CSP SRM 6 - I3r0

369/500/600 Series
SRM Reissue
Manual: CSPSRM6, Structural Repair Manual

Models: 369D/E/FF 500/600N Helicopters
Reissue 3: 25 May 2006
FILING INSTRUCTIONS
Remove old CSPSRM6; Dated 4 July 1992.
(This book is obsolete and should be destroyed)
Insert new CSPSRM6; Dated 26 May 2006.
This Page Intentionally Left Blank
MDHI MODEL HELICOPTERS
MODELS 369D/E/FF - 500/600N
Structural Repair Manual

(CSP-SRM-6)
MD Helicopters, Inc.
4555 East McDowell Road
Mesa, Arizona 85215-9734
Copyright E 19992006 by MD Helicopters, Inc. Reissued No. 3: 26 May 2006

All rights reserved under the copyright laws.
PROPRIETARY RIGHTS NOTICE
The technical data and information contained in this publication is the property of
and proprietary to MD Helicopters, Inc. and is not to be disclosed or reproduced in
whole or in part without the written consent of MD Helicopters, Inc.
RESTRICTED USE
MDHI provides this manual for use by owners, operators and maintainers of MDHI
products and authorized parts. Use by STC or PMA applicants or holders as
documentation to support their certificates is not an authorized use of this manual
and is prohibited. MDHI takes no responsibility for customers use of parts
manufactured under an STC or PMA when this manual is used as documentation with
the Federal Aviation Administration to justify the STC or PMA. Use of unauthorized
parts on MDHI products will void the MDHI warranty offered to the customer on
components and may void the warranty on the helicopter.
MD HELICOPTER, INC.
TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
This manual has been prepared and distributed by the Technical Publications Department and is
intended for use by personnel responsible for the maintenance of MDHI Helicopters. Periodic revision
of this manual will be made to incorporate the latest information. If, in the opinion of the reader, any
information has been omitted or requires clarification, please direct your comments to this office via
this form (or a duplicate). An endeavor will be made to include such information in future revisions.
MD Helicopters, Inc.
Bldg 615 M/S G048
4555 East McDowell Road
Mesa, AZ 85215-9734
Telephone: (800) 310-8539
Technical Publications Order Desk: (480) 346-6372; FAX: (480) 346-6821
Technical Publications Changes: (480) 346-6212; FAX: (480) 346-6809
Date:
Originator:
Address:
E- Mail:
Manual Title: Page Number(s):
Chapter Title: Paragraph Number(s):
ATA Section Number: Step Number(s):
Issue Date:
Figure Number(s):
Revision No. and Date: Table Number(s):
Remarks / Instructions:
Page CRi
Page CRii
MD HELICOPTERS INC.
RECORD OF TEMPORARY REVISIONS
MANUAL TITLE: CSPSRM6 STRUCTURAL REPAIR MANUAL
REV. DATE REMOVED BY REV. DATE REMOVED BY

NO. INSERTED BY INCORPORATING NO. INSERTED BY INCORPORATING
04-001 10-22-04 Reissue 3
Page 1
TR Original
Page 2
Original TR
MD Helicopters Inc. CSPSRM6
STRUCTURAL REPAIR MANUAL
LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGE PAGES, DESTROY SUPERSEDED PAGES
The highest revision number indicates pages changed, added or removed by the current change.
Date of original and revision pages are:
Original . . . . . . . . . . . . . . . . . . . . . . . . 26 May 2006
Cover/Title 53-00-00
Cover/Title . . . . . . . . . . . . . . . . . . . . . . . . . Original 201 thru 230 . . . . . . . . . . . . . . . . . . . . . . . . Original
Change Request 53-10-00
CRi and CRii . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A 201 thru 208 . . . . . . . . . . . . . . . . . . . . . . . . Original
Temporary Revision 53-20-00
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 201 thru 214 . . . . . . . . . . . . . . . . . . . . . . . . Original
List of Effective Pages 53-30-00
201 thru 216 . . . . . . . . . . . . . . . . . . . . . . . . Original
A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
53-30-30
Table of Contents
201 thru 208 . . . . . . . . . . . . . . . . . . . . . . . . Original
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
53-40-00
Chapter 01 201 thru 206 . . . . . . . . . . . . . . . . . . . . . . . . Original
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
53-40-30
01-00-00 201 thru 218 . . . . . . . . . . . . . . . . . . . . . . . . Original
1 thru 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 53-50-10
101 thru 104 . . . . . . . . . . . . . . . . . . . . . . . . Original 201 thru 210 . . . . . . . . . . . . . . . . . . . . . . . . Original
Chapter 32 53-50-30
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 201 thru 212 . . . . . . . . . . . . . . . . . . . . . . . . Original
32-10-00 Chapter 91
201 thru 206 . . . . . . . . . . . . . . . . . . . . . . . . Original i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
Chapter 53 91-00-00
i thru viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 1 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
Page A
LOEP Original
CSPSRM6 MD Helicopters Inc.
Page B
Original LOEP
TABLE OF CONTENTS
CSP-SRM-6
Cover / Title Page
Technical Manual Recommended Change Report
Record of Temporary Revisions
List of Effective Pages
01 Introduction
32 Landing Gear
53 Fuselage
91 Charts
Page i
Contents Original
Page ii
Original Contents
Chapter
01
Introduction

TABLE OF CONTENTS
Para/Figure/Table Title Page
010000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Structural Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Proprietary Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. ATA Numbering System and Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. ATA Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Division of Subject Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Page Number Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Figure and Table Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Associated MDHI Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Handbook of Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Illustrated Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. MDHI Publications Changes and Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Reissue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Application of Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8. Service and Operations Report Form 1601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9. Airframe Station Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Required Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Parts Ordering Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Repair Materials and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Rivet Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F. Publication Index For Fasteners (Rivets, Pins, Lockbolts and Collars) . . . . . . . . 4
G. Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 2. Station Diagram (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3. SRM Sections (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Allowable Damages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Structural Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Repair Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
A. Main Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
B. Boom Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
C. Tailboom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
D. Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page i
01 Contents Original
TABLE OF CONTENTS (Cont.)

3. Crash Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
A. Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
B. Roll Over (After Hard Landing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
C. Tailboom Strike (Chop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
D. NonRepairable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4. Difficult or Major Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5. Criteria for Determination of Repairability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
A. Visual and Initial Check for Repairability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
B. Alignment and More Extensive Checks to Determine Repairability . . . . . . . . . . 102
6. Investigation of Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Page ii
Original 01 Contents
Section
01-00-00
Introduction

INTRODUCTION
STRUCTURAL IDENTIFICATION
1. Proprietary Rights 3. Scope
MD Helicopters, Inc. proprietary rights are This manual groups helicopter structure by
included in the information disclosed herein. location into three sections, Introduction,
Recipient, by accepting this document, agrees landing gear and fuselage. This manual is only
that neither this document nor any part to be used for structural repair. Repair
thereof shall be reproduced or transferred to procedures outlined in this manual provide
other documents or used or disclosed to others information that does not appear in general
for manufacturing or any other purpose, structural publications. Included are special
except as specifically authorized in writing by procedures required to maintain structural
MD Helicopters, Inc. All rights are reserved integrity of this particular helicopter design.
under the copyright laws by MD Helicopters,
Inc. 4. ATA Numbering System and Format
(Ref. Figure 1) This MDHI maintenance
2. Introduction
manual and associated MDHI manuals are
(1). This manual contains only repair and prepared in general compliance with Air
inspection information that is unique to Transport Association Specification for
structure for helicopter Models 369D/E/ Manufacturers Technical Data (ATA100).
FF 500/600N manufactured by MD The uniform numbering system established by
Helicopters, Inc. (MDHI), Mesa Arizo ATA100 is used. This numbering system
na. It is not intended to and does not provides a means for dividing material into
cover standard practices and proce Chapter, Section, Subject and Page.
dures for repair and inspection for the
structure. For such information, refer to (1). Figure 1 shows the numbering system
HMI and other supporting volumes for used in this manual. It is composed of
repair instruction of associated compo three elements, which consist of two
nents. digits each. The chapter and section
elements (subassembly 10, 20, 30, etc.)
(2). Instructions include specific as well as are assigned by ATA100. Subject/Unit
typical methods of repair for various element numbers are assigned by
parts of the helicopter airframe, MDHI.
landing gear, and fuselage attach
fittings. Unless otherwise specified, (2). Figure 2 shows the fuselage divided
instructions are intended for use in into areas for damage investigation and
conjunction with Federal Aviation lists section and figure numbers in this
Agency, Aircraft Inspection and Sheet manual containing repair information
Metal (FAA AC 43.131A) Repair. for the areas.
2ND ELEMENT
1ST ELEMENT 3RD ELEMENT
32 10 10
CHAPTER/SYSTEM SUBJECT/UNIT
LANDING GEAR SYSTEM LANDING GEAR
SECTION/SUB-ASSEMBL Y
LANDING GEAR
Figure 1. ATA Numbering System
Page 1
010000 Original
A. Division of Subject Matter CSPHMI2

Handbook of Maintenance Instructions
This Structural Repair Manual is contained in CSPIPC4
accordance with ATA Specification 100, 232. Illustrated Parts Catalog.
B. Page Number Blocks A. Handbook of Maintenance Instructions
Page number blocks used for each Section in The CSPHMI2, HMI contains illustrated
the Maintenance Manual logically arrange the helicopter removal, installation, maintenance
material as follows: and repair information.
(1). Repairs consists of either a brief B. Illustrated Parts Catalog
subtopic or a combination of the
following subtopics: Structural Identifi CSPIPC4, Illustrated Parts Catalog (IPC),
cation, Allowable Damage or Repairs. and, CSPISC7 and CSPD7, Illustrated
Two methods are used for numbering Structures Catalog (ISC) provide, with text
Repairs page blocks: and illustrations, a complete definition of all
repair parts and spare items available for the
(2). If a single subtopic or all subtopics helicopter. Use the (IPC) and (ISC) only for the
under Repairs are brief, they are purpose of parts procurement.
combined into one topic. All such topics
are numbered within page number 6. MDHI Publications Changes and
block 201 999. Revisions
(3). If individual subtopics become so Changes in the helicopter, equipment, mainte

lengthy that a combination would nance practices, procedures and additional
require numerous pages, each topic is information developed by experience affect
broken out. Page number blocks manual content. To ensure that MDHI
accordingly are as follows: manuals continue to reflect current changes,
revised information is provided by one or more
Structural Identification . . . . . . . 1 99 of the following communications:
Allowable Damage . . . . . . . . . 101 199 A. Revision
Repairs . . . . . . . . . . . . . . . . . . . 201 999 Alteration of portions of the manual by the
replacement, addition and/or deletion of pages
(4). Each page bears an effective date, is accomplished by revision. The List of
either that of original issue or of the Effective pages (LOEP) that accompany each
latest revision. revision identifies all affected pages. Such
C. Figure and Table Numbering pages should be removed from the manual and
destroyed. Added or replaced pages should be
Illustrations and tables use the same number inserted and checked against the LOEP.
ing as the page block in which they appear. For
B. Reissue
example, Figure 202 would be the second
figure in the Repairs section. When referring When large numbers of changes are involved,
to a figure or table within the same section, it the manual is reissued. The preceding issue of
is referenced as follows; (Ref. Fig. 202). When the manual then becomes obsolete and should
referring to a figure or table within another be discarded.
section, it is referenced as follows; (Ref. Table
201, 520000). 7. Application of Notes, Cautions and
Warnings
5. Associated MDHI Manuals
Throughout this manual, and associated
Information beyond the scope of the Mainte manuals, Notes, Cautions and Warnings are
nance Manual may be found in these basic used to emphasize instructions or information
associated manuals which are prepared as considered to be unusual or critical. A NOTE
separate publications but should always be may appear in the text either before or after
kept and used with this manual: instructions to which it applies, depending on
Page 2
Original 010000
the relative significance of the information. 9. Airframe Station Location

CAUTION and WARNING statements are
always placed before the information or (Ref. Figure 2)
instructions to which they apply. The condi (1). All dimensions, shown in inches, are
tions that warrant use of Notes, Cautions and from two reference points designated as
Warnings are defined by the following: Sta. 0.00 and WL 0.00.
(2). Sta. 0.00 is 28.00 inches forward of the
NOTE: An operating procedure or condition fuselage nose on Model 369D and 15.00
that is essential to highlight. inches forward of the nose on Models
369E/FF 500/600N.
Operating procedures and (3). WL 0.00 is tangential to bottom of
CAUTION practices which, if not strictly fuselage at Sta. 90.61.
observed, may result in damage to or de
struction of equipment. (4). Canted Stations (CANT. STA). start at
WL 0.00 unless otherwise specified.
Operating procedures and (5). The CANT. STA. is not the same
WARNING practices which, if not strict distance from Sta. 0.00 over its length
ly observed, may result in personal in and should be referred to in association
jury, or loss of life. with a WL reference.
(6). Measurements from a Station repre
8. Service and Operations Report Form 1601 sented by a rib, frame or bulkhead that
is not accessible may be taken by noting
flange bend direction and compensated
MDHI Service and Operations Report Form on the correct side of visible external
1601 may be used to report to MD Helicopters, skin attachment rivet line.
Inc. in detail any service difficulties encoun
tered with any MDHI helicopter. Use of the A. Required Parts Replacement
form is encouraged and recommended to
enable MDHI to provide owners and operators NOTE: Damage that cannot be satisfactorily
improved service, support and product repaired by patching, or where repair is not
improvements. The form also serves as a economical, requires replacement of the
convenient detailed record for owners and damaged part with a new or serviceable
operators. Copies of the form may be procured unit.
by contacting the Product Support Dept. Mesa, B. Parts Ordering Instructions
Arizona.
Structural repair may require procurement of
parts not listed in Illustrated Parts Catalog
A. Abbreviations (CSPIPC4). When ordering parts, include as
much of the following information as possible:
Throughout this manual abbreviations are in (1). Complete part number, if known or
figures used as follows: available.
AL aluminum
ALY alloy (2). Complete description. Use applicable
BL buttline illustration from this structural repair
CANT. canted manual and illustrated parts catalog to
CRES corrosion resistant steel identify desired part. Reproduce
CL centerline illustration to identified part. Use
DIA diameter sufficient reference markings (pointing
IN inch(s) arrows, etc.) to aid identification of
R radius structural item required. Refer to (SRC)
STA. station Structure Repair Catalog. CSPISC7
WL waterline or CSPD7.
Page 3
010000 Original
(3). Consignees address. repairs whenever required (solid shank rivets

are preferred) except where indicated other
(4). Desired mode of transportation. wise.
(5). Written confirmation of all cabled or NOTE:
telephoned orders is required.
D The blind rivet shank should never be less
NOTE: than 1/8 inch diameter and patch attach
D To avoid misunderstanding, you are re ment should usually consist of rivets of
quested to confirm all cabled orders by same type and size.
letter. Only authorized Service Centers, D If a panel or section of skin is replaced
Distributors and Sales Companies with limited access for replacement of all
should order parts directly from MD He solid shank rivets resulting in a mixture
licopters, Inc.. of types, the following method is pre
D Orders received at MDHI from other ferred.
sources, in most instances and at discre (1). Gain access to rear of structure to be
tion of MDHI will be referred to the Ser riveted by cutting smallest possible
vice Center, Distributor or Sales Compa access hole in area clear of internal
ny closest to the requestor. support structure.
(6). Furnish helicopter model and serial
(2). Complete repair or replacement of skin
number.
panel using solid shank or special rivets
(7). Your complete address. as required. (Always install original or
equivalent type fastener, using oversize
C. Repair Materials and Tools when necessary.)
Repair materials listed in Table 1, and tools (3). At work completion, patch repair access
listed in Table 2 (Ref. Sec. 910000) include hole using blind rivet fasteners.
only those items required for repair of struc
ture discussed in this manual. For all other F. Publication Index For Fasteners (Rivets,
materials and tools, refer to CSPHMI2, Pins, Lockbolts and Collars)
Section 910000, Maintenance Expendable
Materials Table and Ground Support Special National Aerospace Standard 523 contains a
Tool Table. complete code for fasteners specified in this
manual. The listing contains fasteners basic
D. Repair Information code, basic part number, shank material and
description. Manufacturers are also identified
For standard sheet metal repair procedures, for fasteners that are not prefixed by MS or
refer to FAA AC 43.131A, Aircraft Inspection NAS. This rivet code publication may be
and Repair. obtained through:
E. Rivet Selection National Standards Association Inc.
Solid shank rivets are preferred for attach 5161 River Rd.
ment of helicopter external skin. However, Washington, DC 20016
blind (mechanically expanded) rivets may be G. Corrosion Control
used where access to both sides of riveted
space will not permit use of a bucking bar. Refer to CSPA3, Corrosion Control Manual
Blind rivets may be installed in all patch for inspection, treating and repair of corrosion.
Page 4
Original 010000
CANT STA STA STA STA

78.50 146.62 164.87 185.89
CL CANT STA STA STA STA
124.00 137.50 155.75 174.00 CANT STA
MAST 197.78
STA
28.00
WL
WL 45.36 49.37
CORNER C BEAM
PILOTS L
WL 38.64 SEAT
WL 21.50 WL 34.50
WL 32.00
JACKING
POINT
WL 22.75 STA 96.89
WL 11.98
WL 14.19 WL 13.10
WL 0.00 WL 0.00
STA STA STA STA STA STA STA

STA 44.65 56.85 84.79 96.42 108.04 119.67 137.50
0.00
STA STA CANT STA STA STA STA STA
50.50 64.37 78.50 90.61 102.23 113.85 124.00
WL 96.91
WL 55.34 WL 54.17
CANT STA
209.78
CANT STA CANT STA CANT STA CANT STA
197.78 219.96 242.14 264.32
WL 26.67
CANT STA
273.00
CANT STA
281.12
FRAME BASE
NOTE:
WHEN MEASURING EXTERNALLY FROM RIVET LINES,
NOTE THE SIDE AT BULKHEAD OR FRAME INDICATED AS
THE STATION AND COMPENSATE FOR RIVET POSITION 369D
IN THE ATTACHMENT FLANGE.
R01-0003
Figure 2. Station Diagram (Sheet 1 of 4)
Page 5
010000 Original
CANT STA
78.50
STA STA
108.50 STA STA
146.62 164.87 185.89
CL CANT STA STA STA STA
MAST 124.00 137.50 155.75 174.00 CANT STA
197.78
WL 76.70
WL 66.00
STA
15.00
WL
WL 45.36 49.37
CORNER
PILOTS CL BEAM
SEAT
WL 21.50 WL 34.50
WL 32.00
WL 22.75 WL 11.98
WL 14.19 WL 13.10
JACKING POINT
STA 96.89, BL 25.60
WL 0.00 WL 0.00
STA STA STA STA STA STA STA

44.65 56.85 84.79 96.42 108.04 119.67 137.50
STA
0.00 STA STA STA STA STA
50.50 64.37 90.61 102.23 124.00
CANT STA STA
78.50 113.85
WL 102.17
WL 96.91
STA 289.12 (369FF)
WL 55.34 WL 54.17
CANT STA 369FF ONLY

209.78 CANT STA
CANT STA CANT STA CANT STA 264.32
197.78 219.96 242.14
WL 26.67
CANT STA
273.00 WL 25.46 (369E)
WL 22.36 (369FF)
CANT STA
281.12
FRAME BASE
NOTE:
THE STATION AND COMPENSATE FOR RIVET POSITION
IN THE ATTACHMENT FLANGE. 369E/FF
R01-0004
Page 6
Original 010000
STA
129.00
STA
132.90
STA
155.75
STA
124.75 STA STA
146.62 168.20
STA STA
137.50 CANT 174.00
CL
MAST STA
159.97
WL 66.00
STA WL 60.00
15.00
WL 34.50
WL 22.75
WL 14.19 WL 13.10
JACKING POINT
STA 96.89, BL 25.60
WL 0.00 WL 0.00
STA STA STA 96.42 STA STA STA

44.65 56.85 84.79 STA 108.04 119.67 137.50
STA
0.00 STA STA CANT STA STA 102.23 STA STA
50.50 64.37 78.50 90.61 STA 113.85 124.00
STA
AFT JACKING 315.00
POINT STA 275.40,
BL 0.00, WL 41.00
NOTE:
THE STATION AND COMPENSATE FOR RIVET POSITION
IN THE ATTACHMENT FLANGE. 500N
R01-0005
Page 7
010000 Original
STA STA
15.00 100.00
WL
83.00
WL
14.00
WL
0.00
FORWARD MID AFT STA

JACK POINT JACK POINT JACK POINT 338.36
P.STA STA STA STA STA
18.76 96.90 124.00 168.66 303.30
30 IN.
STA
78.50
STA P.STA P.STA
0.00 0.00 30.00
600N
6G06004B
Page 8
Original 010000
369D
EXTENSION
369FF ONLY
369FF ONLY
369E/FF
R01-0001
STRUCTURE SECTION
LANDING GEAR 32-10-00
CANOPY/WINDSHIELD WINDOWS/DOORS 53-10-00
LOWER CENTER FUSELAGE 53-20-00
UPPER AFT SECTION FUSELAGE 53-30-00
TAILBOOM AND THRUSTER 53-40-00
STABILIZERS 53-50-10
Figure 3. SRM Sections (Sheet 1 of 2)
Page 9
010000 Original

500N

600N
R01-0002
STRUCTURE SECTION

LANDING GEAR 32-10-00
CANOPY/WINDSHIELD WINDOWS/DOORS
LOWER CENTER FUSELAGE

53-10-00
53-20-00

UPPER AFT SECTION FUSELAGE 53-30-30
TAILBOOM AND THRUSTER 53-40-30

STABILIZERS 53-50-30
Figure 3. SRM Sections (Sheet 2 of 2)
Page 10
Original 010000
INTRODUCTION
ALLOWABLE DAMAGES
1. Structural Repair impractical due to warpage of Aframe
members and excessive damage to
This manual presents general and detailed other structure that usually results.
information on structure repairs and compo Major repairs or rebuild can usually
nent replacements found to be possible/practi only be accomplished with special
cal and/or reasonably economical. It includes airframe jigs or fixtures making repairs
information on specific tools and other economically questionable or impracti
supporting data required. cal.
The information is based on data obtained B. Boom Fairing
from actual performance of crash damage
repair, visual examination of crash damaged Most common damage to boom fairing is a
helicopters and jigs and fixtures used by MD cracked or damage lower longeron and
Helicopters, Inc. (MDHI) for major repairs. wrinkled or other wise damaged skin.
NOTE: Because of stress and canted Sta.
NOTE: The data does not include details for pe 197.78 alignment requirements, major re
culiar repairs not identified and on which pairs of boom fairing should only be accom
special stress data are required prior to ac plished using an engine and tailboom align
complishment. Request for such data and/or ment check fixture.
permissibility of such repair should always
be referred to a MDHI Field Service Repre C. Tailboom
sentative.
NOTE: Because of tailboom stress and align
Before performing major structural repair, ment requirements, major or rebuild of tail
review the following: boom can only be accomplished by using a
special tailboom holding fixture.
2. Repair Limits D. Stabilizers
Limits to which the airframe can economically NOTE: Extensive repair or rebuild of stabiliz
and feasibly be repaired are determined er(s) can only be accomplished with special
primary by extent of damage. Crash or other jigs and fixtures. Major repair of vertical
damage resulting in distortion of main stabilizer(s) is not allowed.
fuselage structure (including the tailboom)
limits repairs and rebuild. 3. Crash Damage
A. Main Fuselage Airframe crashes usually result the in
following damage with accompanying sheet
The main fuselage is considered to be nonre metal damage, in the approximate sequence
pairable or nonrebuildable if distortion exists presented:
between any one or more of major Aframe
structure members (Sta. 78.50, canted A. Hard Landing
bulkhead structure, mast base structure (1). Outboard left and right distortion of
installation, Sta. 124.00 frame and center pilots seat (canted Sta. 78.50 frame
beam structure). Such distortion usually may not be damaged).
results in one or both of the following:
(2). Breakage of floor longeron.
(1). Engine mount fittingstomast base
misalignment. (3). Breakage of forward landing gear
fitting lugs.
(2). Sta. 197.78 frame fittingtomast base (4). Breakage of rear landing gear fitting.
misalignment. From damaged helicop
ter examined, it has been determined (5). Sta. 78.50 canted frame control tunnel
that repair or rebuild is usually warpage.
Page 101
010000 Original
(6). Damage to center beam. (1). Floor longeron.

(7). Canopy and sheet metal damage. (2). Sta. 78.50 frame installation.
B. Roll Over (After Hard Landing) (3). Center beam.

(4). Sta. 124.00 lower frame installation.
(1). Side structure and sheet metal damage.
(5). Forward landing gear fitting.
(2). Canopy damage.
(6). Aft landing gear fittings.
(3). Fuselage and tailboom twist or mis (7). Oleo supporting fitting.
alignment.
(8). Pilots seat installation (fitting of
C. Tailboom Strike (Chop) controls).
(1). Tailboom damage. (9). Upper longeron installation.
(2). Boom fairing damage. (10). Boom fairing Sta. 197.78 frame fitting.
(11). Boom fairing aft channel.
D. Non-Repairable Items
(12). Cyclic control support bracket assembly.
Mast base structure installation, Sta. 78.50
canted frame structure, Sta. 124.00 frame and (13). Boom fairing.
centerbeam structure are considered as 5. Criteria for Determination of Repairability
nonrepairable if replacement of any of these
fuselage components is required: Determination of repairability requires a close
inspection to identify damage.
(1). Fuselage distortion exists as described A. Visual and Initial Check for Repairability
in Main Fuselage above.
Repairability is to be determined by visual and
(2). Damage is such that it cannot be limited inspections and checks. For example:
permissibly patched as described in this
manual. (1). No visible exterior skin wrinkling at
Sta. 137.50 and Sta. 197.78, with no
(3). Tailboom is considered nonrepairable skin stretch marks.
or nonrebuildable if: (2). No other fuselage distortion and a
(a). Distortion exists. successful completion of Hard Landing
Inspection (Ref. Sec. 055000, CSP
(b). Damage exceeds permissible skin HMI2) indicates that no mast base
and frame member patches as toSta. 197.78 frame misalignment
described in this manual. exists and that masttoSta. 197.78
frame fitting alignment check is
(c). More than minor surface defect generally not required.
repairs are required on forward or
tail rotor gear transmission mount (3). If wrinkles and stretch marks exist,
ing frames. and damage beyond that permissible by
the hard landing inspection is evident,
(4). Vertical stabilizer(s) is considered frame fitting Sta. 197.78tomast base
nonrepairable (Ref. Sec. 535010). misalignment is probable and an
alignment check along with more
4. Difficult or Major Repairs extensive inspection should be made.
Repair and/or replacement of the following (4). Existence of only one skin wrinkle
components is considered to be major and indicates misalignment probably exists.
difficult. These repairs will require extensive
opening of structure for access; working in B. Alignment and More Extensive Checks to
hard to reach areas; repairing or rebuilding Determine Repairability
within close tolerances to ensure proper fits; Visual and initial damage checks that reveal
and use of extreme caution during perfor aggravated damage introduce the requirement
mance. for more extensive checks and inspections.
Page 102
Original 010000
(1). A mast basetoSta. 197.78 frame 6. Investigation of Damage

fitting as well as mast basetoengine
mounting fittings alignment check are Damaged area should be thoroughly cleaned
needed if skin wrinkles, stretch marks and investigated to determine primary cause
and other damage exist in excess of that and full extent of damage.
discussed in step 5. A.
(1). Examine all damage thoroughly
(2). Specific other inspections and checks
regardless of how trivial it may seem.
such as a check or hard point locations
and dimensions between exterior hard
(2). Investigate for cracks, severe scratches
points may be necessary. Warpage or
on stressed parts, distorted or dented
distortion of structural members other
and elongated bolt holes, especially
than Aframe members may affect
after impact damage.
subsequent attachment of optional
equipment.
(3). Examine all parts of structure as well
(3). Cracks or tears in certain areas may as the locally affected area /section for
not be repairable with an overlay patch possible damage.
due to limited space. flush fitting
components. Insertion patching may (4). Perform dyepenetrant inspection of
not be permissible due to stress require any part suspected of having crack
ments. damage.
Page 103
010000 Original
Page 104
Original 010000
Chapter
32
Landing Gear

TABLE OF CONTENTS
321000 Landing Gear System (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Landing Gear Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Ground Handling Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Skid Tube Nutplate Fitting Replacement on Early Configuration Helicopters . . . 202
5. Skid Tube Rivnut Replacement on Current Configuration Helicopters . . . . . . . . . . 202
6. Damper Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Rework of Early Standard Skid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8. Fiberglass Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9. Repair of Oversized Holes in Early Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Landing Gear Repair Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Skid Tube Structural Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Rework of Early Skid Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Page i

Page ii
Section
32-10-00
Landing Gear
System (369D/E/FF -
500N)

LANDING GEAR SYSTEM (369D/E/FF - 500N)

REPAIRS
NOTE: Since the stress loads on the 600N heli tube are required, repair per
copter are significantly different, the re Figure 202.
pairs in this section can only be used for the
369D/E/FF 500N helicopters. For any re (5). Attachment Hole Damage:
pairs on the 600N landing gear, contact MD Worn, enlarged or elongated holes may
Helicopter, Inc. (MDHI) Field Service De be cleaned up to tolerances. Replace a
partment or MDHI Engineering Depart component exceeding maximum limits,
ment. Figure 201.
1. Landing Gear (6). Replacement of Strut:
The landing gear with fuselage supporting Replace strut that is cracked or for
structure and attach points is shown in following damage:
Figure 201. Investigation of landing gear (a). Dents with depth in excess of 0.060
damage must also include inspection of inch (0.1524 mm).
structure and components associated with
landing gear attachment (Ref. Sec. 532000). (b). Scratches or nicks that exceed limits
shown in Figure 201 when measured
2. Landing Gear Repair to surrounding unrepaired surface.
(Ref. Figure 202) For repairs not covered in (7). Replacement of Brace:
following paragraphs, refer to CSPHMI2
Replace brace for the following damage:
and FAA AC 43.131A, Aircraft Inspection and
Repair. (a). Replace cracked, dented or distorted
brace.
Consumable Materials (b). Dents with depth in excess of 0.040
(Ref. Section 91-00-00) inch (1.016 mm).
Item Nomenclature
CM201 Zinc chromate putty
(c). Scratches if repaired area depth
exceeds 0.010 inch (0.254 mm) when
measured to surrounding unrepaired
(1). Repair scratches and nicks by smooth surface.
ing sharp edges. Apply corrosion (8). Replacement of Skid Tube:
protection treatment (Ref. Sec.
204000, CSPHMI2). Replace skid tube when damage cannot
be repaired as shown in Figure 202.
(2). Drill out dents, nicks and scratches (Ref. Chap. 32, CSPHMI2).
requiring repair to nearest blind rivet
size. Do not exceed 0.250 inch (6.35 3. Ground Handling Fitting Replacement
mm) maximum. Clean out puncture
holes in same manner.
Consumable Materials
(3). Apply zinc chromate putty (CM201) to (Ref. Section 91-00-00)
edges of drilled repair hole and install Item Nomenclature
appropriate size rivet to close hole. CM201 Zinc chromate putty
CM301 Primer
(4). If puncture holes, drilledout dents, CM402 Sealing compound
nicks or scratches exceed 0.250 inch
(6.35 mm); if fluorescentpenetrant
inspection reveals damage adjacent to (1). Drill out rivets securing defective
punctures; or if other repairs to skid fitting.
Page 201
321000 Original
(2). Coat mating surfaces with zinc chro 6. Damper Repair

mate putty (CM201) and set replace
ment fitting in place. For exterior damage limits for the landing gear
damper, repair and overhaul information,
(3). Coat new rivets with primer (CM301) Refer to CSPCOM5. Remove scratches and
and install while primer is wet. nicks in damper fittings as follows:
(4). Seal edges with an approximate 0.060 Consumable Materials

inch (0.1524 mm) bead of sealing (Ref. Section 91-00-00)
compound (CM402) for waterproofing. Item Nomenclature
CM801 Abrasive paper, silicon carbide
4. Skid Tube Nutplate Fitting Replacement
on Early Configuration Helicopters CM802 Crocus cloth
Consumable Materials (1). Use grade 400 (or finer) wet or dry
(Ref. Section 91-00-00) abrasive paper (CM801) to remove any
Item Nomenclature raised or sharp edges and to blend
defects smoothly with surrounding
CM402 Sealing compound surfaces.
(2). Use crocus cloth (CM802) to remove
(1). Drill out rivets attaching nutplate any surface scratches left by coarser
fitting to skid tube and remove fitting. abrasive and to polish repaired area to
match surrounding surfaces.
(2). Completely remove any residual zinc
chromate putty or sealing compound (3). Apply corrosion protection treatment
from nutplate mounting area on skid (Ref. Sec. 204000, CSPHMI2).
tube.
7. Rework of Early Standard Skid Assembly
(3). Using sealing compound (CM402),
install replacement nutplate fitting on (Ref. Figure 203) Early skid assemblies are
skid tube. predrilled with additional attachment holes for
the forward foot assemblies to provide for L/H
(4). Rivet nutplate fitting in place. and R/H interchangeability. The following
information is a mandatory procedure for
(5). Apply 0.060 inch (0.1524 mm) bead of sealing the open attachment holes at the
sealing compound around mating part forward foot location on each skid assembly to
edges. prevent water seepage and entrapment and
possible corrosion damage to the skid assem
5. Skid Tube Rivnut Replacement on Current bly.
Configuration Helicopters
(Ref. Section 91-00-00)
Item Nomenclature
Item Nomenclature CM402 Sealing compound
CM402 Sealing compound
(1). Locate the two open attachment holes
between the forward foot assembly and
(1). Drill out damaged rivnut and complete abrasion strip on L/H and R/H skid
ly remove residual sealing compound assemblies.
from rivnut mounting area.
(2). Clean open hole areas of dirt, debris
(2). Install replacement rivnut using etc; seal open attachment holes in each
sealing compound (CM402). skid with sealing compound (CM402).
Page 202
Original 321000
8. Fiberglass Component Inspection

(1). Negligible Damage: Item Nomenclature
CM301 Primer
Minor nicks and scratches that do not CM402 Sealing compound
intersect rivet or screw holes.
(1). Remove nutplate spacer from inside
(2). Patch Repair: diameter of skid tube.
(2). Install blind rivets in open holes that
Cracks and punctures that penetrate held nutplate spacer in place (install
fiberglass laminations are to be patched with wet primer (CM301).
if damage, and does not exceed 20
(3). Ream oversized holes to 0.3120.315
percent of component area. Repair
inch (7.92488.001 mm) diameter.
fiberglass as described in Section
Holes to match in skid tube and foot
530000.
assembly.
(4). Measure required grip length for
NOTE: When structural members bonded with NAS1669 blind fasteners.
in fiberglass are cracked or badly distorted
or when large sections of sharp compound (5). Install NAS16695L4 blind fasteners,
curved areas are severely damaged, replace grip length range 0.2210.228 inch
ment of the damaged part should be consid (5.61345.7912 mm) or NAS1669L5
ered for economical reasons. fasteners with proper grip length as
measured in step (5).. Install with wet
primer (CM301), use care to insure no
9. Repair of Oversized Holes in Early Feet primer gets on thread portion of
fastener.
Repair oversize 0.2540.258 inch (6). Seal all edges of mating parts, includ
(6.45166.5532 mm) diameter holes in ing blind fasteners, with 0.060 inch
369D291131 and 2 foot assembles and (0.1524 mm) bead of sealant (CM402) or
matching holes in skid tubes as follows: equivalent.
Page 203
321000 Original
NOTES:
1. BEFORE REMOVAL, INDEX PARTS BEING REPLACED.
MEASURE FROM STRUTTOHELICOPTER ATTACH
HOLES AND RELOCATE FITTING WITH FLAT SIDES IN
SAME POSITION (REF. CSPHMI2, SEC. 321000).
2. FOR LANDING GEAR ASSOCIATED STRUCTURE
(REF. SEC. 532000).
VERTICAL CL OF STRUT
OLEO ATTACH LUGS
45
90 TYP.
0.010 IN. (0.254 MM) MAX. SCRATCH/NICK LIMITS FOR STRUTS

(TYP FOR ENTIRE LENGTH)
0.020 IN. (0.508 MM) MIN.
ATTACH FITTING (AL ALY)

BRACE (AL ALY) (NOTE 1)
0.313 IN. 0.440 IN. (11.176 MM)
(7.9502 MM) LINE 0.438 IN. (11.1252 MM)
MAX.
0.438 IN.
(11.1252 MM)
0.045 IN.
(1.143 MM)
0.438 IN.
(11.1252 MM) 0.313 IN.
(7.9502 MM) 0.313 IN. (7.9502 MM)
0.440 IN. (11.176 MM) MAX. BPT604 LOCKBOLTS (12 PLCS)
MAX. IN LINE (ALT NAS16693L5)
BRACE AND STRUT

MIN. DEMENSIONS
STRUT ATTACH FITTING
R32-1001A
Figure 201. Landing Gear - Repair Limits
Page 204
Original 321000
REPAIR PERMITTED
NO REPAIR NECESSARY 48.61 IN.

20.97 IN. (123.4694 CM)
(53.2638 CM) 0.50 IN. 5.0 IN.
NO REPAIR PERMITTED 5.06 IN.
(12.8524 CM) (12.7 MM) (12.7 CM)
FOR REPLACEMENT
(REF. CSPHMI2)
REPAIR AREAS
MAX. DAMAGE
4.00 IN. (10.16 CM)
DAMAGED AREA
MSLP B4 TOP
ATTACHMENT RIVETS MIN. 4 ROWS (2 UPPER ROWS)
SPACED 0.720 IN. (18.288 MM) 0.380 IN.
APART EACH SIDE OF DAMAGE (9.652 MM)
(NOTE 1) SPLICE PLATE
0.0900.100 IN. AL ALY 2024 T3
(2.2862.54 MM)
(NOTE 2)
ATTACHMENT RIVETS MIN. 1 ROW 5 ROWS

EACH SIDE EQUALLY SPACED AT EQUALLY SPACED
4X RIVET DIA. MAX.
CL (NOTE 1)
BOTTOM RIVETS MLS1004 COUNTERSUNK RIVETS
ROTATED (3 BOTTOM ROWS)
PATCH REPAIR
8.00 IN. SPLICE SLEEVE

(20.32 CM) 0.0900.100 IN. AL ALY 2024 T3
(2.2862.54 MM) TOP
(NOTE 2)
0.38 IN.
(9.652 MM)
8.00 IN. SEALING COMPOUND
(20.32 CM) (NOTE 2) 28
MSLP B4 RIVETS
(7 ROWS)
REPLACEMENT SECTION (USE SECTION 0.38 IN.

FROM SPARE DAMAGED SKID TUBE) (9.652 MM)
(NOTE 2)
9 ROWS
CL EQUALLY SPACED
ATTACHMENT RIVETS MIN. 5 ROWS
TOP EQUALLY SPACED EACH SIDE OF JOINT
(NOTE 1) MLS1004 COUNTERSUNK RIVETS
(2 BOTTOM ROWS)
NOTES:
1. COAT RIVETS WITH PRIMER (CM301) PRIOR TO INSTALLATION.
2. COAT ALL MATING SURFACES WITH THIN LAYER OF
ZINC CHROMATE PUTTY (CM201) AT INSTALLATION.
APPLY A 0.060 IN. (1.524 MM) FILLET OF SEALING SEALING
COMPOUND (CM405) TO SEAL EXTERIOR MATING SURFACES.
R32-1002A
Figure 202. Skid Tube - Structural Repair
Page 205
321000 Original
DAMPER
(BLACK)
EXTENDED
LOWER FAIRING
DAMPER
(WHITE)
EXTENDED LANDING
GEAR FOOT
SAFETYWALK
TAPE
STRUT EXTENDED LOWER

FAIRING
EXTENDED FOOT
FAIRING BRACKET
HEAVY DUTY ABRASION STRIP
SCREW
EXTENDED
SKID
FAIRING ATTACH POINTS

(TYP)
EXTENDED LANDING
GEAR SKID
FORWARD
FOOT
BOLTS
EXTENDED LANDING
GEAR SKID ASSEMBLY
FORWARD FOOT ASSEMBLY (LH SHOWN)

PN 369D26004101/102 (STANDARD GEAR)
PN 369D29113101/102 (EXTENDED GEAR) SCREW
SEAL ATTACHMENT HOLES

SCREW (2 PLCS EACH SKID)
FORWARD FOOT ATTACHMENT
R32-1003A
Figure 203. Rework of Early Skid Assemblies
Page 206
Original 321000
Chapter
53
Fuselage

TABLE OF CONTENTS
530000 Fuselage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Type of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Metal and Fiberglass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Metal and Honeycomb Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Carbon Fiber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
E. Kevlar Fabric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
F. Transparent Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Primary Structural Member Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Canted Frame Sta. 78.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Center Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Canted Frame Sta. 124.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Mast Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Secondary Structural Member Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Stressed Sheet Metal Panel Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Negligible Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Patch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6. NonStressed Sheet Metal Panel Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . 202
B. Patch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Support of Structure During Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8. Access For Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
9. Fuselage Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
10. Fuselage Fitting Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Insertion Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
C. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
11. Fuselage Sheet Metal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
12. Fuselage Skin Oil Canning (Wrinkles) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Fuselage Skin Wrinkles or Oil Canning Repair . . . . . . . . . . . . . . . . 204
13. Laminated Fiberglass Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
14. Fiberglass Component Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Patch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page i

Table 201. Humidity/Temperature Limits for Fiberglass Repair . . . . . . . . . . . . . . 204
C. Repair of Holes or Cracks in Fiberglass (Patch or Insertion Method) . . . . . . . . . 205
D. Fiberglass Delamination Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
E. Repair of Small Nicks, Scratches or Pores in Fiberglass . . . . . . . . . . . . . . . . . . . . . 206
F. Fiberglass Temporary Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 202. Laminated Fiberglass Repair Typical . . . . . . . . . . . . . . . . . . . . . . . . . 206
15. Stud and Insert Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Stud and Insert Typical Replacement . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204. Skin Paneling Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 205. Support Disassembled (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 206. Structure Isometric View (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . 214
Figure 207. Forward Fuselage (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Figure 208. Landing Gear Rub Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . 220
Figure 209. Seat Belt and Seat Support Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Figure 210. Fuselage Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Figure 211. Flight Control Support Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Figure 212. Pilots Seat Structure (Typical all Models) . . . . . . . . . . . . . . . . . . . . . . 224
16. Composite Repair Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
17. Composite Cosmetic Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
18. Composite Cosmetic Damage Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Figure 213. Composite Cosmetic Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
19. Composite Delamination Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
20. Composite Delamination Damage Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
A. Edge Delamination Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Figure 214. Composite Edge Delamination Damage . . . . . . . . . . . . . . . . . . . . . . . . 226
B. Hole Delamination Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Figure 215. Composite Hole Delamination Damage . . . . . . . . . . . . . . . . . . . . . . . . . 227
C. Internal Delamination Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Figure 216. Composite Internal Delamination Damage . . . . . . . . . . . . . . . . . . . . . 228
21. Composite Fiber Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
22. Composite Fiber Damage Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
A. Fiber Damage from One Side Only: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Figure 217. Composite Fiber Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
B. Fiber Damage Through the Composite Material: . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
531000 Canopy/Windshields and Windows/Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Canopy/Windshield Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page ii

2. Canopy Window Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Pilot and Passenger/Cargo Compartment Door Repair . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Canopy and Window Replacement 369D . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Canopy and Window Replacement Early 369E/FF . . . . . . . . . . . . . . . 204
Figure 203. Canopy and Window Replacement (One Piece Lower Canopy)
Current 369E/FF 500/600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 204. Pilot and Passenger; Cargo Compartment Doors, Typical . . . . . . . . 206
Figure 205. Pilots Compartment Door FrameRepair . . . . . . . . . . . . . . . . . . . . . . . 207
532000 Lower Center Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Lower Center Fuselage Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Cargo Compartment Center Beam Structure Inspection and Repair . . . . . . . . . . . . 201
Figure 201. Lower Center Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Floor Longeron Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 203. Center Beam Structural Repair (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . 204
Figure 204. Typical Fuselage Lower Rib Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3. Forward Landing Gear Center Beam Fitting Replacement . . . . . . . . . . . . . . . . . . . . 206
4. Aft Landing Gear Center Beam Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 205. Forward Landing Gear Center Beam Fitting Replacement
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 206. Landing Gear Center Beam Assembly (Fwd & Aft Fittings) . . . . . . 210
Figure 207. Center Beam Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
5. Aft Oleo Support Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 208. Aft Oleo Support Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
6. Fuel Tank Support Skin Inspection and Repair (Fuel Cells Removed) . . . . . . . . . . . 213
7. Fuel Cell Support Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Figure 209. Fuel Cell Support Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
533000 Upper Aft Section Fuselage (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Upper Aft Fuselage Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cant. Sta. 78.50 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Cant. Sta. 124.00 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Mast Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Aft Fuselage Boom Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
E. Engine Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page iii

2. Boom Fairing Alignment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Engine and Tailboom Alignment Check Fixture Installation . . . . . . . . . . . . . . . . . . . 202
A. Sta. 197.78 Boom Fitting Fixture Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Mast Support Fixture Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
C. Engine Mounts Fixture Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Cant. Sta. 197.78 Frame FittingtoMast Support Fitting Alignment Check . . . . 203
5. Engine MountstoMast Support Fitting Alignment Check . . . . . . . . . . . . . . . . . . . . 203
6. Boom FairingtoFuselage Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 201. Alignment Checks Sta. 197.78 Frame Fitting; Mast Support
Fitting; Engine Mounts; Boom Fairing (Sheet 1 of 4) . . . . . . . . . . . . . 204
7. EngineToTransmission Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8. Engine Mount Shimming (250C20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 202. EngineToTransmission Alignment Check . . . . . . . . . . . . . . . . . . . . . 209
Figure 203. Firewall, Plenum Chamber and Mast Support Structure . . . . . . . . . 210
Figure 204. Upper Aft Structure and Boom Fairing . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 205. Firewall and Plenum Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 206. Tail Rotor Shaft Fairing and Blower Baffle Replacement . . . . . . . . . 213
9. Aft Section Strut Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
10. Inspection and Repair of Lower Engine Mount Installations . . . . . . . . . . . . . . . . . . . 214
Figure 207. Aft Strut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 208. Engine Mount Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 209. Lower Engine Mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Figure 210. Fabrication and Installation of BushingtoAirframe . . . . . . . . . . . . 216
533030 Upper Aft Section Fuselage (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Upper Aft Fuselage Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Composite Components Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Aft Section Strut Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Fan, Fan Gearbox and Boom Fairing Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Engine Mount Shimming (250C20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Aft Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Aft Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 203. Diagonal Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 204. Firewall and Plenum Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 205. Driveshaft Alignment Tools (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . 206
6. Driveshaft Alignment Tools Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
534000 Tailboom (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Tailboom Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page iv

2. Tailboom Sheet Metal Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Patch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Transverse Crack Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Longitudinal Crack Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Tailboom and Stabilizer Fitting Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Studs and Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Insertion Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tailboom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Sta. 197.78 Tailboom Frame Fitting Surface Flatness Check . . . . . 203
4. Control Rod Grommet Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Control Rod Frame Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203. Tailboom Frame Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . 205
Figure 204. Tailboom Damper Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . 206
534030 Tailboom and Thrusters (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Tailboom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tailboom Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Tailboom Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tailboom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Tailboom Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2. Strake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Strake Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Strake Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Stationary Thruster Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Stationary Thruster Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Stationary Thruster Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
C. Stationary Thruster Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Rotating Thruster Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Rotating Thruster Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Rotating Thruster Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
C. Rotating Thruster Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Stator Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Page v

B. Stator Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
C. Stator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Rotating and Stationary Thruster Assembly . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Table 201. Tailboom Forward Flange (Zone One) . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 204. Tailboom Forward Flange (Zone One) . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Table 202. Tailboom Transitions Areas (Zone Two) . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 205. Tailboom Transitions Areas (Zone Two) . . . . . . . . . . . . . . . . . . . . . . . . 210
Table 203. Tailboom General (Zone Three) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 206. Tailboom General (Zone Three) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Table 204. Tailboom Slots and Airfoils (Zone Four) . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 207. Tailboom Slots and Airfoils (Zone Four) . . . . . . . . . . . . . . . . . . . . . . . . 213
Table 205. Horizontal Stabilizer and Tail Skid Attachment Points
(Zone Five) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Figure 208. Horizontal Stabilizer and Tail Skid Attachment Points
(Zone Five) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Table 206. Stationary Thruster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 209. Stationary Thruster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Table 207. Rotating Thruster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Figure 210. Rotating Thruster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Table 208. Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Figure 211. Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
535010 Stabilizer (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Vertical Stabilizers Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Vertical Stabilizers Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Vertical Stabilizer Stressed Sheet Metal Panel Inspection and Repair . . . . . . . . 201
Figure 201. Vertical Stabilizer (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Vertical Stabilizer NonStressed Sheet Metal Inspection and Repair . . . . . . . . . 204
D. Vertical Stabilizer Leading and Trailing Edge Repair . . . . . . . . . . . . . . . . . . . . . . . 204
2. Horizontal Stabilizer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Horizontal Stabilizer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Horizontal Stabilizer Sheet Metal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Horizontal Stabilizer and Tip Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3. Horizontal Stabilizer Tip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Horizontal Stabilizer Tip Plate Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Horizontal Stabilizer Tip Plate Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . 206
C. Horizontal Tip Plate Fiberglass Cap Inspection and Repair . . . . . . . . . . . . . . . . . . 206
Page vi

D. Tip Plate Insert Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Tip Plate Insert Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4. Horizontal Stabilizer Assembly Rework (369E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 204. Horizontal Stabilizer Rework (369E/FF) . . . . . . . . . . . . . . . . . . . . . . . . 209
535030 Stabilizer (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Horizontal Stabilizer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Horizontal Stabilizer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Horizontal Stabilizer Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Horizontal Stabilizer Spar Box Eyebolt Mounting Holes
(Zone One) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Horizontal Stabilizer Spar Box Eyebolt Mounting Holes
(Zone One) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Table 202. Horizontal Stabilizer Spar Box (Zone Two) . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203. Horizontal Stabilizer Spar Box (Zone Two) . . . . . . . . . . . . . . . . . . . . . . 204
C. Horizontal Stabilizer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Table 203. Horizontal Stabilizer Torque Tube Fittings and Access Openings
(Zone Three) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 204. Horizontal Stabilizer Torque Fittings and Access Openings
(Zone Three) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Table 204. Horizontal Stabilizer Leading Edge (Zone Four) . . . . . . . . . . . . . . . . . . 207
Figure 205. Horizontal Stabilizer Leading Edge (Zone Four) . . . . . . . . . . . . . . . . . 207
Table 205. Horizontal Stabilizer Trailing Edge (Zone Five) . . . . . . . . . . . . . . . . . . 208
Figure 206. Horizontal Stabilizer Trailing Edge (Zone Five) . . . . . . . . . . . . . . . . . 208
2. Vertical Stabilizer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
A. Vertical Stabilizer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
B. Vertical Stabilizers Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
C. Vertical Stabilizer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
D. NonStructural Leading and Trailing Edge Repair . . . . . . . . . . . . . . . . . . . . . . . . . 209
Table 206. Vertical Stabilizers Leading Edge, Skin, Ribs, and Area Around
Spar (Zone One) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 207. Vertical Stabilizer (Zone One) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Table 207. Vertical Stabilizer Spar (Zone Two) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 208. Vertical Stabilizer (Zone Two) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Page vii

Page viii
Section
53-00-00
Fuselage Assembly

FUSELAGE ASSEMBLY
REPAIRS
1. Fuselage F. Transparent Plastic
The 500/600N helicopter is similar to the The transparent portions of upper, lower and
369D/E/FF helicopter. Structural differences center canopy windshields and aft section
are modifications to the aft section fuselage windows are made of acrylic plastic.
structure, tailboom and air inlet fairing
assembly. 3. Primary Structural Member Inspection
2. Type of Construction Identification of damage to primary structure
resulting in twisting distortion and displace
The helicopter fuselage, tailboom and tail ment of the member may be determined by
surfaces, and landing gear primary and using alignment tools. MD Helicopters, Inc.
secondary structural construction consists of (MDHI) assistance may be required. An
allmetal, metal and fiberglass, metal and inspection check of alignment performed when
honeycomb structure, carbon fiber and kevlar damage extends beyond a localized area or if
fabric structure components, and transparent cause of damage cannot be determined.
plastic components. Primary structural members are:
A. Metal
A. Canted Frame Sta. 78.50
The 369D/E/FF helicopter fuselage, tailboom
and tail surface sections are conventional, all Damage to the canted Sta. 78.50 frame
metal, riveted structures incorporating formed resulting in twisting, distortion or displace
aluminum alloy, stainless and titanium ment is not repairable without MDHI assis
bulkheads, frames, channels, longerons and tance.
stiffeners. All stressed skins are either smooth
or beaded. B. Center Beam
B. Metal and Fiberglass Major damage to center beam is repairable as

long as damage does not result in twisting,
The engine inlet fairing and fuel cell support distortion or displacement of canted frames
skins are sheet aluminum and glass cloth. The and mast support.
canopy ventilating panel is laminated glass
cloth. C. Canted Frame Sta. 124.00
C. Metal and Honeycomb Structure Damage to canted Sta. 124.00 frame resulting
in twisting, distortion or displacement is not
The 369D/E/FF vertical stabilizer main repairable without MDHI assistance.
structure and horizontal stabilizer tip plates
are of honeycomb construction bonded in D. Mast Support Structure
aluminum skins.
Damage to mast support structure resulting in
D. Carbon Fiber twisting, displacement or distortion is not
repairable without MDHI assistance.
The 500/600N tailboom, stator, rotating
thruster and stationary thruster are
constructed of multiple layers of carbon fiber 4. Secondary Structural Member Inspection
composite material and adhesive.
Damage to secondary structure such as
E. Kevlar Fabric firewall and plenum chamber and pilots
compartment seat structure may be repaired
The 500/600N engine inlet fairings,and without use of alignment tools provided that
tailboom fairings are constructed of Kevlar the damage to major structure has not
fabric material. resulted in twisting, distortion or replacement.
Page 201
530000 Original
5. Stressed Sheet Metal Panel Inspection which are stressed). Guidelines defining repair
and Repair of damage are as follows:
(Ref. Figure 204) Stressed sheet metal panels A. Negligible Damage

consist primarily of helicopter fuselage skins
and bulkhead (frame) webs. The most highly (1). Small dents, scratches, nicks and light
stressed skin sections are those that form the corrosion deposits are considered
cylindrically tapered tailboom and the vertical negligible damage.
stabilizer honeycomb spar skin surfaces.
Classification of damage, guidelines defining (2). Cracks less than 0.250 inch (6.35 mm)
extent of damage requiring complete replace long that are less than onefourth
ment and basic repair methods applicable to width of damaged component, and are a
stressed sheet metal panels of the main least 1 inch (25.4 mm) from end of
fuselage are outlined as follows: damaged component or an attachment
point, may also be considered negligible
NOTE: A skin panel is defined as skin area damage.
bounded by three or more structural mem
bers (stiffeners, stringers, longerons, etc.). NOTE: Any unrepaired damage that pene
trates metal protective coating may cause
A. Negligible Damage corrosion of the effected panel.
No damage is considered negligible. B. Patch Repair
(1). All repairable damage shall be repaired (1). Repair or replacement of nonstressed
upon detection. panels shall be at owners discretion.
(2). Cracks, tears or punctures in stressed 7. Support of Structure During Repair

sheet metal panels, that do not exceed
0.250 inch (6.35 mm) and can be (Ref. Figure 205) Support helicopter structure
removed by drilling out with a 0.250 with padded cradles positioned directly under
inch (6.35 mm) or smaller drill, do not structure bulkhead, on jacks installed at three
require structure doublers. jacking points.
B. Patch Repair
CAUTION
(1). Cracks, tears or punctures in stressed
sheet metal panels exceeding 0.250 inch D Removal of parts for repair or replace
(6.35 mm) are to be patched provided ment may result in other structure being
damage area does not exceed total of 25 overloaded and result in possible damage
percent of panel area (previously (adequate support must be provided at all
repaired areas included). times).
D Placing supports at locations other than
(2). The patch shall be applied to convex directly under a structural bulkhead re
surface of the stressed panel. sults in damage to helicopter skin panels.
(3). Patch with a single row of rivets, using 8. Access For Repair
6 8 diameter spacing.
Instruction for gaining access to helicopter
6. Non-Stressed Sheet Metal Panel structure and for removal of associated
Inspection and Repair components are not provided in this manual.
Before repair or replacement of any helicopter
Nonstressed sheet metal members consist structure, refer to CSPHMI2 for removal
primarily of hinged covers and doors (except and installation instruction for hardware and
fuel cell access doors and controls access door components in damaged area.
Page 202
Original 530000
Any time work is performed C. Replacement

CAUTION near engine and engine cooling
air inlets, use care to prevent entry of for (1). Damage to fittings beyond negligible
eign objects. Tape cover of cardboard or oth damage and insertion repair requires
er suitable material over engine inlet and replacement of entire fitting.
engine cooling air screens. Do not remove
until work is complete and debris is thor NOTE: During replacement of certain structur
oughly cleaned out of area around base of al fittings, special jigs or locating fixtures
mast, inlet plenum, and entire plenum are required to establish and hold critical
chamber is free of foreign material. If en fuselage dimensions. Before attempting re
gine is not installed, thoroughly clean area placement of bulkhead splice fittings (upper
before engine installation. fittings used for attachment of upper engine
mounts), contact a MDHI Field Service Rep
9. Fuselage Fittings resentative.
Any damage in excess of negligible limits 11. Fuselage Sheet Metal Repair
requires replacement of part. Any cracks,
regardless of length, requires replacement of For sheet metal repair procedures not covered
part. in the following paragraphs, refer to FAA AC
43.131A Aircraft Inspection and Repair.
Table 3, 910000 lists materials which may
10. Fuselage Fitting Inspection and Repair be substituted for patch repairs.
(Ref. Figure 209, Figure 210, Figure 211)
Repair of cast and forged fittings should be 12. Fuselage Skin Oil Canning (Wrinkles)
preformed only when replacement components Repair
are not immediately available.
(Ref. Figure 201) An oil can" as applied to
NOTE: Any cracks, regardless of length, re fuselage skin only, is visual observation of a
quires replacement of part. bulge or wrinkle out of contour between
structural members in essentially the un
loaded state.
A. Negligible Damage
(1). When determining if oil can" condition
(1). Longitudinal scratches, nicks or dents exists, use visual observation only.
shall not exceed 0.010 inch (0.254 mm)
depth or 15 percent of fitting length. (2). No external pressure should be applied
to skin.
(2). Transverse scratches, nicks or dents
shall not exceed 0.010 inch (0.254 mm) (3). Any oil canning in fuselage boom
depth or 10 percent of fitting thickness fairing is an indication of structural
(Preceding damage limits apply after damage.
polishing or repair is accomplished).
(4). Shims may also be added between
(3). Following scratch removal, perform lower fuselage frame or ribs during
flatness check of canted Sta. 197.78 installation of replacement external
frame fittings. skin panels or patch repairs.
B. Insertion Repair (5). Make shims from 2024T3 aluminum

alloy sheet stock 0.040 inch (1.016 mm)
(1). Replacement of bushings, or inserts of maximum thickness by 0.050 inch (1.27
dissimilar metal that form a part of the mm) wide.
fitting are considered insertion repairs.
Insertion repair procedures are de (6). Taper shim and pick up minimum of
scribed in FAA AC 43.131A. three rivets.
Page 203
530000 Original
FUSELAGE RIB
OR FRAME
WRINKLE
(EXTERIOR SKIN)
RIB OR FRAME
PICK UP EXISTING RIVETS

(MIN. 3 PLCS)
STIFFENER 1.00 X 1.00 IN. (2.54 X 2.54 CM)

mAX. ONE GAGE THICKER THAN SKIN
MATERIAL. OR SAME MATERIAL AND SHIM, MAKE FROM 0.040 IN.
CROSSSECTION AS LONGEST (1.016 MM)) MAX. THICK 2024T3
ADJACENT STIFFENER. FORM TO FIT AL ALY, 0.50 IN. (12.7 MM) WIDE
CONTOUR. RIVETS AND SPACING SAME
AS NEAREST STIFFENER.
R53-0001A
Figure 201. Fuselage Skin Wrinkles or Oil Canning - Repair
13. Laminated Fiberglass Components areas are severely damaged, replacement of

the damaged part should be considered for
Fiberglass components such as fuel cell economical reasons.
support skins, canopy ventilating panel and
ducts, engine inlet fairings, heating and
cooling ducts and blower scroll maybe re NOTE: Humidity/Temperature Limits in
paired. Table 201 are recommended for best results.
14. Fiberglass Component Inspection and
Repair Table 201. Humidity/Temperature Limits for
A. Negligible Damage Fiberglass Repair
Humidity Ambient Temperature
Minor nicks and scratches that do not intersect
rivets or screws holes. (Percent) (Degrees F) (Degrees C)
75 70 21
B. Patch Repair
71 75 24
Cracks and punctures that penetrate fiber
glass laminates are to be patched if damage 68 80 27
does not exceed 20 percent of component area, 65 85 29
when structural members bonded within
61 90 32
fiberglass are cracked or badly distorted or
when large sections of sharp compoundcurved 58 95 35
Page 204
Original 530000
C. Repair of Holes or Cracks in Fiberglass patches, maintaining relative place

(Patch or Insertion Method) ment order of each cloth.
(Ref. Figure 202) Use protective clothing dur
WARNING ing preparation and use of
resin mixture. Adequate ventilation
must be provided.
Item Nomenclature NOTE: Each layer of fiberglass cloth is approxi
CM202 Methyl-ethyl-ketone mately 0.010 inch (0.254 mm). thick after
CM501 Fiberglass cloth curing. Use sufficient number of layers to at
CM502 Polyester laminating resin
least equal original thickness of material be
ing patched. Warming cloth provides great
CM801 Abrasive paper, silicon carbide er flexibility. Do not use hot iron for warm
CM803 Antimony trioxide (fire retardant for ing cloth.
polyester resin)
(7). Prepare resin (CM502) according to
manufacturers instructions. Stir
Sanding on glass cloth rein thoroughly for uniform mixture. Avoid
WARNING forced laminates produces any whipping or beating that may
fine dust that may cause skin irrita produce air bubbles in mixture. If resin
tions. Breathing of this dust may be is being used to repair air ducts or
harmful. Comply with necessary pro blower scroll, mix in 6 8 percent, by
tective measures. weight, of fire retardant (CM502).
NOTE: When accomplishing patch or insertion NOTE: Resin and catalyst should not be mixed
repair in an area secured by rivets or until required because mixture has limited
screws, always laminate or bond metal or fi pot life. Warming mixture reduces viscosity
berglass doubler washer at each attachment and aids handling, but shortens pot life of
point for reinforcement. mixture. In all cases, refer to resin manufac
turers instructions on use of resin. Process
(1). Cut away damaged area to form square,
ing and repair work should be preformed in
rectangular or circular opening.
an area sheltered from adverse weather con
(2). Trim 30 to 40 degree chamfers at edges ditions and free from dust.
on both sides of repair area. (8). Place wax backup box against surface
(3). Using abrasive paper (CM801), sand of repair area on opposite side of
damaged area (both sides, when working (patch) surface.
possible) to form beveled surfaces. (9). Install first layer of cloth and brush
(4). Thoroughly clean surface of repair area prepared resin over prepared area and
with clean lintfree cloth moistened cloth, thoroughly impregnating cloth.
with MEK (CM202) until resin or cloth Scrape away any excess resin. Repeat
is exposed. procedure until repair area is complete
ly filled. Smooth surface, blending
(5). Dry repair area with clean dry lintfree patch into surrounding area, and
cloth. remove any air bubbles by applying
slight pressure when necessary.
(6). Cut layers of fiberglass cloth (CM501)
to uniformly fill repair area. After (10). Cure at room temperature for 24 hours
completely filling repair area, cut final or allow to stand at room temperature
layer of cloth to completely overlap for 1 hour, followed by heating at 160F
entire repair area. Remove all cloth (71C) for 1 hour.
Page 205
530000 Original
D. Fiberglass Delamination Repair repaired by working prepared resin into void

and curing.
Work prepared resin between plies, apply
pressure to force plies together and cure.
F. Fiberglass Temporary Repair
(1). Cure at room temperature for 24 hours
or allow to stand at room temperature
for 1 hour, followed by heating at 160F Temporary repairs may be made by applying
(71C) for 1 hour. prepared resin to aluminum patch 0.025 inch
E. Repair of Small Nicks, Scratches or Pores (0.635 mm) thick and installing temporary
in Fiberglass patch over damaged area. Permanent types of
repair or replacement of fiberglass should be
Small nicks, scratches or pores may be accomplished as soon as possible.
NOTE 3
NOTE 2, 4
FIBERGLASS PANEL
NOTES:
1. REMOVE DAMAGED AREA BY TRIMMING CHAMFER
EDGE OF CUTOUT AREA 30 TO 45 DEGREES.
2. CUT FIRST FIBERGLASS PATCH WITH 1 IN.
(2.54 CM) MIN. OVERLAP OF CUTOUT AREA.
3. CUT SUCCESSIVE FIBERGLASS PATCHES
NOTE 1 PROGRESSIVELY LARGER TO PROVIDE SCARFED
OR FEATHERED EDGE.
4. USE PHENOLIC MATERIAL OR ALUMINUM IN
WAXED BACKUP BRACKET OR FLANGE ATTACHED AREA.
BLOCK
R53-0002A
Figure 202. Laminated Fiberglass Repair - Typical
Page 206
Original 530000
15. Stud and Insert Replacement (3). Using drill, remove inserts as follows:
(Ref. Figure 203) (a). Drill out inner serrations of locking

ring and serrated collar.
(1). Remove studs using hollow mill.
(b). Drill to depth of first thread.
(a). Mill out inner serrations of lockring
and stud serrated collar (mill to (c). Install bolt with check nut; then
depth of first thread). screw out insert.
(b). Screw out stud.
(d). If required, collapse lockring with
punch and remove.
(c). If locking ring is not forced out
during stud removal, collapse ring
with punch and remove. (4). Install replacement stud or insert as
follows:
(2). For alternate stud removal method:
(a). Install replacement stud or insert by
(a). Cut off stud flush with housing. turning until top of collar serrations
are flush to 0.020 inch (0.508 mm)
(b). Remove serrations by center drilling below surface.
stud.
(b). Install locking ring by lining up
(c). Continue center hole with smaller matching serrations and pressing
drill. into housing.
(d). Use EZYOut or similar tool to back (c). Locking ring is installed flush to
out stud. 0.010 inch (0.254 mm) below housing.
STEP 1 STEP 2 STEP 3

MILL OR DRILL OUT INNER SERRATIONS BACK OUT STUD OR INSERT COLLAPES AND REMOVE LOCKRING
STUD
LOCKRING
R53-0003
Figure 203. Stud and Insert - Typical Replacement
Page 207
530000 Original
7
3 1
B C 7
3 6
1
7
2 5
2 4
A
1
369D
3 7
1
B C 7
B
3 6
1 7
2
5 4
2
1
A
369E
1 7
3
B C 7
B
3 6
1 7
2
2 5 4
1
A
369FF
R53-0004-1
Figure 204. Skin Paneling - Diagram (Sheet 1 of 2)
Page 208
Original 530000
3 D
9 10

3

8
E
G G
1 E
F
2
2 5 4
G
1
A
500N
3
10
D
3
2
E 8
1 G
G

5 4
2 F
1
A
CAUTION:
DO NOT INSTALL CONDITION O MATERIAL.
HEATTREAT PARTS TO T CONDITION INDICATED
AFTER FORMING.
600N
R53-0004-2A
Index No. Gage Commercial Designation

1. 0.016 IN. (0.4064 MM) Al Aly 2024-T42
2. 0.032 IN. (0.8128 MM) (Inner skin) Al Aly 2024-T42
0.020 IN. (0.508 MM) (Outer skin)
3. 0.020 IN. (0.508 MM) Al Aly 2024-T3
4. 0.012 IN. (0.3048 MM) Titanium (Unalloyed)
5. 0.025 IN. (0.635 MM) (Inner channel) Al Aly 7075-T6
0.020 IN. (0.508 MM) (Outer channel)
6. 0.040 IN. (1.016 MM) Al Aly 2024-T3
7. (Ref. Sec. 53-50-00)
8. (Ref. Sec. 53-40-30)
9. & 10. (Ref. Sec. 53-50-30)
Fiberglass Kevlar Fabric Carbon Fiber
A. 6 Layers D. 4 Plies G. 9 Plies
B. 4 Layers E. 5 Plies
C. 4 Layers F. 3 Plies
Figure 204. Skin Paneling - Diagram (Sheet 2 of 2)
Page 209
530000 Original
JACK PAD STA 197.703
CUT HOLES OVER FUEL CELL ACCESS DOORS
1.00 IN. PLYWOOD (TYP)
BOLTS THROUGH DRUM. SHIM AS REQUIRED

BETWEEN DRUM AND PLYWOOD.
2X4 IN. WOOD NAILED TO PLYWOOD
JACK FITTING STA. 96.89

55 GAL DRUM OR EQUIVALENT
CAUTION: REMOVE STABILIZER OR PROVIDE FOR

SUPPORT WHEN INSTALLING TAILBOOM ON CRADLES.
CANT. STA. 274.00
CANT. STA. 209.78 HARDWARE SHOWN

IS TYPICAL
CARGO TIEDOWN FITTING

ATTACHMENT HOLES (4 PLCS)
PLYWOOD
NOTES:
1. HELICOPTER SHOWN WITH LANDING GEAR, ENGINE, MAST,
DRIVE SYSTEM AND FUEL REMOVED.
2. HELICOPTER FUSELAGE MAY BE SUPPORTED ON PADDED
CRADLES POSITIONED DIRECTLY UNDER STA. 78.50 AND
STA. 124.00 STRUCTURAL BULKHEAD.
R53-0005-1
Figure 205. Support - Disassembled (Sheet 1 of 4)
Page 210
Original 530000
JACK PAD STA 197.703



CANT. STA. 274.00
CANT. STA. 209.78 HARDWARE SHOWN

IS TYPICAL

NOTES: PLYWOOD
R53-0005-2
Page 211
530000 Original



HARDWARE SHOWN
IS TYPICAL

NOTES:
1. HELICOPTER SHOWN WITH LANDING GEAR, ENGINE, MAST, PLYWOOD
R53-0005-3
Page 212
Original 530000


HARDWARE SHOWN
IS TYPICAL

NOTES: ATTACHMENT HOLES (4 PLCS)
CRADLES POSITIONED DIRECTLY UNDER STA. 78.50 AND PLYWOOD
R53-0005-4
Page 213
530000 Original
369D R53-0006-1
Figure 206. Structure - Isometric View (Sheet 1 of 4)
Page 214
Original 530000
BOOM EXTENSION
MODEL 369FF ONLY
369E/F R53-0006-2
Page 215
530000 Original
500N R53-0006-3
Page 216
Original 530000
600N R53-0006-4
Page 217
530000 Original
NOTES:
R53-0007-1
1. REFER TO FAA AC 43.131A, AIRCRAFT INSPECTION
AND REPAIR FOR STANDARD SHEET METAL REPAIR.
2. MATERIALS INDICATED ARE TO BE USED AS A
PATCH REPAIR GUIDE ONLY (REF. TABLE 3, 910000)
FOR SUBSTITUDE MATERIALS).
3. REFER TO THE SKIN PANELING DIAGRAM FOR
EXTERIOR SKIN THICKNESS AND MATERIAL.
4. MS20470AD RIVETS USED IN MOST FLOOR
STRUCTURE.
CL
CHANNEL, 0.032 IN. (0.8128
MM) 7075T6 AL ALY
CANT. STA. 78.50
SHOULDER STRAP FITTING BEAM, AL ALY
Figure 207. Forward Fuselage (Sheet 1 of 2)

FWD, 0.016 IN. (0.4064 MM) 2024T42 AL ALY
WEBSAFT, 0.025 IN. (0.635 MM) 2024T42 AL ALY
CHANNELS, 0.024 IN. (0.6096 MM)
UPPER CANOPY FRAME, 0.032 IN. (0.8128 MM) 7075T6 AL ALY
7075T6 AL ALY
HARD POINT EXTRUSION,
7075T6 AL ALY
CANOPY FRAME, 0.032 IN. (0.8128 MM) WEB, 0.016 IN. (0.4064 MM)
2024T42 AL ALY 2024T3 AL ALY
MD Helicopters Inc.
STIFFENER, 0.020 IN. (0.508 MM)

DOOR FRAME ASSY 2024T42 AL ALY
PILOTS SEAT STRUCTURE 7075T6 AL ALY
7075T6 AL ALY
CANT. STA. 78.50 LOWER FRAME, PILOTS SEAT BELT FITTING,
530000
0.040 IN. (1.016 MM) 7075T6 AL ALY INBOARD
LOWER CANOPY FRAME, 0.040 IN.
(1.016 MM) 7075T6 AL ALY LANDING GEAR CENTER BEAM ASSY.,
FWD REPLACEMENT SEC. 532000
LONGERON, EXTRUSION AL ALY
PILOTS SEAT BELT FITTING,
CANT. STA. 64.365 BULKHEAD, 0.025 IN. OUTBOARD
(0.635 MM) 2024T42 AL ALY
STA. 44.65 FRAME, 0.025 IN. DOOR FRAME REPAIR SEC. 531000
(0.635 MM) 2024T42 AL ALY
CANOPY REPLACEMENT WEB, 0.040 IN. (1.016 MM) 2024T3 AL ALY
SEC. 531000
CANOPY PANEL ASSY. WL. 13.10
(4 PLY FIBERGLASS)
EXTRUSION, AL ALY STIFFENERS, 0.025 IN. (0.635 MM) 7075T6 AL ALY
WEB, 0.016 IN. (0.4064 MM) 2024T3 AL ALY ACCESS CHANNELS, 0.025 IN. (0.635 MM) 2024T3 AL ALY
CSPSRM6
LANDING GEAR RUB PLATE

ANGLES, 0.020 IN. (0.508 MM) 2024T3 AL ALY
Page 218
Original
INTERCOSTALS, 0.025 IN. (0.635 MM) 2024T3 AL ALY
ANTITORQUE PEDAL SUPPORT, UPPER FLOOR SKIN, 0.020 IN. (0.508 MM) 2024T3 AL ALY
ANTITORQUE PEDAL SUPPORT, LOWER
WL. 15.75 FLOOR LONGERON REPAIR SEC. 532000)
NOTES:
AND REPAIR FOR STANDARD SHEET METAL REPAIR.
PATCH REPAIR GUIDE ONLY (REF. TABLE 3, 910000)
FOR SUBSTITUDE MATERIALS).
3. REFER TO THE SKIN PANELING DIAGRAM FOR
EXTERIOR SKIN THICKNESS AND MATERIAL. CL
4. MS20470AD RIVETS USED IN MOST FLOOR STRUCTURE. CANT. STA. 78.50
BEAM, AL ALY
FWD, 0.016 IN. (0.4064 MM) 2024T42 AL ALY

WEBSAFT, 0.025 IN. (0.635 MM) 2024T42 AL ALY
UPPER CANOPY FRAME, 0.032 IN.

(0.8128 MM) 7075T6 AL ALY CHANNELS, 0.024 IN. (0.6096 MM)
7075T6 AL ALY
CANOPY FRAME, 0.032 IN.
(0.8128 MM) 2024T42 AL ALY
DOOR FRAME ASSY
PILOTS SEAT STRUCTURE

WEB, 0.016 IN. (0.4064 MM) 2024T3
AL ALY
2024T3 AL ALY
MD Helicopters Inc.
CANT. STA. 78.50 LOWER FRAME 7075T6 AL ALY

(0.040 IN. 2024T3 AL ALY STIFFENER, 0.040 IN. (1.016 MM)
7075T6 AL ALY
LONGERON, EXTRUSION AL ALY PILOTS SEAT BELT FITTING, INBOARD
WEB, 0.040 IN. (1.016 MM) 2024T3 AL ALY

CANT. STA. 64.365 BULKHEAD, LANDING GEAR CENTER BEAM ASSY. FWD
0.025 IN. (0.635 MM) 2024T42 AL ALY
PILOTS SEAT BELT FITTING, OUTBOARD
530000
Figure 207. Forward Fuselage (Sheet 2 of 2)
STA. 44.65 FRAME, 0.025 IN. DOOR FRAME REPAIR SEC. 531000
(0.635 MM) 2024T42 AL ALY
CANOPY REPLACEMENT WL. 13.10
SEC. 531000
CANOPY PANEL ASSY. STIFFENER, 0.025 IN. (0.635 MM)
(4 PLY FIBERGLASS) 7075T6 AL ALY
EXTRUSION, AL ALY ACCESS CHANNEL, 0.025 IN. (0.635 MM)
WEB, 0.016 IN. (0.4064 MM) 2024T3 AL ALY
2024T42 AL ALY LANDING GEAR RUB PLATE
ANGLES, 0.020 IN. (0.508 MM) INTERCOSTALS, 0.025 IN. (0.635 MM) 2024T3 AL ALY
2024T3 AL ALY FLOOR SKIN, 0.020 IN. (0.508 MM) 2024T3 AL ALY
ANTITORQUE PEDAL SUPPORT, UPPER
WL. 15.75 FLOOR LONGERON REPAIR SEC. 532000
ANTITORQUE PEDAL SUPPORT, LOWER
R53-0007-2
CSPSRM6
Page 219
Original
0.80 IN. (20.32 MM) TRACE

STA. 78.50
FUEL TANK AREA
0.60 IN. (15.24 MM)
0.50 IN. (12.7 MM)
EXISTING RIVET CENTERLINE EDGE DISTANCE (TYP)
0.65 IN. (16.51 MM)
0.45 IN. (11.43 MM) EXISTING RIVET MS20470AD4 OR

CENTERLINE CKLP4B RIVETS
STRUT (22 REQUIRED)
CUTOUT
MS20426AD34 RIVETS
(8 REQUIRED)
1.60 IN. (4.064 CM)

EXISTING RIVET
CENTERLINE
0.60 IN. 0.50 IN. (12.7 MM)
0.60 IN. (15.24 MM) (15.24 MM)
0.75 IN. (19.05 MM)
CUTLINE (IF REQUIRED) 0.25 IN.
(6.35 MM) 0.25 IN. (6.35 MM)
TRACE
STA. 78.50
FORWARD RUB PLATE
CAUTION: DO NOT ALLOW DRILL
FUEL 0.25 IN. (6.35 MM) EXISTING RIVET CENTERLINE PENETRATION IN FUEL TANK AREA
TANK BEYOND 0.75 IN. (19.05 MM).
AREA MS20470AD4 OR
CKLP4B RIVETS
(15 REQUIRED)
1.00 IN.
(2.54 CM) 0.50 IN. 0.45 IN. (11.43 MM)
(12.7 MM)
EXISTING RIVET CENTERLINE
STRUT
CUTOUT
0.50 IN. (12.7 MM) (TYP)
EDGE DISTANCE
EXCEPT AS SHOWN
NOTES:
0.60 IN. 1. EXISTING RIVETS SHOWN + ARE TO
(15.24 MM) BE DRILLED OUT FOR ATTACHMENT OF
FAIRING RUB PLATE.
0.60 IN. MS20426AD34 RIVETS 2. RIVETS SHOWN + ARE IN CRITICAL
(15.24 MM) (10 REQUIRED) LOCATIONS: OBSERVE DIMENSIONS.
0.55 IN.
(13.97 MM) 3. LOCATION OF OUTER EDGE RIVETS
SHOWN IS NOT CRITICAL: USE EQUAL
SPACING BETWEEN DIMENSIONED
POINTS.
0.25 IN. 4. BEFORE RIVET INSTALLATION, CLEAN
CUTLINE (IF REQUIRED) RUB PLATE WITH MEK. APPLY A THIN
(6.35 MM)
EVEN COAT OF SEALANT (CM405) TO
CONTACT SIDE.
EXISTING RIVET CENTERLINE 5. AFTER INSTALLATION, FORM A 0.60 IN.
(15.24 MM) WIDE FILLET OF SEALANT
AROUND RUB PLATE EDGES.
AFT RUB PLATE
R53-0008A
Figure 208. Landing Gear Rub Plate - Replacement
Page 220
Original 530000
0.750 IN.
(19.05 MM)
NAS14242 PIN NAS14242 PIN

NAS1080C4 COLLAR NAS1080C4 COLLAR
0.8000.880 IN.
(20.3222.352 MM)
PILOTS SEAT BELT OUTBOARD FITTING PILOTS SEAT BELT INBOARD FITTING
(CRES) (CRES)
CL
NAS14654 PIN B.L. 20.00 STA. 124.00
NAS1080C4 COLLAR
NAS14653 PIN 0.6700.690 IN.

NAS1080C5 COLLAR (17.01817.526 MM)
(OUTBOARD) NAS14666 PIN
0.3120.318 IN. NAS10806 COLLAR
(7.92488.0772 MM)
(2 PLCS)
MLSPM55 RIVETS
(2 PLCS)
STA. 124.00
NAS14663 PIN
NAS10806 COLLAR
MLSPM54 RIVETS (2 PLCS)
(OUTBOARD)
CARGO FLOOR SEAT BELT OUTBOARD FITTING CARGO FLOOR SEAT BELT INBOARD FITTING
(AL ALY) (AL ALY)
NAS14652 PIN
NAS10805 COLLAR
MS20615M3 RIVETS NAS14652 PIN (3 PLCS)
NAS10805 COLLAR
(3 PLCS)
0.1900.196 IN.
(4.8264.9784 MM)
(6 PLCS)
0.1900.196 IN.
(4.8264.9784 MM)
(6 PLCS) MS20615M3 RIVETS
MS20615M4 RIVETS
MS20615M4 RIVETS
SEAT BELT OUTBOARD FITTING

(AL ALY)
SEAT BELT INBOARD FITTING
(AL ALY)
R53-0009A
Figure 209. Seat Belt and Seat Support Fittings
Page 221
530000 Original
CL
0.680 IN.
(17.272 MM) NAS14243 PIN
NAS1080C4 COLLAR
CANT.
STA. 125
MS20407AD4 RIVETS
NAS14653 PIN
NAS10805 COLLAR
(6 PLCS)
NAS14243 PIN
NAS1080C4 COLLAR
SHOULDER STRAP SUPPORT FITTING MS20407AD4 RIVETS

(AL ALY)
MS20407AD5 RIVETS
TANK LINER
CENTER BEAM DRILL 0.2500.254 IN. (6.356.4516 MM)

HOLES TO MATCH CARGO HOOK
MOUNTING BASE
INSTALL LOCKING NUTS (22610048)
WITH FLUSH RIVETS
W.L. 0.00
CARGO HOOK FITTING
(CRES)
0.812 IN.
(20.6248 MM)
MS20470B5 RIVETS
(7 PLCS)
0.31220.3132 IN.
(7.929887.95528 MM)
0.43700.4380 IN.
(11.099811.1252 MM)
WASHER BETWEEN FITTING
NAS14666 PIN AND STRUCTURE (TYP)
NAS1080C6 COLLAR
(2 PLCS)
MS20470B5 RIVET SHOULDER STRAP
(AL ALY)
BL 20.75
MS20470AD5 RIVETS
(12 PLCS)
SEAT STRUCTURE OLEO ATTACHMENT FITTING

(AL ALY)
R53-0010A
Figure 210. Fuselage Fittings
Page 222
Original 530000
0.24950.2505 IN.
0.24950.2505 IN. (6.33736.3627 MM)
(6.33736.3627 MM) MS20470B
ATTACHMENT RIVETS
0.37450.3755 IN.
(9.51239.5377 MM)
1.31201.3130 IN. 0.37450.3755 IN.
(33.324833.3502 MM) (9.51239.5377 MM)
1.43701.4380 IN. 0.24950.2505 IN.

(36.499836.5252 MM) (6.33736.3627 MM)
1.31201.3130 IN.
(33.324833.3502 MM)
0.37450.3755 IN.
(9.51239.5377 MM)
1.43701.4380 IN.
(36.499836.5252 MM)
0.24950.2505 IN.
(6.33736.3627 MM)
FORWARD VIEW AFT VIEW
CYCLIC CONTROL AND SEAT SUPPORT BRACKET

(MAGNESIUM)
STA. 44.65
STA. 44.65 0.2500.254 IN.
(6.356.4516 MM)
MS20470AD4 RIVETS
MS20470AD4
RIVETS 0.2500.254 IN.
(6.356.4516 MM)
PEDAL SUPPORT, LOWER

(AL ALY) PEDAL SUPPORT, UPPER
(AL ALY)
ANTITORQUE PEDAL SUPPORT FITTINGS
SEAT
NUTPLATE STRUCTURE
1.855 IN.
CHECK THAT NOTCH (47.117 MM)
CLEARS NUTPLATE 0.030 IN.
(0.762 MM)
0.2500.254 IN.
(6.356.4516 MM)
RIVET (SHOP
FORMED HEAD)
NAS14242 PIN
2.00 IN. (50.80 MM) NAS1080C4 COLLAR
+0.001 IN. (0.0254 MM)
0.000 IN. (0.0000 MM)
COLLECTIVE STICK/TORQUE TUBE FITTINGS

MS20470B5 RIVETS COLLECTIVE STICK, SEAT STRUCTURE
(10 PLCS)
COLLECTIVE TORQUE TUBE LEFT SUPPORT
R53-001 1A
Figure 211. Flight Control Support Fittings
Page 223
530000 Original
R53-0012
INDEX GAGE MATERIAL
1 0.016 2024T3 AL ALY
2 0.020 2024T3 AL ALY
RH LANDING GEAR 3 0.025 2024T3 AL ALY
OLEO ATTACHMENT 4 0.032 2024T3 AL ALY
2 5 0.070 2024T3 AL ALY
2 6 0.020 2024T42 AL ALY
BL +20.75 7 0.025 2024T42 AL ALY
8 0.032 2024T42 AL ALY
7 9 0.040 2024T42 AL ALY
2 12 10 0.032 7075T6 AL ALY
2 12 11 0.050 7075T6 AL ALY
Figure 212. Pilots Seat Structure (Typical all Models)

1 12 0.071 7075T6 AL ALY
7 BL +6.00
5
CL LEFT COLLECTIVE
TORQUE TUBE SUPPORT

STA 65.040
7 CANT.
5 STA 78.50
MD Helicopters Inc.
11
12
1
1
9 BL 20.75
3
9
369MD COLLECTIVE FRICTION
530000
(MILITARY ONLY)
4 WL 21.50
1
8
CYCLIC CONTROL AND SEAT
SUPPORT BRACKET 3
4
BL 6.00
3
4 LH LANDING GEAR
3 OLEO ATTACHMENT
9
NOTES: 10 6
1. MS20470AD RIVETS ARE USED IN SHEET METAL SEAT 9
STRUCTURE EXCEPT AT FITTING ATTACH POINTS. 1 1 COLLECTIVE STICK FITTING
CSPSRM6
FOR FITTING ATTACHMENT RIVETS, REFER TO 7
Page 224
HELICOPTER FITTING ILLUSTRATION.
Original
2. MATERIALS INDICATED ARE TO BE USED AS A PATCH
REPAIR GUIDE ONLY. REFER TO TABLE 3, 910000,
SUBSTITUDE MATERIALS.
16. Composite Repair Criteria 18. Composite Cosmetic Damage Repair
WARNING (Ref. Section 91-00-00)
Item Nomenclature
CM202 Methyl-ethyl-ketone
D Sanding on composite reinforced
laminates produces fine dust that CM404 Adhesive, epoxy (parts A & B)
may cause skin irritations. Breath CM801 Abrasive paper, silicon carbide
ing of this dust may be harmful. Com
ply with necessary protective mea (1). Dry the damaged area with a heat gun
sures. or heat blanket for 10 minutes at no
more than 150F (66C). Ensure the
D Use protective clothing during prep temperature of the composite part does
aration and use of resin mixture. Ad not exceed 150F (66C).
equate ventilation must be provided.
(2). Using abrasive 180400 grit paper
D Clean Cotton gloves will minimize (CM801), scuff sand the damaged area.
the possibility of composite fiber en Sand paint to featheredge surrounding
tering the body and will limit con the damaged area. Ensure a 2 inch
tamination of the items by human (5.08 cm) diameter is present around
contact. the damage.
(3). Thoroughly clean surface of repair area
D Eye protection to avoid possible eye with lintfree cloth and MEK (CM202)
damage. to remove any impurities.
D Respirator, when sanding and using (4). Mix the appropriate amount of adhe
resins and adhesive to avoid possible sive/resin (CM404) in accordance with
damage to the respiratory system. manufacturers requirements. Fill
damaged area using metal spatula.
(5). Cure at room temperature for 24 hours
17. Composite Cosmetic Damage Inspection or for one hour followed by 160
10F (71 5C) for one hour. Use a
temperature controlled system that will
(Ref. Figure 213) Cosmetic damage will occur eliminate overheating. Do Not use heat
due to small impacts either in flight or on the gun or lamp.
ground. Cosmetic damage consists of damage (6). After curing, sand the area to match
to the outer layer of resin on the composite contour. Paint to match profile.
part. Examples; the composite tailboom may
be scratched, nicked or dented. If no fiber SCRATCH OR NICK
interruption has occurred and no delamination
or voids has resulted, the damage is considered
cosmetic. Cosmetic damage can be found
visually by looking along the length of the
tailboom and by touch and feeling the contour, SURFACE SCRATCH

OR NICK
any abnormalities should be easily detected.

The most important criteria is to ensure that SURFACE RESIN
no fiber fracture has resulted.
NOTE: If fiber have been interrupted, damage

R53-0013
is no longer considered cosmetic. Refer to Fi
ber Damage Inspection. Figure 213. Composite Cosmetic Damage
Page 225
530000 Original
19. Composite Delamination Damage A. Edge Delamination Repair

Inspection
(Ref. Figure 214)
Delamination damage can occur in numerous (1). Dry the damaged area with a heat gun
locations on composite material components. or heat blanket for 10 minutes at no
There are various situations, and each must be more than 150F (66C). Ensure the
addressed separately. temperature of the composite part does
not exceed 150F (66C).
(1). Edge Delamination occurs when plies (2). Using abrasive paper (CM801),
at the edge of a laminate become 180400 grade, remove paint at least 1
separated. Edge delaminations are inch (2.54 cm) from the delaminate
generally detected by a visual inspec boundary of damaged area. Ensure that
tion. A white power residue may appear only the paint is removed. Do Not use
around the surface edges (Ref. a paint stripper.
Figure 214).
(3). Lightly sand the edges of the delamina
tion to remove impurities that may be
(2). Hole Delamination is a separation of present. Do Not use a solvent (MEK).
laminates due to the introduction of a Use low pressure air (plastic squeeze
drilled hole in a cured composite part, bottle) or low pressure air compressor.
also can be caused by incorrect bushing
or fastener size. Delaminations on the
surface side can be detect visually while
a tap test on both sides of the composite WHITEISH
APPEARENCE
is required to determine internally
which side of center the delamination
has occurred. A white power residue
may appear around the hole surface
edges (Ref. Figure 215).
PLIES
(3). Internal Delamination are internal
separations of adjacent plies of lami
nates that do not extend to a hole or
DELAMINATION
edge. Internal delamination can occur
R53-0014
between composite fiber such as blisters
and voids. A tap test is the only tech Figure 214. Composite Edge Delamination
nique that can be used to detect suspect Damage
areas. Visual inspection might indicate
were damage may a be present NOTE: Resin and catalyst should not be mixed
(Figure 216). until required because mixture has limited
pot life. Warming mixture reduces viscosity
and aids handling, but shortens pot life of
20. Composite Delamination Damage Repair mixture. In all cases, refer to manufactur
ers instructions on use of adhesive/resin.
Processing and repair work should be pre
Consumable Materials formed in an area sheltered from adverse
(Ref. Section 91-00-00) weather conditions and free from dust.
Item Nomenclature
(4). Prepare the appropriate amount of
CM202 Methyl-ethyl-ketone adhesive (CM404) in accordance with
CM404 Adhesive, epoxy (parts A & B) (EA9313) manufacturers instructions.
CM801 Abrasive paper, silicon carbide (5). Using a clean brush, coat the edges of
the delamination. Try to work adhesive/
Page 226
Original 530000
resin between plies by alternately NOTE: Resin and catalyst should not be mixed
squeezing and relaxing the area until required because mixture has limited
worked. Do Not extend the delamina pot life. Warming mixture reduces viscosity
tion. and aids handling, but shortens pot life of
mixture. In all cases, refer to manufactur
(6). Apply light pressure to force plies ers instructions on use of adhesive/resin.
together. A spring clamp will be the Processing and repair work should be pre
most effective way to hold the plies formed in an area sheltered from adverse
together. weather conditions and free from dust.
(7). Allow to cure at room temperature for (6). Prepare the appropriate amount of
24 hours or one hour followed by curing adhesive (CM404) in accordance with
at 160 10F (71 5C) for one hour. manufacturers instructions.
Use a temperature controlled system WHITEISH
that will eliminate the chance of APPEARANCE
overheating. Do Not use heat gun or
lamp.
(8). Ensure a complete bond has been

achieved.
(9). After curing, sand the area to match

contour. Paint to match.
B. Hole Delamination Repair
(Ref. Figure 215)
(1). Dry the damaged area with a heat gun DELAMINATION OR

or heat blanket for 10 minutes at no FIBER PULLOUT
PLIES
more than 150F (66C). Ensure the R53-0015
temperature of the composite part does
not exceed 150F (66C). Figure 215. Composite Hole Delamination
Damage
(2). Remove any paint from the repair area.
Do Not use paint stripper. Using (7). Using a clean brush, coat the edges of
abrasive paper (CM801), 180400 the hole delamination. Try to work
grade, remove paint a minimum of 2 resin between plies by alternately
inch (5.08 cm) from the edges of squeezing and relaxing the area
delaminate boundary of damaged area. worked. Do Not extend the delamina
Ensure that only the paint is removed tion.
and not the upper layer of resin. (8). Apply light pressure to force plies
together. A spring clamp will be the
(3). Roll a piece of fine grade sandpaper to
most effective way to hold the plies
form a cylinder and lightly sand the
together.
inner surface of the hole.
(9). Allow to cure at room temperature for
(4). Thoroughly clean surface of repair area 24 hours or for one hour followed by
with lintfree cloth and MEK (CM202) curing at 160 10F (71 5C) for one
to remove any impurities. Continue hour. Use a temperature controlled
cleaning until discoloration does not system that will eliminate the chance of
appear. overheating. Do Not use heat gun or
lamp.
(5). Prepare the appropriate amount of
adhesive/resin (CM404) in accordance (10). Ensure a complete bond has been
with manufacturers requirements. achieved.
Page 227
530000 Original
(11). After curing, sand the area to match NOTE: Injection should be made from the fur
contour. Paint to match. thermost two points of the delamination.
C. Internal Delamination Repair (7). With a hypodermic syringe, inject the

adhesive/resin into one hole and
continue until the adhesive/resin flows
(Ref. Figure 216) from the other holes.
(1). Dry the damaged area with a heat gun (8). Cover holes with pressuresensitive
or heat blanket for 10 minutes at no tape. When necessary, apply pressure
more than 150F (66C). Ensure the by using weight.
temperature of the composite part does
not exceed 150F (66C). (9). Allow to cure at room temperature for
24 hours or for one hour followed by
curing at 160 10F (71 5C) for one
(2). Using abrasive paper (CM801), hour. Use a temperature controlled
180400 grade, remove paint at least 1 system that will eliminate the chance of
inch (2.54 cm) from around the injection overheating. Do Not use heat gun or
area, Ensure that only the paint is lamp.
removed. Do Not use a paint stripper.
(3). Thoroughly clean surface of repair area achieved.
with lintfree cloth and MEK (CM202)
to remove any impurities. Continue (11). After curing, sand the area to match
cleaning until discoloration does not contour. Conduct a tap test to ensure
appear. delamination has been removed. Paint
repair to match profile.
(4). Using a 0.060 inch (1.524 mm) drill,
drill to the delamination at each end.
Use care, do not drill thru the delami
nated area. A maximum of five holes
may be drilled, one at the center and
the rest equally spaced around the
perimeter. The minimum spacing shall
not be less than 0.280 inch (7.112 mm). SEPARATION
(5). Clean drilled holes using low pressure

PLIES
air (plastic squeeze bottle) or low
R53-0016
pressure air compressor.
Figure 216. Composite Internal Delamination
NOTE: Resin and catalyst should not be mixed Damage
until required because mixture has limited
pot life. Warming mixture reduces viscosity 21. Composite Fiber Damage Inspection
mixture. In all cases, refer to manufactur Fiber damage consists of damage to the
ers instructions on use of adhesive/resin. filaments of a composite laminate that results
Processing and repair work should be pre in fibers being broken. Fiber damage is
formed in an area sheltered from adverse identifiable by visual inspection. However, a
weather conditions and free from dust. tap test should be performed to determine the
exact limits of the damage including delamina
(6). Prepare the appropriate amount of tions. A sonic test may be required to deter
adhesive (CM404) in accordance with mine the total extent of damage, including
manufacturers instructions. delamination etc.
Page 228
Original 530000
22. Composite Fiber Damage Repair (7). Match the layup directions of the
laminates plies from the composite
(Ref. Figure 217) All fiber damage should be prepreg material repair kit.
reported to MDHI Product Support Depart
(8). Place the cured repair patch in the
ment.
steppedout area to ensure a accurate
fit, lightly sand any problem areas.
Consumable Materials 0.250 IN. (6.35 MM)
(Ref. Section 91-00-00) MIN. STEP
Item Nomenclature BLEND CONTOUR
CM503 Resin, filler
CM504 Carbon fiber composite
CM801 Abrasive paper, silicon carbide
A. Fiber Damage from One Side Only:
It is important to understand that fiber 1.00 IN. (2.54 CM)

damage does not pass through the entire cross MIN. OVERLAP
section of the composite component.
(1). The damaged area shall be repaired by

stepping out or blending the plies
surrounding the damaged area.
(2). The size of the total repair is calculated

so that is a minimum of 0.250 inch
(6.35 mm) each step and a 1 inch (25.4
mm) top ply over the outlined repair. R53-0017
Figure 217. Composite Fiber Damage

(3). Dry the damaged area with a heat gun
or heat blanket for 10 minutes at no (9). Clean both bonding surfaces with
more than 150F (66C). Ensure the solvent. Continue the cleaning process
temperature of the composite part does until no discoloration of wiping occurs.
not exceed 150 F (66C).
NOTE: Resin and catalyst should not be mixed
until required because mixture has limited
(4). Using a sanding disk (coarse 80 grade)
pot life. Warming mixture reduces viscosity
remove the plies of laminates necessary.
The pattern of the plies will aid to
mixture. In all cases, refer to manufactur
indicate which step is present during
ers instructions on use of adhesive/resin.
removal.
Processing and repair work should be pre
formed in an area sheltered from adverse
(5). Calculate and cut out the stepout size weather conditions and free from dust.
repair patch (CM504). Note the direc
tion of the plies in the repair area. (10). Mix the appropriate amount of adhesive
(CM503) per manufacturers instruc
(6). Ensure that no delaminations are tion.
present between the plies. If required,
(11). Coat both bonding surfaces with
perform an edge delamination repair
adhesive.
just prior to bonding the patch.
(12). Place the repair in position and gently
NOTE: Every precaution should be taken to push down. Hold in place with pres
avoid contaminating the material to ensure suresensitive tape When necessary,
a proper repair. apply pressure by using weight.
Page 229
530000 Original
(13). Allow to cure at room temperature for Clean area and apply a bead of aircraft
24 hours or for one hour followed by high quality sealant around the
curing at 160 10F (71 5C) for one perimeter of the patch. Paint repair to
hour. Use a temperature controlled match profile.
system that will eliminate the chance of
overheating. Do Not use heat gun or B. Fiber Damage Through the Composite
lamp. Material:
achieved. Repair of through penetration damage is
difficult and must be repaired to conform to
(15). After curing, sand the area to match MDHI Specifications. Contact MDHI Field
contour using a fine grade sandpaper Service Representative or Product Support
(CM801). Feather the adhesive edges. Engineering Department.
Page 230
Original 530000
Section
53-10-00
Canopy/Windshields
and Windows/Doors

CANOPY/WINDSHIELD AND WINDOWS/DOORS

REPAIRS
1. Canopy/Windshield Description (3). Any surface defect such as minute spots
or stains that can be removed by light
(Ref. Figure 201, Figure 202, Figure 203) The polishing.
forward fuselage (pilots compartment) consists
of an aluminum framework enclosed by (4). Crazing around delaminated areas less
stretched acrylic plastic windshield sections, than 0.010 inch (0.254 mm) deep.
door frame sections, two forward cockpit doors
(5). Minor polarization faults in small areas
and two aft cargo doors.
of windshield near edges.
(1). The framework is made up of a center B. Replacement
canopy frame, lower canopy frame and
upper canopy frame. If damage is other than negligible, replace
windshield section or window.
(2). A nonaluminum member of the
framework is a fiberglass panel on the 3. Pilot and Passenger/Cargo Compartment
helicopter longitudinal centerline. This Door Repair
panel provides for the installation of
the cabin air ventilation duct, pitot tube (Ref. Figure 204, Figure 205) The entire pilots
and landing/hover light. compartment door frame or any damaged
section of frame may be repaired or replaced.
(3). The acrylic windshield panels are Special holding fixtures are not required for
bonded to plastic edge retainers (Geon), repair or replacement of pilots compartment
which are fasten to the canopy frame by door frames. If frame section is replaced, use
rivets. standard insertion and doubler repair meth
ods. Use following general procedures to insure
(4). On later 369E/FF 500/600N Models, door frame fit.
the pilots, passenger and cargo door
windows are retained in place by a (1). During removal of damaged door frame
rubber extrusion seal/retainer. structure, drill out rivets attaching
hard points, aft door hinges and frame
2. Canopy Window Inspection and Repair gussets so that these members remain
attached to Sta. 78.50 canted bulkhead.
(Ref. Figure 201, Figure 202, Figure 203) For
windshields and window repair methods, refer (2). Position replacement frame or section
to CSPHMI2, Sec. 531000 and FAA AC so edge distance is maintained at all
43.131A, Aircraft Inspection and Repair. rivets equivalent to edge distance on
damaged frame. Clamp frame into
A. Negligible Damage position; do not drill.
Minor defects or imperfections that do not NOTE: Replacement door frames are manufac
impair pilots critical visibility, or that obvious tured to fit and do not require trimming. Do
ly are not signs of impending structural failure not bend, bow or force frame into position.
shall be considered as negligible. Negligible
damage includes: (3). Position attaching canopy frames.
Lower canopy frame attaches to door
(1). Nicks not more than 0.010 inch (0.254 frame with top surface at WL 38.96,
mm) deep and occupying an area not 22.89 inches (58.1406 cm) above
larger than 0.25 x 0.50 inch (6.35 x 12.7 forward upper edge of pilots compart
mm); one only per square foot (929.0304 ment floor. Clamp in position; do not
cm2) allowed. drill.
(2). Scratches not more than 0.010 inch (4). Verify that existing canopy window
(0.254 mm) deep and 5.00 inches (12.7 panel plastic edge retainers provide
cm) long. adequate rivet edge distance. Check
Page 201
531000 Original
that replacement panels have sufficient equipment at hard points to verify

retainer material for trimming and location.
fitting as required.
(6). Pick up rivet holes, temporarily fasten
door in place, and continue with
(5). Temporarily attach any optional installation. Drill holes as required.
Page 202
Original 531000
RIGHT UPPER CANOPY

WINDSHIELD
UPPER CANOPY FRAME
LEFT AFT COMPARTMENT
RIGHT CENTER CANOPY WINDOW
WINDSHIELD
RIGHT LOWER CANOPY

WINDSHIELD
LOWER CANOPY FRAME
LOWER SECTION FLOOR

SUPPORT BULKHEAD
CAUTION: THE PLASTIC CANOPY AND WINDOW PANELS BECOME FILL GAPS AND SEAL RETAINER
BRITTLE WHEN COLD AND COULD CRACK DURING HANDLING. EDGE WITH SEALANT
PANEL REPLACEMENT SHOULD BE PERFORMED UNDER WARM (NOTE 2)
ROOM TEMPERATURE CONDITIONS 70F (21C) OR HIGHER.
AFT COMPARTMENT
WINDOW RETAINER
HELICOPTER
CL TRIM EXCESS RETAINER TO MS20470A OR MS20426A
MAINTAIN STRUCTURE RIVETS. INSTALL WASHER
OVERLAP AND CLEAR RADIUS (AN960KD3L) UNDER SHOP
FORMED HEAD. RIVET
FILL GAPS AND SEAL SPACING 1.00 IN. (2.54 CM)
RETAINER WITH SEALANT (TYP)
(NOTE 2) AFT COMPARTMENT
WINDOW EDGE
NOTES:
1. MS20470A AND MS20426AD RIVETS ARE USED IN
MOST PLACES.
2. APPLY A BEAD OF SEALING COMPOUND BETWEEN
CABIN VENTALATION RETAINER AND STRUCTURE BEFORE FINAL
PANEL INSTALLATION. AFTER INSTALLATION FILL GAPS
WITH COMPOUND AND REMOVE EXCESS.
FRONT CENTER
CANOPY AREA
R53-1001A
Figure 201. Canopy and Window Replacement 369D
Page 203
531000 Original
RIGHT UPPER CANOPY

WINDSHIELD
UPPER CANOPY FRAME
RIGHT CENTER CANOPY

WINDSHIELD
LOWER CANOPY FRAME
RIGHT LOWER CENTER CANOPY

WINDSHIELD
RIGHT LOWER CANOPY

WINDSHIELD
LOWER SECTION FLOOR

SUPPORT BULKHEAD
CAUTION: THE PLASTIC CANOPY AND WINDOW PANELS BECOME

HELICOPTER BRITTLE WHEN COLD AND COULD CRACK DURING HANDLING.
CL PANEL REPLACEMENT SHOULD BE PERFORMED UNDER WARM
FILL GAPS AND SEAL

RETAINER WITH SEALANT
(NOTE 2)
NOTES:
MOST PLACES.
CABIN VENTALATION RETAINER AND STRUCTURE BEFORE FINAL
PANEL INSTALLATION. AFTER INSTALLATION FILL GAPS
WITH COMPOUND AND REMOVE EXCESS.
FRONT CENTER
CANOPY AREA
R53-1002A
Figure 202. Canopy and Window Replacement Early 369E/FF
Page 204
Original 531000
RIGHT UPPER CANOPY

WINDSHIELD
RH UPPER CENTER RH UPPER

CANOPY WINDSHIELD CANOPY FRAME
RH LOWER
CANOPY FRAME
RH LOWER CANOPY WINDOW

WINDSHIELD
HELICOPTER
CL
RETAINER SEAL
FILL GAPS AND SEAL

RETAINER WITH SEALANT
(NOTE 2)
CAUTION: THE PLASTIC CANOPY AND WINDOW PANELS BECOME
BRITTLE WHEN COLD AND COULD CRACK DURING HANDLING.
PANEL REPLACEMENT SHOULD BE PERFORMED UNDER WARM
NOTES:
MOST PLACES.
RETAINER AND STRUCTURE BEFORE FINAL
INSTALLATION. AFTER INSTALLATION FILL GAPS
CABIN VENTALATION WITH COMPOUND AND REMOVE EXCESS.
PANEL
FRONT CENTER
CANOPY AREA
R53-1003A
Figure 203. Canopy and Window Replacement (One Piece Lower Canopy)
Current 369E/FF - 500/600N
Page 205
531000 Original
LATCH COVER
(TYP)
FORWARD LATCH
WINDOW SECOND LATCH
SNAP VENT
DOUBLER
FUSELAGE DOOR SNAP VENT DOOR SEAL
FRAME (TYP)
THIRD LATCH
STOP STOP
AUTOMATIC DOOR AUTOMATIC

LATCH DOOR LATCH
MECHANISM MECHANISM
DOOR SEAL
FOURTH LATCH
LATCH COVER (TYP)

DOOR SEAL (4 PLCS)
DOOR PANEL
RETAINER
DOOR HINGE DOUBLER CLEVIS PIN
SHIM
PRESSURE RIVET (AS REQ)
SENSITIVE TAPE HINGE PIN
WINDOW HINGE PRELOAD

DOOR PANEL SPRING
WINDOW ENGAGEMENT
0.380 IN. (9.652 MM) MIN.
STOP
WINDOW INSTALLATION
DOOR SPRING
DOOR
STRUCTURE
BUSHING
DOOR HINGE HALF
DOOR FRAME (CARGO
DOOR FRAME SHOWN)
HINGE INSTALLATION
SEAL DEPRESSOR
SHIM (NOTE 2)
ANTICHAFING
TAPE STRIKE (NOTE 1, 2)
WASHER
SCREW
NOTES:
1. ALL GAPS BETWEEN STRIKER CORNER JOINTS
DOOR STRIKE ASSEMBLY AND OUTER EDGES TO BESEALED WITH SEALANT.
INSTALLATION 2. BOND STRIKER AND SHIMS TO DOOR FRAME, USING
ADHESIVE.
R53-1004A
Figure 204. Pilot and Passenger; Cargo Compartment Doors, Typical
Page 206
Original 531000
LOOKING FORWARD
CR2249NS4 AND OUTBOARD
OR OCKLB4
RIVETS MS20470AD4 RIVETS
MS20426AD4 CR2249NS4
RIVET OR OCKLB4 DOUBLER, 0.025 IN. (0.635 MM)
RIVETS 2024T3 AL ALY
MS20470AD4 CANT. STA. 78.50

RIVETS MS20426A3 RIVETS
MS20470AD3 RIVETS CANOPY FRAME MS20426AD3

ATTACHMENT RIVETS NOTES 1, 2
SHIM IF REQUIRED
BETWEEN FUSELAGE MS20470AD4
ANGLE, 0.032 IN. (0.8128 MM) AND FRAME FOR RIVETS
2024T3 AL ALY SMOOTH CONTOUR (4 PLCS)
CANOPY FRAME
MS20426AD3
ATTACHMENT
RIVETS
NOTES 1, 2
NOTES:
1. BRACKETRY NOT SHOWN. REFER TO TEXT FOR DAMAGED
WL. 38.64 FRAME REMOVAL AND INSTALLATION.
2. IN GENERAL, REINSTALL MS20470AD3 RIVETS IN MOST
PLACES. USE MS20470AD4 RIVETS AT OVERLAPS,
CR2249NS4 OR OCKLB4 RIVETS IN BLIND AREAS AND
COUNTERSUNK MS20426A3 RIVETS AT DOOR CLOSURE
AND WINDOW ATTACH POINTS.
MS20470AD3 RIVETS
THIS EDGE EXCEPT
USE MS20470AD4
RIVETS AT GUSSET
AND STIFFENER
MS20426A3 RIVETS OVERLAPS
MS20470AD3
SEAT STRUCTURE RIVETS
CR2249NS4 OR OCKLB4
RIVETS MAY BE SUBSTITUTED
FOR SPOT WELDS
CR2249NS4 OR
OCKLB4 RIVETS
P4 RIVETS CR2249NS4 OR CR2249NS4 OR
WL. 15.75
OCKLB4 RIVETS OCKLB4 RIVETS
ATTACHING
BRACKET
STA 44.65 FLOOR LONGERON CR2249NS4 OR

(REF. SEC. 532000 FOR SPLICE REPAIR) OCKLB4 RIVETS
R53-1005
Figure 205. Pilots Compartment Door Frame-Repair
Page 207
531000 Original
Page 208
Original 531000
Section
53-20-00
Lower Center
Fuselage

LOWER CENTER FUSELAGE

REPAIRS
1. Lower Center Fuselage Description (c). The cargo compartment floor is
considered a stress structural area.
(Ref. Figure 201) Lower center fuselage are
those areas located below fuselage floor level. (4). Two longitudinally position hatchan
nels located under the floor on each side
(1). The center beam is located on the lower of the center beam provide support and
longitudinal centerline of the aircraft guide channels for the engine gaspro
fuselage It forms the lowest truss ducer fuel control and the power
member and the foundation to which turbine governor controls.
most of the important structural
members of the fuselage are attached. (5). Beneath the floor level, the Cant. Sta.
78.50 structure serves as the forward
(a). The beam is a formed aluminum bulkhead of the fuel cell area.
webbing and forgings that provide
the strength necessary for landing (6). The bottomside of the floor is rein
gear attachments. forced with spotwelded doublers and
angles.
(b). The web of the Icross sectioned
beam is aluminum skin, with top and 2. Cargo Compartment Center Beam
bottom cap strips of aluminum Structure Inspection and Repair
Tchannels.
(Ref. Figure 203) Cargo compartment floor
(c). The beam is stiffened with vertically
damage can be caused by excessive localization
placed Zchannels.
loading. This can cause buckling of center
(2). The landing gear forgings provide a beam structure. If damage to center beam is
means of attachment for the inboard suspected, check the following.
ends of the landing gear braces and the
cyclic trim actuators. Spherical bear (1). Inspect center beam upper T cap area
ings are utilized at the attachment for indications of web or stiffener
points areas. buckling between Sta. 95 and 115.
Minor buckling of beam is acceptable,
(3). The cargo floor is 0.016 inch (0.4064 provided no T cap rivets are pulled
mm) aluminum sheet with reinforce out and no cracks or tears exist in web
ments above and beneath. or stiffeners.
(a). The top reinforcement is formed by (2). If any top T" cap rivets have pulled out
seven laterally spaced hatsection and/or cracks are evident in web or
shaped channels that are spot stiffeners, helicopter cargo compart
welded to the floor and extend across ment loading must be restricted to 400
the fuselage. pounds maximum until repairs are
performed.
(b). Cutouts for left and right fuel cell
access and for passage of the fuel (3). Damage to upper T" cap, other than
tank filler neck are provided through minor buckling, must be repaired before
the floor. further flight.
Page 201
532000 Original
CENTER BEAM REPAIR, FIGURE 203 & 204

FLOOR WEB, 0.016 IN.
(0.4064 MM) 2024T3 AL ALY
(NOTE 4) STIFFENER, (0.020 IN. (0.508 MM) 7075T6 AL ALY
(TYP. 8 PLCS)
WEB, 0.016 IN. (0.4064 MM) 7075T6 AL ALY

STIFFENERS, 0.032 IN. (0.8128 MM)
7075T6 AL ALY (TYP 7 PLCS) DOUBLER, 0.032 IN. (0.8128 MM)
(NOTE 4) 7075T6 AL ALY
STIFFENER, 0.032 IN. (0.8128 MM) STA. 119.67 RIB, 0.025 IN.
7075T6 AL ALY (0.635 MM) 7075T6 AL ALY
STA. 113.85 RIB, 0.025 IN.

(0.635 MM) 7075T6 AL ALY
STA. 108.04 RIB, 0.025 IN. (0.635 MM)

7075T6 AL ALY
STA. 102.23 RIB, 0.025 IN. (0.635 MM)

STIFFENERS, 0.020 IN. 7075T6 AL ALY
(0.508 MM) 2024T3 AL ALY
JACK FITTING, PART OF STA. 96.42 RIB
WEB, 0.016 IN. (0.4064 MM) STA. 96.42 RIB ASSY, 0.050 IN. (1.27 MM) 7075T6 AL ALY
2024T3 AL ALY
STA. 90.61 RIB, 0.040 IN. (1.016 MM) 7075T6 AL ALY
DOUBLER, 0.025 IN. (0.635 MM)
2024T3 AL ALY STA. 84.79 RIB, 0.032 IN. (0.8128 MM) 7075T6 AL ALY
DOUBLER, 0.050 IN. (1.27 MM) CARGO HOOK FITTING
7075T6 AL ALY
CANT. STA. 78.50 LOWER FRAME, 0.040 IN.
STIFFENER, 0.032 IN. (0.8128 MM) 7075T6 AL ALY (1.016 MM) 2024T3 AL ALY
DOUBLER, 0.050 IN. (1.27 MM) 7075T6 AL ALY
NOTES:
1. REFER TO FAA AC43.131A, AIRCRAFT INSPECTION AND REPAIR FOR STANDARD SHEET METAL
REPAIR PROCEDURES UNLESS OTHERWISE SPECIFIED.
2. MATERIALS INDICATED ARE TO BE USED AS A PATCH REPAIR GUIDE ONLY. REFER TO TABLE 3,
SEC. 910000 FOR SUBSTITUDE MATERIALS.
3. REFER TO THE SKIN PANALING DIAGRAM FOR EXTERIOR SKIN THICKNESS AND MATERIAL.
4. THE FLOOR STRUCTURE IS SHOWN CUT AWAY AT THE CENTER BEAM.
5. REFER TO TEXT FOR OIL CANNING REPAIR AND SKIN FIT SHIMMING.
R53-2001A
Figure 201. Lower Center Fuselage
Page 202
Original 532000
FOR DOOR FRAME

ATTACHMENT DETAILS,
REF. SEC. 531000
MS20470AD4 RIVETS THROUGH
DOUBLER SEAL AND END ANGLES,
ALL OTHER ATTACHMENT RIVETS
MS20470AD3
REPLACEMENT SECTION
OF 369A2530 LONGERON
REMOVE MIN. POSSIBLE DOOR SEAL,

MATERIAL FROM EXTERIOR EXTRUDED AL ALY
SKIN, PATCH REPAIR AS
SHOWN
MS20470AD3 ATTACHMENT RIVETS;

SKIN PATCH MATERIAL, 0.016 IN. 0.0300.060 IN. (0.7621.524 MM), CUT
(0.4064 MM) 2024T42 AL ALY HALF WAY BETWEEN RIVETS TO PICK UP MIN. OF 4 RIVETS
MAINTAIN 2 X DIA. EDGE DISTANCE EACH SIDE OF CUT
DOUBLER ANGLE:
DOUBLER MUST EXTEND COMPLETELY
BETWEEN RIBS AND/OR BULKHEAD
MS20470AD4 RIVETS
FLOOR SKIN
DOOR SEAL
ORIGINAL STRUCTURE
REPLACEMENT
DOUBLER ANGLE:
USE SECTION OF 369A2530 LONGERON,
0.063 IN. (1.6002 MM) MIN. THICKNESS, REPAIR PARTS
BREAKING EDGE TO FIT RADIUS; OR BEND
0.063 IN. (1.6002 MM) THICK AL ALY 70750
CONDITION. HEAT TREAT TO 7075T6 MS20470AD4 RIVETS REPAIR PARTS IN
AFTER FORMING. CROSSSECTION
EXTERIOR SKIN SKIN PATCH REPAIR
R53-2002A
Figure 202. Floor Longeron Repair
Page 203
532000 Original
CAUTION: TO AVOID FUEL

CELL DAMAGE, BREAK
ANY SHARP EDGES THAT
RESULT FROM CENTER
BEAM REPAIRS.
WL 13.10
ORIGINAL STRUCTURE
REPAIR PARTS IN CROSS SECTION
REPAIR PARTS
DYECHECK TEE UNDER HAT SECTION IN

DAMAGED AREA. IF DIECHECK IS POSITIVE
MS20470AD4 RIVETS OR TEE REMAINS DEFORMED (TEE WILL NOT
1.00 IN. SPRING BACK TO ORIGINAL SHAPE AFTER
(25.4 MM) STRAP, 0.050 IN. (1.27 MM) DAMAGE PORTION OR WEB HAS BEEN
7075T6 AL ALY REMOVED) CUT OUT CRACKED OR
WL 13.10 DEFORMED AREA AND SPLICE AS SHOWN.
CARGO COMPARTMENT
FLOOR STRAP 0.0300.060 IN.
ANGLE, 0.032 IN. (0.8128 MM) PICK UP EXISTING (0.7621.524 MM)
7075T6 AL ALY (BOTH SIDES) RIVET HOLES GAP (2 PLCS)
A
CENTER BEAM WEB WL 13.10

EXTRUDED TEE, 0.050 X 0.62 X 1.00 IN.
(1.27 X 1.5748 X 25.4 MM) 7075T6 AL ALY
SECTION AA MS20470AD4 RIVETS

MS20470AD4 RIVETS A INSTALLED AT STIFFENER
CUT OUT DAMAGED AREA OF TEE. CUT HALF WAY BETWEEN

HAT SECTIONS AND BETWEEN TOP AND SIDE RIVETS.
REPLACE DAMAGED PORTION OF TEE WITH EXTRUDED TEE
SECTION (LENGTH AS REQUIRED). ADD ANGLES
NOTE: OVERLAPPING RIVETS EITHER SIDE OF JOINT.ADD STRAP
1. (+) INDICATES EXISTING RIVET LOCATION. OVER TOP OF JOINT. IF EXTRUSION NOT AVAILABLE, SEE
2. (0) INDICATES NEW RIVET LOCATION. ATERNATE TEE REPAIR METHOD (SHEET 2 OF 2).
3. OBSERVE THE FOLLOWING SHEET METAL PRACTICE:
RIVET EDGE DISTANCE 2 X DIA.: LOCATE RIVET
MIN. OF 0.25 IN. (0.635 MM) FROM ADJACENT
STRUCTURE AND/OR JOGGLE BEND.
R53-2003A
Figure 203. Center Beam Structural Repair (Sheet 1 of 2)
Page 204
Original 532000
STRAP
STIFFENER B
FILLER, 0.025 IN. (0.635 MM)
7075T6 AL ALY
0.090 IN. (2.286 MM) R

(TYP) B ANGLE
ANGLE
JOG STIFFENERS OR
USE TAPERED SHIMS
AS REQUIRED
REPLACE DAMAGED PORTION OF TEE WITH TWO ANGLES,
0.025 IN. (0.635 MM) 7075T6 AL ALY. INSTALL BACKTOBACK
WITH 0.025 IN. (0.635 MM) FILLER ON TOP. ADD TWO ANGLES,
0.032 IN. (0.8128 MM) 7075T6 AL ALY, TO BE CONTINOUS
UNDER STIFFENER WHERE TEE HAS BEEN REMOVED.
SECTION B B
TEE REPAIR ALTERNATE METHOD
JOG UP 0.050 IN. (1.27 MM) OR USE

CARGO COMPARTMENT FLOOR MS20470AD3 RIVETS TAPERED SHIM (NEAR SIDE ONLY)
(5 PLCS)
WL
13.10
0.50 IN.
(12.7 MM)
R (TYP)
WL REMOVE DAMAGED
10.00 PORTION OF WEB
AND ADD DOUBLER,
0.016 IN. (0.4064 MM)
7075T6 AL ALY
MS20470AD3 RIVETS
(AS REQUIRED)
C C
0.450 IN.
(1.143 MM)
IF STIFFENERS ARE BUCKLED,
REMOVE DAMAGED PORTION AND
STIFFENER ADD ANGLE, 0.032 IN. (0.8128 MM)
7075T6 AL ALY. OVERLAP ANGLE
MIN. OF 2 RIVETS ON STIFFENER
0.50 IN. (12.7 MM)
0.090 IN.
(2.286 MM) R
SECTION C C
REPAIR OF BUCKLED WEB AND STIFFENERS

(VIEW LOOKING INBOARD LEFT SIDE)
R53-2004A
Figure 203. Center Beam Structural Repair (Sheet 2 of 2)
Page 205
532000 Original
MS20470AD4
ORIGINAL STRUCTURE ATTACHMENT RIVETS
REPAIR PARTS
REPAIR PARTS IN CROSS SECTION
CR22493 ATTACHMENT RIVETS
FUEL SUPPORT SKIN MS20470AD3

ATTACHMENT RIVETS
PATCH TO EXTEND
AT LEAST 3 RIVETS STOP DRILL CRACKS WITH
ON EACH SIDE OF TRIM DAMAGE TO NO. 40 DRILL
DAMAGE SMOOTH CONTOUR
EXTERIOR SKIN USE FILLER FLUSH IN CUT OUT

DAMAGED AREA WHEN NEEDED
NOTE:
IF REQUIRED, CUT HOLE IN TANK LINER
CROSS SECTION FOR ACCESS AND THEN PATCH WITH
FIBERGLASS.
R53-2005
Figure 204. Typical Fuselage Lower Rib Repair

3. Forward Landing Gear Center Beam NOTE: Terminate each cut at a rib or stiffener
Fitting Replacement where possible to avoid a double row of riv
ets in exterior skin patch after repair com
pletion.
(Ref. Figure 205) The following general
procedure is based on minimum access for (4). Remove all rivets from vertical leg of
replacement of forward center beam fitting. T" cap between Sta. 44.65 and 90.61.
Damage to fitting is usually the result of a Gain access to forward section through
hard landing. In this event, other damage may pilots floor access door openings.
occur that will require additional cutting away
(5). Drill out rivets and remove extruded
of damaged material.
angle positioned across bottom of Cant.
Sta. 78.50 bulkhead at BL 0.00.
(1). Remove any externally attached (6). Cut through T cap at approximately
hardware and internal bracketry in the Sta. 86.50 leaving edge distance at rivet
area. holes on each leg at both sides of cut (6
places). The T" cap is spliced at this
point after reinstallation.
(2). Remove all rivets attaching exterior
skin to lower T cap (horizontal legs) NOTE: When cutting "T" cap at Sta. 86.50, slide a
between Sta. 44.65 and 90.61 along BL sheet of thin CRES material between center
0.00. beam web and T cap vertical leg to avoid dam
age to web.
(3). Cut away exterior skin between Sta. (7). Make certain all rivets are removed
44.65 and 90.61 to a width of 8 inches from entire length of forward T" cap
(20.32 cm) on both sides of T cap, section. Apply downward pressure at
starting at BL 0.00. aft (cut) end until T cap section is
Page 206
Original 532000
loose; then slide out section by pulling replacement of aft center beam fitting.
aft and down. Damage to fitting is usually the result of a
hard landing. In this event, other damage may
(8). Remove all rivets attaching forward occur that will require additional cutting away
center beam fitting and remove from of damaged material.
helicopter.
(1). Remove fuel cells and cut away aft wall
(9). As required, rebuild replacement of fiberglass tank liner to expose
fittings. fittingtocenter beam attachment
rivets forward of Sta. 124.00 lower
(10). Fit, drill and rivet new fitting in place. frame.
(11). Reinstall two extruded angles and T NOTE: Do not remove tank liner aluminum at
cap section. Use oversized rivets as tachment angle. Cut fiberglass up to the
required. angle and repair after completion.
(12). Splice repair T cap section at Sta. (2). Remove all rivets attaching aft center
86.50 (Ref. Figure 203). beam fitting and remove from helicop
ter.
(13). Patch repair exterior skin. Install
double row of rivets where replacement (3). As required, rebuild replacement
skin does not overlap rib or stiffener. fitting.
(14). During reinstallation of landing gear (4). Splice repair T" cap, if damaged,
and trim actuators, be sure that according to center beam repairs.
alignment is correct with no binding at
attachment points. At least 0.015 inch (5). Fit, drill and rivet new fitting in place.
(0.381 mm) minimum clearance (6). Patch repair exterior skin. Install
between actuator and center beam double row of rivets where replacement
structure must be maintained. skin does not overlap rib or stiffener.
4. Aft Landing Gear Center Beam Fitting (7). Patch repair fiberglass tank liner.
Replacement
(8). During reinstallation of landing gear,
(Ref. Figure 206) The following general check for correct alignment and binding
procedure is based on minimum access for at attach points.
Page 207
532000 Original
STA. 90.61
CANT. STA. 78.50
STA. 86.50
BL 0.00
STA. 64.36
STA. 44.65
REF. FIG. 206 FOR WEB

BUILDUP AND FITTING
ATTACHMENT RIVETS REMOVE ALL T" CAP RIVETS TO STA. 90.61
CUT AT APPROXIMATELY STA. 86.50. SPLICE
REPAIR AS SHOWN IN FIGURE 203
REMOVE EXTRUDED ANGLE

(BOTH SIDES)
REMOVE DOUBLERS AND

STIFFENERS AS REQUIRED
REMOVE ALL T" CAP RIVETS
TO STA. 44.65 8.00 IN. (20.32 CM)
APPROXIMATELY
(BOTH SIDES)
REMOVE SKIN (BOTH SIDES) BETWEEN
STA. 64.36 AND 90.61 (TERMINATE EACH
CUT AT RIB OR STIFFENER)
R53-2006-1A

(Sheet 1 of 2)
Page 208
Original 532000
STA. 90.61
CANT. STA. 78.50
STA. 86.50
BL 0.00
STA. 64.36
STA. 44.65
REF. FIG. 206 FOR WEB

BUILDUP AND FITTING
ATTACHMENT RIVETS REMOVE ALL T" CAP RIVETS TO STA. 90.61
CUT AT APPROXIMATELY STA. 86.50. SPLICE
REPAIR AS SHOWN IN FIGURE 203
REMOVE EXTRUDED ANGLE

(BOTH SIDES)
REMOVE DOUBLERS AND

STIFFENERS AS REQUIRED
REMOVE ALL T" CAP RIVETS
TO STA. 44.65 8.00 IN. (20.32 CM)
APPROXIMATELY
(BOTH SIDES) REMOVE SKIN (BOTH SIDES) BETWEEN
STA. 64.36 AND 90.61 (TERMINATE EACH
CUT AT RIB OR STIFFENER)
R53-2006-2A

(Sheet 2 of 2)
Page 209
532000 Original
NAS14663 PIN
NAS10806 COLLAR
(4 PLCS)
NAS14666 PIN
NAS10806 COLLAR
NAS14254 PIN
NAS1080C5 COLLAR
(3 PLCS)
NAS14254 PIN
NAS1080C6 COLLAR
NAS14653 PIN
NAS10805 COLLAR
(4 PLCS)
MS20470AD4 RIVETS MS20470AD4/5 RIVETS NAS14265 PIN

(18 PLCS) (AS REQ) NAS1080C5 COLLAR
(3 PLCS)
MS20615M4 RIVETS STIFFENER, 0.050 IN. (1.27 MM)

(28 PLCS EXCEPT AS 7075T6 AL ALY
SHOWN)
WEB, 0.032 IN. (0.8128 MM)
7075T6 AL ALY
NAS14255 PIN
NAS1080C5 COLLAR
NAS14254 PIN (3 PLCS)
NAS1080C6 COLLAR
(4 PLCS)
NAS14653 PIN NAS14264 PIN
NAS10805 COLLAR NAS1080C6 COLLAR
CL (4 PLCS)
STA. 124.00
NAS14254 PIN
NAS1080C6 COLLAR
(4 PLCS) NAS14243/4 PIN
NAS1080C4 COLLAR
STIFFENER, 0.025 IN. (0.635 MM) (CHECK FOR
7075T6 AL ALY CORRECT LENGTH)
(50 PLCS)
WEB, 0.020 IN. (0.508 MM)

7075T6 AL ALY MS20470AD4/5 RIVETS
(AS REQ)
MS20470AD3 RIVETS
(19 PLCS) MS20470AD4/5 RIVETS
(18 PLCS)
MS20470AD4 RIVETS
(60 PLCS)
NAS14264 PIN
NAS1080C6 COLLAR
MS20470AD4 RIVETS (3 PLCS)
(12 PLCS)
MS20470AD4/5 RIVETS
(22 PLCS)
NAS14255 PIN
NAS1080C5 COLLAR NAS14265 PIN
(3 PLCS) NAS1080C6 COLLAR
WEB, 0.032 IN. (0.8128 MM)
7075T6 AL ALY
NAS14253 PIN
NAS1080C5 COLLAR STIFFENER, 0.050 IN. (1.27 MM)
7075T6 AL ALY
CL
EXTRUDED T" CAP
STA. 64.365 (AL ALY)
R53-2007A
Figure 206. Landing Gear Center Beam Assembly (Fwd & Aft Fittings)
Page 210
Original 532000
RETAINING RING
RING
RETAINER
RING
SELFALIGNING
BEARING RETAINING
RING
SELFALIGNING SELFALIGNING
RETAINER BEARING BEARING
RETAINER BEARING
SELFALIGNING RETAINING RING RETAINER
RING
BEARING
RETAINING RING RING
FORWARD FITTING AFT FITTING
FITTING
FITTING
INSTALLER CUP WASHER
EXTRACTOR CUP
BOLT
BUSHING
NUT
TOOL A REMOVAL TOOL B INSTALLATION
BEARING INSTALLATION AND REMOVAL TOOLS

(TYP)
NOTES:
1. REMOVE RETAINER AND RING, IF INSTALLED.
2. REMOVE BEARING WITH EQUIVALENT OF TOOL SHOWN.
3. CLEAN BEARING BORE AND REPLACEMENT BEARING WITH
ACETONE (CM203).
4. INSTALL BEARING WITH RETAINER RING. COAT CONTACT
SURFACES WITH PRIMER (CM301).
5. INSTALL BEARING WITHOUT RETAINER RING. PREPARE
CONTACT SURFACES WITH LOCKING COMPOUND (CM405).
APPLY FILLET OF COMPOUND AT BEARING AND HOUSING.
ALLOW COMPOUND 24 HOURS TO HARDEN BEFORE
INSTALLATION OF LANDING GEAR.
R53-2008A
Figure 207. Center Beam Bearing Replacement
Page 211
532000 Original
5. Aft Oleo Support Fitting Replacement (3). Disconnect upper end of landing gear
damper from aft oleo support fitting to
(Ref. Figure 208) Aft oleo support fitting be replaced and remove any electrical
replacement procedure uses the associated equipment installed on fitting.
upper side engine mount to locate and drill the
fittingtomount attachment hole. Replace (4). Using pencil, trace around sheet metal
ment fitting is supplied undrilled. Before and edges of fitting at bulkheads to
fitting removal, perform an enginetotrans assist in positioning replacement
mission alignment check and inspect engine fitting.
mounts to verify that correct alignment is
maintained at replacement. If additional
structure or engine mount damage is noted, NOTE: During fitting removal, drill out rivets
assistance of MDHI Field Service Representa so that sheet metal stiffeners remain at
tive may be required. tached to fuselage wherever possible. Mark
and retain any shims for reinstallation.
Special Tools (5). Remove damaged fitting by drilling out

(Ref. Section 91-00-00) attachment rivets.
Item Nomenclature
ST107 Engine and tailboom alignment checking (6). Using pencil, outline traced on bulk
fixture heads and sheetmetal, place undrilled
replacement fitting in mounting
position. Mark rivet hole locations and
NOTE: Complete entire procedure for replace check for edge distances equivalent to
ment of one fitting before removing opposite that for damaged fitting.
fitting, if it is to be replaced.
(1). Remove engine and upper side engine (7). With fitting in place, pick up attach
mount on side to be repaired. ment holes and install monel rivets
(2). Jack helicopter until skid tubes of (8). Reinstall landing gear damper; lower
landing gear just clear ground. helicopter and remove jacks.
0.24950.2505 IN.
(6.33736.3627 MM)
SPACER
(0.048 CRES)
MS20615M5 RIVETS
(3 PLCS)
MS20615M5 RIVETS
(6 PLCS)
0.200 IN.
(5.08 MM) MS20615M3 RIVETS
(24 PLCS)
MS20615M4 RIVETS
(3 PLCS)
0.31220.3132 IN. 0.43700.4380 IN.

(7.929887.95528 MM) (11.099811.1252 MM)
NAS14653 PIN
NAS10805 COLLAR
R53-2009A
Figure 208. Aft Oleo Support Fitting
Page 212
Original 532000
NOTE: Mating hole in replacement fitting for (d). Remove mount; then use a D size
lower end of upper engine mount may be lo drill to enlarge fitting boss hole.
cated and drilled out using engine and tail
boom alignment checking fixture (ST107) if (e). Ream hole in boss to 0.24950.2505
available. inch (6.33736.3627 mm) OD.
(9). Locate and drill mating holes in boss of (f). Reinstall mount; then remove all
replacement fitting for lower end of engine supports and recheck align
upper engine mount as follows: ment.
(a). Reinstall engine with original engine 6. Fuel Tank Support Skin Inspection and
mounts and secure mounts, except Repair (Fuel Cells Removed)
for replacement fitting attach point. Repair fuel tank support liner and skin
Support engine with hoist and/or according to instructions found in FAA AC
jacks 4313.1A.
(b). Perform enginetotransmission 7. Fuel Cell Support Skin Replacement
alignment check (Ref. Sec. 533000)
then rigidly secure engine in aligned (Ref. Figure 209) Fuel cell support fiberglass
position. skin may be cut away for access to inspect and
repair exterior skin, supporting ribs or fittings.
(c). Using drill bushing, 0.250 inch (6.35 Replace cutaway skin sections and reinforce
mm) OD x 0.1935 inch (4.9149 mm) fiberglass edges (Ref. Sec. 530000).
ID, insert in engine mount attach
ment hole, drill a No. 10 pilot hole If possible, do not remove alumi
through fitting boss. CAUTION num edge attaching angles.
Page 213
532000 Original
TYPICAL CUT LINES. NO NOT DISTURB SKIN

ATTACHMENT ANGLES DURING REMOVAL FOR
REPAIR OR INSPECTION UNLESS DAMAGED
(NOTE 4)
NAS1738W RIVETS
(ENGINE COMPARTMENT SIDE)
CENTER BEAM STRUCTURE WITH CARGO

FLOOR NOT SHOWN
RIVET (TYP)
DOUBLER (TYP)
DAMAGED AREA CUT OUT FOR

INSPECTION OR REPAIR
PATCH WITH FIBERGLASS SHEET

(NOTE 4)
FIBERGLASS REINFORCING CLOTH

NOTES:
1. CARGO COMPARTMENT FLOOR NOT SHOWN. REMOVE FUEL
CELL ACCESS DOORS AND FUEL FILLER SHIELD FOR ACCESS.
2. USE A ROTARY SANDER FOR RIVET REMOVAL.
3. USE MS20470AD3 RIVETS EXCEPT AS NOTED.
4. IF ATTACHMENT EDGE ANGLES OR DOUBLERS ARE NOT
DISTURBED, DAMAGED AREAS UP TO 100% MAY BE REPLACED
WITH 2 PLY LAMINATED FIBERGLASS SHEET STOCK. BOND TO
EDGES WITH FIBERGLASS CLOTH, USING FIBERGLASS REPAIR
PROCEDURES.
5. INSTALL DOUBLERS ON EITHER SIDE OF CENTER RIVET AREA
ATTACH POINTS.
6. COVER RIVET HEADS AND SHARP EDGES WITH 10 MIL BY 1 IN.
(25.4 MM) TAPE (CM701).
R53-2010A
Figure 209. Fuel Cell Support Skin
Page 214
Original 532000
Section
53-30-00
Upper Aft Section
Fuselage
(369D/E/FF)

UPPER AFT SECTION FUSELAGE (369D/E/FF)

REPAIRS
1. Upper Aft Fuselage Section Description (3). The front of the structure is formed by
two Lchannels.
The upper aft fuselage section consists of Cant.
Sta. 78.50 frame, Cant. Sta. 124.00 frame (4). The rear of the support structure is
(firewall), Mast support structure, Aft Boom supported by two lateral Cchannels.
Fairing, engine air inlet (plenum chamber) (5). The Mast Support Structure in the
installation and engine compartment firewall fuselage assembly is jigaligned to fit
installation. the Cant. Sta. 78.50 and Cant. Sta.
A. Cant. Sta. 78.50 Frame 124.00 mast supports in a manner that
provides a 3 degree forward tilt to the
(1). The Cant. Sta. 78.50 frame is the mast structure.
forward member of the basic truss and D. Aft Fuselage Boom Fairing
establishes the crosssectional contour
of the fuselage. (1). The aft fuselage boom fairing is a
semimonocoque structure and consists
(2). Primary strength is provided by of the tail cone and turtleback.
Cchannels forming the forward mast
support, and beaded panels that are (2). The boom fairing tail cone is part of a
joined together to form a rectangular subassembly that consists of six rings,
structure crosssection. five of which are attached to the upper
engine compartment ring and ring and
B. Cant. Sta. 124.00 Frame rib structure. A sixth ring is suspended
approximately 12 inches (30.48 cm)
(1). The Cant. Sta. 124.00 frame and lower forward of the rearmost fuselage
panel and ring form the aft member of structure.
the basic truss and also establish the
rearward cross section of the fuselage. (3). The rings and single fitting are con
nected into a semimonocoque assem
(2). The main members of the Sta. 124.00 bly, and are attached to the Cant. Sta.
structure are two, forwardcanted, aft 124.00 and mast support structure,
mast supports and a canted frame. forming an integrated aft fuselage
assembly.
(3). The upper firewall (engine compart
ment) is constructed of corrosionresis (4). The turtleback, or lower section, is
tant steel. formed by the Sta. 137.50 ring and
three ribs which straddle a horizontal
(4). The lower firewall panel is 0.016 inch rib.
(0.4064 mm) titanium and forms the
passenger compartment aft wall. (5). The structure forms the top of the
engine compartment.
C. Mast Support Structure E. Engine Air Inlet
(1). The Cant. Sta. 78.50 frame and Cant. (1). Engine Air Inlet fairings untilized on
Sta. 124.00 frame are interconnected at the helicopter are constructed of
the top by the mast support structure. fiberglass and polyurethane foam
reinforcements and a lower aluminum
(2). The mast support structure is composed channel bonded into the structure edge
of fittings, a pan and an aft panel for attachment.
incorporating provisions for attachment
of the static mast assembly base and (2). The front fairings consists of two
main transmission to the airframe removable sections with an airfoil and
structure. vertical walls.
Page 201
533000 Original
(3). The aft portion of the engine inlet (3). If damage requires replacement of
fairing is permanently riveted to the boom fairing, MD Helicopters, Inc.
airframe external skin. (MDHI) assistance may be required.
(4). If damage to boom fairing has not
2. Boom Fairing Alignment Inspection disturbed alignment, repair damage
structure as required.
(Ref. Figure 201) Misalignment of tail rotor
drive shaft can occur as result of boom fairing 3. Engine and Tailboom Alignment Check
damage sustained in a hard landing. Slight oil Fixture Installation
canning, wrinkles, stretch marks or other (Ref. Figure 201) Engine and tailboom
visible distortion of boom fairing skin between alignment check fixture is used to check
boom fairing Sta. 137.50 ring and Cant. Sta. alignment of Cant. Sta. 197.78 frame fitting
197.78 frame fitting may be evidence of boom tomast support fitting and boom fairingto
fairing damage and tail rotor drive shaft fuselage structure. It also is to be used to
misalignment. Verification of boom fairing replace boom fairing on upper aft section
alignment should be accomplished as follows: fuselage structure, Sta. 197.78 frame fitting on
aft end of boom fairing and for locating and
(1). Check surface flatness of Cant. Sta. drilling mating holes for engine mounts in
197.78 (Ref. Sec. 534000, Tailboom replacement aft oleo fittings.
and Stabilizer Repair).
Special Tools
(2). Check for boom stretch marks or other (Ref. Section 91-00-00)
visible distortion of boom fairing skin Item Nomenclature
and/or structure. Any such damage
ST107 Engine and tailboom alignment checking
requires a Cant. Sta. 197.78 frame
fixture
fittingtomast support structure
alignment checks with engine and
tailboom alignment checking fixture. NOTE:
Check enginetotransmission align D Engine and tailboom alignment check fix
ment. ture (ST107) consists of mast support fix
ture, Sta. 197.78 fitting fixture and en
NOTE: gine mounts.
D Slight misalignment of boom fairing with D To install engine and tailboom alignment
the mating upper aft section fuselage fixture, removal of tailboom, engine and
structure is not critically important, if main transmission is required (Ref. CSP
Cant. Sta. 197.78 frame fittingtomast HMI2).
support structure fitting misalignment A. Sta. 197.78 Boom Fitting Fixture
does not exist. Installation
D Cant. Sta. 197.78 frame fittingtomast NOTE: Avoid damaging surfaces (ends) of four
support fitting alignment ensures that an bosses on fixture at installation. Ends must
installed tailboom will not be incorrectly fit flush against frame fitting. Otherwise,
canted, tail rotor will be positioned in cor check for surface flatness and trueness of
rect foreandaft vertical plane and that fixture boss ends.
tail rotor drive shaft will be correctly
aligned with shafts of main and tail rotor (1). Attach Sta. 197.78 fitting fixture to
transmission. Cant. Sta. 197.78 frame fitting. After
fixture attachment, ensure no gap
D Usually, when boom fairing is damaged exists between fixture bosses and frame
and misaligned with mating fuselage fittings at bolt holes; torque nuts to 60
structure from tailboom strike, hard land inchpounds (6.78 Nm).
ing or rollover after hard landing, Sta.
197.78 frame fittingtomast support fit (2). Route gap ends of measuring cable
ting misalignment exists. forward through boom fairing to white
Page 202
Original 533000
disc on aft end of mast support fixture. with measuring cable fully extended
A wood dowel or similar rod aids in (taut without slack).
routing cap end forward.
(3). When making check, ensure no target
(3). Insert penlight through boom bolts rod is installed thru white disc.
access opening in boom fairing and
install clamp on fixture so that light NOTE: Successful check indicates boom fairing
beam will be directed forward toward is correctly positioned foreandaft relative
white disc. to fuselage structure.
B. Mast Support Fixture Installation (4). Use short and long rod targets installed
thru white disc on mast support fixture
(1). Install mast support fixture on under (view B) and Sta. 197.78 fitting fixture
side of mast support structure pan (view C) to check vertical, lateral and
using main transmission mounting foreandaft boom fairingtofuselage
studs. structure alignment (angular displace
ment) according to view D.
(2). Install washers and nut, torque nuts to
60 80 inchpounds (6.78 9.04 NOTE: Successful angular displacement
Nm). checks verify that Sta. 197.78 frame fitting
tomast support fitting alignment is correct.
C. Engine Mounts Fixture Installation
5. Engine Mounts-to-Mast Support Fitting
(1). Insert tube of engine mounts fixture Alignment Check
into tube of mast support fixture and
lock in place with 4 lockpins. (1). Three mating holes on the fixture
should correctly align with holes in aft
(2). Secure lower and both upper side ends of upper side and lower engine
engine mounts to mating bosses on mounts that are secured to fuselage
fixture with attachment hardware. structure. It should be possible to
NOTE: Holes in mounts and bosses should cor install attachment hardware and
rectly align to allow installation of all at secure mounts to fixture bosses without
tachment bolts without application of pres application of pressure of forcing
sure or forcing fixture. fixture.
(3). Ensure WL 34.00 pads of fixture are (2). Inability to install any attachment bolt
positioned correctly (Ref. Boom Fair without forcing fixture indicates that
ingtoFuselage Structure Alignment engine mountstomast support fitting
Check). misalignment exists, which causes
enginetomain transmission misalign
NOTE: After all alignment checks are com ment at installation of engine.
pleted, final enginetotransmission align
ment check must be performed (engine and (3). Correct alignment of holes in mounts
transmission installed) (Ref. Figure 202). and fixture bosses and ability to install
all attachment bolts without forcing
4. Cant. Sta. 197.78 Frame Fitting-to-Mast fixture indicates that correct engine
Support Fitting Alignment Check mounttomast support fitting align
ment exists, which results in engine
(1). Use measuring cable of Sta. 197.78 tomain transmission alignment at
fitting fixture to check for correct installation of engine.
foreandaft distance to Sta. 197.78
frame fitting. Any misalignment must be cor
CAUTION rected before engine is installed
(2). Perform foreandaft linear distance for use. If misalignment is a result of dam
check by ensuring forward end of cable age for which repair information is provided
cap contacts aft end (index surface) of in this manual, allowable repairs may be
white disc, 0.030 inch (0.762 mm), made to correct the misalignment.
Page 203
533000 Original
6. Boom Fairing-to-Fuselage Alignment Frame FittingtoMast Support Fitting

Check Alignment Check).
Correction of boomtofuselage
(1). Check that spaces are equal, 0.115 CAUTION structure misalignment is re
inch (2.921 mm), between WL 34.00 quired to the extent, if any, that causes Sta.
pads of engine mounts fixture and 197.78 frame fitting to mast support fit
engine compartment ribs at left and ting misalignment. Slight boom fairingto
right undersides of upper aft section fuselage structure misalignment that does
fuselage structure. If spaces are not not cause Sta. 197.78 frame fittingtomast
within these limits, upper aft section is support fixture misalignment is allowed, if
excessively displaced radially. requirements of step (1). are met.
NOTE: Successful angular displacement

(2). Perform the foreandaft distance checks verify correct Cant. Sta. 197.78
check using the measuring cable of Sta. frame fittingtomast support fitting align
197.78 fitting fixture and angular ment which assures correct boom fairing
displacement checks using the scope of to fuselage alignment after successful
the same fixture) (Ref. Sta. 197.78 completion of step (1).
ROD TARGET AFT ENGINE AIR INLET FAIRING STA. 197.78

FITTING
BOOM FIXTURE
FAIRING MEASURING
CABLE
ENGINE COMPARTMENT RIB STA.

MAST SUPPORT 197.78
FIXTURE
WL 34.00 PAD
RIBTOPAD SPACES ON BOTH SIDES TO
BE EQUAL (REF. VIEW E)
LOWER ENGINE MOUNT ENGINE MOUNTS
FIXTURE
CAUTION: HANDLE FIXTURE CAREFULLY. DO NOT PRELOAD

UPPER SIDE ENGINE BOOM FAIRING OR OTHER STRUCTURE DURING ALIGNMENT
MOUNT CHECKS (TIEDOWNS, SUPPORTS, WEIGHT OR PRESSURE
ON FAIRING OR OTHER SIMILAR ITEMS THAT MAY PRELOAD
STRUCTURE SHOULD NOT BE USED). CHECK SHOULD BE
PERFORMED WITH FUEL CELLS AND STRESSED CONTROLS
ACCESS PANELS INSTALLED.
STA. STA.
124.00 137.50
R53-3001-1A
Figure 201. Alignment Checks - Sta. 197.78 Frame Fitting; Mast Support
Fitting; Engine Mounts; Boom Fairing (Sheet 1 of 4)
Page 204
Original 533000
MAST BASE
MAST SUPPORT
FITTING
MAIN TRANSMISSION
MOUNTING STUD MAST SUPPORT
STRUCTURE PAN
6080 IN. LB.
(6.789.04 NM)
MAST SUPPORT
FIXTURE
NOTE: THIN COAT OF LUBRICANT APPLIED TO MOUNTING

STUDS EASES INSTALLATION OF FIXTURE ON STUDS.
INSTALL MAST SUPPORT FIXTURE ON UNDERSIDE OF MAST SUPPORT STRUCTURE PAN

(BELOW MAST SUPPORT FITTING AND MAST BASE) AS SHOWN, USING MAIN TRANSMISSION
MOUNTING STUDS AND ATTACHING HARDWARE FOR MAIN TRANSMISSION.
INSTALLATION OF MAST SUPPORT FIXTURE

CAUTION: HANDLE RODS CAREFULLY TO
PREVENT DEFORMATION THAT CAN CAUSE
INCORRECT ALIGNMENT INDICATIONS. WHITE
(DISC)
THUMBSCREW BLACK
DISC
BLACK
(DISC)
SHORT ROD TARGET
BLACK WHITE
(DISC)
BLACK
(DISC)
LONG ROD TARGET
WHITE INDEX SURFACE ROD AND DISC END VIEW
MAST SUPPORT
FIXTURE 1. FOR FOREAND AFT DISTANCE CHECK, ENSURE ROD
TARGET IS NOT INSTALLED THRU WHITE DISC.
2. AT INSTALLATION OF ROD TARGET THRU CENTER HOLE IN
WHITE DISC, PUSH ROD FULLY FORWARD BEFORE
SECURING IN FIXTURE WITH THUMBSCREW.
3. USE SHORT ROD TARGET FOR INITIAL ALIGNMENT CHECK
AFT END SIDE VIEW FIRST, THEN USE LONG ROD TARGET FOR FINAL
ANGULARITY CHECK.
TARGET RODS MAST SUPPORT FIXTURE

R53-3001-3A
Page 205
533000 Original
STA. 197.78
FITTING FIXTURE
60 IN. LB. (6.78NM)
CANT. STA. 197.78 (4 PLCS)
FRAME FITTING
TELESCOPE
MEASURING CABLE
CLAMP
AFT ENGINE AIR

INLET FAIRING
PENLIGHT
BOOM BOLTS ACCESS OPENING

CAP
BOOM FAIRING
UPPER AFT SECTION
LOCKPINS (4)
UPPER SIDE ENGINE MOUNT
(2 PLCS)
100140 IN. LB.

(11.3015.82 NM)
WL 34.00 PADS
LOWER ENGINE
MOUNT
100140 IN. LB.

(11.3015.82 NM)
ENGINE MOUNT BOSS (INTERNALLY THREADED)
ENGINE MOUNTS FIXTURE (3 PLCS)
INSTALLATION OF STA. 197.78 BOOM FITTING FIXTURE
R53-3001-2A
Page 206
Original 533000
TARGET IMAGES VIEWED THRU SCOPE

GO NOGO
1. AFTER SUCCESSFUL FOREANDAFT DISTANCE CHECK, INSTALL SHORT ROD
TARGET FULLY FORWARD THRU HOLE IN WHITE DISC AN AFT END OF MAST SUPPORT
FIXTURE.
2. USING PENLIGHT AND ADDITIONAL LIGHT AS NECCESSARY, VIEW SHORT ROD TARGET
THRU SCOPE AND CHECK THAT SCOPE CROSSHAIRS APPEAR WITHIN OR TANGENT
TO BLACK CIRCLE AREA ON SHORT TARGET ROD (INITIAL CHECK GO INDICATION). IF
CROSSHAIRS APPEAR OUTSIDE OF BLACK AREA, FOREANDAFT CENTERLINE OF
INITIAL CHECK WITH SHORT HOLE ON STA. 197.79 FRAME FITTING FOR TAIL ROTOR DRIVESHAFT IS NOT ALIGNED
TARGET ROD WITH CENTER OF WHITE DISC.
NOTE: CENTER OF WHITE DISC REPRESENTS A POINT ON CENTERLINE BETWEEN SHAFTS
GO NOGO OF MAIN AND TAIL ROTOR TRANSMISSIONS (FOREANDAFT CENTERLINE OF TAIL
ROTOR DRIVESHAFT). AN INITIAL CHECK GO INDICATION VERIFIES ONLY THAT
FOREANDAFT CENTERLINE OF HOLE IS ALIGNED WITH CENTER OF WHITE DISC. IT
DOES NOT INDICATE THAT HOLE CENTERLINE IS ALIGNED WITH DRIVESHAFT
CENTERLINE OR THAT FRAME FITTING IS IN CORRECT LATERAL OR VERTICAL
POSITION.
3. REMOVE SHORT ROD TARGET AND REPLACE WITH LONG ROD TARGET ON MAST
SUPPORT FIXTURE.
4. AFTER INITIAL GO INDICATION, USE PENLIGHT AND ADDITIONAL LIGHT AS
ANGULAR DISPLACEMENT CHECK WITH NECCESSARY TO VIEW LONG TARGET ROD THRU SCOPE RETICLE. CHECK THAT
LONG ROD TARGET BLACK CIRCLE AREA (OF TARGET) APPEARS COMPLETELY WITHIN WHITE CIRCLE
AREA (INDEX SURFACE OF WHITE DISC) FOR AN ALIGNMENT CHECK GO INDICATION.
IF BLACK AREA IS NOT WITHIN WHITE AREA (ALIGNMENT CHECK NOGO INDICATION),
EXCESSIVE STA. 197.78 FRAME FITTING TO MAST SUPPORT FITTING MISALIGNMENT
EXISTS.
CAUTION: DO NOT TURN OR DISTURB KNURLED NOTE: GO INDICATION VERIFIES THAT FRAME FITTING IS CORRECTLY POSITIONED FOR
CALIBRATION ADJUSTMENT RING OR KNOBS. THESE PROPER MOUNTING OF TAILBOOM AND THAT CORRECT TAIL ROTOR DRIVESHAFT
ARE SET AND MARKED WITH COLORED STRIPES ALIGNMENT WILL RESULT AT INSTALLATION OF TAILBOOM. EXCESSIVE MISALIGNMENT
DURING CALIBRATION OF FIXTURE. FOR CALIBRATION, IS INDICATED BY ANGULAR DISPLACEMENT OF LONG TARGET ROD FROM GO
FIXTURE SHOULD BE RETURNED TO MDHI. DO NOT INDICATION POSITION. DIRECTION AND ANGLE OF ANY DISPLACEMENT OF FRAME
LEAN ON, OR APPLY PRESSURE ON BOOM FAIRING FITTING AND AFT END OF BOOM FAIRING FROM CORRECT POSITION IS 180 OPPOSITE
WHEN VIEWING TARGETS. TO ANY DISPLACEMENT OF LONG TARGET ROD VIEWED THRU SCOPE.
TYPICAL EXAMPLES OF MISALIGNMENT
TARGET IMAGE VIEW PROBABLE TROUBLE AND CAUSE CORRECTIVE ACTION
STA. 197.78 FRAME FITTING DISPLACED UP AND TO LEFT. IF REPAIRABLE, REPAIR BOOM FAIRING
MAJOR FOREANDAFT LENGTH OF BOOM FAIRING AND/OR REPLACE FRAME FITTINGS.
DISPLACED SIMILARILY WITH A CENTERLINE OTHERWISE, REPLACE BOOM FAIRING.
APPROXIMATELY PARALLEL TO CENTERLINE OF TAIL
ROTOR DRIVESHAFT.
BOTH NOGO INDICATIONS
SHOWN IN VIEW D NOTE: FOR THESE EXAMPLES, REFER TO STRUCTURAL PARAGRAPH IN INTRODUCTION
FOR DATA ON MOST COMMONLY DAMAGED COMPONENTS OF BOOM FAIRING.
STA. 197.78 FRAME FITTING DISPLACED FORWARD AT IF REPAIRABLE, REMOVE FRAME FITTING.
LOWER UNDERSIDE AND/OR AFT END OF BOOM REPAIR BOOM FAIRING AND REINSTALL
AND FAIRING DISPLACED DOWN. SERVICEABLE FRAME FITTING.
OTHERWISE, REPLACE BOOM FAIRING.
STA. 197.78 FRAME FITTING DISPLACED FORWARD AT IF REPAIRABLE, REMOVE FRAME FITTING.
LOWER LEFT UNDERSIDE AND/OR AFT END OF BOOM REPAIR BOOM FAIRING AND REINSTALL
AND FAIRING AND FRAME FITTING TWISTED SERVICEABLE FRAME FITTING.
COUNTERCLOCKWISE AND DISPLACED DOWN AND OTHERWISE, REPLACE BOOM FAIRING.
OUTBOARD TO LEFT.
SHORT TARGET LONG TARGET

ROD ROD
R53-3001-4A
Page 207
533000 Original
7. Engine-T o-T ransmission Alignment (1). Support engine from engine hoist
Check fittings using hoist. Take all slack out of
hoist support cables, use care to avoid
(Ref. Figure 202) If there has been structural getting hoist cables too tight.
damage to the Cant. Sta. 124.00 frame, engine
mount fittings or mast base, enginetotrans
(2). Remove lockwire and loosen (but do not
mission alignment should be checked.
remove) two bolts securing upper RH
and upper LH engine mounts to upper
Special Tools engine mount fittings.
Item Nomenclature (3). Remove lockwire, nuts and washers
ST102 Engine-to-transmission aligning tool from each of two bolts securing lower
engine mount to bulkhead splice
fittings.
(1). With engine and main transmission
installed, attach alignment tool shaft
(ST102) to main transmission input (4). Gently pivot engine so that lower
shaft and install cone on overrunning engine mount separates from bulkhead
clutch coupling. fitting just enough to install one or two
AN9704 shim washers as required on
(2). Preload dial indicator to 0.10 inch (2.54 the two bolts between the engine mount
mm). Rotate tool shaft with indicator and bulkhead fittings. Bond washers to
360. Maximum runout is 0.050 inch bulkhead fittings using epoxy adhesive
(1.27 mm). (CM401) or equivalent.
(3). Reverse tool and cone and rotate tool
(5). Gently pivot engine back to seat on
360 degrees. Maximum runout is 0.050
shim washers.
inch (1.27 mm).
8. Engine Mount Shimming (250-C20) (6). Reinstall washers and nuts on bolts
securing lower engine mount.
(Ref. Figure 201, Figure 202) This is a proce
dure for installing new shim washers at engine (7). Torque engine mounting bolts to 100
mounts for engine alignment or when proper 140 inchpounds (11.30 15.82 Nm):
distance cannot be attained for engineto lockwire bolts.
transmission drive shaft installation.
(8). Check that engine inlet firewall seal
Consumable Materials ring contacts enginetofirewall seal
(Ref. Section 91-00-00) around entire circumference.
Item Nomenclature
CM401 Adhesive, epoxy (parts A & B) (9). Perform enginetotransmission
alignment check.
Page 208
Original 533000
NOTE 1
TRANSMISSION SHAFT CL NOTE 2
0.100 IN. (2.54 MM) MAX. 369A500040101 CL

WOBBLE (RUNOUT)
ENGINETOTRANSMISSION DRIVE SHAFT

(FASTEN TO ENGINE COUPLING)
ENGINETOTRANSMISSION DRIVE SHAFT

(FASTEN TO TRANSMISSION COUPLING)
0.100 IN. (2.54 MM) MAX.

WOBBLE (RUNOUT)
OVERRUNNING CLUTCH CL
TRANSMISSION INPUT METHOD USING ENGINETOTRANSMISSION DRIVE SHAFT

SHAFT COUPLING
BOLT
WASHER
ENGINETOTRANSMISSION
ALIGNING TOOL (ST102)
WASHER
NUT
COUPLING
OVERRUNNING
CLUTCH
SCREW
METHOD USING 369A500040101

ENGINETOTRANSMISSION ALIGNMENT TOOL
NOTES:
1. WHEN INSTALLING DRIVE SHAFT, PEEL SHIM TO OBTAIN
+0.010/0.020 IN. (+0.254/0.508 MM) AXIAL FIT.
2. 0.050 IN. (1.27 MM) MAX. AVERAGE OFFSET AT THE COUPLING
FLANGE WITH THE LARGEST MISMATCH (OFFSET) WHEN WASHER
ROTATING TOOL ONE FULL TURN (360) (2 PLCS). NUT
R53-3002A
Figure 202. Engine-To-T ransmission Alignment Check
Page 209
533000 Original
R53-3003A
AFT FAIRING (FIBERGLASS)
MS20470AD ATTACHMENT RIVETS
PANEL, 0.050 IN. (1.27 MM)
7075T6 AL ALY AFT SECTION STRUT
MAST SUPPORT FITTING
AL ALY UPPER LONGERON
7075T6 AL ALY EXTRUSION
CHANNEL, 0.025 IN. (0.635 MM)
Figure 203. Firewall, Plenum Chamber and Mast Support Structure

2024T42 AL ALY
TAIL ROTOR DRIVE SHAFT FAIRING
LONGERON, 0.050 IN. (1.27 MM)
7075T6 AL ALY
CHANNEL, 0.071 IN. (1.8034 MM) 7075T6 AL ALY
ATTACHING DOUBLERS, 0.040 IN. (1.016 MM)
7075T6 AL ALY
PAN, 0.100 IN. (2.54 MM) STA. 124.00 CANT. FRAME, 0.032 IN.
7075T6 AL ALY (0.8128 MM) (7075T6 AL ALY
PLENUM CHAMBER AND SHOULDER STRAP SUPPORT FITTING

FIREWALL INSTL.
DOUBLER, 0.020 IN. (0.508 MM)
DOOR FRAME ANGLES, 0.025 IN. 157 CRES
(0.635 MM) 7075T6 AL ALY
MD Helicopters Inc.
STA. 137.50 RING, 0.020 IN. (0.508 MM)

SEAT SUPPORT, OUTBOARD 157 CRES
WL 34.96 RIB, 0.020 IN. (0.508 MM)
BENCH SEAT SUPPORT ANGLE, 157 CRES
0.025 IN. (0.635 MM) 7075T6 AL ALY EXTRUDED ANGLE AL ALY
CARGO FLOOR SEAT BELT UPPER ENGINE MOUNT, LH
533000
FITTING, OUTBOARD
OLEO SUPPORT FITTING
WL 32.00
LOWER STA. 124.00 SKIN DOUBLER, 0.020 IN. (0.508 MM)
(NOTE 4) 157 CRES
SEAT SUPPORT,
INBOARD CHANNEL, 0.032 IN. (0.8128 MM)
7075T6 AL ALY
CARGO FLOOR SEAT BELT LANDING GEAR RUB PLATE
FITTING, INBOARD
LANDING GEAR CENTER WL 13.10
NOTES: BEAM ASSY, AFT
AND REPAIR FOR STANDARD SHEET METAL REPAIR LOWER ENGINE MOUNTS STA. 124.00 LOWER FRAME, 0.020 IN. (0.508 MM)
PROCEDURES UNLESS OTHERWISE SPECIFIED. (369FF ONLY) 157 CRES
2. MATERIALS INDICATED ARE TO BE USED AS A PATCH
REPAIR GUIDE ONLY. FOR SUBSTITUDE MATERIAL,
REFER TO TABLE 3, 910000.
3. REFER TO THE SKIN PANALING DIAGRAM FOR
CSPSRM6
4. THE AFT CARGO COMPARTMENT AND FUEL CELL AREA
Page 210
SKIN AT STA. 124.00 TO WL 32.00 IS 0.016 IN. (0.4064 MM)
Original
COMMERCIALLY PURE TITANIUM SHEET.
5. MS20615 (MONEL) RIVETS ARE USED IN ENGINE
COMPARTMENT. MS20470AD RIVETS ARE USED AT
MOST OTHER SHEET METAL ATTACHMENT LOCATIONS.
STA. 197.78 FRAME FITTING
AL ALY
STA. 185.89 RING, 0.020 IN. (0.508 MM)
2024T45 AL ALY
STA. 174.00 RING, 0.032 IN. (0.8128 MM)
7075T6 AL ALY
TOP CENTER LONGERON 7075T6 AL ALY EXTRUSION DAMPER SUPPORT

BRACKET
STA. 164.87 RING, 0.020 IN. (0.508 MM)
2024T42 AL ALY
STA. 155.75 RING, 0.020 IN. (0.508 MM)
2024T42 AL ALY
STA. 197.78 JACK PAD FITTING
STA. 146.62 RING, 0.020 IN. (0.508 MM)
2024T42 AL ALY LONGERON, 0.016 IN. (0.4064 MM)
BELLCRANK SUPPORT INSTL., 0.032 IN. 7075T6 AL ALY
(0.8128 MM) 2024T3 AL ALY
STA. 185.89 FRAME, 0.020 IN. (0.508 MM)
2024T42 AL ALY
UPPER LONGERON 7075T6
AL ALY EXTRUSION LONGERON, 0.040 IN. (1.016 MM)
7075T6 AL ALY
STA. 137.50 RING, 0.025 IN. CHANNEL, 0.063 IN. (1.6002 MM)
(0.635 MM) 2024T42 AL ALY 7075T6 AL ALY
RIBS, 0.025 IN. (0.635 MM)
7075T6 AL ALY
ENGINE EXHAUST PIPE SUPPORT FITTING
LONGERON, 0.050 IN. (1.27 MM)
7075T6 AL ALY
MD Helicopters Inc.
STA. 164.87 ANGLE, 0.020 IN. (0.508 MM)

7075T6 AL ALY
DOUBLER, MS20470AD ATTACHMENT RIVETS
ENGINE HOIST FITTING (8 PLCS)
STA. 155.75 RING, 0.025 IN. (0.635 MM)

2024T42 AL ALY
533000
NOTES: ENGINE COMPARTMENT, 0.025 IN. (0.635 MM)
Figure 204. Upper Aft Structure and Boom Fairing

1. REFER TO FAA AC 43.131A, AIRCRAFT 157 CRES MS20615M ATTACHMENT RIVETS
INSPECTION AND REPAIR FOR STANDARD AT ALL RINGS AND RIBS
SHEET METAL REPAIR PROCEDURES UNLESS
OTHERWISE SPECIFIED. STA. 146.62 RING, 0.025 IN. (0.635 MM)
2. MATERIALS INDICATED ARE TO BE USED AS A 2024T42 AL ALY
PATCH REPAIR GUIDE ONLY. FOR SUBSTITUDE
MATERIAL, REFER TO TABLE 3, 910000. STA. 137.50 RING, 0.020 IN. (0.508 MM) 157 CRES
3. REFER TO THE SKIN PANALING DIAGRAM FOR MS20615M SKIN ATTACHMENT RIVETS
4. MS20615 (MONEL) RIVETS ARE USED IN
ENGINE COMPARTMENT. MS20470AD RIVETS
ARE USED AT MOST OTHER SHEET METAL
ATTACHMENT LOCATIONS.
R53-3004
CSPSRM6
Page 211
Original
TAIL ROTOR SHAFT FAIRING

AL ALY
PANEL, 0.016 IN.

(0.4064 MM)
CHANNEL 2024T42 AL ALY
PANELS, 0.016 IN. (0.4064 MM)

2024T42 AL ALY PANEL, 0.016 IN.
(0.4064 MM)
2024T42 AL ALY
FIREWALL WEB, 0.014 IN.
(0.3556 MM) PH157 CRES
DOUBLER, 0.012 IN.
OIL COOLER SUPPORTS, (0.3048 MM)
0.020 IN. (0.508 MM) PR157 CRES
2024T3 AL ALY
DRAIN TUBING
CHANNEL,
0.020 IN. (0.508 MM)
PH157 CRES
DOUBLER,
0.016 IN.
(0.4064 MM)
PR157 CRES
DOUBLER, 0.016 IN.

(0.4064 MM) PR157 CRES
PAN, 0.012 IN. (0.3048 MM)
AISI 301 1/4 A CRES SHEET
DRAIN TUBING (CRES)
PLENUM CHAMBER
(NOTE 1)
PAN, 0.012 IN. (0.3048 MM)
AISI 301 1/4 A CRES SHEET
BULKHEAD SPLICE
FITTING (CRES)
FIREWALL WEB,
0.014 IN. (0.3556 MM)
PH157 CRES
DOUBLER, 0.012 IN.
(0.3048 MM)
PR157 CRES
NOTES:
1. NO HOLES ALLOWED. TAPE PLENUM CHAMBER HOLES OR PLUG WITH RIVETS.
2. MS20615M (MONEL) ATTACHMENT RIVETS ARE USED FOR THE FIREWALL (CRES).
MS20470AD RIVETS ARE USED AT MOST OTHER LOCATIONS. R53-3005A
Figure 205. Firewall and Plenum Chamber
Page 212
Original 533000
DOUBLER
STA. 121.50
STA. 137.50 BOOM
FAIRING RING
RUBBER SEAL
(NOTE 3)
PANEL, 0.020 IN. (0.508 MM)

2024T3 AL ALY)
SIDE PANEL
(NOTE 4)
RUBBER SEAL
(NOTE 3)
PANEL, 0.020 IN. (0.508 MM)

STA. 124.00 FRAME 2024T3 AL ALY)
GROMMET
(NOTE 3)
BLOWER BAFFLE ASSEMBLY
NOTES:
1. USE MS20470AD3 RIVETS EXCEPT AS NOTED.
2. TAIL ROTOR SHAFT FAIRING PARTS ARE 6061T6 AL ALY.
3. BOND WITH ADHESIVE (CM401) ACCORDING TO CONTAINER INSTRUCTIONS.
4. CHECK THAT RUBBER SEAL IS COMPRESSED AFTER INSTALLATION.
R53-3006A
Figure 206. Tail Rotor Shaft Fairing and Blower Baffle Replacement
Page 213
533000 Original
9. Aft Section Strut Repair hole elongation and fretting. If neces

sary, repair damage as follows:
(Ref. Figure 207) Repair of aft strut is limited
to smoothing out minor dents, scratches or (a). Using centerline of mount hole as a
nicks. Replace strut if badly damaged. reference point, measure the dam
aged area. If damage area exceeds
10. Inspection and Repair of Lower Engine 0.3125 inch (7.9375 mm) in diameter,
Mount Installations then repair cannot be performed in
the field; contact MDHI Warranty
(Ref. Figure 209, Figure 210) The following is a and Repair for disposition.
procedure for inspecting and repairing (if
necessary) the lower engine mount fittings. (b). If damaged area does not exceed
0.3125 inch (7.9375 mm), open
damaged area to 0.31200.3125 inch
Consumable Materials (7.92487.9375 mm) using centerline
(Ref. Section 91-00-00) of engine mount hole as a guide.
Item Nomenclature
CM301 Primer (c). Fabricate bushing (Ref. Figure 210)
CM804 Pasa-Jell 101 and passivate with PasaJell 101
(CM804).
(1). Inspect all enginetoairframe mount (d). Apply primer (CM301) and install
bolts for proper installation by checking bushing while primer still wet.
the number of threads protruding from (4). Reinstall engine mount.
the nuts.
If an additional washer is added
(2). If more than four threads, 0.143 inch CAUTION while performing the following
(3.6322 mm), protrude beyond the nut step, only add one (1) washer to the nut side
face, remove the engine mount installa of the installation.
tion and inspect the engine mount,
helicopter airframe and associated (5). If more than four (4) threads protrude
hardware for damage. from the nut face after installation,
install an additional AN960C416
NOTE: If any engine mounts, airframe fittings washer, per installation instructions, to
or associated hardware are damaged, re eliminate the possibility of the nut
place during reassembly. Replace damaged shanking out on the bolt. Apply torque
bolts with a new SPS10198146 bolt. stripe across bolt, nut and washer.
(3). Remove engine mount fittings from (6). Check enginetotransmission align
airframe (Ref. CSPHMI2, Sec. ment (Ref. EngineToT ransmission
712000) and inspect airframe for bolt Alignment Check).
Page 214
Original 533000
STA
DRILL 0.1520.155 IN. 137.50
(0.386080.3937 MM) 0.340 IN.
INSTALL NAS14254 PIN (8.636 MM)
NAS1080C5 COLLAR
(3 PLCS)
0.310 IN. (7.874 MM)
(TYP)
AFT END
1.18 IN.
(29.972 MM)
SHIM AS REQUIRED
DRILL 0.1520.155 IN.

(0.386080.3937 MM)
INSTALL NAS14254 PIN
NAS1080C5 COLLAR
(3 PLCS)
0.310 IN. (7.874 MM)
(TYP) CAUTION: INSTALL A SUPPORT JACK AT THE
BOOM FAIRING JACK PAD BEFORE DAMAGED
STRUT IS REMOVED. STRUCTURAL DAMAGE
FORWARD END MAY RESULT IF STRUT IS REMOVED WITHOUT
0.940 IN. SUPPORT OF ACFT STRUCTURE WITH BOOM
(23.876 MM) INSTALLED.
MAST BASE R53-3007A
Figure 207. Aft Strut Replacement
LOCATE 4.10 IN. (10.414 CM)

AFT OF STA. 137.50
MS20470AD4 RIVETS
CL
0.4990.506 IN.
(12.674612.8524 MM) 0.1900.194 IN. WASHER
(4.8264.9276 MM) (CRES)
ENGINE HOIST
MS903540505 0.24950.2505 IN. SCREW
(AL ALY) (6.33736.3627 MM)
RIVETS
ENGINE EXHAUST PIPE SUPPORT

(CRES)
NAS14655 PIN
NAS10805 COLLAR
NAS14655 PIN
NAS10805 COLLAR CANT.
STA. 124.00
ENGINE MOUNT, UPPER LEFT

(CRES)
(TOOLING REQUIRED FOR INSTALLATION)
R53-3008A
Figure 208. Engine Mount Fittings
Page 215
533000 Original
BULKHEAD
SPLICE FITTING
LOWER ENGINE
MOUNT
R53-3014
Figure 209. Lower Engine Mount Installation
NOTE 2
0.4950.500 IN.
(12.57312.7 MM)
0.24950.2505 IN. 0.31400.3145 IN.

(6.33736.3627 MM) (7.97567.9883 MM)
NOTE 1
0.0050.015 IN. FIREWALL
(0.1270.381 MM)
0.0200.040 IN.
(0.5081.016 MM)
BULKHEAD STIFFENER
BULKHEAD SPLICE
FITTING
BUSHING
NOTES:
1. FABRICATE BUSHING FROM CORROSIONRESISTANT
MATERIAL; 174 PH, CONDITION H1025 (RC 35/42) PER AMS 5634.
2. FABRICATED BUSHING TO BE 0.010 IN. (0.254 MM) BELOW
AIRFRAME SURFACE.
LOWER FRAME
SHIM
R53-3015A
Figure 210. Fabrication and Installation of Bushing-to-Airframe
Page 216
Original 533000
Section
53-30-30
Upper Aft Section
Fuselage (500/600N)

UPPER AFT SECTION FUSELAGE (500/600N)

REPAIRS
1. Upper Aft Fuselage Section Description (1). Check surface of Sta. 159.97 for visible
distortion or damage.
The upper aft fuselage section consists of Cant.
Sta. 78.50 frame, Cant. Sta. 124.00 frame, aft (2). Check for visible distortion of boom
boom fairing, mast support structure and fairing skin and/or structure. Any such
engine air inlet fairings, associated access damage requires a Sta. 159.97 frame
panels and doors. The inlet fairings are made fittingtomast support structure
of a lightweight kevlar fabric. alignment checks with drive system
alignment checking fixture (ST108);
2. Composite Components Inspection and Check enginetotransmission align
Repair ment (Ref. Sec. 533000).
NOTE: Slight misalignment of boom fairing
There are no repair procedures for the upper
with the mating upper aft section fuselage
aft fuselage section at this time. Refer to MD
structure is not critically important, if Cant.
Helicopters, Inc. (MDHI) Field Service
Sta. 159.97 frame fittingtomast support
Representatives. Refer to CSPHMI2, Sec.
structure fitting misalignment does not ex
533030 for inspection requirements.
ist. Sta. 159.97 frame fittingtomast sup
port fitting alignment ensures that a
3. Aft Section Strut Repair installed tailboom will not be incorrectly
canted, fan and fan gearbox will be posi
Repair of aft strut is limited to smoothing out
tioned in correct fore and aft vertical
minor dents, scratches or nicks. Replace strut
plane. Usually, when boom fairing is dam
if badly damaged.
aged and misaligned with mating fuselage
structure from chop, hard landing or rol
4. Fan, Fan Gearbox and Boom Fairing lover after hard landing, Sta. 159.97 frame
Alignment fitting to mast support fitting misalign
ment exists.
(Ref. Figure 205) Misalignment of fan and fan
gearbox can occur as a result of boom fairing (3). If damage requires replacement of
damage sustained in a hard landing. Slight oil boom fairing, MDHI assistance may be
canning, wrinkles, stretch marks or other required.
visible distortion of boom fairing skin between
boom fairing Sta. 137.50 ring and Sta. 159.97 (4). If damage to boom fairing has not
frame fitting may be evidence of boom fairing disturbed alignment, repair damage
damage and fan and fan gearbox misalign structure as required.
ment. Verification of boom fairing damage
should be accomplished as follows:
NOTE: Refer to Section 533000 for engine
totransmission alignment.
Special Tools 5. Engine Mount Shimming (250-C20)

(Ref. Sec. 533000) This is a procedure for
Item Nomenclature
installing new shim washers at engine mounts
ST108 Anti-torque fan drive system alignment tool for engine alignment or when proper distance
kit cannot be attained for enginetotransmission
drive shaft installation.
Page 201
533030 Original
FAN AIRINLET
SCREEN
COVER FANHUB
FAIRING AND
TRANSMISSION
INTAKE FAIRING
ACCESS DOOR
ENGINE PLENUM
ACCESS COVER
TAILBOOM FAIRING
BYPASS DOOR
2
3
R53-3009
Figure 201. Aft Section
Page 202
Original 533030
NOTES:
1. REFER TO FAA AC 43.131A, AIRCRAFT
INSPECTION AND REPAIR FOR STANDARD
SHEET METAL REPAIR PROCEDURES UNLESS
OTHERWISE SPECIFIED.
PATCH REPAIR GUIDE ONLY. FOR SUBSTITUDE
MATERIAL, REFER TO TABLE 3, 910000.
3. REFER TO THE SKIN PANALING DIAGRAM FOR
4. MS20615 (MONEL) RIVETS ARE USED IN
ENGINE COMPARTMENT. MS20470AD RIVETS
ARE USED AT MOST OTHER SHEET METAL
ATTACHMENT LOCATIONS.
CANT. STA. 168.20 AFT RING FRAME,

7075T6 AL ALY
BOOM ATTACHMENT FITTING,

7075T6 AL ALY (4 PLCS)
STA. 137.50 BULKHEAD,

AL ALY
FAN SUPPORT FRAME,
7075T7351 AL ALY
LONGERON, UPPER AFT,

7075T7351 AL ALY EXTRUSION
LONGERON, 0.032 IN. (0.8128 MM)
7075T6 AL ALY
MD Helicopters Inc.
UPPER STA. 155.75 FRAME, 0.032 IN.

(0.8128 MM) 2024T3 AL ALY
Figure 202. Aft Structure

UPPER STA. 146.62 FRAME, 0.032 IN.
(0.8128 MM) 2024T3 AL ALY

CANT. STA. 168.20 FRAME, 0.032 IN.
(0.8128 MM) 2024T42 AL ALY
533030
CANT. STA. 159.97 FRAME, 0.032 IN.
(0.8128 MM) 2024T42 AL ALY
STA. 155.75 RING, 0.025 IN. (0.635 MM)

2024T42 AL ALY
ENGINE COMPARTMENT, 0.025 IN. (0.635 MM)
157 CRES MS20615M (MONEL) RIVETS AT ALL
RINGS AND RIBS
STA. 146.62 RING, 0.025 IN. (0.635 MM)

STA. 137.50 RING, 0.020 IN. (0.508 MM) 157 CRES 2024T42 AL ALY
MS20615M (MONEL) SKIN ATTACHMENT RIVETS
R53-3010A
CSPSRM6
Page 203
Original
CANT. STA. 159.97
0.1520.155 (3.86083.937 MM)

NAS142503 PIN
NAS1080C05 COLLAR
(3 PLCS)
MS20470AD4 RIVETS
500N31421 FITTING
500N31305 FITTING
500N31307 TUBE
500N3120 (REF)
500N3122
500N31303 FITTING
STA. 137.50
500N32101
0.1520.155 (3.86083.937 MM)
NAS142503 PIN
NAS1080C05 COLLAR
(COLLAR NEAR SIDE 3 PCLS)
WARNING: INSTALL A SUPPORT JACK AT THE BOOM
FAIRING JACK PAD BEFORE DAMAGED STRUT IS REMOVED.
STRUCTURAL DAMAGE MAY RESULT IF STRUT IS REMOVED
WITHOUT SUPPORT OF AFT STRUCTURE WITH BOOM
INSTALLED.
R53-301 1A
Figure 203. Diagonal Brace
Page 204
Original 533030
MAST FRAME
FAN GEARBOX DRIVE OUTPUT

SEAL DRAIN TUBE
MAIN
TRANSMISSION COOLING BLOWER DRAIN TUBE
AFT MAST SUPPORT

CHANNEL
OUTPUT SHAFT
DRAIN TUBE
Y EXTRUSION
COOLING BLOWER
UPPER FIREWALL
CANT. STA. 124.00

FRAME
R53-3013
Figure 204. Firewall and Plenum Chamber
Page 205
533030 Original
500N50001ATP AND
500N50002ATP TOOLS
INSTALLED
500N50001ATP
500N50002ATP
500N50003ATP
FAN SUPPORT
500N50003ATP2
500N50003ATP6
FAN SUPPORT
R53-3016-1
Figure 205. Driveshaft Alignment Tools (Sheet 1 of 3)
Page 206
Original 533030
6. Driveshaft Alignment Tools Installation (b). Distance 500N50001ATP tool

sticks out beyond 500N50002ATP
(Ref. Figure 205) tool at the 12, 3, 6 and 9 oclock
positions.
Special Tools (B) 12 oclock
(Ref. Section 91-00-00) (B) 3 oclock
Item Nomenclature (B) 6 oclock
ST108 Anti-torque fan drive system alignment tool
(B) 9 oclock
kit
Requirements: 0.250 0.025 in.
NOTE: Tools 500N50001ATP, 500N50002

ATP and 500N50003ATP are the individ STA. (A)
132.50
ual tools that make up the drive system
alignment tool kit.
(1). Install 500N50001ATP alignment 500N50002ATP
tool (ST108) on the helicopter main
transmission mounting studs using
either commercial hardware or existing TRANSMISSION
SUPPORT LEGS
aircraft nuts.
(2). Install 500N50002ATP tool on the
helicopter using bolts with proper grip LOOKING FWD
length (leave all bolts loose).
LEG 1 LEG 2
(a). Slide 500N50002ATP6 tapered
wedge toward fan hub bearing bore
while pushing foreword on
500N50002A TP1 weld assembly; LEG 3 LEG 4
tighten screw to hold wedge in place.
(b). Locate transmission leg with 0.000
clearance and tighten bolt attaching
500N50002A TP tool to the trans 500N50001ATP
mission support.
NOTE: At least one of the legs will always be
0.000 clearance. (B)
(3). Measure the following requirements:

(a). Clearance between 2 tool and
transmission support.
500N50002ATP
(A) LEG 1
(A) LEG 2
(A) LEG 3 R53-3016-2
(A) LEG 4
Figure 205. Driveshaft Alignment Tools
Requirements: Maximum 0.025 in. (Sheet 2 of 3)
Page 207
533030 Original
(c). Smallest and largest dimension CLOCK

between 500N50001ATP tool hole
at transmission support area. Note
clock position for smallest dimension.
Smallest dimension SMALL DIMENSION
Largest dimension
Clock position for
smallest dimension LARGE DIMENSION
Large dimension minus
small dimension
Requirements:
Large minus Small dimension <0.20
inch (5.08 mm).
TRANSMISSION SUPPORT
(4). Remove 500N50002ATP tool from
helicopter.
(5). Install 500N50003ATP tool plate to
the transmission support. 500N50003ATP
(6). Install 500N50003ATP tool shaft and

tapered wedge in helicopter. SPHERICAL ROD END
(7). Push and hold 500N50003ATP tool

shaft forward.
(8). Pull 500N50003ATP tool wedge to
center shaft in fan housing bearing (C)
bore; tighten screw on wedge to hold in
place.
(9). Measure distance between:
(a). Shaft and spherical rod end. (D)
(b). End plate and fan support housing;

measure at 12, 3, 6 and 9 oclock
positions.
(C) Shafttospherical rod end
(D) End platetofan housing
12 oclock
3 oclock 500N50003ATP
6 oclock
9 oclock
Requirements: 0.025 0.020 inch

FAN SUPPORT HOUSING
(0.635 0.508 mm).
R53-3016-3
Average of 4 clock readings
Max. deviation from average
Figure 205. Driveshaft Alignment Tools
Max. deviation requirements: <0.010
inch (0.254 mm). (Sheet 3 of 3)
Page 208
Original 533030
Section
53-40-00
Tailboom
(369D/E/FF)

TAILBOOM (369D/E/FF)
REPAIRS
1. Tailboom Description 3. Tailboom and Stabilizer Fitting Inspection
and Repair
(Ref. Figure 201) The tailboom assembly is a
highly stressed skin section that forms the The tailboom and stabilizer fittings of cast or
cylindricallytapered cone. forged aluminum alloy are critical fatigue
loading parts. Whenever damaged fittings
must be repaired or fitting components
2. Tailboom Sheet Metal Inspection and replaced, replace according to the following:
Repair
A. Negligible Damage
(Ref. Figure 201) For sheet metal repair
procedures not covered in this paragraph, refer (1). Longitudinal scratches, nicks or dents
to FAA AC 43.131A Aircraft Inspection and shall not exceed 0.010 inch (0.254 mm)
Repair. depth or 15 percent of length.
(2). Transverse scratches, nicks or dents

A. Negligible Damage shall not exceed 0.010 inch (0.254 mm)
depth or 10 percent of fitting thickness.
None (Preceding damage limits apply after
polishing is accomplished.)
1. All repairable damage shall be repaired upon
detection. (3). Following scratch removal, perform
flatness check of Sta. 197.78 frame
a. Small cracks or punctures in sheet metal that fitting.
do not exceed 0.160 inch (4.064 mm) in length
can be removed by drilling out with No. 20 or
smaller diameter drill and installing rivet of
B. Studs and Inserts
appropriate size to fill hole.
Replace damaged studs and inserts (Ref. Stud
B. Patch Repair and Insert Replacement, Sec. 530000).
(1). Damage to sheet metal that exceeds C. Insertion Repair

0.160 inch (4.064 mm) in length is to be
Replacement of bushings, or inserts of
patched provided damage area does not
dissimilar metal that form a part of the fitting
exceed total of 25 percent of panel area
are considered insertion repairs. (Insertion
(previously repaired areas included).
repair procedures are described in FAA AC
43.131A.)
(2). Patch material shall be 2024T3, 0.051
inch (12.954 mm) aluminum, applied to D. Replacement
outer surface of boom.
Replace fitting or attach frame components
C. Transverse Crack Repair (tailboom or stabilizer) whenever negligible
repair limits are exceeded.
Patch with staggered triple row of rivets, using
810 diameter spacing for inner and outer
NOTE:
rows and 68 diameter spacing for center row. D Replacement of stabilizer fitting and
boom attach frames is usually uneconom
D. Longitudinal Crack Repair ical.
D For fitting replacement evaluation, con
Patch with single row of rivets using 810 tact a MDHI Field Service Representa
diameter spacing. tive.
Page 201
534000 Original
FRAME ASSEMBLY, AL ALY

(REF. SEC. 530000 FOR STRUD AND INSERT REPLACEMENT
FITTING, AL ALY
(REF. SEC. 530000 FOR INSERT REPLACEMENT
MS20470AD4 RIVETS (TYP)
CANT. STA. 273.90

CANT. STA. 209.78 FRAME, 0.040 IN. FRAME RING, AL ALY
(1.016 MM) 2024T42 AL ALY
MS20470AD4 ATTACHMENT RIVETS
0.379 IN. (9.6266 MM)

MAX. (4 PLCS)
369D/E HELICOPTERS
LONGERON, 0.063 IN. (1.6002 MM) 7075T6 AL ALY

MS20470AD4 SKIN ATTACHMENT RIVETS
STA. 197.78 FRAME FITTING, AL ALY
FRAME ASSEMBLY, AL ALY

(REF. SEC. 530000 FOR STRUD AND INSERT REPLACEMENT
FITTING, AL ALY
(REF. SEC. 530000 FOR INSERT REPLACEMENT
BUSHING
MS20470AD4 RIVETS (TYP)
TAILBOOM
CANT. STA. 209.78 FRAME, 0.040 IN. EXTENSION
(1.016 MM) 2024T42 AL ALY (369FF ONLY)
CANT. STA. 273.90

0.379 IN. (9.6266 MM) FRAME RING, AL ALY
MAX. (4 PLCS)
369FF HELICOPTERS
LONGERON, 0.063 IN. (1.6002 MM) 7075T6 AL ALY

MS20470AD4 SKIN ATTACHMENT RIVETS
STA. 197.78 FRAME FITTING, AL ALY
R53-4001
Figure 201. Tailboom
Page 202
Original 534000
SURFACE A, 0.075 IN. (1.905 MM)

RADIUS (SHADED)
0.008 IN. (0.2032 MM) MAX. HIGH OR LOW
ANY SURFACE A FROM PLANE C
SURFACE B (UNSHADED)
PLANE C
PLANE C ARE THOSE PLANES

ESTABLISHED BY ANY THREE
SURFACES A
BOOM FORWARD
FRAME FITTING
0.002 IN. (0.0508 MM) MAX. HEIGHT

0.002 IN. (0.0508 MM) MAX. SLOPE SURFACE B FROM TWO ADJACENT
PER 1 IN. (25.4 MM) ANY SURFACE A
SURFACE A FROM PLANE C
PLANE C
0.014 IN. (0.3556 MM) MAX. LOW

SURFACE B FROM TWO ADJACENT
SURFACE A
USE SURFACE PLATE AND FEELER GAGE TO

DETERMINE THAT FRAME FITTING IS WITHIN
TOLERANCES SHOWN.
REPLACEMENT OF THE TAILBOOM IS REQUIRED IF
NOT WITHIN TOLERANCE.
R53-4002A
Figure 202. Sta. 197.78 Tailboom Frame Fitting Surface Flatness Check
Page 203
534000 Original
4. Control Rod Grommet Replacement (7). Remove tool and associated hardware.
(Ref. Figure 203) (8). If removed, reinstall in frame.

5. Control Rod Frame Replacement
Special Tools
(Ref. Section 91-00-00) (Ref. Figure 203)
Item Nomenclature (1). Flatten out flare on end of conduit.
ST101 Bushing installation tool
(2). Remove rivets from damaged frame and
gusset.
(1). If necessary, remove frame.
(3). Slide out conduit until frame is free.
(2). Check doubler for condition and (4). Use a long rod with end fitted into
security. conduit grommet as a guide to position
(3). Warm grommet in hot water. replacement frame. Locate and drill
upper and lower holes and install
(4). Insert shank of warm grommet thru clecos.
hole in doubler and frame. (5). Use tailboom control rod to check
alignment.
(5). Install grommet installation tool
(ST101) over grommet on frame with (6). Maintain edge distance, locate and drill
backup plate, bolt and nut. remaining rivets.
(6). While bushing is still warm, quickly (7). Reposition conduit and flare conduit
tighten nut to install bushing in frame. end.
Page 204
Original 534000
GEARBOX AND STABILIZER

MOUNT FRAME
STABILIZER MOUNTING FITTINGS
TAILBOOM EXTENSION
(369FF ONLY)
BUSHINGS
WIRING FORWARD STABILIZER BOOM

CONDUIT MOUNTING FRAME
BUSHING
RIGHT SKIN PANEL
BUSHING
CANT. STA. 209.78

FRAME
GROMMETS
CANT. STA. 264.32 FRAME
LEFT SKIN
PANEL
CANT. STA. 242.14 FRAME
GROMMET
CONTROL ROD
GROMMET CANT. STA. 219.96 FRAME GROMMET
CONDUIT
GROMMET
0.9330.948 IN.
(23.698224.0792 MM)
CANT. STA. 197.78
FRAME FITTING
FRAME
GUSSET
DOUBLER, 0.032 IN. (0.8128 MM)
2024T3 AL ALY MS20470AD3 ATTACHMENT
RIVETS (3 PLCS)
CONTROL ROD GROMMET

DOUBLER CANT. STA. 264.32
NUT
369H3037 BUSHING
(GROMMET)
DOUBLER, 0.032 IN. (0.8128
GROMMET MM) 2024T3 AL ALY
INSTALLATION FRAME
TOOL
0.9330.948 IN.
(23.698224.0792 MM)
BACKUP PLATE DOUBLER
BOLT
MS206153M3 RIVETS
(3 PLCS) ROD GROMMET
CONTROL ROD GROMMET DOUBLER

HOLE REPAIR FORWARD STATION
R53-4003B
Figure 203. Tailboom Frame Replacement and Repair
Page 205
534000 Original
1.50 IN.
0.910 IN. (38.1 MM)
(23.114 MM)
SHIM, 2024T42 AL ALY
0.040 IN. (1.016 MM) MAX. SHIM A
FRAME FITTING MS20470AD4 RIVETS

(10 PLCS)
T
H
MS20426AD3 RIVETS
(FLUSH HEAD ON
TAIL ROTOR DAMPER SIDE) 3.93 IN.
DRIVE SHAFT (9.9822 CM)
BOOM CL
DAMPER 0.379 IN. (9.6266 MM)

OD MAX. (4 PLCS)
DAMPER SUPPORT T
NUTPLATE
FITTING H (2 PLCS)
SHIM 0.040 IN.
(1.016 MM) MAX. SHIM FRAME FITTING
A
0.71 IN.
(18.034 MM) 2.00 IN. DAMPER SUPPORT
(5.08 CM) BRACKET. REPAIR WITH
SECTION AA 0.025 IN. (0.635 MM)
BL 2024T3 AL ALY
0.00
VIEW LOOKING FWD
MS20470AD3 RIVETS
(3 PLCS)
DOUBLER, 0.032 IN. (0.8128 MM)

0.933 0.948 IN. 2024T3 AL ALY
(23.698224.0792 MM)
GROMMET
T
NOTE: DENOTES TOOLING HOLE.
GROMMET INSTALLATION H
R53-4004A
Figure 204. Tailboom Damper Support Replacement
Page 206
Original 534000
Section
53-40-30
Tailboom and
Thrusters (500/600N)

TAILBOOM AND THRUSTERS (500/600N)

REPAIRS
1. Tailboom Assembly NOTE: Whenever there is damage to the tail
boom, special attention must be paid to the
(Ref. Figure 201) buildup connection zones, both the interior
and exterior and the transition zones. A
A. Tailboom Description visual inspection and a tap test must be per
formed to ensure that all cracks are discov
The tailboom is a highly stressed, fully ered. If an area is suspected to contain dam
monocoque, composite construction section age and the tap test does not show all
that forms the cylindricallytapered cone. damage conclusively, an ultrasonic inspec
tion may be required.
(1). The tailboom assembly is constructed of
multiple layers of carbon fiber compos (1). Zone 1: (Ref. Table 201 and Figure 204)
ite and adhesive. encompasses the four bolt holes,
reinforced mounting flange areas
The layers of fabric are offset by laying (tailboomtofuselage), and a distance
the plys (layers) at 45 degree angles. of 8 inches (20.32 cm) from and around
This method of construction allows for the mounting flange area. The
greater strength of the assembly. construction of the tailboom in this area
is solid carbon fiber with 4 stainless
(2). Sixteen airfoils, made of carbon fiber, steel radius blocks separated by
riveted and bonded to eight slot fiberglass at the mounting points.
openings inside the tailboom, make up Thickness varies from 36 plies at the
two longitudinal slots located on the attachment points to 3 plies at tail
right side of the tailboom. boom.
(3). Two flaps (eye brows) made from carbon (a). Cosmetic damage has no specified
fiber cloth, bonded to the outside, shield limits, however if damage is exten
the slot openings and help direct the sive, greater than 4 inches (10.16
airflow downward. cm), contact MD Helicopters, Inc.
(MDHI) Field Service Representa
(4). The airfoils inside the tailboom allow tives or Product Support Engineering
the air to escape along the right side for evaluation.
through the slots creating lift. (b). Fiber damage is limited to a maxi
mum depth of 4 plies and a 2 inch
(5). Two conduit tubes, constructed of (5.08 cm) dimension. This applies to
Kevlar, are bonded to the left side both the interior and exterior of the
interior of the boom to facilitate the tailboom a total of 8 plies, at the built
passage of electrical wiring and thrust up connection zones and the transi
er control cable assembly. tion zones between the buildup area
and the general tailboom thickness.
B. Tailboom Damage Inspection
(c). No fiber damage is allowed in the 3
Due to differences in construction, the tail ply area between connections zones,
boom has been divided into five zones. only cosmetic damage is allowed.
Page 201
534030 Original
STABILIZER MOUNTS
CONDUIT TUBE
UPPER AIRFOIL
TAIL SKID
STRAKE
SUPPORT
LOWER AIRFOIL
TORQUE TUBE HOUSING
R53-4005
Figure 201. Tailboom Assembly
Page 202
Original 534030
(d). No fiber damage is allowed in the (a). Cosmetic damage has no specified
transition area between the 3 plies limits, however if damage is exten
and the general crosssection within sive, greater than 6 inches (15.24
the 8 inches (20.32 cm) zone. cm), contact MDHI Field Service
Representatives or Product Support
(e). The mounting flange can contain Engineering for evaluation.
damage up to 1 inch (2.54 cm) (b). Damage to the carbon sandwich
provided it is within the thin, non material is limited to a maximum of
structure, area and does not enter a 3 inch (7.62 cm) diameter of
the radius between the general boom through penetration with a addition
section and the flange. al 1 inch (2.54 cm) delamination
surrounding it.
(f). The radius blocks may be removed (c). Fiber damage is limited to a maxi
for inspection and rebonded back into mum size of 3 inches (7.62 cm).
position. Using standard fiberglass
practices and procedures (Ref Sec. (4). Zone 4: (Ref. Table 204 and Figure 207)
530000). encompasses the two air slots that pass
the length of the tailboom, included are
the interior airfoils, the eyebrow that
(2). Zone 2: (Ref. Table 202 and Figure 205) cover the slot and a 2 inch (5.08 cm)
relates to all transitions areas through edge around each individual slot. These
out the tailboom zones. Transition areas are most susceptible to damage.
zones are areas where the structure
changes from solid carbon fiber lami (a). Cosmetic damage is limited to a total
nates to a sandwich type construction, of 1 inch (2.54 cm) in zone 4.
carbon fiberresin/filler corecarbon (b). No penetration, fiber, or delamina
fiber. Changes in fiber layup, thick tion damage is allowed in zone 4.
ness from 3 ply to 9 ply, are plytransi
tions. (c). Damage to the airfoils is limited to a
total of 1 inch (2.54 cm) per airfoil.
(a). Cosmetic damage has no specified (5). Zone 5: (Ref. Table 205 and Figure 208)
limits, however if damage is exten is the region in which the mounting
sive, greater than 4 inches (10.16 brackets for the horizontal stabilizer
cm), contact MDHI Field Service are attached to the tailboom, the
Representatives or Product Support tailboom skid is also included. The area
Engineering for evaluation. also includes 10 inches (25.4 cm) from
and around the aft end of the tailboom.
(b). Damage is limited to a maximum of 6 NOTE: The fastener holes for the horizontal
plies or to the core depth on either stabilizer support brackets must be in
the interior and exterior of the spected whenever damage has been inflicted
tailboom. to any of the stabilizer assemblies.
(a). Cosmetic damage has no specified
(c). Damage size is limited to a 2 inch limits, however if damage is exten
(5.08 cm) defect before ply removal. sive, greater than 4 inches (10.16
cm), contact MDHI Field Service
(d). No through penetration or core Representatives or Product Support
replacement is allowed. Engineering for evaluation.
(b). Damage to the horizontal stabilizer
(3). Zone 3: (Ref. Table 203 and Figure 206) fastener holes, tail skid attachment
are areas of the tailboom that are holes and a 1 inch (2.54 cm) area
constructed of the carbon sandwich type around each hole is limited to a total
construction. These areas cover approx of 1 inch (2.54 cm) crack or delamina
imately 70% of the tailboom. tion from the fastener hole.
Page 203
534030 Original
(c). Damage in the 10 inch (25.4 cm) area B. Stationary Thruster Damage Inspection
from and around the aft end of the
tailboom is limited to 1 inch (2.54 cm) NOTE: Whenever there is damage to any part
through penetration. Delaminations of the tailboom, a special inspection of the
are limited to 2 inch (5.08 cm) in size. stationary thruster attachment/mounting
It is possible to have a 1 inch (2.54 points (tailboom to thruster) is required.
cm) hole and a 1 inch (2.54 cm) The vanes to the shell must also be in
delamination around it or a 2 inch spected. A complete assembly visual inspec
(5.08 cm) delamination. tion and a tap test must be performed to en
sure all cracks are discovered. A light
enhanced inspection microscope will aid in
C. Tailboom Repair identifying any defects.
Because composite repair is unique to each (1). Cosmetic damage is limited to 4 inches
situation, contact MDHI Field Service Repre (10.16 cm) on solid carbon panels.
sentatives or Product Support Engineering for (2). The solid carbon panels are limited to a
repair procedures. total damage area of 2 inches (5.08 cm).
2. Strake (3). Damage to attachment areas of the

vanesto fixed thruster can be re
paired provided the original vane
(Ref. Figure 201)
angles are maintained relative to the
thruster.
A. Strake Description
(4). Damage to the stationary thrusterto
A strake, made of composite fiberglass strip boom attachment points is limited to 1
bonded to the tailboom, breaks up air flow on inch (2.54 cm) maximum defect regard
the left side of the tail boom for hovering less of the type of damage.
stability. (5). The same requirements for the pulley
attachment points apply, as in step (4).
B. Strake Repair above.
Cosmetic damage has no specified limits, C. Stationary Thruster Repair

however if damage is extensive, greater than 6 Because composite repair is unique to each
inches (15.24 cm), contact MDHI Field Service situation, contact MDHI Field Service Repre
Representatives or Product Support Engineer sentatives or Product Support Engineering for
ing for evaluation. Refer to CSPHMI2, Sec. repair procedures.
534030 for inspection requirements.
4. Rotating Thruster Assembly
3. Stationary Thruster Assembly (Ref. Figure 202)
(Ref. Figure 202) A. Rotating Thruster Description

The rotating thruster cone (a canshaped
A. Stationary Thruster Description structure) meters exit air for left or right
directional control. The rotating thruster
The stationary thruster assembly is a compos consist of a Kevlar end cap (500N only), and a
ite structure, constructed of layers (plys) of shell/fairing that covers the stationary
carbon fiber and adhesive consisting of solid thruster.
carbon panels and sandwich constructed B. Rotating Thruster Damage Inspection
vanes. The stationary thruster consists of an
internal duct that supports twenty cascade NOTE: Whenever there is damage to the tail
airfoil vanes. The aft end of the stationary boom, a special inspection of the rotating
thruster contains pulley attachment points. thruster attachment points is required. A
The assembly is mounted to the aft end of the visual inspection and a tap test must be per
tailboom by six bolts. formed to ensure all cracks are discovered.
Page 204
Original 534030
(1). Any size damage is repairable on the carbon fiber with a foam core, while the cone is
Kevlar end cap. a solid carbon structure.
(2). Damage to the thruster attachment B. Stator Damage Inspection
holes is limited to a maximum flaw of 1
inch total dimension regardless of NOTE: Whenever there is damage to the tail
damage type. boom, a special inspection of the stator at
tachment points is required. A visual in
(3). Damage to the rotating thruster is spection and a tap test must be performed to
limited to a 3 inch (7.62 cm) penetration ensure all cracks are discovered.
(diameter), plus a maximum 1 inch
(2.54 cm) delamination. Up to 4 inches (1). Damage to the attachment points of the
(10.16 cm) in any combination; 4 inches stator blades to the tailboom interior is
(10.16 cm) of total delamination is limited to 1 inch (2.54 cm) in size
allowed. regardless of the type of damage.
(4). Cosmetic damage up to 6 inches can be (2). Any damage to the stator blades is
repaired on the rotating thruster. Any considered to be repairable or replace
damage in excess of this dimension able. Repairs to the blades should be
must be referred to MDHI Field Service considered to be the wetlayup type.
Representatives or Product Support Care must be taken to ensure that the
Engineering for evaluation. blade is returned to its original profile.
C. Rotating Thruster Repair (3). The cone is not considered a structure

component. Any repairs to the cone
Because composite repair is unique to each must return the cone to its original
situation, contact MDHI Field Service Repre profile. Special attention to repairs to
sentatives or Product Support Engineering for the attachment points bladetocone
repair procedures. and bladetoboom must be made.
5. Stator Assembly (4). If fiber damage (or penetration) over 4

inches (10.16 cm) in length is present,
(Ref. Figure 203) referred to MDHI Field Service Repre
sentatives or Product Support Engi
A. Stator Description neering for evaluation.
A stator, mounted inside the tailboom behind C. Stator Repair
the fan assembly, directs and smooths out low
pressure air in a circular motion flowing Because composite repair is unique to each
through the boom. The stator assembly is situation, contact MDHI Field Service Repre
repairable and contains individually replace sentatives or Product Support Engineering for
able vanes. The vanes are constructed from repair procedures.
Page 205
534030 Original
STATIONARY
THRUSTER
TOP HAT COVER
BEARINGS
THRUSTER FAIRING
ATTACHING
HARDWARE
ATTACHING END CAP

HARDWARE (500N SHOWN)
ROTATING THRUSTER
R53-4007
Figure 202. Rotating and Stationary Thruster Assembly
Page 206
Original 534030
TAILBOOM
REMOVABLE STATOR VANE
R53-4006
Figure 203. Stator Assembly
Page 207
534030 Original
Table 201. Tailboom Forward Flange (Zone One)

Damage Repair Limits Repair
Cosmetic Damage Up to 4 inches (10.16 cm) as required. Greater Refer to Cosmetic Damage Repair,
than 4 inches (10.16 cm) requires notification Ref. Sec. 53-00-00. Unless otherwise
of damage to MDHI Product Support advised by MDHI engineering.
Engineering.
Delamination Damage Up to 2 inches (5.08 cm) maximum at Refer to Delamination Damage Repair,
connection zones. None in thin 3 ply transition Ref. Sec. 53-00-00.
zones or from thin zone to standard boom
zone. Up to 0.50 inch (0.508 mm) in
connection zone taper.
Fiber Damage Up to 2 inches (5.08 cm) maximum 4 plies Refer to Fiber Damage Repair, Ref.
deep (interior and exterior) at connection Sec. 53-00-00. Requires MDHI
zones. None allowable to thin regions. Up to engineering evaluation.
0.50 inch (0.508 mm) at transition from thin
zone to standard boom section, 4 plies depth
maximum.
Penetration Damage No penetration allowable
Page 208
Original 534030
A
B
AA
BB
R53-4010
Figure 204. Tailboom Forward Flange (Zone One)
Page 209
534030 Original
Table 202. Tailboom Transitions Areas (Zone Two)

of damage to MDHI Product Support. advised by MDHI engineering.
Delamination Damage Up to 2 inches (5.08 cm) in size maximum at Refer to Delamination Damage Repair,
any location within the zone. Ref. Sec. 53-00-00. Requires MDHI
engineering evaluation.
Fiber Damage Up to 2 inches (5.08 cm) in size maximum 6 Refer to Fiber Damage Repair, Ref.
plies (or to the core) in depth (interior and Sec. 53-00-00. Requires MDHI
exterior) No core replacement is allowable. engineering evaluation.
Penetration Damage No penetration allowable
2 IN. 2 IN.
(5.08 CM) (5.08 CM)
R53-401 1
Figure 205. Tailboom Transitions Areas (Zone Two)
Page 210
Original 534030
Table 203. Tailboom General (Zone Three)

of damage to MDHI Product Support. advised MDHI engineering.
Delamination Damage Up to 4 inches (10.16 cm) in combination with Refer to Delamination Damage Repair,
any other damage size maximum. May have 2 Ref. Sec. 53-00-00. Requires MDHI
inches (5.08 cm) of penetration and 2 inches engineering evaluation.
(5.08 cm) of delamination or 3 inches of
penetration and 1 inch (2.54 cm) of
delamination)
Fiber Damage Up to 3 inches (7.62 cm) of fiber damage is Refer to Fiber Damage Repair, Ref.
allowable. There is no depth limit specified to Sec. 53-00-00. Requires MDHI
fiber damage. Core replacement is allowable engineering evaluation.
from one side.
Penetration Damage Up to 3 inches (7.62 cm) penetration of carbon Requires MDHI engineering
core structure is allowable. (Can have 1 inch evaluation.
(2.54 cm) delamination surrounding it.)
NOTE: THIS ZONE DOES NOT COVER ANY REGIONS

OF SANDWICH SPECIFIED IN OTHER ZONES.
70% OF TAILBOOM CONSTRUCTED OF

SANDWICH (CARBONCORECARBON)
R53-4012
Figure 206. Tailboom General (Zone Three)
Page 211
534030 Original
Table 204. Tailboom Slots and Airfoils (Zone Four)

Cosmetic Damage Up to 1 inch (2.54 cm) as required. Greater Refer to Cosmetic Damage Repair,
than 1 inch (2.54 cm) requires notification of Ref. Sec. 53-00-00. Unless otherwise
damage to MDHI Product Support.. advised by MDHI engineering.
Delamination Damage No delamination damage allowable in zone Refer to Delamination Damage Repair,
four. Any limit to eyebrow allowable 1 inch Ref. Sec. 53-00-00. Requires MDHI
(2.54 cm) total per airfoil. engineering evaluation.
Fiber Damage Same as for delamination Refer to Fiber Damage Repair, Ref.
Sec. 53-00-00. Requires MDHI
engineering evaluation.
Penetration Damage Same as for fiber damage
Page 212
Original 534030
A A
RIGHT SIDE B
1 IN.
(2.54 CM)
(TYP)
AA
BB
R53-4013
Figure 207. Tailboom Slots and Airfoils (Zone Four)
Page 213
534030 Original
Table 205. Horizontal Stabilizer and Tail Skid Attachment Points (Zone Five)
of damage to MDHI Product Support. advised by MDHI engineering.
Delamination Damage Up to 2 inches (5.08 cm) in size maximum in Refer to Delamination Damage Repair,
all areas except at fastener holes 1 inch (2.54 Ref. Sec. 53-00-00. Requires MDHI
cm) is maximum in any combination. (Can engineering evaluation.
have a 1 inch (2.54 cm) penetration with 1 inch
(2.54 cm) delamination surrounding.)
Fiber Damage Up to 1 inch (2.54 cm) in size total at all Refer to Fiber Damage Repair, Ref.
fastener holes. Up to 1 inch (2.54 cm) in other Sec. 53-00-00. Requires MDHI
areas of zone including edges. No depth limits. engineering evaluation.
Penetration Damage Up to 1 inch (2.54 cm) in size total at all Requires MDHI engineering
fastener holes including tail skid attachment evaluation.
point. (Can have total of 1 inch (2.54 cm)
damage at stabilizer attachments and 1 inch
(2.54 cm) total at tail skid attachment point. Up
to 1 inch (2.54 cm) elsewhere in zone.)
10 IN.
(25.4 CM)
R53-4014
Figure 208. Horizontal Stabilizer and Tail Skid Attachment Points (Zone Five)
Page 214
Original 534030
Table 206. Stationary Thruster

Department for further evaluation.
Delamination Damage Up to 2 inches (5.08 cm) maximum on all Refer to Delamination Damage Repair,
panels, 1 inch (2.54 cm) total on all Ref. Sec. 53-00-00. Requires MDHI
vane/thruster connect regions, and no set engineering evaluation.
limits to vanes providing the repair returns the
vane to original aerodynamic profile.
Fiber Damage Up to 2 inches (5.08 cm) maximum on all Refer to Fiber Damage Repair, Ref.
panels, 1 inch (2.54 cm) total on all Sec. 53-00-00. Requires MDHI
vane/thruster connect regions. Combination of engineering evaluation.
fiber damage and delamination must not
exceed 2 inches (5.08 cm) total on panels and
1 inch (2.54 cm) total on connection. Vanes
have no set limit provided the repair returns
the vane to original aerodynamic profile.
Penetration Damage (Same limits as fiber damage above.) Access
to certain regions may be difficult, extreme
care must be taken.
R53-4015
Figure 209. Stationary Thruster
Page 215
534030 Original
Table 207. Rotating Thruster

Delamination Damage Up to 4 inches (10.16 cm) can be repaired in Refer to Delamination Damage Repair,
any combination. Example, 3 inches (7.62 cm) Ref. Sec. 53-00-00. Requires MDHI
of fiber damage surrounded by 1 inch (2.54 engineering evaluation.
cm) of delamination.
NOTE:
The tip cap can have any size damage.
Fiber Damage Up to 3 inches (7.62 cm) can be repaired on Refer to Fiber Damage Repair, Ref.
the rotating thruster, 1 inch (2.54 cm) Sec. 53-00-00. Requires MDHI
maximum is damage limit to the attachment engineering evaluation.
holes.
Penetration Damage Same limits as fiber damage.
END CAP
(500N SHOWN)
R53-4016
Figure 210. Rotating Thruster
Page 216
Original 534030
Table 208. Stator Assembly

Delamination Damage Up to 4 inches (10.16 cm) can be repaired as Refer to Delamination Damage Repair,
required. Over 4 inches (10.16 cm) requires Ref. Sec. 53-00-00. Requires MDHI
notification of damage to MDHI Product engineering evaluation.
Support Department for further evaluation.
Damage to attachment points vanes-to cone
and vanes-to-boom is limited to 1 inch (2.54
cm)
Fiber Damage Up to 4 inches (10.16 cm) can be repaired on Refer to Fiber Damage Repair, Ref.
the stator, 1 inch (2.54 cm) maximum is Sec. 53-00-00. Requires MDHI
damage limit to the attachment holes. engineering evaluation.
Penetration Damage Same limits as fiber damage.
TAILBOOM
CL
REMOVABLE STATOR VANE
R53-4017
Figure 211. Stator Assembly
Page 217
534030 Original
Page 218
Original 534030
Section
53-50-10
Stabilizer
(369D/E/FF)

STABILIZERS (369D/E/FF)
REPAIRS
1. Vertical Stabilizers Assembly B. Vertical Stabilizer Stressed Sheet Metal
Panel Inspection and Repair
(Ref. Figure 201)
The vertical stabilizer honeycomb core, spars
A. Vertical Stabilizers Description and associated skins are highly stressed area
of the stabilizer structure. Because skins are
bonded, there are no skin lap rivet lines.
The vertical stabilizer is mounted aft, right of
Limited bonding separation, skid assembly
the tailboom and is bolted to the tail rotor
replacement and minor repair of fittings is
transmission and stabilizer mount fittings.
allowed.
(1). The vertical stabilizer consists of two
Ushaped spars with cast attach Consumable Materials
fittings and reinforcement clips at the (Ref. Section 91-00-00)
center. Item Nomenclature
CM403 Adhesive (epoxy)
(a). The upper ends of the spar are joined
by an aluminum fitting which has
provisions for attachment of the (1). Negligible Damage
horizontal stabilizer.
None Replace stabilizer.
(b). The lower ends of the spars are (2). Patch Repair
joined by a welded tail skid assembly.
None Replace stabilizer.
(c). The entire cavity between the spar is
filled with a honeycomb core, to (3). Bonding Separation
which two outside skin surface are Repair voids in stabilizer as follows:
bonded.
(a). Establish perimeter of void(s) by
(2). The leading and trailing edges are tapping a coin on skin surface.
formed with contoured aluminum
sheets bonded to the outside skin (b). On the side of the stabilizer, opposite
panels. the bonding void, drill two holes,
approximately 0.1875 inch (4.7625
(a). The upper and lower sections of the mm) at locations shown in
leading and and trailing edges are Figure 201. Drill holes through skin
reinforced and joined at the center by only.
aluminum ribs. (c). Deburr holes.
(b). The gap formed by these ribs is (d). Mix adhesive (CM403) per manufac
closed with glass cloth and adhesive. turers instructions.
(c). The ends of the leading and trailing (e). Using a syringe, inject epoxy into
edge are closed by ribs riveted and lower hole. Continue injecting epoxy
bonded in placed. until mixture appears at upper hole,
7 oz. (30 cc) limit for total voids).
(3). Provision for electrical wiring for (f). Remove excess adhesive from holes
anticollision and position lights are and clamp. Allow adhesive to cure
contained within the trailing edge per manufacturers instructions.
structure attached to the trailing edge
Ushaped spar. (g). Remove clamps and smooth holes.
Page 201
535010 Original
TOP FITTING, AL ALY

0.268 IN. (6.8072 MM)
MAX. (4 PLCS)
VISIBLE SKIN BOND JOINT
SEALS REPLACEMENT
(REF. CSPHMI2)
HONEYCOMB CORE
NO REPAIR ALLOWED
LEADING EDGE SKIN,

0.020 IN. (0.508 MM)
2024T42 AL ALY AFT SPAR, AL ALY
NO REPAIR ALLOWED
REPAIR AREAS
BONDED SKIN, 0.032 IN. ANTICOLLISION LIGHT
(0.8128 MM) 2024T42 AL ALY SUPPORT, NAS1919
LIMITED REPAIRS ALLOWED ATTACHMENT RIVETS
REFER TO TEXT
FORWARD SPAR, AL ALY

NO REPAIR ALLOWED
CENTER FITTING,
0.334 IN. (8.4836 MM) HONEYCOMB CORE
MAX. (4 PLCS) NO REPAIR ALLOWED
NO REPAIR ALLOWED IN HONEYCOMB CORE,

TRAILING EDGE SKIN SPAR, DOUBLER AND ASSOCIATED SKIN
0.020 IN. (0.508 MM) EXCEPT FOR SKID ASSEMBLY REPLACEMENT
2024T42 AL ALY
REPAIR ALLOWED AT LEADING AND TRAILING

EDGE SKIN 0.750 IN. (19.05 MM) OUTBOARD OF
BOND LINE
HONEYCOMB CORE AND

BONDED SKINS
TRAILING
0.750 IN. 0.750 IN. EDGE
(19.05 MM) (19.05 MM)
LEADING EDGE
HONEYCOMB CORE
NO REPAIR ALLOWED
SPAR
CROSS SECTION
FORWARD AND AFT CLOSING RIBS,
0.025 IN. (0.635 MM) 2024T42 AL ALY
NAS1919 ATTACHMENT RIVETS
SKID ASSEMBLY, 6061T6 AL ALY

NAS1919 ATTACHMENT RIVETS
R53-5001-1A
Figure 201. Vertical Stabilizer (Sheet 1 of 2)
Page 202
Original 535010
VOIDS IN THIS AREA NOT TO

9.00 IN. EXCEED 2.50 IN. (6.35 CM) DIA.
(22.86 CM) (SEE NOTES BELOW)
EXAMPLE OF SKIN
SURFACETOHONEYCOMB
BONDING VOID
ADHESIVE OUT
UPPERMOST AND LOWEST

POINT OF VOID. DRILL
0.1875 IN. (4.7625 MM)
HOLES (2 PLCS)
VOID
ADHESIVE IN
WOODEN BLOCKS
OR EQUIVALENT
NO VOID REPAIRS ALLOWED
WITHIN THE PARAMETER OF THIS
NO VOIDS ARE ALLOWED DOUBLER (SEE NOTES BELOW)
WITHIN THE PERIPHERY
OF THIS DOUBLER AREA
(SEE NOTES BELOW)
POSITIONING
OF CLAMPS
VERTICAL STABILIZER SURFACE

SKINTOHONEYCOMB CORE
BONDING AREA
WAX PAPER OR
EQUIVALENT
NOTES:
1. ALLOW ANY COMBINATION OF 2 VOIDS PROVIDED THE LOCATION
AND DIAMETER REQUIREMENTS ARE MET.
2. A COMBINATION OF VOIDS NOT TO EXCEED A TOTAL COMBINED
DIAMETER OF 6 IN. (15.24 CM).
3. VOLUME OF EPOXY NOT TO EXCEED 7 OZ. (30 CC) FOR TOTAL
NUMBER OF VOIDS REPAIRED PER SHIP.
R53-5001-2A
Figure 201. Vertical Stabilizer (Sheet 2 of 2)
Page 203
535010 Original
(h). Record total amount of adhesive used (b). Prefit and contour patch to ensure
for repair in the aircraft log book. good surface contact.
NOTE: Volume of epoxy shall not exceed 7 oz. (2). Remove paint to bare metal and clean
(30 cc) for total number of voids repaired per with MEK (CM202).
ship. Contact MD Helicopters, Inc. (MDHI)
Field Service Department if this total (3). Mix adhesive (CM401) according to
amount is exceeded. container instructions; spread a thin
layer on each joining surface.
C. Vertical Stabilizer Non-Stressed Sheet
Metal Inspection and Repair (4). Position patch. No pressure other than
that used to maintain position is
The vertical stabilizer leading and trailing required.
edges are nonstructural and may be repaired
with bonded aluminum alloy patches only. No (5). Allow to cure for 24 hours at room
added rivets are allowed through forward and temperature or 1 hour at 190 210F
aft spars. (88 99C).
(1). Negligible Damage (6). Using abrasive paper (CM801), contour
repaired area.
(a). Small, smooth contour dents,
scratches and light corrosion deposits 2. Horizontal Stabilizer Assembly
are considered negligible damage.
(Ref. Figure 202)
(b). Smooth contour dents greater than
0.030 inch (0.762 mm) radius are A. Horizontal Stabilizer Description
considered negligible, but bonded
patch may be installed. The horizontal stabilizer is mounted on top of
the vertical stabilizer.
(2). Patch Repair
(1). The horizontal stabilizer consists of two
(a). Repair dents with less than 0.030 Ushaped spars and four riveted
inch (0.762 mm) radius or with sharp attachment fittings located in the
edge by drilling out damage and center. A center rib assembly, four ribs,
application of bonded patch. two end caps and two skin sections are
(b). Repair cracks by stop drilling and used to close the internal structure.
application of bonded patch. (2). The skin is riveted to the ribs and spars
D. Vertical Stabilizer Leading and Trailing and the gap formed by the two skin
Edge Repair halves is closed with fiberglass cloth
and adhesive.
Consumable Materials (3). Provisions for electrical wiring and

(Ref. Section 91-00-00) attachment of the position light are on
Item Nomenclature the center rib assembly.
B. Horizontal Stabilizer Sheet Metal Repair
CM401 Adhesive, epoxy (parts A & B)
CM801 Abrasive paper, silicon carbide For sheet metal repairs not covered in the
following paragraphs, refer to FAA AC
43.131A, Aircraft Inspection and Repair.
(1). If cracked, stop drill; then form 0.020
inch (0.508 mm) 2024T42 aluminum (1). Negligible Damage
patch.
Scratches, nicks, light corrosion deposits and
(a). Patch must extend 0.750 inch (19.05 smooth contour dents that blend smoothly into
mm) beyond any part of crack, surrounding surfaces are considered negligible
damage or dent. damage.
Page 204
Original 535010
TAB, 0.020 IN. (0.508 MM) 2024T3 AL ALY

DOUBLERS, 0.025 IN. (0.635 MM)

2024T42 AL ALY
POSITION LIGHT BRACKET,
AL ALY
CENTER RIB ASSEMBLY, 0.025 IN. (0.635 MM)

2024T42 AL ALY
SKIN, 0.020 IN. (0.508 MM) INTERMEDIATE RIB ASSEMBLY, 0.025 IN. (0.635 MM)
2024T42 AL ALY 2024T42 AL ALY
NAS1919 SKIN ATTACHMENT RIVETS AFT SPAR, 0.040 IN. (1.016 MM)
2024T42 AL ALY
OUTBOARD RIB ASSEMBLY,
0.025 IN. (0.635 MM)
2024T42 AL ALY
FORWARD AND AFT

ATTACHMENT FITTING, AL ALY
FORWARD SPAR, 0.040 IN. (1.016 MM)

2024T42 AL ALY
END CAP, 0.040 IN. (1.016 MM)
MS21061L3 NUTPLATES 2024T42 AL ALY
UPPER CAP, 2PLY FIBERGLASS
LEADING EDGES, 0.016 IN. (0.4064 MM)

2024T42 AL ALY
HONEYCOMB CORE
HONEYCOMB CORE
DOUBLER, 0.020 IN. (0.508 MM)

2024T3 AL ALY
SKIN, 0.016 IN. (0.4064 MM)

2024T42 AL ALY
SKIN, 2PLY KEVLAR
LOWER CAP
2PLY FIBERGLASS
359D 369E/FF
R53-5002A
Figure 202. Horizontal Stabilizer and Tip Plates
Page 205
535010 Original
(2). Patch Repair (b). There are two onepound carbon

steel weights installed on the D/E
(a). Cracks in stabilizer skin do not Model horizontal stabilizer between
require a patch if they can be drilled the ends and tip plates.
out to a 0.250 inch (6.35 mm) hole.
B. Horizontal Stabilizer Tip Plate Inspection
(b). Check for extension of cracks from and Repair
stopdrilled holes.
(1). Negligible Damage Edges and Caps
(c). Any damage longer than 0.250 inch
(6.35 mm) must be removed and skin (a). For 369D Model, refer to Vertical
patched. Stabilizer Leading and Trailing Edge
Repair.
(d). Skin is patch repairable up to 100
percent. (b). For 369E/FF Models, refer to Hori
zontal Tip Plate Fiberglass Cap
(3). Trailing Edge Tab Replacement Repair.
(a). Drill out trailing edge rivets. (2). Negligible Damage Honeycomb Core
and Skin
(b). Refit replacement trailing edge,
maintaining 2.00 inch (5.08 cm) None Replace tip plate.
width and continuation of stabilizer
lower surface contour. (3). Negligible DamageMounting Holes
(4). Nutplate Replacement None Replace tip plate.
(a). Cut access hole clear of spars. C. Horizontal Tip Plate Fiberglass Cap
Inspection and Repair
(b). Drill out rivets and replace nutplate.
3. Horizontal Stabilizer Tip Plate Consumable Materials
(Ref. Figure 202) Item Nomenclature
A. Horizontal Stabilizer Tip Plate Description
CM502 Polyester laminating resin
The horizontal stabilizer tip plates are CM801 Abrasive paper, silicon carbide
mounted on the outside edges of the horizontal
stabilizer.
(1). Using abrasive paper (CM801), sand
(1). The 369D Model stabilizer tip plates damaged area.
consists of a one piece aluminum skin
wrapped around a Nomex honeycomb (2). Thoroughly clean surface of repair area
core with the trailing edge formed by with lintfree cloth moistened with
the bend radius. MEK (CM202) until resin or cloth is
exposed. Allow to dry completely.
(a). The leading edge is formed by two
aluminum caps bonded to the skin. (3). Prepare resin (CM502) according to
container instructions. Stir thoroughly
(b). The upper and lower ends are closed to ensure uniform mixture. Avoid any
with fiberglass end caps. whipping or beating that may produce
any air bubbles in mixture.
(2). The 369E/FF Model stabilizer tip plates
are constructed of 2 ply Kelvar skin (4). Rebuild work or damaged area with
bonded over a Nomex honeycomb core. resin.
(a). Four Aluminum sleeve bushings are (5). Cure at room temperature for 24 hours
installed through each structure to or allow to stand at room temperature
provide for attachment to the hori for 1 hour, followed by heating at 160F
zontal. (71C) for 1 hour.
Page 206
Original 535010
(6). Using abrasive paper, contour repaired not allow adhesive on inner diameter of
area. fastener.
D. Tip Plate Insert Replacement (4). Press plug into either side of hole in tip
plate until shin snaps over plug
(Ref. Figure 203) Replace inserts as follows: retention feature.
Consumable Materials (5). Press sleeve into hole on other side.

Item Nomenclature Do not apply excessive pressure
CAUTION to avoid collapsing insert.
CM401 Adhesive, epoxy (parts A & B)
(6). Using a flat anvil or base plate to

(1). Drill out flared portion of sleeve using a support the plug component and a flat
0.1980.204 inch (5.02925.1816 mm) backup anvil surface to support the
drill. sleeve, press together until both anvil
faces are flush with tip plate surfaces.
(2). Remove plug and sleeve from tip plate This will upset plug component into
assembly. chamfered area of sleeve providing
positive retention.
(3). Before installation of new fasteners,
apply a coating of adhesive (CM401) (7). Allow adhesive to cure for 24 hours at
under head of plug and sleeve but do room temperature.
APPLY ADHESIVE UNDER

HEADS OF FASTENERS
HORIZONTAL STABILIZER
TIP PLATE
SLEEVE
TIP WEIGHT
PLUG
R53-5003
Figure 203. Tip Plate Insert Replacement
Page 207
535010 Original
4. Horizontal Stabilizer Assembly Rework N2 (369FF); Observe horizontal stabiliz

(369E/FF) er tab.
(Ref. Figure 204) The following is a rework of (6). If tab resonance occurs and tail rotor
the horizontal stabilizer (P/N 421087503, balancing is unacceptable, apply primer
505) skin and tabs. The addition of stiffeners (CM301) to nonbonding surfaces and
(P/N 42108721, 22) and tab weights (P/N install 4210879 tab weights adjacent
4210879) are to reduce vibration and and immediately inboard from the
prevent cracking. existing tab weights (if installed) per
the following instructions.
Consumable Materials NOTE:
(Ref. Section 91-00-00) D If tab resonance is not evident and the tab
Item Nomenclature weights are not installed, proceed to step
CM301 Primer (7).
CM403 Adhesive (epoxy) D If the outboard tab weights have been
previously removed, install weights in the
outboard locations. If required, a maxi
(1). Remove horizontal stabilizer from mum of two sets of tab weights may be
aircraft (Ref. CSPHMI2) and support installed to eliminate tab resonance.
safely on suitable work table.
(a). Clean all tab weight and horizontal
(2). Install stiffeners on outboard ends of stabilizer bonding surfaces down to
stabilizer as follows. the primer in the area to be bonded.
(a). Drill out existing rivets using a #27 (b). Apply adhesive (CM403) to tab
size drill bit. weights and horizontal stabilizer and
position tab weights. Fair in edges
(b). Position stiffener and drill remaining with adhesive squeeze out.
holes using a #40 size drill bit.
(c). Install rivets in the same pattern as
(c). Apply primer (CM301) to holes. existing tab weights prior to adhesive
curing. Allow adhesive to cure and
(d). Install NAS1738B43 and touch up finish to match adjacent
MS20470AD34 rivets. area.
(3). Perform tail rotor balancing (Ref. (7). Repeat tail rotor balancing (Ref.
CSPHMI2). CSPHMI2). Operate engine at above
N2 settings and verify horizontal
(4). Install horizontal stabilizer (Ref. stabilizer tab resonance has been
CSPHMI2). eliminated.
(5). With helicopter located on a flat smooth NOTE: If tab resonance still exists, contact
surface, operate engine at 102 105 MDHI Field Service Representative for dis
percent N2 (369E) or 99 102 percent position.
Page 208
Original 535010
MS20470AD3 RIVETS
(6 PLCS)
4210879 TAB WEIGHT
0.220 IN.
12.00 IN. (5.588 MM)
(30.48 CM) (TYP)
6.0 IN.
(15.24 CM)
2.0 IN.
(5.08 CM)
0.220 IN.
(5.588 MM)
4210879 TAB WEIGHT (TYP)
MATERIAL ALUMINUM ALLOY 2024T3
ALTERNATE 0.032 IN. (0.8128 MM) 2024T42
PRIME WITH PRIMER (CM301).
369E/FF CONFIGURATION
MS20470AD34 RIVETS
(3 PLCS)
42108721 STIFFENER
(22 OPPOSITE SIDE)
NAS1738B43 RIVETS
(2 PLCS)
R53-5004A
Figure 204. Horizontal Stabilizer Rework (369E/FF)
Page 209
535010 Original
Page 210
Original 535010
Section
53-50-30
Stabilizer (500/600N)

STABILIZERS (500/600N)
REPAIRS
1. Horizontal Stabilizer Assembly edge, hollow core spar, sparbox fitting
and access panels.
A. Horizontal Stabilizer Description
(3). Two controls rods and bellcrank are
(Ref. Figure 201) routed in the center aft of the sparbox.
(4). A degree plate is bonded on the out
(1). The horizontal stabilizer is a NACA board ends of the stabilizer near the
2421 inverted airfoil constructed of tailing edge for rigging the vertical
laminated fiberglass composite ribs and stabilizer directional controls and is
skin, bonded to a formed graphite located in position by a jig fixture.
composite spar shaped in the form of a
rectangular box. (5). The horizontal stabilizer mounts atop
the tailboom, four eye bolts secure the
(2). The horizontal stabilizer includes a horizontal stabilizer to clevis attach
nonstructural leading and trailing ment points on the tailboom.
CENTER ACCESS COVER
HORIZONTAL STABILIZER
VERTICAL STABILIZER TORQUE TUBE
TIP ACCESS COVER
R535006
Figure 201. Horizontal Stabilizer
Page 201
535030 Original
B. Horizontal Stabilizer Damage Inspection (c). Delamination damage is limited to 1

inch (2.54 cm). Example, a crack can
Due to differences in construction, the horizon be 0.50 inch (12.7 mm) followed by
tal stabilizer has been divided into five zones. 0.50 inch (12.7 mm) of delamination.
NOTE: (d). Fiber damage has the same limita
D To inspect the horizontal stabilizer at tions as cracking. No thorough
tachment holes the eyebolts must be re penetration allowed.
moved. These connection points must be
inspected whenever damage is inflicted (2). Zone 2: (Ref. Table 202 and Figure 203)
on the stabilizer assemblies A visual in The overall rectangular section forms
spection and a tap test must be performed zone 2 of the spar box less the other
to ensure that all cracks are discovered. If represented zones.
an area is suspected to contain damage
and the tap test does not show all damage (a). Cosmetic damage up to 6 inches
conclusively, a ultrasonic inspection may (15.24 cm) in length can be repaired.
be required. If greater than 6 inches (15.24 cm),
refer damage to MDHI Field Service
D For assistances, contact MD Helicopters,
Representatives or Product Support
Inc. (MDHI) Field Service Representa
Engineering for evaluation.
tives or Product Support Engineering.
(1). Zone 1: (Ref. Table 201 and Figure 202) (b). Delamination damage up to 1 inch
A 2 inch (5.08 cm) region around each (2.54 cm) can be repaired in addition
eyebolt connection area forms zone 1 on too through penetration of 1 inch
the spar box. The radius blocks are also (2.54 cm). A hole can be 1 inch (2.54
included in this zone. cm) followed by 1 inch (2.54 cm) of
delamination around it or can have 2
(a). Cosmetic damage in zone 1 can be inches (5.08 cm) of delamination.
repaired if damage does not exceed 3
inches (7.62 cm) in length. If greater (c). Fiber damage is limited to 1 inch
than 3 inches (7.62 cm), refer to (2.54 cm) in diameter with a further
MDHI Field Service Representatives 1 inch (2.54 cm) delamination
or Product Support Engineering for surrounding the damaged area.
evaluation.
(d). The corners of the spar box have a
(b). A total of one 1 inch (2.54 cm) crack, total damage limit of 1 inch (2.54
or hole, is the maximum allowable cm), this includes all types of dam
damage that can be repaired on the age. The corner of the spar box are
spar box in zone 1. likely points for failure.
Page 202
Original 535030
Table 201. Horizontal Stabilizer Spar Box Eyebolt Mounting Holes (Zone One)
than 3 inches (7.62 cm) requires notification of Section 53-00-00. Unless otherwise
damage to MDHI Product Support advised by MDHI engineering.
Engineering.
Delamination Damage Up to 1 inch (2.54 cm) of delamination damage Refer to Delamination Damage Repair,
can be repaired, 1 inch (2.54 cm) is the Section 53-00-00. Requires MDHI
maximum in any combination. (Can have a engineering evaluation.
0.50 inch 12.7 mm) crack with 0.50 inch (12.7
mm) delamination or 1 inch (2.54 cm) of
delamination.
Fiber Damage Up to 1 inch (2.54 cm) fiber damage, total of all Refer to Fiber Damage Repair,
4 attachment holes, no depth limit. Can have Section 53-00-00. Requires MDHI
0.250 inch (6.35 mm) fiber damage at all four engineering evaluation.
attachment points or 0.50 inch (12.7 mm) at
only two attachment points or 1 inch (2.54 cm)
delamination at only one attachment point.)
Penetration Damage Up to 1 inch delamination, total of all 4 Requires MDHI engineering
attachment holes, Can have 0.250 inch (6.35 evaluation.
mm) damage at all four attachment points or
0.50 inch (12.7 mm) at only two attachment
points or 1 inch (2.54 cm) delamination at only
one attachment point.
535007
Figure 202. Horizontal Stabilizer Spar Box Eyebolt Mounting Holes (Zone One)
Page 203
535030 Original
Table 202. Horizontal Stabilizer Spar Box (Zone Two)

than 6 inches (15.24 cm) requires notification Section 53-00-00. Unless otherwise
Engineering.
Delamination Damage Delamination damage is limited up to 2 inches Refer to Delamination Damage Repair,
(5.08 cm) size with a maximum of 1 inch (2.54 Section 53-00-00. Requires MDHI
cm) fiber damage or penetration in engineering evaluation.
combination. Example, a 1 inch (2.54 cm) hole
of delamination surrounding it. Up to 1 inch
(2.54 cm) total for damage present in spar
corners.
Fiber Damage Fiber damage is limited up to 1 inch (2.54 cm) Refer to Fiber Damage Repair,
in total size. This can be surrounded by 1 inch Section 53-00-00. Requires MDHI
(2.54 cm) delamination. engineering evaluation.
Penetration Damage Up to 1 inch (2.54 cm) total size is limit Requires MDHI engineering
damage to spar box. This can be surrounded evaluation.
by 1 inch (2.54 cm) delamination.
535011
Figure 203. Horizontal Stabilizer Spar Box (Zone Two)
Page 204
Original 535030
(3). Zone 3: (Ref. Table 203 and Figure 204) (c). Delamination to the leading edge is
is a 2 inch (5.08 cm) area around the limited to 2.50 inches (6.35 cm). This
edge of the torque tube fitting holes and damage is allowed on both sides of
a 2 inch (5.08 cm) area around the spar the leading edge at the same time
box access door opening. The 2 inch without penetration.
(5.08 cm) area includes all fastener
holes. (d). Delamination of any length can be
repaired in the bond line between the
(a). Cosmetic damage up to 4 inches leading edge and the spar box.
(10.16 cm) in length can be repaired.
If greater than 4 inches (10.16 cm), (5). Zone 5: (Ref. Table 205 and Figure 206)
report damage to MDHI Field Service consist of the Kevlar trailing edge of the
Representatives or Product Support horizontal stabilizer. The bond line
Engineering for evaluation. between the spar box and the trailing
edge is also included.
(b). Damage in this area is limited to a 1
inch (2.54 cm) total; crack or dela (a). Cosmetic damage in zone 5 can be
mination measured in a perpendicu repaired if damage does not exceed 8
lar direction from the edge of each inches (20.32 cm) in length. If greater
fitting cutout, four torque tube fitting than 8 inches (20.32 cm), refer to
cutouts and two access holes. Each MDHI Field Service Representatives
are considered separate entities and or Product Support Engineering for
are allowed the same damage limits. evaluation.
(4). Zone 4: (Ref. Table 204 and Figure 205) (b). Any debonding of the adhesive
consist of the entire leading edge. The between the spar box and trailing
bond line between the leading edge and edge can be repaired.
the spar box is included in the zone.
(c). Damage to the trailing edge is
(a). Cosmetic damage up to 6 inches limited to 3 inches (7.62 cm) total, of
(15.24 cm) in length can be repaired. through penetration or fiber damage
If greater than 6 inches (15.24 cm), in any area of the trailing edge, with
refer damage to MDHI Field Service an additional 1 inch (2.54 cm) of
Representatives or Product Support delamination surrounding the
Engineering for evaluation. penetration.
(b). Damage to the leading edge is limited C. Horizontal Stabilizer Repair
to 1.50 inches (3.81 cm) of through
penetration or fiber damage with an Because composite repair is unique to each
additional 1 inch (2.54 cm) of dela situation, contact MDHI Field Service Repre
mination surrounding the penetra sentatives or Product Support Engineering for
tion. repair procedures.
Page 205
535030 Original
Table 203. Horizontal Stabilizer Torque Tube Fittings and Access Openings (Zone Three)
Engineering.
Delamination Damage Delamination damage is limited up to 1 inch Refer to Delamination Damage Repair,
(2.54 cm) in any combination. Example, 0.50 Section 53-00-00. Requires MDHI
inch (12.7 mm) fiber damage or penetration engineering evaluation.
surrounded by 0.50 inch (12.7 mm)
delamination.
Fiber Damage Fiber damage is limited up to 1 inch (2.54 cm) Refer to Fiber Damage Repair,
total size. 1 inch (2.54 cm) includes Section 53-00-00. Requires MDHI
delamination damage. No depth limit to engineering evaluation.
damage.
Penetration Damage Up to 1 inch (2.54 cm) of penetration damage Requires MDHI engineering
is the limit. A 1 inch (2.54 cm) dimension is the evaluation.
total dimension including delamination.
535008
Figure 204. Horizontal Stabilizer Torque Fittings and Access Openings (Zone Three)
Page 206
Original 535030
Table 204. Horizontal Stabilizer Leading Edge (Zone Four)

Engineering.
Delamination Damage Delamination damage is limited up to 2.50 Refer to Delamination Damage Repair,
inches (6.35 cm) total on either side of Section 53-00-00. Requires MDHI
centerline (Left) or (Right) in any combination. engineering evaluation.
Voids to bond line can be repaired, with no
limitations
Fiber Damage Up to 1.50 inch (3.81 cm) maximum size of Refer to Fiber Damage Repair,
fiber damage each side of centerline is Section 53-00-00. Requires MDHI
repairable. Can be surrounded by 1 inch (2.54 engineering evaluation.
cm) of delamination.
Penetration Damage Same requirements as fiber damage.
535009
Figure 205. Horizontal Stabilizer Leading Edge (Zone Four)
Page 207
535030 Original
Table 205. Horizontal Stabilizer Trailing Edge (Zone Five)

Engineering.
Delamination Damage Delamination damage is limited up to a Refer to Delamination Damage Repair,
maximum of 4 inches (10.16 cm) at the trailing Section 53-00-00. Requires MDHI
edge. Any combination is acceptable provided engineering evaluation.
fiber damage and penetration limits are not
exceeded.
Fiber Damage Fiber damage is limited to 3 inches (7.62 cm). Refer to Fiber Damage Repair,
This can be surrounded by 1 inch (2.54 cm) of Section 53-00-00. Requires MDHI
delamination. engineering evaluation.
Penetration Damage Same limits as for fiber damage.
535010
Figure 206. Horizontal Stabilizer Trailing Edge (Zone Five)
Page 208
Original 535030
2. Vertical Stabilizer Assembly (b). Damage to the leading edge, skin,

ribs and the 1 inch (2.54 cm) area
A. Vertical Stabilizer Description around the spar is limited to 2 inches
(1). The vertical stabilizers consist of two; (5.08 cm) of total damage, through
(upper and lower) and are constructed penetration or fiber damage.
of laminated fiberglass composite ribs
and skin, bonded to a formed fiberglass (c). Delamination damage is limited to 3
composite spar. Both are identical in inches (7.62 cm) total of repairable
construction except the upper vertical is delamination.
six inches taller than the lower.
(2). The vertical stabilizers includes a (d). Voids in in the leading edge and bond
hollow core spar, retaining fittings and lines are repairable, no limitations.
nonstructural leading and trailing
edges. (2). Zone 2: (Ref. Table 207 and Figure 208)
(3). Trim tabs are bonded to the trailing is the spar that passes through the
edge of the stabilizers. vertical stabilizers, the supports for the
torque tubes and the skin surrounding
(4). The vertical stabilizers are mounted to and covering the spar.
the horizontal on aluminum torque
tube fittings to form a vertical assembly (a). Damage to the spar and to the skin
that takes the shape of an NACA 0012 covering the spar including the rivets
symmetrical airfoil. holes, is limited to a total dimension
B. Vertical Stabilizers Damage Inspection of 1 inch (2.54 cm). This includes all
possible damage (through penetra
Due to differences in construction, the vertical tion, fiber damage, and cosmetic).
stabilizer has been divided into two zones. Damage exceeding these limits will
have to be appraised individually and
NOTE: Inspection of the torque tubes attach could result in the replacement of the
ments and the spar will have to be per stabilizer(s).
formed whenever any damage is inflicted to
the stabilizer assemblies. Inspection of the
spar will require to have the skin removed (b). No damage to the torque tube
depending on the damage. It is advisable attachment brackets is allowed.
that MDHI or Composite Technology Inc.
perform the inspection and repairs. C. Vertical Stabilizer Repair
(1). Zone 1: (Ref. Table 206 and Figure 207)
encompasses the leading edge, skin, Because composite repair is unique to each
ribs (except for the spar), and a 1 inch situation, contact MDHI Field Service Repre
(2.54 cm) area around the spar. sentatives or Product Support Engineering for
repair procedures.
(a). Cosmetic damage of the vertical
stabilizer can be repaired if damage
does not exceed 6 inches (15.24 cm) in D. Non-Structural Leading and Trailing
length. If greater than 6 inches Edge Repair
(15.24 cm), refer to MDHI Field
Service Representatives or Product There are no repair procedures at this time.
Support Engineering for evaluation. Refer to MDHI Field Service Representatives.
Page 209
535030 Original
Table 206. Vertical Stabilizers Leading Edge, Skin, Ribs, and Area Around Spar (Zone One)
Engineering.
maximum of 3 inches (7.62 cm) to the vertical Section 53-00-00. Requires MDHI
stabilizer skin. Voids in bond lines can be engineering evaluation.
repaired to any limit.
This can be surrounded by 1 inch (2.54 cm) of Section 53-00-00. Requires MDHI
delamination damage. No depth limit is set on engineering evaluation.
the fiber damage.
Penetration Damage Same limits as for fiber damage.
UPPER TIP CAP
UPPER VERTICAL
UPPER TRIM TAB
R53-5005
Figure 207. Vertical Stabilizer (Zone One)
Page 210
Original 535030
Table 207. Vertical Stabilizer Spar (Zone Two)

than 1 inches (2.54 cm) requires notification of Section 53-00-00. Unless otherwise
damage to MDHI Product Support advised by MDHI engineering.
Engineering.
maximum of 1 inch (2.54 cm) in any Section 53-00-00. Requires MDHI
combination. Can have 0.50 inch (12.7 mm) engineering evaluation.
fiber damage or penetration damage with 0.50
inch (12.7 mm) delamination surrounding it.
Can have 1 inch (2.54 cm) of fiber damage Section 53-00-00. Requires MDHI
with no delamination. engineering evaluation.
Penetration Damage Up to 1 inch (2.54 cm) penetration to the spar. Requires MDHI engineering
Any damage to the torque tube attach brackets evaluation.
can not be repaired, brackets must be
replaced.
SKIN SPAR
C C
CL
CC
53-5012
Figure 208. Vertical Stabilizer (Zone Two)
Page 211
535030 Original
Page 212
Original 535030
Chapter
91
Charts

TABLE OF CONTENTS
910000 Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Expendable Materials and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Manufacturer/Supplier Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. Expendable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 2. Manufacturer/Supplier Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 3. Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 4. Tool Manufacturer/Supplier Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Standard Gages and Material Substitutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 5. Standard Gages and Material Substitutes . . . . . . . . . . . . . . . . . . . . . . . . . 5
Page i

Page ii
Section
91-00-00
Charts

CHARTS
EXPENDABLE MATERIALS AND SPECIAL TOOLS
1. General The following consumable materials are
approved for use on the MD500/600 Series. Do
This chapter provides a table of Consumable not use replacement materials unless equal in
Materials and a table of Special Tools used on quality and grade. Refer to notes at the end of
the MD500/600 Series Helicopter. Table 1.
The information in each table is divided into
3. Special Tools
groups. Within each group, materials or tools
are identified by a number. Numbers have a Table 3 identifies special tools, necessary for
prefix of CM identifying a consumable maintenance operations.
material, or a ST identifying a special tool. CM
and ST numbers are used throughout the Each tool is assigned an ST number, with an
maintenance manual, allowing quick reference associated part number, descriptive title and
for Consumable Materials and Special Tools. function.
2. Consumable Materials 4. Manufacturer/Supplier Number

Table 1 lists Consumable Materials, such as Table 2 lists Manufacturer/Supplier (Vendor)
fuels and oils used to support repair or Number with address. Table 2 is used with
servicing procedures. Table 1, Consumable Materials.
Consumable materials are assigned a CM Table 4 lists Tool Manufacturer/Supplier
number, with associated material name, (Vendor) Number with address. Table 4 is used
specification number and commercial name. with Table 3, Special Tools.
910000 Page 1
Original
Table 1. Expendable Materials

Item Specification No. (1) Vendor
No. Material Type Class Grade Commercial Name/No. (2) (Table 2)
Solvents, Cleaners and Corrosion Preventative Compounds
CM201 Zinc chromate putty MIL-P-81 16 Compound 3998 MS6
CM202 Methyl-ethyl-ketone TT-M-261 (3)
Paints, Primers and Coating Compounds
CM301 Primer TT-P-1757B (3)
Adhesives, Cements and Sealants
CM401 Adhesive, epoxy (parts A & B) EA9314 MS1
CM402 Sealing compound HMS 16-1097 Pro-Seal 890 MS3
(fuel resistant) 1 . . . . . B2 MS10
MIL-S-8802
CM403 Adhesive (epoxy) EA9313 MS2
MS8
CM404 Adhesive, epoxy (parts A & B) EA960F MS1
Composite Materials
CM501 Fiberglass cloth (0.022, 2 ply) MIL-C-9084 MS5
No. 181
CM502 Polyester laminating resin MIL-R-7575 (3)
CM503 Resin, filler Epon 960F MS11
CM504 Carbon fiber composite (3)
CM505 Kevlar MS4
Lockwire, Fasteners and Tape
CM701 Tape, pressure sensitive PPP-T-60 MS9
(waterproof for packaging and 1 ..... 1
sealing, width and thickness as
noted)
Miscellaneous Materials
CM801 Abrasive paper, silicon carbide P-P-101 (3)
(grade as noted)
CM802 Crocus cloth P-C-458 (3)
CM803 Antimony trioxide (fire retardant (3)
for polyester resin)
CM804 Passivation, treatment for MIL-S-5002 Pasa-Jell 101 MS10
corrosion-resistant steel. QQ-P-35
NOTES:
(1) Numbers are U.S.A. Specifications and Standards The prefix symbols are defined as follows: AMS -
American Material Standard; MS - Military Standard; MIL - Military Specifications; Single, double or triple
alpha prefix of the same letter - Federal Specification; AN - Air Force-Navy Aeronautical Standard; NAS -
National Aerospace Standard.
(2) Primary selection. Any equivalent material may be used as an alternate selection.
(3) Use of the best comparable grade material when the conformity of available material of the same type with
the listed Specification No. cannot be determined.
(4) Before using materials listed in this table, check with local Enviromental Protection Agency. Not all
materials listed above may be authorized for use in some areas.
Page 2
Original
910000
Table 2. Manufacturer/Supplier Number

Number Name Number Name
MS1 Dexter Adhesives MS7 Loctite Inc.
2850 Willow Path Road 702 N. Mountain Road
Pittsburg, CA 94565 Newington, CT 06111
(800) 424-9300 (203) 278-1280
MS2 Crest Products MS8 Narmco Materials Div.
Santa Anna, CA 92704 Costa Mesa, CA
MS3 Coast Proseal MS9 Permabond International Corp.
Compton, CA 480 S. Dean St.
MS4 E.I. Du Pont Englewood, NJ 07631
Wilmington, DE 19898 MS10 Product Research and Chemical Co.
(800) 441-9450 5426 San Fernando Rd.
MS5 Ferro Corp. Glendale, CA 91209
Composites Division MS11 Shell Chemical Co.
34 Smith St. Pittsburgh, PA
Norwalk, CT 06852
MS6 Fuller OBrien Co.
S. San Francisco, CA
910000 Page 3
Original
Table 3. Special Tools

Item Vendor
No. Part No. Nomenclature Function (Table 4)
ST101 WSI-HT-12AS Bushing installation tool Installing grommets for tail rotor TS3
(WSI-B-12AS grommet) control rod.
ST102 369A5000-40101 Engine-to-transmission Checking alignment of engine and TS2
aligning tool main transmission.
ST103 118M-5-L5-5/32 Lockbolt installation set Installing swage locking collar on TS1
(5/32 in. dia. pin and collar) pull-type locking pin.
ST104 118D-5-L5-5/32 Lockbolt installation set Installing swage locking collar on TS1
(1 in. head offset 45, for 5/32 pull-type locking pin.
in. dia. pin and collar)
ST105 118M-5-6L-3/16 Lockbolt installation set Installing swage locking collar on TS1
(3/16 in. dia. pin and collar) pull-type locking pin.
ST106 Modified ST105 Lockbolt installation set Installing swage locking collar on TS1
(1 in. head offset 45, for 3/16 pull-type locking pin.
in. dia. pin and collar)
(may be made by modification
of ST105)
ST107 369A9900-80906 Engine and tailboom alignment Checking alignment of canted Sta. TS2
checking fixture 197.78 frame fittings and boom
fairing to fuselage structure
alignment.
ST108 500N5000ATP Anti-torque fan drive system Checking alignment of fan TS2
alignment tool kit transmission support assembly
and fan support structure
assembly to mast support
structure.
Table 4. Tool Manufacturer/Supplier Number

Number Name Number Name
TS1 Huck Mfg. Co., TS3 Western Sky Industries
12624 Daphne, 21300 Cloud Way
Hawthorne, CA Hayward, CA 94545
TS2 MD Helicopters Inc.
4555 E. McDowell Rd.
Mesa, AZ 85215-9734
Page 4
Original
910000
5. Standard Gages and Material Substitutes When doing structural repair on the aircraft,
Table 5 is a list of material types and gages Table 5 should be used for acquiring proper
used in structural rework of the MDHI Models gage and type of metal. For further informa
369D/E/FF 500/600N Helicopters. tion, see notes at end of Table 5.
Table 5. Standard Gages and Material Substitutes

Standard Material Gages
0.010 0.040 0.100
0.012 0.051 0.125
0.016 0.063 0.160
0.020 0.071 0.180
0.025 0.080 0.200
0.032 0.090 0.224
Material Substitutes
Material Alloy and Temper Substitute Alloy and Temper
Aluminum 2024-T3 (all gages) 2024-T81 same gage
2024-T42 (all gages) 2024-T3 same gage
7075-T6
0.012-0.051 2024-T42 two gages thicker
(0.051 to 0.090) 2024-T42 three gages thicker
Corrosion-Resistant Steel PH 17-7 1/2 hard 301 CRES one gage
(CRES) Condition 1050 thicker
0.014
PH 17-7 1/2 hard 301 CRES two gage thicker
Condition
0.016 to 0.025
NOTES:
(1) Material listed are substitute materials for repair use only. Following factors must be considered during
material selection.
(2) Whenever possible use same material for repair
(3) Forming limitations differ in material and sheet metal gages. (For sheet metal
parts, before repair, refer to selection of material FAA AC 43.13-1A.)
(4) Bend radii for heat-treated material must be larger than for same condition O Material.
Use of condition O material followed by heat treatment may be required.
910000 Page 5
Original
Page 6
Original
910000

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369/500/600 Series

Manual: CSPSRM6, Structural Repair Manual

Structural Repair Manual

Copyright E 19992006 by MD Helicopters, Inc. Reissued No. 3: 26 May 2006

RECORD OF TEMPORARY REVISIONS

MANUAL TITLE: CSPSRM6 STRUCTURAL REPAIR MANUAL

REV. DATE REMOVED BY REV. DATE REMOVED BY

LIST OF EFFECTIVE PAGES

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TABLE OF CONTENTS (Cont.)

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Figure 1. ATA Numbering System

A. Division of Subject Matter CSPHMI2

(3). If individual subtopics become so Changes in the helicopter, equipment, mainte

the relative significance of the information. 9. Airframe Station Location

(3). Consignees address. repairs whenever required (solid shank rivets

CANT STA STA STA STA

STA STA STA STA STA STA STA

Figure 2. Station Diagram (Sheet 1 of 4)

STA STA STA STA STA STA STA

STA 289.12 (369FF)

CANT STA 369FF ONLY

Figure 2. Station Diagram (Sheet 2 of 4)

STA STA STA 96.42 STA STA STA

Figure 2. Station Diagram (Sheet 3 of 4)

FORWARD MID AFT STA

Figure 2. Station Diagram (Sheet 4 of 4)

LANDING GEAR 32-10-00

CANOPY/WINDSHIELD WINDOWS/DOORS 53-10-00

LOWER CENTER FUSELAGE 53-20-00

UPPER AFT SECTION FUSELAGE 53-30-00

TAILBOOM AND THRUSTER 53-40-00

Figure 3. SRM Sections (Sheet 1 of 2)

LOWER CENTER FUSELAGE

TAILBOOM AND THRUSTER 53-40-30

Figure 3. SRM Sections (Sheet 2 of 2)

(6). Damage to center beam. (1). Floor longeron.

B. Roll Over (After Hard Landing) (3). Center beam.

(1). A mast basetoSta. 197.78 frame 6. Investigation of Damage

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321000 Landing Gear System (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

TABLE OF CONTENTS (Cont.)

This Page Intentionally Left Blank

This Page Intentionally Left Blank

LANDING GEAR SYSTEM (369D/E/FF - 500N)

(2). Coat mating surfaces with zinc chro 6. Damper Repair

(4). Seal edges with an approximate 0.060 Consumable Materials

8. Fiberglass Component Inspection

OLEO ATTACH LUGS

0.010 IN. (0.254 MM) MAX. SCRATCH/NICK LIMITS FOR STRUTS

ATTACH FITTING (AL ALY)

BRACE AND STRUT

Figure 201. Landing Gear - Repair Limits

NO REPAIR NECESSARY 48.61 IN.

ATTACHMENT RIVETS MIN. 1 ROW 5 ROWS

8.00 IN. SPLICE SLEEVE

REPLACEMENT SECTION (USE SECTION 0.38 IN.

Figure 202. Skid Tube - Structural Repair

STRUT EXTENDED LOWER

FAIRING ATTACH POINTS