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Rotorcraft

900 Series

MD Explorerr
(MDHI Model MD900r)

CSP−SPM
STANDARD PRACTICE MANUAL

Cover/Title Page

MD Helicopters Inc.
4555 East McDowell Road
Mesa, Arizona 85215−9734

Copyright E 1999-2016 by MD Helicopters, Inc. Original Issue: 23 December 1997


All rights reserved under the copyright laws.
Revision 24: 15 April 2016
Rotorcraft
900 Series

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 customer's 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 Helicopters Inc.
4555 East McDowell Road
Mesa, Arizona 85215−9734
Manual: CSP-SPM STANDARD PRACTICE MANUAL
Models: MD900r Helicopters
Issue: 23 December 1997
Revision 24: 15 April 2016

FILING INSTRUCTIONS:
Do not put this revision in the manual, if the manual does not have all the
CAUTION revisions from before.
1. Before you put this revision in the manual, make sure this manual has all the revisions from
before. Look at the List of Effective Pages for the last revision.
2. This revision includes all Temporary Revisions since the last revision. It is permitted to put this
revision in the manual if the Temporary Revisions are not put in.
3. To include this revision in the manual, remove the old pages and put in the new pages as
shown:

Remove Pages Insert Pages Remove Pages Insert Pages


Cover/Title 20−40−00
Cover/Title . . . . . . . . . . . . . . . Cover/Title 201 thru 208 . . . . . . . . . . . . 201 thru 208
LOEP 20−60−00
A and B . . . . . . . . . . . . . . . . A and B 9 and 10 . . . . . . . . . . . . . . . 9 and 10
Chapter 20 259 thru 270 . . . . . . . . . . . . 259 thru 270
Table of Contents 20−80−00
i thru x . . . . . . . . . . . . . . . . . i thru x 201 thru 204 . . . . . . . . . . . . 201 thru 204
20−20−00 91−00−00
201 thru 210 . . . . . . . . . . . . 201 thru 210 205 thru 208 . . . . . . . . . . . . 205 thru 208
20−30−00 211 and 212 . . . . . . . . . . . . 211 and 212
207 thru 212 . . . . . . . . . . . . 207 thru 210 215 thru 218 . . . . . . . . . . . . 215 thru 218

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

TECHNICAL PUBLICATIONS
RECOMMENDED CHANGE REQUEST
This manual is prepared and supplied by the MD Helicopters, Inc. Technical Publications
Department, and is intended for use by personnel who have approval for the maintenance of MDHI
helicopters. Regular revisions of this manual will be made to include current data. If, in the opinion
of the reader, data is not clear or needs necessary clarification, please point your comments to this
office through this form (or a copy). Necessary efforts will be made to include such data 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 Changes: (480) 346−6212; FAX: (480) 346−6809
Technical Publications Order Desk: (480) 346−6372, FAX: (480) 346−6821

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:

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STANDARD PRACTICE MANUAL

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STANDARD PRACTICE MANUAL

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RECORD OF TEMPORARY REVISIONS

Rev. Date Date Rev. Date Date


No. Inserted By Removed By No. Inserted By Removed By

99−001 Removed by
Revision 5

08−001 Removed by
Revision 17
08−002

10−001 Removed by
Revision 18
10−002

11−001 Removed by
Revision 19
11−002

11−003

12−001

12−002

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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 change pages are:
Original . . . . . . . . . . . . . . . . . 23 December 1997 Revision 13 . . . . . . . . . . . . . . . . . . . 4 April 2005
Revision 1 . . . . . . . . . . . . . . . . . . . 22 April 1998 Revision 14 . . . . . . . . . . . . . . . . . . 25 April 2006
Revision 2 . . . . . . . . . . . . . . . 16 February 1999 Revision 15 . . . . . . . . . . . . . 13 September 2006
Revision 3 . . . . . . . . . . . . . . . . . . . . 31 May 1999 Revision 16 . . . . . . . . . . . . . . . 1 February 2007
Revision 4 . . . . . . . . . . . . . . 30 September 1999 Revision 17 . . . . . . . . . . . . . . . . . . . 21 July 2008
Revision 5 . . . . . . . . . . . . . . . 29 February 2000
Revision 18 . . . . . . . . . . . . . . . . . . 14 June 2011
Revision 6 . . . . . . . . . . . . . . . . . 20 August 2000
Revision 19 . . . . . . . . . . . . . . 21 December 2012
Revision 7 . . . . . . . . . . . . . . . . . . . . 6 April 2001
Revision 8 . . . . . . . . . . . . . . . . . . . . 8 April 2002 Revision 20 . . . . . . . . . . . . . . . . . . . . 5 July 2013
Revision 9 . . . . . . . . . . . . . . . . . . 9 August 2002 Revision 21 . . . . . . . . . . . . . . 31 December 2013
Revision 10 . . . . . . . . . . . . . . . 24 January 2003 Revision 22 . . . . . . . . . . . . . . . . . 17 March 2015
Revision 11 . . . . . . . . . . . . . . . . . . 20 June 2003 Revision 23 . . . . . . . . . . . . . . . . . . . 12 May 2015
Revision 12 . . . . . . . . . . . . . 12 November 2004 Revision 24 . . . . . . . . . . . . . . . . . . 15 April 2016

Cover/Title 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20


Cover/Title Page . . . . . . . . . . . . . . . . Revision 24 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
Change Request Chapter 20
CRi and CRii . . . . . . . . . . . . . . . . . . . Revision 16 i thru x . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
20−00−00
Temporary Revision
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
TRi . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
20−10−00
TRii . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18
201 thru 207 . . . . . . . . . . . . . . . . . . . . Original
List of Effective Pages 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18
A and B . . . . . . . . . . . . . . . . . . . . . . . . Revision 24 209 thru 212 . . . . . . . . . . . . . . . . . . . . Original
Table of Contents 213 and 214 . . . . . . . . . . . . . . . . . . . . Revision 16
i thru ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18 20−20−00
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
Chapter 01 202 thru 210 . . . . . . . . . . . . . . . . . . . . Revision 24
20−30−00
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
01−00−00 201 thru 207 . . . . . . . . . . . . . . . . . . . . Revision 19
1 .............................. Revision 5 208 thru 210 . . . . . . . . . . . . . . . . . . . . Revision 24
2 .............................. Original 20−40−00
3 .............................. Revision 14 201 thru 207 . . . . . . . . . . . . . . . . . . . . Revision 24
4 .............................. Original 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 20−50−00
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
202 thru 207 . . . . . . . . . . . . . . . . . . . . Original 202 and 203 . . . . . . . . . . . . . . . . . . . . Revision 19
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 3 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
209 and 210 . . . . . . . . . . . . . . . . . . . . Revision 19 205 and 206 . . . . . . . . . . . . . . . . . . . . Revision 16

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20−60−00 801 thru 806 . . . . . . . . . . . . . . . . . . . . Revision 17


1 thru 5 . . . . . . . . . . . . . . . . . . . . . . . . Revision 16 20−70−00
6 and 7 . . . . . . . . . . . . . . . . . . . . . . . . Revision 12 201 thru 210 . . . . . . . . . . . . . . . . . . . . Revision 20
8 and 9 . . . . . . . . . . . . . . . . . . . . . . . . Revision 16 20−80−00
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24 201 thru 203 . . . . . . . . . . . . . . . . . . . . Revision 24
11 and 12 . . . . . . . . . . . . . . . . . . . . . . Revision 16 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17
13 and 14 . . . . . . . . . . . . . . . . . . . . . . Revision 12 20−90−00
101 thru 106 . . . . . . . . . . . . . . . . . . . . Revision 16 201 and 202 . . . . . . . . . . . . . . . . . . . . Revision 12
201 thru 205 . . . . . . . . . . . . . . . . . . . . Revision 16 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18
206 thru 208 . . . . . . . . . . . . . . . . . . . . Revision 17 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
Chapter 91
209 thru 215 . . . . . . . . . . . . . . . . . . . . Revision 16
216 thru 219 . . . . . . . . . . . . . . . . . . . . Revision 17 i............................... Revision 21
220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18 ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18
91−00−00
221 and 222 . . . . . . . . . . . . . . . . . . . . Revision 16
223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
201 thru 204 . . . . . . . . . . . . . . . . . . . . Revision 19
224 thru 227 . . . . . . . . . . . . . . . . . . . . Revision 16
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18
228 thru 231 . . . . . . . . . . . . . . . . . . . . Revision 15 206 and 207 . . . . . . . . . . . . . . . . . . . . Revision 24
232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16 208 thru 211 . . . . . . . . . . . . . . . . . . . . Revision 21
233 thru 239 . . . . . . . . . . . . . . . . . . . . Revision 15 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
240 thru 248 . . . . . . . . . . . . . . . . . . . . Revision 16 213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
249 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17 214 and 215 . . . . . . . . . . . . . . . . . . . . Revision 21
250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
251 thru 259 . . . . . . . . . . . . . . . . . . . . Revision 17 217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
260 thru 269 . . . . . . . . . . . . . . . . . . . . Revision 24 218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15 219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16 220 and 221 . . . . . . . . . . . . . . . . . . . . Revision 23
272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17 222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
273 and 274 . . . . . . . . . . . . . . . . . . . . Revision 15 223 thru 226 . . . . . . . . . . . . . . . . . . . . Revision 23
601 thru 612 . . . . . . . . . . . . . . . . . . . . Revision 16 227 thru 244 . . . . . . . . . . . . . . . . . . . . Revision 21

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Revision 24 LOEP
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

CSP−SPM
Front Matter
Cover/Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover/Title Page
CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Change Request
TR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record of Temporary Revisions
LOEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Effective Pages
Aircraft General
Chapter 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
Chapter 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Practices
Charts
Chapter 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consumables and Tools

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Contents Revision 18
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

01 Introduction 20−50−00 Electrical Bond and Environmental


01−00−00 Introduction Seal
20−60−00 Electrical
20 Standard Practices
20−70−00 Composite Repairs
20−00−00 Introduction
20−80−00 Tubing
20−10−00 Torques
20−20−00 Cleaning 20−90−00 Nondestructive Inspection

20−30−00 Painting 91 Charts


20−40−00 Corrosion Control 91−00−00 Consumables and Tools

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Revision 18 Contents
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Chapter

INTRODUCTION
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

TABLE OF CONTENTS
Para/Figure/Table Title Page

01-00-00 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Aircraft Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Helicopter Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Associated Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. ATA Numbering System and Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. ATA Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Division of Subject Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Page Number Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8. Figure and Table Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10. MDHI Publications Revisions and Reissues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Temporary Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Reissue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11. Service Bulletins and Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12. Application of Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Service and Operations Report Form 853A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Maintenance and Operational Test Requirements and Precautions . . . . . . . . . . . . . 201
2. Rotorcraft Flight Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Standard Hardware Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Special Hardware Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Special Hardware Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Warning and Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Hazardous Materials Warning Statements and Icons . . . . . . . . . . . . . . . . . . . . . . . 201
B. Hazardous Material Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. High Voltage Safety Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
D. Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Table 201. Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

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TABLE OF CONTENTS (Cont.)


Para/Figure/Table Title Page

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Section

01−00−00
Introduction
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

INTRODUCTION
DESCRIPTION AND OPERATION
1. Scope 4. Associated Manuals
MDHI standard practice manual provides
general information and procedural instruc­ Information beyond the scope of MDHI
tions for performing standard practices used maintenance manuals can be found in
on MD-900 helicopters Directives and Related Manufacturers'
Publications listed in Chapter 1 of the helicop­
This manual is one of a group of publications ter's Maintenance Manual.
that form the information file for the MD-900
helicopter. The maintenance and inspection A. Illustrations
procedures are to be used for the MD Explorer
helicopter only. Study its contents to get an
understanding of the arrangement and use of The majority of illustrations represented in
this and related manuals before working on this manual, are oriented in a left hand
the aircraft. trimetric view.

2. Aircraft Configuration
5. ATA Numbering System and Format
This manual is applicable to Model MD-900
helicopters (Ref. Figure 1)
900 CONFIG designates MD-900 serial
numbers 90000010 thru 90000051. The 900 The Standard Practice Manual and related
configuration is the MD-900 as originally type manuals are prepared in general compliance
certificated. with Air Transport Association Specification
for Manufacturers' Technical Data, ATA-100.
902 CONFIG designates MD-900 serial
number 90000052 and subsequent. The 902
The uniform numbering system established by
configuration incorporates changes to the
ATA-100 is used. This numbering system
original MD-900 to meet the requirements of
supplies a procedure for dividing material into
FAR Part 27 Appendix C Category A.
chapter, section, subject and page. The number
3. Helicopter Publications is composed of three elements, which have two
numbers each. The chapter and section
Operators and maintenance personnel should elements (subassembly 10, 20, 30, etc.) are
refer to the current publications index for a normally established by ATA-100. Subject/
complete listing of all maintenance informa­ Unit element numbers are assigned by light
tion available. helicopter technical publications.

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01-00-00 Revision 5
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STANDARD PRACTICE MANUAL

1ST ELEMENT 2ND ELEMENT 3RD ELEMENT

20-20-00
CHAPTER/SYSTEM SUBJECT/UNIT
STANDARD PRACTICES CLEANING
SECTION/SUB-ASSEMBLY
CLEANING
SP01-001

Figure 1. ATA Numbering System


6. Division of Subject Material 8. Figure and Table Numbering
Illustrations and tables use the same number­
This Standard Practice Manual is provided in
ing as the page block in which they appear.
multiple sections using ATA Specification 100
For example, Figure 202 will be the second
as a guide.
figure in the Maintenance Practices section.
When referring to a figure in the same section,
Chapter 20 contains Standard Practices it is identified as follows (Ref. Figure 202).
information and instructions When referring to a figure in a different
section, it is identified as follows (Ref. Section
Chapter 91 lists consumable materials, special 20-30-00, Figure 201).
tools, and associated supplier data.
9. Effectivity
7. Page Number Blocks Effectivity may be applied to information as
follows:
Page number blocks used for each section of
the Standard Practice Manual logically place D When the effectivity is part of a heading, the
the material in sequence, as follows: effectivity applies to all indentured data
applicable to the heading.
If a subtopic becomes so lengthy that a D When the effectivity is at the beginning of a
combination would require numerous pages, procedural step, the effectivity applies to all
each topic is broken out into page number data in the step and any substeps inden­
blocks as follows: tured under the step.

D Description and Operation . . . 1 through 99 D When the effectivity is located in a figure


title or table title, the effectivity applies to
the entire figure or table.
D Maintenance Practices . . . . 201 through 299
D When the effectivity is embedded within a
Each page bears a revision identification, paragraph, procedural step, figure, or table
either “Original” or the last revision number in cell, the effectivity only applies to the data
which the page was modified. indicated.

Page 2
Original 01-00-00
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

10. MDHI Publications Revisions and 12. Application of Warnings, Cautions, and
Reissues Notes
Changes in the helicopter, equipment, mainte­ Throughout this manual, Notes, Cautions and
nance practices, procedures and additional Warnings are used to emphasize instructions
information, update and replace standard or information considered to be unusual or
practice manual content. To ensure that critical. A note can appear in text either before
manuals continue to show current changes, or after instructions to which it applies,
revised information is supplied as follows: depending on the related significance of the
information. Caution and Warning statements
A. Temporary Revision always precede the information or instructions
to which they apply. The conditions that
Important changes to parts of the manual that warrant use of Notes, Cautions and Warnings
may be required between scheduled revisions are given by the subsequent.
are issued in the form of a Temporary Revision
(TR). TRs are issued on colored paper and Operating procedures and
include the TR number at the bottom of the WARNING practices which, if not
page. A page transmittal sheet accompanies strictly monitored, can cause person­
the TR and is to be posted in front of the nel injury, or loss of life.
LOEP. When posted, the Record of Temporary
Operating procedures and prac­
Revisions located in the front of the manual CAUTION tices which, if not strictly moni­
preceding the LOEP is to be filled out.
tored, can cause damage or destruction of
Temporary Revisions are incorporated into the equipment.
next scheduled Revision.
NOTE: An operating procedure or condition
B. Revision that is essential to highlight.

Change to parts of the manual by the replace­ A. Warning Symbols


ment, addition and/or deletion of pages is done Symbols are used as a method for displaying
by revision. The List of Effective Pages (LOEP) immediate graphic information. The following
that accompanies each revision, identifies all symbols have been developed as easily
affected pages. Such pages must be removed understood graphic keys to technical descrip­
from the manual and discarded. Added or tions of a hazard.
replaced pages must be put in and examined
against the List of Effective Pages (LOEP).
Text that is changed in a revision will be
identified by a black revision bar in the left or
right margin adjacent to the revised text. B = Burns/Irritate Chemical
Figures that have a major change will be The symbol of a liquid fal­
identified by a revision bar in the left or right WARNING ling off in drops on a hand,
margin. Figures that have a minor change will shows that the material will cause
have the change pointed to by a hand in the burns or irritation to human skin or
graphic. tissue.
C. Reissue
When several changes are included, the
manual is reissued. The preceding issue of the
manual then becomes obsolete and must be
discarded. BA = Bacteria/Biological

11. Service Bulletins and Letters The abstract bug symbol


WARNING shows that a material can
Service information is to be considered part of contain bacteria or viruses that are a
the manual. danger to life or health.

Page 3
01-00-00 Revision 14
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

C = Cold EX = Explosion

This quickly expanding


The symbol of a hand above WARNING symbol shows that the mate­
WARNING an icy area shows that the rial can explode if subjected to high
material is very cold and can injure hu­ temperature, sources of ignition, or
man skin or tissue. high pressure

ËË
H = Hot/Burn
E = Eye Injury
The symbol of a hand above
The symbol of a person WARNING a fiery area shows that the
WARNING wearing goggles shows that material is very hot and can injure hu­
the material will injure eyes. man skin or tissue.

EL = Electrical/Shock I = Bodily Strike Injury

The symbol of a hand with The symbol of a person be­


WARNING an electrical wire making a WARNING ing struck by an object
shock, shows a danger to life or health. shows a danger to life or health.

P = Poison
F = Flammable
The symbol of a skull and
WARNING crossbones shows that the
The symbol of a flame, shows material is poisonous or is a danger to
WARNING a material can burn.
life.

R = Radiation
FO = Falling Object
The symbol of three circular
The symbol of a person be­ WARNING wedges shows that a materi­
WARNING ing struck by a falling ob­ al gives off radioactive energy and can
ject, shows a danger to life or health. injure human tissue or organs.

Page 4
Original 01-00-00
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

B. Service and Operations Report


Form 853A

S = Electrostatic Discharge MDHI Service and Operations Report Form


853A can be used to report any service
The abstract circle segments problems found with MDHI helicopters.
WARNING and arrows symbol, show
damage by electrostatic discharge, or
injury, or death. Use of this form is recommended, to allow
MDHI supply owners and operators better
service.

The form also serves as a detailed record for


owners and operators. Copies of the form can
V = Vapor be procured by contacting:
The symbol of a human fig­
WARNING ure in a cloud shows that MD Helicopters, Inc.
material gases give a danger to life or 4555 East McDowell Road
health. Mesa, Arizona 85215-9734

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

This page intentionally left blank!

Page 6
Revision 14 01-00-00
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

INTRODUCTION
MAINTENANCE PRACTICES
1. Maintenance and Operational Test 10 in-lb 2
Requirements and Precautions 1.1 Nm

All helicopter maintenance is to comply with 1


5
the following requirements and precautions.
6
2. Rotorcraft Flight Manual

Maintenance tests requiring helicopter 9


operation must be done in accordance with 4
requirements and limits given in the applica­
8
ble Rotorcraft Flight Manual and all applica­
ble Optional Equipment Supplements.
1

3. Maintenance Manual
7
Refer to the applicable Rotorcraft Maintenance
Manual for maintenance and operational test
requirements and precautions specific to the
3
model of helicopter you are maintaining.

SP01-002
4. Torque Values
Figure 201. Special Hardware Torque
Torque values, whether standard or special, 5. Warning and Caution Statements
are not identified in the task. For a detailed
list of standard torque values (Ref. Section Detailed warnings and cautions appear only in
20-10-00, Table 202). this Chapter. Throughout this manual,
hazardous warnings for a material will appear
as a descriptive title with the associated icons.
A. Standard Hardware Torque Values
One warning/caution will appear after the task
Standard hardware torque values are not title. A warning/caution will appear each time
identified in the repair task or illustration. An a related task is continued.
example of a standard torque would be: Torque Prior to starting any task, review the Warn­
screw (5). Item (5) in the illustration will not ings and Cautions. If the Warning/Caution
show a torque value. descriptive title and icons are not fully
understood, refer to Warning Symbols (Ref.
B. Special Hardware Torque Values Section 01-00-00).
A. Hazardous Materials Warning Statements
(Ref. Figure 201) and Icons
The following warnings give a descriptive title,
Special hardware torque values are not followed by warning icons, and a paragraph
identified in the task, but are shown in the explaining the related hazards.
illustration. An example of a special torque
would be: Torque clamp (1). Item (1) in the Refer to the Consumable Materials Table (Ref.
illustration will show the special torque in a Section 91-00-00, Table 201) for the material
box pointing to item (1). and associated warning symbols.

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Warnings for hazardous material are designed Battery


to warn personnel of hazards associated with
such items, when they come in contact with
them during actual use. Consult your local
safety and health staff concerning any
questions on hazardous chemicals, personal When inspecting a battery,
protective equipment requirements, and WARNING never smoke or expose bat­
appropriate handling and emergency proce­ tery to sparks or flames. The gas mix­
dures. ture in each cell of the battery which
escapes thru the holes in the vent plugs
B. Hazardous Material Disposal can ignite causing an internal explo­
sion.
Comply with Federal, State and local regula­
tions for proper disposal of hazardous materi­ Whenever disconnecting battery ter­
als. Remove to permitted waste disposal minals, always disconnect GROUND
facility. terminal first. When reconnecting, al­
ways connect GROUND terminal last.
To prevent severe injury to eyes, face,
Aviation Turbine Fuel limbs and body, due to fire or danger­
ous explosion from flames or sparks,
keep flames or sparks away from vent
openings of battery.
Inhaling of hydrogen gas produced in
Jet engine fuel is toxic and the normal operation of the battery
WARNING explosive. Do not breathe could result in partial or permanent
vapors. Do not get fuel on clothes or damage to the respiratory system.
skin. Use water to remove fuel from
skin. If injury occurs, seek medical aid.
Battery Fluid
Use only nonsparking tools and explo­
sion proof work lights. Attach helicop­
ter to an approved electrical ground.
Switch OFF all electrical power. Dis­
connect external power and battery Battery fluid is an acid that
before opening fuel system. Ensure WARNING harms skin and clothes.
work area is sufficiently open to the People working with batteries must
air. wear special gloves, clothing and eye
Do not allow sparks or flame near heli­ protection. A 15 percent mix of boric
copter when servicing or maintaining acid in water must be used to rinse
fuel system. Make certain helicopter is spilled acid. Spill areas must then be
grounded. If injury occurs, seek medi­ well flushed with water. If injury oc­
cal aid. curs, seek medical aid.
Fuel/air vapor discharged during
bleeding is a fire hazard. Prevent fuel Catalyzed Adhesive
vapor accumulation, ignition and fire.
Perform work in an open, well venti­
lated area away from all potential igni­
tion sources. Attach helicopter to an
approved electrical ground. Wear ap­ Hydrogen is produced when
proved eye protection. WARNING catalyst is mixed with
Do not use oxygen to remove or venti­ A-4000 adhesive. Containers of such
late fuel tank or fuel system compo­ material should be vented to avoid
nents. Fuel, either vapor or liquid, will pressure buildup. Personal injury may
violently react with oxygen-rich air. result.

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STANDARD PRACTICE MANUAL

Cleaning Chemicals Consumable Container Warnings

Observe all cautions and


WARNING warnings on containers of
Chemicals used for cleaning consumable materials specified for use
WARNING are explosive, flammable in this Maintenance Manual. When ap­
and highly poisonous. Wear protective plicable wear approved protective
clothing and guards when working clothing during handling.
with cleaning materials. Always en­
sure maximum ventilation when using
solvents and cleaning solutions. Acci­ Control Rod Thread Engagement
dental breathing of vapors can cause
Ensure correct control rod
dizziness and nausea. If cleaning solu­ WARNING adjustable end thread en­
tion contacts skin, rinse immediately
gagement after making last rod length
with water. If cleaning solution con­
adjustment. Try to pass a length of
tacts eyes, flush with water and seek
lockwire through witness hole. Rod
medical aid.
end-fitting must block hole and pre­
vent wire insertion. Move controls
through full travel and examine con­
trol system clearance. Ensure rod end
Solvent, Cleaning (C420)
jam nuts are tight. Do not install used
cotter pins.

Dry Cleaning Solvent

Methyl-Ethyl-Ketone is
WARNING highly toxic to skin and re­
spiratory tract. It may cause blindness Dry cleaning solvent is flam­
if it enters the eyes. Avoid all exposure. WARNING mable. Do not use it near ox­
Eye, skin, and respiratory protection ygen storage or oxygen transfer sys­
required. Emergency eyewash unit re­ tems. Do not use it near heat or open
quired. flame. Do not apply electrical power to
aircraft while it is being used. Wear
protective clothing, goggles, and respi­
rator. If injury occurs, seek medical
Cleaning Operations aid.

Engine Exhaust

ËË
Wear approved mask,
WARNING goggles, gloves and apron Stay clear of engine exhaust
during cleaning operations. Avoid con­ WARNING when engines are operating.
tact with skin and eyes. If contact oc­ Exhaust gases are hot and could cause
curs, flush affected areas with water burns. Particles in the exhaust could
and change contaminated clothing. damage eyes. If injury occurs, seek
Seek medical aid immediately. medical aid.

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Engine Sound Fire Extinguisher

Sound of running engines


WARNING can exceed U.S. Surgeon
General's noise limits (TB MED 251).
Ear plugs or aviation helmet must be The cartridge is an explo­
worn when working on helicopter at WARNING sive device. Inadvertent det­
these times. If injury occurs, seek med­ onation of a cartridge can cause per­
ical aid. sonnel injury. For safe handling, the
electrical connector pins must be
shorted to the body.
Epoxy Primer and Coating
The bottle is pressurized. Do not drop.
Use care in handling.
Do not apply pressure or insert any­
thing into the fill or discharge ports
Do not use voltmeter, flashlight bat­
Epoxy polyamide primer tery, continuity light or any device to
WARNING and polyurethane coating test the cartridge. These devices can
are flammable and toxic to eyes, skin cause detonation of the cartridge. Use
and respiratory tract. Skin and eye a current limited multimeter tester.
protection are required. Avoid re­
peated or prolonged contact. Good Fire Extinguisher Fluid
general ventilation is normally ade­
quate.

Epoxy Primer Storage Be certain fire extinguisher


WARNING is fastened securely to work
surface before attempting removal of
extinguishing agent.
Fire extinguisher fluids can make the
Do not transport or store eyes and nose sore. Use solvents only in
WARNING mixed epoxy primer well aired places. Do not breathe sol­
MIL-P-23377, Type 1 Class 3 in alumi­ vent vapors or let them touch the skin
num containers. Epoxy primer can or eyes. If injury occurs, seek medical
react explosively with aluminum. aid.
Flammable Consumables
External Power

Consumables that are flam­


WARNING mable or explosive must be
Application of aircraft pow­ kept away from heat, spark and flame.
WARNING er or Ground Power Unit Make certain that appropriate fire
(GPU) operation could cause injury to fighting equipment for the consum­
personnel. Make certain all switches ables involved is available.
and controls are in a safe condition. In­ Ground Operations
form all personnel working on helicop­
ter that external power is being ap­ Engines shall be started and
plied. If injury occurs, seek medical WARNING run by assigned personnel
aid. only.

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

C. High Voltage Safety Steps Heat Guns or Ovens


If someone is victim of electrical shock, proceed
with the following safety steps: ËË
(1). Do not try to pull or grab individual.
Do not use heat guns or
(2). Turn off electrical power. WARNING ovens near flammables. Fa­
tal explosions may result. Handling hot
(3). If you cannot turn off electrical power; items presents a serious burn poten­
pull, push or lift the person to safety, tial. Temperature resistant gloves are
using a dry wooden pole, rope, or some required. Post warning signs in work
other insulating material. area to alert people to high tempera­
(4). Send for help as soon as possible. ture items.

(5). Immediately start artificial resuscita­


tion. High Pressure Nitrogen

High Voltage

Shock struts contain nitro­


WARNING gen under high pressure. A
High voltage is used in the sudden blast could cause injury. To
WARNING operation of this equipment. prevent possible injury, follow defla­
Death on contact may result if person­ tion instructions carefully. If injury oc­
nel fail to observe safety precautions. curs, seek medical aid.
Never work on electronic
WARNING equipment unless there is Hoisting
another person nearby who is familiar
with the operation and hazards of the
equipment and who is competent in ad­
ministering first aid. When technicians
are aided by operators, they must be Hoisted components can
warned about dangerous areas. WARNING cause injury or death if they
fall. Keep away from all hoisted compo­
Whenever possible, the pow­ nents and loaded crane. If injury oc­
WARNING er supply to the equipment curs, seek medical aid.
must be shut off before beginning work
on the equipment. Take particular care Extreme precaution must be taken
to ground every capacitor likely to when hoisting aircraft to ensure safety
hold a dangerous potential. When of maintenance personnel. Do not
working inside the equipment, after climb on aircraft while it is off the
power has been turned off, always ground.
ground every part before touching it.
Hydraulic Fluid
Be careful not to contact
WARNING high voltage input connec­
tions of 115/230 volts ac when installing
or operating the equipment.
Whenever the nature of the Hydraulic fluid is toxic to
WARNING operation permits, keep one WARNING skin, eyes and respiratory
hand away from the equipment to re­ tract. Skin and eye protection are re­
duce the hazard of current flowing quired. Avoid repeated or prolonged
through vital organs of the body. contact. Good ventilation is required.

Page 205
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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Ignition Exciter Protective Equipment

The ignition system con­


WARNING tains high-voltage electric­
ity that can cause injury or death. Ex­ Protective equipment shall
treme caution must be used when WARNING be used when working with
working on ignition system. If injury resin, solvent, or any material that may
occurs, seek medical aid. cause a health or safety problem. This
may include, but is not limited to the
use of gloves, safety glasses, respira­
Jacking
tors, and other equipment, as required.

Refrigerant
Do not climb on aircraft
WARNING while on jacks to prevent
damage to maintenance personnel or
aircraft.
Do not perform this task in high winds.

Moving Flight Controls Freon is an asphyxiant and


WARNING toxic to skin and eyes. Skin
and eye protection are required. Use
only in a well ventilated area.

Notify personnel working


WARNING on aircraft, prior to cycling
Rotor Blades
the flight control system. Failure to do
so, could result in death or serious in­
jury.

Power Off

Rotor blades can cause inju­


WARNING ry or death. Stay clear of ro­
tating blades. Blades can still rotate
Turn off power before de­ with engines off. Make certain rotor
WARNING taching or attaching wires brake is on when working in path of
and connectors. High current +28 vdc blades. Inform all personnel working
and/or 115 vac are present. Failure to on helicopter that blades can rotate if
do so, could result in death or serious rotor brake is off or inoperative. If in­
injury. jury occurs, seek medical aid.

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STANDARD PRACTICE MANUAL

Rotor Vibrations D. Caution Statements


Sudden onset of excessive The following cautions give a descriptive title,
WARNING and/or unusual rotor vibra­ followed by a paragraph explaining the related
tions shall be investigated as to cause, hazard.
prior to continued flight. Under no cir­ Air in Fuel System
cumstance should main rotor tracking Air in the fuel system will cause
be attempted to correct the problem CAUTION a power reduction or flameout.
until a thorough inspection of the main Perform a fuel system vacuum leak review
rotor blades, hub assembly and flex­ and system air bleed, after opening fuel sys­
beam have been performed. tem to air and before releasing helicopter for
flight. Ensure start pump operates before
Safety Checks removing fuel samples from system drain
valves.
Failure to perform safety re­
WARNING views could cause injury to
Battery Discharge
personnel. Safety reviews must be per­
Avoid using battery as power
formed when called for in a task. Safe­ CAUTION supply for extended periods. Ex­
ty reviews make certain the helicopter
is in a safe condition for performing ternal power should be used when possible,
tasks. If injury occurs, seek medical during ground maintenance inspections to
aid. avoid battery discharge.

Commercial Cleaning Agents


Solder Installation and Removal
Some commercial cleaning
CAUTION agents, such as readily avail­
able household cleaners, contain chemicals
that can cause corrosive action and/or leave
residue that can result in corrosion. Exam­
Soldering/desoldering may ples of cleaning agents that are not to be
WARNING result in the emission of haz­
used are Fantastic or 409 type cleaners, or
ardous metallic fumes and vapors from locally made strong soap cleaners.
fluxes used. Workers should position
themselves so as to not directly inhale
the fumes or vapors. Cooling Blower Impeller
Cooling blower impeller must be
CAUTION hand held for nut removal and
installation. Do not hold impeller blades
with any type of tool. Small impeller dam­
age can cause imbalance and vibration. Do
not use any device that puts a strain on
blower scroll.

Corrosion Preventative Lubricant


Use corrosion preventive lubri­
CAUTION cant on main rotor blade droop
stop system to retard wear, seizure and cor­
rosion. Spray lubricant can be used as an al­
ternate, but does not retard corrosion.

Page 207
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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Flight Control Movement O-Rings

Do not cycle rotor flight controls Assemble and install a compo­


CAUTION through their range of motion CAUTION nent with only new, correctly
unless external hydraulic power is supplied sized and installed O-rings.
to aircraft. Center cyclic stick to minimize
stress on static main rotor flexbeams before
moving collective stick through its full range
Residual Fluids
of travel. Position collective stick in approxi­
mately the 80% ± 5% up position before
moving cyclic stick through extreme travel Residual fluids may remain in
CAUTION hydraulic or fuel lines. Take pre­
positions.
cautions when removing system compo­
nents to avoid spilling fluids inside aircraft.
Cotter Pins

Assemble and install a compo­ Rigging Main Rotor Flight Controls


CAUTION nent with only new cotter pins.
Rigging main rotor flight con­
CAUTION trols may be performed without
Engine FOD removing main rotor blades, provided lower
end of pitch change links are disconnected
Avoid foreign object contamina­ from swashplate.
CAUTION tion of engine when working in
engine inlet area.
Rotor Component Damage

External Hydraulic Power Do not move the rotor blade tip


CAUTION up more than 4.0 ft. (1.22 m)
Do not make full or abrupt when the rotor is not in operation. And do
CAUTION movements of the main rotor not move the flexbeam up more than 1.0 in.
flight controls with external hydraulic pow­ (2.54 cm) at the blade attach point. Dam­
er supplied to aircraft. The main rotor flex­ age to the flexbeam can occur.
beams cannot accommodate full control ex­
cursions (combinations of full collective and
full cyclic movements) without centrifugal
Scratching Composite Surface
force.
Use care to prevent scratching
CAUTION of composite surface when
FOD
cleaning main rotor blades. Never use vola­
Inspect aircraft and area tile solvents or abrasive materials. Never
CAUTION around fuel system, hydraulic apply bending loads to blades or blade tabs
system and flight controls for FOD debris during cleaning.
before releasing helicopter for flight.

System Contamination
Lead Lag Loads
Prevent system contamination
Lead-lag loads more than 25 CAUTION and damage. Cap all open fuel,
CAUTION pounds applied at the main ro­ hydraulic and oil lines and fittings. Install
tor blade tips, can damage the elastomeric protective covers on all component open­
damper and lead to damper failure. Do not ings. Bag and identify small parts to pre­
exceed 25 pound lead-lag load at blade tip. vent loss or damage.

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Teflon Bearings 6. Abbreviations


Carefully apply grease, oil, dry- (Ref. Table 201)
CAUTION film lubricants, etc., near Teflon
bearings. Most lubricants catch and keep The following table is a list of abbreviations
dirt that will quickly deteriorate a Teflon used throughout MD900 maintenance
bearing. manuals.
Table 201. Abbreviations
Use Term Use Term
A A D D
A ampere DECAL decalcomania
ac alternating current dB decibel(s)
Ah ampere−hour(s) dc direct current
AM amplitude modulation DD digital display
AOG Aircraft on Ground E E
atm atmosphere ECS Environmental Control System
B EEC Electronic Engine Control
b bit EHF extremely high frequency
Bd baud emf electromotive force
bhp brake horsepower eV electron Volt
bp boiling point F
Btu British thermal unit _F degrees Fahrenheit
BL Butt Lines FOD Foreign Object Damage
C FMU Fuel Metering Unit
C coulomb FS Fuselage Stations
c cycle ft foot / feet
_C degrees Celsius ft2 square foot / feet
cal calorie ft−lb foot−pound(s)
CAS calibrated airspeed ft/s feet per second
cfm cubic feet per minute fwd forward
CFU Collective Friction Unit G
CG center of gravity g Gram(s)
cg centigram gal gallon(s)
CID Commercial Item Description GPM gallons per minute
CLP Collective Lever Position gal/s gallons per second
CMM Component Maintenance Manual GSE Ground Support Equipment
cm Centimeter(s)
cm2 square centimeter(s)
CNDTC conductance
cSt centistokes

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 201. Abbreviations (Cont.)


Use Term Use Term
H M
h hour m Meter(s)
HF high frequency mA Milliampere(s)
hp horsepower mbar Millibar(s)
Hz hertz MDHI MD Helicopters, Inc.
I MeV mega−electron Volts
IAS Indicated Airspeed mg Milligram(s)
id inside diameter MHF Medium−High Frequency
IFR Instrument Flight Rules MHz megahertz
IIDS Integrated Instrument Display mHz millihertz
System
mi mile(s)
in. inch
mi/h miles per hour
in−lb inch−pound(s)
min minute (time)
IPL Illustrated Parts List
mL milliliter
IPS Inlet Particle Separator
mm millimeter
ISC Illustrated Structures Catalog
mo month
K
ms millisecond
K kelvin
mV millivolt
kg kilogram
MW megawatt
kHz kilohertz
mW milliWatt
km kilometer
μA microAmpere
km/h kilometer per hour
μbar microbar
kt knot(s)
μF microfarad
kV kilovolt(s)
μg microgram
kVa kilo−volt−ampere(s)
μs microsecond
L
μV microVolt
L liter(s)
μW microWatt
lb pound(s)
LH/lh Left Hand/left hand
LF low frequency
lm lumen
LPM liters per minute

Page 210
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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Table 201. Abbreviations (Cont.)


Use Term Use Term
N R
N Newton rad radian
NACA National Advisory Committee for Ref. reference
Aeronautics
RF radio frequency
Ng gas generator speed
RH/rh right hand
Nm Newton meter
r/min revolutions per minute
nmi nautical mile
rms root mean square
No. number r/s revolutions per second
Npt power turbine speed
RFM rotorcraft flight manual
NR rotor speed
RMM rotorcraft maintenance manual
ns nanosecond
S
O s second
od outside diameter
SH sheet
OVBD overboard
shp shaft horsepower
oz ounce
SRM structural repair manual
W Ohm(s) STA station
P
T
pct percent
TAS true airspeed
PL place
ton ton
PLI preload indicator U
pnl panel UHF ultrahigh frequency
psi pounds per square inch V
psig pounds per square inch gage V Volt
pt pint VA Volt−Ampere
PTFE polytetrafluoroethylene Vac Volt, alternating current
Q Vdc Volt, direct current
qt quart VHF very high frequency
W
W Watt
WL waterline
Y
yd yard
yr year

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Chapter

STANDARD PRACTICES
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

TABLE OF CONTENTS
Para/Figure/Table Title Page

20-00-00 Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20-10-00 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Torque Wrench Precision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Application of Torque Wrench Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Recommended Installation Torque Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Bolts and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Castellated Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Control Tube Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Corrected Torque Wrench Reading Using An Adapter . . . . . . . . . . . . 202
3. Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Special Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Standard Hardware Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
C. Tube or Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
D. Bulkhead and Boss Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Torque Value Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Inch-Pounds to Foot-Pounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Foot-Pounds to Inch-Pounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
C. Inch-Pounds to Newton-Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
D. Foot-Pounds to Newton-Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Identification Stripe (Torque Stripe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Table 201. Standard Hardware Torque (Ref. Table 202) . . . . . . . . . . . . . . . . . . . . . 204
Table 202. Recommended Standard Thread Fasteners Torque . . . . . . . . . . . . . . . 205
Table 203. Torque Values for Tube or Hose Assemblies . . . . . . . . . . . . . . . . . . . . . 209
Table 204. Torque Values for Boss and Bulkhead Fittings . . . . . . . . . . . . . . . . . . . 212
20-20-00 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Environmental Sealing Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

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C. Transparent Plastic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Bearing Cleaning — Standard Method (Vapor Degreaser) . . . . . . . . . . . . . . . . . . . 202
E. Bearing Cleaning — Alternate Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
F. Titanium Metals Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Fuselage Interior Trim and Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Fuselage Interior Trim and Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4. Rotorcraft Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Clean the Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Rotorcraft Rinse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
C. Rotorcraft Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Lubrication and Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Cooling Ducts Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Shroud, Housing Assembly, and Impeller Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 207
C. Heat Exchanger Internal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
D. Heat Exchanger External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Air-Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Evaporator Internal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
B. Evaporator External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
C. Condenser Internal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
D. Condenser External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
E. Hose and Tube Internal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
20-30-00 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Paint Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Small Sanded Areas (Repaired Scratches, Nicks, Gouges, Etc.) . . . . . . . . . . . . . . 201
B. Loose or Dried Paint and Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Titanium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Primer Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Epoxy Primer (MIL-PRF-23377, Type 1, Class 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Epoxy Primer (MDM15-1100, Type 1, Class 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Epoxy Primer (MIL-PRF-23377, Type 1, Class 1 and 2; MIL-PRF-23377,
Type 2, Class 1 and 2; MDM15-1100, Type 1, Class 2) . . . . . . . . . . . . . . . . . . . . . . 203
D. Epoxy Primer (MIL-PRF-23377, Type 2, Class 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 204
E. Epoxy Primer (MIL-PRF-85582, Type 1, Class 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 205
F. Epoxy Primer (MIL-PRF-23377, Type 1, Class 1 and 2) . . . . . . . . . . . . . . . . . . . . 205

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3. Exterior Topcoat Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Polyurethane Coating (MIL-C-83286) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Finish Enamel Coating (MDM15-1100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4. Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
5. Main Rotor Drive Plate and Drive Plate Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
6. Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Zone 1 and Zone 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 201. Main Rotor Blade Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
B. Zone 2 — Inboard and Outboard Abrasion Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
C. Top Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
7. Ink Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
20-40-00 Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Corrosion Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Visual Check and Inspection for Corrosion Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Visual Corrosion Guide — General Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Visual Corrosion Guide — Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Temporary Corrosion Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Temporary Treatment Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Corrosion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Paint Removal Chemical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Paint Removal Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
C. Corrosion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Mechanical Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Nicks, Scratches, Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Sealing Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8. Aluminum Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Surface Touch-Up Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
20-50-00 Electrical Bond and Environmental Seal . . . . . . . . . . . . . . . . . . . . . . . . . . A
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Electrical Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Electrical Bonding Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

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B. Electrical Bond Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Bonding Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 202. Equipment Class Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2. Environmental Sealing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Faying Surface Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 201. Faying Surface Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Fillet Surface Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Fillet Surface Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203. Fillet Sealing Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
C. Gasket Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
D. Mechanical Fastener Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 204. Mechanical Fastener Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
20-60-00 Electrical Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Connector Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Terminal Junction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Ground Block Modules and Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Terminal Blocks and Terminal Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2. Ground Module and Stud Locations (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 3
Figure 3. Track and Terminal Block Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4. Terminal Blocks and Contact Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 5. Forward Interconnect Panel (A612) Terminal Blocks . . . . . . . . . . . . . . . 7
Figure 6. Electrical Load Center (A620) Terminal Blocks and Modules . . . . . . . . 7
Figure 7. Audio Interconnect Assembly (A675) Terminal Blocks . . . . . . . . . . . . . . 8
4. Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 8. Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 1. System Identification Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 2. EMI Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. Wire Type Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 3. Wire Type Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6. Wire Harness and Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A. Wire Harness Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 9. Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
B. Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 10. Connector Identification Device Location . . . . . . . . . . . . . . . . . . . . . . . . 12

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Figure 11. Connector Identification Marking Location . . . . . . . . . . . . . . . . . . . . . . . 13
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
A. Safety Procedures and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
B. Released Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
C. Radio Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
D. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Installation and Removal of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Terminal Block Module, Terminal Junction System Removal . . . . . . . . . . . . . . . . 201
B. Terminal Block Module, Terminal Junction System Installation . . . . . . . . . . . . . 201
C. Track Assembly, Terminal Junction System Removal . . . . . . . . . . . . . . . . . . . . . . . 201
D. Track Assembly, Terminal Junction System Installation . . . . . . . . . . . . . . . . . . . . 201
E. Terminal Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
F. Terminal Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
G. Ground Block Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
H. Ground Block Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Terminal Junction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
I. H Rail Electrical Relay Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
J. H Rail Electrical Relay Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
K. H Rail Electrical Relay Socket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
L. H Rail Electrical Relay Socket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
M. H Rail Track Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
N. H Rail Track Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
O. Hybrid Relay Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
P. Hybrid Relay Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Q. Hybrid Relay Socket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
R. Hybrid Relay Socket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 202. H Rail and Hybrid Electrical Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
S. Ground Stud Removal MDP 15-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
T. Ground Stud Installation MDP 15-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
U. Electrical Contactor (Relay) Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
V. Electrical Contactor (Relay) Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 203. Electrical Contactors (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
W. Circuit Breaker Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
X. Circuit Breaker Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

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Figure 204. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Y. Rotary Switch Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Z. Rotary Switch Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 205. Rotary Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
AA. Toggle Switch Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
AB. Toggle Switch Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Figure 206. Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
AC. Indicator Light Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
AD. Indicator Light Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 207. Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
AE. Supplemental Fuel Transfer Indicator Light Removal . . . . . . . . . . . . . . . . . . . . . 216
AF. Supplemental Fuel Transfer Indicator Light Installation . . . . . . . . . . . . . . . . . . . 216
Figure 208. Supplemental Fuel Transfer Indicator Light . . . . . . . . . . . . . . . . . . . . 217
AG. Indicator Lamp Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
AH. Indicator Lamp Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
AI. Indicator Lamp Bulb Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
AJ. Indicator Lamp Bulb Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Figure 209. Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
2. Electrical Connector Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
A. Circular Electrical Connector Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
B. Circular Electrical Connector Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . 220
C. Circular Receptacle Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
D. Circular Receptacle Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Figure 210. Circular Electrical Connector (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . 223
E. Rectangular Electrical Connector Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . 224
F. Rectangular Electrical Connector Installation (Typical) . . . . . . . . . . . . . . . . . . . . . 224
G. Rectangular Receptacle Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
H. Rectangular Receptacle Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
I. Coaxial Connector Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
J. Coaxial Connector Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
K. Coaxial Receptacle Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
L. Coaxial Receptacle Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3. Wire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
A. Wire Maintenance Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
B. Wire Maintenance Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
C. Tying of Wires, Harnesses, and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Table 201. Tape Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

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Figure 211. Clove Hitch and Three-turn Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Figure 212. Installation of Tying Tape (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 229
D. Expandable Sleeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Figure 213. Sleeving With End Folded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Table 202. Expandable Sleeving Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Figure 214. Expandable Sleeving Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
E. Heat Shrinkable Sleeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Table 203. Heat Shrink Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Table 204. Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
F. Electrical Insulation Sleeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Table 205. Insulation Sleeving Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Figure 215. Electrical Insulation Sleeving Installation . . . . . . . . . . . . . . . . . . . . . . 234
G. Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Figure 216. Clamp Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Figure 217. Incorrect Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Figure 218. Correct Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Figure 219. Clamps Attached to Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
H. Electrical Wire Identification Label Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Figure 220. Wire Identification Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
I. Coaxial Cable Identification Label Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Figure 221. Coaxial Cable Identification Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4. General Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
A. Wire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
B. Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Figure 222. Wire Harness Bundled by Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
C. Coaxial Cable Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
D. Coaxial Cable Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Figure 223. Coaxial Cable Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5. Wire Cleaning and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
A. Spare Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Table 206. End Cap Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Figure 224. End Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
B. Spare Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Figure 225. Spare Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
C. Protection for Wire Harnesses and Electrical Connectors . . . . . . . . . . . . . . . . . . . . 245
Figure 226. Protection for Wire Harnesses and Electrical Connectors . . . . . . . . . 245
D. Protection of Electro-Static Discharge Sensitive (ESDS) Components . . . . . . . . 246
E. Connector and Module Contamination Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

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F. Wire Harness Contamination Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
6. Wire Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
A. Solder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
B. Solder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Figure 227. Tin Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Figure 228. Solder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
C. Wire Insulation Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
D. Shielded Wire Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Figure 229. Prepare Shield and Wire for Termination . . . . . . . . . . . . . . . . . . . . . . . 251
Table 207. Solder Sleeve Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Figure 230. End Strip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Figure 231. Window Strip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Figure 232. Daisy Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Figure 233. Shield Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Figure 234. Shield Not Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
E. Solder Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Figure 235. Solder Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
F. Crimp Style Contact Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Table 208. Crimp Tools (Power), Terminal Lugs and Splices . . . . . . . . . . . . . . . . . 260
Table 209. Contact Term Code, Crimp Tool, and Positioner . . . . . . . . . . . . . . . . . . 260
Figure 236. Contact Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Table 210. Contact Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Figure 237. Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
G. Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Table 211. Installation/Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
H. Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Figure 238. Contact Insertion and Extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
I. Removal of Contacts Without Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Table 212. Push Rods for Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
J. Environmental Sealing Plug Removal and Installation . . . . . . . . . . . . . . . . . . . . . 267
Table 213. Sealing Plug Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
K. Terminal Lug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Table 214. Terminal Lug and Crimp Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . 268
Figure 239. Terminal Lug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
L. Terminal Lug Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Figure 240. Terminal Lug to Electrical Connector (Typical) . . . . . . . . . . . . . . . . . . 272
Figure 241. Terminal Lug Connected to Receptacle (Typical) . . . . . . . . . . . . . . . . . 272
Figure 242. Terminal Lug Connected to Stud (Typical) . . . . . . . . . . . . . . . . . . . . . . 273

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TABLE OF CONTENTS (Cont.)


Para/Figure/Table Title Page

Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Module Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Grommet Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Connector and Accessories Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 602. Connector Inserts (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
3. Wire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
A. Wire Harness Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 603. Drip Loops and Lugs With Wires Pointed Down . . . . . . . . . . . . . . . . . 605
B. Single Wire and Shielded Wire Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Table 601. Conductor Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Table 602. Shield Strand Damage Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
C. Coaxial Cable Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
D. Soldered Contact Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Figure 604. Solder Contact Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
E. Solder Joint Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Figure 605. Solder Joint Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
4. Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
A. Open Circuit Condition Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
B. Short Circuit Condition Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
C. Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Wiring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Non-Shielded Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Table 801. Splice and Crimp Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Non-Shielded Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
B. Shielded Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Table 802. Solder Sleeve Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Table 803. Shield Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802. Shielded Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
C. Shielded Wire - Picked Shield Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Table 804. Solder Sleeve Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
D. Wire Insulation Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
20-70-00 Composite Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Repair of Composite Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Installation of Inserts in Carbon-Epoxy or Fiberglass-Epoxy Sandwich Panels . 201
A. Drill the Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

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TABLE OF CONTENTS (Cont.)


Para/Figure/Table Title Page
Figure 201. Types of Drill Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 202. Drill the Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 203. Alignment Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 204. Drill a Hole in a Thick Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Install the Doublers on Sandwich Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 205. Location of Vent Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
C. General Instructions to Drill the Holes for the Inserts . . . . . . . . . . . . . . . . . . . . . . 204
Figure 206. Installation of Blind Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
D. Installation of Blind Inserts with Potting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Table 201. Blind Inserts with Potting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 207. Installation of Thru Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
E. Installation of Thru Inserts with Potting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 208. Installation of Adhesive Hard Points . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
F. Installation of Adhesive Hard Point Thru Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Table 202. Thru Inserts with Potting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 209. Installation of Dome-Head Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
G. Installation of Dome-Head Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Table 203. Dome-Head Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
20-80-00 Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Permaswage® Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Engagement Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 202. Swaging Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 203. Swage Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
20-90-00 Nondestructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Nondestructive Inspection Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Visual Inspection Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Dye Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Coin Tap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Coin Tap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
D. Fluorescent Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
E. Magnetic Particle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
F. Eddy-Current Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

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STANDARD PRACTICE MANUAL

Section

20−00−00
Standard Practices
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

STANDARD PRACTICES
DESCRIPTION AND OPERATION
1. Introduction 2. Consumable Materials
A list of consumable materials is contained in
This chapter contains maintenance informa­ Chapter 91. This comprehensive listing
tion and procedures that are common standard provides a description, specification and
practices used on the MD 900 helicopter. suggested source. Within this manual,
Typical information contained in the chapter consumable items in the maintenance tasks
are referred to by ``C” number. When a task
are standard torque charts and application
states to use cleaning solvent (C424) refer to
procedures, cleaning, painting, corrosion
Chapter 91 and find item C424 for type of
prevention, bonding, bearings/bushing
cleaning solvent to use.
removal and installation, electrical standard
practices and nondestructive inspection Handling and storage of consumable materials
techniques. The electrical standard practice shall be in accordance with manufacturers'
section contains its own description and instructions except as noted in the procedural
operation page block. task text.

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Section

20−10−00
Torques
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

TORQUES
MAINTENANCE PRACTICES
1. Torque Wrenches torque values that must be added to the
torque.
Torque wrenches must be of good quality and
calibration must be verified at regular (4). If adapters and torque wrench are not
intervals to verify precision. at right angles (90 degrees) to each
other, wrench or indicator reading must
A. Torque Wrench Precision be corrected. (Ref. Figure 201)
(1). Torque wrenches must be calibrated at 2. Recommended Installation Torque Range
regular intervals. Torque wrenches
must not be used if calibration has A. Nuts
expired or calibration is unknown. The nut shall be torqued within the specified
range.
(2). The lower 20 percent of the torque
wrench range must not be used. B. Bolts and Screws
B. Application of Torque Wrench Loads When it is impossible to torque the nut, the
bolt or screw shall be torqued to the high side
Requirements governing application of torque of the recommended torque range specified.
loads apply throughout this manual except
where otherwise specifically indicated. C. Castellated Nuts

(1). Manufacturer-applied lubricant must Castellated nuts shall be torqued to the


not be removed or additional lubricant minimum side of the recommended torque
added. range. Continue to tighten the nut until the
hole of the cotter pin lines up with the
(2). Bolts, nuts and the surfaces they bear castellation without exceeding the maximum
on must be clean, dry and free of specified torque. Install new cotter pins only.
lubricant except as stated in require­
D. Control Tube Jam Nut
ment above.
NOTE: Do not torque with rod end against fit­
(3). Locking torque (run-on, drag) required ting.
to install self-locking nut or bolt up to
point of final tightening must always be Tighten jam nuts against control rods by
added to final torque value specified. holding rod end with wrench. Ensure rod ends
Table 202 Section I, lists the locking are not preloaded after torquing jam nuts.

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TORQUE HANDGRIP
ADAPTER WRENCH DRIVE WRENCH CENTERLINE
DRIVE CENTERLINE (PREDETERMINED)
CENTERLINE

E L

L
FORMULA T x =Y
L+E
EXAMPLE: (WITH “E” AS PLUS DIMENSION)
T = 135 IN-LB 10 1350
Y = UNKNOWN Y = 135 x = = 117.39
L = 10.0 in. 10 + 1.5 11.5
E = 1.5 in. Y = 117 in.-lb

TORQUE HANDGRIP
ADAPTER WRENCH
WRENCH DRIVE CENTERLINE
DRIVE
CENTERLINE (PREDETERMINED)
CENTERLINE

L
FORMULA T x =Y
T = 135 IN-LB L-E
Y = UNKNOWN
L = 10.0 in. EXAMPLE: (WITH “E” AS MINUS DIMENSION)
E = 1.5 in.
10 1350
Y = 135 x = = 158.82
10 - 1.5 8.5

Y = 159 in.-lb
LEGEND

T = ACTUAL (DESIRED) TORQUE


Y = INDICATED TORQUE
L = EFFECTIVE LENGTH LEVER
E = EFFECTIVE LENGTH OF EXTENSION
9G20-001

Figure 201. Corrected Torque Wrench Reading Using An Adapter

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STANDARD PRACTICE MANUAL

3. Torque Values Section I - lists torque values for flared tube


or hose assemblies.
Do not exceed maximum
WARNING allowable torque value. Section II - lists torque values for flareless
Overstressing of fastener (nut or bolt) tube or hose assemblies.
may result.
D. Bulkhead and Boss Fittings
Standard hardware torque values are not
called out in the maintenance task instruc­ Table 204 is a three section table listing torque
tions or in the associated task illustrations. values for boss and bulkhead fittings:
The standard torque values are referenced
under Recommended Standard Thread Section I - lists torque values for fitting to
Fasteners Torque (Ref. Table 202). boss for non-positioning union.

Special torque values are called out in the Section II - lists torque values for fitting to
maintenance task illustrations. boss for positioning universal fitting.

A. Special Torque Values Section III - lists torque values for bulkhead
fitting installation.
Special torque values are specified in the
illustration referenced in the procedural steps 4. Torque Value Conversion
of the maintenance task instructions. The
special torque values take preference over A. Inch−Pounds to Foot−Pounds
standard hardware torque values.
To convert inch-pounds to foot-pounds, divide
B. Standard Hardware Torque Values inch-pounds by 12.

Table 202 is a five section table listing torque B. Foot−Pounds to Inch−Pounds


values for standard hardware by thread size.
To find out which section to go to, identify the To convert foot-pounds to inch-pounds,
hardware part number, locate the part number multiply foot-pounds by 12.
in Standard Hardware Torque Table (Ref.
Table 201) and read the third column for C. Inch−Pounds to Newton−Meters
Section and Column. EXAMPLE: AN310
To convert inch-pounds to newton-meters,
(fastener) is a HN (hex nut) and the torque
multiply by 0.11296.
value is in Section II, Column 2.
D. Foot−Pounds to Newton−Meters
Section I - lists locking torque (run-on, drag)
values for self-locking bolts, screws and nuts. To convert foot-pounds to newton-meters,
Section II - lists torque values for fine thread multiply by 1.356.
fasteners (125,000 to 145,000 psi).
5. Identification Stripe (Torque Stripe)
Section III - lists torque values for coarse
thread fasteners (125,000 to 145,000 psi). After torque of a fastener, a continuous stripe
should extend from the threaded end of the
Section IV - lists torque values for thread bolt, down the side of the nut and washer, and
fasteners (160,000 to 180,000 psi). onto the base material.

Section V - lists torque values for fasteners Torque stripe will aid in the inspection of
with phillips recesses. fastener to determine if the fastener has lost
its torque, and is rotating.
C. Tube or Hose Assemblies
NOTE: Identification stripe shall not be applied
Table 203 is a two section table listing torque to fasteners located in fuel or other liquids
values for flared and flareless tube or hose that could be contaminated by the striping
assemblies: material.

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STANDARD PRACTICE MANUAL

Table 201. Standard Hardware Torque Item Section /


(Ref. Table 202) Fastener Code* Column
Item Section / NAS1303 HHB IV, 2
Fastener Code* Column
NAS1304 HHB IV, 2
AN310−315 HN II, 2
NAS1351 CS II, 2
AN316−320 HN II, 1
NAS1423 HN II, 1
AN4 HHB II, 2
NAS509 HN II, 1
AN502 FHB II, 2 NAS517 FHS V
MS17826 CN II, 1 NAS563 HHB IV, 2
MS20004 IWB IV, 2 NAS564 HHB IV, 2
MS21042 HN II, 1 NAS600−604 PHS V

MS21043 HN II, 1 NAS6203−6206 HHB IV, 2

MS21044 HN II, 2 NAS623 PHS V

MS21083C HN II, 1 NAS6304 HHB IV, 2


NAS6603−6606 HHB IV, 2
MS21083N HN II, 1
NAS6706 HHB IV, 2
MS24694S FHS V
NAS673V− HHB IV, 2
MS27039C PHS V 676V
MS35691 HN II, 1 * Item Codes
MS9208 12B II, 2 CN = castellated nut;
CS = cap screw;
MS9363 HN II, 1
FHB = flush head bolt;
NAS1096 HHB V FHS = flush head screw;
NAS1189 FHS V HHB = hex head bolt;
HN = hex nut;
NAS1190 PHS V
IWB = internal wrenching bolt;
NAS1203 FHB V PHS = pan head screw;
NAS1291C HN II, 1 12B = 12 − point bolt

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STANDARD PRACTICE MANUAL

Table 202. Recommended Standard Thread Fasteners Torque


Section I. Locking Torque Values for Self−Locking Bolts, Screws and Nuts
Fine Thread Coarse Thread
Thread Recommended Maximum Thread Recommended Maximum
Size in−lb (N m) in−lb (N m) Size in−lb (N m) in−lb (N m)
− − − 0.1640−32 1.5 (0.16 N⋅m) 15 (1.69 N⋅m)
0.1900−32 2.0 (0.22 N⋅m) 18 (2.03 N⋅m) 0.1900−24 2.0 (0.22 N⋅m) 18 (2.03 N⋅m)
0.2500−28 3.5 (0.39 N⋅m) 30 (3.38 N⋅m) 0.2500−20 4.5 (0.50 N⋅m) 30 (3.38 N⋅m)
0.3125−24 6.5 (0.73 N⋅m) 60 (6.77 N⋅m) 0.3125−18 7.5 (0.84 N⋅m) 60 (6.77 N⋅m)
0.3750−24 9.5 (1.07 N⋅m) 80 (9.03 N⋅m) 0.3750−16 12.0 (1.35 N⋅m) 80 (9.03 N⋅m)
0.4375−20 14 (1.58 N⋅m) 100 (11.29 N⋅m) 0.4375−14 16.5 (1.86 N⋅m) 100 (11.29 N⋅m)
0.5000−20 18 (2.03 N⋅m) 150 (16.94 N⋅m) 0.5000−13 24 (2.71 N⋅m) 150 (16.94 N⋅m)
0.5625−18 24 (2.71 N⋅m) 200 (22.59 N⋅m) 0.5625−12 30 (3.38 N⋅m) 200 (22.59 N⋅m)
0.6250−18 32 (3.61 N⋅m) 300 (33.88 N⋅m) 0.6250−11 40 (4.51 N⋅m) 300 (33.88 N⋅m)
0.7500−16 50 (5.64 N⋅m) 400 (45.18 N⋅m) 0.7500−10 60 (6.77 N⋅m) 400 (45.18 N⋅m)
0.8750−14 70 (7.9 N⋅m) 600 (67.77 N⋅m) 0.8750−9 82 (9.26 N⋅m) 600 (67.77 N⋅m)
1.0000−12 90 (10.16 N⋅m) 800 (90.36 N⋅m) 1.0000−8 110 (12.42 N⋅m) 800 (90.36 N⋅m)
1.1250−12 117 (13.21 N⋅m) 900 (101.66 N⋅m) − − −
1.2500−12 143 (16.15 N⋅m) 1,000 (112.96 N⋅m) − − −

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STANDARD PRACTICE MANUAL

Table 202. Recommended Standard Thread Fasteners Torque (Cont.)


Section II. Torque Values for Fine Thread Fasteners (125,000 to 145,000 psi)
Shear Tension
Column Number 1 Column Number 2
Recommended Maximum Recommended Maximum
Thread Size in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m)
0.1900−32 12−15 25 20−25 40
(1.35−1.69 N⋅m) (2.82 N⋅m) (2.25−2.82 N⋅m) (4.51 N⋅m)
0.2500−28 30−40 60 50−70 100
(3.38−4.51 N⋅m) (6.77 N⋅m) (5.64−7.90 N⋅m) (11.29 N⋅m)
0.3125−24 60−85 140 100−140 225
(6.77−9.6 N⋅m) (15.81 N⋅m) (11.29−15.81 N⋅m) (25.41 N⋅m)
0.3750−24 95−110 240 160−190 390
(10.73−11.29 N⋅m) (27.11 N⋅m) (18.07−21.46 N⋅m) (44.05 N⋅m)
0.4375−20 270−300 500 450−500 840
(30.49−33.88 N⋅m) (56.48 N⋅m) (50.83−56.48 N⋅m) (94.88 N⋅m)
0.5000−20 290−410 660 480−690 1,100
(32.75−46.31 N⋅m) (74.55 N⋅m) (54.22−77.94 N⋅m) (124.25 N⋅m)
0.5625−18 480−600 960 800−1,000 1,600
(54.22−67.77 N⋅m) (108.44 N⋅m) (90.36−112.96 N⋅m) (180.73 N⋅m)
0.6250−18 660−780 1,400 1,100−1,300 2,400
(74.55−88.1 N⋅m) (158.14 N⋅m) (124.25−146.84 N⋅m) (271.1 N⋅m)
0.7500−16 1,300−1,500 3,000 2,300−2,500 5,000
(146.84−169.44 N⋅m) (338.88 N⋅m) (259.8−282.4 N⋅m) (564.8 N⋅m)
0.8750−14 1,500−1,800 4,200 2,500−3,000 7,000
(169.44−203.32 N⋅m) (474.43 N⋅m) (282.4−338.88 N⋅m) (790.72 N⋅m)
1.0000−12 2,200−3,300 6,000 3,700−5,500 10,000
(248.51−372.76 N⋅m) (677.76 N⋅m) (417.95−621.28 N⋅m) (1129.6 N⋅m)
1.1250−12 3,000−4,200 9,000 5,000−7,000 15,000
(338.88−474.43 N⋅m) (1016.64 N⋅m) (564.8−790.72 N⋅m) (1694.4 N⋅m)
1.2500−12 5,400−6,600 15,000 9,000−11,000 25,000
(609.98−745.53 N⋅m) (1694.4 N⋅m) (1016.64−1242.56 N⋅m) (2824. N⋅m)

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STANDARD PRACTICE MANUAL

Table 202. Recommended Standard Thread Fasteners Torque (Cont.)


Section III. Torque Values for Coarse Thread Fasteners (125,000 to 145,000 psi)
Shear Tension
Column Number 1 Column Number 2
Recommended Maximum Recommended Maximum
Thread Size in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m)
0.1640−32 7−9 12 12−15 20
(0.79−1.01 N⋅m) (1.35 N⋅m) (1.35−1.69 N⋅m) (2.25 N⋅m)
0.1900−24 12−15 21 20−25 35
(1.35−1.69 N⋅m) (2.37 N⋅m) (2.25−2.82 N⋅m) (3.95 N⋅m)
0.2500−20 25−30 45 40−50 75
(2.82−3.38 N⋅m) (5.08 N⋅m) (4.51−5.64 N⋅m) (8.47 N⋅m)
0.3125−18 48−55 100 80−90 160
(5.42−6.21 N⋅m) (11.29 N⋅m) (9.03−10.16 N⋅m) (18.07 N⋅m)
0.3750−16 95−110 170 160−185 275
(10.73−12.42 N⋅m) (19.2 N⋅m) (18.07−20.89 N⋅m) (31.06 N⋅m)
0.4375−14 140−155 280 235−255 475
(15.81−17.5 N⋅m) (31.62 N⋅m) (26.54−28.8 N⋅m) (53.65 N⋅m)
0.5000−13 240−290 520 400−480 880
(27.11−32.75 N⋅m) (58.73 N⋅m) (45.18−54.22 N⋅m) (99.4 N⋅m)
0.5625−12 300−420 650 500−700 1,100
(33.88−47.44 N⋅m) (73.42 N⋅m) (56.48−79.07 N⋅m) (124.25 N⋅m)
0.6250−11 420−540 900 700−900 1,500
(47.44−60.99 N⋅m) (101.66 N⋅m) (79.07−101.66 N⋅m) (169.44 N⋅m)
0.7500−10 700−950 1,500 1,150−1,600 2,500
(79.07−107.31 N⋅m) (169.44 N⋅m) (129.9−180.73 N⋅m) (282.4 N⋅m)
0.8750−9 1,300−1,800 2,700 2,200−3,000 4,600
(146.84−203.32 N⋅m) (304.99 N⋅m) (248.51−338.88 N⋅m) (519.61 N⋅m)
1.0000−8 2,200−3,000 4,500 3,700−5,000 7,600
(248.51−338.88 N⋅m) (508.32 N⋅m) (417.95−564.8 N⋅m) (858.49 N⋅m)
1.1250−8 3,300−4,000 7,200 5,500−6,500 12,000
(372.76−451.84 N⋅m) (813.31 N⋅m) (621.28−734.24 N⋅m) (1355.52 N⋅m)
1.2500−8 4,000−5,000 10,000 6,500−8,000 16,000
(451.84−564.8 N⋅m) (1129.6 N⋅m) (734.24−903.68 N⋅m) (1807.36 N⋅m)

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STANDARD PRACTICE MANUAL

Table 202. Recommended Standard Thread Fasteners Torque (Cont.)


Section IV. Torque Values for Thread Fasteners (160,000 to 180,000 psi)
Shear Tension
Column Number 1 Column Number 2
Recommended Maximum Recommended Maximum
Thread Size in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m)
0.1640−32 − − 15−25 30
(1.69−2.82 N⋅m) (3.38 N⋅m)
0.1900−32 12−15 25 36−46 50
(1.35−1.69 N⋅m) (2.82 N⋅m) (4.06−5.19 N⋅m) (5.64 N⋅m)
0.2500−28 30−40 60 70−90 125
(3.38−4.51 N⋅m) (6.77 N⋅m) (7.9−10.1 N⋅m) (14.12 N⋅m)
0.3125−24 60−85 140 130−180 250
(6.77−9.6 N⋅m) (15.81 N⋅m) (14.69−20.34 N⋅m) (28.24 N⋅m)
0.3750−24 95−110 240 220−360 430
(10.73−12.42 N⋅m) (27.11 N⋅m) (24.85−40.66 N⋅m) (48.57 N⋅m)
0.4375−20 270−300 500 370−610 925
(30.49−33.88 N⋅m) (56.48 N⋅m) (41.79−68.9 N⋅m) (104.48 N⋅m)
0.5000−20 290−410 660 650−950 1,250
(32.75−46.31 N⋅m) (74.55 N⋅m) (73.42−107.31 N⋅m) (141.2 N⋅m)
0.5625−18 480−600 960 1,000−1,300 1,650
(54.22−67.77 N⋅m) (108.44 N⋅m) (112.96−146.84 N⋅m) (186.38 N⋅m)
0.6250−18 660−780 1,400 1,400−1,700 2,400
(74.55−88.1 N⋅m) (158.14 N⋅m) (158.14−192.03 N⋅m) (271.1 N⋅m)
0.7500−16 1,300−1,500 3,000 2,400−3,100 4,600
(146.84−169.44 N⋅m) (338.88 N⋅m) (271.1−350.17 N⋅m) (519.61 N⋅m)
0.8750−14 1,500−1,800 4,200 3,700−4,100 6,100
(169.44−203.32 N⋅m) (474.43 N⋅m) (417.95−463.13 N⋅m) (689.05 N⋅m)
1.0000−12 2,200−3,300 6,000 5,100−7,900 11,500
(248.51−372.76 N⋅m) (677.76 N⋅m) (576.09−892.38 N⋅m) (1299.04 N⋅m)
1.1250−12 3,000−4,200 9,000 6,900−9,500 14,000
(338.88−474.43 N⋅m) (1016.64 N⋅m) (779.42−1073.12 N⋅m) (1581.44 N⋅m)
1.2500−12 5,400−6,600 15,000 11,500−14,000 21,000
(609.98−745.53 N⋅m) (1694.4 N⋅m) (1299.04−1581.44 N⋅m) (2372.16 N⋅m)

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STANDARD PRACTICE MANUAL

Table 202. Recommended Standard Thread Fasteners Torque (Cont.)


Section V. Torque Values for Fasteners with Phillips Recesses
Thread Size Recommended in−lb (N⋅m) Maximum in−lb (N⋅m)
0.1640 − 32 12−15 (1.35−1.69 N⋅m) 23 (2.59 N⋅m)
0.1900 − 32 20−25 (2.25−2.82 N⋅m) 35 (3.95 N⋅m)
0.2500 − 28 60−70 (6.77−7.90 N⋅m) 90 (10.16 N⋅m)
0.3125 − 24 110−125 (12.42−14.12 N⋅m) 150 (16.94 N⋅m)
0.3750 − 24 150−175 (16.94−19.76 N⋅m) 225 (25.41 N⋅m)
0.4375 − 20 230−280 (25.98−31.62 N⋅m) 450 (50.83 N⋅m)
0.5000 − 20 550−650 (62.12−73.42 N⋅m) 850 (96.01 N⋅m)
0.5625 − 18 750−900 (84.72−101.66 N⋅m) 1,200 (135.55 N⋅m)
0.6250 − 18 1,100−1,300 (124.25−146.84 N⋅m) 1,600 (180.73 N⋅m)

Table 203. Torque Values for Tube or Hose Assemblies


Section I. Torque Values for Flared Tube or Hose Assemblies
Aluminum Cres
Recommended Maximum Recommended Maximum
Tube Dash No. Tube O.D. in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m)
−2 0.1250 20 30 75 85
(2.25 N⋅m) (3.38 N⋅m) (8.47 N⋅m) (9.6 N⋅m)
−3 0.1875 25 35 95 105
(2.82 N⋅m) (3.95 N⋅m) (10.73 N⋅m) (11.86 N⋅m)
−4 0.2500 50 65 135 150
(5.64 N⋅m) (7.34 N⋅m) (15.24 N⋅m) (16.94 N⋅m)
−5 0.3125 70 90 170 200
(7.9 N⋅m) (10.16 N⋅m) (19.2 N⋅m) (22.59 N⋅m)
−6 0.3750 110 130 270 300
(12.42 N⋅m) (14.68 N⋅m) (30.49 N⋅m) (33.88 N⋅m)
−8 0.5000 230 260 450 500
(25.98 N⋅m) (29.36 N⋅m) (50.83 N⋅m) (56.48 N⋅m)
−10 0.6250 330 360 650 700
(37.27 N⋅m) (40.66 N⋅m) (73.42 N⋅m) (79.07 N⋅m)
−12 0.7500 460 500 900 1,000
(51.96 N⋅m) (56.48 N⋅m) (101.66 N⋅m) (112.96 N⋅m)
−16 1.0000 500 700 1,200 1,400
(56.48 N⋅m) (79.07 N⋅m) (135.55 N⋅m) (158.14 N⋅m)

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 203. Torque Values for Tube or Hose Assemblies (Cont.)


Section II. Torque Values for Flareless Tube or Hose Assemblies
Tubing (Inch) Aluminum Alloy Stainless and Titanium
Dash Recommended Maximum Recommended Maximum
No. O.D. Wall Thickness in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m)
0.1875 0.016 80 90
(9.03 N⋅m) (10.16 N⋅m)
0.018 80 90 95 105
−3
(9.03 N⋅m) (10.16 N⋅m) (10.73 N⋅m) (11.86 N⋅m)
0.020 95 105
(10.73 N⋅m) (11.86 N⋅m)

0.016 80 90
(9.03 N⋅m) (10.16 N⋅m)
0.020 95 105
(10.73 N⋅m) (11.86 N⋅m) 135 145
−4 0.2500
0.028 120 135 (15.24 N⋅m) (16.37 N⋅m)
(13.55 N⋅m) (15.24 N⋅m)
0.035 135 145
(15.24 N⋅m) (16.37 N⋅m)

0.3125 0.020 110 130


(12.42 N⋅m) (14.68 N⋅m)
0.028 120 135 150 175
−5
(13.55 N⋅m) (15.24 N⋅m) (16.94 N⋅m) (19.76 N⋅m)
0.035 135 145
(15.24 N⋅m) (16.37 N⋅m)

0.020 110 130


(12.42 N⋅m) (14.68 N⋅m)
0.028 120 135
(13.55 N⋅m) (15.24 N⋅m) 215 245
−6 0.3750
0.035 190 215 (24.28 N⋅m) (27.67 N⋅m)
(21.46 N⋅m) (24.28 N⋅m
0.042 190 215
(21.46 N⋅m) (24.28 N⋅m

0.020 190 215


(21.46 N⋅m) (24.28 N⋅m
0.028 290 310
(32.75 N⋅m) (35.01 N⋅m) 470 510
−8 0.5000
0.035 340 380 (53.09 N⋅m (57.60 N⋅m)
(38.4 N⋅m) (42.92 N⋅m)
0.049 340 380
(38.4 N⋅m) (42.92 N⋅m)

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STANDARD PRACTICE MANUAL

Table 203. Torque Values for Tube or Hose Assemblies (Cont.)


Section II. Torque Values for Flareless Tube or Hose Assemblies (Cont.)
Tubing (Inch) Aluminum Alloy Stainless and Titanium
Dash Recommended Maximum Recommended Maximum
No. O.D. Wall Thickness in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m)
0.020 340 380
(38.4 N⋅m) (42.92 N⋅m)
0.028 340 380
(38.4 N⋅m) (42.92 N⋅m)
0.035 380 450 620 680
−10 0.6250
(42.92 N⋅m) (50.83 N⋅m) (70.03 N⋅m) (76.81 N⋅m)
0.042 380 450
(42.92 N⋅m) (50.83 N⋅m)
0.049 380 450
(42.92 N⋅m) (50.83 N⋅m)
0.020 380 450
(42.92 N⋅m) (50.83 N⋅m)
0.028 380 450
(42.92 N⋅m) (50.83 N⋅m)
0.035 380 450
(42.92 N⋅m) (50.83 N⋅m) 855 945
−12 0.7500
0.042 400 470 (96.58 N⋅m) (106.74 N⋅m)
(45.18 N⋅m) (53.09 N⋅m)
0.049 400 470
(45.18 N⋅m) (53.09 N⋅m)
0.058 400 470
(45.18 N⋅m) (53.09 N⋅m)
0.020 470 530
(53.09 N⋅m) (59.86 N⋅m)
0.028 600 660
(67.77 N⋅m) (74.55 N⋅m)
0.035 640 700 1,140 1,260
−16 1.0000
(72.29 N⋅m) (79.07 N⋅m) (128.77 N⋅m) (142.32 N⋅m)

0.049 750 850


(84.72 N⋅m) (96.01 N⋅m)
0.065 1,140 1,260
(128.77 N⋅m) (142.32 N⋅m)

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STANDARD PRACTICE MANUAL

Table 204. Torque Values for Boss and Bulkhead Fittings


Section I. Torque Values for Fitting to Boss for Non−Positioning Union
Aluminum Steel
Tube
Dash Tube Recommended Maximum Recommended Maximum
No. O.D. Thread Size in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m)
−2 0.1250 0.3125−24 50 55 60 75
(5.64 N⋅m) (6.21 N⋅m) (6.77 N⋅m) (8.47 N⋅m)

−3 0.1875 0.3750−24 65 75 90 100


(7.34 N⋅m) (8.47 N⋅m) (10.16 N⋅m) (11.29 N⋅m)

−4 0.2500 0.4375−20 95 105 135 150


(10.73 N⋅m) (11.86 N⋅m) (15.24 N⋅m) (16.94 N⋅m)

−5 0.3125 0.5000−20 125 135 180 200


(14.12 N⋅m) (15.24 N⋅m) (20.33 N⋅m) (22.59 N⋅m)

−6 0.3750 0.5625−18 155 165 270 300


(17.5 N⋅m) (18.63 N⋅m) (30.49 N⋅m) (33.88 N⋅m)

−8 0.5000 0.7500−16 280 305 400 450


(31.62 N⋅m) (34.45 N⋅m) (45.18 N⋅m) (50.83 N⋅m)

−10 0.6250 0.8750−14 380 405 670 700


(42.92 N⋅m) (45.74 N⋅m) (75.68 N⋅m) (79.07 N⋅m)

−12 0.7500 1.0625−12 550 600 900 1000


(62.12 N⋅m) (67.77 N⋅m) (101.66 N⋅m) (112.96 N⋅m)

−16 1.000 1.3125−12 800 900 1200 1400


(90.36 N⋅m) (101.66 N⋅m) (135.55 N⋅m) (158.14 N⋅m)

Page 212
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STANDARD PRACTICE MANUAL

Table 204. Torque Values for Boss and Bulkhead Fittings (Cont.)
Section II. Torque Values for Fitting to Boss for Positioning Universal Fitting
Aluminum Steel
Tube
Dash Tube Recommended Maximum Recommended Maximum
No. O.D. Thread Size in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m) in−lb (N⋅m)
−2 0.1250 0.3125−24 22 24 25 35
(2.48 N⋅m) (2.71 N⋅m) (2.82 N⋅m) (3.95 N⋅m)

−3 0.1875 0.3750−24 28 32 50 75
(3.16 N⋅m) (3.61 N⋅m) (5.64 N⋅m) (8.47 N⋅m)

−4 0.2500 0.4375−20 38 42 55 80
(4.29 N⋅m) (4.74 N⋅m) (6.21 N⋅m) (9.03 N⋅m)

−5 0.3125 0.5000−20 58 63 75 100


(6.55 N⋅m) (7.11 N⋅m) (8.47 N⋅m) (11.29 N⋅m)

−6 0.3750 0.5625−18 70 80 100 150


(7.9 N⋅m) (9.03 N⋅m) (11.29 N⋅m) (16.94 N⋅m)

−8 0.5000 0.7500−16 145 155 180 230


(16.37 N⋅m) (17.5 N⋅m) (20.33 N⋅m) (25.98 N⋅m)

−10 0.6250 0.8750−14 190 210 250 350


(21.46 N⋅m) (23.72 N⋅m) (28.24 N⋅m) (39.53 N⋅m)

−12 0.7500 1.0625−12 285 315 420 600


(32.19 N⋅m) (35.58 N⋅m) (47.44 N⋅m) (67.77 N⋅m)

−16 1.000 1.3125−12 475 525 600 840


(53.65 N⋅m) (59.3 N⋅m) (67.77 N⋅m) (94.88 N⋅m)

Section III. Torque Values for Bulkhead Fitting Installation


Tube Bulkhead Hole Recommended Maximum
Dash No. Tube O.D. Thread Size Diameter Inch in−lb (N⋅m) in−lb (N⋅m)
−2 0.1250 0.3125−24 0.318 to 0.338 35 (3.95 N⋅m) 50 (5.64 N⋅m)
−3 0.1875 0.3750−24 0.380 to 0.400 65 (7.34 N⋅m) 80 (9.03 N⋅m)
−4 0.2500 0.4375−20 0.443 to 0.463 85 (9.6 N⋅m) 105 (11.86 N⋅m)
−5 0.3125 0.5000−20 0.505 to 0.525 105 (11.86 N⋅m) 125 (14.12 N⋅m)
−6 0.3750 0.5625−18 0.568 to 0.588 120 (13.55 N⋅m) 150 (16.94 N⋅m)
−8 0.5000 0.7500−16 0.755 to 0.775 240 (27.11 N⋅m) 280 (31.62 N⋅m)
−10 0.6250 0.8750−14 0.880 to 0.900 320 (36.14 N⋅m) 380 (42.92 N⋅m)
−12 0.7500 1.0625−12 1.068 to 1.088 500 (56.48 N⋅m) 600 (67.77 N⋅m)
−16 1.0000 1.3125−12 1.318 to 1.338 720 (81.33 N⋅m) 880 (99.4 N⋅m)

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STANDARD PRACTICE MANUAL

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STANDARD PRACTICE MANUAL

Section

20−20−00
Cleaning
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

CLEANING
MAINTENANCE PRACTICES
1. General (4). Use a clean dry non-lint cloth (C802) in
the other hand to clean up immediately.
Commercial Cleaning Agents
CAUTION NOTE: Replace both cleaning and drying cloths
frequently to prevent contamination from
General cleaning of oil and dirt deposits from dirty cloths. Discard dirty cloths in nonflam­
the rotorcraft and its components can be done mable safety containers.
with dry-cleaning solvent, standard commer­
cial-grade kerosene, or a solution of detergent (5). Subsequent applications of solvent and
soap and water. Exceptions that must be wiping must be made until there is no
obeyed are specified in this section. visible dirt on the last cloth used.

Storage, use, and disposal of all B. Environmental Sealing Cleaning


CAUTION solvents must obey government
and local health and safety regulations. Consumable Materials
(Ref. Section 91−00−00)
2. Cleaning Methods Item Nomenclature

A. General Cleaning
C420 Solvent, Cleaning
C425 Solvent, Cleaning
C802 Cloth, Non−Lint
Consumable Materials
(Ref. Section 91−00−00)
Item Nomenclature (1). Remove adhesive from parts with a
C420 Solvent, Cleaning nonmetallic scraper.
C425 Solvent, Cleaning Solvent, Cleaning (C425)
C802 Cloth, Non−Lint

(1). Remove adhesive from parts with a


nonmetallic scraper. Solvent, Cleaning (C420)
Solvent, Cleaning (C425)

(2). Clean the surface with a clean non-lint


cloth (C802) moistened with cleaning
Solvent, Cleaning (C420) solvent (C425).
NOTE: For hard-to-clean areas, cleaning sol­
vent (C420) can be used.
(3). Surfaces must be wiped dry before the
(2). Clean surface with a clean non-lint solvent evaporates.
cloth (C802) moistened with cleaning
solvent (C425). (4). Use a clean dry non-lint cloth (C802) in
the other hand to clean up immediately.
NOTE: For hard-to-clean areas, cleaning sol­
vent (C420) can be used. NOTE: Replace both cleaning and drying cloths
frequently to prevent contamination from
(3). Surfaces must be wiped dry before the dirty cloths. Discard dirty cloths in nonflam­
solvent evaporates. mable safety containers.

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STANDARD PRACTICE MANUAL

(5). Subsequent applications of solvent and Solvent, Cleaning (C423)


wiping must be made until there is no
visible dirt on the last cloth used.

NOTE: Cleaned surfaces must be protected


from contamination if left exposed for peri­ Do not let the bearing turn
ods longer than 10 minutes before sealant WARNING (spin) during the spray
applications. cleaning procedure.

NOTE:
C. Transparent Plastic Cleaning
D The vapor degreasing solvent must be
cleaning solvent (C423), or another suit­
(1). Clean outside surfaces of plastic panels able chlorinated or fluorinated hydrocar­
with a rinse of clean water and lightly bon.
rub with the palm of your hand.
D As necessary, use an air-operated de­
greaser hand-spray gun to remove heavy
(2). Use a mild soap and water solution or deposits of contaminants (grease).
aircraft-type plastic cleaner to remove
oil spots and similar residue. (1). To place degreaser in operation, proceed
as follows:
Do not dry the plastic panels (a). Turn on cooling coils for vapor level
CAUTION with a cloth. This can cause control.
abrasive particles on the panel surface to
scratch or dull the plastic. Electrostatic (b). Turn on steam or electric power for
charges can also build-up, which will at­ heating coils.
tract dust particles.
(c). Adjust heat to maintain a vapor level
above the bottom coil of the cooling
(3). After dirt is removed from the plastic
coil and no higher than the second
surfaces, rinse with clean water.
coil up from the bottom.

(4). Let surfaces dry in air. (d). Adjust water flow rate through the
vapor level control coils to maintain a
water outlet temperature of 110 to
(5). Clean inside surfaces of plastic panels 125°F (43 to 52°C).
with an aircraft-type plastic cleaner
and tissue-quality paper wipes. NOTE: Clean gloves shall be worn whenever
handling bearing parts.
D. Bearing Cleaning — Standard Method (2). Immerse parts in degreaser vapors for
(Vapor Degreaser) 2 minutes minimum.

(3). Raise parts to a point above the vapor


Consumable Materials level, and allow to cool.
(Ref. Section 91−00−00)
Item Nomenclature NOTE: Vapors should condense on the part
upon re-immersion in the vapor. If con­
C111 Oil
densation does not occur, part has not cooled
C423 Solvent, Cleaning long enough.
C432 Cleaner
(4). Repeat steps (2). and (3). a minimum of
C434 Solvent three times to make sure complete
removal of contaminants.

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Cleaner (C432) Make sure to carefully put in


CAUTION the grease and to not put in too
much. Over-lubrication or “lump packing”
can increase friction, and in some condi­
tions, can cause rough operation.

(5). Immediately immerse the parts in 2). Do not put too much grease in the
cleaner (C432). bearing.
(b). Tool Pack:
(a). Agitate the parts to make sure all
surfaces are contacted by cleaner Grease (C104)
(C432).

(b). Drain completely and immediately go


to Step (6).
1). Use a bearing packing tool to apply
Solvent (C434) a uniform coating of grease (C104)
in the bearing.
2). Use the minimum pressure neces­
sary to sufficiently go into all sides
of the bearing.
Oil (C111)
E. Bearing Cleaning — Alternate Method

Consumable Materials
(Ref. Section 91−00−00)
Item Nomenclature
(6). Immerse parts in a solution of 90 parts
of solvent (C434) and 10 parts of C423 Solvent, Cleaning
preservative oil (C111).
Do not let the bearing turn
(7). Dry parts in forced air oven at 120 to WARNING (spin) during the spray
130°F (49 to 55°C) for 5 to 7 minutes
cleaning procedure.
or until no solvent odor is noticeable.
NOTE:
(8). Use grease (C104) that is used in the
D Clean gloves must be worn whenever you
bearing to immediately lubricate the
touch bearing parts.
bearings with one of two methods:
D As necessary, use an air-operated de­
D Hand Pack (ref. Procedure greaser hand-spray gun to remove heavy
2.D.(8).(a).) or deposits of contaminants (grease).
D Tool Pack (ref. Procedure 2.D.(8).(b).) Solvent, Cleaning (C423)

(a). Hand Pack:

Grease (C104)
(1). Immerse bearing parts in a metal
container filled with cleaning solvent
(C423) at room temperature.
(2). Agitate parts manually until all visible
1). Force by hand grease (C104) in the foreign material has been removed from
bearing. the parts surface.

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(3). Drain fluid from container and replace Grease (C104)


with clean solvent.

(4). Do steps (1). and (2). again.

(5). Oven dry bearings for 10 to 15 min­ 1). Use a bearing packing tool to apply
utes at 120 to 130°F (49 to 55°C). a uniform coating of grease (C104)
in the bearing.
Grease (C104)
2). Use the minimum pressure neces­
sary to sufficiently go into all sides
of the bearing.
F. Titanium Metals Cleaning
(6). Use grease (C104) that is used in the
bearing to immediately lubricate the
bearings with one of two methods: Consumable Materials
(Ref. Section 91−00−00)
D Hand Pack (ref. Procedure Item Nomenclature
2.E.(6).(a).) or C420 Solvent, Cleaning
D Tool Pack (ref. Procedure 2.E.(6).(b).) C421 Solvent, Cleaning

(a). Hand Pack: Solvent, Cleaning (C420)


Grease (C104)

Solvent, Cleaning (C421)

1). Force by hand grease (C104) in the


bearing.

Make sure to carefully put in


CAUTION the grease and to not put in too CAUTION
Do not use steel wool, iron
scrapers, or steel brushes. Dam­
much. Over-lubrication or “lump packing”
age to the titanium can occur.
can increase friction, and in some condi­
tions, can cause rough operation. Do not use chlorinated solvents.
CAUTION Damage to the titanium can
2). Do not put too much grease in the occur.
bearing.
(1). Wipe with cleaning solvent (C420) or
(b). Tool Pack: cleaning solvent (C421) and a clean rag.

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3. Fuselage Interior Trim and Upholstery panels with a mild soap and lukewarm
water solution.
A. Fuselage Interior Trim and Upholstery
Cleaning
(a). Avoid complete soaking of upholstery
Carpet cleaning agents may and trim panels.
CAUTION damage underlying metal or
composite surfaces. Carpet or seats must be (b). Wipe solution residue from uphol­
removed from helicopter prior to cleaning stery with cloth dampened with clean
and allowed to air dry prior to reinstalla­ water.
tion.
(1). Clean dirt or dust accumulations from Use solvents sparingly. Some
floors and other metal surfaces with a CAUTION solvents can soften or dull mate­
vacuum cleaner or a small hand brush. rial. Test an inconspicuous area before use.
Flammable solvent that can af­
CAUTION fect material flammability must (3). Remove imbedded grease or dirt from
be removed completely after cleaning. upholstery and carpeting by sponging
or wiping with an upholstery cleaning
(2). Sponge soiled upholstery and trim solvent.

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4. Rotorcraft Exterior (3). Remove water that has collected on the


surfaces and nacelles of the rotorcraft.
A. Clean the Main Rotor Blades
(4). Dry the rotorcraft.
Do not bend the blades or blade
CAUTION tabs during cleaning. Damage
(5). Apply a corrosion preventive compound
to the blades can occur. (C219) to areas on rotorcraft vulnerable
Carefully clean the main rotor to corrosion (ref. Section 20-40-00).
CAUTION blades. Do not use volatile sol­
C. Rotorcraft Wash
vents or abrasive materials. Scratches to
the fiberglass skin can occur. NOTE: Do a rotorcraft wash with fresh water
Do not point high-pressure con­ every 14 days during operation in a corro­
CAUTION centrations of soap and/or clean sive environment (abrasive dust, acidic or
water at the engine air intake areas, instru­ high-mineral-content soils, agricultural
ment static source ports, and main rotor agents, extreme temperatures, industrial
swashplate bearings. Damage to compo­ air pollution, or salt water).
nents and/or a decrease in performance or
Do not use a high-pressure hose
incorrect indications can occur. CAUTION to clean the rotorcraft. Damage
(1). Clean rotor blades when necessary with to the rotorcraft and components can occur.
a solution of clean water and mild soap.
Do not let cleaning solutions or
B. Rotorcraft Rinse CAUTION water get in drains, pipes, or
ports. Contamination or blockage of systems
NOTE: Do a rotorcraft rinse with fresh water can occur, especially in cold temperatures.
every day during operation in a corrosive
environment (abrasive dust, acidic or high- (1). Clean the rotorcraft with clean, fresh
mineral-content soils, agricultural agents, water and a soft fan spray pattern to
extreme temperatures, industrial air pollu­ avoid damage and water intrusion.
tion, or salt water).
NOTE: Use a water flow rate of approximately
Do not use a high-pressure hose
CAUTION to clean the rotorcraft. Damage 8 gallons/minute (30.28 liters/minute)
with a supply pressure of 20 to 25 psi
to the rotorcraft and components can occur. (137.90 to 172.37 kPa).
Do not let cleaning solutions or
CAUTION water get in drains, pipes, or
(2). Use a solution of clean fresh water and
mild soap to clean the exterior of the
ports. Contamination or blockage of systems
rotorcraft.
can occur, especially in cold temperatures.
(1). Clean the rotorcraft with clean, fresh (3). If necessary, clean system specific
water and a soft fan spray pattern to components.
avoid damage and water intrusion.
NOTE: Obey instructions in this section so
NOTE: Use a water flow rate of approximately parts and finishes are not damaged.
8 gallons/minute (30.28 liters/minute)
with a supply pressure of 20 to 25 psi (4). Remove water that has collected on the
(137.90 to 172.37 kPa). surfaces and nacelles of the rotorcraft.

(2). If necessary, clean system specific (5). Dry the rotorcraft.


components.
(6). Apply a corrosion preventive compound
NOTE: Obey instructions in this section so (C219) to areas on rotorcraft vulnerable
parts and finishes are not damaged. to corrosion (ref. Section 20-40-00).

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5. Lubrication and Cooling System


Special Tools
A. Cooling Ducts Cleaning (Ref. Section 91−00−00)
Item Nomenclature
T308 Ultrasonic Cleaner Tank
Consumable Materials
(Ref. Section 91−00−00)
Item Nomenclature Solvent (C434)
C802 Cloth, Non−Lint

(1). Use a clean non-lint cloth (C802) and


cotton swabs moistened with a mild (1). Place heat exchanger in ultrasonic
soap and water solution. cleaner tank (T308) and fill with
solvent (C434) at room temperature.
(2). Rinse cleaned parts with fresh water. (2). Run ultrasonic tank for a minimum of 5
minutes.
(3). Dry parts with a clean non-lint cloth
(C802) and cotton swabs. (3). Remove heat exchanger and flow
filtered, oil-free, nitrogen gas or
B. Shroud, Housing Assembly, and Impeller compressed air through heat exchanger
Cleaning until dry.
(4). Dry heat exchanger in a hot air oven
Consumable Materials for a minimum of 1 hour at 200°F
(Ref. Section 91−00−00) (93°C).
Item Nomenclature (5). Remove heat exchanger from oven and
C802 Cloth, Non−Lint allow heat exchanger to return to room
C434 Solvent temperature in a clean dry condition.
D. Heat Exchanger External Cleaning
Solvent (C434)
Consumable Materials
(Ref. Section 91−00−00)
Item Nomenclature
C802 Cloth, Non−Lint
C434 Solvent
(1). Use a clean non-lint cloth (C802) and
cotton swabs moistened with solvent
(C434). (1). Cap and/or plug all openings on heat
exchanger.
(2). Dry parts with a clean non-lint cloth Solvent (C434)
(C802) and cotton swabs.

C. Heat Exchanger Internal Cleaning

Consumable Materials (2). Use a clean non-lint cloth (C802) and


(Ref. Section 91−00−00) cotton swabs moistened with solvent
Item Nomenclature (C434).
C434 Solvent (3). Dry parts with a clean non-lint cloth
(C802) and cotton swabs.

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6. Air−Conditioning System (15). Install expansion valve (ref.


CSP-900RMM-2, Section 21-50-00).
A. Evaporator Internal Cleaning
B. Evaporator External Cleaning
Consumable Materials
(Ref. Section 91−00−00) Consumable Materials
Item Nomenclature (Ref. Section 91−00−00)
Item Nomenclature
C434 Solvent
C434 Solvent

(1). Remove expansion valve (ref.


CSP-900RMM-2, Section 21-50-00). (1). Remove expansion valve (ref.
CSP-900RMM-2, Section 21-50-00).
(2). Install adapters in inlet and outlet
ports. (2). Blow clean compressed air at 50 to 70
psig (344 to 482 kPa) through cooling
(3). Install a 100-mesh screen at inlet and fins in opposite direction of usual air
outlet ports. flow.

Solvent (C434) (3). Blow clean compressed air at 50 to 70


psig (344 to 482 kPa) through cooling
fins in direction of usual air flow.
(4). Do steps (2). and (3). again.

(4). Supply solvent (C434) through evapora­ (5). If necessary, remove blockage from inlet
tor at a flow rate of 26.5 gallon/min­ air fins with a nylon brush.
ute (100 liter/minute) and 50 psig
(345 kPa) to outlet port. (6). Do steps (2). and (3). again.
Solvent (C434)
(5). After 30 minutes, examine screen at
inlet port for unwanted materials.
(6). If necessary, remove unwanted materi­
als from screen.
(7). Put evaporator in solvent (C434) and
(7). Supply solvent (C434) through evapora­ shake.
tor at a flow rate of 26.5 gallon/min­
ute (100 liter/minute) and 50 psig (8). Dry with clean compressed air at 50 to
(345 kPa) to inlet port. 70 psig (344 to 482 kPa).

(8). After 30 minutes, examine screen at (9). Install expansion valve (ref.
outlet port for unwanted materials. CSP-900RMM-2, Section 21-50-00).

(9). If necessary, remove unwanted materi­ C. Condenser Internal Cleaning


als from screen.
Consumable Materials
(10). Do steps (4). thru (9). until there is no
(Ref. Section 91−00−00)
unwanted material on the screens.
Item Nomenclature
(11). Remove 100-mesh screens. C434 Solvent

(12). Remove adapters.


(1). Install adapters in inlet and outlet
(13). Drain solvent (C434) from evaporator. ports.
(14). Immediately install plugs in inlet and (2). Install a 100-mesh screen at inlet and
outlet ports. outlet ports.

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Solvent (C434) (3). Do steps (1). and (2). again.

(4). If necessary, remove blockage from inlet


air fins with a nylon brush.

(5). Do steps (1). and (2). again.


(3). Supply solvent (C434) through condens­
er at a flow rate of 26.5 gallon/minute Solvent (C434)
(100 liter/minute) and 50 psig (345
kPa) to outlet port.

(4). After 30 minutes, examine screen at


inlet port for unwanted materials.
(6). Put condenser in solvent (C434) and
(5). If necessary, remove unwanted materi­ shake.
als from screen.
(7). Dry with clean compressed air at 50-70
(6). Supply solvent (C434) through condens­ psig (344-482 kPa).
er at a flow rate of 26.5 gallon/minute
(100 liter/minute) and 50 psig (345 E. Hose and Tube Internal Cleaning
kPa) to inlet port.

(7). After 30 minutes, examine screen at Consumable Materials


outlet port for unwanted materials. (Ref. Section 91−00−00)
Item Nomenclature
(8). If necessary, remove unwanted materi­
C434 Solvent
als from screen.

(9). Do steps (3). thru (8). until there is no


(1). Disconnect hoses from compressor (ref.
unwanted material on the screens.
CSP-900RMM-2, Section 21-50-00).
(10). Remove 100-mesh screens.
(2). Disconnect tubes from evaporator (ref.
(11). Remove adapters. CSP-900RMM-2, Section 21-50-00).

(12). Drain solvent (C434) from evaporator. (3). Connect an applicable hose and fittings
to the tubes disconnected from evapora­
(13). Immediately install plugs in inlet and tor.
outlet ports.
(4). Disconnect tubes from condenser(s) (ref.
D. Condenser External Cleaning CSP-900RMM-2, Section 21-50-00).

(5). Connect an applicable hose and fittings


Consumable Materials to the tubes disconnected from condens­
(Ref. Section 91−00−00) er(s).
Item Nomenclature
C434 Solvent (6). Remove receiver dehydrator.

(7). Connect an applicable hose and fittings


(1). Blow clean compressed air at 50 to 70 to the tubes disconnected from receiver
psig (344 to 482 kPa) through cooling dehydrator.
fins in opposite direction of usual air
flow. (8). Install adapters in hoses disconnected
from compressor.
(2). Blow clean compressed air at 50 to 70
psig (344 to 482 kPa) through cooling (9). Install a 100-mesh screen at inlet and
fins in direction of usual air flow. outlet hoses.

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Solvent (C434) (19). Drain solvent (C434) from hoses and


tubes.
(20). Blow clean compressed air at 50 to 70
psig (344 to 482 kPa) through hoses
and tubes. Blow air into inlet hose until
(10). Supply solvent (C434) through hoses there is no more solvent.
and tubes at a flow rate of 26.5 gallon/
minute (100 liter/minute) and 50 (21). Blow clean compressed air at 50 to 70
psig (345 kPa) to inlet hose. psig (344 to 482 kPa) through hoses
and tubes. Blow air into outlet hose
(11). After 30 minutes, examine screen at until there is no more solvent.
outlet hose for unwanted materials.
(22). Immediately connect inlet and outlet
(12). If necessary, remove unwanted materi­ hoses to compressor (ref.
als from screen. CSP-900RMM-2, Section 21-50-00).

(13). Supply solvent (C434) through hoses (23). Remove hose and fittings from tubes
and tubes at a flow rate of 26.5 gallon/ disconnected from evaporator and
minute (100 liter/minute) and 50 immediately connect tubes to evapora­
psig (345 kPa) to outlet hose. tor (ref. CSP-900RMM-2, Section
21-50-00).
(14). After 30 minutes, examine screen at
inlet hose for unwanted materials. (24). Remove hose and fittings from tubes
disconnected from condenser(s) and
(15). If necessary, remove unwanted materi­ immediately connect tubes to condens­
als from screen. er(s) (ref. CSP-900RMM-2, Section
21-50-00).
(16). Do steps (10). thru (15). until there is
no unwanted material on the screens. (25). Remove hose and fittings from tubes
disconnected from receiver dehydrator
(17). Remove 100-mesh screens. and immediately connect tubes to new
receiver dehydrator (ref.
(18). Remove adapters. CSP-900RMM-2, Section 21-50-00).

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Section

20−30−00
Paint
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

PAINT
MAINTENANCE PROCEDURES
1. Paint Repair (2). Vacuum area to remove unwanted
materials.
A. Small Sanded Areas (Repaired
Scratches, Nicks, Gouges, Etc.) (3). Repair paint (ref. Paint Repair - Small
Sanded Areas).
Consumable Materials C. Aluminum
(Ref. Section 91−00−00)
Item Nomenclature (1). If necessary, repair surface treatment
C423 Solvent, Cleaning to in repair area (ref. Section
20-40-00).

Solvent, Cleaning (C423) NOTE: Small repair areas do not have an effect
on lightning protection.
(2). Apply primer to match original.
(3). Apply topcoat to match original finish.
(1). Clean surface with cleaning solvent
(C423) or equivalent and dry immedi­ D. Titanium
ately.
(1). Clean titanium (ref. Section 20-20-00).
NOTE: Small repair areas do not have an effect
on lightning protection. 2. Primer Application
(2). Apply a thin layer of primer to match A. Epoxy Primer (MIL−PRF−23377, Type 1,
original finish. Class 2)
(3). Feather primer on adjacent color finish.
Consumable Materials
(4). Dry primer in air for 30 minutes. (Ref. Section 91−00−00)
Item Nomenclature
(5). Apply topcoat to match original finish.
C309 Primer
B. Loose or Dried Paint and Primer C431 Solvent

Consumable Materials Do not use primer (C309) on


(Ref. Section 91−00−00) CAUTION main rotor blades.
Item Nomenclature
C807 Sandpaper Primer (C309)

CAUTION
D Do not sand into or expose graphite/epoxy (1). Shake or mix primer (C309).
fibers.
D Do not use aluminum oxide abrasives on (2). Lightly mix catalyst.
graphite/epoxy materials. NOTE: Add catalyst to primer, never add prim­
D Do not sand into chemical film protection. er to catalyst.
(1). Sand surface smooth with adjacent (3). Add catalyst to primer and mix fully (ref.
area with sandpaper (C807). manufacturers instructions).

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Solvent (C431) B. Epoxy Primer (MDM15−1100, Type 1,


Class 2)

Consumable Materials
(Ref. Section 91−00−00)
Item Nomenclature
(4). After a minimum of 30 minutes, add
solvent (C431) as necessary and mix C301 Primer, Epoxy
fully. C430 Solvent Thinner

(5). Put the primer through a filter before Do not use epoxy primer (C301)
you use it. CAUTION on main rotor blades.
NOTE: Primer, Epoxy (C301)
D Epoxy primer must be shaken or mixed
again after 2 hours.
D You must not add new primer to primer
mixed before. (1). Shake or mix epoxy primer (C301).
D If you do not use epoxy primer in 8 hours, (2). Lightly mix catalyst.
you must discard it as dangerous un­
wanted material. NOTE: Add catalyst to primer, never add prim­
er to catalyst.
D Apply masking tape to electrical bond sur­
faces before you apply primer. (3). Add catalyst to primer and mix fully (ref.
manufacturers instructions).
D Electrical bond surfaces on aluminum ma­
terials can be identified by a gold, brown, Solvent Thinner (C430)
straw, or yellow surface color.
D Electrical bond surfaces on composite ma­
terials can be identified by an expanded
aluminum foil shielding (silver color). (4). Add solvent thinner (C430) as neces­
sary, to a maximum of 30 percent by
The total thickness of fairing volume and mix fully.
CAUTION compound, primer, and topcoat
on external surfaces must not be more than (5). After a minimum of 1 hour you can use
0.007 inch (7 mils) to make sure the Astro­ the mixed primer.
strikeT gives good lightning protection. (6). Put the primer through a filter before
you use it.
(6). Apply a thin layer of epoxy primer, total
dry film thickness must be 0.0006 to NOTE:
0.0010 inch (0.6 to 1.0 mils). D Epoxy primer must be shaken or mixed
again after 2 hours.
(7). Dry epoxy primer, use one of the D You must not add new primer to primer
procedures that follow: mixed before.
(a). Dry in air for a minimum of 1 hour. D If you do not use epoxy primer in 8 hours,
you must discard it as dangerous un­
wanted material.
Do not heat bonded assemblies
CAUTION more than 150°F (66°C). D Apply masking tape to electrical bond sur­
faces before you apply primer.
(b). Dry in air for a minimum of 30 D Electrical bond surfaces on aluminum ma­
minutes, then at 150°F (66°C) for terials can be identified by a gold, brown,
25 to 30 minutes. straw, or yellow surface color.

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D Electrical bond surfaces on composite ma­


CAUTION
terials can be identified by an expanded
aluminum foil shielding (silver color). D Do not use primer (C308) or primer
(C310) on main rotor blades.
D Deleted.
The total thickness of fairing
CAUTION Primer (C308)
compound, primer, and topcoat
on external surfaces must not be more than
0.007 inch (7 mils) to make sure the Astro­
strikeT gives good lightning protection.
Primer (C310)

(7). Apply a thin layer of epoxy primer, the


total dry film thickness must be 0.0008
to 0.0012 inch (0.8 to 1.2 mils).
(1). Shake or mix primer (C308) or primer
(C310).
(8). Dry epoxy primer, use one of the (2). Lightly mix catalyst.
procedures that follow: (3). Add catalyst to primer and mix fully (ref.
manufacturers instructions).
NOTE: Add catalyst to primer. Never add prim­
(a). Dry in air for a minimum of 1 hour. er to catalyst.
Solvent Thinner (C430)
Do not heat bonded assemblies
CAUTION
more than 150°F (66°C).

(4). After a minimum of 30 minutes, add 1


(b). Dry in air for a minimum of 30 to 1 1/2 volumes of solvent thinner
minutes, then at 150°F (66°C) for (C430) and mix fully.
25 to 30 minutes. (5). Put the primer through a filter before
you use it.
C. Epoxy Primer (MIL−PRF−23377, Type 1, NOTE:
Class 1 and 2; MIL−PRF−23377, Type 2, D Epoxy primer must be shaken or mixed
Class 1 and 2; MDM15−1100, Type 1, again after 2 hours.
Class 2) D You must not add new primer to primer
mixed before.
D If you do not use epoxy primer in 8 hours,
you must discard it as dangerous un­
Consumable Materials wanted material.
(Ref. Section 91−00−00) D Apply masking tape to electrical bond sur­
Item Nomenclature faces before you apply primer.
D Electrical bond surfaces on aluminum ma­
C308 Primer terials can be identified by a gold, brown,
C310 Primer straw, or yellow surface color.
D Electrical bond surfaces on composite ma­
C430 Solvent Thinner terials can be identified by an expanded
aluminum foil shielding (silver color).

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The total thickness of fairing NOTE: Do not add thinner to epoxy primer.
CAUTION compound, primer, and topcoat
on external surfaces must not be more than (5). Put the primer through a filter before
0.007 inch (7 mils) to make sure the Astro­ you use it.
strikeT gives good lightning protection.
NOTE:
(6). Apply a thin layer of primer (C308) or
D Epoxy primer must be shaken or mixed
primer (C310).
again after 2 hours.
(a). The total dry film thickness must be D You must not add new primer to primer
0.0006 to 0.0010 inch (0.6 to 1.0 mixed before.
mils).
D If you do not use epoxy primer in 4 hours,
(7). Dry primer (C308) or primer (C310) you must discard it as dangerous un­
with one of these procedures: wanted material.
D Apply masking tape to electrical bond sur­
(a). Dry in air for a minimum of 1 hour. faces before you apply primer.
Do not heat bonded assemblies D Electrical bond surfaces on aluminum ma­
CAUTION more than 150°F (66°C). terials can be identified by a gold, brown,
straw, or yellow surface color.
(b). Dry in air for a minimum of 5 to 6 D Electrical bond surfaces on composite ma­
minutes, then at 150°F (66°C) for terials can be identified by an expanded
25 to 30 minutes. aluminum foil shielding (silver color).
D. Epoxy Primer (MIL−PRF−23377, Type 2, The total thickness of fairing
Class 2) CAUTION compound, primer, and topcoat
on external surfaces must not be more than
Consumable Materials 0.007 inch (7 mils) to make sure the Astro­
(Ref. Section 91−00−00) strikeT gives good lightning protection.
Item Nomenclature
(6). Apply a thin layer of epoxy primer
C307 Primer, Epoxy (C307).

(a). The total dry film thickness must be


Do not use epoxy primer (C307)
CAUTION on main rotor blades.
0.0006 to 0.0010 inch (0.6 to 1.0
mils).
Primer, Epoxy (C307)
(7). Dry epoxy primer (C307) with one of
these procedures:

(a). Dry in air for a minimum of 1 hour.

(1). Shake or mix epoxy primer (C307). (b). For metal components - dry in air
for a minimum of 30 minutes, then
(2). Lightly mix catalyst. at 150°F (66°C) for 10 to 11 min­
utes.
(3). Add catalyst to primer and mix fully (ref.
manufacturers instructions). Do not heat bonded assemblies
CAUTION more than 150°F (66°C).
NOTE: Add catalyst to primer. Never add prim­
er to catalyst. (c). For bonded and laminated
components - dry in air for a
(4). After a minimum of 30 minutes you minimum of 30 minutes, then at
can use the mixed primer. 150°F (66°C) for 25 to 30 minutes.

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E. Epoxy Primer (MIL−PRF−85582, Type 1, D If you do not use epoxy primer in 8 hours,
Class 2) you must discard it as dangerous un­
wanted material.
Consumable Materials D Apply masking tape to electrical bond sur­
(Ref. Section 91−00−00) faces before you apply primer.
Item Nomenclature D Electrical bond surfaces on aluminum ma­
C317 Primer, Epoxy terials can be identified by a gold, brown,
C429 Solvent Cleaner straw, or yellow surface color.
C436 Acetone D Electrical bond surfaces on composite ma­
terials can be identified by an expanded
aluminum foil shielding (silver color).
Do not use epoxy primer (C317)
CAUTION on main rotor blades. (5). Apply a thin layer of epoxy primer
(C317).
Solvent Cleaner (C429)
(a). The total dry film thickness must be
0.0006 to 0.0010 inch (0.6 to 1.0
mils).

(6). Dry epoxy primer (C317) as follows:


(1). Clean surface with solvent cleaner
(C429) or equivalent and dry in air for a (a). Dry in air for a minimum of 1 hour.
minimum of 15 minutes.
Do not heat bonded assemblies
(2). Apply masking tape around repair area. CAUTION more than 150°F (66°C).
Primer, Epoxy (C317) (b). Dry in air for 5 to 6 minutes, then
at 130°F (55°C) for a minimum of 1
hour.

(c). Then at 150°F (66°C) for 25 to 30


Acetone (C436) minutes.

F. Epoxy Primer (MIL−PRF−23377, Type 1,


Class 1 and 2)

If you use epoxy primer (C317) Consumable Materials


CAUTION for wet installation of fasteners, (Ref. Section 91−00−00)
Item Nomenclature
thin epoxy primer (C317) with acetone
(C436) to make epoxy primer (C317) more li­ C318 Primer, Epoxy
quid. Do not use water. Corrosion can occur. C429 Solvent Cleaner

(3). Mix epoxy primer (C317) (ref. manufac­


turers instructions). Solvent Cleaner (C429)
(4). Put epoxy primer (C317) through a
filter before you use it.

NOTE:
D Epoxy primer must be shaken or mixed (1). Clean surface with solvent cleaner
(C429) or equivalent and dry in air for a
again after 2 hours.
minimum of 15 minutes.
D You must not add new primer to primer
mixed before. (2). Apply masking tape around repair area.

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Primer, Epoxy (C318) NOTE:


D Do not use polyurethane coating (C314)
on main rotor blades.
D If it has been more than 48 hours since
primer was applied, or heat was applied
(3). Mix epoxy primer (C318) (ref. manufac­ to dry primer, you must condition primer
turers instructions). before you apply topcoat.
(1). Condition primer as follows:
(4). Put epoxy primer (C318) through a
filter before you use it. (a). Lightly sand surface, use sandpaper
(C807) or finer.
NOTE: Solvent, Cleaning (C423)
D Epoxy primer must be shaken or mixed
again after 2 hours.
D You must not add new primer to primer
mixed before.
Solvent Cleaner (C429)
D If you do not use epoxy primer in 4 hours,
you must discard it as dangerous un­
wanted material.

(5). Apply a thin layer of epoxy primer (b). Fully clean surface with cleaning
(C318). solvent (C423) or solvent cleaner
(C429).
(a). The total dry film thickness must be
0.0006 to 0.0010 inch (0.6 to 1.0 (c). Apply a thin layer of epoxy primer,
mils). total dry-film thickness must be
0.0003 to 0.0006 inch (0.3 to 0.6
(6). Dry epoxy primer (C318) with one of mils).
these procedures: (d). Dry in air for a minimum of 1 to 2
hours.
(a). Dry in air for a minimum of 7 days.
Polyurethane Coating (C314)
Do not heat bonded assemblies
CAUTION more than 150°F (66°C).

(b). Dry in air for a minimum of 30


minutes, then at 150°F (66°C) for (2). Shake or mix polyurethane coating
25 to 30 minutes. (C314).
(3). Lightly mix catalyst.
3. Exterior Topcoat Application
(4). Add catalyst to polyurethane and mix
A. Polyurethane Coating (MIL−C−83286) fully (ref. manufacturers instructions).
NOTE: Add catalyst to polyurethane. Never
Consumable Materials add polyurethane to catalyst.
(Ref. Section 91−00−00) (5). Put the polyurethane coating through a
Item Nomenclature filter before you use it.
C314 Polyurethane Coating NOTE:
C423 Solvent, Cleaning D Use polyurethane coating no more than 1
C429 Solvent Cleaner hour after it is mixed.
C807 Sandpaper D Polyurethane coating must be shaken or
mixed again after 2 hours.

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D You must not add new polyurethane coa­ NOTE: Do not add thinner to enamel.
ting to polyurethane coating mixed be­
fore. Finish Enamel (C320)
D If you do not use polyurethane coating in
8 hours, you must discard it as danger­
ous unwanted material.

The total thickness of fairing Finish Enamel, Black (C303)


CAUTION compound, primer, and topcoat
on external surfaces must not be more than
0.007 inch (7 mils) to make sure the Astro­
striket gives good lightning protection.

(6). After no more than 1 hour, apply (2). Fully mix enamel components (ref.
polyurethane coating to a total dry-film manufacturers instructions).
thickness of 0.0014 to 0.0020 inch (1.4
to 2.0 mils). (3). Put the enamel coating through a filter
before you use it.
(7). Dry polyurethane coating in air for 30
minutes to 1 hour between layers. NOTE: If you do not use enamel coating in 4
hours, you must discard it as dangerous
(8). Dry polyurethane coating with one of unwanted material.
the procedures that follow:
Finish Enamel (C320)
(a). Dry in air for a minimum of 24
hours.

Do not heat bonded assemblies


CAUTION more than 150°F (66°C). Finish Enamel, Black (C303)
(b). Dry in air for 45 minutes, then at
150°F (66°C) for 50 to 55 minutes.

(c). Dry in air for 45 minutes, then at


110 to 130°F (43 to 55°C) for a
maximum of 2 hours. (4). Apply finish enamel (C320) or black
finish enamel (C303) to a total dry film
B. Finish Enamel Coating (MDM15−1100) thickness of 0.0017 to 0.0025 inch (1.7
to 2.5 mils).
Consumable Materials (5). Dry enamel with one of the procedures
(Ref. Section 91−00−00) that follow:
Item Nomenclature
C303 Finish Enamel, Black (a). Dry in air for a minimum of 8 hours.
C320 Finish Enamel
Do not heat rotor blade more
C429 Solvent Cleaner CAUTION than 160°F (71°C).

Solvent Cleaner (C429) (b). Dry in air for 30 minutes, then at


140 to 160°F (60 to 72°C) for 30 to
40 minutes.

(c). Dry in air for 30 minutes, then at


(1). Fully clean surface with solvent cleaner 120 to 130°F (49 to 55°C) for a
(C429) or equivalent. minimum of 1 hour.

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4. Main Rotor Hub 6. Main Rotor Blade


(Ref. Figure 201)
Consumable Materials
(Ref. Section 91−00−00) The procedures that follow can be done to
Item Nomenclature small areas where paint is missing from blade
surface. Paint must not have an unwanted
C302 Finish Enamel, White
effect on blade balance.
C317 Primer, Epoxy
A. Zone 1 and Zone 3

(1). Repair surface treatment for aluminum


alloy (ref. Section 20-40-00). Consumable Materials
(Ref. Section 91−00−00)
Primer, Epoxy (C317) Item Nomenclature
C317 Primer, Epoxy
C318 Primer, Epoxy
C429 Solvent Cleaner
C814 Abrasive Paper
(2). Apply epoxy primer (C317).
(1). Make repair area smooth with adjacent
Finish Enamel, White (C302)
surfaces with abrasive paper (C814) or
finer.
Solvent Cleaner (C429)

(3). Apply white finish enamel (C302).

5. Main Rotor Drive Plate and Drive Plate


Cover
(2). Clean repair area, use solvent cleaner
(C429) or equivalent.
Consumable Materials
(Ref. Section 91−00−00) (3). Dry in air for a minimum of 15 min­
Item Nomenclature utes.
C302 Finish Enamel, White (4). Apply masking tape around repair
C317 Primer, Epoxy area.
Primer, Epoxy (C317)
Primer, Epoxy (C317)

Primer, Epoxy (C318)


(1). Apply epoxy primer (C317).

Finish Enamel, White (C302)

(5). Apply epoxy primer (C317) or epoxy


primer (C318).
(6). Apply the top coat to the main rotor
(2). Apply white finish enamel (C302). blade (ref. Procedure 6.C.).

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ZONE 3
WARNING STRIPE

ZONE 1
ALL UPPER AND LOWER SURFACES, 8 IN
BUT NOT INBOARD AND OUTBOARD ZONE 2 (203 mm)
ABRASION STRIP AND WARNING STRIPE ZONE 2
INBOARD ABRASION STRIP OUTBOARD ABRASION STRIP
9P20−084

Figure 201. Main Rotor Blade Paint


B. Zone 2 — Inboard and Outboard Primer, Epoxy (C317)
Abrasion Strip

Consumable Materials
(Ref. Section 91−00−00) Primer, Epoxy (C318)
Item Nomenclature
C317 Primer, Epoxy
C318 Primer, Epoxy
C437 Cleaner, Alkaline (6). Apply epoxy primer (C317) or epoxy
C814 Abrasive Paper primer (C318).
C817 Pad, Scouring, Cellulose/Nylon (7). Apply the top to the main rotor blade
(ref. Procedure 6.C.).

(1). Make repair area smooth with adjacent C. Top Coat


surfaces with abrasive paper (C814) or
finer. Consumable Materials
(Ref. Section 91−00−00)
Cleaner, Alkaline (C437) Item Nomenclature
C303 Finish Enamel, Black
C317 Primer, Epoxy
C318 Primer, Epoxy
C320 Finish Enamel
C429 Solvent Cleaner
(2). Clean abrasion strips with alkaline
cleaner (C437) or equivalent.
Primer, Epoxy (C317)
(3). Flush abrasion strips with distilled
water and clean with scouring pad
(C817) or equivalent to remove un­
wanted material.
Primer, Epoxy (C318)
(4). Dry in air for a minimum of 30 min­
utes.

(5). Apply masking tape around repair (1). Apply epoxy primer (C317) or epoxy
area. primer (C318).

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NOTE: Do not clean area if top coat is applied (b). Rubber stamp inks
before primer is dry.
(c). Videojet printing inks (spray type)
Solvent Cleaner (C429)
(d). Inks that can be cured by ultraviolet
light
(2). Use a permanent marker (C829) to
apply handwritten markings that are
legible and consistent.
(2). Clean repair area with solvent cleaner
(C429) or equivalent. (3). Rubber stamp inks must be applied
with a rubber stamp.
(3). Dry in air for a minimum of 15 min­
utes. (4). Videojet printing inks must be applied
with a Videojet printing head.
Finish Enamel (C320)
(5). Inks that can be cured by ultraviolet
light must be applied with a jet print­
ing head and cured with an ultraviolet
light source.
Finish Enamel, Black (C303) (6). Surface area must be clean to make
sure sufficient ink adhesion is made.
(7). Components which will subsequently be
bonded will not require permanent ink
marking if the the final assembly is
NOTE: permanently identified.
D Paint upper surface white finish enamel
(C320) (color # 17773). (8). The character size for rubber stamps
must be sufficient to provide legible
D Paint lower surface flat black finish marking and applicable for the size of
enamel (C303)(color # 37030 or 37038). the part.
D Paint warning strip orange-yellow finish
enamel (C320)(color #13507) (9). The color of the ink must contrast with
the background color of the part or
(4). Apply finish enamel (C320) or black assembly.
finish enamel (C303).
(10). Permanent ink markings must be dried
7. Ink Marking at ambient temperature for a one hour
minimum before the component or
assembly is handled, tested, or pro­
Consumable Materials cessed to the next step.
(Ref. Section 91−00−00)
Item Nomenclature (11). A two-minute minimum dry time at
ambient temperature must be permit­
C321 Coating, Varnish
ted for the Videojet ink application.
C829 Marker, Permanent
Coating, Varnish (C321)
These requirements must be met for ink
marking:

(1). Ink must be one-component and


solvent based. Examples include: (12). Ink markings can be protected from
long-term exposure and erosion with a
(a). A permanent marker (C829) thin layer of varnish (C321).

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Section

20−40−00
Corrosion Control
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

CORROSION CONTROL
MAINTENANCE PRACTICES
1. Corrosion Control D Intergranular — The selective attack on
the grain boundaries in metals. An micro­
A. Introduction scopic inspection is necessary to find
intergranular corrosion.
Corrosion is the deterioration of a substance,
usually a metal, because of a reaction with the D Exfoliation — A form of intergranular
environment. Corrosion occurs when these four corrosion, exfoliation occurs along the grain
components meet: boundaries and essentially parallel to the
surface. This leads to actual separation of
D An anode the grains, leaving the metal in a laminated,
flaky, or blistered condition.
D A cathode
D Stress Corrosion Cracking — Can be
D An electrolyte (water is the most common attributed to the combined effects of a stress
electrolyte) (applied or residual) and corrosive environ­
ment.
D A metallic path for the electrons to flow D Corrosion Fatigue — Similar to stress
though corrosion, corrosion fatigue is caused by the
combined effects of a corrosive environment
Corrosion is a very complex reaction that
and mechanical factors. Corrosion fatigue
covers many factors, which includes materials,
normally starts at a pit and spreads from
environments, and configurations. The
there.
airframe, which is made of composites,
aluminum, steel, stainless steel, and titanium, 2. Preventive Maintenance
must be regularly examined for signs of
corrosion. Points of dissimilar material and
Consumable Materials
overlap contact must be given special atten­
(Ref. Section 91−00−00)
tion.
Item Nomenclature
B. Corrosion Types C216 Sealant, Fuel Resistant
C219 Compound, Corrosion Preventive (CPC)
These types of corrosion can result from the
effects of these factors identified as follows:
(1). Rinse and wash the rotorcraft regular­
D General — Appears as a uniform layer of ly (ref. Section 20-20-00).
corrosion product, also known as oxide, over (a). Make sure to rinse the tailboom and
the exposed metal surface. The overall thruster attachment areas.
thickness of base metal lessens until an
eventual failure occurs. CPC (C219)

D Pitting — Pitting corrosion is a very


localized attack of the metal. The pits are
random in location and vary in depth.
Do not apply corrosion preve­
D Galvanic — The result of dissimilar metals CAUTION ntive compound (C219) to fabric
in contact and in the presence of an electro­ or Teflon-lined bearings. Damage to compo­
lyte. nents can occur.
D Crevice — Caused when an electrolyte goes (2). After the rotorcraft has been in contact
into the interface or small crevice formed by with water, apply a water-displacing
the contact of two metals or a metal and corrosion preventive compound (C219)
non-metal material. to the these areas:

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(a). Exposed cadmium-plated parts and (c). Examine all areas where safety wire
crevices that are not sealed. is used for signs of corrosion, special­
ly where the safety wire touches
(b). Avionics and connectors. magnesium castings.
(c). The joints between the tailboom and (d). Examine the paint for blisters, chips,
fuselage, and between the thruster corrosion, discoloration, nicks,
and tailboom. scratches, and wear.
(2). Examine the main rotor blades at the
(d). Non-moving components or areas
leading and trailing edges and around
that can benefit from temporary
the abrasion strips for moisture
protection.
entrapment, corrosion, or looseness.
(3). Examine the rotorcraft for corrosion (3). Examine the main rotor hub and mast:
(ref. Procedure 3.).
(a). Examine all visible areas on the hub
(4). Apply a mechanical fastener seal to for signs of corrosion.
exposed ends of cadmium-plated nuts
(b). Examine the scissor assembly and
and bolts with sealant (C216).
attachment hardware for signs of
(5). Seal edges of composite materials that corrosion.
incorporate expanded aluminum foil (c). Examine the finish on the pitch
with sealant (C216). control rod and link assemblies for
damage.
3. Visual Check and Inspection for
Corrosion Guides (d). Examine the rod end bearings and
attachment hardware for corrosion.
Operators must have a corrosion control (e). Examine the surfaces and attach­
program that includes climate, environmental ment hardware on the upper and
impacts (for example: abrasive dust, acidic or lower swashplates for corrosion.
high-mineral-content soils, agricultural
agents, extreme temperatures, industrial air (f). Examine the finish on the mixer
pollution, moisture, salt water, or volcanic assembly for damage and corrosion.
ash), and rotorcraft mission. At a minimum,
(4). Examine the flight controls:
the corrosion control program must be done
annually. Do an analysis of the corrosive (a). Examine the collective and cyclic
conditions of the local area of operations and components for damage to finish and
the frequency of operations and, if necessary, evidence of corrosion. Components
increase the frequency of the corrosion control shall include push/pull tubes, rods
program (for example: biannually, quarterly, and rod ends (inside and outside
monthly, etc.). cabin), bellcranks and attachment
hardware.
A. Visual Corrosion Guide — General Check
(b). Examine the rudder pedals, support
NOTE: Refer to Section 20-90-00 for visual in­ structure, and attachment hardware
spection techniques. for damage to the finish and corro­
sion.
(1). Do a general check:
(5). Examine the powerplant and engine
(a). Examine joints, seams, bearings, and compartment:
bearing housings for voids that can (a). Open the access cowls and examine
entrap moisture. the visible areas.
(b). Examine areas where dissimilar (b). Examine the engine control rods, rod
metals are used for paint damage, ends, bellcranks and attachment
nicks, chips, and corrosion. hardware for signs of corrosion.

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(c). Examine the flex and rigid fuel lines, B. Visual Corrosion Guide — Periodic
fittings, and attachment hardware Inspection
for signs of corrosion.
NOTE: Refer to Section 20-90-00 for visual in­
(6). Examine the exterior surfaces: spection techniques.

(a). Examine the paint for nicks, chips, (1). As necessary, remove the access panels
blisters, and evidence of corrosion. to do inspections (ref. CSP-900RMM-2,
Section 06-00-00).
(b). Examine around the rivet heads and
attachment hardware for corrosion. (2). Do an inspection of main rotor hub:

(c). Examine the mount areas and areas (a). Examine the hub, hub follower, and
around the attachment hardware on droop stop ring for damage to the
the horizontal and vertical stabilizer protective surface.
for corrosion. 1). Examine all mating surfaces in
these areas for corrosion.
(d). Examine the area around all lighting
mount brackets and mating surfaces (b). Examine the scissor assembly and
for voids and corrosion. attachment hardware for signs of
corrosion.
(e). Examine the latches and hinges on
all crew and passenger doors for (c). Examine the finish on the pitch
corrosion. control rod and link assemblies for
damage.
(7). Examine the landing gear:
(d). Examine all attachment hardware
(a). Examine the foot assembly to skid for cadmium-plating deterioration.
joints and attachment hardware for
corrosion. 1). Examine the areas where safety
wire is used for corrosion.
(b). Examine all of the skid and the
attachment hardware for pitting, (e). Examine the inner surfaces on the
nicks, paint damage, and corrosion. upper and lower swashplates for
corrosion.
(c). Examine the sealing compound for
the jumper connections, crosstubes, 1). Examine the bearing for moisture
fuselage fittings, saddles, and entrapment or corrosion products
stop-clamps for condition and cracks. and all faying areas for corrosion.

(8). Examine the crew and passenger (3). Do an inspection on the main rotor
interiors: mast:

(a). Examine the floor, side panels, under (a). Examine cadmium plating for
seats, and seat backs, and general damage.
area for evidence of corrosion. 1). Examine the inside of the mast
and the upper and lower bearing
(b). Examine the joints and seams for
shoulders for fretting or other
moisture entrapment.
corrosion.
(9). Remove all corrosion that is found (ref. (b). Examine the areas around the mast
Procedure 5. for general instructions on base and attachment hardware for
corrosion removal, or go to the applica­ corrosion.
ble section in the RMM for detailed
component instructions). (4). Do an inspection on the main rotor
transmission:
(10). Do a touch-up of finishes and fill voids
as necessary (ref. CSP-SPM). (a). Examine the paint for damage.

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1). Examine the bolt heads that (a). Examine all areas in the engine
attach the upper cover to the base compartment for corrosion.
for corrosion.
(b). Examine all wiring, connectors,
2). Examine all other bolt heads on tubes, and fittings for deterioration
the transmission for corrosion. or corrosion.

(b). Examine the area around the upper (c). Examine the engine mounts, pads,
seal and sight gauge for signs of rods, and attachment hardware for
corrosion. corrosion products.

(c). Examine all safety wire for corrosion. (8). Do an inspection of the fuel system:
(a). Examine all flex and rigid fuel lines,
(d). When transmission is disassembled,
fittings, shutoff valve, fuel pump, and
examine the inside surfaces for
hardware for corrosion or damage.
corrosion or evidence of corrosion.
(b). Examine all fuel vent system hard­
(5). Do an inspection on the drive system: ware for blockage or signs of corro­
sion.
(a). Examine the main rotor to fan
assembly drive shaft surface for (9). Do an inspection of the landing gear:
damage to the finish or corrosion.
(a). Examine the strut for paint damage
(b). Examine the shaft couplings finish or corrosion.
for damage or corrosion.
1). Examine the attachment hardware
1). Examine the attachment hardware and mating areas for corrosion.
for cadmium plating deterioration
or corrosion. (b). Examine the brace for paint damage
and corrosion on attachment hard­
(6). Do an inspection on flight controls: ware.

(a). Examine the collective and cyclic (c). Examine the foot assembly for
sticks, all tubes, pivots, and pitting, fretting, or corrosion.
bellcranks for damage to paint.
1). Examine the foot-to-skid joint for
(b). Examine all rods, rod ends, supports voids and signs of corrosion.
and attachment hardware for 2). Examine the attachment hardware
corrosion products. for corrosion.
(c). Examine the interior of all bellcrank (d). Inspect skid for pitting, chips,
castings for corrosion. fretting, and nicks, for corrosion.
Inspect shoes for voids and corrosion
(d). Examine the wiring for wear and products. Inspect attachment hard­
corrosion. ware for corrosion.
(e). Examine the cyclic support casting (e). Do a visual inspection of the sealing
for pitting and corrosion. compound for the jumper connec­
tions, crosstubes, fuselage fittings,
(f). Examine the rudder pedals, support saddles, and stop-clamps for condi­
structure, tubes, bellcranks, attach­ tion and cracks.
ment hardware, and interior of
castings for corrosion. (10). Do an inspection of fuselage structure:
(7). Do an inspection of the engine compart­ (a). Examine the pitot tube fitting for
ment: evidence of corrosion or damage.

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(b). Examine the instrument panel, (8). If protective coatings are not available,
instruments, avionics, electrical apply corrosion preventive compound
equipment, and support structure (C219) or grease liberally to affected
around instrument panel area for areas (ref. Section 20-40-00).
corrosion.
5. Corrosion Removal
(c). Examine the joints and seams where
support castings attach to the seat Remove paint by either chemical or mechani­
structure for corrosion. cal methods (ref. Procedures 5.A. or 5.B.)
before the corrosion is removed (ref. Procedure
(11). Remove all corrosion that is found (ref. 5.C.).
Procedure 5. for general instructions on
corrosion removal, or go to the applica­ A. Paint Removal Chemical
ble section in CSP-900RMM-2 or
CSP-900RMM-3 for detailed compo­ Consumable Materials
nent instructions). (Ref. Section 91−00−00)
(12). Do a touch-up of finishes and fill voids Item Nomenclature
as necessary (ref. Section 20-30-00). C313 Paint Stripper

(13). Install and secure all removed access


panels. Do not use a chemical paint
CAUTION stripper on composite materials.
4. Temporary Corrosion Treatment Chemical paint strippers can cause compos­
ite components to debond and/or loose adhe­
NOTE: The following instructions are to be sion of the epoxy matrix.
used only in cases where materials or equip­
ment are not available for complete corro­ (1). Apply masking tape to all nonmetallic
sion removal, and corrosion damage is not surfaces in the area to be stripped as
critical to rotorcraft airworthiness. well as to areas where the solution can
get entrapped.
A. Temporary Treatment Instruction
Paint Stripper (C313)
(1). Examine the area or part in question
for the extent of corrosion.
(a). If corrosion damage is extensive to
the point area or part cannot with­
stand normal loads before aircraft (2). Apply sufficient paint stripper (C313)
can reach a repair station, contact with a fiber brush to cover the area of
Field Service Representative for paint removal.
instructions. NOTE: If the paint stripper evaporates quickly
(2). Remove loose paint and powdery or works slowly, cover the area with a plastic
products of corrosion with a sharp sheet.
phenolic scraper or heavy fiber brush. (3). Let the paint remover stay on the
(3). Wash affected areas with mild soap. surface for a sufficient time to cause the
paint to wrinkle, disbond, and blister
(4). Rinse with fresh water. (about 10 to 30 minutes).

(5). Dry the surface. (4). Scrub the area with a nonmetallic
scraper or abrasive pad to further
(6). Apply two coats of primer (ref. Section loosen paint.
20-30-00).
(5). As necessary, apply paint stripper
(7). Apply a top coat, if necessary (ref. (C313) again to the areas where the
Section 20-30-00). paint still tightly bonds to the surface.

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(6). Wash and scrub the surface with (2). Make sure all active corrosion and
demineralized water and alkaline corrosion products have been removed.
cleaner to neutralize the paint stripper.
(3). Use sandpaper (C807) to blend the
(7). Remove the masking tape and remain­ edges of paint adjacent to the repair
ing paint. area to create a smooth transition.
(8). Rinse with demineralized water. (4). Vacuum area thoroughly to remove all
contaminates.
B. Paint Removal Mechanical
(5). Touch-up surface treatment and
CAUTION coatings to match original.
D Do not sand into or expose composite 6. Mechanical Defects
fibers.
D Do not remove more material than neces­ A. Nicks, Scratches, Dents
sary. (1). Determine if damage is through the
D Do not use aluminum oxide abrasives on paint.
epoxy/graphite materials.
(a). If not, touch-up paint (ref. Section
(1). Use an abrasive flap wheel, abrasive 20-30-00, and the applicable chapter
disk, abrasive paper, or plastic media of CSP-900RMM-2).
blast to remove the paint.
(2). If damage is through paint surface,
C. Corrosion Removal determine if the repair is within the
allowable limits (ref. CSP-900RMM-2).
Consumable Materials
(3). If damage is not within the repairable
(Ref. Section 91−00−00)
limits, contact MDHI Field Service for
Item Nomenclature
assistance.
C810 Abrasive Cloth
C807 Sandpaper NOTE: On high-strength steels, do not use
power tools other than a flap brush or man­
drel with abrasive mat; overheating and
NOTE: Aircraft shall be electrically grounded notching can occur.
during all corrosion removal operations.
(1). Corrosion must be removed by the CAUTION
mildest methods possible.
D Do not sand into or expose composite
(a). Hand scrub with a dry, nonmetallic fibers.
brush or pad. D Do not remove more material than neces­
Do not use aluminum oxide sary.
CAUTION abrasives on epoxy/graphite D Do not use aluminum oxide abrasives on
materials. epoxy or graphite materials.
(b). Use abrasive cloth (C810). (4). Remove defect with a flap wheel,
abrasive disk, abrasive paper, or plastic
(c). Use sandpaper (C807).
media blast.
(d). Glass bead blast.
(5). Use sandpaper (C807) to blend the
(e). 240-grit abrasive wheel. edges of paint adjacent to the repair
area to create a smooth transition.
NOTE: On high-strength steels, do not use
power tools other than a flap brush or man­ (6). Apply surface treatment and paint
drel with abrasive mat; overheating and touch-up as necessary (ref. Section
notching can occur. 20-30-00).

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STANDARD PRACTICE MANUAL

7. Sealing Compound Solvent Cleaner (C429)

A. Application

Replace loose or missing sealant on exterior


surfaces. Sealant is used to fill seams and (2). Wipe surface with solvent cleaner
joints that might trap water. (C429) or equivalent.
(a). Let air dry for fifteen (15) minutes.
(1). Make sure that the seam or joint is
clean and free of foreign matter and (3). If surface treatment is not applied
moisture. within thirty (30) minutes, do the
solvent wipe again.
(2). Apply sealing compound (ref. Section
20-50-00, and applicable chapter of Chemical Film (C316)
CSP-900RMM-2).

(3). Force sealant well down into seam to


eliminate air pockets.
Alodine (C241)
(4). Fillet sealant to give joint or seam a
smooth appearance.

(5). Apply paint touch-up as necessary (ref.


Chemical Coating (C233)
Section 20-30-00).

8. Aluminum Alloy

A. Surface Touch−Up Treatment (4). Apply surface treatment (ref. applicable


Chapter of CSP-900RMM-2) with
NOTE: If there is a question of whether or not cotton swab or equivalent.
the protective coating is removed, surface
(a). Keep the surface moist for 1 to 3
treatment must be applied.
minutes with multiple applications.
(b). The surface will become amber or
Consumable Materials brown in color.
(Ref. Section 91−00−00)
Item Nomenclature (5). Irrigate surface with demineralized
C233 Chemical Coating water to remove the surface treatment
chemical.
C241 Alodine
C316 Chemical Film (a). Let air dry for approximately one (1)
hour.
C429 Solvent Cleaner
C817 Pad, Scouring, Cellulose/Nylon (b). If compressed air is available, blow
the moisture away from the joints or
crevices.
(1). Scuff surface with a scouring pad
(C817). (6). If there is a surface without a color
change, do the procedure again.
NOTE: Do not touch or otherwise contaminate (7). Apply paint touch-up as necessary (ref.
surface after solvent wipe. Section 20-30-00).

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STANDARD PRACTICE MANUAL

Section

20−50−00
Electrical Bond and
Environmental Seal
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

ELECTRICAL BONDING AND ENVIRONMENTAL SEALING


MAINTENANCE PRACTICES
1. Electrical Bonding Solvent, Cleaning (C423)

A. Electrical Bonding Preparation

Consumable Materials (b). Grease, oil, or similar nonconductive


(Ref. Section 91−00−00) films shall be removed from surfaces
Item Nomenclature with a cleaning solvent (C423).
C423 Solvent, Cleaning
(c). Prior to any bond assembly, the
C802 Cloth, Non−Lint bonding surfaces shall be wiped with
a cleaning solvent (C423).
Do not use camel hair or natural (d). Whenever bare metal surfaces of
CAUTION bristle brushes, carbon steel aluminum alloy are exposed in
brushes, or steel wool. Use of these items preparation for electrical bonding, a
may damage the aircraft. protective-conductive coating must
be applied before you make the bond
NOTE: Preparation of surfaces is done to main­ (ref. Section 20-40-00, Procedure
tain initial level of electrical bonding protec­ 8.A.).
tion when replacing or repairing compo­
(3). If electrical bond is suspect or fault
nents on helicopter.
develops with equipment, perform
electrical bond test.
(1). The following are typical items that
may be required for use in surface B. Electrical Bond Testing
preparation. This list is not intended to
be limiting. (Ref. Table 201 and Table 202)

(a). Brushes with nylon or other acid Special Tools


resistant bristles. Rotary or corrosion (Ref. Section 91−00−00)
resistant steel brushes. Item Nomenclature
T1002 Milli−Ohm Meter
(b). Aluminum wool, nylon scrub pads,
garnet paper (7/0), fiberglass
brushes, and similar hand-type (1). Electrical bond testing is performed to
abrasive or burnishing items. verify conductivity of bonded members.
This guarantees a good solid return
(c). Use non-lint cloth (C802), sponges path for the electronics in the system.
(plastic) and other water absorption (2). A typical electrical bond measurement
or drying items. milli-ohm meter (T1002) shall be
capable of performing resistance
(2). Surface preparation. measurement utilizing a Kelvin
resistive bridge network together with
NOTE: Surfaces to be electrically bonded shall four terminal measurement for apply­
be free from finishes, lubricants, or foreign ing constant current across the un­
matter that will impede electrical current known resistance and measuring
flow. corresponding voltage drop. Meters
shall be capable of measuring 1
(a). Using a nonmetallic scraper, remove milli-ohm (0.001 ohm) with 20
adhesive from parts. micro-ohm resolution.

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 201. Bonding Classes


Maximum DC Resistance
Between Bonded Members
Class Application (ohms)
A Antenna Installation 0.0025
C Current Path Return 0.005
Housing of Line Replaceable Unit (LRU)
Cable Shield to Cable Connector Housing
Common Termination System Ground Module Base

H Shock Hazard 0.100


L Lightning Protection 0.005
R RF Potentials 0.0025
S Static Charge 1.000

Table 202. Equipment Class Requirements


Ref. Equipment Class
CSP−900RMM−2/−3
Section
21−50−00 Evaporator Fan R
Vent Fan R
Condenser (CURRENT CONFIG) H

25−00−00 None −−
26−00−00 None −−
28−00−00 All Fuel System Components That Must Have Electrical Bonding R
29−00−00 None −−
32−00−00 Landing Gear L
Side−Stop Clamp L
Saddle L

52−00−00 None −−
53−00−00 All Fuselage Components That Must Have Electrical Bonding R
62−00−00 Main Rotor Blade H
Main Rotor Hub S
63−00−00 Main Transmission L
Rotor Brake Control Valve S
63−30−00 Heat Exchanger H
64−00−00 None −−

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Table 202. Equipment Class Requirements (Cont.)


Ref. Equipment Class
CSP−900RMM−2/−3
Section
67−00−00 Collective Control Module S
Stationary Thruster Assembly Installation to Tailboom L
Terminal Lug Attachment to Thruster Drum Bracket Assembly and
Stationary Thruster Assembly L
Thruster Lightning Strike Shield to Thruster Drum Bracket Assembly L
Bonding Strap (W124−J142) on Pilot Cyclic Stick to Bulkhead L
Bonding Strap (W125−J143) on Copilot Cyclic Stick to Bulkhead L
Collective Stick Bracket Assembly L
Lanyards on Expandable Diameter (Quick Release) Bolt Assemblies on
Copilot Cyclic Stick Attach Points to Cyclic Base Assembly L
Directional Pedals Bracket Assemblies, Pilot and Copilot, to Mounting
Airframe Structure. L
All Other Flight Controls That Must Have Electrical Bonding R
67−20−00 Lightning Strike Ground Jumper Assembly L
Lightning Strike Shield L
Thruster Drain Bracket Assembly L

71−00−00 Powerplant (Engines) R


Igniter Box R
Fuel Catch Can S

75−00−00 None −−
76−00−00 Electronic Engine Control (EEC) R
78−00−00 None −−
79−00−00 None −−
95−00−00 Instrument Panel R
All Instruments That Must Have Electrical Bonding R
96−00−00 All Electrical Power Equipment That Must Have Electrical Bonding R
97−00−00 Audio Select Panel R

NOTES:
(1) Unless otherwise specified in Table 202, the maximum resistance values across an electrical bond
cannot be more than 2.5 milli−ohms (0.0025 ohms).
(2) Class bond values are located in Table 201.

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

2. Environmental Sealing Methods sealant squeeze-out in excess of 0.125


inch (3.175 mm) with a non-metallic
NOTE: spatula or equivalent.
D Areas to be sealed shall be clean, dry, and
free of grease, oil, and other foreign mate­ SKINS
rial which can reduce the adhesion of the
sealing compound. Clean area for envi­
ronmental sealing (Ref. Section
20-20-00).
FASTENER
D Surfaces to be sealed shall be 50 to 120 °F SEAL BETWEEN
(10 to 49 °C) during application of seal­ SKINS
ant.
D Dispose of all unused hazardous materi­
als according to Federal, State and local
regulations. 9G20−003
A. Faying Surface Sealing Figure 201. Faying Surface Sealing
(Ref. Figure 201)
B. Fillet Surface Sealing
(1). Apply a 0.010 to 0.020 inch (0.254 to
0.508 mm) coat of sealant to all faying (Ref. Figure 202 and Figure 203)
surfaces of a component which adjoin a
skin splice or other leakage path. (1). Apply a bead of sealing compound to all
seams and joints which are subject to
(2). Align faying surfaces carefully and join incursion of water. There shall be no
in a single operation. Avoid reposition­ gaps or bridges in the sealing bead
ing or shifting of the faying surfaces along the seam joint.
during assembly. The faying surfaces
shall be firmly pressed into position
within the work life of the sealant ANGLE
compound.

ÎÎÎÎ
FORMED FILLET

ÎÎÎÎ
(3). After parts are joined, fasteners shall ABOVE SKIN EDGE
be installed within the work life of the SKIN
sealant. Parts without fasteners shall
be held in position, mechanically ÎÎÎÎ
ÎÎÎÎ
ÎÎÎÎ
maintaining contact pressure, until the
sealant is sufficiently cured to resist
normal assembly forces. 45 DEGREE TAPERED FILLET
9G20−004
(4). Ensure that sealant squeeze-out is
visible at all seam areas. Remove Figure 202. Fillet Surface Sealing

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Original 20-50-00
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

0.12 in.
uniform thickness of 0.015 inch (0.28
(3.05 mm) mm).
0.06 in.
MINIMUM

ÎÎÎ
(1.5 mm)
MINIMUM (2). Install gasket. Assemble parts and
tighten any mechanical fasteners
ÎÎÎ within the period of the work life of the
sealant. Install mechanical fasteners in
pairs approximately 90 degrees apart
<0.15 in. 0.12 in.
(3.81 mm)) 0.25 in. (3.05 mm) from the preceding pair.
(6.35 mm) MINIMUM
MINIMUM D. Mechanical Fastener Sealing
(Ref. Figure 204)

ÎÎ
0.25 in.
(6.35 mm)
(1). Seal mechanical fasteners as shown.
ÎÎ
MINIMUM

ÎÎÎÎÎÎ
BOLT HEAD 0.06 in.

ÎÎÎÎÎÎ
(1.5 mm)
0.12 in.
MINIMUM
(3.05 mm)

ÎÎÎÎÎÎ
0.15 TO 0.25
(3.81 TO 6.35 mm) MINIMUM

0.25 in.
0.25 in. (6.35 mm) 0.12 in.
(6.35 mm) MINIMUM (3.05 mm)
MINIMUM MINIMUM

ÎÎ
ÎÎ
NUT AND THREAD

0.12 in. (3.05 mm)


0.12 in. MINIMUM
(3.05 mm)
0.06 TO 0.12 in.

ÎÎÎÎÎÎÎÎÎ
MINIMUM
(1.5 mm)

ÎÎÎÎÎÎÎÎÎ
MINIMUM
9G20−005

Figure 203. Fillet Sealing Dimensions


ÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎ
C. Gasket Sealing
0.12 in.
(1). Apply sealant to both faying surfaces. (3.05 mm)
MINIMUM 9G20−002
Work out air bubbles with a spatula or
equivalent, spreading sealant to a Figure 204. Mechanical Fastener Sealing

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STANDARD PRACTICE MANUAL

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STANDARD PRACTICE MANUAL

Section

20−60−00
Electrical Standard
Practices
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

ELECTRICAL STANDARD PRACTICES


DESCRIPTION AND OPERATION
1. General types include circular, rectangular, and
coaxial. Usually, there is a part of the connec­
This section has maintenance procedures for tor that supports the the wire harness at the
electrical and electronic wires, connectors, and connector. These can be adapters, backshells,
terminations. Included are safety and mainte­ strain reliefs, and other supports.
nance procedures for the helicopter systems
and helicopter-related wires for components. All wire groups, harnesses, and cables have
attached identification devices that contain
2. Electrical Connectors their related connector identification number.
(Ref. Figure 1) The connector identification numbers are
related to their location in the helicopter. As
There are two classes of electrical connectors an example; P102 is in the nose and cockpit
installed on the MD900. One class is plugs, area, P407 is in the upper deck area. Plugs are
and the other is receptacles. The connector identified as PXXX and receptacles as JXXX.

UPPER DECK AREA,


NUMBER 400/500 CONNECTORS

BAGGAGE COMPARTMENT AND AFT OF TAILBOOM


ATTACH AREA, NUMBER 300 CONNECTORS

CABIN AREA,
NOSE AND COCKPIT NUMBER 200
AREA, NUMBER 100 CONNECTORS
CONNECTORS

9G20−016A

Figure 1. Connector Identification Number

Page 1
20-60-00 Revision 16
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

3. Terminal Junction System The letters on the face of the terminal blocks
are identification of the electrical contacts in
The terminal junction system has track at­ that block. The lines around the letters on the
tached block modules, stud attached block face of the terminal block show which contacts
modules, and wire contacts. The system inter­ are connected internally.
connects electrical components in an electrical
or electronic system. Terminal junctions are a
replacement for standard terminal strips. Each Terminal blocks are identified as TBX-XX.
wire can be removed or installed with no effect The number that follows TB shows the track
on the other wires and contacts. number. The number(s) that follow the dash
show the position in the track. The letter that
A. Ground Block Modules and Studs
follows the TB number shows the contact
(Ref. Figure 1 and Figure 2) position in the terminal block.
Ground blocks are a terminal block attached
by a stud, washers, and nut. This supplies all Terminal modules have a terminal block
wire installed in the terminal block an permanently attached to a flange. The
electrical current path to ground. Ground terminal module is attached to a surface by
studs are not part of the terminal junction washers and a nut. Terminal modules are
system but have the same function as ground installed internal to the electrical load center.
blocks. Thus, their description is given here.
Module identification is the same as terminal
Studs supply an electrical ground to wires
blocks, except that the number that follows the
terminated with lugs. Ground blocks and studs
are identified as GSXXX. The number after TB is always one.
GS is the connector identification number and
shows the area where it is installed. Ground
blocks have a code letter after the connector Forward Interconnect Panel (A612) -
identification number that shows the contact terminal boards are identified as (A612)TB2,
position in the block. (A612)TB3, and (A612)TB4 with ten spaces
each (Ref. Figure 5).
B. Terminal Blocks and Terminal Modules
(Ref. Figure 3 and Figure 4) Electrical Load Center (A620) - terminal
Terminal blocks that are installed in the boards are identified as (A620)TB1 and
standard helicopter are on the forward (A620)TB2 with ten spaces each (Ref.
interconnect panel, the back of the battery Figure 6).
compartment, and internal to the electrical
load center. There can be other locations
because of customer requested options and Audio Interconnect Assembly (A675) - is
modifications. All terminal blocks are installed identified as (A675)TB-1 with sixteen spaces
in tracks. (Ref. Figure 7).

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

RBL
9.56

GS114

GS113 1

GS112

GS111 GS109
GS107 GS105 GS103 GS101
3
GS100
GS108 GS106 GS104 GS102
GS110

FS
97.47 VIEW LOOKING DOWN
BELOW COCKPIT FLOOR

GS131 (RH SIDE)


GS130 (LH SIDE)

GS401 GS400
WL
3.9 92.00
GS133 (RH SIDE) GROUND MODULE INTERNAL
GS132 (LH SIDE) 1
BUSSING (TYPICALLY GS401-C 2
DENOTES MODULE 401
CONTACT HOLE C)

LBL
LBL 14.75
1 WL
16.00 159.00
VIEW LOOKING AFT AT FS 155.50 VIEW LOOKING FWD AT FS 155.50
BELOW COCKPIT FLOOR LH ABOVE TRANSMISSION DECK
(RH OPPOSITE)
FS
FS
155.50
209.03
WL WL
159.0 159.00

GS200

GS202

VIEW LOOKING INBD AT LBL 4.05 VIEW LOOKING OUTBD AT LBL 7.75 1
CABIN AREA TRANSMISSION 1 CABIN AREA TRANSMISSION
DECK STRUCTURE DECK STRUCTURE

9G20−013

Figure 2. Ground Module and Stud Locations (Sheet 1 of 2)

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20-60-00 Revision 16
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

WL
106.00
LBL
28.00

LBL
GS201
12.00
WL
94.04
2
GS300

VIEW LOOKING FWD AT FS 218.50 VIEW LOOKING FWD AT FS 235.53


BELOW CABIN FLOOR OUTBD OF KEEL BAGGAGE AREA UNDER FLOOR

RBL
18.58 LBL
18.58
FS
235.00 FS
235.00
GS301 GS303 GS305 GS307

1 (3 PL)
GS306 GS304 GS302

1 (4 PL)

VIEW LOOKING UP AT WL 155.00 VIEW LOOKING UP AT WL 155.00


BAGGAGE AREA, ENGINE DECK STRUCTURE BAGGAGE AREA, ENGINE DECK STRUCTURE
BELOW CABIN FLOOR OUTBD OF KEEL

1. GROUND MODULE P/N M81714/63−20S (REF. FIGURE 3. GROUND MODULE P/N M81714/63−16S (REF. FIGURE 4
4 ITEM Q) ITEM P)
2. GROUND STUD
Figure 2 Ground Module and Stud Locations (Sheet 2 of 2)

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

A620 W8
W6 W7
TB2 TB1
TB1 TB1
A620
TB1

W4

A612 INTERIOR VIEW LOOKING UP


TB3

A612 A675
TB4 TB-1

A612
TB2

LOOKING FORWARD
LOOKING INBOARD
RIGHT SIDE

9G20−009

Figure 3. Track and Terminal Block Locations

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20-60-00 Revision 16
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

P/N: M81714/60-22-01 P/N: M81714/60-22-02 P/N: M81714/60-22-04 P/N: M81714/60-22-05

A B C D A B C D A B C D A B C D

E F G H E F G H E F G H E F G H

J K L M J K L M J K L M J K L M

N P R S N P R S N P R S N P R S

T W Y Z T W Y Z T W Y Z T W Y Z

A B C D
P/N: M81714/60-22-10 P/N: M81714/60-20-01 P/N: M81714/60-20-02 P/N: M81714/60-2-03

A B C D
A B C A B C A B C

E F G H
D E F D E F D E F

J K L M
G H J G H J G H J
N P R S
K L M K L M K L M

T W Y Z

E F G H
P/N: M81714/60-20-04 P/N: M81714/60-20-06 P/N: M81714/60-16-01 P/N: M81714/60-16-02

A B C A B C
A B A B
D E F D E F
C D C D
G H J G H J
E F E F
K L M K L M

J K L M
P/N: M81714/63-16S
P/N: M81714/60-16-03 P/N: M81714/62-20AR P/N: M81714/63-12F P/N: M81714/63-20S
A

F A B C
B
A B A D
G D E F
C
C D B E
H G H J
D
E F C F
J K L M
E

N O P Q
9G20−015

Figure 4. Terminal Blocks and Contact Positions

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

TB2
1 2 3 4 5 6 7 8 9 10

D D D D D D G F F F

1 2 3 4 5 6 7 8 9 10

TB3

1 2 3 4 5 6 7 8 9 10

D D D D D D D D D D

1 2 3 4 5 6 7 8 9 10

TB4
1 2 3 4 5 6 7 8 9 10

D M D D D

1 2 3 4 5 6 7 8 9 10
9G20−010

Figure 5. Forward Interconnect Panel (A612) Terminal Blocks

TB1
1 2 3 4 5 6 7 8 9 10

G D C J D D M D

1 2 3 4 5 6 7 8 9 10

TB2

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

W6TB1 W7TB1 W8TB1

p p p

9G20−011

Figure 6. Electrical Load Center (A620) Terminal Blocks and Modules

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

OPTIONAL AVIONICS MODULE SPACE


TB-1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

D D D D D D D D D D D D

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

9G20−012

Figure 7. Audio Interconnect Assembly (A675) Terminal Blocks


4. Wire Identification wire size, EMI category, and color if applicable.
(Ref. Figure 8, Table 1, and Table 2) Thus, replacement wire will be accurately
identified.
The wire identification number shows: the
system, sequence number, segment number,

WIRE SIZE
SEQUENCE NUMBER OF
EMI CATEGORY
WIRES IN A SYSTEM

LVSCS8A22 5 WHT

SYSTEM IDENTIFICATION;
LEFT VERTICAL STABILIZER CONTROL COLOR OR STRIPE
SYSTEM (LVSCS)

SEGMENT NUMBER OF SEQUENCE NUMBER


(THE NEXT SEGMENT WOULD BE 8B22)
9G20-017A

Figure 8. Wire Identification

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Table 1. System Identification Codes


System Code Description
A Avionics
AMS43 AMS43 Radio Installation
C Controls, Hydraulics
E Engine
G Generations
H Heating/ECS, Heated Pitot
KT70 KT70 Radio Installation
KX165 KX165A Installation
L Lighting
LVSCS Left VSCS Installation
M IPS, Cargo Hook, Floats
NACA NACA (National Advisory Committee for Aeronautics) Submerged Duct Engine Inlet
P Power, Generator
Q Fuel
R Audio Radios
RVSCS Right VSCS Installation
T IIDS, Rotor Brake, Encoding Altimeter
W Collective/Cyclic Wire Harnesses, Fire Detection, Fire Suppression

Table 2. EMI Categories


Category Description
1 All AC power wires
2 Radio frequency coaxial cables
3 All DC wires and all ON−OFF controls wires
4 Digital 5−25 volts peak−to−peak
5 Digital less than 5 volts peak−to−peak, analog and Electro−Explosive Device (EED) control circuit

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

5. Wire Type Code part number and description of replacement


(Ref. Table 3) wire in the wire type table. You must use this
table when replacement of wire is necessary.
Use the type code from the wire list (ref.
CSP-RMM-3, Section 98-50-00) to find the
Table 3. Wire Type Table
Type Description Part Number
Code
AJ 1000V Silver−Coated Copper Conductor M22759/9−22−0
GA 200C High−Strength Copper Alloy Conductor M22759/35−(14)−9
GB 150C Normal Weight Tin−Coated Copper Conductor M22759/34−(*)−9
GV 150C Lightweight Tin−Coated Copper Conductor M22759/32−(*)−9
HG Dual Shield 50−Ohm Transmission Line 0.195 Inch (5 mm) Outside M17/128−RG400
Diameter
RA 150C Single Conductor Tin−Coated Copper M27500−24SE1T23
RB 150C Twin Conductor Tin−Coated Copper M27500−24SE2T23
RC 150C Three Conductor Tin−Coated Copper M27500−24SE3T23
RD 150C Four Conductor Tin−Coated Copper M27500−24SE4T23
RE 150C Five Conductor Tin−Coated Copper M27500−24SE5T23
SB 200C Twin Conductor Tin−Coated Copper M27500−(*)SP2U00
SC 200C Three Conductor Tin−Coated Copper M27500−(*)SP3U00
SD 200C Four Conductor Tin−Coated Copper M27500−(*)SP4U00
SE 200C Five Conductor Tin−Coated Copper M27500−(*)SP5U00
SH 150C Single Conductor Tin−Coated Copper M27500−(*)SP1T23
SJ 150C Twin Conductor Tin−Coated Copper M27500−(*)SP2T23
SK 150C Three Conductor Tin−Coated Copper M27500−(*)SP3T23
SL 150C Four Conductor Tin−Coated Copper M27500−(*)SP4T23
SM 150C Five Conductor Tin−Coated Copper M27500−(*)SP5T23
SY 200C Single Conductor Silver−Coated Copper M22759/43−(*)−9
UM 200C Single Conductor Large Gage Flexible Nickel−Coated Copper HS5649−(*)
XE 150C Single Conductor Tin−Coated Copper Dual Shield M27500−24SE1V73
XF 150C Twin Conductor Tin−Coated Copper Dual Shield M27500−24SE2V73
XG 150C Three Conductor Tin−Coated Copper Dual Shield M27500−24SE3V73
ZZ Pigtail Termination Solder Sleeve

NOTES:
(1) * AWG wire size.

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

6. Wire Harness and Connector stamp, and date of manufacture. Optional


Identification data such as engineer drawing revision letter,
manufacture plan revision number, serial
A. Wire Harness Identification number, and supplier part number can also be
(Ref. Figure 9) included. Identification plates are installed on
the main part of the harness, and are attached
All wire harness assemblies are identified with by tying tape. Wire bundles have identification
Federal Supplier Code of Manufacture (FSCM) plates attached along their length to identify
or CAGE number, part number, inspection the wire harness in them.

FSCM
MDHI PART NUMBER

FSCM 1KVX4
INSPECTION STAMP
ASSY900A2710452 - 1
DWG REV. E
PLN REV. 8
3 - 6 - 84

ENGINEER DRAWING AND


MANUFACTURE PLAN REVISION DATE OF MANUFACTURE
(OPTIONAL)
9G20−043A

Figure 9. Identification Plate


B. Connector Identification cation devices are installed no more than 6 in.
(15.24 cm) from the plug they identify.
(Ref. Figure 10 and Figure 11)
All plugs are identified with a device attached All receptacles are identified with an identifi­
to the wire harness or bundle adjacent to that cation number on both sides of the helicopter
plug. The identification device has data that structure adjacent to the receptacle. The
includes connector identification numbers for identification number for the plug that
the plug and mating receptacle, harness attaches to the receptacle is on the plug side of
number, and component name. The device is the helicopter structure. The wire harness or
usually an identification plate. But, heat wire bundle attached to the receptacle has an
shrinkable sleeving can be installed with identification device attached for that recep­
identification data as an alternative. Identifi­ tacle.

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STANDARD PRACTICE MANUAL

NO MORE THAN
3 IN. (76 mm)
CONNECTOR WITHOUT
A I.D COMPRESSION NUT
OR STRAIN RELIEF

NO MORE THAN
3 IN. (76 mm)

B I.D CONNECTOR WITH


COMPRESSION NUT

NO MORE THAN
3 IN. (76 mm)

C CONNECTOR WITH
I.D STRAIN RELIEF

NO MORE THAN
3 IN. (76 mm)

D I.D

SHIELD TERMINATION
OR SPLICE

9G20−044A

Figure 10. Connector Identification Device Location

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STANDARD PRACTICE MANUAL

STRUCTURE

RECEPTACLE
PLUG RECEPTACLE

HARNESS

PLUG SIDE

IDENTIFICATION
DEVICE STRUCTURE

9G20−045

Figure 11. Connector Identification Marking Location

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ELECTRICAL STANDARD PRACTICES


FAULT ISOLATION
1. General B. Released Circuit Breaker
Do not close a circuit break­
This section gives failure isolation procedures WARNING er while there is electrical
for faults which can occur in the helicopter
power connected to the circuit. Close
wires and electronic systems. You must obey
only after the fault that caused it to
all safety procedures and precautions. For
open has been identified and cor­
more data, refer to applicable section in
rected, or electrical power has been
maintenance manual.
disconnected.
A. Safety Procedures and Precautions NOTE: A released circuit breaker is usually
caused by a short circuit in wires from cir­
Unless you do a test for a cuit breaker to component or a defective
WARNING specified voltage, the heli­ component.
copter must have electrical power re­
Power Off
moved when you do maintenance on
wires or electrical systems.

(1). To make sure a circuit breaker stays


open until a test is completed, do the
procedure that follows: (1). Make sure all electrical power is
disconnected from helicopter (Ref.
CSP-900RMM-3, Section 96-00-00).
(a). Pull out circuit breaker and install a
plastic cable tie under circuit breaker (2). Find if there are other circuit breakers
button. in electrical circuit on output side of
released circuit breaker (Ref.
(b). Tag circuit breaker DO NOT RE­ CSP-900RMM-3, Section 98-00-00).
MOVE.
(a). If there are other circuit breakers in
electrical circuit, go to step (3).
(c). Put your name and the date on tag.
(b). If there are no other circuit breakers
Make sure electrical power in electrical circuit, go to step (6).
WARNING will not be connected to heli­
(3). Look at the other circuit breakers.
copter until procedure is completed.
(a). If there are other released circuit
(2). To make sure electrical power will not breakers in electrical circuit, go to
be connected to helicopter, do the step (4).
procedure that follows:
(b). If there are no other released circuit
breakers in electrical circuit, go to
(a). Tag POWER switch on ELEC­
step (5).
TRICAL MASTER panel DO NOT
APPLY POWER. (4). If there are other released circuit
breakers, do the procedure that follows:
(b). Put your name and the date on tag.
(a). Do a test for an open circuit condition
on wires between last released circuit
(c). Disconnect electrical connector P1
breaker and component (Ref. Electri­
from battery, and tag DO NOT
cal Tests).
CONNECT.
(b). If there is an open circuit condition,
(d). Put your name and the date on tag. repair wires (Ref. Wire Repair).

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(c). Do a test for a short circuit condition (7). Disconnect wires from components in
on wires between last released circuit electrical circuit with released circuit
breaker and component (Ref. Electri­ breaker.
cal Tests).
(8). Insulate disconnected wires.
(d). If there is a short circuit condition, (9). Close all circuit breakers in electrical
repair wires (Ref. Wire Repair). circuit.
(e). If there is no open or short circuit High Voltage
condition, go to step (7).

(5). If there are other circuit breakers, but


none are released, do the procedure
that follows:
(10). Connect electrical power to helicopter
(a). Do a test for an open circuit condition (Ref. CSP-900RMM-3, Section
on wires between released circuit 96-00-00).
breaker and all other circuit breakers (11). Supply electrical power to circuit.
in electrical circuit (Ref. Electrical
Tests). (12). Look at circuit breaker.

(b). If there is an open circuit condition, (13). If circuit breaker is open, go to Step
repair wires (Ref. Wire Repair). (16).
(14). If circuit breaker stays closed, do the
(c). Do a test for a short circuit condition procedure that follows:
on wires between released circuit
breaker and all other circuit breakers Power Off
in electrical circuit (Ref. Electrical
Tests).

(d). If there is a short circuit condition,


repair wires (Ref. Wire Repair). (a). Make sure all electrical power is
(e). If there is no open or short circuit disconnected from helicopter (Ref.
condition, go to step (7). CSP-900RMM-3, Section 96-00-00).
(b). Have all components been replaced?
(6). If there are no other circuit breakers,
do the procedure that follows: 1). No, go to step (14).(c).

(a). Do a test for an open circuit condition 2). Yes, go to step (15).
on wires between released circuit (c). Connect wires to one component in
breaker and component (Ref. Electri­ electrical circuit with released circuit
cal Tests). breaker.
(b). If there is an open circuit condition, High Voltage
repair wires (Ref. Wire Repair).

(c). Do a test for a short circuit condition


on wires between released circuit
breaker and component (Ref. Electri­
(d). Connect electrical power to helicopter
cal Tests).
(Ref. CSP-900RMM-3, Section
(d). If there is a short circuit condition, 96-00-00).
repair wires (Ref. Wire Repair). (e). Look at circuit breaker.
(e). If there is no open or short circuit 1). If circuit breaker stays closed, go to
condition, go to step (7). step (14).

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2). If circuit breaker is open, replace mance not sufficient. This cause is unusual
component and then go to step and a Field Service Representative must
(14). give a correction procedure.
(15). Do an operational check of system (Ref. D System Interference - Occurs when radio
applicable system section). frequency interference or other system
electro-magnetic interference has an
(16). If circuit breaker is open, do the unwanted effect on other avionic system.
procedure that follows: The helicopter is tested for system interfer­
ence before it is delivered, but modifications
Power Off or other installations can have an unwanted
effect on avionic systems. This cause is
unusual and a Field Service Representative
must give a correction procedure.

(a). Make sure all electrical power is (1). Do an operational check/test of system
disconnected from helicopter (Ref. with radio interference (Ref. applicable
CSP-900RMM-3, Section 96-00-00). system section).

(b). Do a test for correct voltage of (2). If no interference was found during
electrical power at input to circuit operational test, go to step (5).
breaker (Ref. Electrical Tests). (3). If interference was found during
(c). If voltage is correct, replace circuit operational test, do the procedure that
breaker (Ref. Removal and Installa­ follows:
tion of Electrical Components). (a). Use operational test, component self
(d). If voltage is incorrect, troubleshoot tests, or system fault isolation
electrical power system (Ref. procedures to find defective compo­
CSP-900RMM-3, Section 96-00-00). nent (Ref. applicable system section).
Power Off
C. Radio Interference
It is possible to have radio interference on a
helicopter with more than one transceiver.
This interference is reduced to a minimum on
installations done by MDHI. Radio antennas (b). Make sure all electrical power is
are installed with maximum distance between disconnected from helicopter (Ref.
them and cables are shielded. But there can CSP-900RMM-3, Section 96-00-00).
still be too much interference. The cause of too
much interference is usually in one of the (c). Replace defective component (Ref.
categories that follow: applicable section).

D Unserviceable Component - Unservice­ High Voltage


able electrical components are most fre­
quently the cause for radio interference.
D Incorrect Installation - Incorrect
installation of electrical connectors, electri­ (d). Connect electrical power to helicopter
cal cables, or electrical components can (Ref. CSP-900RMM-3, Section
cause corrosion, damage, and incorrect 96-00-00).
electrical ground.
(e). Operate system and do a check for
D Incorrect Components - Helicopter size radio interference.
or other limits can prevent sufficient
distance between antennas. It is possible for (f). If there is no radio interference, go to
interference to make component perfor­ step (6).

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(g). If there is radio interference, go to High Voltage


Step (4).

(4). If there is radio interference after


defective components have been
replaced, do the procedure that follows: (j). Connect electrical power to helicopter
(Ref. CSP-900RMM-3, Section
Power Off 96-00-00).
(k). Operate system and do a check for
radio interference.
(l). If there is no radio interference, go to
step (6).
(a). Make sure all electrical power is
(m). If there is radio interference, contin­
disconnected from helicopter (Ref.
ue the procedure.
CSP-900RMM-3, Section 96-00-00).
Power Off
(b). Do the wire harness inspection
procedure on system wires (Ref. wire
inspection). Look carefully at areas
where maintenance has been done.
(n). Make sure all electrical power is
(c). Do a test for an open circuit condition disconnected from helicopter (Ref.
on wires between released circuit CSP-900RMM-3, Section 96-00-00).
breaker and all other circuit breakers
NOTE: Voltage Standing Wave Ratio (VSWR)
in electrical circuit (Ref. Electrical can be measured with an antenna tester, di­
Tests).
rectional coupler, or through line wattmeter.
(d). If there is an open circuit condition, (o). Do a measurement of the VSWR of
repair wires (Ref. Wire Repair). system RF cables and antennas.
(p). If VSWR of RF cable and antenna
(e). Do a test for a short circuit condition together are more than the maxi­
on wires between released circuit mum specified antenna VSWR,
breaker and all other circuit breakers replace cable and antenna (Ref.
in electrical circuit (Ref. Electrical manufacture's instructions).
Tests).
NOTE: Insertion loss may be measured with a
(f). If there is a short circuit condition, network analyzer or wattmeter.
repair wires (Ref. Wire Repair). (q). Measure insertion loss of system RF
cables. Replace cable if loss is more
(g). Do a visual inspection of system than manufacture's specified limit.
Radio Frequency (RF) cable recep­
tacles for corrosion and incorrect (r). If there is radio interference, contact
installation. None permitted. Field Service Representative for
correction procedure.
(h). Do an inspection of system antennas (5). If there is no radio interference during
for incorrect installation, and test for operational test of system, do the
incorrect electrical bond (Ref applica­ procedure that follows:
ble system section). None permitted.
(a). Apply electrical power to all other
avionic systems.
(i). Do an inspection of system compo­
nents for incorrect installation and (b). Operate other avionic systems while
incorrect electrical bond (Ref. applica­ you operate system with radio
ble system section). interference. Check for interference.

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(c). If there is radio interference, find connectors that have been disconnected
which avionic system(s) is the cause for maintenance before.
of radio interference.
(3). Connect all disconnected connectors.
(d). Radio interference is the result of
incorrect components being installed High Voltage
or systems interference. Contact
Field Service Representative for
correction procedure.

Power Off
(4). Connect electrical power to helicopter
(Ref. CSP-900RMM-3, Section
96-00-00).

(5). Operate system and do a check for


(6). Make sure all electrical power is faults.
disconnected from helicopter (Ref.
CSP-900RMM-3, Section 96-00-00). (6). If a fault occurs, do the procedure that
follows:
D. Components
(a). Make sure system is on.
Avionic system faults are usually the result of
incorrect operation or incorrect maintenance (b). Make sure switches and contacts are
procedures. When incorrect operation, incor­ in the correct position.
rect maintenance procedures, or defective
wires are not the cause of the fault, system (c). Make sure ON indication lights are
components can be defective. not defective (if applicable). If
defective, replace light or component
When you find an avionic system fault caused light is installed on.
by a defective component, do fault isolation
(d). Do an inspection for open circuit
procedures first on components that get the
breakers.
most heat, vibration, moisture, corrosion, high
voltages, and high current. Do fault isolation
(e). If there is a circuit breaker that is
procedures first on the components that follow:
open because of system operation, do
the released circuit breaker proce­
D Power supplies
dure.
D Power amplifiers (f). If there is a circuit breaker that was
opened for maintenance, do the
D Output stages procedure that follows:
D Electrical connectors that get high vibration Power Off
or are frequently connected and discon­
nected.

(1). Make sure avionic system with fault


has all wires terminated correctly and
wire harness plugs are connected to 1). Make sure all electrical power is
correct receptacles. disconnected from helicopter (Ref.
CSP-900RMM-3, Section
(2). Disconnect system electrical connectors 96-00-00).
that get high vibration or are frequent­
ly disconnected, and do an inspection 2). Close circuit breakers that were
for bent contacts. Look carefully at opened for maintenance.

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High Voltage (l). Make sure wires are terminated


correctly and connect system electri­
cal connectors. Do not connect
electrical connectors to component.
High Voltage
3). Connect electrical power to helicop­
ter (Ref. CSP-900RMM-3, Section
96-00-00).
4). Operate system and do a check for
faults. (m). Connect electrical power to helicopter
5). If a fault occurs, go to step (6).(h). (Ref. CSP-900RMM-3, Section
96-00-00).
Power Off
(n). Apply electrical power to system with
fault.
(o). Do a test for correct voltage at
component electrical connector (Ref.
(g). Make sure all electrical power is Electrical Tests).
disconnected from helicopter (Ref.
CSP-900RMM-3, Section 96-00-00). (p). If the voltage is incorrect, replace
power supply.
(h). Find which wires supply electrical
power and which wires supply (q). If voltage is correct, replace compo­
electrical ground to component, use nent.
interconnect wire diagrams (Ref.
CSP-900RMM-3, Section 98-00-00). (r). Do an operational check of system
(Ref. applicable system section).
(i). Do a test for an open circuit condition
on wires that supply electrical power Power Off
and electrical ground to component
(Ref. Electrical Tests).
(j). If there is an open circuit condition,
repair wires (Ref. Wire Repair).
(s). Make sure all electrical power is
(k). Make sure switches and contacts are disconnected from helicopter (Ref.
in the correct position. CSP-900RMM-3, Section 96-00-00).

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ELECTRICAL STANDARD PRACTICES


MAINTENANCE PRACTICES
1. Installation and Removal of Electrical B. Terminal Block Module, Terminal
Components Junction System Installation
A. Terminal Block Module, Terminal (Ref. Figure 201)
Junction System Removal
Power Off
(Ref. Figure 201)

Special Tools
(Ref. Section 91−00−00)
(1). Make sure all electrical power is
Item Nomenclature
disconnected from helicopter (ref.
T1008 Removal Tool CSP-900RMM-3, Section 96-00-00).
(2). Install module into track and push
Power Off until you hear a click and module
assembly stops.
(3). Pull on module assembly to make sure
it is locked in by retaining clips.
(4). Install wires and sealing plugs in
(1). Make sure all electrical power is module (Ref. Wire Terminations).
disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00). (5). Complete wire harness (Ref. Wire
Maintenance).
(2). If necessary, remove access panels (Ref. (6). Install electrical component if removed.
CSP-900RMM-2 Section 06-00-00).
(7). Install access panels if removed (Ref.
(3). If necessary, remove electrical compo­ CSP-900RMM-2 Section 06-00-00).
nent. (8). Connect electrical power to helicopter
(Ref. CSP-900RMM-3, Section
(4). Prepare wires for removal (Ref. Wire 96-00-00).
Maintenance).
C. Track Assembly, Terminal Junction
(5). Remove all sealing plugs and wires System Removal
from module (7) (Ref. Wire Termina­
tions). (Ref. Figure 201)
(1). Remove all terminal block modules.
(6). Put removal tool (T1008) (1) into track
assembly (2) to release retaining clips NOTE: It is possible that nutplates are
(6). installed in position of nuts.
(7). Push in removal tool (1) until retaining (2). Remove nuts (3), washers (4), and
clips (6) unlock. screws (5). Remove track assembly (2).
D. Track Assembly, Terminal Junction
(8). Hold module (7) tightly with removal System Installation
tool (1) and remove.
(Ref. Figure 201)
(9). Inspect module (7) for contamination
and insert grommets for damage (Ref. NOTE: It is possible that nutplates are
Module Inspection). installed in position of nuts.
(10). If necessary, install protective covers on (1). Put track in position and install screws,
exposed wires (Ref. Cleaning and washers, and nuts. Torque nuts.
Protection). (2). Install terminal block modules.

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E. Terminal Module Removal (2). Apply a thin film of silicone compound


(C223) to mating surface of module.
(Ref. Figure 201)
(3). Put module in installed position.
Consumable Materials (4). Install screws, washers, and nuts.
(Ref. Section 91−00−00) Torque nuts 20-25 in-lb (2.26-2.82
Item Nomenclature Nwm). After 20-30 minutes torque
C223 Silicone Compound, Non−Corrosive again.
(5). Test module for class “R” electrical bond
(Ref. Section 20-50-00).
Power Off
(6). Install wires and sealing plugs into
module (Ref. Wire Terminations).
(7). Complete wire harness (Ref. Wire
Maintenance).
(1). Make sure all electrical power is
disconnected from helicopter (ref. (8). Install electrical component if removed.
CSP-900RMM-3, Section 96-00-00). (9). Install access panels if removed (Ref.
CSP-900RMM-2 Section 06-00-00).
(2). If necessary, remove access panels (Ref.
CSP-900RMM-2 Section 06-00-00). (10). Connect electrical power to helicopter
(Ref. CSP-900RMM-3, Section
(3). If necessary, remove electrical compo­ 96-00-00).
nent. G. Ground Block Module Removal
(4). Prepare wires for removal (Ref. Wire (Ref. Figure 201)
Maintenance).
(5). Remove all sealing plugs and wires Consumable Materials
from module (Ref. Wire Terminations). (Ref. Section 91−00−00)
Item Nomenclature
(6). Remove nuts (10), washers (9), and C216 Sealant, Fuel Resistant
screws (8). Remove module (11).
(7). Inspect module (11) for contamination Power Off
and insert grommets for damage (Ref.
Module Inspection).
(8). If necessary, install protective covers on
exposed wires (Ref. Cleaning and
(1). Make sure all electrical power is
Protection).
disconnected from helicopter (ref.
F. Terminal Module Installation CSP-900RMM-3, Section 96-00-00).

(Ref. Figure 201) (2). If necessary, remove access panels (Ref.


CSP-900RMM-2 Section 06-00-00).
Power Off (3). If necessary, remove electrical compo­
nent.
(4). Prepare wires for removal (Ref. Wire
Maintenance).
Make sure all electrical power is disconnected (5). Remove all sealing plugs and wires
from helicopter (ref. CSP-900RMM-3, Section from module (Ref. Wire Terminations).
96-00-00).
(6). Remove sealant from module (17), nut
(1). Prepare surfaces for electrical bond (14), lock washer (15), and washers
(Ref. Section 20-50-00). (13).

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STANDARD PRACTICE MANUAL

(7). Remove nut (14), lock washer (15), and (4). Install washers and nut. Torque nut
washers (13). Remove module (17). 27-29 in-lb (3.07-3.30 Nwm).
(8). Inspect module (17) for contamination (5). Test module for class “R” electrical bond
and insert grommets for damage (Ref. (Ref. Section 20-50-00).
Module Inspection).
H. Ground Block Module Installation (6). Environmentally seal module, washers,
and nut with sealant (C216) (Ref.
(Ref. Figure 201) Section 20-50-00).
Power Off (7). Install wires and sealing plugs in
module (Ref. Wire Terminations).

(8). Complete wire harness (Ref. Wire


Maintenance).
(1). Make sure all electrical power is
disconnected from helicopter (ref. (9). Install electrical component if removed.
CSP-900RMM-3, Section 96-00-00).
(10). Install access panels if removed (Ref.
(2). Prepare surfaces for electrical bond CSP-900RMM-2 Section 06-00-00).
(Ref. Section 20-50-00).
(11). Connect electrical power to helicopter
(3). Install module. Make sure stabilizer (Ref. CSP-900RMM-3, Section
tab (16) is engaged in small hole. 96-00-00).
1

11

7
17
6

5 (2 PL)
16
8 (2 PL)
12 9 (2 PL)

15 10 (2 PL) 2
13
TERMINAL MODULE
(TYPICAL)
14
4 (2 PL)
GROUND BLOCK MODULE
(TYPICAL) 3 (2 PL)

TRACK ASSEMBLY AND


TERMINAL BLOCK MODULE ARRANGEMENT
(TYPICAL)
9G20−018A
1. REMOVAL TOOL 10. NUT
2. TRACK ASSEMBLY 11. MODULE
3. NUT 12. STUD
4. WASHER 13. WASHER
5. SCREW 14. NUT
6. RETAINING CLIP 15. LOCK WASHER
7. TERMINAL BLOCK MODULE 16. STABILIZER TAB
8. SCREW 17. GROUND BLOCK MODULE
9. WASHER
Figure 201. Terminal Junction System

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I. H Rail Electrical Relay Removal (3). Pull on relay to make sure it is locked
in by retaining clips.
(Ref. Figure 202)
(4). Install electrical component if removed.
Special Tools (5). Install access panels if removed (Ref.
(Ref. Section 91−00−00) CSP-900RMM-2 Section 06-00-00).
Item Nomenclature
(6). Connect electrical power to helicopter
T1008 Removal Tool (Ref. CSP-900RMM-3, Section
96-00-00).
Power Off K. H Rail Electrical Relay Socket Removal
(Ref. Figure 202)

Special Tools
(Ref. Section 91−00−00)
(1). Make sure all electrical power is
Item Nomenclature
disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00). T1008 Removal Tool

(2). If necessary, remove access panels (Ref.


CSP-900RMM-2 Section 06-00-00). Power Off

(3). If necessary, remove electrical compo­


nent.
NOTE: Use two removal tools to remove three (1). Make sure all electrical power is
pole relays. disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00).
(4). Put removal tool (T1008) (20) into track
assembly (11) to release track retaining (2). Remove H rail electrical relay.
clips (17).
(3). Prepare wires for removal (Ref. Wire
(5). Push in removal tool (20) until track Maintenance).
retaining clips (17) unlock. (4). Remove all sealing plugs and wires
(6). Hold relay (18, 19) tightly with removal from relay socket (Ref. Wire Termina­
tool (20) and remove. tions).

(7). Inspect relay socket (12) for contamina­


NOTE:
tion and damage to insert grommets D It is not necessary to use removal tool if
(Ref. Module Inspection). relay socket does not have lock plates.
D Use two removal tools to remove three
J. H Rail Electrical Relay Installation pole relay sockets.
(Ref. Figure 202) (5). Put removal tool (T1008) (20) into track
assembly to release track retaining
Power Off clips (17).
(6). Push in removal tool (20) until track
retaining clips (17) unlock.
(7). Hold relay socket (12) tightly with
(1). Make sure all electrical power is removal tool (20) and push relay socket
disconnected from helicopter (ref. from track.
CSP-900RMM-3, Section 96-00-00).
(8). Inspect relay socket (12) for contamina­
(2). Install relay into track and push until tion and damage to insert grommets
you hear a click and relay stops. (Ref. Module Inspection).

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(9). If necessary, install protective covers on (1). Put track in position and install screws,
exposed wires (Ref. Cleaning and spacers (if removed), washers, and
Protection). nuts. Torque nuts.
L. H Rail Electrical Relay Socket Installation (2). Install H rail electrical relay sockets.
O. Hybrid Relay Removal
(Ref. Figure 202)
(Ref. Figure 202)
Power Off
Power Off

(1). Make sure all electrical power is


disconnected from helicopter (ref. (1). Make sure all electrical power is
CSP-900RMM-3, Section 96-00-00). disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00).
NOTE: You will not hear a click, if relay socket
does not have lock plates. (2). If necessary, remove access panels (Ref.
CSP-900RMM-2 Section 06-00-00).
(2). Install relay socket into track and push
until you hear a click and socket stops. (3). If necessary, remove electrical compo­
nent.
NOTE: Do not pull on relay socket if it does not
(4). Remove nuts (1) and washers (2).
have lock plates.
(5). Remove hybrid relay (3).
(3). Pull on relay socket to make sure it is
locked in by retaining clips. (6). Inspect hybrid relay socket (8) for
contamination and damage to insert
(4). Install wires and sealing plugs in relay
grommets (Ref. Module Inspection).
socket (Ref. Wire Terminations).
P. Hybrid Relay Installation
(5). Complete wire harness (Ref. Wire
Maintenance). (Ref. Figure 202)
(6). Install H rail electrical relay. Power Off
M. H Rail Track Assembly Removal
(Ref. Figure 202)
(1). Remove all H rail electrical relay (1). Make sure all electrical power is
sockets from track. disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00).
NOTE: It is possible that nutplates are
installed in position of nuts. (2). Install hybrid relay.
(2). Remove nuts (13), washers (14), spacers (3). Install washers and nuts. Torque nuts.
(15) (if installed), and screws (16).
Remove track (11). (4). Install electrical component if removed.

N. H Rail Track Assembly Installation (5). Install access panels if removed (Ref.
CSP-900RMM-2 Section 06-00-00).
(Ref. Figure 202)
(6). Connect electrical power to helicopter
NOTE: It is possible that nutplates are (Ref. CSP-900RMM-3, Section
installed in position of nuts. 96-00-00).

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Q. Hybrid Relay Socket Removal (7). Inspect hybrid relay socket (8) for
contamination and damage to insert
(Ref. Figure 202) grommets (Ref. Module Inspection).
Power Off (8). If necessary, install protective covers on
exposed wires (Ref. Cleaning and
Protection).
R. Hybrid Relay Socket Installation
(1). Make sure all electrical power is (Ref. Figure 202)
disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00). Power Off

NOTE: Hybrid relay socket can be installed top


mount or bottom mount.
(2). Remove hybrid relay.
(1). Make sure all electrical power is
NOTE: Top mount attaches with studs (10) and disconnected from helicopter (ref.
bottom mount attaches with studs (9). CSP-900RMM-3, Section 96-00-00).

(3). Prepare wires for removal (Ref. Wire (2). Install wires and sealing plugs in relay
Maintenance). socket (Ref. Wire Terminations).
(3). Install hybrid relay socket.
(4). Remove all wires and sealing plugs
from hybrid relay socket (Ref. Wire (4). Install washers and nuts. Torque nuts.
Terminations).
(5). Complete wire harness (Ref. Wire
(5). Remove nuts (4, 7) and washers (5, 7). Maintenance).
(6). Remove hybrid relay socket (8). (6). Install hybrid relay.

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20

17 10 (3 PL)
19
18 9 (3 PL)

16 (4 PL)
8

7 (3 PL)
1 (3 PL)

11 6 (3 PL)
15 (4 PL)
2 (3 PL)

14 (4 PL)
13 (4 PL)
5 (3 PL)
4 (3 PL)
12 3
HYBRID RELAY AND SOCKET ARRANGEMENT
(TOP MOUNT SHOWN)
TRACK ASSEMBLY AND RELAY ARRANGEMENT
(TYPICAL)

9G20−082

1. NUT 11. H RAIL TRACK ASSEMBLY


2. WASHER 12. RELAY SOCKET
3. HYBRID RELAY 13. NUT
4. NUT 14. WASHER
5. WASHER 15. SPACER
6. WASHER 16. SCREW
7. NUT 17. RETAINING CLIP (TYPICAL)
8. HYBRID RELAY SOCKET 18. TWO POLE RELAY
9. STUD BOTTOM MOUNT 19. THREE POLE RELAY
10. STUD TOP MOUNT 20. REMOVAL TOOL
Figure 202. H Rail and Hybrid Electrical Relay
S. Ground Stud Removal (2). If necessary, remove access panels (Ref.
CSP-900RMM-2 Section 06-00-00).
Consumable Materials (3). If necessary, remove electrical compo­
(Ref. Section 91−00−00) nent.
Item Nomenclature
C216 Sealant, Fuel Resistant (4). Prepare wires for removal (Ref. Wire
Maintenance).

Power Off (5). Remove sealant from ground stud and


electrical terminal.
(6). Remove nut and washers that attach
electrical terminal to stud. Remove
terminal.
(1). Make sure all electrical power is
disconnected from helicopter (ref. (7). Remove nut and washer that attach
CSP-900RMM-3, Section 96-00-00). stud. Remove stud.

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(8). If necessary, install protective covers on (2). If necessary, remove access panels (Ref.
exposed wires (Ref. Cleaning and CSP-900RMM-2 Section 06-00-00).
Protection).
(3). If necessary, remove electrical compo­
T. Ground Stud Installation nent.
Power Off (4). Prepare wires for removal (Ref. Wire
Maintenance).
(5). Remove nuts (2), lock washers (6) (if
installed), and washers (1). Remove
wires.
(1). Make sure all electrical power is
disconnected from helicopter (ref. (6). Remove bolts (7) or screws (5) and
CSP-900RMM-3, Section 96-00-00). washers (4). Remove contactor (3).
(2). Prepare surfaces for electrical bond (7). If necessary, install protective covers on
(Ref. Section 20-50-00). exposed wires (Ref. Cleaning and
(3). Install stud, washer, and nut. Torque Protection).
nut. V. Electrical Contactor (Relay) Installation
(4). Install terminal, washer, and nut. (Typical)
Torque nut. (Ref. Figure 203)
(5). Test terminal for class “R” electrical Power Off
bond (Ref. Section 20-50-00).
NOTE: If a rubber nipple is installed, it is not
necessary to seal terminal, washer, and nut.
(6). Environmentally seal stud, washer, (1). Make sure all electrical power is
terminal, and nut with sealant (C216) disconnected from helicopter (ref.
(Ref. Section 20-50-00). CSP-900RMM-3, Section 96-00-00).
(7). Complete wire harness (Ref. Wire (2). Prepare surface for electrical bond (Ref.
Maintenance). Section 20-50-00).
(8). Install electrical component if removed. (3). Install contactor, washers, and bolts or
(9). Install access panels if removed (Ref. screws. Torque bolts or screws.
CSP-900RMM-2 Section 06-00-00). (4). Install wires, washers, lock washers (if
(10). Connect electrical power to helicopter removed), and nuts. Tighten nut
(Ref. CSP-900RMM-3, Section sufficiently to prevent movement of
96-00-00). wire terminals.

U. Electrical Contactor (Relay) Removal (5). Test contactor for class “R” electrical
(Typical) bond.

(Ref. Figure 203) (6). Complete wire harness (Ref. Wire


Maintenance).
Power Off
(7). Install electrical component if removed.
(8). Install access panels if removed (Ref.
CSP-900RMM-2 Section 06-00-00).
(1). Make sure all electrical power is (9). Connect electrical power to helicopter
disconnected from helicopter (ref. (Ref. CSP-900RMM-3, Section
CSP-900RMM-3, Section 96-00-00). 96-00-00).

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4 (3 PL) 5 (2 PL)
5 (3 PL) 1
2
4 (2 PL)

3
3 1
2

1
6
2

4 (4 PL)

7 (4 PL)

1
6
2

1
6

2
1

2 9G20-060A

1. WASHER 5. SCREW
2. NUT 6. LOCK WASHER
3. CONTACTOR 7. BOLT
4. WASHER
Figure 203. Electrical Contactors (Typical)

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W. Circuit Breaker Removal (Typical) X. Circuit Breaker Installation (Typical)

(Ref. Figure 204) (Ref. Figure 204)

Power Off Power Off

Make sure all electrical power is disconnected


(1). Make sure all electrical power is from helicopter (ref. CSP-900RMM-3, Section
disconnected from helicopter (ref. 96-00-00).
CSP-900RMM-3, Section 96-00-00).
(1). Install circuit breaker, washer, and nut.
(2). If necessary, remove access panels (Ref. Tighten nut sufficiently to prevent
CSP-900RMM-2 Section 06-00-00). movement of circuit breaker.
(3). If necessary, remove electrical compo­ (2). Connect wires to circuit breaker and
nent. install washers and screws. Tighten
screws sufficiently to prevent move­
(4). Prepare wires for removal (Ref. Wire ment of wire terminals.
Maintenance).
(3). Complete wire harness (Ref. Wire
(5). Remove screws (4) and washers (5). Maintenance).
Remove wires. (4). Install electrical component if removed.
(6). Remove nut (2) and washer (3). Remove (5). Install access panels if removed (Ref.
circuit breaker (1). CSP-900RMM-2 Section 06-00-00).
(7). If necessary, install protective covers on (6). Connect electrical power to helicopter
exposed wires (Ref. Cleaning and (Ref. CSP-900RMM-3, Section
Protection). 96-00-00).

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4
4 5
5
9G20−019A

1. CIRCUIT BREAKER 4. SCREW


2. NUT 5. WASHER
3. WASHER
Figure 204. Circuit Breaker
Y. Rotary Switch Removal (Typical) (5). Remove lightplate (8).

(Ref. Figure 205) (6). Remove nut (9).


(7). Remove lock washer (5).
Power Off
(8). Remove rotary switch (1) from electrical
component (7).
(9). Remove key washer (6).

(1). Make sure all electrical power is (10). Remove nut (4).
disconnected from helicopter (ref. (11). Prepare wires for removal (Ref. Wire
CSP-900RMM-3, Section 96-00-00). Maintenance).
(2). If necessary, remove access panels (Ref. (12). Disconnect wires from rotary switch (1)
CSP-900RMM-2 Section 06-00-00). (Ref. Wire Termination). Remove
switch.
(3). If necessary, remove electrical compo­
nent (7). (13). If necessary, install protective covers on
exposed wires (Ref. Cleaning and
(4). Loosen screws (2) and remove knob (3). Protection).

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Z. Rotary Switch Installation (Typical) (5). Align key washer and rotary switch
with alignment hole.
(Ref. Figure 205)
(6). Adjust nuts until rotary switch shaft is
Power Off sufficiently above the lightplate for
knob installation. Tighten nuts suffi­
ciently to prevent movement of rotary
switch.

(7). Install lightplate.


Make sure all electrical power is disconnected
from helicopter (ref. CSP-900RMM-3, Section
(8). Install knob and tighten screws.
96-00-00).

(1). Connect wires to rotary switch (Ref. (9). Complete wire harness (Ref. Wire
Wire Termination). Maintenance).

(2). Install nut and key washer. Do not (10). Install electrical component if removed.
tighten nut.
(11). Install access panels if removed (Ref.
(3). Install rotary switch in electrical CSP-900RMM-2 Section 06-00-00).
component.
(12). Connect electrical power to helicopter
(4). Install lock washer and nut. Do not (Ref. CSP-900RMM-3, Section
tighten nut. 96-00-00).

3
2 (2 PL)
8

9
5

1 4

9G20−020

1. ROTARY SWITCH 6. KEY WASHER


2. SCREW 7. ELECTRICAL COMPONENT
3. KNOB 8. LIGHTPLATE
4. NUT 9. NUT
5. LOCK WASHER

Figure 205. Rotary Switch

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AA. Toggle Switch Removal (Typical) AB. Toggle Switch Installation (Typical)

(Ref. Figure 206) (Ref. Figure 206)


Power Off
Power Off

(1). Make sure all electrical power is


(1). Make sure all electrical power is disconnected from helicopter (ref.
disconnected from helicopter (ref. CSP-900RMM-3, Section 96-00-00).
CSP-900RMM-3, Section 96-00-00). (2). Install nut and key washer. Do not
tighten nut.
(2). If necessary, remove access panels (Ref.
CSP-900RMM-2 Section 06-00-00). (3). Install toggle switch.

(3). If necessary, remove electrical compo­ (4). Install lock washer and nut. Do not
nent (4). tighten nut.
(5). Align key washer and toggle switch
(4). Prepare wires for removal (Ref. Wire with alignment hole.
Maintenance).
(6). Adjust nuts until toggle switch is
(5). Remove wires attached to switch (1). sufficiently above the lightplate.
Tighten nuts sufficiently to prevent
(6). Remove lightplate (7). movement of toggle switch.
(7). Install lightplate.
(7). Remove nut (6).
(8). Complete wire harness (Ref. Wire
(8). Remove lock washer (5). Maintenance).

(9). Remove toggle switch (1). (9). Install electrical component if removed.
(10). Install access panels if removed (Ref.
(10). Remove key washer (3) and nut (2). CSP-900RMM-2 Section 06-00-00).
(11). If necessary, install protective covers on (11). Connect electrical power to helicopter
exposed wires (Ref. Cleaning and (Ref. CSP-900RMM-3, Section
Protection). 96-00-00).

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9G20−021

1. TOGGLE SWITCH 5. LOCK WASHER


2. NUT 6. NUT
3. KEY WASHER 7. LIGHTPLATE
4. ELECTRICAL COMPONENT
Figure 206. Toggle Switch
AC. Indicator Light Removal (Typical) (7). Remove nut (4) and lock washer (3).
(Ref. Figure 207) (8). Remove indicator light (1) and nut (2).
Power Off (9). Disconnect wires from indicator light
(1) (Ref. Wire Terminations).
(10). If necessary, install protective covers on
exposed wires (Ref. Cleaning and
Protection).
(1). Make sure all electrical power is AD. Indicator Light Installation (Typical)
disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00). (Ref. Figure 207)
Power Off
(2). If necessary, remove access panels (Ref.
CSP-900RMM-2 Section 06-00-00).
(3). If necessary, remove panel.
(4). Prepare wires for removal (Ref. Wire (1). Make sure all electrical power is
Maintenance). disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00).
(5). Remove bulb housing (5).
(2). Connect wires to indicator light
(6). Remove bulb (6) from bulb housing (5). assembly (Ref. Wire Terminations).

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(3). Install nut and indicator light. (10). Connect electrical power to helicopter
(Ref. CSP-900RMM-3, Section
(4). Install lock washer and nut. Tighten 96-00-00).
nuts sufficiently to prevent movement
of indicator light assembly. Battery Discharge
CAUTION
(5). Instal bulb in bulb housing.
(6). Install bulb housing. (11). On ELECTRICAL POWER panel, set
POWER switch to BAT/EXT.
(7). Complete wire harness (Ref. Wire
Maintenance). (12). Check indicator lamp operation with
(8). Install panel if removed. PRESS-TO-TEST switch.

(9). Install access panels if removed (Ref. (13). On ELECTRICAL POWER panel, set
CSP-900RMM-2 Section 06-00-00). POWER switch to OFF.

ÖÖ
4 3 2 1

ÖÖ
COLORED LENS
ÖÖ
ÖÖ
ÖÖ 6

9G20−022B

1. INDICATOR LIGHT 4. NUT


2. NUT 5. BULB HOUSING
3. LOCK WASHER 6. BULB
Figure 207. Indicator Light

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AE. Supplemental Fuel Transfer Indicator AF. Supplemental Fuel Transfer Indicator
Light Removal Light Installation
(Ref. Figure 208)
(Ref. Figure 208)
Power Off
Power Off

(1). Make sure all electrical power is


disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00).
(1). Make sure all electrical power is (2). Put lens into panel and push until lens
disconnected from helicopter (ref. stops.
CSP-900RMM-3, Section 96-00-00).
NOTE: Cathode terminal (7) connects to
ground wire.
(2). If necessary, remove panel (3).
(3). Connect wires to base (Ref. Wire
Termination).
(3). Prepare wires for removal (Ref. Wire
Maintenance). (4). If necessary, cut terminals on light
emitting diode to 0.28 in. (7.11 mm).
(4). Hold lens (4) and pull base (5) from NOTE: Cathode pin (6) on flat side of light
lens. emitting diode connects to cathode terminal.
(5). Install light emitting diode in base.
(5). Pull light emitting diode (2) from base
(6). Hold front of lens and push base on
(5).
rear of lens until lock flanges engage.
(7). Complete wire harness (Ref. Wire
(6). Disconnect wires attached to base (5) Maintenance).
(Ref. Wire Termination).
(8). Install panel if removed.
(7). Push lock flanges on lens (4) together (9). Connect electrical power to helicopter
and remove from panel (3). (Ref. CSP-900RMM-3, Section
96-00-00).
(8). If necessary, install protective covers on (10). Do the Supplemental Fuel Quantity
exposed wires (Ref. Cleaning and Operational Test (Ref.
Protection). CSP-900RMM-2, Section 28-10-00).

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2 REF

2 REF

0.28 IN (7.11 MM)

6 (NOTE 2)

2 5

4
7 (NOTE 3)
3 VIEW
ROTATED
1 (NOTE 1)

NOTES:
1. FUEL TRANSFER LIGHT MUST BE INSTALLED IN SIGHT OF PILOT. 9G20−031A
2. CATHODE PIN IS ON FLAT SIDE OF LED. CATHODE PIN CONNECTS TO CATHODE TERMINAL.
3. CATHODE TERMINAL CONNECTS TO GROUND WIRE.
1. FUEL TRANSFER LIGHT 5. BASE
2. LIGHT EMITTING DIODE 6. CATHODE PIN
3. PANEL 7. CATHODE TERMINAL
4. LENS
Figure 208. Supplemental Fuel Transfer Indicator Light
AG. Indicator Lamp Removal (Typical) (6). Remove housing (3) from panel (4)
sufficiently to disconnect wires from
(Ref. Figure 209) connector block (2).
Power Off (7). Disconnect wires from connector block
(2). Tag wires (Ref. Wire Termination).
(8). Remove housing (3).
(9). If necessary, install protective covers on
(1). Make sure all electrical power is exposed wires (Ref. Cleaning and
disconnected from helicopter (ref. Protection).
CSP-900RMM-3, Section 96-00-00).
AH. Indicator Lamp Installation (Typical)
Lamp components can be hot
CAUTION even if lamps are off. (Ref. Figure 209)
Power Off
NOTE: Apply 1-6 lbs. (0.45-2.72Kg) of force to
legend face.
(2). Grasp edges of legend face (7) and pull
module (6) out of housing (3).
(1). Make sure all electrical power is
(3). Loosen screws (8) until mounting pawl disconnected from helicopter (ref.
(9) disengages slot (10). CSP-900RMM-3, Section 96-00-00).
(4). Remove mounting sleeve (1) from (2). Connect wires to connector block (Ref.
housing (3). Wire Terminations).
(5). Prepare wires for removal (Ref. Wire NOTE: Apply 1-6 lbs. (0.45-2.72Kg) of force to
Maintenance). legend face.

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(3). Grasp edges of legend face and pull Lamp components can be hot
module out of housing. CAUTION even if lamps are off.
NOTE: NOTE: Apply 1-6 lbs. (0.45-2.72Kg) of force to
D Make sure mounting pawls are inside of legend face.
housing.
D Make sure mounting pawls are moved (2). Grasp edges of legend face (7) and pull
closer to the connector block end of hous­ module (6) out of housing (3).
ing.
(3). Turn module (6) down.
(4). Install housing into panel.
(5). Install mounting sleeve on housing and (4). Remove bulb (5).
hold against panel.
AJ. Indicator Lamp Bulb Installation (Typical)
(6). Tighten screws until the mounting
pawls engage slot and housing is tight (Ref. Figure 209)
to panel.
(7). Turn module up and align with hous­ Power Off
ing.
(8). Put module into housing and push until
module stops.
(9). Complete wire harness (Ref. Wire (1). Make sure all electrical power is
Maintenance). disconnected from helicopter (ref.
(10). Connect electrical power to helicopter CSP-900RMM-3, Section 96-00-00).
(Ref. CSP-900RMM-3, Section
96-00-00). (2). Install bulb in module.
Battery Discharge. (3). Turn module up and align with hous­
CAUTION
ing.
(11). On ELECTRICAL POWER panel, set
POWER switch to BAT/EXT. (4). Put module into housing and push until
module stops.
(12). Check indicator lamp operation with
PRESS-TO-TEST switch. (5). Connect electrical power to helicopter
(Ref. CSP-900RMM-3, Section
(13). On ELECTRICAL POWER panel, set
96-00-00).
POWER switch to OFF.
AI. Indicator Lamp Bulb Removal (Typical) Battery Discharge
CAUTION
(Ref. Figure 209)
Power Off (6). On ELECTRICAL POWER panel, set
POWER switch to BAT/EXT.

(7). Check indicator lamp operation with


PRESS-TO-TEST switch.
(1). Make sure all electrical power is
disconnected from helicopter (ref. (8). On ELECTRICAL POWER panel, set
CSP-900RMM-3, Section 96-00-00). POWER switch to OFF.

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10 (2 PLACES)
2
3
4

5 (4 PLACES)

9 (2 PLACES)

8 (2 PLACES)
7

9G95−072A

1. MOUNTING SLEEVE 6. MODULE


2. CONNECTOR BLOCK 7. LEGEND FACE
3. HOUSING 8. SCREW
4. PANEL 9. MOUNTING PAWL
5. BULB 10. SLOT
Figure 209. Indicator Lamp

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2. Electrical Connector Maintenance B. Circular Electrical Connector Installation


(Typical)
A. Circular Electrical Connector Removal
(Typical) (Ref. Figure 210)

(Ref. Figure 210) Consumable Materials


(Ref. Section 91−00−00)
Power Off Item Nomenclature
C602 Rubber Strip, Self Fusing

Power Off
(1). Make sure all electrical power is
disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00).

(2). If necessary, remove access panels (ref. (1). Make sure all electrical power is
CSP-900RMM-2 Section 06-00-00). disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00).
(3). If necessary, remove and discard lock (2). Install rear accessory and adapter body
wire. on wire harness.
(4). Disconnect electrical connector (6) from NOTE: Do not install contacts without wires
receptacle. into connector.

(5). Prepare wires for removal (Ref. Wire (3). Install sealing plugs and contacts with
Maintenance). wires into connector (Ref. Wire Ter­
minations).
(6). Remove screws (1), washers (2), and
(4). Install adapter body on connector.
terminal lug (if installed). Remove
Tighten sufficiently to prevent move­
strain relief (7).
ment of adapter body.
(7). Remove rubber wrap tape (3). (5). If necessary, install backshell.
(8). Loosen rear accessory (4) and move it NOTE:
away from adapter body (5). D If there are picked shields , refer to
Shielded Wire Preparation and Termina­
NOTE: Record location of shield and ground tion for rear accessory and strain relief
terminations. All shields and grounds must installation.
be the same at installation.
D Installation of rear accessory can cause
(9). If necessary, remove backshell. adapter body grommet deformation. De­
formation is permitted if it does not dam­
(10). Loosen adapter body (5) and move it age grommet and it continues to make a
away from connector (6). seal.
(6). Attach rear accessory to adapter or
(11). Remove all sealing plugs and contacts backshell (if installed). Tighten suffi­
from connector (6) (ref. Wire Termina­ ciently to prevent movement of rear
tions). accessory.
(12). If necessary, install protective covers on (7). Apply rubber tape (C602) a minimum of
exposed wires (ref. Cleaning and two wraps around wire bundle and
Protection). under center of strain relief.

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(8). Install strain relief, terminal lug (if C. Circular Receptacle Removal (Typical)
installed), screws, and washers.
Tighten screws sufficiently to prevent (Ref. Figure 210)
movement of strain relief. (1). Disconnect electrical connector from
(9). Do the Continuity Test procedure (Ref. receptacle.
Electrical Tests). (2). If necessary, remove environmental
seal from screws, washers, nuts (if
(10). Complete wire harness (Ref. Wire
installed), and receptacle.
Maintenance).
(3). Remove screws, washers, and nuts (if
(11). Connect electrical connector to recep­ installed) that attach receptacle.
tacle. Make sure electrical connector is Remove receptacle.
fully engaged.
(4). Prepare wires for removal (Ref. Wire
(12). Make sure there is no strain on wires. Maintenance).
If necessary, adjust electrical connector
alignment as follows: (5). If necessary, do the procedures that
follow:
(a). Loosen adapter body until rear
accessory rotates freely. (a). Remove strain relief, terminal lug (if
installed), screws, and washers.
(b). Rotate rear accessory until strain on
wires is released. (b). Remove all rubber wrap tape.

(c). Tighten adapter body sufficiently to (c). Loosen rear accessory and move
prevent movement of the rear away from adapter body.
accessory. (d). Disassemble backshell, and remove if
(13). Apply indication stripe (torque stripe) possible.
(Ref. Section 20-10-00). NOTE: Record location of shield and ground
(14). If necessary, safety connector with terminations. All shields and grounds must
lockwire. be the same at installation.

(15). Install access panels if removed (Ref. (e). Loosen adapter body and move away
CSP-900RMM-2 Section 06-00-00). from receptacle.
(16). Connect electrical power to helicopter (6). Remove all sealing plugs and contacts
(Ref. CSP-900RMM-3, Section from connector (6) (Ref. Wire Termina­
96-00-00). tions).
(17). Do an operational check of applicable (7). If necessary, install protective covers on
system(s) (Ref. applicable system exposed wires (Ref. Cleaning and
section). Protection).

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D. Circular Receptacle Installation (Typical) (e). Install strain relief, lugged solder
sleeve (if installed), screws, and
(Ref. Figure 210) washers. Tighten screws sufficiently
to prevent movement of strain relief.
Consumable Materials (4). Do the Continuity Test procedure (Ref.
(Ref. Section 91−00−00) Electrical Tests).
Item Nomenclature
(5). Complete wire harness (Ref. Wire
C602 Rubber Strip, Self Fusing
Maintenance).
C216 Sealant, Fuel Resistant
(6). Prepare surface for electrical bond (Ref.
Section 20-50-00).
(1). If necessary, install rear accessory and
adapter body on wire harness. (7). Install receptacle, screws, washers and
nuts (if installed).
NOTE: Do not install contacts without wires (8). Test receptacle for class “R” electrical
into receptacle. bond (Ref. Section 20-50-00).
(2). Install sealing plugs and contacts with Sealant, Fuel Resistant (C216)
wires into receptacle (Ref. Wire Ter­
minations).

(3). If necessary, do the procedures that


follow:
(9). If necessary, environmentally seal
(a). Install adapter body on receptacle. receptacle and attach hardware with
Tighten sufficiently to prevent sealant (C216) (Ref. 20-50-00). Seal
movement of adapter body. only if:
(a). Receptacle is constantly in weather.
(b). Install backshell.
(b). Receptacle was sealed before.
NOTE:
(10). Make sure there is no strain on wires.
D If there are picked shields , refer to If necessary, adjust wire routing and
Shielded Wire Preparation and Termina­ receptacle alignment as follows:
tion for rear accessory and strain relief
installation. (a). Adjust harness routing and clamp
position to reduce strain.
D Installation of rear accessory can cause
adapter body grommet deformation. De­ (b). Loosen adapter body until rear
formation is permitted if it does not dam­ accessory rotates freely.
age grommet and it continues to make a
seal. (c). Rotate rear accessory until strain on
wires is released.
(c). Attach rear accessory to adapter or
backshell (if installed). Tighten (d). Tighten adapter body sufficiently to
sufficiently to prevent movement of prevent movement of the rear
rear accessory. accessory.
(11). Apply indication stripe (torque stripe)
(d). Apply rubber tape (C602) a minimum (Ref. Section 20-10-00).
of two wraps around wire bundle and
centered under strain relief. (12). Connect electrical connector.

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STANDARD PRACTICE MANUAL

1
8 2

3
5 4
6

9G20−046A

1. SCREW 5. ADAPTER BODY


2. WASHER 6. CONNECTOR
3. RUBBER WRAP TAPE 7. STRAIN RELIEF
4. REAR ACCESSORY 8. WIRE HARNESS
Figure 210. Circular Electrical Connector (Typical)

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STANDARD PRACTICE MANUAL

E. Rectangular Electrical Connector (4). Assemble electrical connector (Ref.


Removal (Typical) manufacture's instructions).
Power Off (5). Install connector on receptacle.

(6). Turn both jack screws one full turn.

(7). Tighten one jack screw fully. Tighten


(1). Make sure all electrical power is other jack screw.
disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00). (8). Make sure electrical connector is fully
mated to receptacle.
(2). If necessary, remove access panels (Ref.
CSP-900RMM-2 Section 06-00-00).
(9). Complete wire harness (Ref. Wire
(3). Loosen both jack screws one full turn. Maintenance).

(4). Loosen one jack screw fully. (10). Make sure there is no strain on wires.
Adjust harness routing and clamp
(5). Loosen other jack screw, and disconnect position to reduce strain.
electrical connector from receptacle.
(11). Install access panels if removed (Ref.
(6). Disassemble connector (Ref. manufac­ CSP-900RMM-2 Section 06-00-00).
ture's instructions.
(12). Connect electrical power to helicopter
(7). Prepare wires for removal (Ref. Wire (Ref. CSP-900RMM-3, Section
Maintenance). 96-00-00).
(8). Remove all sealing plugs and contacts (13). Do an operational check of applicable
from connector (Ref. manufacture's system(s) (Ref. applicable system
instructions). section).
(9). If necessary, install protective covers on
exposed wires (Ref. Cleaning and G. Rectangular Receptacle Removal
Protection). (Typical)

F. Rectangular Electrical Connector (1). Disconnect rectangular electrical


Installation (Typical) connector from receptacle.
Power Off (2). Remove screws, washers, and nuts (if
installed) that attach receptacle.
Remove receptacle.

(3). Disassemble receptacle (Ref. manufac­


(1). Make sure all electrical power is ture's instructions.
disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00). (4). Prepare wires for removal (Ref. Wire
Maintenance).
NOTE: Do not install contacts without wires
into connector. (5). Remove all sealing plugs and contacts
(2). Install sealing plugs and contacts with from connector (Ref. manufacture's
wires into connector (Ref. manufac­ instructions).
ture's instructions).
(6). If necessary, install protective covers on
(3). Do the Continuity Test procedure (Ref. exposed wires (Ref. Cleaning and
Electrical Tests). Protection).

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H. Rectangular Receptacle Installation (5). Remove connector from coaxial cable.


(Typical) Using one of the procedures that follow:
NOTE: Do not install contacts without wires (a). Cut coaxial cable just behind connec­
into receptacle. tor. Preferred method.
(1). Install sealing plugs and contacts with
wires into receptacle (Ref. manufac­ (b). Disassemble and remove connector.
ture's instructions). Do not remove contact.
(2). Do the Continuity Test procedure (Ref. (6). If necessary, install protective cover on
Electrical Tests). exposed cable (Ref. Cleaning and
(3). Complete wire harness (Ref. Wire Protection).
Maintenance).
J. Coaxial Connector Installation (Typical)
(4). Assemble receptacle (Ref. manufac­
ture's instructions). NOTE:
(5). Prepare surface for electrical bond (Ref. D Some coaxial cables have a very impor­
Section 20-50-00). tant length. Make sure you do not cut co­
axial cable less than this length.
(6). Install receptacle, screws, washers, and
nuts (if installed). Tighten screws D Inspect cable condition. If cable end is
sufficiently to prevent movement of damaged, cut off damage.
receptacle.
D Heat-shrinkable sleeving must be
(7). Test receptacle for class “R” electrical installed on all crimp-ferrule style con­
bond (Ref. Section 20-50-00). nectors to provide cable strain relief (Ref.
Wire Maintenance).
(8). Connect rectangular electrical connec­
tor. (1). Install connector on coaxial cable (Ref.
(9). Make sure there is no strain on wires. manufacture's instructions).
Adjust harness routing and clamp
position to reduce strain. (2). Complete coaxial cable (Ref. Wire
Maintenance).
I. Coaxial Connector Removal (Typical)
(3). Do the Open Circuit Test procedure
Power Off
(Ref. Electrical Tests).

(4). Connect coaxial connector. Make sure


locks engage.
(1). Make sure all electrical power is
(5). Make sure there is no strain on wires.
disconnected from helicopter (ref. Adjust harness routing and clamp
CSP-900RMM-3, Section 96-00-00). position to reduce strain.
(2). If necessary, remove access panels (Ref.
CSP-900RMM-2 Section 06-00-00). (6). Install access panels if removed (Ref.
CSP-900RMM-2 Section 06-00-00).
(3). Prepare coaxial cable for maintenance
(7). Connect electrical power to helicopter
(Ref. Wire Maintenance).
(Ref. CSP-900RMM-3, Section
Do not cut coaxial cables less 96-00-00).
CAUTION than critical length. Signal loss
and signal degradation will occur. (8). Do an operational check of applicable
system(s) (Ref. applicable system
(4). Disconnect connector. section).

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K. Coaxial Receptacle Removal (Typical) NOTE:


D Some coaxial cables have a very impor­
(1). Disconnect coaxial connector. tant length. Make sure you do not cut co­
axial cable less than this length.
D Inspect cable condition. If cable end is
(2). Prepare coaxial cable for maintenance
damaged, cut off damage.
(Ref. Wire Maintenance).
D Heat-shrinkable sleeving must be
installed on all crimp-ferrule style con­
(3). If necessary, remove environmental nectors to provide cable strain relief (Ref.
seal from coaxial receptacle. Wire Maintenance).
(1). Prepare surfaces for electrical bond (Ref
(4). Remove nuts and washers from coaxial Section 20-50-00).
receptacle.
(2). Install receptacle (Ref. manufacture's
instructions).
(5). Remove coaxial receptacle.
(3). Test receptacle for class “R” electrical
bond (Ref. Section 20-50-00).
Do not cut coaxial cables less
CAUTION than critical length. Signal loss (4). Complete coaxial cable (Ref. Wire
and signal degradation will occur. Maintenance).
(5). Do the Open Circuit Test procedure
(6). Remove receptacle from coaxial cable. (Ref. Electrical Tests).
Using one of the procedures that follow:
(6). Install coaxial receptacle, washers, and
nuts. Tighten nuts sufficiently to
(a). Cut coaxial cable just behind recep­ prevent movement of receptacle.
tacle. Preferred method.
(7). Make sure there is no strain on wires.
Adjust harness routing and clamp
(b). Disassemble and remove receptacle. position to reduce strain.
Do not remove contact.
Sealant, Fuel Resistant (C216)
(7). If necessary, install protective cover on
exposed cable (Ref. Cleaning and
Protection).
(8). If necessary, environmentally seal
L. Coaxial Receptacle Installation (Typical) receptacle, washers, and nuts with
sealant (C216) (Ref. Section 20-50-00).
Seal only if:
Consumable Materials
(a). Receptacle is constantly in weather.
(Ref. Section 91−00−00)
Item Nomenclature (b). Receptacle was sealed before.
C216 Sealant, Fuel Resistant (9). Connect coaxial connector. Make sure
locks engage.

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STANDARD PRACTICE MANUAL

3. Wire Maintenance C. Tying of Wires, Harnesses, and Cables

A. Wire Maintenance Preparation (Ref. Table 201, Figure 211 and Figure 212)

Power Off Consumable Materials


(Ref. Section 91−00−00)
Item Nomenclature
C703 Tape, Lacing and Tying
C708 Tape, Lacing and Tying
NOTE: This procedure prepares wires and co­ C321 Coating, Varnish
axial cables for general maintenance.

(1). If necessary, remove wire harness NOTE:


support clamps. D Keep the number of ties to a minimum.
Install ties as necessary to keep harness
(2). Remove or move anti-rub sleeves and tight not rigid, and without separation of
identification tags 12 in. (30.5 cm) wires.
from work area. Keep all identification
tags removed. D Do not install tying tape at more than 18
in. (457.2 mm) distance between each
(3). Remove tying tape 12 in. (30.5 cm) tie.
from area where you will do mainte­
(1). Refer to Table 201 for selection of
nance.
tying tape.
B. Wire Maintenance Completion Position tape to revent damage
CAUTION to wires by splice edges.
NOTE: This procedure makes wire harnesses
and coaxial cables complete after mainte­ (2). Wrap tape loosely around harness two
nance. times.
(1). Inspect cables or wires (Ref. Wire (3). Wrap end of tape around the two wraps
Inspection). to form a clove hitch.

Do not exceed minimum bend (4). Pull ends of tape to make wraps tight.
CAUTION radius of individual wires, (5). Wrap one end of tape around the other
cables, or harness (Ref. Wire Inspection). end three times.
(2). If necessary, apply tying tape. (6). Pull ends of tape to make wraps tight.

(3). Attach all removed identification tags. (7). Cut ends of tape 0.19-0.38 in. (5-10
mm) in length.
(4). If necessary, install anti-rub sleeves.
Coating, Varnish (C321)
(5). Install all harness support clamps
removed. If necessary, change clamp
size.

(6). Inspect completed maintenance (Ref. (8). If tying tape (C708) is installed, apply
Wire Inspection). varnish (C321) to knot.

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STANDARD PRACTICE MANUAL

Table 201. Tape Selection


Specification Material Finish Color Nominal
Application
(Code) (Ref.) Width
(Max. Temp)
(Code)
General Purpose A−A−52081 Polyester Fungicide Black 0.110 in.
(280 °F, 137 °C) Wax (Size 2)
(Finish B) or
High Temperature A−A−52083 Fiberglass TFE White 0.085 in.
(800 °F, 426 °C) (Finish D) or (Size 3)
Natural

9G20−026

Figure 211. Clove Hitch and Three−turn Loop

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STANDARD PRACTICE MANUAL

STRAIN RELIEF
TIE

TERMINAL STRIP
BRANCH TIES

TYING OF WIRE BUNDLE


WITH SHIELD TERMINATIONS

9G20−027
BREAKOUT
BRANCH TIES

Figure 212. Installation of Tying Tape (Sheet 1 of 2)

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STANDARD PRACTICE MANUAL

INDIVIDUAL GROUP
TIES 9G20−028

Figure 212. Installation of Tying Tape (Sheet 2 of 2)

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STANDARD PRACTICE MANUAL

D. Expandable Sleeving NOTE: Connectors must be removed before you


install expandable sleeving.
(Ref. Table 202, Figure 213 and Figure 214)
(3). Install sleeve on bundle, with folded
end first.
Consumable Materials
(Ref. Section 91−00−00) (4). Pull out folded in end of sleeving.
Item Nomenclature
C818 Sleeve, Protective, Expandable and (5). Adjust sleeving to center of area.
Insulating
(6). Push both ends of sleeving in along
bundle 2 in. (5.08 cm) and install tying
NOTE: You must install anti-rub sleeving re­ tape.
moved for maintenance.
(7). Push/Pull sleeving to overlap tied ends
(1). Cut expandable sleeving (C818) to and install tying tape approximately
overlap 2 in. (5.08 cm) each end of 0.5 in. (1.27 cm) from first tie.
area to be covered.
(8). Install tying tape on sleeving at 3-4 in.
(2). Fold in one end of sleeving. (7.62-10.16 cm) distance.

TURN END OF SLEEVE IN


Table 202. Expandable Sleeving Selection
Specification/Part No. Inside Diameter

ÖÖ MHS5330−1024 0.125 in. (3.18 mm)

ÖÖÖÖ
ÖÖ ÖÖÖÖÖÖ
ÖÖÖÖÖÖÖÖÖÖ
MHS5330−1031
MHS5330−1039
0.250 in. (6.35 mm)
0.500 in. (1.27 cm)
MHS5330−1043 0.750 in. (1.91 cm)
MHS5330−1049 1.25 in. (3.18 cm)
EXPANDABLE SLEEVING
9G20−032A MHS5330−1050 1.75 in. (4.45 cm)
MHS5330−1051 2.00 in. (5.10 cm)
Figure 213. Sleeving With End Folded MHS5330−1052 2.50 in. (6.35 cm)

HARNESS TYING TAPE OVERLAP HARNESS TYING TAPE SLEEVING

SLEEVING
RESULT OF OVERLAP FIRST TYING TAPE
NOT VISIBLE 9G20−033A

Figure 214. Expandable Sleeving Installation

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STANDARD PRACTICE MANUAL

E. Heat Shrinkable Sleeving (8). Inspect sleeving for correct position.


(Ref. Table 203 and Table 204)

Consumable Materials Table 203. Heat Shrink Selection


(Ref. Section 91−00−00) Part No. Class Inside Diameter
Item Nomenclature
M23053/5−101−(2) 1 0.046 in. (1.17 mm)
C819 Insulation Sleeving, Electrical, Heat
Shrinkable M23053/5−102−(2) 1 0.063 in. (1.60 mm)
M23053/5−103−(2) 1 0.093 in. (2.36 mm)
M23053/5−104−(2) 1 0.125 in. (3.18 mm)
Special Tools
(Ref. Section 91−00−00) M23053/5−105−(2) 1 0.187 in. (4.75 mm)
Item Nomenclature
M23053/5−106−(2) 1 0.250 in. (6.35 mm)
T2004 Heat Gun
M23053/5−107−(2) 1 0.375 in. (9.53 mm)

NOTE: M23053/5−108−(2) 1 0.500 in. 12.7 mm)


D You must install anti-rub sleeving re­ M23053/5−109−(2) 1 0.750 in. (1.91 cm)
moved for maintenance.
M23053/5−110−(2) 1 1.00 in. (2.54 cm)
D Heat shrinkable sleeving can be installed
for wire/cable identification and strain re­ M23053/5−111−(2) 1 1.50 in. (3.81 cm)
lief. M23053/5−112−(2) 1 2.00 in. (5.08 cm)
(1). Cut heat shrinkable sleeving (C819) to
length. Cut 0.50 in. (1.27 cm) more
than area of wear when installed for NOTES:
anti-rub.
NOTE: Connectors must be removed before you (2) Color code number (Ref. Table 204).
install heat shrinkable sleeving.
(2). Install sleeving on area to be protected.
Table 204. Color Code
(3). Protect heat sensitive components near
area. Code Color
0 Black
Do not apply heat for more than
CAUTION 10 seconds in one position. 1 Brown
Damage to sleeving or insulation can occur.
2 Red
(4). Apply heat to sleeving, hold heat gun
3 Orange
(T2004) 3-4 in. (76-102 mm) from
sleeving. 4 Yellow
(5). Move heat along sleeving until sleeving 5 Green
is correct dimension. 6 Blue
(6). Inspect sleeving for cracks and splits. 7 Violet
None allowed.
8 Gray
(7). Inspect sleeving for discoloration. None
allowed. 9 White

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F. Electrical Insulation Sleeving (a). Minimum overlap if bundle is less


than 1.5 in. (3.81 cm) in diameter,
(Ref. Table 205 and Figure 215) 0.25 in. (6.35 mm).
(b). Minimum overlap if bundle is more
Consumable Materials than 1.5 in. (3.81 cm) in diameter,
(Ref. Section 91−00−00) 0.5 in. (1.27 cm).
Item Nomenclature
(4). Wrap sleeving around bundle and
C816 Insulation Sleeving, Electrical, Resin overlap.
Coated
(5). Apply tying tape along sleeving at each
3-4 in. (7.62-10.16 cm) distance.
NOTE:
Table 205. Insulation Sleeving Selection
D You must install anti-rub sleeving re­
Specification/Part No. Inside Diameter
moved for maintenance.
MHS5485−1250 1.25 in. (3.18 cm)
D Install additional insulation sleeving to
wire harnesses in abrasive conditions. MHS5485−1500 1.50 in. (3.81 cm)
MHS5485−1750 1.75 in. (4.45 cm)
(1). Cut electrical insulation sleeving MHS5485−2000 2.00 in. (5.08 cm)
(C816) to length.
MHS5485−2250 2.25 in. (5.72 cm)
(2). Cut sleeving open. MHS5485−2500 2.50 in. (6.35 cm)
MHS5485−2750 2.75 in. (6.99 cm)
(3). Cut sleeving to give a minimum overlap
as follows: MHS5485−3000 3.00 in. (7.62 cm)

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STANDARD PRACTICE MANUAL

CUT OPEN

TYING TAPE

MINIMUM OVERLAP

SMALL CABLE
LENGTHWISE WRAP

TYING TAPE

MINIMUM OVERLAP

LARGE DIAMETER CABLE


SPIRAL WRAP 9G20−034A

Figure 215. Electrical Insulation Sleeving Installation

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STANDARD PRACTICE MANUAL

G. Clamp Installation (d). Clamp must not restrict wires


attached to moving components.
(Ref. Figure 216, Figure 217, Figure 218 and
Figure 219) (e). Clamp must not let wires contact
sharp edges of equipment or struc­
Consumable Materials ture.
(Ref. Section 91−00−00)
Item Nomenclature (f). Clamp must not contact equipment
C602 Rubber Strip, Self Fusing or structure.

(g). Make flat or bend clamp for clear­


NOTE: This procedure applies to installation of ance. Make flat no more than 0.25
clamps when wire harnesses have been in. (6.35 mm). Maximum bend 455.
changed and new clamps must be added.
(1). Find correct dimension clamp as
follows:
0.25 IN.
(a). Clamp must hold wires without (6.35 MM)
damaging insulation.
(b). All wires must be inside cushion.
(c). Cushion must form a continuous
surface around wires when clamp is
closed.
(d). If necessary, wrap wires with rubber
tape (C602) to give a correct dimen­
sion.
(2). Install clamp on wires. Adjust wires or
clamp position as follows: 45°

(a). Clamp must not be installed in the


radius bends.
(b). Clamp must not be installed on
permanent splices.
9G20−038A
(c). Clamp can be installed on disconnect
splices, tying tape, end caps, and
shield terminations. Figure 216. Clamp Adjustment

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

A B C

NUT NOT TIGHT AND WIRES CUSHION IS NOT IN CLAMP TOO LARGE
BETWEEN METAL OF CLAMP CORRECT POSITION

TWISTED AND
CUSHION DISTORTED

CLAMP IN RADIUS
OF BEND

9G20−036A

Figure 217. Incorrect Clamp Installation

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STANDARD PRACTICE MANUAL

DO NOT CLAMP
IN THIS AREA
90°

USE CIRRECT BEND RADIUS

90°

CUSHION IN CORRECT POSITION


AND NUT TIGHT
NOT TWISTED AND
CUSHION NOT DISTORTED

9G20−037A
RUBBER WRAP NECESSARY FOR
CORRECT CLAMP INSTALLATION

Figure 218. Correct Clamp Installation

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STANDARD PRACTICE MANUAL

AIRCRAFT STRUCTURE

TUBE

CLAMP
CLAMP SPACER
NOTE: NOT RECOMMENDED
BUT PERMITTED
ANGLE BRACKET

AIRCRAFT STRUCTURE

ANGLE

Z EXTRUSION
ANGLE BRACKET 9G20−040A

Figure 219. Clamps Attached to Structure


H. Electrical Wire Identification Label (1). Get correct dimension heat shrinkable
Installation sleeving (C819).

(Ref. Figure 220) (2). Cut sleeving into 1.25 in. (3.18 cm)
pieces.

Consumable Materials (3). Print wire identification code on two


(Ref. Section 91−00−00) sleeving segments as follows:
Item Nomenclature (a). Use wire number standard (Ref. Wire
C819 Insulation Sleeving, Electrical, Heat Identification).
Shrinkable
(b). Print wire identification code hori­
zontally left to right or vertically top
NOTE: to bottom.

D Wires less than 6 in. (15.24 cm) do not (c). Symbols must be easy to read and
need to be identified. permanent.
D Each wire in a shielded cable must be (4). Install sleeves 3 in. (7.62 cm) from
identified. each end of wire.

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STANDARD PRACTICE MANUAL

(1). Get correct dimension heat shrinkable


PREFERRED sleeving (C819).
METHOD
(2). Cut sleeving into 1.25 in. (3.18 cm)
E137A22 3 pieces.
(3). Print connector identification number,
HEAT SHRINKABLE receptacle identification number, wire
SLEEVING
harness number, and component name
on two sleeving pieces as follows:
E

2
1

2
3

3
7
A
ALTERNATE (a). Print horizontally left to right.
METHOD
(b). Symbols must be easy to read and
permanent.
(4). Print wire identification code on two
9G20−041 sleeving pieces as follows:
(a). Use wire number standard (Ref. Wire
Figure 220. Wire Identification Label Identification).
(b). Print wire identification code hori­
I. Coaxial Cable Identification Label zontally left to right or vertically top
Installation to bottom.

(Ref. Figure 221) (c). Symbols must be easy to read and


permanent.

Consumable Materials NOTE: Install sleeving with wire code on cable


(Ref. Section 91−00−00) first. Then install sleeving with connector,
Item Nomenclature harness, and component identification num­
bers.
C819 Insulation Sleeving, Electrical, Heat
Shrinkable (5). Install sleeves 3.5 in. (8.89 cm) from
each ends of coaxial cable.

LABELS OF SHRINKABLE SLEEVING

W436 P842
KLX1352L99 2
M/W W435J842

3.5 IN.

9G20−042

Figure 221. Coaxial Cable Identification Label

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STANDARD PRACTICE MANUAL

4. General Wire B. Wire Installation

(Ref. Figure 222)


A. Wire Removal
Power Off
Power Off

(1). Make sure all electrical power is


disconnected from helicopter (ref.
(1). Make sure all electrical power is CSP-900RMM-3, Section 96-00-00).
disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00). (2). If necessary, remove access panels (Ref.
CSP-900RMM-2 Section 06-00-00).
(2). If necessary, remove access panels (Ref.
Do not pull wires through
CSP-900RMM-2 Section 06-00-00). CAUTION clamps. Insulation damage can
occur.
Locate and remove wire by
CAUTION hand. Do not use tools to locate NOTE:
a wire, damage to wires can occur.
D Keep wire as short as possible.
D Wire attached to components that move,
(3). Locate wire to be removed.
must be installed to twist and not bend.

NOTE: Prevent strain on wires and electrical D Wire must be parallel with other wires
components. and have no kinks.

(3). Prepare harness for wire installation


(4). Give temporary support to wire (Ref. Wire Maintenance).
harness.
(4). If necessary, install wire identification
label (Ref. Wire Maintenance).
(5). Prepare wires for removal (Ref. Wire
Maintenance). (5). Find Electro-Magnetic Interference
(EMI) category of wires.
(6). Disconnect wire (Ref. Wire Termina­
tions). (6). Isolate wires of same EMI category
from wires in other categories. Bundle
each category with tying tape.
(7). Remove wire.
(7). Install wire or wire bundle along side
(8). Complete wire harness (Ref. Wire and parallel to wire harness.
Maintenance).
(8). Make sure wire is of sufficient length
(9). If necessary, install protective covers on (Ref. Wire Inspection).
exposed wires (Ref. Cleaning and
Protection). NOTE:
D If necessary, remove tying tape to keep
(10). Install access panels if removed (Ref. number of ties to a minimum.
CSP-900RMM-2 Section 06-00-00).
D Do not remove EMI category bundle ties.
(11). Connect electrical power to helicopter
(Ref. CSP-900RMM-3, Section (9). Install tying tape to make a complete
96-00-00). harness.

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(4). Prepare coaxial cable for removal (Ref.


Wire Maintenance).
HARNESS
TIE (5). Disconnect coaxial cable connectors at
each end of cable.

CAT 3 (6). Remove coaxial cable.


CAT 1 CAT 5 (7). Install access panels if removed (Ref.
CSP-900RMM-2 Section 06-00-00).
CAT 4 (8). Connect electrical power to helicopter
(Ref. CSP-900RMM-3, Section
96-00-00).
EMI CATAGORY D. Coaxial Cable Installation (Typical)
BUNDLE TIE
(Ref. Figure 223)
9G20−029A
Power Off

Figure 222. Wire Harness Bundled by


Category
(1). Make sure all electrical power is
(10). Terminate wire ends (Ref. Wire Ter­
minations). disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00).
(11). Do the Continuity Test procedure (Ref. (2). If necessary, remove access panels (Ref.
Electrical Tests). CSP-900RMM-2 Section 06-00-00).
(12). Complete wire harness (Ref. Wire NOTE:
Maintenance).
D Keep coaxial cable as short as possible to
(13). Install access panels if removed (Ref. minimize high frequency transmission
CSP-900RMM-2 Section 06-00-00). losses.
(14). Connect electrical power to helicopter D Coaxial cables must not be twisted.
(Ref. CSP-900RMM-3, Section
96-00-00). (3). Install coaxial cable.
(15). Do an operational check of applicable (4). Make sure cable is of sufficient length
system(s) (Ref. applicable system (Ref. Wire Inspection).
section).
(5). If cable has too much length, do the
C. Coaxial Cable Removal (Typical) procedure that follows:
(a). Find best location to wind cable.
Power Off
(b). Wind cable. Do not wind tighter than
minimum bend radius (Ref. Wire
Inspection).
(c). Put wound cable between first and
(1). Make sure all electrical power is second clamps.
disconnected from helicopter (ref.
CSP-900RMM-3, Section 96-00-00). (d). Install tying tape on wound cable
(Ref. Wire Maintenance).
(2). If necessary, remove access panels (Ref.
CSP-900RMM-2 Section 06-00-00). (e). Cable must not rub on structure or
components. If necessary, adjust
(3). Locate coaxial cable to be removed. position of tying tape.

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STANDARD PRACTICE MANUAL

(6). If necessary, install coaxial cable (9). Connect coaxial connectors.


identification label (Ref. Wire Mainte­
(10). Install access panels if removed (Ref.
nance).
CSP-900RMM-2 Section 06-00-00).
(7). If necessary, install connectors on cable (11). Connect electrical power to helicopter
(Ref. Electrical Connector Mainte­ (Ref. CSP-900RMM-3, Section
nance). 96-00-00).
(8). Install cable isolated from other coaxial (12). Do an operational check of applicable
cables and Wire (Ref. Wire Mainte­ system(s) (Ref. applicable system
nance). section).

COAXIAL
CABLE

FIRST
CLAMP

WOUND
CABLE

SECOND 9G20−030A
CLAMP

Figure 223. Coaxial Cable Installation (Typical)

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STANDARD PRACTICE MANUAL

5. Wire Cleaning and Protection (3). Protect heat sensitive components near
area.
A. Spare Wires
Do not apply heat for more than
(Ref. Table 206 and Figure 224) CAUTION 10 seconds in one position.
Damage to end cap or insulation can occur.
Consumable Materials
(Ref. Section 91−00−00) (4). Apply heat to end cap, hold heat gun
Item Nomenclature (T2004) 3-4 in. (76-102 mm) from end
cap.
C819 Insulation Sleeving, Electrical, Heat
Shrinkable
C821 End Cap, Wire
(5). Move heat along end cap until end cap
is correct dimension.

(6). Inspect end cap for cracks and splits.


Special Tools None allowed.
(Ref. Section 91−00−00)
Item Nomenclature
(7). Inspect end cap for discoloration. None
T2004 Heat Gun allowed.

(8). Make sure end cap is tight.


(1). Put spare wire ends together.

NOTE: Do not remove contacts from wires. (9). When possible, keep spare wires on
outside of harness.
(2). Install correct end cap (C821) on each
spare wire. Make sure end of wire (10). Install tying tape on spare wires. Do
contacts end of cap. not put tape on end caps.

Table 206. End Cap Selection


Wire Insulation End Cap
AWG Thickness (1)
Color Part Number
24 Thin White MHS5077−4001
22 Thin
24 Regular Red MHS5077−4003
22 Regular
20 All
18 All
16 All
14
Thin
14 Regular Gray MHS5077−4005
12 All
10 Thin
10 Regular Brown MHS5077−4006

NOTES:
(1) This is a general property applicable to most types of wire. If necessary, use different end cap.

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STANDARD PRACTICE MANUAL

9G20-023

Figure 224. End Caps

B. Spare Connector
PLASTIC BAG

(Ref. Figure 225)


PLASTIC CAP

(1). Install plastic cap on connector.

(2). Put a plastic bag on connector and


attach with tying tape (Ref. Wire ATTACH TO STRUCTURE OR
WIRE HARNESS HERE
Maintenance).

(3). If possible, keep mating end up.


TYING TAPE TWO PLACES

(4). Attach connector to structure or wire


harness with tying tape (Ref. Wire
Maintenance).

(5). Install access panels if removed (Ref.


CSP-900RMM-2 Section 06-00-00).
9G20-024A
(6). Connect electrical power to helicopter
(Ref. CSP-900RMM-3, Section
96-00-00). Figure 225. Spare Connector

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STANDARD PRACTICE MANUAL

C. Protection for Wire Harnesses and (a). Install tying tape (Ref. Wire Mainte­
Electrical Connectors nance), rubber band, or equivalent on
plastic bag.

NOTE: This procedure gives protection to wires (2). Install a plastic cap on mating end of
and electrical connectors during mainte­ electrical connector.
nance. (a). Make sure cap is correct dimension
and remains in position.
(1). Put a plastic bag on electrical connector (b). Make sure cap is put on coupling nut
or wires. or threads.
PLASTIC BAG
LACING TAPE OR EQUIVALENT

ŠŠŠŠŠŠ
ŠŠŠŠŠŠ
ŠŠŠŠŠŠ
ŠŠŠŠŠŠ
ŠŠŠŠŠŠ
ŠŠŠŠŠŠ
ŠŠŠŠŠŠ
ŠŠŠŠŠŠ

ŠŠŠ
ŠŠŠ
ŠŠŠ
ŠŠŠ
ŠŠŠ
ŠŠŠ
ŠŠŠ
ŠŠŠ
9G20−047A
PLASTIC CAP

Figure 226. Protection for Wire Harnesses and Electrical Connectors

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D. Protection of Electro−Static Discharge E. Connector and Module Contamination


Sensitive (ESDS) Components Removal

Consumable Materials
Discharging through ESDS
CAUTION components can cause compo­
(Ref. Section 91−00−00)
Item Nomenclature
nent failure, major electrical properties
change, or decrease in performance. C421 Solvent, Cleaning
C423 Solvent, Cleaning

(1). Protect ESDS components as follows:


NOTE:
D Connectors and modules must be cleaned
(a). Ground aircraft with grounding wire. when they become contaminated.
D Use a plastic bottle to apply the cleaning
solvent.
(b). Touch ground (earth) a minimum of 3
seconds before you touch ESDS Solvent, Cleaning (C421)
components. Solvent, Cleaning (C423)

NOTE: ESD caps are usually black in color, and


have a static-sensitive symbol.
(1). Clean electrical connector as follows:
(c). Install ESD caps on all component (a). Flush connector clean with cleaning
electrical receptacles. solvent.
(b). Let connector air dry a minimum of
(d). Put component in a electrostatic 15 minutes.
shielding and/or static dissipative
multi-wall bag. (2). Clean module as follows:
(a). Remove module (Ref. Installation
and Removal of Electrical Compo­
(e). Install ESD caps on all electrical nents).
connectors that were disconnected
from ESDS component. (b). Point termination side of module
down.

(f). Put component in a static-dissipative (c). Wipe surface clean with cleaning
or anti-static type container. solvent. Do not push contamination
into holes.
(d). Let module air dry a minimum of 15
(2). Remove ESD protection immediately minutes.
before installation and electrical
connection. (e). Install module.

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F. Wire Harness Contamination Removal NOTE: There are two solder removal procedu­
res.
Consumable Materials (2). Solder removal procedure number one:
(Ref. Section 91−00−00)
Item Nomenclature (a). Put solder removal braid (solder
C421 Solvent, Cleaning wick) on solder joint.
C423 Solvent, Cleaning
(b). Put soldering iron tip on braid.
C802 Cloth, Non−Lint
(c). As solder is pulled into braid, move
new braid into joint until solder is
(1). Prepare contaminated area of wire
removed.
harness for maintenance (Ref. Wire
Maintenance). (d). Remove wire from joint.
Solvent, Cleaning (C421)
(e). Remove remaining solder as neces­
Solvent, Cleaning (C423) sary.
(3). Solder removal procedure number two:
(a). Put soldering iron tip on solder joint
and melt solder.
(2). Clean wires with cleaning solvent.
(b). Remove heated solder with a vacuum
(3). Dry wires, use one of the procedures
solder removal tool.
that follow:
(a). Apply low pressure dry clean air to (c). Remove wire from joint.
wires until dry. (d). Remove remaining solder as neces­
(b). Dry wires fully with non-lint cloth sary.
(C802).
B. Solder Installation
(4). Complete wire harness (Ref. Wire
Maintenance). (Ref. Figure 227 and Figure 228)

6. Wire Terminations Consumable Materials


A. Solder Removal (Ref. Section 91−00−00)
Item Nomenclature
Use a heat sink on heat sensi­ C419 Alcohol, Isopropyl
CAUTION tive electronic components to C819 Insulation Sleeving, Electrical, Heat
prevent damage. Shrinkable
Solder Installation and Removal
Use a heat sink on heat sensi­
CAUTION tive electronic components to
prevent damage.
(1). If necessary, apply a heat sink to wire. NOTE: This procedure includes different types
Apply between solder joint and compo­ of joints. Not all steps are applicable to all
nent. types of joint.

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Alcohol, Isopropyl (C419) (c). Put soldering iron tip on terminal.


(d). Supply solder to joint.
(e). Apply a smooth layer of solder with a
thin edge.
Solder Installation and Removal (f). Remove solder and soldering iron.
(g). Remove all residue with isopropyl
alcohol (C419).
(h). Inspect solder joint (Ref. Wire
NOTE: Inspection).
D Insulation can touch solder joint, but (5). Solder wire to wire as follows:
must not be covered by solder.
(a). Put heat shrinkable sleeving (C819)
D Distance between insulation and ter­
on wire and move away from joint
mination must be less than 2 wire diame­
(Ref. Wire Maintenance).
ters. Do not let wire short.
(b). Bend wires to a hook shape.
(1). Remove insulation from wire.
(c). Attach wires to together and close
(2). Clean components, wire, or terminals hooks. Do not overlapp conductors.
with isopropyl alcohol (C419).
(d). If necessary, apply a heat sink to
(3). Tin wire with solder. wire between joint and component.
(e). Put soldering iron tip on joint.
(f). Supply solder to joint.
SOLDER
(g). Apply a solder fillet between wires.
(h). Remove solder and soldering iron.
(i). Remove residue with isopropyl
alcohol (C419).
(j). Inspect solder joint (Ref. Wire
Inspection).
(k). Install sleeving on joint (Ref. Wire
Maintenance).
(6). Solder wire into solder cup as follows:
WIRE
SOLDERING IRON TIP
NOTE: Use solder with a diameter smaller
than the inside diameter of solder cup.
(a). Put soldering iron tip on rear of
9G20−049A solder cup.
(b). Apply solder to solder cup until it has
Figure 227. Tin Wire a sufficient quantity.
(c). Put wire into solder cup. Let solder
(4). Solder wire to terminals as follows: flow on wire.
(a). Mechanically attach wire to terminal. (d). Remove soldering iron and let joint
harden.
(b). If necessary, apply a heat sink to
wire between terminal and compo­ (e). Remove residue with isopropyl
nent. alcohol (C419).

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(f). Inspect solder joint (Ref. Wire (d). Put wire into contact. Let solder flow
Inspection). on wire.
(7). Solder wire to solder type contact as
follows: (e). Remove soldering iron and let joint
harden.
(a). Put a small quantity of solder on
soldering iron tip.
(f). Remove residue with isopropyl
(b). Put soldering iron tip on inspection alcohol (C419).
hole in contact.
(c). Apply solder to contact barrel until it (g). Inspect solder joint (Ref. Wire
has a sufficient quantity. Inspection).

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STANDARD PRACTICE MANUAL

WIRE WRAP FULL CONTACT


180° MINIMUM WITH TERMINAL
NO WIRE OVERLAP PERMITTED

0° 180°
SOLDER APPLIED TO TERMINAL
AWAY FROM SOLDERING IRON TIP

WIRE

SOLDERING IRON TIP


INSULATION CLEAR­ AGAINST TERMINAL
ANCE

TERMINAL INSTALLATION

SINGLE WIRE WRAP MULTIPLE WIRE WRAP SOLDER


MELTED
MECHANICALLY ATTACH TO TERMINAL FLUX
MELTED SOL­
DER

SOLDERING IRON TIP


AGAINST BACK OF SOLDER CUP

SOLDER CUP INSTALLATION

PREFILL CUP INSERT WIRE REMOVE HEAT


SOLDER CUP INSTALLATION STEPS

INSPECTION HOLE

9G20−050A
SINGLE WIRE MULTIPLE WIRES
SOLDER TYPE CONTACT INSTALLATION

Figure 228. Solder Installation

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STANDARD PRACTICE MANUAL

C. Wire Insulation Removal Do not damage shield braid


CAUTION when you do this procedure.
(1). Make correct tool selection for removal Component malfunction can occur.
of wire insulation as follows:
(a). Tool must be of automatic, hand NOTE:
operated, controlled action, fixed
blade or thermal type.
D This procedure gives instructions for
(b). Tool must be of the correct design for many installations. Not all steps are ap­
wire type and dimension. plicable.

(c). Use of chemical stripping agents is D If a picked shield is not long enough to
not permitted. terminate to backshell or adapter, do the
Shielded Wire - Picked Shield Repair pro­
(2). Strip to provide the correct insulation cedure.
clearance.
(3). Remove wire insulation. (1). Remove approximately 6 in. (152 mm)
(4). Inspect wire (Ref. Wire Inspection). of cable insulation from cable end.

D. Shielded Wire Termination


(2). Terminate wire(s) to connector and
(Ref. Table 207) shield to adapter as follows:

(Ref. Figure 229, Figure 230, Figure 231,


Figure 232, Figure 234, and Figure 233) (a). Make a small hole in braid (pick
point) no less than 0.75 in. (19 mm)
Consumable Materials from end of cable insulation.
(Ref. Section 91−00−00)
Item Nomenclature
(b). Pull inner wire(s) out through hole.
C602 Rubber Strip, Self Fusing
C819 Insulation Sleeving, Electrical, Heat
Shrinkable (c). Cut wire(s) no more than 2.0 in. (51
C822 Splice, Shield Termination mm) from end of cable insulation. Do
not cut shields.

2.0 IN. ( 5.08 CM )


CABLE INSULATION MAXIMUM
0.75 IN. ( 1.91 CM )
MINIMUM

WIRE
PICK POINT

PICKED SHIELD
9G20−054B

Figure 229. Prepare Shield and Wire for Termination

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(d). Remove wire insulation. (a). Cut shield braid 0.25-0.34 in.
(6.35-8.64 mm) from end of cable
(e). If necessary, install contacts on insulation.
wire(s) (Ref. Wire Terminations).
(4). Make a selection of correct solder sleeve
(f). Terminate wire(s) to connector. (C822).
(g). Push shield along wire as near to Table 207. Solder Sleeve Selection
connector as possible.
Part Number Solder
Limits
(h). Fold picked shield back along wire Sleeve Wire
bundle. MHS4786−434 22 AWG 0.25−0.42 in.
(0.64−1.07 cm)
NOTE: The procedure that follows applies to
backshell if one is installed. MHS4786−534 22 AWG 0.38−0.52 in.
(0.97−1.32 cm)
(i). Tie shield(s) to wire bundle with MHS4786−961 22 AWG 0.06−0.10 in.
tying tape 1.00-1.25 in. (25.4-31.8 (1.52−2.54 mm)
mm) from rear of backshell or
MHS4786−962 22 AWG 0.08−0.14 in.
adapter.
(2.03−3.56 mm)
(j). Fold shield on top of tape and back MHS4786−963 22 AWG 0.11−0.20 in.
along wire bundle. Put shield in (2.79−5.08 mm)
shield slots on backshell or adapter. MHS4786−964 22 AWG 0.16−0.25 in.
NOTE: Put shields in different slots to prevent (4.06−6.35 mm)
too much thickness or strain on shields and MHS4786−965 22 AWG 0.20−0.30 in.
wires. (5.08−7.62 mm)

(k). Align ground springs on rear accesso­ NOTE: It is permitted to fold braid along in­
ry with shield slots on backshell or sulation to decrease flow of solder into cable
adapter. insulation or for better solder sleeve fit.
(l). Attach accessory to backshell or (a). Put solder sleeve on cable. Align
adapter. Torque accessory 20 in-lbs solder with center of shield braid.
(2.26 N·m).
(b). Install solder sleeve.
(m). Wind rubber tape (C602) a minimum
of two times around wire bundle at (c). Cut wire(s) 2.0 in. (51 mm) maxi­
strain relief center. mum from end of braided shield.
(d). Cut solder sleeve wire minimum
(n). Install strain relief, washers, and
length necessary to make termina­
screws. Tighten screws sufficiently to
tion without strain.
prevent movement of strain relief.
(e). Remove wire insulation.
(o). Cut shield(s) that are out around
rear accessory. (f). If necessary, install contacts on
wire(s).
(3). Terminate wire and shield to connector
or component as follows (end strip (g). Terminate wire(s) to connector or
method): component.

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STANDARD PRACTICE MANUAL

2.0 IN. (5.08 CM)


MAXIMUM

CABLE WITH MORE


THAN ONE WIRE

CABLE WITH ONE WIRE

0.25-0.34 IN.
(6.35-8.64 MM)

END STRIP WITH SHIELD FORWARD

2.0 IN. (5.08 CM)


MAXIMUM

CABLE WITH MORE


THAN ONE WIRE

CABLE WITH ONE WIRE

0.25-0.34 IN.
(6.35-8.64 MM)

END STRIP WITH SHIELD FOLDED ALONG CABLE INSULATION

SOLDER ALIGNED CUT WIRE MINIMUM LENGTH NECESSARY TO


WITH SHIELD CENTER MAKE TERMINATION WITHOUT STRAIN

SOLDER SLEEVE

CABLE WITH MORE


THAN ONE WIRE

2.0 IN. (5.08 CM)


MAXIMUM 9G20−055B
SEALS
SOLDER SLEEVE POSITION

Figure 230. End Strip Method

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(5). Terminate wire to connector, and shield (l). Fold picked shield along wire bundle.
to both connector and adapter as
follows (window strip method): NOTE: The procedure that follows applies to
backshell if one is installed.
(a). Disconnect a 0.5 in. (12.7 mm) piece
of cable insulation. (m). Tie shield(s) to wire bundle with
tying tape 1.00-1.25 in. (25.4-31.8
(b). Push disconnected cable insulation mm) from rear of backshell or
along wire 0.20-0.30 in. (5.08-7.62 adapter.
mm).
(n). Fold shield on top of tape and back
(c). Make a small hole in braid (pick along wire bundle. Put shield in
point) no less than 0.75 in. (19.1 shield slots on backshell or adapter.
mm) from end of disconnected cable
insulation. NOTE: Put shields in different slots to prevent
too much thickness or strain on shields and
(d). Pull inner wire(s) out through hole. wires.
(e). Put solder sleeve on cable. Align (o). Align ground springs on rear accesso­
solder with center of shield braid. ry with shield slots on backshell or
adapter.
(f). Install solder sleeve.
(g). Cut wire(s) 2.0 in. (51 mm) maxi­ (p). Attach accessory to backshell or
mum from end of disconnected cable adapter. Torque accessory 20 in-lbs
insulation. (2.26 N·m).

(h). Cut solder sleeve wire minimum (q). Wind rubber tape (C602) a minimum
length necessary to make termina­ of two times around wire bundle at
tion without strain. strain relief center.

(i). Remove wire insulation. (r). Install strain relief, washers, and
screws. Tighten screws sufficiently to
(j). If necessary, install contacts on prevent movement of strain relief.
wire(s).
(s). Cut shield(s) that are out around
(k). Terminate wire(s) to connector. rear accessory.
SHIELD
0.5 IN. 2.0 IN. (51 MM)
(12.7 MM) MAXIMUM
0.20-0.30 IN. 0.75 IN. (19.1 MM)
(5.08-7.62 MM) MINIMUM

WIRE
PICK POINT

CABLE INSULATION DISCONNECTED CABLE INSULATION


PICKED SHIELD

CUT WIRE MINIMUM LENGTH NECESSARY TO


SOLDER SLEEVE MAKE TERMINATION WITHOUT STRAIN

Ï Ï
Ï
Ï Ï
Ï 9G20−056B

Figure 231. Window Strip Method

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(6). Terminate shields in series (daisy (i). Cut shield braid flush to end of
chain) as follows: disconnected cable insulation.
NOTE: Install last solder sleeve in daisy chain (j). Put solder sleeve on cable. Align
on cable that is nearest to termination point solder with center of shield braid.
for that solder sleeve wire.
(k). Install a 0.5 in. (12.7 mm) piece of
(a). Find which cable will be last in daisy heat shrinkable sleeving (C819) on
chain, and isolate from other cables. cable (Ref. Wire Maintenance Proce­
dures). Align center of sleeving with
(b). Cut shield braid on isolated cable
end of cable insulation.
0.25-0.34 in. (6.35-8.64 mm) from
end of cable insulation. (l). Cut cable wires 2.0 in. (51 mm)
maximum from end of cable insula­
(c). Put solder sleeve on cable. Align
tion.
solder with center of shield braid.
(d). Cut wire(s) 2.0 in. (51 mm) maxi­ (m). Cut solder sleeve wires minimum
mum from end of braided shield. length necessary to make termina­
tion without strain.
(e). Cut solder sleeve wire minimum
length necessary to make termina­ (n). Remove wire insulation.
tion without strain. (o). Cut shield braid on remaining cables
(f). Remove wire insulation. 0.25-0.34 in. (6.35-8.64 mm) from
end of cable insulation.
NOTE:
(p). Put solder sleeve on cable. Align
D On large electrical connectors it can be
solder with center of shield braid.
necessary to divide the cables into three
or more groups. (q). Cut cable wires 2.0 in. (51 mm)
D If more groups are necessary, disconnect maximum from end of cable insula­
piece of cable insulation 0.5 in. (12.7 tion.
mm) longer than longest length in other
groups. (r). Cut solder sleeve wires minimum
length necessary to make termina­
D Solder sleeve wire can be installed in each tion without strain.
of the two directions.
D Do not make a loop in solder sleeve wire. (s). Remove wire insulation.
D It can be easier in some installations to (t). Put wire from one solder sleeve into
install some solder sleeves fully before the next solder sleeve. No more than
you put all of them on. 2 wires are permitted in each solder
sleeve.
(g). On each second cable, disconnect a
0.5 in. (12.7 mm)) piece of cable (u). Continue until last solder sleeve in
insulation. daisy chain.
(h). Push disconnected cable insulation (v). Install all solder sleeves.
along wire 0.20-0.30 in. (5.08-7.62
mm). (w). Terminate wires.

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STANDARD PRACTICE MANUAL

SOLDER ON CENTER
OF SHIELD AND WIRES
CUT WIRE MINIMUM LENGTH NECESSARY TO
MAKE TERMINATION WITHOUT STRAIN
CUT WIRE MINIMUM LENGTH NECESSARY TO
MAKE TERMINATION TO NEXT SOLDER SLEEVE
WITHOUT STRAIN, NO LOOP IS PERMITTED

2.0 IN. (51 MM)


MAXIMUM
WIRE CAN BE INSTALLED IN EACH OF THE
TWO DIRECTIONS, NO LOOP IS PERMITTED

HEAT SHRINKABLE
SLEEVING 9G20−057B

Figure 232. Daisy Chain

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STANDARD PRACTICE MANUAL

CONNECTOR
PICKED SHIELD

SHIELDED CABLES

PUT SOLDER SLEEVE ON ONE OF THE


TWO SIDES OF THE SADDLE CLAMP
TYING SOLDER SLEEVE
ADAPTER BODY
1.00-1.25 IN (25.4-31.8 MM)
ADAPTER TO TYING TAPE

SHIELDED CABLES

SADDLE CLAMP (INSTALLED POSITION)

TYING PICKED SHIELD BEFORE YOU FOLD BACK AND PUT IN SHIELD SLOTS
SHIELD POSITIONED IN SHIELD SLOT
SHIELD FOLDED BACK TO SHIELD SLOT (TYPICAL)

IF POSSIBLE, PUT ONE SHIELD IN EACH SLOT

SHIELD POSITION

TRIM SHIELD HERE SILICONE RUBBER TAPE (NOTE)

COMPLETED TERMINATION 9G20−058B


NOTE: DO NOT LET SHIELDS SHOW AT
REAR EDGE OF RUBBER TAPE

Figure 233. Shield Termination

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(7). Terminate wire to connector with shield (d). Adjust heat shrinkable sleeving so
not connected as follows: sleeving center is aligned with shield
end and install.
(a). Cut shield flush with end of cable
insulation.
(e). Remove wire insulation.
(b). Cut wire(s) 2.0 in. (51 mm) maxi­
mum from end of cable insulation. (f). If necessary, install contacts on
(c). Put a 0.75 in. (19.1 mm) piece of wire(s).
heat shrinkable sleeving (C819) on
cable (Ref. Wire Maintenance). (g). Install wire(s) into connector.
0.75 IN.
(19.1 MM)

INSULATED
WIRES

SHIELD

2.0 IN. (51 MM)


CABLE INSULATION MAXIMUM
HEAT SHRINKABLE
SLEEVING
SHIELDED CABLE WITH
MORE THAN ONE WIRE

0.75 IN.
INSULATED SHIELD (19.1 MM)
WIRE

2.0 IN. (51 MM)


MAXIMUM
CABLE INSULATION HEAT SHRINKABLE
SLEEVING

SHIELDED CABLE 9G20−052B


WITH ONE WIRE

Figure 234. Shield Not Connected

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STANDARD PRACTICE MANUAL

E. Solder Sleeve Installation (4). Inspect installation as follows:


(Ref. Figure 235) NOTE: Outer sleeve can be light brown color, if
solder fillet is in view.
Special Tools (a). Outer sleeve, cable, and wire for
(Ref. Section 91−00−00) damage. None permitted.
Item Nomenclature
T2004 Heat Gun (b). Solder sleeve wire and shield wires
are straight with none broken or
missing.
(1). Make sure solder sleeve is in correct
position. (c). There is a continuous solder fillet
between the shield and along 50
NOTE: Do not move heat gun along wire. This percent of bare solder sleeve wire on
can cause solder to move along solder sleeve a minimum of one side of joint.
wire.
(d). Contour of shield and solder sleeve
(2). Move heat gun around solder sleeve. wires are in view outside of fillet.

(3). Remove heat gun when solder sleeve NOTE: Seal can be in solder area, if solder fillet
looks as follows: is in view.

(a). Outer sleeve has fully closed. (e). Sealing rings have melted and flowed
around the wire/cable at both ends of
(b). Sealing rings have melted and sleeve.
flowed.
(f). No wire shows outside of outer
(c). Solder has fully melted to shield and sleeve, cable insulation, or wire
solder sleeve wire. insulation.
DAMAGE TO OUTER SLEEVE, CABLE, OR WIRE IS NOT PERMITTED
LIGHT BROWN COLOR IS PERMITTED, IF SOLDER FILLET IS IN VIEW

SOLDER SLEEVE WIRE AND SHIELD WIRES ARE


STRAIGHT WITH NONE BROKEN OR MISSING

50 PERCENT OF BARE WIRE LENGTH

SOLDER HAS COMPLETELY MELTED TO SHIELD AND SOLDER SLEEVE WIRE


CONTOUR OF SHIELD AND SOLDER SLEEVE WIRES ARE IN VIEW

SEALING RINGS HAVE MELTED AND FLOWED AT BOTH ENDS


SEAL CAN BE IN SOLDER AREA, IF SOLDER FILLET IS IN VIEW 9G20−059A

Figure 235. Solder Sleeve Installation

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

F. Crimp Style Contact Connection NOTE: Crimp tools have a crimp stop that lets
them be interchangeable between pins and
(Ref. Table 209, Table 210, Figure 236, and sockets.
Figure 237)

Special Tools (1). Remove wire insulation.


(Ref. Section 91−00−00)
Item Nomenclature (2). Make a selection of contact, and
T1013 Crimping Tool crimping tool (T1013) (crimp tool and
positioner).
Table 208. Crimp Tools (Power), Terminal Lugs and Splices

Term Contact For Color Wire Power Die Die Die


Code Part Number Stud Bands Range Tool Locator Locator Locator
(AWG) (Other) (BUR) (T&B)
194 MS25036−127 3/8 RD 2 Model 400 414DA−2IT 414DA−2IT−B 414DA−2IT−B
5007−1 5032−4 5052
Model 500 514DA−2IT 514DA−2IT−B 514DA−2IT−B
5505 5505−1 5505−3
198 MS25036-126 1/4 RD 2 Model 400 414DA−2IT 414DA−2IT−B 414DA−2IT−B
5007−1 5032−4 5052
Model 500 514DA−2IT 514DA−2IT−B 514DA−2IT−B
5505 5505−1 5505−3

Table 209. Contact Term Code, Crimp Tool, and Positioner


Term Contact Size Color Wire Range Crimp Tool Positioner
Code Part Number Bands (1) (AWG) Part Number Part Number
590 M39029/31−240 20 RD YE BK 20 22 24 M22520/1−01 M22520/1−02 (RD)
M22520/2−01 M22520/2−02
M22520/7−01 M22520/7−02
593 M39029/32−259 20 RD GR WT 20 22 24 M22520/1−01 M22520/1−02 (RD)
M22520/2−01 M22520/2−02
M22520/7−01 M22520/7−02
707 M39029/35−275 16 RD VT GR 20 22 24 M22520/1−01 M22520/1−03 (BL/RD)
720 HS5768−22P 22 GR 22 24 26 28 M22520/2−01 TP−20140G
764 M39029/4−110 20 BR BR BK 20 22 24 M22520/1−01 M22520/1−02 (RD)
M22520/2−01 M22520/2−02
M22520/7−01 M22520/7−02
765 M39029/5−115 20 BR BR GR 20 22 24 M22520/1−01 M22520/1−02 (RD)
M22520/2−01 M22520/2−02
M22520/7−01 M22520/7−02
767 M39029/5−116 16 BR BR BL 16 18 20 M22520/1−01 M22520/1−02 (BL)
M22520/7−01 M22520/7−03
768 M39029/4−113 12 BR BR OR 12 14 M22520/1−01 M22520/1−02 (YE)

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STANDARD PRACTICE MANUAL

Table 209. Contact Term Code, Crimp Tool, and Positioner (Cont.)
Term Contact Size Color Wire Range Crimp Tool Positioner
Code Part Number Bands (1) (AWG) Part Number Part Number
769 M39029/5−118 12 BR BR GY 12 14 M22520/1−01 M22520/1−02 (YE)
798 HS5025−1892 20 NONE 20 22 24 M22520/1−01 TH254
891 M39029/30−217 16S RD BR VT 16 18 20 M22520/1−01 M22520/1−02 (BL)
900 M39029/1−100 16 BR BK BK 22 24 M22520/2−01 M22520/2−11
904 M39029/22−191 22 BR WT BR 22 24 26 M22520/7−01 M22520/7−11
905 M39029/22−192 20 BR WT RD 20 22 24 M22520/7−01 M22520/7−12
906 M39029/22−193 16 BR WT OR 16 18 20 M22520/7−01 M22520/7−13
912 M39029/29−212 16 RD BR RD 16 18 20 M22520/1−01 M22520/1−02 (BL)
M22520/7−01 M22520/7−03
915 M39029/58−360 22 OR BL BK 22 24 M22520/2−01 M22520/2−09
M22520/7−01 M22520/7−07
916 M39029/56−348 22 OR YE GY 22 24 M22520/2−01 M22520/2−07
M22520/7−01 M22520/7−05
917 M39029/58−363 20 OR BL OR 20 22 24 M22520/1−01 M22520/1−04 (RD)
M22520/2−01 M22520/2−10
M22520/7−01 M22520/7−08
918 M39029/56−351 20 OR GR BR 20 22 24 M22520/1−01 M22520/1−04 (RD)
M22520/2−01 M22520/2−10
M22520/7−01 M22520/7−08
922 M39029/56−352 16 OR GR RD 16 18 20 M22520/1−01 M22520/1−04 (BL)
M22520/7−01 M22520/7−04
923 M39029/56−353 12 OR GR OR 12 14 M22520/1−01 M22520/1−04 (YE)
924 M39029/58−364 16 OR BL YE 16 18 20 M22520/1−01 M22520/1−04 (BL)
M22520/7−01 M22520/7−04
925 M39029/58−365 12 OR BL GR 12 14 M22520/1−01 M22520/1−04 (YE)
928 M39029/57−358 16 OR GR GY 16 18 20 M22520/1−01 M22520/1−04 (BL)
M22520/7−01 M22520/7−04
936 M39029/63−368 20 OR BL GY 20 22 24 M22520/2−01 M22520/2−08
937 M39029/64−369 20 OR BL WT 20 22 24 M22520/2−01 M22520/2−08
938 HS4783−12 12 YE YE 12 14 M22520/1−01 M22520/1−16
952 1662−202−1631 20 NONE 22 24 M22520/1−01 TH343
953 1662−202−1231 12 NONE 16 18 20 M22520/1−01 TH343
955 M39029/106−614 22 BL BR YE 22 24 M22520/2−01 M22520/2−07
M22520/7−01 M22520/7−05

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 209. Contact Term Code, Crimp Tool, and Positioner (Cont.)
Term Contact Size Color Wire Range Crimp Tool Positioner
Code Part Number Bands (1) (AWG) Part Number Part Number
957 M39029/106−616 16 BL BR BL 16 18 20 M22520/1−01 M22520/1−04 (BL)
M22520/7−01 M22520/7−04
959 M39029/107−620 22 BL RD BK 22 24 M22520/2−01 M22520/2−09
M22520/7−01 M22520/7−07
961 M39029/107−622 16 BL RD RD 16 18 20 M22520/1−01 M22520/1−04 (BL)
M22520/7−01 M22520/7−04

NOTES:
(1) Color Codes: BK=Black, BL=Blue, BR=Brown, GR=Green, GY=Gray, OR=Orange, RD=Red, VT=Violet,
WT=White, YE=Yellow.

NUMBER 1 COLOR BAND


NUMBER 2 COLOR BAND
NUMBER 3 COLOR BAND

MANUFACTURERS SYMBOL
OR TRADE MARK
WIRE MATING END
BARREL END
NOTE: 9G20−061A
COLOR BANDS SHOW LAST THREE
NUMBERS OF CONTACT PART NUMBER

Figure 236. Contact Identification


Table 210. Contact Color Codes (a). Contact shoulder must be tight
Code Color (Number) against positioner.
BK Black (0) (4). Put bare wire into contact crimp barrel.
BR Brown (1) (a). There must be no separation or
RD Red (2) overlap of wire in barrel.
OR Orange (3) (5). Make sure wire is in correct position.
YE Yellow (4) Operate crimp tool.
GR Green (5) (6). Remove crimped contact from tool.
BL Blue (6) (7). Give a light pull between wire and
VT Violet (7) contact. No movement permitted
GY Gray (8) (8). Inspect crimped contact as follows:
WT White (9)
(a). You can see crimped wire through
contact inspection hole.
(3). Put contact into crimp tool positioner (b). No wire end is out through inspection
with crimp barrel up. hole or rear of crimp barrel.

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STANDARD PRACTICE MANUAL

(c). Crimp is not aligned with inspection (d). Wire insulation is no more than
hole. 0.032 in. (0.81 mm) from end of
crimp barrel.
CRIMP
0.032 IN. (0.81 MM)
MAXIMUM

INSPECTION HOLE
WIRE IN VIEW THROUGH ALL 0.032 IN. (0.81 MM)
OF INSPECTION WINDOW MAXIMUM

SOCKET

CRIMP
PIN

CORRECT INSTALLATION INCORRECT INSTALLATION

INSULATION IN CRIMP BARREL

WIRE NOT IN VIEW IN


INSPECTION HOLE.

WIRE STRANDS OUT


FROM INSPECTION HOLE

WIRE STRANDS NOT


IN CRIMP BARREL
9G20−062A

Figure 237. Contact Installation

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

G. Contact Removal Too much force applied with


CAUTION contact extraction tool will dam­
(Ref. Table 211 and Figure 238)
age lock spring in component.
Special Tools (1). Make a selection of correct installation/
(Ref. Section 91−00−00) removal tool (T1004).
Item Nomenclature
T1004 Installation/Removal Tool, Contact

Table 211. Installation/Removal Tool

ÑÑÑÑÑÑÑ
Term Contact Size Installation Tool Part Removal Tool Part
Code Part Number Number/Color Number/Color

ÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ
590 M39029/31−240 20 M81969/17−03 M81969/19−07

ÑÑÑÑÑÑÑ
593 M39029/32−259 20 M81969/17−03 M81969/19−07

ÑÑÑÑÑÑÑ
707 M39029/35−275 16 M81969/18−01 M81969/20−01

ÑÑÑÑÑÑÑ
720 HS5768−22P 22 M81969/14−01/Green M81969/14−01/White

ÑÑÑÑÑÑÑ
764 M39029/4−110 20 M81969/14−11/Red M81969/14−11/White
765 M39029/5−115 20 M81969/14−11/Red M81969/14−11/White

ÑÑÑÑÑÑÑ
767 M39029/5−116 16 M81969/14−03/Blue M81969/14−03/White
768
ÑÑÑÑÑÑÑ
M39029/4−113 12 M81969/14−11/Red M81969/14−11/White
769
798 ÑÑÑÑÑÑÑ
M39029/5−118

ÑÑÑÑÑÑÑ
HS5025−1892
12
20
M81969/14−04/Yellow
11−6782(1)
M81969/14−04/White
11−6900(1)
891
ÑÑÑÑÑÑÑ
M39029/30−217 16S M81969/14−03/Blue M81969/14−03/White
900
ÑÑÑÑÑÑÑ
M39029/1−100 16 M81969/14−11/Red M81969/14−11/White
904
ÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ
M39029/22−191 22 M81969/14−01/Green M81969/14−01/White

ÑÑÑÑÑÑÑ
905 M39029/22−192 20 M81969/14−10/Red M81969/14−10/Orange

ÑÑÑÑÑÑÑ
906 M39029/22−193 16 M81969/14−03/Blue M81969/14−03/White

ÑÑÑÑÑÑÑ
912 M39029/29−212 16 M81969/14−03/Blue M81969/14−03/White
915 M39029/58−360 22 M81969/14−01/Green M81969/14−01/White

ÑÑÑÑÑÑÑ
916 M39029/56−348 22 M81969/14−01/Green M81969/14−01/White

ÑÑÑÑÑÑÑ
917 M39029/58−363 20 M81969/14−11/Red M81969/14−11/White
918 M39029/56−351 20 M81969/14−11/Red M81969/14−11/White

ÑÑÑÑÑÑÑ
922 M39029/56−352 16 M81969/14−03/Blue M81969/14−03/White

ÑÑÑÑÑÑÑ
923 M39029/56−353 12 M81969/14−04/Yellow M81969/14−04/White

ÑÑÑÑÑÑÑ
924 M39029/58−364 16 M81969/14−03/Blue M81969/14−03/White
925
ÑÑÑÑÑÑÑ
M39029/58−365 12 M81969/14−04/Yellow M81969/14−04/White
928
ÑÑÑÑÑÑÑ
M39029/57−358 16 M81969/14−03/Blue M81969/14−03/White
936
ÑÑÑÑÑÑÑ
M39029/63−368 20 M81969/14−11/Red M81969/14−11/White
937
938 ÑÑÑÑÑÑÑ
M39029/64−369
HS4783−12
20
12
M81969/39−01/Green
M81969/16−03/Yellow
M81969/39−01/White
M81969/16−03/White
952 1662−202−1631 20 None M15570−20(2)
953 1662−202−1231 12 None M15570−16(2)
955 M39029/106−614 22 M81969/14−01/Green M81969/14−01/White

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STANDARD PRACTICE MANUAL

Table 211. Installation/Removal Tool (Cont.)


Term Contact Size Installation Tool Part Removal Tool Part
Code Part Number Number/Color Number/Color

ÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑ
957 M39029/106−616 16 M81969/14−03/Blue M81969/14−03/White
959 M39029/107−620 22 M81969/14−01/Green M81969/14−01/White
961 M39029/107−622 16 M81969/14−03/Blue M81969/14−03/White
NOTES:
(1) Amphenol Bendix (CAGE Code 77820).
(2) Deutsch ECD (CAGE Code 11139).

(2). Put wire in groove on removal end of (3). Lightly pull on wire to make sure
tool. contact is locked.
(3). Move tool along wire and push into hole (4). If contact does not lock, do the proce­
until tool touches contact shoulder and dure that follows:
resistance is felt.
(a). Make a selection of correct size
(4). Hold wire tight against tool and remove installation/removal tool (T1004).
tool with contact. (b). Put wire in groove on insertion end of
tool and move contact shoulder
H. Contact Installation
against tip of tool.
NOTE: Install contacts with wires by hand to (c). Put contact into hole and push in on
prevent damage to component grommet. tool until fully engaged.
(1). Hold wire near end of contact tightly (d). Push in lightly on wire and remove
and put contact into hole. tool.
(2). Push until contact is fully engaged and (e). Lightly pull on wire to make sure
locked. contact is locked.

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

INSERTION/EXTRACTION TOOL

WIRE CONTACT SHOULDER

ÏÏ
COMPONENT

INSERTION/EXTRACTION TOOL

CONTACT HOLE (TYP)

GROMMET 9G20−063A

Figure 238. Contact Insertion and Extraction

I. Removal of Contacts Without Wires (4). Use push rod to push contact out rear of
(Ref. Table 212) connector. Be careful not to damage
grommet.
NOTE:
D Use this procedure to remove contacts Table 212. Push Rods for Contact Removal
without wires from connectors only. Contact Size Rod Diameter
D Replace terminal blocks, ground blocks,
22 0.019−0.021 in. (0.483−0.533 mm)
terminal modules and electrical relay
sockets that have contacts without wires. 20 0.034−0.036 in. (0.864−0.914 mm)
(1). Make a selection of correct size installa­ 16 0.054−0.056 in. (1.37−1.42 mm)
tion/removal tool (T1004). 12 0.093−0.095 in. (2.36−2.41 mm)
Too much force applied with
CAUTION contact extraction tool will dam­
age lock spring in component.
(2). Put extraction end into hole until tool
touches contact shoulder and resistance
is felt.
(3). Make a selection of correct size diame­
ter push rod.

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STANDARD PRACTICE MANUAL

J. Environmental Sealing Plug Removal and (4). To use lug crimper (hand) (T1014), do
Installation the procedure that follows:
(a). Carefully operate tool until lug is
Consumable Materials kept in crimp tool.
(Ref. Section 91−00−00)
Item Nomenclature (b). Insert wire fully into lug.
C823 Plug, Grommet Seal
(c). Make sure wire is in correct position.

(1). Hold end of sealing plug (C823) above (d). Make sure there is no separation or
grommet with your fingers. overlap of wire in barrel.

(2). Remove plug from component. (e). Make sure there is no insulation
inside barrel.
NOTE: Fill open cavities in module and connec­
tor with sealing plugs. Do not put contacts (f). Operate tool and remove crimped lug.
without wires in holes.
(5). To use lug crimper (power) (T1015), do
(3). If necessary, make a selection of correct the procedure that follows:
size sealing plug.
(a). Insert wire fully into lug.
Table 213. Sealing Plug Selection
(b). Make sure wire is in correct position.
Part Number Contact Size Color
MS27488−22 22 Black (c). Make sure there is no separation or
overlap of wire in barrel.
MS27488−20 20 Red
MS27488−16 16 Blue (d). Make sure there is no insulation
inside barrel.
MS27488−12 12 Yellow
(e). Operate tool and remove crimped lug.
(4). Point large end of plug away from
grommet, and put plug into hole. (6). Give a light pull between wire and lug.
No movement permitted.
(5). Push plug in until large part is against
grommet. (7). Inspect lug installation as follows:
K. Terminal Lug Installation (a). Crimp is approximately at center of
crimp barrel.
(Ref. Table 214 and Figure 239)
(b). If there is a strain relief, make sure
Special Tools it is installed correctly on wire
(Ref. Section 91−00−00) insulation.
Item Nomenclature
(c). All of wire is inside crimp barrel.
T1014 Crimping Tool (Hand), Terminal Lugs
T1015 Crimping Tool (Power), Terminal Lugs (d). You can see wire at inspection
window.

(1). Make a selection of correct terminal lug (e). Wire is not out of inspection window
and crimp tool. more than 0.031 in (0.79 mm).

(2). Remove wire insulation. Remove length (f). Crimp is not aligned with inspection
of crimp barrel plus 0.063 in. (1.60 window.
mm).
(g). Wire insulation is no more than
(3). Insert lug into crimp tool. Make sure 0.031 in. (0.79 mm) from end of
lug is tight against tool positioner. crimp barrel.

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STANDARD PRACTICE MANUAL

Table 214. Terminal Lug and Crimp Tool Selection


Crimp Tool
Terminal Lug Stud Wire Range Support

ÑÑÑÑÑÑÑ
Part Number Size Color (1) (AWG)
ÑÑÑÑÑÑ
Mfr. Part Number
ÑÑÑÑÑ
Setting

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ
MS25036−101 8 RD 18−22

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


MS25036−102 6 RD 18−22

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


MS25036−103 10 RD 18−22

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


0.375 in.
MS25036−105 RD 18−22

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


(9.53 mm)

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


MS25036−106 6 BL 14−16
AMP 59250 2

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


MS25036−107 6 BL 14−16

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


MS25036−108 10 BL 14−16

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


0.313 in.

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


MS25036−109 BL 14−16
(7.94 mm)

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


0.375 in.
MS25036−110 BL 14−16

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


(9.53 mm)

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


MS25036−111 6 YE 10−12

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


MS25036−112 10 YE 10−12

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


0.313 in. AMP 59239−4 1

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


MS25036−113 YE 10−12
(7.94 mm)

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


0.375 in.
MS25036−114 YE 10−12

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


(9.53 mm)

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


MS25036−115 10 RD 8

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


0.250 in. Power Tool
MS25036−116 RD 8 Model 400

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


(6.35 mm) PICO Requires
Model 500

ÑÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑ


Die Locator
0.313 in.
MS25036−117 RD 8
(7.94 mm)

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STANDARD PRACTICE MANUAL

Table 214. Terminal Lug and Crimp Tool Selection (Cont.)


Crimp Tool
Terminal Lug Stud Wire Range Support

ÑÑÑÑÑÑÑ
Part Number Size Color (1) (AWG)
ÑÑÑÑÑ
Mfr. Part Number
ÑÑÑÑÑÑ
Setting

ÑÑÑÑÑÑÑ 0.375 in. RD 8


ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ
MS25036−118
(9.53 mm)

ÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ
0.250 in. BL 6
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑ ÑÑÑÑÑÑ
MS25036−120
(6.35 mm)

ÑÑÑÑÑÑÑ 0.313 in.


ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ
MS25036−121 BL 6
(7.94 mm)

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


0.375 in.
MS25036−122 BL 6

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


(9.53 mm)

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


0.250 in. Model 400 Power Tool
MS25036−123 YE 4 PICO Requires

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


(6.35 mm) Model 500
Die Locator

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


0.313 in.
MS25036−124 YE 4

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


(7.94 mm)

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


0.375 in.
MS25036−125 YE 4
(9.53 mm)

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ
0.250 in.
MS25036−126 RD 2
(6.35 mm)

ÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ
MS25036−127
0.375 in.
(9.53 mm)
RD 2 ÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ
MS25036−143 2 YE 24−26
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ
MS25036−145 6 YE 24−26
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ
1

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


MS25036−146 8 YE 24−26

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


MS25036−147 10 YE 24−26

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


MS25036−148 4 RD 18−22

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


MS25036−149 8 RD 18−22 AMP 59250

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


0.250 in.
MS25036−150 RD 18−22

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


(6.35 mm)
2

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


MS25036−152 4 BL 14−16

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


MS25036−153 8 BL 14−16

ÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ
MS25036−154
0.250 in.
(6.35 mm)
BL 14−16
ÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ
MS25036−156 8 YE 10−12

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


0.250 in. AMP 59239−4 1

ÑÑÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑ


MS25036−157 YE 10−12
(6.35 mm)

NOTES:
(1) Color Codes: BK=Black, BR=Brown, RD=Red, YE=Yellow, BL=Blue.

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STANDARD PRACTICE MANUAL

BARREL LENGTH
$ 0.063 IN. (1.588 MM)

INSULATION REMOVAL

CRIMP BARREL

0.031 IN. (0.79 MM) MAXIMUM


INSPECTION WINDOW

0.031 IN. (0.79 MM) MAXIMUM


STRAIN
RELIEF
TERMINAL LUG WITH SINGLE WIRE

0.03125 IN. (0.79 MM) MAXIMUM

0.031 IN. (0.79 MM) MAXIMUM

9G20−064A
TERMINAL LUG WITH MULTIPLE WIRES

Figure 239. Terminal Lug Installation

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STANDARD PRACTICE MANUAL

L. Terminal Lug Connection (b). Do not install all terminal lugs on


one side of clamp.
(Ref. Figure 240, Figure 241, and Figure 242)
(c). Make sure no more than 3 terminal
Consumable Materials lugs are installed on each screw.
(Ref. Section 91−00−00)
Item Nomenclature (d). Make sure cable causes clearance
C216 Sealant, Fuel Resistant between mating surfaces of strain
relief clamps and accessory.

NOTE: NOTE: It is permitted to use more washers if


D This procedure is applicable to aircraft necessary for connection of terminal lugs to
changes that install more terminal lugs. connectors.
When you do maintenance on standard
aircraft wires, terminal lugs must be (e). If there is clearance, fill with wash­
installed as they were. ers. Do not put washers between
terminal lug and rear accessory.
D This procedure gives instructions for
many different installations. Not all steps
are necessary. NOTE: It is permitted to use longer screws and
lock nuts if necessary for connection of ter­
D When drip loops in wires are necessary minal lugs to connectors.
close to a connection, it is permitted to at­
tach lugs in a down direction (Ref. Wire (f). Use screws, washers, and nut (if
Inspection). installed) that are supplied with
(1). When connection of terminal lugs to an strain relief to attach terminal lugs
electrical connector is necessary, do the and strain relief clamps to rear
procedure that follows: accessory.

(a). Install terminal lugs against rear (g). Test terminal lug for class “R”
accessory where strain relief clamps electrical bond (Ref. Section
attach. 20-50-00).

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STANDARD PRACTICE MANUAL

LOCKWASHER
REAR STRAIN RELIEF
ACCESSORY CLAMP
WASHERS
(SPACERS)
STRAIN RELIEF
CLAMP

WASHERS
(SPACERS)

REAR
ACCESSORY

LOCKWASHER

9G20−066

Figure 240. Terminal Lug to Electrical Connector (Typical)


(2). When connection of terminal lugs to a
receptacle is necessary, do the proce­
dure that follows:
RECEPTACLE
(a). Install terminal lugs against rear of
MOUNT SCREW
receptacle flange. SURFACE
WIRE
(b). Make sure no more than 3 terminal
lugs are installed on each screw.
WASHER
NOTE: It is permitted to use longer screws and
lock nuts if necessary for connection of ter­
minal lugs to receptacles. TERMINAL LUG
RECEPTACLE LOCKNUT
FLANGE
(c). Use screws, washers, and nut (if
installed) that are supplied with
receptacle to attach terminal lugs.
9G20−067A

(d). Test terminal lug for class “R”


electrical bond (Ref. Section Figure 241. Terminal Lug Connected to
20-50-00). Receptacle (Typical)

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STANDARD PRACTICE MANUAL

(3). When connection of lugs to studs is (e). Bend lugs no more than 90 degrees
necessary, do the procedure that as necessary for installation.
follows:
(f). Make sure no more than 4 lugs are
(a). Make sure stud is tight. Put lug on installed on each stud.
stud.
(g). Install washers and nut. Tighten nut
(b). Align lug on stud so movement of lug sufficiently to prevent movement of
will tighten connection and prevent lug.
strain on crimp joint. (h). Test lugs for class “R” electrical bond
(Ref. Section 20-50-00).
(c). Install more than one lug with
smallest lug near screw head and NOTE: If a rubber nipple is installed, it is not
largest lug near receptacle flange. necessary to environmentally seal assem­
bly.
(d). Install adjacent lugs with crimp
barrel inspection window of first lug (i). Environmentally seal assembly with
near stud and subsequent lug sealant (C216) (Ref. Section
opposite. 20-50-00).

NUT
LOCKWASHER 4
2
WASHER

WASHER 3 1
TERMINAL LUG
STUD NUT OR FLANGE

SEQUENCE OF TERMINAL LUG INSTALLATION


1. INSPECTION WINDOW NEAR STUD
2. INSPECTION WINDOW OPPOSITE
3. INSPECTION WINDOW NEAR STUD
4. INSPECTION WINDOW OPPOSITE

ALIGN LUGS ON STUD SO MOVEMENT OF LUG WILL TIGHTEN


CONNECTION AND PREVENT STRAIN ON CRIMP JOINT 9G20−068A

Figure 242. Terminal Lug Connected to Stud (Typical)

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This page intentionally left blank!

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ELECTRICAL STANDARD PRACTICES

INSPECTION/TEST
1. Module Inspection (3). Examine module for contamination by
fluids and dirt particles.
(Ref. Figure 601)
(a). Remove contamination if found (Ref.
Cleaning and Protection).
NOTE: This procedure includes inspection of
terminal blocks, terminal modules, ground
blocks, and electrical relays. 2. Connector and Accessories Inspection

(Ref. Figure 602)


(1). Examine the module grommet as
follows: NOTE: This procedure includes inspection of
plugs, receptacles, backshells, and connec­
(a). Module insert grommets for cuts, tor accessories.
cracks, and splits from contact cavity
to grommet outside edge, or from (1). Examine connector and accessory as
cavity to cavity. None permitted. follows:

(b). Scratches, cuts, and gouges in the NOTE: Small scratches on surfaces, keys, and
grommet that do not prevent wire keyways through finish is normal and are
seal or function of module are permitted.
permitted.
(a). Scratches, gouges, dents, or other
(2). Replace module if grommet is unser­ damage that causes burrs or rough
viceable (Ref. Installation and Removal edges in base material, keys, and
of Electrical Components). keyways. None permitted.

(b). Scratches, gouges, dents, or other


damage that prevent correct func­
tion. None permitted.

(c). Make sure marks on grommet are


1
easy to read. No damage permitted.
2
NOTE: Bent or displaced segments are per­
mitted if connector can be connected and
disconnected to receptacle without more
damage.
2
(d). Connectors with an Electro-Magnetic
1 Interference (EMI) spring for broken
or missing segments. None per­
mitted.

NOTES: (2). Examine connector for contamination


1. SPLIT OR CUT FROM CONTACT CAVITY by fluids and dirt particles.
TO GROMMET EDGE. NONE PERMITTED.
2. SPLIT OR CUT FROM CONTACT CAVITY 9G20−065A
TO CONTACT CAVITY. NONE PERMITTED. (a). Remove contamination if found (Ref.
Cleaning and Protection).

Figure 601. Grommet Damage (3). Examine connector grommet for .

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

NOTE 5

NOTE 1

NOTE 2 NOTE 3 NOTE 6

NOTE 7

NOTE 9
NOTE 4

NOTE 8

PERMITTED NOT PERMITTED


WIRE SIDE WIRE SIDE
NOTE 4

NOTE 9
NOTE 5
NOTE 2
NOTE 11

NOTE 8 NOTE 6

NOTE 1

NOTE 10

PERMITTED NOT PERMITTED


PIN SIDE PIN SIDE

NOTES:
1. DAMAGE IN WEB OR EDGE OF PIN BARRIER WHICH IS NO MORE THAN 50% OF AREA OF WEB OR WIDTH OF PIN BARRIER IS PERMITTED.
2. SMALL GOUGES, CUTS, AND TEARS IN CAVITY SEPARATOR ARE PERMITTED.
3. SMALL SCRATCHES, CHIPS, NICKS, OR GOUGES WHICH ARE NOT THROUGH OUTER WEB OR ARE IN CAVITY SEPARATOR ARE PERMITTED.
4. SMALL DEFECTS WHICH DO NOT CAUSE VOIDS BETWEEN GROMMET AND WIRE AFTER WIRE IS INSTALLED IN CONNECTOR ARE PERMITTED.
5. A GOUGE, CUT, TEAR, CRACK, OR CHIP FROM OUTER EDGE OF GROMMET FACE TO A CONTACT CAVITY OR PIN BARRIER IS NOT PERMITTED.
6. A GOUGE, CUT, TEAR, CRACK, OR CHIP ACROSS OUTER WEB OR PIN BARRIER TO CAVITY SEPARATOR OR TO ANOTHER CAVITY IS NOT PERMITTED.
7. MORE THAN ONE CRACK, TEAR, OR CUT ACROSS OUTER WEB WHICH IS NO MORE THAN 50% OF AREA OF WED IS NOT PERMITTED.
8. A CHIP, NICK, CUT, TEAR, CRACK, OR GOUGE WHICH IS INTO OUTER WEB, INNER EDGE OF PIN BARRIER, OR IS MORE THAN 50% IS NOT PERMITTED.
9. A LARGE GOUGE, CUT, TEAR, CRACK, OR CHIP IN THE CAVITY SEPARATOR IS NOT PERMITTED. 9G20−069A
10. A GOUGE, SPLIT, OR CRACK ALONG EDGE OF PIN BARRIER IS NOT PERMITTED.
11 A TORN OR MISSING PIN BARRIER IS NOT PERMITTED

Figure 602. Connector Inserts (Sheet 1 of 2)

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STANDARD PRACTICE MANUAL

NOTE 5

NOTE 1

NOTE 2

NOTE 4
NOTE 6

NOTE 3

PERMITTED NOT PERMITTED


HARD DIELECTRIC PHENOLIC INSERT HARD DIELECTRIC PHENOLIC INSERT
NOTES:
1. A SMALL SCRATCH OR POROSITY IN CONTACT CAVITY AREA IS PERMITTED.
2. SMALL SCRATCHES IN HARD DIELECTRIC FACE ARE PERMITTED.
3. CHIPS THAT DO NOT GO FROM CAVITY TO CAVITY ARE PERMITTED.
4. A CHIP, POROSITY, OR DAMAGE WHICH GOES FROM ONE CONTACT CAVITY TO ANOTHER CONTACT CAVITY IS NOT PERMITTED.
5. CRACKS IN HARD DIELECTRIC FACE ARE NOT PERMITTED.
6. A CHIP OR POROSITY WHICH GOES FROM A CONTACT CAVITY TO OUTER EDGE OF INSERT OR INTO HARD DIELECTRIC FACE IS NOT PERMITTED.
9G20−073A

Figure 602. Connector Inserts (Sheet 2 of 6)


3. Wire Inspection (b). Examine coaxial cable that touches
structure for damage. If there is too
A. Wire Harness Inspection much damage, replace cable.
(Ref. Figure 603) (c). Install anti-rub sleeving on section of
wire harness that touches structure
NOTE:
(Ref. Wire Maintenance). A harness
D Do this inspection when you complete with protection that touches a
maintenance on a wire harness. smooth surface is permitted.
D This procedure is also applicable to RF
cables. (d). Adjust harness if it touches a sharp
edge. Wires that touch a sharp edge
D Not all steps in this procedure are appli­ is not permitted.
cable to all completed maintenance.
(2). Do an inspection of wire harness for
(1). Do an inspection for wire harness that correct installation and protection as
touches helicopter structure. If harness follows:
touches structure, do the procedure
that follows: (a). Examine wire harness clamps.
Replace clamp if cushion is damaged,
(a). Examine wires that touch structure and tighten attach hardware if loose.
for damage. If there is too much
damage, repair or replace wires. (b). If necessary, install more clamps.

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STANDARD PRACTICE MANUAL

(c). Examine harness for broken or (d). Minimum bend radius for a coaxial
missing tying tape. If necessary, cable must not cause unsatisfactory
install tying tape. function of cable, and be no less than
6 times the outside diameter.
NOTE: If anti-rub sleeving is worn or dam­
aged, adjust wire harness to prevent more (5). Do an inspection of wire harness for
damage. strain at termination, easy movement
of components that move, and correct
(d). Inspect anti-rub sleeving for wear or service loop for component installation
damage. If necessary, replace sleev­ and maintenance as follows:
ing. (a). Service loop must give panel at­
tached instruments or console control
(3). Do an inspection of wire harness units clearance from instrument
installation as follows: panel or structure by a minimum of
1.5 in. (38 mm).
(a). Make sure minimum distance
between harness and movable (b). When harness is terminated to a
components is 0.5 in. (12.7 mm). connector, supply a minimum of 1 in.
(2.54 cm) more wire length for
(b). Make sure wires connected to compo­ connector replacement.
nents that move twist and do not
(c). When harness is terminated to lugs,
bend.
supply a minimum of 3 times the
barrel length more wire length.
(c). Make sure wires do not have kinks
and are parallel. No kinks or wires (d). Wire alignment can be a maximum of
that are not parallel permitted. 0.5 in. (13 mm) from straight
between clamps.
(d). If necessary, adjust harness.
(e). If necessary, adjust harness installa­
(4). Do an inspection of bends in wire tion.
harness as follows: (6). Do an inspection for correct drip loops
as follows:
(a). Minimum bend radius for a single
wire is 10 times the outside diameter (a). Drip loops are necessary where
of the wire. moisture on wire can flow down wire
to termination and cause corrosion.
(b). Minimum bend radius for single
wire, bundle, or harness at termina­ (b). Make sure terminal lugs are
tions is 3 times the outside diameter installed with wire pointed down and
of largest included single wire. wire has a drip loop if possible.
(c). Make sure there is a minimum or
(c). Minimum bend radius for a bundle or more bend radius in wires.
harness is 6 times the outside
diameter. Bend radius of a bundle or (7). Examine wire harness for contamina­
harness can not be less than 10 times tion by fluids and dirt particles. If there
the outside diameter of largest is contamination, remove (Ref. Clean­
included single wire. ing and Protection).

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STANDARD PRACTICE MANUAL

TERMINAL LUG WITH


DRIP LOOPS WIRE POINTED DOWN

DRIP LOOPS
9G20−075A

Figure 603. Drip Loops and Lugs With Wires Pointed Down
B. Single Wire and Shielded Wire Damage Table 601. Conductor Damage Limits
Limits Strand Maximum Strand
Quantity Damage Permitted
(Ref. Table 601 and Table 602)
1−18 0 nicked or broken
NOTE: This procedure has instructions for in­ 19−36 2 nicked, 0 broken
spection of non-shielded and shielded wire.
37 4 nicked, 0 broken
Not all steps are applicable.
More Than 37 6 nicked or broken
(1). Examine wire or cable insulation for
cuts, punctures, burns, or other (3). Examine shields for broken strands.
damage. Damage that exposes the Nicks or other damage which does not
conductor or shield is not permitted. cut through a shield strand is per­
mitted.
(a). If conductor or shield strand damage
is in limit, repair wire insulation (a). Damage must not be more than
(Ref. Wire Repair). limits shown in Table 602.

(2). Examine wires for nicks, cuts, breaks, (b). If damage is not more than limit, Do
or other damage. Damage must not be a test for an open circuit condition
more than limits shown in Table 601. (Ref. Electrical Tests).
Table 602. Shield Strand Damage Limit
Quantity of Maximum Permitted Broken Strands Maximum Permitted Broken Strands
Wires in Cable (24 and 22 AWG) (20, 18, and 16 AWG)
1 10 15
2 or 3 15 20
4 20 25
5, 6, or 7 22 30

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STANDARD PRACTICE MANUAL

C. Coaxial Cable Damage Limits D. Soldered Contact Inspection


(Ref. Figure 604)
(1). Examine coaxial cable for too much
(1). Do an inspection of wire insulation as
tension or dents which damage cable.
follows:
Damage which decreases cable diame­
ter by more than 10 % is not permitted. (a). Too much solder on strands which
caused solder to go into wire insula­
tion is not permitted.
(2). Examine cable for kinks. None per­
mitted. (b). Burned wire insulation is not per­
mitted.
(3). Examine cable for nicked, cut, split, or (2). Do an inspection of solder on contact
torn insulation. Damage through and in inspection hole as follows:
insulation is not permitted.
(a). Solder must fill inspection hole.
(b). Solder on external surface of contact
(4). If damage is not more than limit, do a
must not be more that a thin layer.
test for an open circuit condition (Ref.
Electrical Tests). (3). Lightly pull wire to make sure contact
is tightly connected.
(5). If necessary, repair wire insulation (Ref. (4). If necessary, repair solder contact
Wire Repair). installation (Ref. Wire Terminations).

SERVICEABLE NOTES:
1. WIRE IS IN CENTER OF CONTACT BARREL.
2. INSPECTION HOLE IS FULL OF SOLDER.
3. SOLDER ON EXTERIOR OF CONTACT IS A THIN LAYER.
4. SOLDER FORMS A FILLET TO CONTACT CUP.

SERVICEABLE

UNSERVICEABLE NOTES:
1. SOLDER DOES NOT FORM A FILLET TO CONTACT CUP.
2. SOLDER NOT VISIBLE IN INSPECTION HOLE.
3. TOO MUCH SOLDER ON EXTERIOR OF CONTACT
4. TOO MUCH SOLDER IN INSPECTION HOLE.

UNSERVICEABLE 9G20−076A

Figure 604. Solder Contact Inspection

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STANDARD PRACTICE MANUAL

E. Solder Joint Inspection (b). Too much solder on strands which


caused solder to go into wire insula­
(Ref. Figure 605) tion is not permitted.
(1). Do an inspection of solder joint as
follows: (c). Burned wire insulation is not permit­
ted.
(a). Solder joint must have a shiny,
smooth surface, tight connection, and
a fillet. (3). Do an inspection of area where mainte­
nance was done for unwanted solder.
(b). Unwanted material, indication of too
much heat, rough surface, holes,
cracks, too much flux remaining, or (a). A thin layer of unwanted solder on
too much solder are not permitted. component or around solder joint is
permitted if it does not prevent
(2). Do an inspection of stranded wires as subsequent assembly and operation
follows: is satisfactory.
(a). Solder must fully flow on stranded
wires, go into inner strands, and not (b). Solder across circuits is not per­
change wire contour. mitted.

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STANDARD PRACTICE MANUAL

WIRE CONDUCTOR
CONDUCTOR FULLY
COVERED WITH SOLDER

SOLDER FROM
TINNING WIRE CONTOUR VISIBLE AND
FULLY COVERED WITH SOLDER
180 DEGREE WIRE OVERLAP
OF OTHER WIRE WITH SOLDER FROM
NO OVERLAP OF SAME WIRE TINNING

SOLDER FILLET BETWEEN


WIRE AND CONTACT CUP

WIRE CONDUCTOR VISIBLE SOLDER FILLET BETWEEN


COMPONENT LEAD AND WIRE

COMPONENT LEAD
WIRE TO COMPONENT LEAD SOLDER JOINT
SOLDER CUP JOINT

SOLDER FILLET BETWEEN


TERMINAL AND WIRE
180 DEGREE WIRE OVERLAP
OF TERMINAL WITH NO
OVERLAP ON WIRE SOLDER FROM TINNING

WIRE CONTOUR VISIBLE

CONDUCTOR FULLY
COVERED WITH SOLDER

9G20−048A
TERMINAL SOLDER JOINT

Figure 605. Solder Joint Inspection

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STANDARD PRACTICE MANUAL

4. Electrical Tests (a). Lightly pull on wire to make sure it


is correctly installed and locked in
A. Open Circuit Condition Test module. If lock mechanism is broken,
replace module (Ref. Installation and
Removal of Electrical Components).
Special Tools
(Ref. Section 91−00−00) (b). Remove wire with contact (Ref. Wire
Item Nomenclature Terminations).
T1001 Analog Multimeter, Portable (5). If wire terminates to a terminal lug, do
the procedure that follows:
NOTE: (a). If necessary, remove sealant from
terminal lug and component.
D An open circuit condition test makes sure
there are no opens in the electrical circuit (b). Make sure lug is correctly installed
and that terminations are correctly con­ and tight.
nected.
(c). Use termination as test point.
D Do a test for an open circuit condition to
make sure electrical cables, harness, and (6). If wire terminates to a solder joint, do
circuits are not damaged. the procedure that follows:
D A test for an open circuit condition should (a). Do the Solder Joint Inspection
be done before all other electrical tests to procedure.
keep electrical shock and possible damage
of components to a minimum. (b). Use solder joint as test point.

D Because there are different types of ter­ (7). Do the test for an open circuit condi­
minations, not all steps are applicable. tion, use analog multimeter (T1001).
NOTE:
Power Off
D Include all splices in the test.
D Include all diodes in test to make sure of
correct direction and function.
D Do not include semiconductors in test. Do
(1). Make sure all electrical power is the test to semiconductor terminations.
removed from helicopter (Ref. D Do not include Zener diodes in test. Do
CSP-900RMM-3 Section 96-00-00). the test to Zener diode terminations.
D Include transformers in test. Add speci­
(2). If necessary, remove access panels (Ref. fied transformer coil resistance to maxi­
CSP-900RMM-2 Section 06-00-00). mum resistance permitted.
(3). If wire terminates in an electrical D Include manually operated switches and
connector, do the procedure that circuit breakers in test. Do the test with
follows: contacts in closed position.
D Include electromechanical relays in test.
(a). Disconnect connector and examine Add specified relay coil resistance to max­
contacts. Replace unserviceable imum resistance permitted.
contacts (Ref. Wire Terminations). D Normally closed contacts must show con­
tinuity through circuit.
(b). Install contacts that are loose. If lock
mechanism is broken, replace D Normally open contacts must show an
connector (Ref. Electrical Connector open circuit condition.
Maintenance). D If there are electrical components in cir­
cuit being tested (transformer coils, resis­
(4). If wire terminates in a module, do the tors, etc.), set multimeter to measure re­
procedure that follows: sistance.

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STANDARD PRACTICE MANUAL

(a). Set multimeter for continuity test or (2). If necessary, remove access panels (Ref.
to measure resistance. CSP-900RMM-2, Section 06-00-00).

(b). Connect multimeter leads to both (3). Do a Test for an open circuit condition.
ends of circuit. If necessary, use other
adapters. (4). Do the test for a short circuit condition,
use analog multimeter (T1001).
(c). Make sure you hear a beep or get an
indication of no more than 10 ohms. (a). Set multimeter for continuity test or
to measure resistance.
NOTE: It is not necessary to do a test for an
open circuit condition on single end (b). Connect multimeter leads to both
grounded shields. ends of circuit. If necessary, use other
adapters.
(8). When you test shielded wire, do a test
(c). If you hear a beep or get an indica­
for an open circuit condition on the
tion of 10 ohms or less, there is a
shield.
short circuit condition.
(9). If necessary, Do other electrical tests.
(d). If you get an indication of 500,000
(10). If necessary, connect electrical connec­ ohms or more, there is an open
tors, connect wired contacts, and circuit condition.
environmentally seal terminal lugs. (5). If wire in test is non-shielded, do the
procedure that follows:
(11). Install removed access panels (Ref.
CSP-900RMM-2, Section 06-00-00). (a). Do a test for a short circuit condition
between wire and helicopter ground.
(12). Connect electrical power to helicopter
(Ref. CSP-900RMM-3, Section (b). Do a test for a short circuit condition
96-00-00). between wire and other wires in
same harness, or wires you think are
B. Short Circuit Condition Test unserviceable.

Special Tools (6). If wire in test is shielded, do the


(Ref. Section 91−00−00) procedure that follows:
Item Nomenclature
(a). Do a test for a short circuit condition
T1001 Analog Multimeter, Portable between conductor and shield.
(b). Do a test for a short circuit condition
NOTE: between wire and helicopter ground.
D Do a short circuit test to make sure a wire
(c). Do a test for a short circuit condition
is not shorted to ground, another wire, or
between wire and other wires in
to a shield.
same shielded cable, same harness,
D This procedure is also applicable to RF or wires you think are unserviceable.
cables.
(7). If wire in test is a coaxial cable, do the
Power Off procedure that follows:
(a). Do a test for a short circuit condition
between center wire and connector.
NOTE: If there is a short circuit condition be­
(1). Make sure all electrical power is tween center wire of cable and connector
removed from helicopter (Ref. when cable is connected to a component,
CSP-900RMM-3, Section 96-00-00). that component is defective.

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STANDARD PRACTICE MANUAL

(b). Connect one end of cable to compo­ High Voltage


nent and do a test for a short circuit
condition between center wire and
connector.
(c). Disconnect connector and connect
other end to component. Do a test for (4). Apply external electrical power to
a short circuit condition between helicopter (Ref. CSP-900RMM-3,
center wire and connector. Section 96-00-00).

(8). If necessary, do other electrical tests. (5). Set switches and circuit breakers in
correct positions, and apply electrical
(9). If necessary, connect electrical connec­ power to system in test (Ref.
tors, connect wired contacts, and CSP-900RMM-3, Section 96-00-00
environmentally seal terminal lugs. and 98-00-00).
(10). Install removed access panels (Ref. (6). Do the voltage test, use analog multi­
CSP-900RMM-2, Section 06-00-00). meter (T1001).
(11). Connect electrical power to helicopter (a). Set multimeter to measure DC
(Ref. CSP-900RMM-3, Section voltage.
96-00-00).
(b). Connect multimeter leads to circuit.
C. Voltage Test If necessary, use other adapters.

Special Tools (7). If there is no voltage or voltage is not


(Ref. Section 91−00−00) correct, do the procedure that follows:
Item Nomenclature
(a). Isolate defective component that
T1001 Analog Multimeter, Portable supplies electrical power or signal.
Replace defective component (Ref.
NOTE: applicable system section).
D A voltage test makes sure that power and (b). If replacement component does not
instrument signals are in limits. correct fault, wire is defective.
D Do a voltage test only after you do a test Power Off
for an open circuit condition and a short
circuit condition.
D This test procedure is not applicable to
coaxial cables.
(1). If necessary, remove access panels (Ref. (8). Make sure all electrical power is
CSP-900RMM-2, Section 06-00-00). removed from helicopter (Ref.
CSP-900RMM-3, Section 96-00-00).
(2). Do a test for an open circuit condition
and a short circuit condition. (9). If necessary, connect electrical connec­
tors, connect wired contacts, and
(3). Disconnect electrical connectors and environmentally seal terminal lugs.
wired contacts of electrical circuit that
is in test. Make sure all other connec­ (10). Install removed access panels (Ref.
tors and contacts are connected. CSP-900RMM-2, Section 06-00-00).

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STANDARD PRACTICE MANUAL

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STANDARD PRACTICE MANUAL

ELECTRICAL STANDARD PRACTICES


WIRING REPAIR
1. Wire Repair barrel plus 0.032 in. (0.81 mm) (Ref.
Wire Terminations).
A. Non−Shielded Wire Repair
(5). Put one wire end into crimp barrel of
(Ref. Table 801 and Figure 801) splice and put splice in crimping tool
(T1013).
Consumable Materials
(Ref. Section 91−00−00) (6). Fully actuate tool, and remove splice.
Item Nomenclature
(7). Put other wire end into empty end of
C824 Splice, Crimp Style, Sealed crimp barrel, and put splice in crimping
tool (T1013). Turn crimp barrel so that
crimp indentation will be 180 degrees
Special Tools to first crimp.
(Ref. Section 91−00−00)
Item Nomenclature (8). Fully actuate tool.
T1013 Crimping Tool
(9). Examine installation as follows:
T2004 Heat Gun
(a). Make sure you can see bare wire in
inspection window of crimp barrel.
NOTE: Do this procedure when wire condition
is unacceptable, and wire length is suffi­
(b). Make sure no bare wire is out of
cient.
inspection window or crimp barrel.
(1). Cut wire the minimum necessary to
remove damaged part. (c). Make sure crimp indentations are
approximately in center of crimp
(2). Make a selection of the applicable splice barrel.
(C824) and crimping tool (T1013).
(d). Make sure crimp indentations are
(3). Put sealing sleeve on wire, and move not at barrel ends or on inspection
away from maintenance area. window.

(4). Remove wire insulation from both ends (e). Replace splice if installation is
of wire, equal to the length of the crimp unsatisfactory.

Table 801. Splice and Crimp Tool Selection

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
Part Number Color Code Wire Size (AWG) Crimp Tool

ÁÁÁÁÁÁÁÁ
M81824/1−1 RED 26−24−22−20
ÁÁÁÁÁÁÁÁÁÁ AD−1377

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
M81824/1−2 BLUE 20−18−16 Raychem Part No.
992008−000

ÁÁÁÁÁÁÁÁ
M81824/1−3 YELLOW

(10). Put sealing sleeve on completed splice.


16−14−12
ÁÁÁÁÁÁÁÁÁÁ
(MIL−C−22520/37−01)

(a). Heat sealing sleeve until seals at


Align center of sleeve with center of ends of sleeve melt and flow along
splice. wire insulation.

(11). Install sealing sleeve as follows, use (b). Heat sealing sleeve until sleeve stops
heat gun (T2004). shrinking.

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

(12). Examine sealing sleeve as follows: (b). Replace in-line splice if installation
(a). Too much heat has caused sleeve to is unsatisfactory.
darkened or make visual inspection
of crimp not possible.
INSPECTION WINDOW
CRIMP BARREL LENGTH

0.032 IN. ( 0.81 MM ) MAXIMUM

BARE WIRE

CRIMP BARREL SEALING SLEEVE

ÌÌ
ÌÌ
ÌÌ
ÌÌ
COLOR STRIPE (NOTE)
SEAL MATERIAL SEAL MATERIAL

0.032 IN. ( 0.81 MM ) MAXIMUM


ÌÌ ÌÌ
BARE WIRE CAN BE SEEN IN INSPECTION WINDOW

ÌÌ ÌÌ
ÌÌ
ÌÌ ÌÌ
ÌÌ
INDENTATIONS IN CRIMP BARREL
180 DEGREES TO EACH OTHER
SEALING SLEEVE SHRUNK
TO FIT WIRE INSULATION

ÌÌ
ÌÌÌ ÌÌÌ
Ì
ÌÌ
ÌÌÌ
ÌÌ
ÌÌÌ ÌÌÌ
Ì
ÌÌÌ
Ì
COMPLETED REPAIR
SEAL MATERIAL MELTED AND
FLOWED ALONG WIRE INSULATION

NOTE: ON ONE END OF SEALING SLEEVE, THE SEAL MATERIAL WILL HAVE THE SAME COLOR CODE AS THE COLOR CODE ON 9G20−077A
THE CRIMP BARREL. IT IS NOT NECESSARY TO HAVE THE COLOR CODES STRIPES OF THE SEALING SLEEVE AND
CRIMP BARREL ON THE SAME END OF THE INSTALLED SPLICE.

Figure 801. Non−Shielded Wire Repair

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STANDARD PRACTICE MANUAL

B. Shielded Wire Repair Table 802. Solder Sleeve Selection


Part Number Size
(Ref. Table 802 and Table 803) MHS5471−1009 0.175−0.335 in.
(4.45−8.51 mm)
(Ref. Figure 802) MHS5471−1012 0.250−0.450 in.
(6.35−11.4 mm)
MHS5471−1015 0.375−0.570 in.
Consumable Materials (9.53−14.48 mm)
(Ref. Section 91−00−00) MHS5471−1018 0.475−0.690 in.
Item Nomenclature (12.02−17.53 mm)
C819 Insulation Sleeving, Electrical, Heat MHS5471−1021 0.580−0.800 in.
Shrinkable (14.73−20.32 mm)
C824 Splice, Crimp Style, Sealed MHS5471−1025 0.675−0.965 in.
C825 Splice, Shield (17.15−24.5 mm)

C826 Braided Wire, Tubular (5). Make a selection of the correct size
shield (C826).
(6). Cut shield (C826) to a length sufficient
to overlap repair at both ends after
CAUTION
splice(s) have been installed.
D Do not repair EMI category 4 or 5 Table 803. Shield Selection
shielded wire. Contact Field Service Engi­ Part Number Dimension
neering.
QQB575R36T0250 .250 in.
D Shield braid that is damaged more than (6.35 mm)
limits must be replace. Damaged shields QQB575R36T0375 .375 in.
can cause component malfunction be­ (9.53 mm)
cause of unsatisfactory signal.
QQB575R36T0500 .500 in.
D Do the repair in wire harness so as to pre­ (12.7 mm)
vent a strain at a bend or divide.
(7). Put heat shrinkable sleeving, two
solder sleeves, and repair shield on
NOTE: This procedure gives instructions for cables. Move away from maintenance
many installations. Not all steps are appli­ area.
cable.
NOTE:
D Insulation removal lengths for cable and
(1). Cut cable the minimum necessary to cable wires will change, because of the
remove damaged part. number of splices in the repair.
D Remove cable wire insulation so center of
(2). Make a selection of the correct size heat first splice is 1.0 in. (25.4 mm) from end
shrinkable sleeving (C819) (Ref. Wire of shield.
Maintenance). D Remove cable wire insulation so center of
each second splice is 1.25 in. (31.8 mm)
more from end of shield than first splice.
(3). Cut heat shrinkable sleeving (C819) to
a length sufficient to seal repair. (8). Prepare both ends of shield and wire for
termination, use end strip method (Ref.
Wire Terminations).
(4). Make a selection of the smallest size
solder sleeve (C825) that will fit on (9). Install splices (Ref. Non-Shielded Wire
cable. Repair).

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

(10). Move repair shield so that it overlaps (13). Move solder sleeve so solder is on
cable shield at both ends. overlap between repair shield and cable
shields.

(11). Make repair shield tight on cable along (14). Install solder sleeves (Ref. Solder
its length with your hand, to keep gaps Sleeve Installation).
in shield material to a minimum. (15). Move heat shrinkable sleeving and trim
as necessary to get a minimum overlap
of 0.5 in. (12.7 mm) beyond solder
(12). Trim repair shield and cable shield sleeves at both sides.
material as necessary to correct braid
length and remove braid wires that are (16). Install heat shrinkable sleeving (Ref.
out from braid. Heat Shrinkable Sleeving).

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STANDARD PRACTICE MANUAL

HEAT SHRINKABLE SLEEVING

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ REPAIR BRAID

SOLDER SLEEVE SEALING SLEEVE CRIMP BARREL

SHIELD REPAIR COMPONENTS

ÌÌÌ ÌÌÌ
1 IN. 1 IN.
(25.4 MM) (25.4 MM)

ÌÌÌ ONE WIRE ONE SPLICE ÌÌÌ


ÌÌÌ ÌÌÌ 1 IN. (25.4 MM)

ÌÌÌ
1 IN. (25.4 MM)
ÌÌÌ
2 WIRES 2 SPLICES

1 IN. (25.4 MM) 1.25 IN. 1.25 IN. 1 IN. (25.4 MM)

ÌÌÌ ÌÌÌ
(31.75 MM) (31.75 MM)

ÌÌÌ 3 WIRES 3 SPLICES


NOTE 1
ÌÌÌ
WIRE INSULATION REMOVAL FOR WIRE SPLICE

ÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌ
HEAT SHRINKABLE SLEEVING
SOLDER SLEEVE
ÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌ
SOLDER SLEEVE

ÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌ REPAIR SHIELD
END 1 END 2
NOTE 2
SOLDER SLEEVE (2 PL)

ÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌ REPAIR SHIELD

NOTE 3

ÌÌÌÌÌÌÌÌ
SOLDER SLEEVE (2 PL)

ÌÌÌÌÌÌÌÌ HEAT SHRINKABLE SLEEVING

NOTE 4

SHIELD REPAIR COMPONENT INSTALLATION


NOTES:
1. MAXIMUM DIMENSION TO PERMIT INSTALLATION OF SHIELD REPAIR COMPONENTS.
2. ALIGN REPAIR SHIELD ENDS WITH END OF CABLE INSULATION OR CABLE SHIELD FOLD BACK.
3. ALIGN SOLDER WITH AREA WHERE REPAIR SHIELD AND CABLE SHIELD OVERLAP. MAKE SURE NO SHIELD WIRES 9G20−078A
ARE OUT OF SOLDER SLEEVE.
4. MAKE SURE HEAT SHRINKABLE SLEEVING GOES A MINIMUM OF 0.5 IN (12.7 MM) FARTHER THAN END OF SOLDER SLEEVE.

Figure 802. Shielded Wire Repair

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

C. Shielded Wire − Picked Shield Repair (4). Install solder sleeve on cable (Ref.
Solder Sleeve Installation).
(Ref. Table 804)
(5). Terminate braid wire (Ref. Wire
Consumable Materials Terminations).
(Ref. Section 91−00−00)
Item Nomenclature (a). If braid wire is too short for termina­
tion, repair or replace shielded wire.
C822 Splice, Shield Termination
D. Wire Insulation Repair
NOTE: Do this procedure when a picked shield
is too short or is damaged more than limits. Consumable Materials
(1). Cut picked shield to align with end of (Ref. Section 91−00−00)
cable insulation. Item Nomenclature
C602 Rubber Strip, Self Fusing
(2). Remove 0.25-0.34 in. (6.35-8.64 mm)
cable insulation.
NOTE: You can fold cable shield on cable in­ NOTE:
sulation or let stay straight. D Do this procedure when damage is in lim­
its.
(3). Make a selection of the correct size
solder sleeve (C822). D This procedure is applicable to coax
cables.
Table 804. Solder Sleeve Selection
(1). Clean damaged area (Ref. Wire Clean­
Part Number (1) Size
ing and Protection).
MHS4786−632 0.080−0.140 in.
(2.03−3.56 mm) (2). Wind rubber tape (C602) a minimum of
MHS4786−633 0.110−0.200 in. two times around damaged part of wire.
(2.79−5.08 mm)
(3). If applicable, attach wire to harness
MHS4786−634 0.150−0.250 in. with tying tape. Apply tying tape less
(3.81−6.35 mm) than 4.0 in. (102 mm) from damage
MHS4786−635 0.200−0.300 in. (Ref. Wire Maintenance).
(5.08−7.62 mm)
(4). If applicable, install anti-rub sleeving.
NOTES: Overlap repair 4.0 in. (102 mm) on
(1) These solder sleeves have a flat, bare each side of damage (Ref. Wire Mainte­
braid wire attached. nance).

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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Section

20−70−00
Composite Materials
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

COMPOSITE MATERIALS
MAINTENANCE PRACTICES
1. Repair of Composite Materials
Acceptable damage criteria to composite
materials is shown in the applicable areas of
Chapter 53, CSP-900RMM-2.
Do not use paint stripper on
CAUTION composite/nonmetallic parts.
Composite parts can lose their strength if
they come in contact with paint stripper.
Composite parts must not be repaired without
disposition from a MD Helicopters, Inc.,
cognizant engineering representative.
2. Installation of Inserts in Carbon−Epoxy or
Fiberglass−Epoxy Sandwich Panels
A. Drill the Holes
(1). Use a three-fluted parabolic, carbide
flat flute, or carbide standard twisted THREE-FLUTED CARBIDE CARBIDE
PARABOLIC FLAT FLUTE STANDARD TWISTED REAMER
flute drill bit to drill thru the sandwich FLUTE
panel (ref. Figure 201).
NOTE: MDHI recommends you use the three-
fluted parabolic drill bit. Equivalent altern­ 9p20−085
atives can be used.
(a). If necessary to meet a small toler­ Figure 201. Types of Drill Bits
ance, drill the hole 0.002 to 0.006
inch (0.05 to 0.15 mm) undersize.
(b). Use a reamer to open the hole to the NOTE: MDHI recommends you use a drill stop
necessary size. for thru holes to control the tip of the drill
bit as it exits the sandwich panel.
(2). Use a vacuum during drill or ream
operations to keep the area clean and to
prevent the drill and sandwich panel (3). Use a piece of wood as a backup for the
from excessive heat (ref. Figure 202). exit hole to prevent delamination.

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

(c). The thickness of a hole fixture, when


used without an alignment bushing
or drill guide, must be more than the
conical length of the drill bit.

VACUUM
HOSE DRILL
ALIGNMENT
TOOL
TOP SKIN

HONEYCOMB CONICAL
OR FILLER LENGTH
BUSHING / DRILL
GUIDE CONICAL
THICKNESS LENGTH

BOTTOM
SKIN

WOOD BACKUP

9p20−086 FIXTURE / JIG FIXTURE / JIG


THICKNESS

Figure 202. Drill the Hole WITH WITHOUT


BUSHING / DRILL BUSHING / DRILL
GUIDE GUIDE
Hole diameters can move 9p20−087
CAUTION slightly off center if the hole is
drilled multiple times. Use an alignment Figure 203. Alignment Tools
bushing, drill guide, hole fixture or jig to (d). Drill the hole in one step, instead of
hold the center of the hole diameter. multiple steps to increase the diamet­
er or depth.
(4). Use a metal jig, drill guide, alignment (e). Holes more than 0.203 inch (5.16
bushing or tool, or combination thereof mm) diameter must be drilled with
to match drill holes (ref. Figure 203). alignment tool(s).
(a). Make sure the tools are securely Do not use a drill with a small
CAUTION diameter to drill thru a thick
attached to the sandwich panel.
panel. This can cause a misalignment
(b). The thickness of an alignment between the holes in the top and bottom sur­
bushing or drill guide, when used faces.
with a hole fixture or jig, must be (5). If the sandwich panel is too thick, use a
more than the conical length of the #40 carbide drill to drill a pilot hole
drill bit. thru the panel (ref. Figure 204).

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STANDARD PRACTICE MANUAL

(b). If the doubler surface is a composite


material, lightly scuff the mating
surface of the doubler with the
sandwich panel to a dull finish with
sandpaper.
(c). If the doubler surface is metal and
plated for corrosion protection, clean
#40 CARBIDE DRILL the mating surface of the doubler
ALIGNMENT with sandwich panel with cleaning
TOOL solvent (C420).
TOP SKIN
(d). If the doubler surface is metal, but
not plated:
1). Clean the mating surface with
HONEYCOMB
OR FILLER cleaning solvent (C420).
2). Put the doubler in etching solution
momentarily.
BOTTOM
SKIN Alodine (C241)

FLEX
WOOD BACKUP

9p20−088 3). Put the doubler in alodine (C241)


momentarily.
Figure 204. Drill a Hole in a Thick Panel
4). Let the doubler fully dry before
B. Install the Doublers on Sandwich Panels installation.
(e). If the doubler surface is pre-impreg­
Consumable Materials nated e-glass:
(Ref. Section 91−00−00)
Item Nomenclature
1). Lightly scuff the mating surface of
the sandwich panel with the
C241 Alodine doubler to a dull finish with
C411 Adhesive, Epoxy sandpaper.
C420 Solvent, Cleaning
2). Clean the surface with cleaning
solvent (C420).
(1). Lightly scuff the mating surface of the Adhesive, Epoxy (C411)
sandwich panel with the doubler to a
dull finish with sandpaper.
Solvent, Cleaning (C420)
Wear clean latex or cotton
CAUTION gloves during the installation to
prevent contamination of the mating sur­
faces.
(2). Clean the surface with cleaning solvent
(C420). (4). Apply epoxy adhesive (C411) on the
mating surfaces of the sandwich panel
(3). Prepare the doubler for installation: and doubler.
(a). If necessary, remove peel ply from (5). Install the doubler on the sandwich
doubler. panel.

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

(a). Clean unwanted epoxy adhesive (3). Use a piece of wood as a backup for the
(C411) from the surfaces. exit hole to prevent delamination.
(b). Apply pressure on the two surfaces (4). Do not cut into the inner face of the
with clamps to hold the doubler and far-side skin.
sandwich panel together, or put
weights to hold the doubler in place, (5). Do not remove burrs at the hole
or put a vacuum bag over the bonded periphery.
surfaces (if possible).
(6). Remove loose material.
NOTE: MDHI recommends the vacuum bag
method (if possible) because it applies an (7). Lightly scuff the inner face of the
equal pressure over the area to be bonded, far-side skin.
minimizes or eliminates air pockets
between bonded surfaces, and for better ad­ (8). If hard points or inserts are to be
hesion. installed in a panel, which cannot be
put in a flat or horizontal position, drill
(6). Let the epoxy adhesive (C411) dry (ref. vent holes (ref. Figure 205).
manufacturer instructions).

INSTALLATION HOLE
VENT (REF. TABLE 201)
HARD POINT
UP VENT
INSERT

ALIGNMENT DRILL MOTOR


BUSHING

INJECT POTTING
MATERIAL HERE 0.20 INCH
(5.1 MM) CUTTER

UNWANTED SEALANT GUN


MATERIAL

9p20−090
9p20−089

Figure 206. Installation of Blind Inserts


Figure 205. Location of Vent Holes

C. General Instructions to Drill the Holes for D. Installation of Blind Inserts with Potting
the Inserts Holes

(1). Drill holes perpendicular 89.5 to 90.5 (Ref. Figure 206)


degrees to the surface.
NOTE: Use this procedure for NAS1832,
(2). Drill the necessary concentric holes NAS1835, NAS1836, or equivalent blind in­
with minimum burr. serts (ref. Table 201).

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STANDARD PRACTICE MANUAL

Do not drill thru the opposite (5). Fill the cavity with potting material
CAUTION skin or cut into its inner face. (ref. the engineering drawing, mainten­
ance manual, service bulletin, or
(1). Drill the hole to the diameter shown technical bulletin for the material to be
(ref. Table 201) thru the top skin and used).
core.
(a). Put potting material in the insertion
(2). Remove 0.20 inch (5.1 mm) minimum hole with a pressurized sealant gun
more than the diameter in Step (1). of until the potting material comes out
core material with an alignment the opposite hole free of air bubbles.
bushing, cutter, and drill motor.
(b). Let the potting material cure (ref.
NOTE: Use a low rpm drill speed to core the manufacturer instructions).
diameter. (6). After the potting material has become a
hard gel, remove unwanted potting
(3). Remove loose material.
material with a sharp knife.
(4). Install the blind insert flush with the (7). Remove the aluminum tape.
surface with a NAS1837 installation
tool or equivalent, or aluminum tape. (8). As necessary, clean the surfaces.
Table 201. Blind Inserts with Potting Holes

Basic PN Dash No. Thread Type, Inch (mm) Installation Hole Size, Inch (mm)
NAS1832 −06 Regular 0.1380 (3.505) 0.561 to 0.566 (14.25 to 14.38)
−08 Regular 0.1640 (4.166) 0.561 to 0.566 (14.25 to 14.38)
−3 Regular 0.1900 (4.826) 0.561 to 0.566 (14.25 to 14.38)
−4 Regular 0.2500 (6.350) 0.686 to 0.691 (17.42 to 17.55)
−5 Regular 0.3125 (7.938) 0.686 to 0.691 (17.42 to 17.55)
−6 Regular 0.3750 (9.525) 0.842 to 0.847 (21.39 to 21.51)
NAS1835 −08 Floating 0.1640 (4.166) 0.686 to 0.691 (17.42 to 17.55)
−3 Floating 0.1900 (4.826) 0.686 to 0.691 (17.42 to 17.55)
−4 Floating 0.2500 (6.350) 0.749 to 0.755 (19.02 to 19.18)
−5 Floating 0.3125 (7.938) 0.811 to 0.817 (20.60 to 20.75)
−6 Floating 0.3750 (9.525) 0.874 to 0.880 (22.20 to 22.35)
NAS1836 −06 Lightweight 0.1380 (3.505) 0.452 to 0.457 (11.48 to 11.61)
−08 Lightweight 0.1640 (4.166) 0.452 to 0.457 (11.48 to 11.61)
−3 Lightweight 0.1900 (4.826) 0.452 to 0.457 (11.48 to 11.61)
−4 Lightweight 0.2500 (6.350) 0.499 to 0.504 (12.67 to 12.80)

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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

INSTALLATION HOLE
(4). Remove loose material.
(REF. TABLE 202)
(5). Install the blind insert flush with the
surface with a NAS1837 installation
tool or equivalent, or aluminum tape.
SCREW CLEARANCE
DIAMETER
(6). Fill the cavity with potting material
(ref. the engineering drawing, mainten­
ALIGNMENT DRILL MOTOR ance manual, service bulletin, or
BUSHING technical bulletin for the material to be
used).

(a). Put potting material in the insertion


hole with a pressurized sealant gun
0.20 INCH until the potting material comes out
CUTTER
(5.1 MM) the opposite hole free of air bubbles.

(b). Let the potting material cure (ref.


SEALANT GUN
manufacturer instructions).
UNWANTED
MATERIAL
(7). After the potting material has become a
hard gel, remove unwanted potting
material with a sharp knife.

(8). Remove the aluminum tape.


9p20−091
(9). As necessary, clean the surfaces.
Figure 207. Installation of Thru Inserts
SCREW DRILL MOTO
CLEARANCE ALIGNMENT
E. Installation of Thru Inserts with Potting DIAMETER BUSHING
Holes

(Ref. Figure 207)

NOTE: Use this procedure for NAS1833, 0.20 INCH


CUTTER
(5.1 MM)
NAS1834, or equivalent thru inserts (ref.
Table 202).
SEALANT GUN
(1). Drill thru the sandwich panel to the UNWANTED TAPE
MATERIAL
diameter necessary for the screw to be
used with the insert.

(2). Drill the hole to the diameter shown


(ref. Table 202) thru the top skin and 0.098 INCH DIA.
core. 0.18 INCH (2.49 MM)
(4.6 MM) MIN.

Do not cut into the inner face of


CAUTION the opposite skin.
CLEARANCE DRILL

(3). Remove 0.20 inch (5.1 mm) minimum


more than the diameter in Step (1). of
core material with an alignment
bushing, cutter, and drill motor. 9p20−092

NOTE: Use a low rpm drill speed to core the Figure 208. Installation of Adhesive Hard
diameter. Points

Page 206
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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

F. Installation of Adhesive Hard Point Thru inch (4.6 mm) from the edge of the
Holes hole, opposite from each other.

(Ref. Figure 208) (8). Put aluminum tape over the holes.

Do not drill thru the opposite (9). Make holes in the aluminum tape for
CAUTION skin or cut into its inner face. the two 0.098 inch (2.49 mm) diamet­
er holes.
(1). Drill the hole to the diameter shown on (10). Fill the cavity with potting material
the engineering drawing, maintenance (ref. the engineering drawing, mainten­
manual, service bulletin, or technical ance manual, service bulletin, or
bulletin. technical bulletin for the material to be
used).
(2). Do not cut into the inner face of the
far-side skin. (a). Put potting material in the insertion
hole with a pressurized sealant gun
(3). Do not remove burrs at the hole until the potting material comes out
periphery. the opposite hole free of air bubbles.

(4). Remove 0.20 inch (5.1 mm) minimum (b). Let the potting material cure (ref.
more than the diameter in Step (1). of manufacturer instructions).
core material with an alignment
bushing, cutter, and drill motor. (11). After the potting material has become a
hard gel, remove unwanted potting
NOTE: Use a low rpm drill speed to core the material with a sharp knife.
diameter.
(12). Remove the aluminum tape.
(5). Remove loose material. (13). As necessary, clean the surfaces.
(6). Lightly scuff the inner face of the (14). After the potting material has cured,
far-side skin. drill the hole again thru the panel (ref.
the engineering drawing, maintenance
(7). Drill two 0.098 inch (2.49 mm) manual, service bulletin, or technical
diameter holes approximately 0.18 bulletin).
Table 202. Thru Inserts with Potting Holes

Basic PN Dash No. Thread Type, Inch (mm) Installation Hole Size, Inch (mm)
NAS1833 −06 0.1380 (3.505) 0.561 to 0.566 (14.25 to 14.38)
(Threaded) −08 0.1640 (4.166) 0.561 to 0.566 (14.25 to 14.38)
−3 0.1900 (4.826) 0.561 to 0.566 (14.25 to 14.38)
−4 0.2500 (6.350) 0.686 to 0.691 (17.42 to 17.55)
−5 0.3125 (7.938) 0.686 to 0.691 (17.42 to 17.55)
−6 0.3750 (9.525) 0.842 to 0.847 (21.39 to 21.51)
NAS1834 −06 0.140 (3.56) 0.561 to 0.566 (14.25 to 14.38)
(Clearance) −08 0.169 (4.29) 0.561 to 0.566 (14.25 to 14.38)
−3 0.196 (5.00) 0.561 to 0.566 (14.25 to 14.38)
−4 0.257 (6.53) 0.686 to 0.691 (17.42 to 17.55)
−5 0.316 (8.03) 0.686 to 0.691 (17.42 to 17.55)
−6 0.377 (9.58) 0.842 to 0.847 (21.39 to 21.51)

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STANDARD PRACTICE MANUAL

SCREW NOTE: Use a low rpm drill speed to core the


CLEARANCE diameter.
DIAMETER

(4). Remove loose material.


(5). Lightly scuff the inner face of the
INSTALLATION HOLE far-side skin.
(REF. TABLE 203)
(6). Drill two 0.098 inch (2.49 mm)
diameter holes approximately 0.18
0.20 INCH CUTTER inch (4.6 mm) from the edge of the
(5.1 MM) hole, screw side, opposite from each
other.

DRILL MOTOR
(7). Install the insert with the correct screw,
washer, and nut.
ALIGNMENT
BUSHING (a). Pull the insert tightly against the
opposite side of the panel.
UNWANTED SEALANT GUN
MATERIAL
(b). If the head of the insert is not
against the panel, use two washers
maximum under the screw to make
sure the fit is correct.
(c). Put aluminum tape on the injection
9p20−093 and vent holes to prevent an adhes­
ive bond with the panel surface.
Figure 209. Installation of Dome−Head
Inserts (8). Fill the cavity with potting material
(ref. the engineering drawing, mainten­
G. Installation of Dome−Head Inserts ance manual, service bulletin, or
(Ref. Figure 209) technical bulletin for the material to be
used).
(1). Drill thru the sandwich panel to the
diameter necessary for the screw to be (a). Put potting material in the insertion
used with the insert. hole with a pressurized sealant gun
until the potting material comes out
(2). On the side of the panel where the head the opposite hole free of air bubbles.
of the insert will be, drill an installation
hole the diameter of insert body (ref. (b). Let the potting material cure (ref.
Table 203). manufacturer instructions).
Do not cut into the inner face of (9). After the potting material has become a
CAUTION the opposite skin. hard gel, remove unwanted potting
material with a sharp knife.
(3). Remove 0.20 inch (5.1 mm) minimum
more than the diameter in Step (1). of (10). Remove the aluminum tape.
core material with an alignment
bushing, cutter, and drill motor. (11). As necessary, clean the surfaces.

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Table 203. Dome−Head Inserts

Basic PN Dash No. Thread Type, Inch (mm) Installation Hole Size, Inch (mm)
BHT80−007 −1 0.1380 (3.505) 0.315 to 0.320 (8.00 to 8.13)
−2 0.1640 (4.166) 0.315 to 0.320 (8.00 to 8.13)
−3 0.1900 (4.826) 0.378 to 0.383 (9.60 to 9.73)
−4 0.2500 (6.350) 0.378 to 0.383 (9.60 to 9.73)
−4A 0.2500 (6.350) 0.440 to 0.445 (11.18 to 11.30)
−5 0.3125 (7.938) 0.440 to 0.445 (11.18 to 11.30)

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Section

20−80−00
Tubing
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

TUBING STANDARD PRACTICES


MAINTENANCE PRACTICES
1. Permaswage [ Fittings (5). If necessary, remove paint or primer
(ref. Section 20-40-00).
A. Installation
NOTE: The tube must not have paint or primer
The fittings can be swaged no on the last 2.0 inch (50.8 mm) of the mat­
CAUTION more than two times. ing surface where the fitting will be
installed.
Consumable Materials Do not mark titanium tubes
(Ref. Section 91−00−00) CAUTION with a marking pen that con­
Item Nomenclature tains chloride or graphite.
C423 Solvent, Cleaning
C829 Marker, Permanent (6). To mark a tube with the marking tool
(part of the permaswage® kit (T2005))
do these steps:
Special Tools
(Ref. Section 91−00−00) (a). Put the lip stop of the marking tool
Item Nomenclature against the end of the tube with the
T2005 Permaswage® Kit applicable fitting dash number in
view on the marking tool.

If a tube is to be cut while on the (b). Fully fill in the applicable slot in the
CAUTION rotorcraft, use a chipless-type marking tool with the marking tool.
tube cutter.
(c). Make another mark approximately
(1). Cut the tube end at 88 to 92 degrees 180 degrees from the first mark.
in relation to outer side of tube wall.
(7). To mark a tube when the marking tool
(2). Deburr the inner and outer side of the is unavailable, do these steps:
tube wall.
(a). Find the maximum and minimum
(a). Do not remove more than 25 per­ engagement lengths for the applica­
cent of the tube wall thickness. ble tube size (ref. Table 201).

(3). Examine the tube ends to make sure Table 201. Engagement Length
the area where the fitting will be
Tube Dimension Minimum Maximum
installed is smooth and has no burrs or
scratches. 0.250 inch 0.615 inch 0.915 inch
(6.35 mm) (15.62 mm) (23.24 mm)
(a). A scratch depth of 0.001 inch (0.03 0.375 inch 0.690 inch 0.990 inch
mm) maximum is permitted. (9.53 mm) (17.53 mm) (25.15 mm)
Solvent, Cleaning (C423)
(b). Make a mark around the tube at the
minimum engagement dimension
with permanent marker (C829).

(c). Make a mark around the tube at the


(4). If necessary, clean the tube with maximum engagement dimension
cleaning solvent (C423). with permanent marker (C829).

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(8). Find the applicable swaging tool (f). Tighten the knurled nut with your
number and its related parts (ref. hand.
Table 202).
(g). Move the fitting on the tube so that
Table 202. Swaging Tool part of the insertion mark is in view.
Tube Power Unit Head Assembly (h). Move the assembled power unit
Dimension along the tube until the inner side of
0.250 inch DLT05MAPW0000 DLT05PSHA3004 the silver-colored endplate is approx­
(6.35 mm) imately 0.030 inch (0.76 mm) from
the end of the fitting.
0.375 inch 0.690 inch 0.990 inch
9.53 mm) (17.53 mm) (25.15 mm) NOTE: The insertion mark must not be fully in
view.
(9). Examine the swaging die segment slots
for unwanted material. (i). Make sure part of the insertion mark
is in view.
Solvent, Cleaning (C423)
(j). Keep the power unit in this position.
(k). Operate the hydraulic power unit.
(l). Make sure the pressure gauge
(10). If necessary, clean the die segment slots indicates 5,250 to 5,750 psig (36.20
with cleaning solvent (C423). to 39.65 MPa).

(11). Let the cleaned die segment slots fully (m). Release the hydraulic pressure on the
dry. power unit.

(12). Connect the power supply hose to the (n). Loosen the knurled nut on the power
swaging tool. unit and remove from swage yoke.
(o). Remove the die holder and the swage
(13). If necessary, bleed air from the power
yoke.
supply or power supply hose (ref. the
manufacturer instructions). (15). Visually examine the fitting for cracks.
(14). Install the fitting as follows: (a). No cracks are permitted.
(a). Put the fitting in its installed posi­ (16). Make sure part of the insertion mark is
tion on the tube. in view.
(b). Put the swage yoke of swaging tool (17). When the applicable go/no-go inspec­
on the fitting with the silver-colored tion gauge is available, do these steps:
endplate adjacent to the end of the
fitting. (a). Put the applicable go/no-go inspec­
tion gauge on the fitting and move
(c). Put the die holder in the yoke the gauge along the tube with the
assembly with the silver-colored gauge edges between the flash marks
endplate adjacent to the end of the caused by the swaging dies.
fitting.
(b). Put the applicable go/no-go inspec­
(d). Put the square head of the strut on tion gauge on the fitting again 90
the power unit horizontally in the degrees from the position measured
swage yoke. in Step (a).
(e). Align the square head of the strut (18). If an applicable go/no-go inspection
and the swage yoke. gauge is not available, do these steps:

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(a). Find the swage dimensions (ref. (19). If swage is not satisfactory, do steps (9).
Table 203). thru (18). again.

Table 203. Swage Dimensions (20). Install a pressure cap or plug on one
Tube Maximum Swage Minimum end of the tube assembly.
Dimension Dimension Swage Length
(21). If a fitting is aluminum, apply 2,000
0.250 inch 0.315 inch 0.460 inch psig (13.79 MPa) pressure to other end
(6.35 mm) (8.00 mm) (11.68 mm) of tube assembly for five (5) minutes
0.375 inch 0.447 inch 0.530 inch minimum.
9.53 mm) (11.35 mm) (13.46 mm)
(a). No leakage is permitted.
(b). Measure the fitting for the correct
maximum swage dimension between (22). If a fitting is corrosion resistant steel
(CRES) or titanium, apply 6,000 psig
the flash marks caused by the
(41.37 MPa) pressure to other end of
swaging dies.
tube assembly for five (5) minutes
(c). Measure the fitting again for the minimum.
correct maximum swage dimension
90 degrees from position measured in (a). No leakage is permitted.
Step (b).
(23). If there is leakage and the fitting has
(d). Measure the fitting for the correct not been swaged two times, do steps
minimum swage length. (9). thru (22). again.

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Section

20−90−00
Nondestructive
Inspection
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

NONDESTRUCTIVE INSPECTION
MAINTENANCE PRACTICES
1. Nondestructive Inspection Methods (c). A 2-10 power magnifying glass to
expose defects that cannot be seen by
A. Visual Inspection the unaided eye.
(Ref. Figure 201) (d). A borescope to allow remote visual
inspection of internal surfaces or
(1). Select applicable visual inspection aids otherwise inaccessible areas.
from the following list:
(2). Perform a preliminary inspection of
(a). A flashlight with the correct explo­ overall general area for cleanliness,
sive atmosphere rating, beam spread, presence of foreign objects, deformed or
efficiency, and brightness for the missing fasteners, security of parts,
inspection being performed. corrosion, and damage.
(b). An inspection mirror on a ball joint (3). Treat any corrosion found during
for use in viewing an area that is not preliminary inspection (Ref. Section
in the normal line of sight. 20-40-00).

EYE ABOVE REFLECTED


LIGHT BEAM

INCANDESCENT
LIGHT BEAM

LINE OF SIGHT

REFLECTED LIGHT BEAM


5 o TO 45 o

CRACK OPEN TO SURFACE


9G20−081
FAYING SURFACES

Figure 201. Visual Inspection Technique


(4). Clean the areas or surface of parts to be (5). Using optical aids as required, inspect
inspected (Ref. Section 20-20-00). area as follows:

(a). Examine surface for cracks using a


(a). Remove any contaminates that
flashlight, and confirm with a
might hinder surface indications. magnifying glass. Refer to Figure 201
for use of a lightbeam to detect
(b). Do not remove protective finishes. cracks.

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STANDARD PRACTICE MANUAL

(b). Examine surface for other disconti­ Solvent, Cleaning (C423)


nuities, such as: discoloration from
overheating; buckled, bulging, dented
skin; cracked, chafed, split, or dented
tubing; chafed electrical wiring;
delaminations of composites; and
(6). If part is serviceable or repairable,
damaged protective finishes. clean part free of penetrant and
B. Dye Penetrant Inspection developer with cleaning solvent (C423).
C. Coin Tap Inspection
Consumable Materials
(Ref. Figure 202)
(Ref. Section 91−00−00)
Item Nomenclature
C423 Solvent, Cleaning Consumable Materials
(Ref. Section 91−00−00)
C808 Dye Penetrant Kit
Item Nomenclature
C429 Solvent Cleaner
Solvent, Cleaning (C423)
The coin tap method of inspection is used
evaluate composite structures. The coin tap is
limited to detecting shallow defects.

(1). Using cleaning solvent (C423), clean When inspecting cored structure, two sided
area to be inspected. access is required. When multiple laminates
are installed over core, the core bondline
NOTE: cannot be evaluated.
D Manufacturers instructions on Dye Pene­ The sound of an acceptable part can vary
trant Kit take precedence over the follow­ considerably and the entire area must be
ing steps. tapped in order to detect any variance.
D Parts to be inspected must be dry and Compare the sound of the suspected area with
heated to at least 70 °F (21.1 °C), but not the sound of a known acceptable area.
over 130 °F (54.4 °C).
An acceptable area will have a slightly sharper
(2). Apply penetrant from dye penetrant kit or crisper sounding response. A dead or flat
(C808) by brushing, spraying or by sound is unacceptable, and requires a more
dipping. Allow to stand for a minimum thorough type of NDI.
of 2 minutes.
Any suspect areas must be in­
CAUTION spected by person(s) qualified in
(3). Remove excess penetrant with remover
(available with dye penetrant kit the appropriate NDI. Contact MDHI cogni­
(C808)), or by cleaning with plain zant engineering for recommended NDI pro­
water. Allow part to dry. cedures and applications.

(4). Apply a light even layer of developer Solvent Cleaner (C429)


from dye penetrant kit (C808) by
brushing, spraying or by dipping. When
dipping, avoid excess quantity.

(5). Penetrant, which has penetrated into (1). Thoroughly clean area to be inspected
cracks (or other openings) in the surface with solvent cleaner (C429).
of the part will be drawn out by the
developer resulting in a bright red (2). Perform a visual inspection for any
indication. raised or blistered appearing areas.

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0.25 IN DIA
(6.35 mm)

2.00 IN
(50.8 mm)
0.375 IN
(9.52 mm)
DIA BALL

MATERIAL: MILD STEEL OR BRASS

9G20−008

Figure 202. Coin Tap Inspection


NOTE: Tap the entire area to be inspected in­ E. Magnetic Particle Inspection
cluding any surrounding area of like
construction. Refer to the appropriate manufacturer's
(3). Using a coin, light hammer, or other related instructions for type of equipment and
suitable blunt object, lightly tap the materials being used.
surface of the part to be inspected.
F. Eddy−Current Inspection
D. Fluorescent Penetrant Inspection
Refer to the appropriate manufacturer's Refer to the appropriate manufacturer's
related instructions for type of equipment and related instructions for type of equipment and
materials being used. materials being used.

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STANDARD PRACTICE MANUAL

Chapter

CHARTS
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

TABLE OF CONTENTS
Para/Figure/Table Title Page

91-00-00 Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Consumables, Servicing, Support Equipment, and Finishes . . . . . . . . . . . . . . 201
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Manufacturer / Supplier Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Ground Support Equipment and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Tool Manufacturer / Supplier Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2. Consumable Materials Warning Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Consumable and Servicing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Table 202. Manufacturer / Supplier Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Table 203. Ground Support Equipment and Special Tools . . . . . . . . . . . . . . . . . . . 227
Table 204. Tool Manufacturer / Supplier Number . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Page i
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TABLE OF CONTENTS (Cont.)


Para/Figure/Table Title Page

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STANDARD PRACTICE MANUAL

Section

91−00−00
Charts
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

CHARTS
CONSUMABLES, SERVICING, SUPPORT EQUIPMENT, AND
FINISHES
1. General D C100 - Fuels, Oils and Lubricants
This chapter provides a table of Consumable D C200 - Corrosion Preventative Coatings
and Servicing Materials, and a table of Ground and Compounds
Support Equipment and Special Tools used on D C300 - Paints, Primers and Coating
the MD Explorer. Compounds
The information in each table is divided into D C400 - Solvents, Cleaners and Adhesives
groups. Within each group, materials or tools
are identified by a number. Numbers have a D C500 - Composite Materials
prefix of C identifying a consumable or D C600 - Rubber Material
servicing material, or a T identifying a tool. C
and T numbers are used throughout the D C700 - Lockwire, Fasteners and Tape
maintenance manual, allowing quick reference
D C800 - Miscellaneous Materials
for Consumable Materials and Ground
Support Equipment and Special Tools. B. Manufacturer / Supplier Number
A. Consumable Materials Table 202 lists Manufacturer / Supplier
Table 201 lists Consumable and Servicing Number with address and phone number.
Materials, such as fuels and oils used to Table 202 is used with Table 201, Consumable
support repair or servicing procedures. For Materials.
additional servicing information, such as C. Ground Support Equipment and Special
capacities refer to the applicable rotorcraft Tools
maintenance manual.
Table 203 identifies ground support equipment
Materials not identified and special tools, necessary for maintenance
WARNING with the Specification No.,
operations.
when listed, may not meet the require­
ments of their application. Tools are listed in groups, with each tool
assigned a T number, with an associated part
Materials are approved for use on the MD number, descriptive title and function.
Explorer. Do not replace materials, unless
equal to quality and grade. Refer to notes at D T100 - Ground Handling Requirement
the end of Table 201.
D T200 - Jacking and Leveling Requirement
Materials are listed with hazardous warning D T300 - Main Transmission Requirement
codes. The WARNING codes are given a
descriptive title (ref. Note 7, Table 201). A D T400 - Engine Requirement
detailed explanation of WARNING codes, an
example is shown below, is in Section D T500 - Flight Control Requirement
01-00-00. D T600 - Anti-Torque Requirement
Consumable Container Warnings D T700 - ECS Requirement
D T800 - Fuel Requirement
D T900 - Main Rotor Requirement
D T1000- Electrical/Instrument/Avionic
The following lists each group of consumable Requirement
materials by descriptive title and the C
number for each material in the group. D T2000- Miscellaneous Requirement

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D. Tool Manufacturer / Supplier Number Warnings are explained by an icon, a letter


Table 204 lists Tool Manufacturer / Supplier designator and a descriptive title. If warning
Number with address and phone number. icons are not fully understood, go to Warning
Table 204 is used with Table 203, Ground Symbols for more details (ref. Section
Support Equipment and Special Tools. 01-00-00).
2. Consumable Materials Warning Icons
The warning icons shown below are those most
commonly seen associated with consumable
materials.

B = Burns / Irritate Chemical F = Flammable

E = Eye Injury P = Poison

EX = Explosion V = Vapor

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Table 201. Consumable and Servicing Materials (1)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)

Fuels, Oils, and Lubricants

C101 Lubricant, Solid Film MDM 4−1078 Molykote 3402C MS22


(B−E−P−V) T1 . . . . −− . . . . −− Lubribond 220 MS24
MIL−L−23398 Perma−Slik G MS24

C102 Lubricant, Solid Film MDM 4−1078 Techlube PT−24M MS49


(B−E−EX−P−V) T3 . . . . −− . . . . −−

C103 Lubricant Dow Corning 200, MS22


(E) 100CST

C104 Grease MDM 20−1244 Mobilith SHC 220 MS43


(B−E) T2 . . . . −− . . . . −−

C105 Hydraulic Fluid MIL−H−5606 (3) Commercial


(B−E)

C106 Oil, Lubrication MIL−PRF−23699 AeroShell Turbine Oil MS52


(B−E) T2 . . . . −− . . . . −− 500 MS53
(5 Centistokes)
AeroShell Turbine Oil MS52
560 MS53
BP Turbo Oil 25 MS29
BP Turbo Oil 2380 MS29
Castrol 5000 Engine MS9
Oil MS10
MS11
Mobil Jet Oil II MS45
MS46
CANADA ONLY MS26
Mobil Jet Oil 254 MS45
MS46
RoycoR Turbine Oil MS51
500
RoycoR Turbine Oil MS51
560
Turbonycoil 525−2A MS48
Engine Oil

C107 Grease, Aircraft MIL−G−81322 Mobil Grease 28 MS46


(B−E−V) AeroShell 22 MS52

C108 Powder, Molybdenum Disulfide Molycote Z MS22


(B−E−EX)

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Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Fuels, Oils, and Lubricants
C109 Grease MIL−G−6032 VV−P−236 MS22
(B−E) MS51
MS58

C110 Grease, Synthetic 3913−G1 MS56


(B−E)

C111 Oil VV−L−800 MS10


(B−E−EX−V)

C112 Hydraulic Fluid MIL−H−83282 Commercial


(B−E) MIL−PRF−83282

C113 Fuel, Aviation Turbine MIL−T−5624 JP−4, JP−5, additional MS52


(B−E−EX−F−P−V) fuels (ref. Pratt & MS64
Whitney Canada)

C114 Fuel, Aviation Turbine ASTM D1655 Jet A, Jet A−1, Commercial
(B−E−EX−F−P−V) additional fuels (ref. MS64
Pratt & Whitney
Canada)

C115 Grease, General Purpose Caltex No. 2 MS8

C116 Oil, Daphne, Hermetic 150C 150CX MS38


(B−E−V)

C117 Oil, Daphne, Hermetic R−134A RG20, RS20 MS38


(B−E−V)
Daphne Hermetic Oil MS3
PR

C118 Oil, Preservation MIL−L−6081 Brayco 460 MS10


(B−E−V) Grade 1010

C119 Grease, Lubrication MIL−G−23827 AeroShell Grease 7 MS52


(B−E−V)

C120 Lubricant, Spray Tri−Flow MS66


(B−E−F−P−V) Break−Free

C121 Grease, Flourosilicone Dow Corning FS3452 MS22


(B−E−V)

C122 Oil, Lubrication Pre−SB900−118: MS46


(B−E) Mobil SHC 626

Post−SB900−118:
Mobil AGL

C123 Grease, VSCS Actuator 168043 MS7


(B−E−EX−V)

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Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Fuels, Oils, and Lubricants
C124 Deleted (Ref. Item C106)

C125 Grease, Mineral, Helicopter MIL−G−25537 AeroShell Grease 14 MS52


(B−E−F−P−V)

Page 205
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Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Corrosion Preventative Coatings and Compounds

C201 Sealing Compound MDM16−1097 P/S 890 MS15


(B−E−F−V) MIL−S−8802
T1 . . . . CA . . . 1/2

C202 Sealing Compound MDM16−1097 P/S 890 MS15


(B−E−F−V) MIL−S−8802
T1 . . . . CA . . . 1

C203 Sealing Compound MDM16−1097 P/S 890 MS15


(B−E−F−V) MIL−S−8802
T1 . . . . CA . . . 2

C204 Sealing Compound MDM16−1097 P/S 890 MS15


(B−E−F−V) MIL−S−8802
T1 . . . . CA . . . R5

C205 Sealing Compound MDM16−1097 P/S 890 MS15


(B−E−F−V) MIL−S−8802
T1 . . . . CB . . . 1/2

C206 Sealing Compound MDM16−1097 P/S 890 MS15


(B−E−F−V) MIL−S−8802
T1 . . . . CB . . . 1

C207 Sealing Compound, Fuel Resistant MDM16−1097 P/S 890 MS15


(B−E−F−V) MIL−S−8802
T1 . . . . CB . . . 2

C208 Sealing Compound, Fuel Resistant MDM16−1097 P/S 890 MS15


(B−E−F−V) MIL−S−8802
T1 . . . . CB . . . 4

C209 Sealing Compound, Dichromate MDM16−1097 P/S 890 MS15


Cured MIL−S−8802
(B−E−F−V) T1 . . . . CB . . . R5

C210 Sealing Compound, Dichromate MDM16−1097 P/S 890 MS15


Cured (B−E−F−V) MIL−S−8802
T1 . . . . CC . . . 20

C211 Sealing Compound, Corrosion MDM16−1097 Commercial


Inhibitive MIL−S−81733
(B−E−F−V) T3 . . . . CB . . . 1/2

C212 Sealing Compound, Corrosion MDM16−1097 Commercial


Inhibitive MIL−S−81733
(B−E−F−V) T3 . . . . CB . . . 1

C213 Sealing Compound, Corrosion MDM16−1097 Commercial


Inhibitive MIL−S−81733
(B−E−F−V) T3 . . . . CB . . . 2

Page 206
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STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Corrosion Preventative Coatings and Compounds
C214 Sealing Compound, Corrosion MDM16−1097 Commercial
Inhibitive MIL−S−81733
(B−E−F−V) T3 . . . . CB . . . G4

C215 Sealing Compound, Fireproof MDM16−1191 Pro−Seal 700 MS15


(B−E−P−V) MIL−S−38249 TT−S−735 Commercial

C216 Sealant, Fuel Resistant MDM16−1097 MS63


(B−E−V) MIL−S−8802
T2 . . . . CB . . . G1/2

C217 Sealing Compound, Corrosion MRM730061 MS15


Inhibitive MIL−S−81733
(B−E−F−V) T2 . . . . C2 . . . −−

C218 Corrosion Inhibitor MIL−PRF−16173 LPS 3® Rust Inhibitor MS27


(B−E−F−V) −− . . . . C1 . . . G2

C219 Compound, Corrosion Preventive MIL−PRF−16173 MS6


(CPC) (B−E−F−V) −− . . . . C2 . . . G3 Commercial

C220 Antiseize Compound MIL−T−83483 Molybdenum Disulfide MS4


(B−E−F) Grease

C221 Silicone Compound MDM16−1118 Silastic 732 MS22


(B−E−V) T1 . . . . C1 . . . −− RTV 157 MS31

C222 Fluorosilicone Compound MDM16−1118 730 FS MS22


(B−E−EX−V) T1 . . . . C3 . . . −−

C223 Compound, Heat Sink, Silicone MIL−C−47113 Dow Corning 340 MS22
and/or Non−Silicone T1 . . . . −− . . . . −− Heat Sink Supplies
(B−E−V)

C224 Not Used At This Time

C225 Sealing and Locking Compound MIL−S−22473 Loctite® 085 Yellow MS36
(B−E−V) −− . . . . −− . . . . GB

C226 Sealing and Locking Compound MIL−S−22473 Loctite® 084 Blue MS36
(B−E−P−V) −− . . . . −− . . . . GC

C227 Sealing and Locking Compound MIL−S−22473 Loctite® 080 Purple MS36
(B−E−P) −− . . . . −− . . . . GE

C228 Sealant Primer MIL−S−22473 Loctite® T 7471t MS36


(B−E−EX−V) −− . . . . −− . . . . GT Primer

C229 Sealant, Conductive MDM16−1261 Cho−bond 2165 MS12


(B−E−EX−F−P−V) SAE AMS3266 PR−1764 Class B MS15

Page 207
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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Corrosion Preventative Coatings and Compounds
C230 Sealant, Electrically Conductive MDM16−1157 Cho−bond 1030 MS12
(B−E−EX−V)
NOTE: C229 is preferred.
C231 Primer, Epoxy MIL−PRF−23377 Oakite 15 MS15
(B−EX−P−V) T1 . . . . C1 . . . −− MS17
MS55
C232 Sealant MIL−PRF−81733 Pro−Seal 870 A−2 MS15
(B−E−EX−F−P−V) T1 . . . . C2 . . . −−

C233 Chemical Coating MIL−DTL−81706 Alodine 600 MS36


(B−E−EX−F−P−V) T1 . . . . C3 . . . −−

C234 Sealing Compound MIL−S−29574 PR 1826 B2 MS15


(B−E−EX−F−P−V) T1 . . . . B2 . . . A MS43

C235 Release Agent, Fluorocarbon REN RP 79−2 MS41


(B−E−V) Sprayonr S00311 MS55

C236 Not Used At This Time


C237 Sealant MDM16−1149 Pro−Seal 890 MS15
(B−E−V) T3 . . . . −− . . . . −−

C238 Corrosive Preventive Compound Deoxidine 624 MS36


(B−E−P−V)

C239 Sealant MIL−S−46163 Loctite; Removable MS36


(B−E−P) T2 . . . . −− . . . . N Threadlocker 242

C240 Anti−Seize Compound, High Temp MIL−A−907E Loctite; Thread MS36


(B−E−P−V) Compound 767,
Anti−seize, High Temp
C241 Alodine MIL−DTL−81706 Alodine 1201 MS36
(B−E−P−V) T1 . . . . C1A . . −−

C242 Adhesion Promoter SAE AMS3100 PR148 MS15


(B−E−F−P−V)

C243 Corrosion Preventive Compound, MIL−PRF−16173 Commercial


Solvent Cutback, Cold−Application −− . . . . −− . . . . G4

C244 Oxide Film, Corrosion−Resistant Semco® Pasa−Jell MS15


(B−E−P−V) 101

C245 Conductive Grease Noalox® Anti−Oxidant MS13


(B−E−P) Compound

C246 Conductive Oil Penetroxt A−13 MS33


(B−E−F−P) Oxide Inhibiting
Compound

Page 208
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STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Corrosion Preventative Coatings and Compounds
C247 Petroleum Wax Sanchem NO−OX−ID MS69
(B−E−P−V) A−Special

Page 209
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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Paints, Primers and Coating Compounds

C301 Primer, Epoxy MDM15−1100 FED−STD−595 Commercial


(B−E−F−V) T1 . . . . C2 . . . −− Green #34151

C302 Finish Enamel MDM15−1100 FED−STD−595 Commercial


(B−E−F−V) MIL−PRF−22750 White #17925

C303 Finish Enamel MDM15−1100 FED−STD−595 Commercial


(B−E−F−V) MIL−PRF−22750 Black #37038

C304 Paint, Base (B−E−F−V) MDM15−1107 #1 MS43

C305 Paint, Base MDM15−1107 #2 MS43


(B−E−F−V)

C306 Paint, Accent (B−E−F−V) MDM15−1107 #2 MS43

C307 Primer, Epoxy MIL−PRF−23377 515X410 MS15


(B−E−F−V) T2 . . . . C2 . . . −−

C308 Primer MIL−PRF−23377 MS19


(B−E−EX−F−P−V) T1 . . . . C1 . . . −− or
T1 . . . . C2 . . . −−

MIL−PRF−23377
T2 . . . . C1 . . . −− or
T2 . . . . C2 . . . −−

MDM15−1100 FED−STD−595
T1 . . . . C2 . . . −− Green #34151

C309 Primer MIL−PRF−23377 MS39


(B−E−F−V) T1 . . . . C2 . . . −−

C310 Primer MIL−PRF−23377 513X390 MS15


(B−E−F−V) T1 . . . . C1 . . . −− MS17
MS55

C311 Heresite Primer P−413 MS37


(B−E−P−V)

C312 Heresite Paint B−12 MS37


(B−E−P−V)

C313 Paint Stripper Turco 5873 MS36


(B−E−P−V) Turco 5351
Turco 6813

C314 Polyurethane Coating MIL−C−83286 MS19


(B−E−EX−F−P−V)

C315 Lacquer Thinner (B−E−EX−F) TT−T−266 MS34

Page 210
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STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Paints, Primers and Coating Compounds
C316 Chemical Film MIL−DTL−81706 Iridite 14−2 MS50
(B−E−F−V) T1 . . . . C1A . . −−

C317 Primer, Epoxy MIL−PRF−85582 MS19


(B−E−EX−F−P−V) T1 . . . . C2 . . . −−

C318 Primer, Epoxy MIL−PRF−23377 MS19


(B−E−F−V) T1 . . . . C1 . . . −− or
T1 . . . . C2 . . . −−

C319 Lacquer, Acrylic, Gloss Red 11136 MDM15−1083 DES 420MHS #11136 MS15
(B−E−F−P−V) (Color No. 11136) Gloss Red

C320 Finish Enamel Imron® 5000t MS23


(B−E−F−P−V) Topcoat or
Imron® 6000t
Basecoat / Clearcoat

C321 Coating, Varnish−Fungus Resistant MIL−V−173 MS49


(B−E−F−P−V) ASTM−D3955

C322 Marking Ink, Black NSN 73X Black Marking Ink MS72
(B−E−F−P−V) 7510P73XBLACK

C323 Primer, Zinc Chromate MIL−P−8585 TT−P−1757 Commercial


(B−E−EX−F−P−V)

C324 Coating Compound, Nonslip A−A−59166 EPOXO−5044 MS40


(B−E−F−P−V) T2 . . . . −− . . . . −− Black #37038 MS14
MS34

Page 211
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STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Solvents, Cleaners and Adhesives
C401 Adhesive, Epoxy MDM20−1267/1757 Hysolr EA 9394 MS36
(B−E−F−V)
C402 Adhesive, Epoxy MDM16−1068 Hysolr EA 9330.3 MS36
(B−E−F−V) −− . . . . C1 . . . −−
C403 Bonding, General MDM16−1068 Scotch−Weldt MS62
(B−E−F−V) −− . . . . C2 . . . −− EC1838
A−1177−B Obsolete
C404 Adhesive, Epoxy MDM16−1068 Hysolr EA 9313 MS36
(B−E−F−V) −− . . . . C5 . . . −−
C405 Adhesive, Epoxy MDM16−1068 Hysolr EA 960F MS36
(B−E−F−V) −− . . . . C6 . . . −− RP 1257−3 MS41
C406 Adhesive, Epoxy MDM16−1068 Hysolr EA 9309.3NA MS36
(B−E−F−V) −− . . . . C7 . . . −−
C407 Adhesive, Epoxy MDM16−1068 MS21
(B−E−F−V) −− . . . . C8 . . . −−
C408 Adhesive, Epoxy MDM16−1068 MS21
(B−E−F−V) −− . . . . C9 . . . −−
C409 Adhesive, Epoxy Paste MDM16−1068 Hysolr EA 9394 MS36
(B−E−F−V) −− . . . . C9 . . . GB
C410 Adhesive, Epoxy Paste MDM16−1068 Hysolr EA 956 MS36
(B−E−F−V) −− . . . . C11 . . −− Hysolr EA 9323
C411 Adhesive, Epoxy MDM16−1068 BR95 MS16
(B−E−F−V) −− . . . . C12 . . −− Hysolr EA 9321 MS36
C412 Adhesive Promoter, Epoxy MDM16−1068 Hysolr EA 9203 MS36
(B−E−F−V) −− . . . . C13 . . −−
C413 Adhesive Film MDM16−1078 AF143 MS62
T4 . . . . C1 . . . −− FM300M MS18
C414 Adhesive Film MDM16−1111 Hysolr EA 9628H MS36
−− . . . . C3 . . . −−
C415 Adhesive Sealant MIL−A−46106 M4610631 ARN MS32
(B−E−V) T1 . . . . −− . . . . −−
C416 Adhesive Sealant MMM−A−1754 MS43
C417 Release Agent MDM20−1267/1087 Sprayonr S00311 MS55
(B−E−P−V) Alternatives:
Release Allr 40 or MS1
Release Allr 45
C418 Release Agent MDM20−1267/1763 Frekote 44−NC MS21
(B−E−EX−F−P−V)

Page 212
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STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Solvents, Cleaners and Adhesives
C419 Alcohol, Isopropyl MS59
(B−E−F−V)

C420 Solvent, Cleaning ASTM D740 Methyl Ethyl Ketone MS59


(B−E−EX−F−P−V) (3)

C421 Cleaning Solvent Naphtha Aliphatic MS43


(B−E−EX−F−P−V) (TT−N−95) T2

C422 Adhesive Paste, Acrylic MDM16−1226 EA9366 MS21


(B−E−P−V)

C423 Solvent, Cleaning O−T−620 Trichloroethane MS6


(B−E−EX−F−P−V) 1.1.1 (3)

C424 Solvent, Cleaning Turco MS36


(B−E−P−V) W0−1

C425 Solvent, Cleaning M−114 M MS28


(B−E−V)

C426 Adhesive, Epoxy MDM16−1147 3Mt Scotch−Weldt MS62


(B−E−P−V) −− . . . . C2 . . . −− 2216 B/A

C427 Adhesive Sealer MIL−R−46082 Loctite MS36


(B−E) T1 . . . . −− . . . . −−

C428 Pasa−Jell 101 MS15


(B−E−V)

C429 Solvent Cleaner Desoclean 45 MS15


(B−E−EX−F−P−V) 020X413

C430 Solvent Thinner MIL−T−81772 MS39


(B−E−F−P−V) T2 . . . . −− . . . . −−

C431 Solvent Chlorothene MS22


(B−E−F)

C432 Cleaner Methyl Alcohol MS25


(B−E−F−P−V) MS35

C433 Solvent Neu−Tri MS22


(B−E−V)

C434 Solvent P−D−680 Mineral Spirits MS25


(B−E−F−V) T1 . . . . −− . . . . −− (Safety Solvent)

C435 Adhesive, Electrically Conductive MDM16−1068 Crest 2092 A/B MS65


(B−E−F−P−V) −− . . . . C4 . . . −−

C436 Acetone ASTM D329 Acetone Commercial


(B−E−F−P−V)

Page 213
91-00-00 Revision 23
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Solvents, Cleaners and Adhesives
C437 Cleaner, Alkaline Turco 3878 MS36
(B−E−P−V) (Liquid Alkaline Rust
Remover)

C438 Adhesive, Epoxy Hysol EA 960F QT MS21


(B−E−P−V) System

C439 Solvent, Perchloroethylene SVG Dow Chemical MS22


(B−E−P−V) Company Product
Code: 59010

C440 Adhesive, Acrylic Loctiter 330 MS36


(B−E−F−V)

C441 Activator Loctiter 7387 MS36


(B−E−EX−F−P−V)

C442 Adhesive, Ethyl−2−Cyanoacrylate, MIL−A−46050 ZipGripr 4495 MS73


Medium Viscosity (Super Glue) T2 . . . . C2 . . . −− ZipGripr GPE 100
CID A−A−3097
T2 . . . . C2 . . . −−

C443 Cleaner, Alkaline Turco 5578−L MS36


(B−E−P−V)

C444 Adhesive, Instant MDM16−1070 Loctiter 410t Prismr MS36


(B−E−V) T1 . . . . −− . . . . −−

C445 Mold Release, 500°F (260°C) Liquid MDM20−1267/1374 Release Allr MS2
(B−E−V) T7 . . . . C2 . . . −− Safelease 30

C446 Mold Release, 425°F (218°C) Aerosol MDM20−1267/1374 Tiolonr X−20 MS57
(B−E−P−V) T7 . . . . C2 . . . −−

Page 214
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STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Composite Materials
C501 Fiber Cloth, E−Glass MIL−C−9084, Commercial
(E) SAE AMS−C−9084

C502 Glass Fiber, Sheet, Laminate MIL−P−25421 Commercial


(E) T1 . . . . C1 . . . −−

C503 Foam, Syntactic (Low Density Filled MDM17−1002 EA 9396 A/B MS21
Epoxy Resin) EC3524 A/B MS62
(B−E−V)

C504 Resin, Epoxy MDM16−1115 Araldite® 501 MS41


(B−E−F−P−V) T3 . . . . −− . . . . −−
Epoxy Resin MS68
FH−2434−A
Curing Agent
FH−2180−B

C505 Foam, Rigid, Structural, Closed Cell MDM17−1205 MS71


T2 . . . . C1 . . . −−

C506 Cloth, Graphite MDM16−1163 MS42


(E) T2 . . . . C1 . . . GB

C507 Foaming Adhesive MDM16−1284 MS18


(B−E−F−P−V)

C508 Shielding, Expanding Foil MDM16−1255 Astrostriket MS20


(B−E) T1 . . . . −− . . . . −−

Page 215
91-00-00 Revision 21
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Rubber Material
C601 Rubber, Silicone ZZ−R−765 Rubber, Silicone, Low Commercial
−− . . . . C1A . . G50 Temperature Resistant

C602 Rubber Strip A−A−59163 Insulation Tape, Commercial


T1 . . . . C1 . . . −− Electrical, Self−Adher-
ing Unsupported
Silicone Rubber,
Rectangular Cross−
Section, Inch−Pound
Dimensions

C603 Not Used At This Time


C604 Not Used At This Time
C605 Not Used At This Time
C606 Rubber Tubing AMS 3212 Acrylonitrile Butadiene Commercial
NR 250 PRO 63 (NBR) Rubber,
Aromatic, Fuel
Resistant 55−65

C607 Not Used At This Time


C608 Rubber Tubing AMS 3212 Acrylonitrile Butadiene Commercial
NR 500 PRO 63 (NBR) Rubber,
Aromatic, Fuel
Resistant 55−65

C609 Not Used At This Time


C610 Rubber, Expanded ASTM−D−1056 Flexible Cellular Commercial
T2 . . . . CA . . . G1 Material — Expanded
Rubber

Page 216
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STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Lockwire, Fasteners and Tape
C701 Lockwire MS20995C20 (3) Commercial
C702 Lockwire MS20995C32 (3) Commercial
C703 Tape, Lacing and Tying, Polyester CID A−A−52081, Commercial
Finish B, Size 2
C704 Tape, Polyethylene MDM16−1029 Commercial
T3 . . . . C2 . . . −−
C705 Tape, Polyethylene MDM16−1029 Commercial
T3 . . . . C1 . . . −−
C706 Tape, Glass−Fiber MDM16−1236 Commercial
T1 . . . . C2 . . . GB
C707 Tape, Pressure−Sensitive Adhesive GSA FSS L−T−100 Commercial
C708 Tape, Lacing and Tying, Glass CID A−A−52083, Commercial
Finish D, Size 4
C709 Tape, Adhesive MHS5277K1208 Commercial
C710 Tape, Glass Fabric, Aluminized; MDM15−1182 W2R00 3Mt 363 or 363LC Commercial
2.00−Inch−Wide
C711 Strap, Tiedown MS3367 Commercial
T1 . . . . C1 . . . −−
C712 Lockwire MS20995NC32 Commercial
C713 Tape, Nonslip 3M610−192231 MS62
TB . . . Black
C714 Tape, Adhesive, Clear (3) Commercial
C715 Lockwire MS20995CY15 (3) Commercial
C716 Tape, Electrical MIL−I−23594 Commercial
T1 . . . . C4 . . . WR75
C717 Tape, Polyethylene MDM16−1029 3Mt UHMW 5421 MS62
C718 Tape, Vinyl Foam MDM16−1124 4504 3Mt 4504 MS62
C719 Tape, Aluminum, MDM15−1195 MS62
4 inch (10.16 cm)
C720 Tape, Fastener, Hook & Loop MHS4590−7/−8 MS62
C721 Tape, Foam MDM16−1124 4516 MS62
C722 Lockwire MS20995NC20 Commercial
C723 Lockwire MS20995C15 Commercial
C724 Protective Tape, Polyurethane 3Mt 8671−3 (3 inch) MS62
3Mt 8671−6 (6 inch)

Page 217
91-00-00 Revision 21
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Lockwire, Fasteners and Tape
C725 Adhesive Promoter 3Mt 86A MS62
C726 Strap, Tiedown MS3367−1−9 Commercial
T1 . . . . C1 . . . −−

C727 Strap, Tiedown MS3367−4−9 Commercial


T1 . . . . C1 . . . −−

Page 218
Revision 24 91-00-00
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Miscellaneous Materials

C801 Foam MDM17−1186 Commercial


C802 Cloth, Non−Lint

C803 Nylon Cord, Braided MIL−C−5040C MS30


T3 . . . . −− . . . . −−

C804 Abrasive Cloth #600 Commercial

C805 Extinguishing Agent Halon 1301 MS23


(B−E−EX−F−V) MS33

C806 Refrigerant, R12 Freon R−12 MS23


(B−E−V)

C807 Sandpaper 320 grit Commercial


C808 Dye Penetrant Kit MIL−I−25135 (3) MS5
MS42

C809 Leak Detector, Liquid Snoop MS47

C810 Abrasive Cloth Aluminum Oxide 240 Commercial


Grit

C811 Plastic Restoration Kit NSN Micro−Mesh Kit MS44


5350−01−290−4002 KR−70
EZ9016 EZCLEAR MS74 (8)
Aviation 230V Kit
EZ9018 EZCLEAR
Aviation Premium Kit

C812 Filler Compound Commercial

C813 Nylon Abrasive Mat MIL−A−9962 Aluminum Oxide Commercial


T1 . . . . −− . . . . GA

C814 Abrasive Paper Aluminum Oxide Commercial


Paper 300 or 400 grit

C815 Refrigerant, R134A 134A MS2


(B−E−V)

C816 Insulation Sleeving, Electrical, MHS5485 MS43


Silicone Resin Coated

C817 Pad, Scouring, Cellulose/Nylon Scotch−Britet 63 MS62

C818 Sleeve, Protective, Expandable and MHS5330 MS43


Insulating MS70

C819 Insulation Sleeving, Electrical, Heat MIL−I−23053/5 Commercial


Shrinkable AMS−I−23053/5

Page 219
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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 201. Consumable and Servicing Materials (1) (Cont.)


Mfg./Supplier
Item Material and Specification No. (2) Commercial No. (Ref.
No. Warning Icons (6) Type Class Grade Name/No. (3) Table 202)
Miscellaneous Materials
C820 In−Line Junction, Splice M81714/65−22−1 Commercial
C821 Cap, Electrical, Wire End MHS5077 MS43
C822 Splice, Shield Termination, Solder MHS4786 MS43
Type MIL−S−83519/2 Commercial
SAE−AS83519/2
C823 Plug, Grommet Seal MS27488 Commercial
C824 Splice, Crimp Style, Environment MIL−S−81824/1 Commercial
Resistant MHS4946 MS43

C825 Splice, Overbraid Applications, Solder MHS5471 MS43


Type MIL−S−83519/1 Commercial

C826 Braid, Wire, Tubular QQ−B−575 Commercial


A−A−59569

C827 Desiccant MIL−D−3464 Commercial


T1 . . . . −− . . . . −−
T2 . . . . −− . . . . −−
C828 Abrasive Cloth, Crocus ANSI−B74.18 Commercial
C829 Marker, Permanent — . . . . −− . . . . −− Sharpie® 13601 or Commercial
32001

NOTES:

(1) Materials in this table have been determined appropriate for use by testing of materials meeting the
specification listed in the Specification No. column. Material information may also be listed in the
Commercial Name/No. column. MDHI Material & Specification Engineering has occasionally found material
identified to the Commercial Name/No. listed, unable to meet the requirements of the Specification No.
Material used should be obtained by and identified with the Specification No., when listed, with or without
the Commercial Name/No.

(2) Numbers are U.S. Specifications and Standards. Prefix symbols are specified as follows:
AMS − American Materials Standard;
AN − Air Force/Navy Aeronautical Standard;
MIL − Military Specification;
MS − Military Standard;
NAS − National Aerospace Standard;
Single, Double or Triple alpha prefix of the same letter − Federal Specification.

(3) Primary selection. All equivalent material can be used as a different selection. Time increments on
manufacturers instructions must be adhered to, unless given differently in a specific task.

(4) Use the best comparable grade material when conformity of available materials of same type with given
Specification Number cannot be found.

Page 220
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STANDARD PRACTICE MANUAL

NOTES: (Continued)

(5) When ordering paint, give each paint by type (i.e., acrylic, epoxy, polyurethane); by color and AC part
number. Also include compatible MHS or federal standard (FED−STD) number to make sure correct type
and color paint is supplied. The color code numbers for finish paints used on MD900 are entered in
helicopter log books before delivery of the rotorcraft. Make sure when ordering paints that AC Number and
SA Number are compatible.
(6) Warnings are explained by an icon, a letter designator and a descriptive title. If warning icons are not fully
understood, refer to Warning Symbols for more details (ref. Section 01−00−00).
(7) The specifications in the list below shows the conversion of older McDonnell Douglas/Boeing specifications
to that of MD Helicopters, Inc. The MD Helicopters, Inc. specifications are equivalent to the
McDonnell Douglas/Boeing specifications.

Boeing
MD Helicopters Examples
McDonnell Douglas
HP MDP HP1−1 is now MDP 1−1
HMD MDM HMS16−1097 is now MDM 16−1097
HS, HSD, MD MHS HS4810 is now MHS 4810

Do not use EZCLEAR kits on hard-coated windscreens.


CAUTION
(8) Select one of the following EZCLEAR kits:
S EZ9016 EZCLEAR Aviation 230V Kit for applications with the European style 230V polisher
or
S EZ9018 EZCLEAR Aviation Premium Kit for applications with the US style 120V polisher
Stock the kits with the EZ65001P EZCLEAR Aviation Restoration Pack.

Page 221
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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 202. Manufacturer/Supplier Number


Number Name (CAGE Code) Address Telephone
MS1 Airtech International, Inc. (53912) 5700 Skylab Road (714) 899−8100
Huntington Beach, CA 92647
www.airtechonline.com
MS2 Airtech Europe Sarl (B7368) Z.I. Haneboesch +352−582282−1
L−4562 Differdange
www.airtech.lu
MS3 Apollo America Corp. (1FCW2) 2000 Town Centre, Suite 1450 (248) 355−0666
Southfield, MI 48075−1253

MS4 Armite Laboratories Inc. (84180) 1560 Superior Avenue, Suite A−4 (949) 646−9035
Costa Mesa, CA 92627
MS5 Ardrox, Inc. 19 Woodburn Avenue, PO Box 814 (800) 297−3208
St. Catherines, Ontario
Canada L2R 6Y3
MS6 Ashland Industrial Products Inc. 3499 Dabney Road (859) 357−7777
(9T904) Lexington, KY 40509

MS7 Astronautics Corp. of America 4115 N. Teutonia Avenue (414) 449−4255


(10138) Milwaukee, WI 53209
www.astronautics.com
MS8 Castrol 1925 North Marianna Avenue
Los Angeles, CA 90032−007
MS9 Castrol Canada Inc. 3620 Lakeshore Boulevard West, (416) 252−5511
Toronto, Ontario, M8W 1P2, Canada

MS10 Castrol Industrial North America Inc. 1001− West 31st Street (800) 621−2661
Downers Grove, IL 60515 (630) 241−4000

MS11 Castrol (UK) Ltd. Burmah Castrol House, Pipers Way 01−793511521
Swindon Wiltshire SN3 1RE England
MS12 Parker−Hannifin Corp., Parker 77 Dragon Court (781) 935−4850
Chomerics Division (18565) Woburn, MA 01801
www.parker.com
MS13 Burndy LLC (1NJK8) 47 East Industrial Park Drive (800) 346−4175
Manchester, NH 03109 (603) 647−5000

MS14 Randolph Products Co. 33 Haynes Circle (413) 592−4191


Chicopee, MA 01020
www.randolphproducts.com
MS15 PRC−Desoto International, Inc., 24811 Rockefeller Avenue (661) 678−4209
Aerospace Division (83574) Valencia, CA 91355

MS16 American Cyanamid Co., Industrial 1300 Revolution Street (410) 939−1910
Chemicals and Plastics Division Havre de Grace, MD 21078−3837
(07542)
MS17 Crown Metro Specialty Products, Inc. 307 Echelon Road, PO Box 5857 (864) 299−1331
(02DS4) Greenville, SC 29606

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Table 202. Manufacturer/Supplier Number (Cont.)


Number Name (CAGE Code) Address Telephone
MS18 Cytec Engineered Materials, Inc. 1191 North Hawk Circle (714) 362−8444
(1XNT8) Anaheim, CA 92807
www.cytec.com
MS19 Deft, Inc. (33461) 17451 Von Karman Avenue (800) 544−3338
Irvine, CA 92614 (949) 474−6714
MS20 Astroseal Manufacturing (0KWM1) 85 Airport Industrial Road (860) 526−8605
PO Box 377, Chester, CT 06412

MS21 The Dexter Corp., Hysol Division One Dexter Drive (603) 474−5541
(1JB33) Seabrook, NH 03874

MS22 Dow Corning Corp. (5D028) 3901 South Saginaw Road (800) 248−2481
Midland, MI 48686
www.dowcorning.com
MS23 DuPont (9V583) 1007 North Market Street (800) 441−7515
Wilmington, DE 19898 (302) 774−1000
www.dupont.com
MS24 E/M Corp. 100−T Cooper Circle (800) 428−7802
Peachtree City, GA 30269 (770) 261−4800

MS25 EM Separations Technology PO Box 70, 480 Democrat Road (609) 224−0742
Gibbstown, NJ 08027

MS26 Esso Petroleum Canada 55 St. Clair Avenue West


Toronto, Ontario M5W 2J8, Canada

MS27 LPS Laboratories, a Division of 4647 Hugh Howell Road (770) 243−8800
Illinois Tool Works Inc. (66724) Tucker, Georgia 30084
www.lpslabs.com
MS28 Fine Organics Corp. (05867) 420 Kuller Road, Suite 2, (973) 478−1000
Clifton, NJ 07011
fineorganicscorp.com
MS29 Air BP Lubricants (1UGB2) 1500 Valley Road, (973) 686−5607
Wayne, NJ 07470

MS30 FWF Industries, Inc. (3F196) 4 Carrington Street (401) 728−1920


Lincoln, RI 02865

MS31 Momentive Performance Materials 22 Corporate Woods Boulevard (800) 295−2392


Inc. (01139) Albany, NY 12211

MS32 General Electric Co., Plastic One Plastics Avenue (413) 448−7569
Operation (72799) Pittsfield, MA 01201

MS33 Ideal Industries, Inc. (30119) 1 West Becker Place (800) 435−0705
Sycamore, IL 60178
www.idealindustries.com
MS34 Griggs Paint Co. 3635 South 16th Street (888) 947−4447
Phoenix, AZ 85040−1310
www.griggspaint.com

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Table 202. Manufacturer/Supplier Number (Cont.)


Number Name (CAGE Code) Address Telephone
MS35 Harcros Chemicals Inc. (1MJX1) 3810 South Elwood (800) 363−6230
Tulsa, OK 74107

MS36 Henkel Corp. 32100 Stephenson Highway (800) 953−5858


Madison Heights, MI 48071
www.henkel.com
MS37 Heresite Protective Coatings Inc. 822 South 14th Street (920) 684−6646
(0VKU9) Manitowoc, WI 54220

MS38 Idemitsu Kosan Co., Ltd. (SDY61) 1−1 Marunouchi 3−Chome, +81 (3) 3213−3137
Chiyoda−ku, 100−8321, Japan

MS39 Kop−Coat, Inc. 436 7th Avenue (412) 227−2426


1850 Koppers Building
Pittsburgh, PA 15219
www.kop−coat.com
MS40 ITW Insulcast (053W7) 565 Eagle Rock Avenue (800) 645−7546
Roseland, NJ 07068 (215) 855−8450
www.insulcast.com
MS41 Huntsman Advanced Materials 5121 San Fernando Road West (818) 265−7298
America Inc. (99384) Los Angeles, CA 90039
www.huntsman.com/advanced_
materials/
MS42 Magna Flux 11898−T Burnside Lane (815) 623−7634
Roscoe, IL 61073
MS43 MD Helicopters, Inc. (1KVX4) 4555 East McDowell Road (800) 388−3378
Mesa, AZ 85215−9734 (480) 346−6377
www.mdhelicopters.com
MS44 Micro−Surface Finishing Products 1217 W. 3rd St. (563) 732−3240
Inc. (32834) Wilton, IA 52778
www.micro−surface.com
MS45 Mobil Oil Corp., Sales − Supply 150 East 42nd Street (212) 563−0199
Division (6A691) New York, NY 10017
MS46 ExxonMobil Oil Corp., Aviation 3225 Gallows Road (703) 846−7856
Lubricants (53C29) Fairfax, VA 22037
exxonmobilaviationlubricants.com
MS47 Nupro Co. (18034) 4800 East 345th Street (440) 951−9729
Willoughby, OH 44094
MS48 NYCO SA 66 Avenue des Champs−Élysées +33 (0) 1−4561−5000
BP 414 75366 Paris Cedex 8, France
www.nyco.fr
MS49 Product Techniques, Inc. 3271 South Riverside Avenue (909) 877−3951
Rialto, CA 92376
MS50 MacDermid Americas 245 Freight Street (203) 575−5700
Waterbury, CT 06702

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Table 202. Manufacturer/Supplier Number (Cont.)


Number Name (CAGE Code) Address Telephone
MS51 Anderol Inc. (07950) 215 Merry Lane, PO Box 518 (973) 887−7410
East Hanover, NJ 07936 (888) 263−3765
www.anderol.com
MS52 Shell Aviation Ltd. (KA832) Shell Centre (800) 840−5737
London SE1 7NA, UK 020−7934−8220

MS53 Shell Canada Products Ltd. 250 Laurier Boulevard (613) 498−5700
Brockville, ON K6V5V7 CAN
MS54 Not Used At This Time
MS55 The Sherwin−Williams Co. (54636) 101 Prospect Avenue NW (800) 515−4825
Cleveland, OH 44115

MS56 Syn−Tech Ltd. (53592) 1433 West Fullerton Avenue, Suite G (630) 628−7290
Addison, IL 60101
www.syn−techlube.com
MS57 Tiodize Co., Inc. 5858 Engineer Drive, (714) 898−4277
Huntington Beach, CA 92649
www.tiodize.com
MS58 Interstate Chemical Co., Inc., United 1432 Chestnut Street, PO Box 1218 (724) 981−3771
Erie (55466) Erie, PA 16502

MS59 Van Waters & Rogers Inc. PO Box 34325 (425) 889−3400
Seattle, WA 98124−1325
MS60 Not Used At This Time
MS61 Not Used At This Time
MS62 3M Company 3M Center, Building 304−01−01 (800) 364−3577
St. Paul, MN 55144−1000

MS63 Advanced Chemistry & Technology, 7341 Anaconda Avenue (770) 963−3653
Inc. (1DWR5) Garden Grove, CA 92841
www.actechaero.com
MS64 Pratt & Whitney Canada Inc. (00198) 1000 Marie−Victorin Boulevard (800) 268−8000
Longueuil, QC J4G 1A1, Canada (450) 647−7623
MS65 Crest Products Corporation 18203−T Mount Baldy Circle (714) 965−9292
Fountain Valley, CA 92708

MS66 NOMA Bearing Corporation 1555 W. Rosecrans Avenue (310) 329−1800


Gardena, CA 90249
www.iksbearing.com
MS67 Not Used At This Time
MS68 Fiber−Resin Corporation 20701 Nordhoff Street (800) 624−9487
Chatsworth, CA 91311 (651) 236−3000

MS69 Sanchem Inc., a Subsidiary of 1600 South Canal Street (800) 621−1603
Santell Chemical Co. (56086) Chicago, IL 60616 (312) 733−6100
sanchem.com

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CSP−SPM MD Helicopters, Inc.
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Table 202. Manufacturer/Supplier Number (Cont.)


Number Name (CAGE Code) Address Telephone
MS70 Federal−Mogul Corp., Systems 1277 Joe Battle Boulevard (610) 280−1349
Protection Group (81851) El Paso, TX 79936
www.federal−mogul.com/spg
MS71 Divinycell International, Inc. 315 Seahawk Drive (972) 228−2419
DeSoto, TX 75115
MS72 Independent Ink Inc. (12744) 14705 South Avalon Boulevard (800) 424−9300
Gardena, CA 90248 (310) 523−4657
MS73 Devcon Corp. (16059) 30 Endicott Street (978) 777−1100
Danvers, MA 01923
www.devcon.com

MS74 Plastek LLC (3YWD6) 3300 Industry Drive (650) 367−7075


Signal Hill, CA 90755
www.plastekcorporation.com

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STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools

Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Ground Handling Requirement

T101 BDW−BKH Ground Handling The ground handling wheel set straddles TS6
Wheel Set the landing gear skid tubes at protruding
pins on either side. The hydraulic ram is
actuated by pumping the handle, which
raises the helicopter.

T102 HM−7M (S/N 121) Tow Bar The towbar attaches to the skid tubes TS6
and is used in conjunction with the
GHWS.

T103 162−192TU Heli−Porter The heli−porter is designed for TS26


helicopter users who have a towing
tractor or vehicle.

T104 S3B180ARPRB Aft Mooring Helicopter aft tiedowns. TS1


Tiedowns

T105 S1AQ180PR Forward Mooring Helicopter forward tiedowns. TS1


Tiedowns

T106 MD900−110 Upper Deck Encloses the NOTAR® inlet, particle TS19
Cover separator inlets and exhaust stacks.

T107 MD900−700 Pitot Cover Pitot protection. TS19

T108 MD900−615 Blade Tiedown Socks which fit over the blade tip with a TS19
length of rope, which can be tied down.

T109 MD900−000 Bubble Cover Encloses the entire canopy. TS19


Canopy

T110 55530−50 Grounding Strap Statically ground helicopter (use TS2


equivalent comparable tool).

T111 06−4005−0511 Fluid Service Unit Service the landing gear damper. TS31

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STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Jacking and Leveling Requirement

T201 900G2300102−103 Jack Pad Kit Safely lift the helicopter. TS19

T201−1 900G2300102−103 Aft Jack Pads Detachable jack pads, used with jack TS19
pad kit.

T201−2 900G2300102−103 Forward Jack Stress support bar, used with jack pad TS19
Pad Assembly kit.

T202 900GENERPAC Aircraft Jacks Aircraft jacking requirements. TS11

T203 Pro 360 Inclinometer Leveling and measures droop angle TS28
degrees.

T204 AC100 Aircraft Weighing Gives total weight of aircraft. TS14


System

T205 6C236 Plumb Bob Aircraft leveling requirements. TS13

T206 Commercially Available Forward Jack Used with forward jack pad assembly TS20
Pad Grease and jacks to adjust a change in
Plate longitudinal dimension.

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Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Main Transmission Requirement

T301 900G2400201−101 Transmission Remove and install main transmission. TS19


Removal Kit

T301−1 900G2400201−101 Dolly Assembly Remove transmission from rotorcraft. TS19

T301−2 900G2400201−101 Tray Assembly Support transmission after removal on TS19


upper deck.

T301−3 900G2400201−101 Pin Attaches two−part dolly assembly. TS19

T301−4 900G2400201−101 Lifting Plate Lift transmission off upper deck. TS19

T302 SLT61−2SP3 Lockwasher Used with SL61WT series lockwashers TS27


Puller (on blower impeller).

T303 GT1−90007441000 Transmission Used to remove the shur−lok impeller TS19 TS20
Blower Shaft nut.
Socket

T304 900G8910120−101 Guide Pins Input quill alignment. TS19 TS20

T305 114−248 Piston Jack Main rotor brake lining replacement. TS5

T306 900G8910125−101 Jackscrews Remove input pinion assembly. TS19 TS20

T307 H301−84 Heli−Lock Drain Transmission fluid drain line. TS19


Attachment

T308 CDU−1812 Ultrasonic Clean heat exchanger, minimum eight TS8


Cleaner Tank gallon capacity (use equivalent
comparable tool).

T309 900G8910330−101 Mount Assembly Used to hold input pinion assembly. TS19

T310 900G8910342−101 Pusher Assembly Used to install bearing on the input TS19
pinion assembly.

T311 900G8910346−101 Wrench Used to remove/install locknut from/on TS19


input pinion.

T312 900G8910348−101 Guide Used to install clutch into outer race. TS19

T313 900G8910350−101 Puller Assembly Used to remove clutch outer race TS19
assembly from input pinion assembly.

T314 900G8910368−101 Pusher Used to install the seal in the seal TS19
housing of input drive assembly.

T315 900G8910370−101 Puller Assembly Used to remove lockwasher from the TS19
locknut of the input pinion assembly.

T316 900G8910380−101 Pusher Used to install wear sleeve on clutch TS19


outer race assembly.

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Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Main Transmission Requirement
T317 900G8910384−101 Remover Used to remove wear sleeve from clutch TS19
Assembly outer race assembly.

T318 900G8910400−101 Mount Assembly Used to hold the anti−torque fan drive TS19
assembly.

T319 900G8910408−101 Wrench Used to remove/install locknut from/on TS19


Assembly anti−torque fan drive assembly.

T320 900G8910410−101 Puller Assembly Used to remove the flange assembly TS19
from the anti−torque fan drive assembly.

T321 900G8910432−101 Pusher Used to install the seal in the seal TS19
housing of the anti−torque fan drive
assembly.

T322 900G8910446−101 Puller Assembly Used to remove the lockwasher from the TS19
locknut of the anti−torque fan drive
assembly.

T323 900G8910456−101 Pusher Used to install the wear sleeve on the TS19
flange assembly of the anti−torque fan
drive.

T324 900G8910460−101 Remover Used to remove the wear sleeve from TS19
Assembly the flange assembly of the anti−torque
fan drive.

T325 900G8910468−101 Pusher Used to install the lockwasher on the TS19


locknut of the anti−torque fan drive
assembly.

T326 900G8910492−101 Pusher Used to install the seal in the seal TS19
housing of accessory drive assembly.

T327 900G8910494−101 Pusher Used to install the wear sleeve on the TS19
accessory pinion.

T328 900G8910500−101 Remover Used to remove the wear sleeve from TS19
Assembly the accessory pinion.

T329 900G8910534−101 Pusher Used to install the seal in the seal TS19
housing of the blower pinion.

T330 900G8910548−101 Pusher Used to install wear sleeve on the TS19


blower pinion.

T331 900G8910550−101 Remover Used to remove the wear sleeve from TS19
Assembly the blower pinion.

T332 900G8910336−101 Mount Used to hold oil seal housing when input TS19
oil seal is removed.

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Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Main Transmission Requirement
T333 900G8910369−101 Pusher Used to remove input oil seal from the TS19
seal housing.
T334 900G8910430−101 Pusher Used to remove the anti−torque oil seal TS19
from the seal housing.
T335 900G8910483−101 Pusher Used to remove the accessory oil seal TS19
from the seal housing.
T336 900G8910484−101 Mount Used to hold the accessory oil seal TS19
housing when accessory oil seal is
removed.
T337 900G8910590−101 Pusher Assembly Used to remove the oil seal from the TS19
seal housing.
T338 900G8910381−101 Guide Used to guide the pusher when wear TS19
sleeve is installed into clutch outer race.
T339 900G8910512−101 Mount Used to hold the blower drive pinion TS19
assembly when the blower pinion is
removed.
T340 900G8910515−101 Pusher Used to install the blower pinion to the TS19
blower drive pinion assembly.
T341 900G8910520−101 Mount Assembly Used to hold the blower pinion. TS19
T342 900G8910525−101 Wrench Used to remove/install the locknut TS19
Assembly from/on the blower drive pinion
assembly.
T343 900G8910535−101 Puller Assembly Used to remove lockwasher from the TS19
locknut of the blower drive pinion
assembly.
T344 900G8910596−101 Puller Assembly Used to remove the seal housing from TS19
the accessory drive assembly.
T345 900G8910382−101 Pusher Used to install the lockwasher on to the TS19
input drive pinion assembly.
T346 900G8910594−101 Pusher Used to install the lockwasher on to the TS19
blower drive pinion assembly.
T347 900G8910476−101 Support Used to hold the accessory drive TS19
Assembly assembly.
T348 900G8910510−101 Mount Used to hold the accessory seal housing TS19
when accessory oil seal is installed.

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STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Engine Requirement

T401 900P7600001−IG1 Inspection Gauge Inspect engine to transmission TS19


(Engine Align- alignment.
ment Gauge)

T402 PWC42001 Engine Sling Lift engine off deck (nonprocurable − TS17
order PWC64211).

T403 PWC64211 Engine Hoist Lift engine off deck (alternative to TS17
PWC42001).

T404 PWC60070 Engine Mainte- Support engine off aircraft. TS24


nance Stand

T405 900G3893082 Engine Control Rig manual engine controls. TS19 TS20
Rig Pin

T406 Ref. PWC Compressor Engine wash kit for internal engine TS23
Maintenance Manual Wash Rig cleaning

T406−1 Commercially Available Adapter Alternate AN fitting as required

Page 232
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Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Flight Control Requirement
T501 900G1010006 Rig Pins Rig flight controls. TS19 TS20
T501−1 900G1010006 Rig Pin, 1.5 Inch Rig drum assembly of directional TS20
Long controls.
T501−2 900G1010006 Rig Pin, 2.5 Inch Rig collective bellcrank assembly, TS20
Long longitudinal trim actuator arm, cyclic
base assembly and trim actuator arm of
the lateral controls.
T501−3 900G1010006 Rig Pin, 2.75 Rig fan and pedal at the splitter TS20
Inch Long assembly of the directional controls. Rig
VSCS. Rig sector assembly of
directional controls
T501−4 900G1010006 Rig Pin, 3.75 Rig pilot’s directional bellcrank TS20
Inch Long assembly.
T501−5 900G1010006 Rig Pin, 4.00 Rig longitudinal movement of stick TS20
Inch Long assembly.
T501−6 900G1010006 Rig Pin, 5.00 Rig longitudinal bellcrank assembly. TS20
Inch Long
T501−7 900G1010006 Rig Pin, 6.00 Rig co−pilot’s directional bellcrank TS20
Inch Long assembly.
T502 VSCS Rig Pin Kit Rig vertical stabilizer. TS19 TS20
T502−1 900G2341100 VSCS Rig Pin Rig vertical stabilizer on rotorcraft, SN TS19 TS20
00010 thru 99999, without VSCS
modification
T503 900ER750015 Trim Servo Test Rig cyclic trim motor resistor TS19
PTE1−1TD Box
T504 Support Tool, Swashplate disassembly and TS20
Spherical Slider reassembly.
Bearing
T505 Press Plate, Swashplate disassembly and TS20
Swashplate reassembly. (Includes 3 each
NAS6604−60 bolts)
T506 Support Tool, Swashplate disassembly and TS20
Angular Contact reassembly.
Ball Bearing
T507 Support Tool, Swashplate disassembly and TS20
Non−Rotating reassembly.
Swashplate
T508 Bearing Removal Bearing replacement, main rotor TS20
/ Installation Tool swashplate drive scissors assembly
Set

Page 233
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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Anti−Torque Requirement

T601 7.00−12 Inner Tube Hold Fan Tip Seal in place during TS19
sealant cure. Commercial

T602 ATP1−500N5365−1 D Fan Tip Seal Tool Anti−Torque fan tip seal cutter. TS19
Change or later

T603 GT2−900R7441000 Anti−Torque Install two lockwashers on the drive TS19 TS20
Shaft Socket shaft assembly.

T604 900G3441005−101 Anti−Torque Service anti−torque bearing with grease. TS19 TS20
Bearing Grease
Tool

T605 AJ1−900R1441000 Anti−Torque Fan Support anti−torque hub during blade TS19 TS20
Build−up Stand installation/balancing.

T606 Directional Used to replace supply adapter fitting on TS35


Actuator Supply the anti−torque/directional actuator.
Adapter Tools

T606−1 RF04LPDE Removal Tool Remove Adapter (Fitting) and Lockring TS35

T606−2 RF9804DW Combination Install Adapter (Fitting) and Lockring TS35


Wrench and
Drive Tool

T606−3 ORT312 O−ring Tool Install O−ring TS35

T607 Directional Used to replace return adapter fitting on TS35


Actuator Return the anti−torque/directional actuator.
Adapter Tools

T607−1 RF05LPDE Removal Tool Remove Adapter (Fitting) and Lockring TS35

T607−2 RF9805DW Combination Install Adapter (Fitting) and Lockring TS35


Wrench and
Drive Tool

T607−3 ORT375 O−ring Tool Install O−ring TS35

Page 234
Revision 21 91-00-00
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
ECS Requirement

T701 6E007 Refrigerant Remove refrigerant from air conditioning TS25


Recovery and system, recycle and recharge it.
Recycling Station

T702 TIF−5650 Electronic Leak Detects leaking refrigerant. TS16


Detector

T703 TW932−8 Assembly Tool Install heat/defog seals. TS30

T703−1 TW932−12 Assembly Tool Install heat/defog seals. TS30

T703−2 TW931−8 Reforming Tool Install heat/defog seals. TS30


Assembly

T703−3 TW931−12 Reforming Tool Install heat/defog seals. TS30


Assembly

Page 235
91-00-00 Revision 21
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Fuel Requirement
T801 AFT1−900P7661000 Fuel Cell Rod Pull fuel cell against cabin floor for bolt TS19 TS20
installation.

T802 E2−10−1 Cartridge Pulling Remove and replace fuel pump filter TS23
Tool cartridge.

T803 Not Used At This Time.


T804 13455K21 Pump Fuel Suction Removes fuel from fuel cell. TS21
52155K42 Plug (2 ea.) Pump Kit
52155K462 Cap (2 ea.)

T804−1 5282K65 Hose (2 ea.) Fuel Suction Pump hoses, used with fuel suction TS21
with 5282K92 Socket Pump Hose Set pump kit to defuel helicopter.
52155K72 Plug (2 ea.)

T805 Not Used At This Time.


T806 Not Used At This Time.

T807 Commercially Available Thermometer Measure fuel temperature N/A


−60°F to 160°F scale (−51°C to 71°C)

T808 Commercially Available Scale Weighing fuel and fire extinguisher N/A
(0.01 scale accuracy).

Page 236
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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Main Rotor Requirement

T901 900G1400101−101 Helicopter Sling Lift main rotor, or complete rotorcraft. TS19

T902 900G1150001−101 Main Rotor Blade Bend the main rotor blade tab in TS19
Tab Bending Tool degrees. Kit includes tab bender, dial
Kit indicator, and tab measuring tool.

T903 8500C Main Rotor Blade Kit includes analyzer/balancer/printer TS7


Track and Bal- and strobe to track and balance rotor
ance Kit gear. Balance/Analyzer will not be used
if IIDS software is functioning.

T904 135M−12 Main Rotor Blade Visually track main rotor blades to TS7
Track Strobe determine whether blades are flying
relative to one another. Use if IIDS is
functional.

T905 900G1401010−101 Mast Support Hoist static mast base assembly. TS19
(Ref. CSP−900IPL−4, Base Lifting Tool TS20
91−10−00, Fig. 4)

T906 IF5D4X1−14 Borescope 5 mm diameter flexible borescope, light TS22


source included (use equivalent
comparable tool).

T907 (Ref. CSP−900IPL−4, Upper Bearing Remove the main rotor hub upper TS19
91−10−00, Fig. 12) Removal Tool bearing.

T908 900R2101003−101− Flexbeam Wear Five blocks hold the flexbeam wear TS19
ATP1 (Ref. Shim Installation shims in place in the upper and lower TS20
CSP−900IPL−4, Tool – Upper and hubs while the adhesive cures.
91−10−00, Fig. 17) Lower Hub (NOTE: PN 900R2101003−101−ATP1
replaces PN 900G2101003.)

T909 (Ref. CSP−900IPL−4, Upper Seal Tool, Install main rotor hub upper seal. TS20
91−10−00, Fig. 18) Hub

T910 (Ref. CSP−900IPL−4, Lower Bearing/ Install main rotor hub lower bearing/liner TS20
91−10−00, Fig. 18) Liner Tool, Hub

T911 (Ref. CSP−900IPL−4, Lower Bearing − Install main rotor hub lower bearing TS20
91−10−00, Fig. 18) Seal and Outer outer race and seal.
Race Installation
Tool, Hub

T912 (Ref. CSP−900IPL−4, Upper Bearing − Install main rotor hub upper bearing TS20
91−10−00, Fig. 18) Outer Race outer race.
Installation Tool,
Hub

T913 (Ref. CSP−900IPL−4, Plate Tool, Hub Used to cover other main rotor hub tools TS20
91−10−00, Fig. 18) to apply pressure.

Page 237
91-00-00 Revision 21
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Main Rotor Requirement
T914 (Ref. CSP−900IPL−4, Center Seal Tool, Install main rotor hub center seal and TS20
91−10−00, Fig. 18) Hub used to cover other main rotor hub tools
to apply pressure.

T915 (Ref. CSP−900IPL−4, Bearing Preload Used to set−up main rotor hub preload TS20
91−10−00, Fig. 18) Tool, Hub for shim selection.

T916 (Ref. CSP−900IPL−4, Mast Tool, Hub Simulates mast during main rotor hub TS20
91−10−00, Fig. 18) reassembly.

T917 (Ref. CSP−900IPL−4, Race Removal Removal of main rotor hub bearing TS20
91−10−00, Fig. 18) Tool races.

T918 Bearing Flange Removal of main rotor swashplate drive TS20


Cutting Tool link attach bearing swage flange.

T919 900R2101004−ATP Main Rotor Removal of the lower seal. TS20


(Ref. CSP−900IPL−4, Bearing Removal
91−10−00, Fig. 21) Tool

T920 900R8104000−101 Guide Pin Tool, Installation of the main rotor blades. TS19
Main Rotor

Page 238
Revision 21 91-00-00
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Electrical/Instruments/Avionics Requirement

T1001 1A587 Analog Multime- General purpose, troubleshoot electrical TS13


ter, Portable wiring for ground (or Simpson).

T1002 247000 Mili−Ohm Meter Measure electrical bond to 1 milliohm TS4


with 20 microhm resolution.

T1002−1 241005−7 Kelvin Clip Lead Clips used with the Micro−Ohm Meter. TS4
Probes

T1003 8012A or Portable Digital Do low current ignitor test. Current TS12
187 or Multimeter limited digital multimeter, 20 milliamps or
189 less.

T1004 M81969 Insertion/Extrac- Insert and extract electrical connector TS9


tion Tool, Contact pins and sockets.

T1005 DPS350 Air Data Test Set Do pitot static system leak test. TS3

T1006 30621−1 Shunt Plug Cover Protective cover for fire bottle cartridges. TS18

T1007 SC063 Sight Compass Remagnetized aircraft compass 180° TS3


away from normal.

T1008 CTJ−R06 Terminal Block Deutsch terminal block module removal TS9
Module Removal tool.
Tool

T1009 500N9701−13 Stabilizer Assem- Troubleshoot vertical stabilizer control TS19


bly Test Box system.

T1010 900G8930001−101 Power Assurance Do a power assurance check with a TS19


Cable laptop computer.

T1011 900G8930003−101 IIDS Interface Transfer data between the IIDS and the TS19
Cable Ground Based Maintenance Computer.

T1012 65765K11 Megohmmeter Electrical insulation testing. TS21

T1013 M22520 Crimp Tool Crimpers and positioners for crimp style TS9
Assembly contacts and splices. TS39

T1014 59250 Crimp Tools Crimp tools for terminal lugs. TS37
59239−4 (Hand)

T1015 Model 400 Crimp Tools Pneumatic crimp tools for terminal lugs. TS38
Model 500 (Power)

T1016 SKA100−4 Single Static Port Do pitot static system leak test. TS40
Test Adapter

T1017 SKA100−4−4 Dual Static Port Do pitot static system leak test. TS40
Test Adapter

Page 239
91-00-00 Revision 21
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Miscellaneous
T2001 2E030/30 Hydraulic Mule Service and operational inspections of TS15
flight control and hydraulic systems (use
equivalent comparable tool).

T2002 TI1000−GPU−24 Ground Power Provide 28 vdc to aircraft and 1500 TS29
Unit amps cranking power (use equivalent
comparable tool).

T2003 Commercially Available Maintenance Moveable ladder used while servicing TS31
Stand helicopter (use equivalent comparable
tool).

T2004 Commercially Available Heat Gun Temperature range of 300−500 _F N/A


(149−260 _C) use equivalent
comparable tool.

T2005 DLTFRPSKT3003 Permaswage® Installation of permanent tube TS10


Kit connectors on hydraulic, pneumatic and
fuel systems.

T2006 Commercially Available Drain Line AN807−8D fitting with tygon tubing
(0.50 inch diameter/9 foot length).

T2007 MD900−100 Rotor Hub Cover Complete main rotor system protection. TS19

T2008 MD900−120 Engine Area Protects NOTAR® inlet, particle TS19


Cover separator inlets, exhaust stacks and
main rotor.

T2009 MD900−400 NOTARR Boom Attaches to the thruster cover. TS19


Cover

T2010 MD900−500 NOTARR Thrust- Protects thruster cover. TS19


er Cover

T2011 MD900−600 Blade Covers Standard blade protection. TS19

T2012 MD900−610 Blade Covers Cold weather blade covers, with heater. TS19
(Cold Weather)

T2013 MD900−800 Fuselage Cover TS19

T2014 900G8930002 Pressure Test Kit Pressure test fuel cell for leaks after TS19
installation, but prior to fueling.
Simulate a bypass condition to the
differential pressure switch on the inlet
particle separator − bypass doors.

T2014−1 9811K28 Filter, 10 Micron Use with Pressure Test Kit. TS19/TS21

T2014−2 3845K3 Pressure Gauge, Use with Pressure Test Kit. TS19/TS21
0.5 Increment

Page 240
Revision 21 91-00-00
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Table 203. Ground Support Equipment and Special Tools (Cont.)


Mfg/Supplier
No. (Ref.
Item Part No. Nomenclature Function Table 204)
Miscellaneous
T2014−3 45475K34 Shut−Off Valve Use with Pressure Test Kit. TS19/TS21

T2014−4 3T306 Manometer Use with Pressure Test Kit. TS19/TS13


Examine fuel cell pressure integrity.

T2014−5 AN815−8D Adapter Use with Pressure Test Kit. TS19


Attaches fuel pressurizing kit to fuel cell.

T2014−6 PVR−2 Regulator, Air Use with Pressure Test Kit. TS19/TS36
Pressure Regulates air pressure to fuel pressure
kit.

T2015 TP170 Tensiometer Verify tension of forward and aft thruster TS32
control cable assemblies (0−70 lb range)
(use equivalent comparable tool).

T2016 TG70 Strap Wrench, Tighten engine electrical connectors. TS9


Mini Perform mechanical engine controls
functional test.

T2017 Commercially Available Drain Line Tygon tubing (0.375 dia/6 foot length). N/A

T2018 Dake Model 25H Press, Hydraulic Standard hydraulic press functions. TS33
or equivalent

T2019 Commercially Available Micrometer, Measures thickness or diameter. N/A


Outside,
5 − 6 Inch

T2020 Commercially Available Micrometer, Measures thickness or diameter. N/A


Outside,
6 − 7 Inch

T2021 Commercially Available Dial Bore Gage, Measures inside diameter. N/A
2 − 6 Inch

T2022 Commercially Available Dial Bore Gage, Measures Inside diameter. N/A
6 − 20 Inch

T2023 Commercially Available Pull Gage, Digital Measures pull force. N/A

T2024 RT−6−324 Staking Tool, Staking bearing race in housing. TS34


Tri−Roller

T2025 AT−6−411 Staking Tool, Staking bearing race in housing. TS34


Anvil

T2026 MSI 91035−1 Safety Chamber Testing of fire bottle discharge cartridge. TS18

T2027 Druck DPI 601 Pressure Testing pressure transducers. N/A


or equivalent Calibrator

Page 241
91-00-00 Revision 21
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 204. Tool Manufacturer/Supplier Number


Number Name (CAGE Code) Address Telephone

TS1 Air Cargo Equipment Corporation 2930 East Maria Street (310) 898 2200
Rancho Dominguez, CA 90221−5817 (310) 898−2213

TS2 Avibank Manufacturing Inc. (84256) 11500 Sherman Way (818) 392−2164
North Hollywood, CA 91605

TS3 Barfield Instrument Corp. (3H846) 4101 NW 29th Street (305) 871−3900
Miami, FL 33102
www.barfieldinc.com

TS4 MeterCenter, a Division of Lovelace 2046 West Peninsula Circle (800) 230−6008
Co., LLC Chandler, AZ 85248 (480) 659−8351
www.biddlemegger.com

TS5 Goodrich Aircraft Wheels and Brakes 101 Waco Street, PO Box 340 (937) 339−3811
Troy, OH 45373

TS6 Brackett Aircraft Co., Inc. (56833) 7045 Flightline Drive (928) 757−4005
Kingman, AZ 86401
www.brackettaircraft.com

TS7 Chadwich−Helmuth 4601 North Arden Drive (626) 575−6161


El Monte, CA 91731

TS8 Crest Ultrasonics Corp. (22221) PO Box 7266, Scotch Road (800) 992−7378
Trenton, NJ 08628
www.crest−ultrasonics.com

TS9 Daniels Manufacturing Corp. (11851) 526 Thorpe Road (407) 855−6161
Orlando, FL 32824

TS10 DMC 14800 South Figueroa (310) 323−6200


Gardena, CA 90248 17191

TS11 Enerpac Corp. (5AVD1) 6101 North Baker Road (920) 623−7291
Milwaukee, WI 53201

TS12 Fluke Electronics Corp. 6920 Seaway Boulevard, PO Box (800) 903−5853
9090, Everett, WA 98203

TS13 Grainger Industrial Supply 455 Knightsbridge Parkway (847) 793−6300


Lincolnshire, IL 60069−3620

TS14 Intercomp Co. (7W667) 3839 County Road 116 (800) 328−3336
Medina, MN 55340 (763) 476−2531
www.intercompco.com

TS15 Interface Devices Inc. 230 Depot Road (800) 539−0193


Milford, CT 06460
www.interfacedevices.com

TS16 Johnstone Supply 250 South Mulberry Street, Suite 112 (602) 962−7972
Mesa, AZ 85202
www.johnstonesupply.com

Page 242
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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL

Table 204. Tool Manufacturer/Supplier Number (Cont.)


Number Name (CAGE Code) Address Telephone
TS17 Kell−Strom Tool International Inc. 214 Church Street (860) 529−6851
(75245) Wethersfield, CT 06109
www.kell−strom.com

TS18 Mass Systems (0FRR4) 4750 Littlejohn Street (626) 337−4640


Baldwin Park, CA 91706
www.mass−systems.com

TS19 MD Helicopters, Inc. (1KVX4) 4555 East McDowell Road (800) 388−3378
Mesa, AZ 85215−9734 (480) 346−6377
www.mdhelicopters.com

TS20 Field Fabricated Contact MD Helicopters, Inc. (800) 388−3378


(480) 346−6377

TS21 McMaster−Carr Supply Co. 9630 Norwalk Boulevard (562) 692−5911


Sante Fe Springs, CA 90670

TS22 Olympus America Inc. (06GN2) 4 Nevada Drive (516) 328−2723


New Hyde Park, NY 11042

TS23 Parker−Hannifin Corp., Fluid 711 Taylor Street (440) 284−6300


Systems Division Elyria, OH 44036
www.parker.com

TS24 Pratt & Whitney Canada Inc. (00198) 1000 Marie−Victorin Boulevard (800) 268−8000
Longueuil, QC J4G 1A1, Canada (450) 677−9411

TS25 SPX Corp. (07295) 655 Eisenhower Drive (507) 455−7000


Owatonna, MN 55060

TS26 Sharon Manufacturing Inc. (5W780) 6867 Ridge Road (330) 239−1561
Sharon Center, OH 44274
www.sharonmfg.net

TS27 Shur−Lok Co., SPS Fastener 2541 White Road (949) 655−9256
Division (97393) Irvine, CA 92614
www.shur−lok.com

TS28 Geneva Gage, LLC 1257 Northwest Highway 20, (800) 714−4243
Albany, OR 97321 (541) 924−9010
www.1gg.com

TS29 Tesla Industries Inc. (0VWE2) 109 Centerpoint Boulevard (302) 324−8910
New Castle, DE 19720
www.teslaind.com

TS30 Transdigm Inc., Adel Wiggins Group 5000 Triggs Street (323) 881−7639
− Commercial Division (83930) Los Angeles, CA 90022

TS31 Tronair Inc. (59603) 1740 Eber Road, Suite E (800) 426−6301
Holland, OH 43528 (419) 866−6301
www.tronair.com

Page 243
91-00-00 Revision 21
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL

Table 204. Tool Manufacturer/Supplier Number (Cont.)


Number Name (CAGE Code) Address Telephone
TS32 US Industrial Tool and Supply Co. 14083 South Normandie Avenue (800) 521−7394
Gardena, CA 90249 (310) 464−8400
www.ustool.com
TS33 JSJ Corp., Dake Division (15746) 724 Robbins Road (800) 937−3253
Grand Haven, MI 49417 (616) 842−7110
www.dakecorp.com
TS34 CABCO Industries, Inc. (50830) 14372 Olde Highway 80, Suite D (702) 515−1288
El Cajon, CA 92021
www.cabcoindustries.com
TS35 Eaton Aerospace LLC, Sterer 4690 Colorado Blvd. (800) 369−1911
Engineering Valve and Actuator Los Angeles, CA 90039
Division (09790)
TS36 Circor Aerospace Inc., Circle Seal 2301 Wardlow Circle (951) 270−6200
Controls (91816) Corona, CA. 92880
www.circoraerospace.com
TS37 Tyco Electronics Corp. (00779) 2800 Fulling Mill Road, Building 38 (800) 806−0480
Middletown, PA 17057 (717) 564−1000
www.tycoelectronics.com
TS38 Pico Crimping Tools Co., Inc. (29268) 444 Constitution Avenue (805) 388−5510
Camarillo, CA 93012
www.picotools.com
TS39 Tyco Electronics Corp., Raychem 300 Constitution Drive (800) 806−0480
Division (06090) Menlo Park, CA 94025 (650) 361−3333
www.tycoelectronics.com
TS40 Nav−Aids Ltd. (38002) 2955 Diab Street (514) 332−3077
Montreal, QC H4S IMI, Canada (877) 332−3055
www.navaidsltd.net

Page 244
Revision 21 91-00-00

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