Professional Documents
Culture Documents
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
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
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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
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3. To include this revision in the manual, remove the old pages and put in the new pages as
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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:
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Address:
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Remarks / Instructions:
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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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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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Section
01−00−00
Introduction
CSP−SPM MD Helicopters, Inc.
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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STANDARD PRACTICE MANUAL
20-20-00
CHAPTER/SYSTEM SUBJECT/UNIT
STANDARD PRACTICES CLEANING
SECTION/SUB-ASSEMBLY
CLEANING
SP01-001
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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.
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STANDARD PRACTICE MANUAL
C = Cold EX = Explosion
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.
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.
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INTRODUCTION
MAINTENANCE PRACTICES
1. Maintenance and Operational Test 10 in-lb 2
Requirements and Precautions 1.1 Nm
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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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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High Voltage
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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.
Power Off
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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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Chapter
STANDARD PRACTICES
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
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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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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
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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
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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.
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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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)
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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)
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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.
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
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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.
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(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).
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)
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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(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
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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). 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).
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(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).
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(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
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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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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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).
(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).
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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(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).
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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL
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.
(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.
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STANDARD PRACTICE MANUAL
Page 208
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STANDARD PRACTICE MANUAL
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
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.).
(5). Apply masking tape around repair (1). Apply epoxy primer (C317) or epoxy
area. primer (C318).
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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL
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:
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STANDARD PRACTICE MANUAL
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)
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STANDARD PRACTICE MANUAL
(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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STANDARD PRACTICE MANUAL
(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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STANDARD PRACTICE MANUAL
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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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL
(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
(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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CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL
(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
A. Application
8. Aluminum Alloy
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STANDARD PRACTICE MANUAL
Page 208
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MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL
Section
20−50−00
Electrical Bond and
Environmental Seal
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL
Page 201
20-50-00 Revision 20
CSP−SPM MD Helicopters, Inc.
STANDARD PRACTICE MANUAL
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
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
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
Page 204
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
ÎÎÎÎÎÎÎÎÎ
MINIMUM
(1.5 mm)
ÎÎÎÎÎÎÎÎÎ
MINIMUM
9G20−005
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STANDARD PRACTICE MANUAL
Page 206
Revision 16 20-50-00
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL
Section
20−60−00
Electrical Standard
Practices
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL
CABIN AREA,
NOSE AND COCKPIT NUMBER 200
AREA, NUMBER 100 CONNECTORS
CONNECTORS
9G20−016A
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).
Page 2
Revision 16 20-60-00
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
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
Page 3
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
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)
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)
Page 4
Revision 16 20-60-00
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL
A620 W8
W6 W7
TB2 TB1
TB1 TB1
A620
TB1
W4
A612 A675
TB4 TB-1
A612
TB2
LOOKING FORWARD
LOOKING INBOARD
RIGHT SIDE
9G20−009
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STANDARD PRACTICE MANUAL
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
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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
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
p p p
9G20−011
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STANDARD PRACTICE MANUAL
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
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)
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STANDARD PRACTICE MANUAL
NOTES:
(1) * AWG wire size.
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FSCM
MDHI PART NUMBER
FSCM 1KVX4
INSPECTION STAMP
ASSY900A2710452 - 1
DWG REV. E
PLN REV. 8
3 - 6 - 84
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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)
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
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STANDARD PRACTICE MANUAL
STRUCTURE
RECEPTACLE
PLUG RECEPTACLE
HARNESS
PLUG SIDE
IDENTIFICATION
DEVICE STRUCTURE
9G20−045
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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).
(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).
(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).
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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).
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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).
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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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(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).
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)
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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
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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
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
(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
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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.
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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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4
4 5
5
9G20−019A
(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.
(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
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AA. Toggle Switch Removal (Typical) AB. Toggle Switch Installation (Typical)
(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
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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
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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
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2 REF
2 REF
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.
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10 (2 PLACES)
2
3
4
5 (4 PLACES)
9 (2 PLACES)
8 (2 PLACES)
7
9G95−072A
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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).
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1
8 2
3
5 4
6
9G20−046A
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(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)
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A. Wire Maintenance Preparation (Ref. Table 201, Figure 211 and Figure 212)
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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9G20−026
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STRAIN RELIEF
TIE
TERMINAL STRIP
BRANCH TIES
9G20−027
BREAKOUT
BRANCH TIES
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STANDARD PRACTICE MANUAL
INDIVIDUAL GROUP
TIES 9G20−028
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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)
SLEEVING
RESULT OF OVERLAP FIRST TYING TAPE
NOT VISIBLE 9G20−033A
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STANDARD PRACTICE MANUAL
CUT OPEN
TYING TAPE
MINIMUM OVERLAP
SMALL CABLE
LENGTHWISE WRAP
TYING TAPE
MINIMUM OVERLAP
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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
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STANDARD PRACTICE MANUAL
DO NOT CLAMP
IN THIS AREA
90°
90°
9G20−037A
RUBBER WRAP NECESSARY FOR
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
(Ref. Figure 220) (2). Cut sleeving into 1.25 in. (3.18 cm)
pieces.
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
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.
W436 P842
KLX1352L99 2
M/W W435J842
3.5 IN.
9G20−042
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NOTE: Prevent strain on wires and electrical D Wire must be parallel with other wires
components. and have no kinks.
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COAXIAL
CABLE
FIRST
CLAMP
WOUND
CABLE
SECOND 9G20−030A
CLAMP
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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.
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.
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
B. Spare Connector
PLASTIC BAG
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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
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STANDARD PRACTICE MANUAL
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
(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)
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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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0° 180°
SOLDER APPLIED TO TERMINAL
AWAY FROM SOLDERING IRON TIP
WIRE
TERMINAL INSTALLATION
INSPECTION HOLE
9G20−050A
SINGLE WIRE MULTIPLE WIRES
SOLDER TYPE CONTACT INSTALLATION
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(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.
WIRE
PICK POINT
PICKED SHIELD
9G20−054B
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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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0.25-0.34 IN.
(6.35-8.64 MM)
0.25-0.34 IN.
(6.35-8.64 MM)
SOLDER SLEEVE
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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
Ï Ï
Ï
Ï Ï
Ï 9G20−056B
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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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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
HEAT SHRINKABLE
SLEEVING 9G20−057B
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CONNECTOR
PICKED SHIELD
SHIELDED CABLES
SHIELDED CABLES
TYING PICKED SHIELD BEFORE YOU FOLD BACK AND PUT IN SHIELD SLOTS
SHIELD POSITIONED IN SHIELD SLOT
SHIELD FOLDED BACK TO SHIELD SLOT (TYPICAL)
SHIELD POSITION
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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
0.75 IN.
INSULATED SHIELD (19.1 MM)
WIRE
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STANDARD PRACTICE MANUAL
(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
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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)
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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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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.
MANUFACTURERS SYMBOL
OR TRADE MARK
WIRE MATING END
BARREL END
NOTE: 9G20−061A
COLOR BANDS SHOW LAST THREE
NUMBERS OF CONTACT PART NUMBER
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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
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STANDARD PRACTICE MANUAL
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
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
ÏÏ
COMPONENT
INSERTION/EXTRACTION TOOL
GROMMET 9G20−063A
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
ÑÑÑÑÑÑÑ
Part Number Size Color (1) (AWG)
ÑÑÑÑÑÑ
Mfr. Part Number
ÑÑÑÑÑ
Setting
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STANDARD PRACTICE MANUAL
ÑÑÑÑÑÑÑ
Part Number Size Color (1) (AWG)
ÑÑÑÑÑ
Mfr. Part Number
ÑÑÑÑÑÑ
Setting
ÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑ
0.250 in. BL 6
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑ ÑÑÑÑÑÑ
MS25036−120
(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
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
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
9G20−064A
TERMINAL LUG WITH MULTIPLE WIRES
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STANDARD PRACTICE MANUAL
(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
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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
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STANDARD PRACTICE MANUAL
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STANDARD PRACTICE MANUAL
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
(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.
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STANDARD PRACTICE MANUAL
NOTE 5
NOTE 1
NOTE 7
NOTE 9
NOTE 4
NOTE 8
NOTE 9
NOTE 5
NOTE 2
NOTE 11
NOTE 8 NOTE 6
NOTE 1
NOTE 10
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
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STANDARD PRACTICE MANUAL
NOTE 5
NOTE 1
NOTE 2
NOTE 4
NOTE 6
NOTE 3
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CSP−SPM MD Helicopters, Inc.
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
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
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
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STANDARD PRACTICE MANUAL
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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
COMPONENT LEAD
WIRE TO COMPONENT LEAD SOLDER JOINT
SOLDER CUP JOINT
CONDUCTOR FULLY
COVERED WITH SOLDER
9G20−048A
TERMINAL SOLDER JOINT
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STANDARD PRACTICE MANUAL
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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CSP−SPM MD Helicopters, Inc.
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.
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STANDARD PRACTICE MANUAL
(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.
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STANDARD PRACTICE MANUAL
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(4). Remove wire insulation from both ends (e). Replace splice if installation is
of wire, equal to the length of the crimp unsatisfactory.
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
(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
BARE WIRE
ÌÌ
ÌÌ
ÌÌ
ÌÌ
COLOR STRIPE (NOTE)
SEAL MATERIAL SEAL MATERIAL
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.
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STANDARD PRACTICE MANUAL
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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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
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ REPAIR BRAID
ÌÌÌ ÌÌÌ
1 IN. 1 IN.
(25.4 MM) (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)
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)
NOTE 4
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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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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
VACUUM
HOSE DRILL
ALIGNMENT
TOOL
TOP SKIN
HONEYCOMB CONICAL
OR FILLER LENGTH
BUSHING / DRILL
GUIDE CONICAL
THICKNESS LENGTH
BOTTOM
SKIN
WOOD BACKUP
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STANDARD PRACTICE MANUAL
FLEX
WOOD BACKUP
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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
INJECT POTTING
MATERIAL HERE 0.20 INCH
(5.1 MM) CUTTER
9p20−090
9p20−089
C. General Instructions to Drill the Holes for D. Installation of Blind Inserts with Potting
the Inserts Holes
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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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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).
NOTE: Use a low rpm drill speed to core the Figure 208. Installation of Adhesive Hard
diameter. Points
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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
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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STANDARD PRACTICE MANUAL
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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STANDARD PRACTICE MANUAL
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STANDARD PRACTICE MANUAL
Section
20−80−00
Tubing
MD Helicopters, Inc. CSP−SPM
STANDARD PRACTICE MANUAL
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).
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STANDARD PRACTICE MANUAL
(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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STANDARD PRACTICE MANUAL
(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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STANDARD PRACTICE MANUAL
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).
INCANDESCENT
LIGHT BEAM
LINE OF SIGHT
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STANDARD PRACTICE MANUAL
(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.
(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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STANDARD PRACTICE MANUAL
0.25 IN DIA
(6.35 mm)
2.00 IN
(50.8 mm)
0.375 IN
(9.52 mm)
DIA BALL
9G20−008
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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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Page ii
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MD Helicopters, Inc. CSP−SPM
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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EX = Explosion V = Vapor
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STANDARD PRACTICE MANUAL
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STANDARD PRACTICE MANUAL
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)
Post−SB900−118:
Mobil AGL
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STANDARD PRACTICE MANUAL
C223 Compound, Heat Sink, Silicone MIL−C−47113 Dow Corning 340 MS22
and/or Non−Silicone T1 . . . . −− . . . . −− Heat Sink Supplies
(B−E−V)
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
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STANDARD PRACTICE MANUAL
MIL−PRF−23377
T2 . . . . C1 . . . −− or
T2 . . . . C2 . . . −−
MDM15−1100 FED−STD−595
T1 . . . . C2 . . . −− Green #34151
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STANDARD PRACTICE MANUAL
C319 Lacquer, Acrylic, Gloss Red 11136 MDM15−1083 DES 420MHS #11136 MS15
(B−E−F−P−V) (Color No. 11136) Gloss Red
C322 Marking Ink, Black NSN 73X Black Marking Ink MS72
(B−E−F−P−V) 7510P73XBLACK
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STANDARD PRACTICE MANUAL
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 . . . −−
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STANDARD PRACTICE MANUAL
C503 Foam, Syntactic (Low Density Filled MDM17−1002 EA 9396 A/B MS21
Epoxy Resin) EC3524 A/B MS62
(B−E−V)
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STANDARD PRACTICE MANUAL
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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.
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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
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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
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
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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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
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
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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MS38 Idemitsu Kosan Co., Ltd. (SDY61) 1−1 Marunouchi 3−Chome, +81 (3) 3213−3137
Chiyoda−ku, 100−8321, Japan
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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
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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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.
T106 MD900−110 Upper Deck Encloses the NOTAR® inlet, particle TS19
Cover separator inlets and exhaust stacks.
T108 MD900−615 Blade Tiedown Socks which fit over the blade tip with a TS19
length of rope, which can be tied down.
T111 06−4005−0511 Fluid Service Unit Service the landing gear damper. TS31
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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.
T203 Pro 360 Inclinometer Leveling and measures droop angle TS28
degrees.
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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T301−4 900G2400201−101 Lifting Plate Lift transmission off upper deck. TS19
T303 GT1−90007441000 Transmission Used to remove the shur−lok impeller TS19 TS20
Blower Shaft nut.
Socket
T305 114−248 Piston Jack Main rotor brake lining replacement. TS5
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.
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.
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T318 900G8910400−101 Mount Assembly Used to hold the anti−torque fan drive TS19
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.
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.
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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T402 PWC42001 Engine Sling Lift engine off deck (nonprocurable − TS17
order PWC64211).
T403 PWC64211 Engine Hoist Lift engine off deck (alternative to TS17
PWC42001).
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
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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.
T606−1 RF04LPDE Removal Tool Remove Adapter (Fitting) and Lockring TS35
T607−1 RF05LPDE Removal Tool Remove Adapter (Fitting) and Lockring TS35
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T802 E2−10−1 Cartridge Pulling Remove and replace fuel pump filter TS23
Tool cartridge.
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.)
T808 Commercially Available Scale Weighing fuel and fire extinguisher N/A
(0.01 scale accuracy).
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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.
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)
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.
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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.
T920 900R8104000−101 Guide Pin Tool, Installation of the main rotor blades. TS19
Main Rotor
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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.
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
T1008 CTJ−R06 Terminal Block Deutsch terminal block module removal TS9
Module Removal tool.
Tool
T1011 900G8930003−101 IIDS Interface Transfer data between the IIDS and the TS19
Cable Ground Based Maintenance Computer.
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
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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).
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
T2012 MD900−610 Blade Covers Cold weather blade covers, with heater. TS19
(Cold Weather)
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
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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).
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
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
T2026 MSI 91035−1 Safety Chamber Testing of fire bottle discharge cartridge. TS18
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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
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
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
TS14 Intercomp Co. (7W667) 3839 County Road 116 (800) 328−3336
Medina, MN 55340 (763) 476−2531
www.intercompco.com
TS16 Johnstone Supply 250 South Mulberry Street, Suite 112 (602) 962−7972
Mesa, AZ 85202
www.johnstonesupply.com
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TS19 MD Helicopters, Inc. (1KVX4) 4555 East McDowell Road (800) 388−3378
Mesa, AZ 85215−9734 (480) 346−6377
www.mdhelicopters.com
TS24 Pratt & Whitney Canada Inc. (00198) 1000 Marie−Victorin Boulevard (800) 268−8000
Longueuil, QC J4G 1A1, Canada (450) 677−9411
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
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