found to be cracked or to have loose
bushings with airworthy parts before further flight.
(c) An alternative method of compliance or adjustment of the compliance time that

Angeles Aircraft Certification Office, FAA. Operators shall submit their requests through an
NOTE: Information concerning the existence of

approved alternative methods of
compliance with this AD, if any, may be obtained from the Los Angeles Aircraft Certification
Office.
(d) Special flight permits may be issued in accordance with sections 21.197 and
helicopter to a location where the requirements of this AD can be accomplished.
(e) The
inspections and replacements, if necessary, shall be done in accordance
with McDonnell Douglas Helicopter Company Service Information Notice No. HN-211.4,
DN-51.6, EN-42.4, FN-31.4, dated January 27, 1993. This incorporation by reference was
approved by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and
1 CFR Part 51. Copies may be obtained from McDonnell Douglas Helicopter Systems,
Technical Publications, Bldg. 530/B111, 5000 E. McDowell Road, Mesa, Arizona 85205-
9797. Copies may be inspected at the FAA, Office of the Assistant Chief Counsel, 2601
Meacham Blvd., Room 663, Fort Worth, Texas; or at the Office of the Federal Register, 800
North Capitol Street, NW., suite 700, Washington, DC.
(f) This amendment becomes effective on March 21, 1995.

Mr. Brent Banbley,
Aerospace Engineer, FAA, Los Angeles Aircraft Certification Office,
Transport Airplane Directorate, 3960 Paramount Blvd., Lakewood, ~California 90712,
telephone (310) 627-5237, fax (310) 627-5210.
95-03-13
96-1 0-09 MCDONNELL DOUGLAS HELICOPTER
SYSTEMS: Amendment 39-9615. Docket No. 96-SW-02-AD.
Applicability: Model 369, 369A, 3690, 369E, 369F, 369FF, 369H, 369HE,
369HM, 369HS, and 500N helicopters, certificated in any category.
NOTE 1: This ADapplies to each helicopter identified in the preceding

applicability provision, regardless of whether it has been modified, altered, or repaired
in the area subject to the requirements of this AD. For helicopters that have been
modified, altered, or repaired so that the performance of the requirements of this AD is
affected, the owner/operator must use the authority provided in paragraph (c) to request
approval from the FAA. This approval may address either no action, if the current
configuration eliminates the unsafe condition, or different actions necessary to address
the unsafe condition described in this AD. Such a request should include an
assessment of the effect of the changed configuration on the unsafe condition
addressed by this AD. In no case does the presence of any modification, alteration, or
repair remove any helicopter from the applicability of this AD.
Toprevent failure of a main rotor blade (blade) resulting in separation of the

blade and subsequent loss of control of the helicopter, accomplish the following:
(a) Within 10 hours time-in-service (TIS) after the effective date of this AD,
perform a visual inspection of each blade root end for cracking and paint or sealant
cracking, paying particular attention to chordwise cracking, and for separation between
the lower surface root end fitting and doubler, in accordance with Part I of the
Accomplishment Instructions of McDonnell Douglas Helicopter Systems Service
Information Notice (SIN) HN-239, DN-188, EN-81, FN-67, and NN-008, dated October
27, 1995. If any blade crack is noted, before further flight, remove the blade and replace
it with an blade. If paint or sealant cracking or separation is noted, accomplish
the inspection in paragraph 3E of Part II of the Accomplishment Instructions of SIN HN-
239, DN-188, EN-81, FN-67, and NN-008, dated October 27, 1995, using a piece of
Mylar/viewfoil that is no thicker than .OOCinch and that is cut to a size between 0.9 inch
and 1.1 inches wide and between 3.9 inches and 4.1 inches long. If any corner of the
Mylar can be inserted between the lower surface root end fitting and doubler surface to
a depth of 0.1 inch or greater, remove the blade from service
and replace it with an
airworthy blade.

blades
(b) Thereafter, at intervals not to exceed 100 hours TIS, remove the
and inspect for cracking, paying particular attention to chordwise cracking, and
in accordance with
separation between the lower surface root end fitting and doubler
Part II of the Accomplishment Instructions of McDonnell Douglas Helicopter Systems
SIN HN-239, DN-188, EN-81, FN-67, and NN-008, dated October 27, 1995. If missing
or cracked adhesive or paint is detected at the
lower surface root end fitting to doubler
bonding line, accomplish the inspection in paragraph 3E of Part II of the

Accomplishment Instructions of SIN HN-239, DN-188, EN-81, FN-67, and NN-008,
than .OOCinch
dated October 27, 1995 using a piece of Mylar/viewfoil that is no thicker
that is cut to size between 0.9 inch and 1.1 inches wide and between 3.9 inches and
a
4.1 inches long. If any corner of the Mylar can be inserted between
the lower surface
root end doubler surface to a depth of 0.1 inch or greater, remove the blade
fitting8nd
from service and replace it with an airworthy blade.
(c) An alternative method of compliance or adjustment of the compliance time

the Manager,
that provides an acceptable level of safety may be used if approved by
their requests
Los Angeles Aircraft Certification Office, FAA. Operators shall submit
who comment and
through an FAA Principal Maintenance Inspector, may concur or
then send it to the Manager, Los Angeles Aircraft Certification Office.
NOTE 2: Information concerning the existence of approved alternative

methods of compliance with this AD, if any, may be obtained from the Los Angeles
Aircraft Certification Office.
(d) Special flight permits will not be issued.
(e) The inspections shall be done in accordance with McDonnell Douglas

EN-81, FN-67,
Helicopter Systems Service Information Notice (SIN) HN-239, DN-188,
and NN-008, dated October 27, 1995. This incorporation by reference was approved by
1 CFR part
the Director of the Federal Register in accordance with 5 U.S.C. 552(6) and
Technical
51. Copies may be obtained from McDonnell Douglas Helicopter Systems,
85215-9797.
Publications, Bldg. 530/8111, 5000 E. McDowell Rd., Mesa, Arizona
Chief Counsel, 2601
Copies may be inspected at the FAA, Office of the Assistant
Meacham Blvd., Room 663, Fort Worth, Texas; or at the Office of the Federal Register,
800 North Capitol Street, NW., suite 700, Washington, DC.
This amendment becomes effective May 29, 1996.

(f)

Certification
Mr. John Cecil, Aerospace Engineer, ANM- 120L, Los Angeles Aircraft
Office, Northwest Mountain Region, 3960 Paramount Blvd., Lakewood, California,
telephone (310) 627-5322, fax (310) 627-5210.
96-1 0-09
97-115108
Applicability:Model 369D, E, F, FF, 500N, AH-6, and MH-6 helicopters, with

main rotor transmission, part number (P/N) 369D25100, installed, certificated in any
category.
NOTE 1: This AD applies to each helicopter identified in the preceding

affected, the owner/operator must use the authority provided in paragraph (d) to
request approval from the FAA. This approval may address either no action, if the
current configuration eliminates the unsafe condition, or different actions necessary to
address the unsafe condition described in this AD. Such a request should include an
To prevent failure of the transmission output drive gear (gear), part number P/N
369D25127-11, which could result in loss of main rotor control and subsequent loss of
(a) Within the next 10 hours time-in-service (TIS) after the effective date of
this AD, determine through an inspection of records, contact with the manufacturer, or
using a bright light and viewing through the open liquid level plug port, if the installed
S/N
gear serial number (S/N) is S/N 005570-0646 through S/N 005570-0765, or
005570-0876 through S/N 005570-0998.
(b) If the gear has an affected SIN, remove the gear and replace it with an
airworthy gear, that has a S/N other than the S/Ns listed in paragraph (a) of this AD, as
follows:
(1) For helicopters equipped with a cargo hook assembly, with a

separate, permanently-maintained log of actual hours time-in-service (TIS) of external
load operation, remove and replace the gear within the next 25 hours TIS for external
load operations, or within the next 400 hours TIS for non-external load operation,
whichever comes first.

(2) For helicopters equipped with a cargo hook assembly, with no
separate, permanently-maintained log of actual external load operation, remove and
replace the gear within the next 25 hours TIS after the effective date of this AD.
Ownersloperators may begin maintaining a separate permanent log of external load
operations and comply with the requirements of paragraph (b)(l) of this AD.
(3) For helicopters without cargo hook assemblies, remove and

replace the gear within the next 400 hours TIS after the effective date of this AD.
(c) Replacementof the affected gear with an airworthy gear having a S/N
other than those S/Ns listed in paragraph (a) of this AD is considered a terminating
action for the requirements of this AD.
(d) An alternative method of compliance or adjustment of the compliance time

that provides an acceptable level of safety may be used if approved by the Manager,
Los Angeles Aircraft Certification Office. Operators shall submit their requests through a
FAA Principal Maintenance Inspector, who may concur or comment and then send it to
the Manager, Los Angeles Aircraft Certification Office.

(e) may be issued in accordance with sections 21.197

Special flight permits
and 21.199 of the Federal Aviation Regulations (14 CFR 21.1 97 and 21.199) to operate
the helicopter to a location where the requirements of this AD can be accomplished.
(f) This amendment becomes effective on August 4, 1997.
FOR FURTHER INFORMATION CONTACT: Mr. Bruce Conze, Aerospace Engineer,

FAA, Los Angeles Propulsion
Aircraft Certification Office, Branch, 3960 Paramount
Blvd., Lakewood, California 90712, telephone (562) 627-5261, fax (562) 627- 5210.
97-15-08
98-09-02 MCDONNELL DOUGLAS HELICOPTER
SYSTEMS: Amendment 39-10481. Docket No. 97-SW-52-AD. Supersedes AD

88-10-04, amendment 39-5897 and AD 88-10-04 R1, Amendment 39-6173.
Applicability: Model 369, 369A, 369D, 369E, 369F, 369FF, 369H, 369HE,
369HM, 369HS, 500N, YOH-6A, and OH-6A helicopters, certificated in any category.

Compliance: Required within 50 hours time-in-service after the effective date of

this AD, unless accomplished previously.
To prevent failure of the overrunning clutch assembly outer race, which could
result in loss of engine drive to the rotor system and a subsequent forced landing,
(a) Inspect the overrunning clutch outer race, part number (P/N) 369A5352,
to determine its serial number (S/N) in accordance with paragraphs A through C of the
Accomplishment Instructions contained in McDonnell Douglas Helicopter Systems
Service Information Notice HN-215.2, DN-156.2, EN-46.2, FN-34.2, NN-010, dated
March 18, 1997 (service information notice).
(b) Remove any overrunning clutch outer race, P/N 369A5352, having a S/N
of 0692 through 0927, and replace it with an airworthy overrunning clutch outer race,
P/N 369A5352-5, together with a wave washer, P/N W1593-018, in accordance with the
service information notice.
(c) An alternative method of compliance or adjustment of the compliance time

eos Angeles Aircraft Certification Office, FAA. Operators shall submit their requests
through an FAA Principal Maintenance Inspector, who may concur or comment and

(d) Special flight permits may be issued in accordance with sections 21.197
and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.1 99) to operate
(e) The inspection and replacement shall be done in accordance with

McDonnell Douglas Helicopter Systems Service Information Notice HN-215.2,
DN-156.2, EN-46.2, FN-34.2, NN-010, dated April 11, 1997. This incorporation by
reference was approved by the Director of the Federal Register in accordance with 5
U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from McDonnell Douglas
Helicopter Systems, Technical Publications, Bldg. 530/B11, 5000 E. McDowell Road,
Mesa, Arizona 85205-9797. Copies may be inspected at the FAA, Office of the
Regional Counsel, Southwest Region, 2801 Meacham Blvd., Room 663, Fort Worth,
Texas; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite
700, Washington, DC.
(f) This amendment becomes effective on May 6, 1998.

Mr. Bruce Conze, Aerospace Engineer, FAA, Los Angeles Aircraft Certification Office,
Airframe Branch, 3960 Paramount Boulevard, Lakewood, California 90712, telephone
(562) 627-5261, fax (562) 627-5210.
98-09-02
98-~ 5-26 MCDONNELL DOUGLAS HELICOPTER
SYSTEMS: Amendment 39-10675. Docket No. 98-SW-22-AD. Supersedes Priority

Letter AD 98-03-15, Docket No. 98-SW-O6-AD.
Model 369A, 369D, 369E, 369F, 369FF, 369H, 369HE, 369HM,

Applicability:
369HS, 500N, 600N, and OH-6A helicopters with main rotor blades Part Number
(P/N) 369A11OO-507 with Serial Number (S/N) D139 through D203, D2O9 through
D223; P/N 369D21100-517 with S/N H664, H665, H667, H669, H671, H672, H674,
H676, H679, H68O, H683 through H724, H726 through Hg99, JOOO through J039,
JO41 through JO55; or P/N 369D21102-517 with S/N 1976 through 2100, 2106
through 2115, installed, certificated in any category.

affected, the owner/operator must use the authority provided in paragraph (f) to request
(a) For Model 369A, 369D, 369E, 369F, 369FF, 369H, 369HE, 369HM,
369HS, 500N, and OH-6A helicopters with any affected main rotor blade (blade) that
has 600 or more hours time-in-service (TIS), to detect cracks that could lead to failure
of the blade and subsequent loss of control of the helicopter, before further flight and
thereafter at intervals not to exceed 25 hours TIS, accomplish the following:
(1) With each blade lifted off the droop stop, using a 10X or higher
magnifying glass, visually inspect the blade for any chordwise cracking starting at the
root fitting edge on the blade lower surface doubler and skin or cracks on the doubler
adjacent to the root end fitting (Figure 1). If any cracking is discovered, remove the
blade and replace it with an airworthy blade.
NOTE 2: Boeing McDonnell Douglas Helicopter Systems Service Bulletin

No.SB369H-243R3, SB369E-088R3, SB5O0N-O15R3, SB369D-195R3,
SB369F-O75R3, SB600N-007R2, dated July 13, 1998 (SB), pertains to the subject of
this AD.

(2) droop stop, inspect the lower surface
With each blade lifted off the
for missing or cracked adhesive or paint at the root end fitting-to-doubler bond line
(Figure 1). If any missing or cracked adhesive or paint is discovered, remove and
inspect the blade in accordance with paragraph 3E of Part II of the Accomplishment
Instructions in McDonnell Douglas Helicopter Systems Service Information Notice No.
HN-239, DN-188, EN-81, FN-67, NN-008, dated October 27, 1995. If there is any
disbonding in excess of the allowable margins specified in paragraph 3E of Part II of the
service information notice, replace the blade with an airworthy blade.
(b) helicopters, before further flight, remove any affected

For the Model 600N
blade from service and replace an airworthy blade not listed in the applicability
it with
section of this AD. Blades removed from the Model 600N helicopters are not eligible for
use on any rotorcraft.
NOTE 3: The recurring inspection requirements, contained in paragraph (a)

of this AD, DO NOT apply to the Model 600N helicopters.
(c) Affected blades are to be removed from service on or before reaching

either of the applicable new life limits. The new life limits are determined by hours TIS
or number of torque events (TE). A torque event is defined as the transition to a hover
from forward flight. For this definition of TE, forward flight is considered to be flight at
any airspeed after attaining translational lift.
(1) For blades that do not have TE logged, prior to further flight, log the
TE in the rotorcraft log or equivalent record as follows:
(i) Log the number of TE, if known.
(ii)
For noncargo hook operations, if the number of TE is
unknown, log 6 TE for each hour TIS.
For cargo hook (external load) operations, or for any

(iii)
combination of noncargo hook operations and cargo hook (external load) operations, if
the number of TE is unknown, log 20 TE for each hour TIS.
(2) Make any entry into the component record or equivalent record to
reflect new life limits for blade P/Ns as follows.
(i) For P/N 369A1100-507, Models 369A, 369H, 369HE,

369HM, 369HS, and OH-6A, enter 1,750 hours TIS or 10,600 TE, whichever occurs
first.
(ii) For P/N 369D21100-517, Models 369D and 369E, enter

2,500 hours TIS or 15,000 TE, whichever occurs first.
98-15-26
(iii) For P/N 369D21102-517, Model 369F, 369FF, and 500N,
enter 2,500 hours TIS or 15,000 TE, whichever occurs first.
(d) After compliance paragraph (c) of this AD, during each operation
with
thereafter, maintain a count of TE performed and additional hours TIS accumulated,
and, at the end of each days operations, add those counts to the accumulated number
of TE and hours TIS on the rotorcraft log or equivalent record.
The blades longer retired based upon only hours TIS. This AD
(e) are no
revises the Airworthiness Limitations Section of the maintenance manual by

establishing a new retirement life for certain blade P/Ns based on hours TIS or a
number of TE, whichever occurs first.
(f) An alternative method of compliance or adjustment of the compliance

time that provides an acceptable level of safety may be used if approved by the
Manager, Los Angeles Aircraft Certification Office, FAA. Operators shall submit their
requests through an FAAPrincipal Maintenance Inspector, who may concur or
comment and then send it to the Manager, Los Angeles Aircraft Certification Office.
NOTE 4: concerning the existence of approved alternative

Information
(g) Special flight permits will not be issued.
(h) The inspection required by paragraph (a)(2) of this AD shall be done in

accordance with McDonnell Douglas Helicopter Systems Service Information Notice
No. HN-239, DN-188, EN-81, FN-67, NN-008, dated-October 27, 1995. This
incorporation by reference was approved by the Director of the Federal Register in
accordance with 5 U.S.C. 552(6) and 1 CFR part 51. Copies may obtained from
McDonnell Douglas Helicopter Systems, Commercial Technical Publications, Bldg.
M615/G048, 5000 E. McDowell Road, Mesa, Arizona 85215-9797, telephone
(602) 891-3667, fax (602) 891-6522. Copies may be examined at the FAA, Office of the
Texas, or at the Office of the Federal Register, 800 North Capital Street NW., suite 700,
Washington, DC.
(i) This amendment becomes effective on August 3, 1998.
FOR FURTHER INFORMATION CONTACT: Mr. John L. Cecil, Aerospace Engineer,

FAA, Los Angeles Aircraft Certification Office, 3960 Paramount Blvd., Lakewood,
California 90712, telephone (562) 627-5229, fax (562) 627-5210.
98-1 5-26
98121 111 2 .COON.ELLWUllLP~S HELIC~PTER
Applicability: Model 369D, 369E, 369FF, 500N, AH-6, and MH-6 helicopters,
with overrunning clutch assembly, part number (P/N) 369F5450-501, installed,

affected, the owner/operator must use the authority provided in paragraph (d) to
request approval from the FAA. This approval may address either no action, if the
current configuration eliminates the unsafe condition, or different actions necessary to
address the unsafe condition described in this AD. Such a request should include an
To detect wear of other clutchcomponents, excessive vibration which could lead

to failure of the overrunning clutch, wear on the bearing carrier, and subsequent loss of
power to the helicopter rotor drive system, accomplish the following:
(a) Visually inspect the overrunning clutch retainer, P/N 369F5460-1, carrier,
P/N 369F5461-1, housing, P/N 369F5451-1, and pin, P/N MS16556-801, for clutch or
carrier wear or pin damage in accordance with the Accomplishment Instructions in
McDonnell Douglas Helicopter Systems Service Information Notice No. DN-190, EN-83,
FN-70, NN-O11, dated July 25, 1997. For helicopters with a clutch assembly having less
than 100 hours time-in-service (TIS), conduct the visual inspection before or upon
reaching 100 hours TIS. For helicopters with a clutch assembly having 100 or more
hours TIS, conduct the visual inspection within 25 hours TIS.
(b) Repeat the inspection required by paragraph (a) at intervals not to exceed
100 hours TIS.
(c) If the inspections specified in paragraph (a) or (b) reveal wear or damage
to components, replace those components with airworthy components prior to further
flight.

(d) An alternative method of compliance or adjustment of the compliance
time that provides an acceptable level of safety may be used if approved by the
Manager, Los Angeles Aircraft Certification Office, FAA. Operators shall submit their
requests through an FAA Principal Maintenance Inspector, who may concur or
comment and then send it to the Manager, Los Angeles Aircraft Certification Office.

(e) may be issued in accordance with sections 21.197

and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate
(f) The inspections shall be done in accordance with McDonnell Douglas

Helicopter Systems Service Information Notice No. DN-190, EN-83, FN-70, NN-O1?,
dated July 25, 1997. This incorporation by reference was approved by the Director of
the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies
Service
may be obtained from McDonnell Douglas Helicopter Systems, Field
Department, 5000 E. McDowell Road, Mesa, Arizona, telephone (800) 388-3378, fax
(602) 891-6782. Copies may be inspected at the FAA, Office of the Regional Counsel,
Southwest Region, 2601 Meacham Blvd., Room 663, Fort Worth, Texas; or at the
Office of the Federal Register, 800 North Capitol Street, NW., suite 700, Washington,
DC.
(g) This amendment becomes effective on October 22, 1998.
FOR FURTHER INFORMATION CONTACT: Mr. Bruce Conze, Aerospace Engineer,

FAA, Los Angeles Aircraft Certification Office, 3960 Paramount Boulevard, Lakewood,
98-21-12
MCDONNELL DOUGLAS HELICOPTER SYSTEnnS
99-04-12 MCDONNELL DOUGLAS HELICOPTER
Applicability: Model 369D, 369E, 369FF, 369H, MD500N, and MDGOON

helicopters, with input shaft coupling assemblies, part number (P/N)
369F5133-1, serial number (S/N) 030829-0126 through 030829-0207, installed on
main transmission, P/N 369F5100-503, and on overrunning clutch, P/N 369F5450,
NOTE i: applies to each helicopter identified in the preceding

This AD
the unsafe condition described in this AD. Such request should include an
a

addressed by this AD. In no case does the presence of any modification,
alteration, or repair remove any helicopter from the applicability of this
AD.
Compliance: Required within 100 hours time-in-service after the effective

date of this AD, unless accomplished previously.
To prevent failure of the spline teeth in each input shaft coupling assembly
(coupling assembly), loss of drive to the main rotor system, and subsequent loss of
(a) Visually inspect the coupling assemblies, P/N 369F5133-1, installed on

main transmission, P/N 369F5100-503, and on overrunning clutch, P/N 369F5450,
for pitting under the solid film lubricant in the spline area of the coupling.
(b) If there is pitting in the splines, replace the coupling assembly with
an airworthy coupling assembly, P/N 369F5133-1, that has been inspected as
required by paragraph (a) of this AD.
NOTE 2: Boeing Service Bulletin SB369H-240, SB369E-085, SB500N-0~3,

SB369D-192, SB369F-072, SB600N-003, dated September 26, 1997, pertains to this
AD.
(c) An alternative method of compliance or adjustment of the compliance

time that provides an acceptable level of safety may be used if approved by

theManager, Los Angeles Aircraft Certification Office, FAA. Operators shall
submit their requests through an FAA Principal Maintenance Inspector, who may
concur or comment and then send it to the Manager, Los Angeles Aircraft

methods of compliance with this AD, if any, may be obtained from the Los
Angeles Aircraft Certification Office.
(d) Special flight permits may be issued in accordance with sections 21.197
and 21.1 99 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to
operate the helicopter to a location where the requirements of this AD can be
accomplished.
(e) This amendment becomes effective on March 23, 1999.
FOR FURTHER INFORMATION CONTACT: Bruce Conze, Aerospace Engineer,

Los Angeles Aircraft Certification Office, 3960 Paramount Blvd., Lakewood, California,
90712, telephone (562) 627-5261, fax (562) 627-5210.
99-04-12
99-1 3-09 MD HELICOPTERS, INC.: Amendment
39-11228. Docket No. 99-SW-40-AD.
Applicability: Model 369D and E helicopters, with four-bladed tail rotor fork (fork)
assemblies, part number (P/N) 369D21701-21, installed, certificated in any category.
NOTE 1: applies to each helicopter identified in the preceding

This AD
applicability provision, regardless of whether it has been otherwise modified, altered, or
repaired in the area subject to the requirements of this AD. For helicopters that have
been modified, altered, or repaired so that the performance of the requirements of this
AD is affected, the owner/operator must request approval for an alternative method of
compliance in accordance with paragraph (d) of this AD. The request should include an
assessment of the effect of the modification, alteration, or repair on the unsafe condition
addressed by this AD; and, if the unsafe condition has.inot been eliminated, the request
should include specific proposed actions to address it.
To prevent failure assembly, P/N 369D21701-21, which can result in

of the fork
loss of a tail rotor blade and subsequent loss of control of the helicopter, accomplish the
following:
(a) Before further flight, inspect each fork assembly, P/N 369D21701-21, for
the presence of ridges on the arms. See Figure 1, sheets 1 and 2.
NOTE 2: Helicopters, Inc., Service Bulletin SB369D-198, SB369E-092,

MD
dated May 10, 1999, pertains to the subject of this AD.
(1) If ridges are found, no further action is required by this AD.
(2) ridges are found, chemically remove paint from the machined
If no
areas, fork assembly for a crack using the dye-penetrant procedure of

inspect the
Mit-STD-6866 or ASTM-E1417, and conduct a visual inspection using a 1 OX or higher
magnifying glass. (See Figure sheets 1 and 2.) Replace a cracked fork assembly with
an airworthy fork assembly. A fork assembly without ridges, P/N 369D21701-21, may
not be installed.
NOTE 3: assembly is titanium, which requires dwell

The fork times for the
dye-penetrant inspection that are appropriate for titanium.
MD HELICOPTERS, INC.
(b) Thereafter, at intervals not to exceed 50 hours time-in-service (TIS),
crack
visually inspect each fork assembly without ridges, P/N 369D21701-21, for a
sheets 1 and 2.) If crack is
using a 10X or higher magnifying glass. (See Figure 1, a
found, replace the cracked fork assembly with an airworthy fork assembly. A fork
assembly without ridges, P/N 369D21701-21, may not be installed.
(c) Replacingunairworthy fork assembly with an airworthy fork assembly

an
AD.
other than P/N 369D21701-21 without ridges constitutes terminating action for this
(d) An alternative method of compliance or adjustment of the compliance time

Los Angeles Aircraft Certification Office, FAA. Operators shall submit their requests
comment and
through an FAA Principal Maintenance Inspector, who may concur or
NOTE 4. Information concerning the existence of approved alternative

methods of compliance with this AD, ifany, maybe obtained from the Los
Angeles Aircraft Certification Office.
(e) Special flight permits will not be issued.
(f) This amendment becomes effective on August 4, 1999, to all persons

except those persons to whom it was made immediately effective by Priority Letter AD
99-13-09, issued June 16, 1999, which contained the requirements of this amendment.

John L. Cecil, Aerospace Engineer, FAA, LosAngeles Aircraft Certification Office,
Airframe Branch, 3960 Paramount Blvd., Lakewood, California 90712, telephone
(562) 627-5228, fax (562) 627-5210.
99-1 3-09
99- i 3-09
RIDGES
Figure 1. Fork Assembly with ridges (Sheet I of 2).
AD 99-13-09
ORIGINAL
As Received By
ATP
99-13-09 j
NO RIDGES REMOVE PAINT AM3

INSPECT WITHIN
THIS AREA
FOR CRACKS
Figure 1. Fork Assembly without ridges (Sheet 2 o~ 2).
AD 99-15-09
ORIGINAL
As Received By
ATP
Ji
99-20-12 MD HELICOPTERS, INC. (MDHI):
Amendment 39-11342. Docket No. 98-SW-80-AD. Issued September 22, 1999.
Applicability: Model 369[3, 3696, 369FF, 500N, and 600N helicopters, with
oil cooler blower bracket (bracket), part number(P/N) 369F5190-1, installed,
NOTE 1: This AD applies to each helicopter identified in the

preceding applicability provision, regardless of whether it has been otherwise
modified, altered, or repaired in the area subject to the requirements of this AD.
For helicopters that have been modified, altered, or repaired so that the
performance of the requirements of this AD is affected, the owner/operator must
request approval for an alternative method of compliance in accordance with
paragraph (b) of this AD. The request should include an assessment of the effect
of the modification, alteration, or repair on the unsafe condition addressed by this
AD; and, if the unsafe condition has not been eliminated, the request should
include specific proposed actions to address it.
Compliance: Required within 100 hours time-in-service, unless

accomplished previously.
Toprevent failure of a bracket, loss of cooling of engine oil and

transmission oil, and a subsequent forced landing, accomplish the following:
Remove the bracket, P/N 369F5190-1, and replace it with an

(a)
airworthy bracket, P/N 369F5194-1.
(b) An alternative method of compliance or adjustment of the

compliance time that provides an acceptable level of safety may be used if
approved by the Manager, Los Angeles Aircraft Certification Office. Operators
shall submit their request through an FAA Principal Maintenance Inspector, who
the Manager, Los Angeles Aircraft
may concur or comment and then send it to
NOTE 2: Information concerning the existence of approved

alternative methods of compliance with this Ad, if any, may be obtained from the
Los Angeles Aircraft Certification Office.
(c) may be issued in accordance with sections

21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and
21.199) to operate the helicopter to a location where the requirements of this AD
can be accomplished.
(d) This amendment becomes effective on November 4, 1999.

Bruce Conze, Aerospace Engineer, FAA, Los Angeles Aircraft Certification Office,
3960 Paramount Blvd, Lakewood, California 90712, telephone (562) 627-5261, fax
(562) 627-5210.
99-20-12
Mo HELICOPTERS, INC.
2000-08-22 MDHELICOPTERSINC:
Amendment 39-11708, Docket No. 2000-SW-02-AD.
Applicability: Model 369D, 369E, and 500N helicopters, with analog/digital turbine
outlet temperature (TOT) indicator, part number (P/N) 369D24513-1, installed; and
Model 600N helicopters, with analog/digital TOT indicator, P/N 9A3420, installed;
NOTE 1: applies to each helicopter identified in the preceding

This AD
compliance in accordance with paragraph (f) of this AD. The request should include an
addressed by this AD; and if the unsafe condition has not been eliminated, the request
To prevent an erroneous TOT indication, damage to critical engine components,

loss of engine power, and a subsequent forced landing, accomplish the following:
(a) For Model 369E, 369D, and 500N helicopters: Within the next 50 hours
time-in-service (TIS) or on or before June 15, 2000, whichever occurs first; test the TOT
indicating system to verify correct calibration in accordance with the Accomplishment
Instructions, Part I, of MD Helicopters, Inc. (MDHI) Service Bulletin SB369D-199,
SB369E-093, SB500N-019, dated January 11, 2000 (SB). Thereafter, repeat the test at
intervals not to exceed 300 hours TIS.
(b) If during any test required by paragraph (a) of this AD the TOT indicator
readings for the tester setting temperatures in Table 1, Part I, of the SE are not within
the indicator reading range, before further flight, perform the actions in the
Accomplishment Instructions, Part I, paragraph (6)(b) of the SE.
(c) For Model 600N helicopters: Within the next 50 hours TIS or on or before
June 15, 2000, whichever occurs first; test the TOT indicating system, including the
electronic control unit (ECU) TOT sensing system, to verify correct calibration in
accordance with the Accomplishment Instructions, Part I, of MDHI SB600N-026, dated
January 11, 2000 (SB 600N). Thereafter, repeat the test at intervals not to exceed 300
hours TIS.
Mo HELICOPTERS INC.
(d) during any calibration test required by paragraph (c) of this AD the TOT
If
indicator readings for the tester setting temperatures in Table 1, Part I, of SE 600N, are
not within the indicator reading range, before further flight, perform the actions in the
Accomplishment Instructions, Part I, paragraph (7)(b) of SE 600N.
(e) If any test required by paragraph (c) of this AD the Full Authority
during
Digital Electronic Control (FADEC) maintenance lap-top terminal does not indicate ECU
TOT within ~t5 degrees Celsius of the tester setting in Table 1, Part I, of SE 600N,
before further flight, perform the actions in the Accomplishment Instructions, Part Ill, of
the SE 600N.
(f) An alternative method of compliance or adjustment of the compliance time

Los Angeles Aircraft Certification Office. Operators shall submit their requests through
an FAA Principal Maintenance Inspector, who may concur or comment and then send
it
to the Manager, Los Angeles Aircraft Certification Office.

(g) may be issued in accordance with sections 21.197

and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate
(h) The tests shall be done in accordance with MD Helicopters Inc. Service
Bulletin SB369D-199, SB369E-093, SB500N-019 for Model 369D, 369E, and 500N
helicopters and Service Bulletin SB600N-026 for Model 600N helicopters, both dated
January 11, 2000. This incorporation by reference was approved by the Director of the
Federal Register 552(a) and 1 CFR part 51. Copies may be
in accordance with 5 U.S.C.
obtained from MD Helicopters Inc., Attn: Customer Support Division, 4555 E. McDowell
Rd., Mail Stop M615-GO48, Mesa, Arizona 85215-9797, telephone 1-800-388-3378 or
480-346-6387; datafax 480 346-6813. Copies may be inspected at the FAA, Office of
the Regional Counsel, Southwest Region, 2601 Meacham Blvd., Room 663, Fort Worth,
Texas; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite 700,
Washington, DC.
(i) This amendment becomes effective on May 22, 2000.

Elizabeth Bumann, Aviation Safety Engineer, FAA, Los Angeles Aircraft Certification
Office, 3960 Paramount Blvd., Lakewood, California 90712-4137, telephone
(562) 627-5265; fax (562) 627-5210.
issued in Fort Worth, Texas, April 18, 2000.

on
Mark R. Schilling, Acting Manager, Rotorcraft Directorate, Aircraft Certification Service.
2000-08-22
MD HELICOPTERS INC.
2000-25-52 MD HELICOPTERS, INC.: Amendment
39-12083. Docket No. 2000-SW-63-AD. Supersedes Emergency AD 2000-24-51,

Docket No. 2000-SW-62-AD.
Applicability: Model 369A, H, HE, HM, HS, D, E, FF, and 500N

helicopters, with main rotor blade (blade), part number (P/N) 500P2100-BSC (serial
number (S/N) with a prefix of "K" and 101 through 562); P/N 500P2100-101 or P/N
500P2100-301 (S/N with a prefix of "A" and 001 through 999 or S/N with a prefix of "B"
and 001 through 529); or blade, P/N 500P2300-501 (S/N with a prefix of "T" and 101
through 107), manufactured by Helicopter Technology Company, LLC, installed,

compliance in accordance with paragraph (b) of this AD. The request should include an
addressed by this AD; and if the unsafe condition has not been eliminated, the request
Compliance: Required before further flight, unless accomplished previously.
To detect a void in the bonding that could result in a crack due to corrosion pits
on the blade spar bonded surfaces, failure of a blade, and subsequent loss of control of
the helicopter, accomplish the following:
(a) Perform a tap inspection on both the upper and lower surfaces of each
blade in accordance with the "INSPECTION" paragraph of Helicopter Technology
Company, LLC, Mandatory Service Bulletin Notice No. 2100-2R2, dated November 14,
2000 (SB). If any voids on a blade are detected that exceed specified inspection
requirements of the SE, replace the unairworthy blade with an airworthy blade before
further flight.
(b) An alternative method of compliance or adjustment of the compliance time

thatprovides an acceptable level of safety may be used if approved by the Manager,
Rotorcraft Certification Office, FAA. Operators shall submit their requests through an
FAA Principal Maintenance Inspector, who may concur or comment and then send it to
the Manager, Rotorcraft Certification Office.
methods of compliance with this AD, if any, may be obtained from the Rotorcraft
(c) Special flight permits may be issued in accordance with 74 CFR 21.1 97
and 21.199 to operate the helicopter to a location where the requirements of this AD
can be accomplished.
(d) inspections shall be accomplished in accordance with the

The tap
"INSPECTION" paragraph of Helicopter Technology Company, LLC, Mandatory Service
Bulletin Notice No. 2100-2R2, dated November 14, 2000. This incorporation by
reference was approved by the Director of the Federal Register in accordance with 5
U.S.C. 552(6) and 1 CFR part 51. Copies may be obtained from Helicopter Technology
Company, LLC, 12923 South Spring St., Los Angeles, CA 90061, telephone
of the
(310) 523-2750, fax (310) 523-2745. Copies may be inspected at the FAA, Office
Federal Register, 800 North Capitol Street, NW., suite 700,
Texas; or at the Office of the
Washington, DC.
(e) This amendment becomes effective on February 6, 2001, to all persons

AD
except those persons to whom it was made immediately effective by Emergency
2000-25-52, issued December 5, 2000, which contained the requirements of this
amendment.
FOR FURTHER INFORMATION CONTACT: Marc Belhumeur, Aviation Safety

Texas
Engineer, FAA, Rotorcraft Directorate, Rotorcraft Certification Office, Fort Worth,
761 93-0170, telephone (817) 222-5177, fax (817) 222-5783.
Issued in Fort Worth, Texas, on January 10, 2001.
Henry A. Armstrong, Manager, Rotorcraft Directorate, Aircraft Certification Service.
2000-25-52
2002-13-05 R1.,
Helicopters, Inc.: Amendment 39-13022, Docket No. 2001-SW40-AD.
Revises AD 2002-13-05, Amendment 39-12793.
Applicability: The following MD Helicopters, Inc. helicopter

models, certificated in any category:
Helicopter model With Modified In accordance with
(1) 3690, 3695, 369F, Tailboom, serial number Aerometals Supplemental Type
369FF (S/N) 5001-5032 Certificate (STC) SH5055NM
(2) 3690 and 369E Tail Rotor Gearbox Attach Aerometals STC SH4801NM
Bolts
Note 1: This AD
applies to each helicopter identified in the
preceding applicability provision, regardless of whether it has been
otherwise modified, altered, or repaired in the area subject to the
requirements of this AD. For helicopters that have been modified, altered,
or repaired so that the performance of the requirements of this AD is
affected, the owner/operator must request approval for an alternative

method of compliance in accordance with paragraph (c) of this AD. The
request should include an assessment of the effect of the modification,
alteration, or repair on the unsafe condition addressed by this AD; and if
the unsafe condition has not been eliminated, the request should include
specific proposed actions to address it.
Compliance: Required as indicated, unless accomplished

previously.
To prevent loss of the tail gearbox due to attaching bolts of
rotor
inadequate grip length and subsequent loss of control of the helicopter,
(a) Within 25 hours time-in-service (TIS):
(1) For each tail rotor gearbox attaching bolt (bolt):
(i) Determine the part number (P/N).
(ii) If the P/N cannot be determined or if the bolt is

not P/N NAS1304-26, before further flight, replace the bolt with bolt, P/N
NAS1 304-26.
(iii) Torque the bolt to 100-110 in-lbs and apply a
slippage mark.
(2) Remove the tailboom control rod and determine the

number of bolt threads protruding from each nutplate on the internal
surface of the aft tailboom frame casting, P/N 369D23503, as shown in
Figure 1 of this AD. At least one thread must protrude. If more than four
threads protrude, add an additional washer, P/N AN960D416, under the
bolt head. Torque the bolt to 100-110 in-lbs, and reapply a slippage mark.
See Figure 1:
(b) Between 2 and 10 hours TIS after accomplishing the

requirements of paragraph (a) of this AD, inspect the torque on each bolt
by applying 100 in-lbs. If any bolt movement occurs, retorque the bolt to
100-110 in-tbs. Reapply a slippage mark to the bolt regardless of the
outcome of the torque test. Reinspect the torque between 2 and 10 hours
TIS thereafter until no bolt movement occurs.
Note 2: Aerometals Service Bulletin SB-001, dated August 3,

2000, pertains to the subject of this AD.
(c) An alternative method of compliance or adjustment of the

compliance time that provides an acceptable level of safety may be used if
approved by the Manager, Los Angeles Aircraft Certification Office
(LAACO), FAA. Operators shall submit their requests through an FAA
Principal Maintenance Inspector, who may concur or comment and then
send it to the Manager, LAACO.
Note 3: Information concerning the existence of approved

alternative methods of compliance with this AD, if any, may be obtained
from the LAACO.
(d) Special flight permits will not be issued.
(e) This amendment becomes effective on February 25, 2003.
FOR FURTHER INFORMATION CONTACT: John Cecil, Aviation Safety

Engineer, FAA, Los Angeles Aircraft Certification Office, Airframe Branch,
3960 Paramount Blvd., Lakewood, California 90712-4137, telephone
(562) 627-5223, fax (562) 627-5210.
Issued in Fort Worth, Texas, on January 11, 2003.

David A. Downey, Manager, Rotorcraft Directorate, Aircraft Certification
Se rvice.
2002-13-05 R1
NAS1304-26 Baits
4 Places
AN960D416 Washers
4 Places
Tail Rotor Gearb~x
~WC
,"P
Aft
Tallbaom Frame30S2D963gnitsrC
Irrsleetlon Wole
inspect this area oferrdh bolt.
Bolt must protrude as least one
thread past end af uutplate a places.
IiYerure 1 Xnspection Location

Page 1
CORRECTION: [Paragraph (c) Register published AD contained a typo. The

of this Federal
last part number in the last sentence of that paragraph is incorrectly listed as 500P3500-70.
The part number should be "500P3500-701: We will publish a correction in the Federal
Register. This copy is correct.]
2003-08-51 C
Amendment 39-~ 3215
Docket No. 2003-SW-~ 7-AD
Applicability: Model 369A, D, E, H, HE, HM, HS, F, and FF helicopters, with tail rotor blades,
part number (P/N) 369D21640-501, 369021641-501, 369D21642-501, 369D21643-501,
500P3100-101, 500P3100-301, 500P3300-501,or 500P3500-701, installed, certificated in any
category.
To prevent a tail rotor blade pitch horn (pitch horn) from separating from the tail rotor blade,
leading to an unbalanced condition, vibration, loss of tail rotor pitch control, and loss of
directional control of the helicopter, accomplish the following:
(a) This airworthiness directive (AD) establishes a new retirement life of 400 hours
time-in-service (TlS) for the tail rotor blades listed in the Applicability section. For helicopters
with an affected tail rotor blade installed that has 390 through 700 hours TIS, remove and
replace the tail rotor blade with an airworthy tail rotor blade within 10 hours TIS.
(b) Before further flight, perform a one-time visual inspection of each pitch horn for a crack or
corrosion in the area indicated by Note 2 in Figure 1 of this AD. Paint removal in accordance
with Note 1 of Figure 1 of this AD is not required for the visual inspection.
(c) Revise the helicopter Airworthiness Limitations section of the maintenance manual by
making pen-and-ink changes to indicate the new retirement life of 400 hours TIS for the tail
rotor blades, P/N
369D21640-501, 369D2164~-501, 369D21642-501, 369021643-501,
500P3100-101, 500P3100-301, 500P3300-501,and 500P3500-701.
(d) For
helicopters with a tail rotor blade installed that has more than 700 hours TIS, a
one-time special flight permit to fly it to a repair facility may be issued only upon completion of
an eddy current surface scan of each affected pitch horn (see Figure 1 of this AD). Paint
removal in accordance with Note 1 of the Figure 1 of this AD IS required for the surface scan.
If a crack is found, remove the tail rotor blade and replace it with an airworthy tail rotor blade
before further flight.
(e) Within 24 hours after completing the requirements of this Emergency AD, report the
2003-08-51 C Mo HELICOPTERS, INC.

Page 2
information requested in Appendix A for all tail rotor blades listed in the Applicability section,
including the tail rotor blades that were removed as a result of this AD. Report the information
to: Manager, Los Angeles Aircraft Certification Office, ATTN: Fred Guerin, 3960 Paramount
Blvd., Lakewood, California 90712, telephone (562) 627-5232. Reports may also be fared to
(562) 627-5210 or emailed to fred .guerin~faa.gov.
(f) requirements contained in this AD have been approved by the Office

Information collection
of Management and Budget (OMB) under the provisions of the Paperwork Reduction Act of
1980 (44 U.S.C. 3501 et seq.) and have been assigned OMB Control Number 2120-0056.
(g) Torequest a different method of compliance or a different compliance time for this AD,
follow the procedures in 14 CFR 39.19. Contact the Los Angeles Aircraft Certification Office,
Transport Airplane Directorate, FAA, for information about previously approved alternative
methods of compliance.
(h) This amendment becomes effective July 17, 2003, to all persons except those persons
on
to whom it was made immediately effective by Emergency AD 2003-08-51, issued April 15,
2003, which contained the requirements of this amendment.
FOR FURTHER INFORMATION CONTACT: Fred Guerin, Aviation Safety Engineer, FAA, Los
Angeles Aircraft Certification Office, Airframe Branch, 3960 Paramount Blvd., Lakewood,
Issued in Fort Worth, Texas, on June 3, 2003.
Mark R. Schilling, Acting Manager, Rotorcraft Directorate, Aircraft Certification Sen/ice.

Page 3
~jl m~Rt
IKPtl t IPBBP
t jl
(r
j
liOx=YW(Q k~.
~aeL
$F r. ~YSls B~ COMACXI~OL
CI~SJIXt t
(bRI
PSar~ m, Itia6filA r*wltuta~+ra\
Figure
ORIGINAL
By 1
As
Figure
2003-08-51 C
Page 4
Tail Rotor Blade Assembly Inspection
Appendix A-Tail Rotor Blade Inspection (Sample Format)
Send within 24 hours to:
Manager, Los Angeles Aircraft Certification Office, ATTN: Fred Guerin, 3960 Paramount
Blvd., Lakewood, California 90712.
Fax: (562) 627-5210.
Email: fred.guerin~faa.gov.
Date:
Operator or Company Name:
Name of Contact Person:
Address:
Telephone:
Fax:
Aircraft Serial Numbec
Aircraft Registration Numbec
Estimated average flight hours per year:
T/R Blade Part Numbec Serial Number: Total Time:
Crack found? (Yes/No): Corrosion Found? (Yes/No)

T/R Blade Part Number: Serial Number: Total Time:



Comments/Additional Information:

Page 1
2003 24 01
NID HELICOPTERS, INC.
Amendment 39-13370
Docket No. 2003-SW-16-AD
Applicability: Models 369A, H, HE, HM, HS, D, or E, with a main rotor blade (blade), part
number (P/N) 500P2100-BSC, 500P2100-101, or 500P2100-301, and modified with Helicopter
Technology Company, LLC, Supplemental Type Certificate (STC) No. SR09172RC,
SR09O74RC, or SR09184RC, installed, certificated in any category.
To prevent fatigue cracking of the blade, blade failure, and subsequent loss of control of the
helicopter, accomplish the following:
(a) Within 12 hours time-in-service (TIS)

days, whichever occurs first, determine and
or 30
record on the component history card or equivalent record the number of torque events (TEs)
accumulated on each blade. Record a torque event (TE) for each transition to a hover or
landing from forward flight with an airspeed of 30 or more knots or any external lift operation.
An external lift operation is defined as the pickup and drop-off of an external load. (An external
lift operation with a return flight at an airspeed of 30 or more knots back to the pick-up location
would be recorded as two TEs).
(1)If you cannot determine the actual number of TEs for a blade, assume and record 13,720
TEs as the accumulated total number of TEs on that blade.
(2) Thereafter, after each days operation or after 100 external lift operations, whichever
occurs first, record on the component history card or equivalent record the number of TEs
that occurred during that period for each blade.
NOTE 1
Helicopter Technology Company, LLC, Mandatory Service Bulletin Notice

No. 2100-3R2, dated December 30, 2002, pertains to the subject of this AD.
(b) For each blade with 750 or more hours TIS and 13,720 or more TEs, before further flight
and thereafter at intervals not to exceed 35 hours TIS or 200 TEs, whichever occurs first:
(1) Lift the outboard end of the blade until the blade is off the droop stop.
(2) Using a bright light and a 10x higher magnifying glass, inspect for a crack on the first
or
24-inch inboard area of the bottom side of the blade. Pay particular attention to the area
around the root fitting, its adjacent doubler and skin, and in line with the root fitting attach
bolts. Also, pay particular attention at blade stations: 22.6, 24.1, 25.1, 25.3, 27.9, and 36.4
2003-24-01 Mn HELICOPTERS, INC.

Page 2
(these blade stations are located 4.9, 6.4, 7.4, 7.6, 10.2, and 18.7 inches outboard (parallel
to the blade) from the center of the root fitting and lead lag attach bolt holes closest to the
trailing edge).
(3) Using a bright light, inspect for a crack on the remaining length of the bottom side of the
blade.
(4) Lower the blade back onto the droop stop.
(5) Using a bright light andhigher magnifying glass, inspect for a crack on the first
a 10x or
24-inch inboard topside

area of of the blade.
Pay particular attention to the area around the
root fitting, its adjacent doubler and skin, and in line with root fitting attach bolts. Also pay
particular attention at blade stations: 22.6, 24.1, 25.1, 25.3, 27.9, and 36.4 (these blade
stations are located 4.9, 6.4, 7.4, 7.6, 10.2, and 18.7 inches outboard (parallel to the blade)
from the center of the root fitting bushing and lead lag attach bolt hole closest to the trailing
edge).
(6) Using a bright light, inspect for a crack on the remaining length of the topside of each
blade.
(c) If a crack is found, replace the blade with an airworthy blade before further flight.
(d) Onbefore 3,530 hours TIS, replace each blade, P/N 500P2100-BSC
or or P/N
500P2100-101, with an airworthy blade.
(e) On or before 2,440 hours TIS, replace each blade, P/N 500P2100-301, with an airworthy
blade.
(f) This AD revises the Limitations and Conditions of Helicopter Technology Company, LLC,
STC Nos. SRO9172RC, SR09O74RC, or SRO9184RC by establishing a life limit of 3,530 hours
TIS for blade, P/N 500P2100-BSC and P/N 500P2100-101, and 2,440 hours TIS for blade P/N
500P2100-301.
NOTE 2
TEs are used only to establish an additional inspection interval and not to
establish an alternative retirement life.
(g) request a different method of compliance or a different compliance time for this AD,
To
follow the procedures in 14 CFR 39.19. Contact the Rotorcraft Certification Office, Rotorcraft
Directorate, FAA, for information about previously approved alternative methods of compliance.
(h) This amendment becomes effective on December 10, 2003.
FOR FURTHER INFORMATION CONTACT: Marc Belhumeur, Aviation Safety Engineer, FAA,
Rotorcraft Directorate, Rotorcraft Certification Office, Fort Worth, Texas 76193-0170, telephone
(817) 222-5177, fax (817) 222-5783.
2003-24-01 Mn HELICOPTERS, INC.

Page 3
Issued in Fort Worth, Texas, on November 17, 2003.
David A. Downey, Manager, Rotorcraft Directorate, Aircraft Certification Sen/ice.
2003-24-01 Mo HELICOPTERS, INC.

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ATP

INDEX COPYRIGHT 2004

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 Manufacturers Publications:

McDonnell Douglas Hel.

Issue Type Eye-Readable Code

SERVICE INFO NOTICE SIN

10/18/2001 Copyright Aircraft Technical Publishers Page 1 of 1

ATP Grid Index to Manufacturers Publications:

DN-51.8 Inspection of main rotor blade 1)

SB369D-191 MAIN ROTOR TRANSMISSION 1)

SB369D-192 INPUT SHAFT COUPLING ASSEMBLY 1)99-04-12

SB369D-193 R1 TAIL ROTOR BLADE, LEADING EDGE 1)

~B369D-195 R3 MAIN ROTOR BLADE ROOT END 1) 98-15-26

SB369D-196 OIL COOLER BRACKET REPLACEMENT 1)

1)2/24/2004 Copyright Aircraft Technical Publishers Page 1 of 2

SB369D-197 Engine fuel filter pressure 1)

SB369D- 198 Tail rotor fork inspection, 1) 99-13-09

SB369D- 199 Turbine outlet temperature 1) 2000-08-22

SB369D-200 Landing gear strut inspection 1)

SB369D-201 R2 Main rotor blade assembly 1)

SB369D-202 Main transmission bonding 1)

02/24/2004 Copyright Aircraft Technical Publishers Page 2 of 2

SERVICE BULLETIN DATE:

/I MANoAToRvl/ll/ll/ll/II/ MANDATORYIII//III//I111 MANDATORYIJ

INSPECTION OF MAIN ROTOR BLADE ROOT FITTING

B. Assemblv/ComPonents Affected By This Bulletin:

(I) Denotes portion of text added or revised.

SERVICE BULLETIN DATE: 3 JANUARY 2000

II MANDAToRvlllllll;/ll1111 MANDATORVIIIIIIIIIIIl/l MANDATORYII

Contact MDHI Warranty and Repair Dept.

Nomenclature Part No. Qty. Source

369H 1203-51 A/R MDHI

Main Rotor Blade 369A1100-511 AIR MDHI

Main Rotor 81ade 369021100-523 A/R MDHI

Main Rotor Blade 369021102-523 A/R MDHI

Epoxy paint (white, florescent yellow or orange) Commercial

Sealer, corrosion inhibiting I Product Research

Primer (MIL-P-8585) (RM009222) or Commercial

(Alternate) Sealer, (MiL-P-23377, Type 2, Class 2) ICommercial

TOOLS AND EQUIPMENT

Magnifying glass 5X Commercial

Kit, dye penetrant (MIL-I-25135) Commercial

J. Wei~ht and Balance Data:

Weight and balance not affected.

369H Basic HMI (CSP-H-2) Revised 23 August 1996, or latest revision

/I MANDATORY IIIIIIIIIIIII/ MANDATORY 11/1111111/II1 MANDATORY JI

(1). Remove affected main rotor blades per applicable HMI.

NOTE: Do not remove bushings or corrosion inhibiting sealer.

II MANDATORY IIIIIIIIIIIIII MANDATORY IIIIIIIIIIIIII MANDATORY II

to four locations shown in Figure 2.

HN-214, DN-154, EN-44 or FN-33, Service Information Notices.

If cracked or broken l~ig is noted in main rotor blade upper

UPPER ROOT FITTING

LEAD-LAG LINK ATTACH LU~

MAIN ROTOR BLADE ~YoPrr2qLACEs)1)

LOWER ROOT FITTING

II MnNDAToRYIIIIIIIIIII/II MANDATORY/IIIIIIIIII111 MANDATORYII

SERVICE BULLETIN DATE:

II MnNDnToRvll/lllll/l//Il MnNDnToRv/l/lll/llll111 MnNonToRvll

UPPER ROOT FITTING

SERVICE BULLETIN DATE: