MD 500D - Flight Manual, POH

Training Reference Only

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SB369H-245 SB369D-201 SB369E-O95 SB500N-O23

SERVICE II

BULLETIN

SB369F-O79 SB600N-O31

DATE: 15MAY 2001 PAGE 1 OF 2

MANDATORY11111111111111

MANDATORY11111111111111

MANDATORYII

MAIN ROTOR BLADE ASSEMBLY TORQUE EVENT INSPECTION 1. PLANNING INFORMATION: A. Aircraft

Mfected;

All 369H/HE/HS/HM/D/E/FF,

500N, and 600N series helicopters.

B. Assembl

Com onents Mfected

Main Main Main Main Main Main

Assembly Assembly Assembly Assembly Assembly Assembly

Rotor Blade Rotor Blade Rotor Blade Rotor Blade Rotor Blade Rotor Blade

b this Bulletin:

(PIN 369A1100-501, -503, -505, -507, -511) (PIN 369D21100, -501, -503, -516, -517, -523) (PIN 369D21102, -503, -517, -523) (PIN 369D21120-501) (PIN 369D21121-501) (PIN 369D21123-501)

C. Reason: Some operators have experienced cracking of main rotor blades. All of these cracked blades have been associated with a high number of external lifts per hour which exceed the fatigue spectrum. This bulletin references criteria to assist operators in understanding their level of usage, the impact of that usage on the main rotor blade life and the corresponding inspections required to locate cracks that might occur. Failure to comply with this bulletin may result in the loss of a main rotor blade.

D. Descrintion: Procedures in this Bulletin provide owners and operators with information pertaining to performing the main rotor blade torque event inspection and determining an inspection interval.

E. Time Qf Comnliance: This Bulletin shall be accomplished at the next 100-Hour inspection, or no later than 90 .;1h.. days after the issue date of this Bulletin. It

F. FAA Annroval: The design engineering aspects of this Bulletin have been shown to comply with the applicable Federal Aviation Regulations, and are FAA Approved.

G. Warrant~ Polic~: N/A H. Disnosition of Parts Removed: Scrap I. Other Publications Mfected: Handbook of Maintenance Instructions (CSP-H-2), Revision 17, 15 May 2001 or later Appendix B (CSP-H-4), Revision 1, 14 May 2001 or later Handbook of Maintenance Instructions (CSP-HMI-2), Revision 29 dated 11 May 2001 or

later Rotorcraft Log Book (CSP-RLB), Revision 2 dated 17 February 2000 or later. Copyright 1999-2001 by MD Helicopters Inc. .This docum~nt may.be reprl?dul!ec!and distributed provided no fee is charged, the text is not modJfied, and thJS copyrJght notu:e JSmcluded.

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MANDATORY11111111111111

MANDATORY11111111111111

MANDATORYII

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SB369H-245 SB369E-O95

SB369D-201 SB369F-O79

SB500N-O23

SB600N-O31

DATE:

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15MAY 2001

SERVICE

PAGE 2 OF 2 II

MANDATORY11111111111111

MANDATORY 11111111111111

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ULLETIN MANDATORYII

J. Points of Contact: For further assistance, contact your local MDHI Field Service Representative (refer to the latest revision of the "At Your Service" handbook for address and telephone numbers) or contact the Field Service Department at MDHI, Mesa, Arizona. Telephone 1-800-388-3378 or (480) 346-6387. DATAFAX: (480) 346-6813.

2. ACCOMPLISHMENTINSTRUCTIONS: (Ref. Handbook of Maintenance Instructions (CSP-H-2) and Appendix B (CSP-H-4) or Handbook of Maintenance Instructions (CSP-HMI-2).

A. Prenaration (1). Review the definition of a Torque Event (TE) (Ref. CSP-HMI-2 04-00-00, Torque Event (TE».

or CSP-H-4, Section

(2). Review Rotorcraft Log Book entries to determine current number ofTE accumulated on each main rotor blade. If the current number of TE cannot be reliably determined, 13,720 TE shall be used. (3). Record current number of TE accumulated on each main rotor blade in Rotorcraft Log Book. Continue to record the number of TE accumulated throughout the life of the main rotor blades.

B. Insnection

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(1). Determine the main rotor blade TE inspection interval, using current number of TE (Ref. CSP-HMI-2 or CSP-H-4, Section 04-00-00, Table 1. Airworthiness Limitations Component Mandatory Replacement Schedule). (2). Inspect main rotor blades at the required interval (Ref. CSP-H-2, Section 07 or CSP-HMI-2, Section 62-10-00, Main Rotor Blade Torque Event Inspection).

3. COMPLIANCE RECORD Record compliance to this Service Bulletin in the Compliance Record section of the helicopter Log Book.

Copyright 1999-2001 by MD Helicopters Inc. .This docum~nt may .berepr~du~ea:and distributed provided no fee is charged, the text is not modtfied, and thts copyr£ght nouce I;S£ncluded.

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MANDATORY11111111111111

MANDATORY 11111111111111

MANDATORYII

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SERVICE

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SL369H-132Rl*

SL369D-II1Rl*

SL369E-O63Rl* SL369F-O5 SL500N-OO8Rl*SL600N-OO5Rl* LETTER

DATE: 15MAY2001 PAGE 1 OF 2

I

* Supersedes Service Letters SL369H-132, SL369D-l11, SL369E-O63, SL369F-O56, SL500N-OO8, SL600N-OO5, dated 11 January 1999.

TORQUE

MD HELICOPTERS EVENT/RETIREMENT

MODEL 369/500N/600N INDEX NUMBER EXPLANATION

MD Helicopters, Inc. (MDHI) is currently establishing a new approach to tracking certain retirement lives and inspection intervals of various helicopter implemented to ensure safe operation of the helicopter within

components. This is being the widest range of helicopter

I

usage. Components are assigned retirement lives based on flight test, fatigue test and field experience. This life is based on a flight spectrum that is representative of maneuvers a particular model helicopter is expected to see. A flight spectrum defines flight maneuvers and a percentage of time performing these maneuvers. Each maneuver produces different loads. The number of times these loads are applied has a cumulative effect on component lives.

I

The MDHI flight spectrum is FAA approved and represents our knowledge of helicopter usage. . This spectrum is conservative in its representation. However, helicopter usage has changed since we first established our helicopter spectrum. Some operators have reported exceeding the estimated average amount of high stress maneuvers in our flight spectrum. This can result in reduced service life or early failure of components. Because of this, MDHI reevaluated the I manner of establishing limited lives which currently considers only Time In Service (TIS). Flight and fatigue testing have determined that a "Torque Event" (TE) accelerates fatigue damage on certain components. A Torque Event is defined as the transition to a hover from forward flight or any external lift operation. For this definition of TE, forward flight is . considered to be flight at any airspeed in any direction after attaining transitional lift. A flight that has a takeoff and a landing is one (1) TE. Hover taxi with no external lift will typically result in no TE's. For sling operators, each load will count as two (2) TE (pick-up and drop-off). For example, if an operator takes off and moves six (6) sling loads then lands, this would total twelve (12) Torque Events (thirteen (13) if the helicopter drops off the last load and then flies to another landing area). An external lift can either be on the cargo hook, external hoist or in external baskets. An autorotation from forward flight to a landing or a hover is one (1) TE. In order to account for a greater number of Torque Events than what was represented in our original FAA approved flight spectrum, we are asking owners and operators to record the number of Torque Events that their helicopters experience. The number of Torque Events should be entered into the helicopter Log Book. For each flight, the pilot should maintain a count of TE's performed. At the end of each day, the number of TE's should be added to the accumulated number of TE's in the helicopter log or equivalent record.

Copyright 1999-2001 by MD Helicopters Inc. This document may .berepr~u.cec.zand distributed provided no fee is charged, the text is not modifred, and this capyrzght notzce zszncluded.

SL369H-132Rl* SL369D-IIIRl*

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SL369E-O63Rl*SL369F-O56Rl* SL500N-OO8Rl*SL600N-OO5Rl* DATE: 15MAY2001

"'7"'-.

SERVICE

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LETTER

PAGE 2 OF 2

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Components affected by TE's will no longer have retirement lives or inspection intervals based solely on TIS. Components that are effected by Torque Events will have an inspection interval based on TE or be assigned a maximum Retirement Index Number (RIN). This RIN corresponds to the maximum allowed fatigue damage resulting from Torque Events and accumulated flight hours. The RIN is an adjustment factor times flight hours plus another adjustment factor times TE, or RIN = (Adjustment factor one x flight hours) + (Adjustment factor two x TE). For example, if factor one = 160 and adjustment factor two = 24 and flight hours equal 1,190 hours with 12,800 TE, RIN = (160 x 1,190) + (24 x 12,800) = 497,600 RIN. The RIN system accounts for flight hours and TEs and results in equal conservatism being applied to all operators. A new component will begin with an accumulated RIN of zero that will be increased as TEs and TIS occur. The operator will record the number of TEs, TIS and increase the number of RIN's accordingly. When the maximum number of hours or the maximum number of RIN is reached (whichever occurs first), the component will be removed from service.

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For components that have inspections intervals based on TE, the inspection interval will occur at a set TE interval. Refer to the latest revision of CSP-HMI-2 or CSP-H-4, Section 04-00-00, Table 1 Airworthiness Limitations Component Mandatory Replacement Schedule for component life limits, retirement index number formulas and inspection interval requirements. For further assistance, contact your local MDHI Field Service Representative (refer to the latest revision. of the "At Your Service" handbook f?r address and telephone numbers) or contact the Field ServIce Department at MDHI, Mesa, Arizona. Telephone 1-800-388-3378 or (480) 346-6387. DATAFAX: (480) 346-6813.

Co

ri ht 1999-2001 by MD Helicopters Inc. This document may .berepr~du~e~and distributed provided no fee is charged, the py g text is not modified, and this copyr~ght not~ceLS~ncluded.

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MD Helicopters,

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MAINTENANCE

plus another adjustment factor times Torque Events. When a component reaches 1,000,000 RIN's, it has reached it's maximum life and is to be scrapped.

Inc.

MANUAL

Hover taxi with no external load will typically result in no TEs. 6. External Lift and Torque Event (TE) Requirements The 369D/E/F/FF -500/600N helicopters are

5. Torque Event (TE)

multi-use helicopters. If theorhelicopter is used primarily for external lifts training flights

.(high A Torque Event (TE) 1S defined as:

TE flights), may components. be a reduction in inspection intervalsthere of some

The transition to a hover from forward flight. Any external lift operation. NOTE: An external lift can either be on the cargo hook, external hoist or in external baskets. .(2).operators, an external For external lift load is recorded as two (2) TE's (pickup and drop-off).

I-CAUT-ioN' For safe operation of the heli'::--~~~~l~~ copter, TE's must be recorded in the Rotorcraft Log Book. Each external lift will be recorded as two (2) TE's. (1). Determin.e the num~er of TE's and external lifts the h.elic°p.ter accumulates per hour of flight time. Record all TE's Rotorcraft Log Book and continue to in record all TE's. (3). Perform required TE inspections.

Page 6

Revision 29

04-00-00

FAA APPROVED

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.MD ..'

Helicopters,

Inc.

CSP-HMI-2

MAINTENANCE MANUAL

Table 1. Airworthiness Limitations Component Mandatory Replacement Component (1)

Schedule Finite Life

Part Number (2)

Model

Hours (1)

Man datory

Inspection Hours

Main Rotor System Blade assembly, main rotor

3690/E(5)(6)

369021100 369021100-516 369021100-517 369021100-517 369021120-501 369021100-523

3530 3530 2500 3530 3530 4000

(37) (37) (31) (37) (37) (37)

25 (11)(20) 100 (20) 25 (22) 100 (20) 100 (20) 100 (20)

369F/FF

(6)

369021102 369021102-503 369021102-517 369021102-517 369021121-501 369021102-523

3430 3430 2500 3430 3430 4000

(37) (37) (31) (37) (37) (37)

25 (11) (20) 100 (20) 25 (22) 100 (20) 100 (20) 100 (20)

500N

(6) 369021102-503 369021102-517 369021102-517 369021121-501

3430 2500 3430 3430 4000

(37) 100 (31) 25 (37) 100 (37) 100 (31) 100

.369021102-523 600N

369021102-517 369021102-523

3690/E/F/FF

369A 1004 369A1004-3 369A1004-5

2850 2850 7600

500/600N

369A1004-5

7600

369021201

8900

Pitch housing assembly, main rotor hub

3690/E/F/FF 500N 3690

369021300 369021300-501

9100 9100

369021300-501

9100

Retention strap assembly, main rotor hub

369E/F/FF 500N 3690 369E/F/FF

369021210 369021210-501 369021210-501

500/600N 3690 3690/E/F/FF 500N 600N

Folding pin, main rotor blade attach

Hub subassembly,

Bolt -lead-lag

main rotor

hub, main rotor

(21)

1900 (32)(37) 3200 (33)(37)

(20) (22) (20) (20) (20)

100 100

(20) (20)

2770

100

(4)

2770

100

(4)

369021210-501

2770

100

(4)

369A1220

6120

369021220

6120

369021220

5400

(34)

Page

FAA APPROVED

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Revision 29

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MD Helicopters,

Inc.

CSP-Hl\n-2

MAINTENANCE MANUAL -(28)

Log all landings: Brace life is limited to 35400 logged landings or 5900 hours flight time if landing are not logged (assumed six landings per one hour of flight time). (29) Log all landings: Strut life is limited to 4170 logged landings or 696 hours flight time if landing are not logged (assumed six landings per one hour of flight time). (30) Log aJllandings: Foot life is limited to 23780 logged landings or 3900 hours flight time if landing are not logged (assumed six landings per one hour of flight time). (31) The following main rotor blades have a finite life of 2,500 hours or 15,000 torque events*, whichever occurs first; PIN 369021100-517 with SIN H664, H665, H667, H669, H671, H672, H674, H676, H679, H680, H683 thru H724, H726 thru H999 and JOOOthru J039, J041 thru J055 and PIN 369021102-517 with SIN 1976 thru 2100,2106 thru 2115. * TORQUE EVENT (TE) -A TE is recorded for every transition from forward flight to a hover (Reference Service Bulletins SB3690-195R3,

SB369E-088R3,

SB369F-075R3,

SB500N-015R3).

(32) RIN = (200 x Hrs.) + (52 x TE). (33) RIN = (160 x Hrs.) + (24 x TE). (34) RIN = (153 x Hrs.) + (3 x TE). (35) RIN = (50 x Hrs.) + (3 x TE).

.

(36) RIN = (768 x Hrs.) + (11 x TE). (37) After accumulation of 750 flight hours and 13,720 TE, perform Main Rotor Blade Torque Event Inspection {Ref. Sec. 62-10-00) every 35 flight hours or 200 TE's (whichever occurs first).

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FAA APPROVED

04-00-00

Revision 29

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Inc.

CSP-fil\tII':2.

MAINTENAJ.~CEMANUAL Table 1. 100-Hour or Annual Inspection (Cont.) Registration Helicopter

No.

Serial No.

Hours

Torque Events

Model

Requirement

Chap/Sect

WARNING: Do not leave pitot heater ON for more than one minute during personnel may result. ALL 600N

ALL

next check;

PITOT HTR switch ON for a few seconds. Heated pitot tube will feel warm to the touch; turn switch to OFF after check. Apply power to aircraft and disconnect CIT sensor (Ref. CIT (Compressor Inlet Temperature) Sensor Replacement); Verify ECU FAIL light illuminates. Re-connect CIT sensor. Clean battery and inspect for: * Connector pins for evidence of corrosion.

Initial

severe burns

to

95 76-00-00

96

*

Leakage (if battery is leaking (wet), remove and replace battery).

*

Battery case for cracks in support flanges.

*

Dc wiring for chafing caused by wiring rubbing against battery case.

*

Deep cycle charge (recondition) battery every 100 hours or on

conditional basis at operator's discretion. ALL

Functionally check and inspect all installed avionics, auxiliary or optional systems and equipment. Do not actuate hoist guillotine or emergency floats.

97

ENGINE COMPARTMENT ALL

Exhaust stack(s) and exhaust supports for cracks, defects and improper

78

attachment. ALL

Engine compartment plumbing and electrical relay installation on left or right side oleo (landing gear damper) support fitting for good condition and security of mounting. Diodes for broken terminals and wires. Diode bracket for security and corrosion.

96

ALL

Entire engine for:

71

*

Loose

*

Accessories for security and broken or missing lockwire.

75 76

*

Fuel and oil lines for chafing and kinking.

*

Fuel drain line valve for leakage.

*

Oil cooler and cooler deflector for security and obvious damage.

*

Accessible areas for obvious damage; evidence of fuel and oil leaks.

*

Engine mounts for cracks and play in mounting hardware at engine and

bolts; loose or broken connections.

airframe (retorque any loose mounting bolts). * Fuel control and compressor exterior for condition and security. 369D/E/FF

RPM governor lever control rod (replace if aluminum).

500N 369D/E/FF 500N

Clean and lubricate drive splines of starter-generator drive shaft, and female splines in engine accessory gear case on dry spline installations.

369D/E/FF 500N

Anti-ice air tubes and compressor scroll for cracks or breaks at the anti-ice air valve and bleed port. If cracks exist, check engine for possible vibration causes (Ref. Engine Anti-icing System and applicable AJlison Engine

76-10-00 96 75-10-00

Operation and Maintenance Manual).

Form HOEO05 (Rev 05/01)

05-20-00

Page 9 Revision 29

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MU MellcopIers, Inc. MAINTENANCE MANUAL

Table Registration Helicopter

1. 100-Hour

No.

or Annual

Inspection

(Cont.)

-

Serial No.

Hours

Torque Events

Model

Requirement

Chap/Sect

Initial

AFTER INSPECTION ALL

Touch-up all damaged paint and exterior markings, as necessary.

20

ALL

Ensure all fluid levels are correct; service as required.

ALL

Perform operational check of particle separator filter (Ref. Scavenge Air

71-10-10

ALL

Operational Check). Install or close all stressed panels, covers and trim panels removed or opened for inspection. Check closure, fit and security. All loose equipment for

52-50-00

12

proper stowage. CAUTION: Helicopter must not be flown unless controls access panel and fuel cell access panels in cargo compartment are securely installed. These are stressed panels. POST INSPECTION RUN UP See applicable Pilot's Flight Manual for cockpit check and engine starting procedures. procedures, refer to applicable section of this manual. 100-HOUR

OR ANNUAL

For troubleshooting

INSPECTION CERTIFICATION

It is certified that this helicopter has been thoroughly inspected as required by FAR, found to be airworthy, and appropriate entries made in the helicopter log book. It is further certified that the helicopter conforms to FAA specifications, that all FAA Airworthiness Directives and Manufacturer's Service Notices and Maintenance Manual data have been complied with, and the helicopter records are in proper order Signature Rating Type or Certificate No. Date 2.

Retirement Index Numbers Attachment ..requiring Table 2 IS to be used for calculating and recording the Retirement Index Number (RIN) or Torque Events (TE) of components that are affected by Torque Events (TE). This record ofRINs/TE's permanent record. Table 2. Component

Pag~ ~o 29 ReVIsIon

should Permanent

Part No.

Refer to Section 04-00-00 for components calculation of RIN's/TE's and information pertaining to calculation of RIN's/TE's.

Component must be scrapped 1,000,000 RIN's or maximum 04-00-00).

be kept as a Record

of Retirement

Serial No.

Hours

05 -- 20 00 ,,

c

Index

NumbersiTorque TE's

. when It reaches TE's (Ref. Sec. Events

RIN's

Signature

Form HOEO05 (Rev 05/01)

Group of Companies

Hughes 500 Series Repetitive Airworthiness Directives and Service Bulletins A/C Reg.: ___________ A/C W.O. No.: ___________ A/C T.A.T.: _____________ Date: _______________  Denotes certification by approved pilots is acceptable AD/ DN AD86-20-07

Reference DN143.1 Part II

Description

Hours

Check for T/R backlash or looseness by rocking the T/R back & forth in its plane of rotation. The blade should not move in excess of 0.75 inches at the blade tip without rotation of the main rotor (applicable to

*DAILY

Examine T/R Transmission. Installation by checking torque stripes for movement of the trans. (Cracks in the torque paint), fretting products, gapping between faying surfaces &/or rotation of the nuts & studs.

*25

Bendix couplings only)

AD88-17-09 R1

AD 95-03-13

DN-151 Part II Para. (a) DN-51.8 Part II Note:

(Applicable to Hughes tailbooms only)

Insp. of main rotor blade root fitting assembly & m/r hub lead-lag link assembly for cracks, condition & slippage marks on bushings.

(Applicable to Main Rotor blades -515 and prior dash numbers) (Applicable to links -31 and prior dash numbers)

*25 *15 hrs

35 Hrs or Inspect M/R blades with a 10x magnifying glass for cracks on the first SB 2100-3R3, 200 Tq SB 369D-201R2 24 inch inboard area of the bottom side of blade Events AD 89-02-01 R1 DN-154 With M/R blades removed, inspect strap pack laminates in accordance 100 Part 1 Para C with Para (a)-(l) of DN-154, Part I, Insp. Procedures. (Applicable to all 25 hrs Note: our Aircraft) Compliance change with 2 failed laminates

AD 2005-21-02

DN-151

AD 88-17-09 R1 Part IV

Para (a)(b)

AD 94-24-04

DN-185 Part III

AD 95-03-13

DN-51.8 Part I

AD 96-10-09

DN-188 Part II CSP-HMI-2

SB369D-193 R1 64-10-00 AD 2007-12-23 November 9, 2007

SB 369D-200 or SB 369E-094

Check the torque of each T/R transmission-mounting nut to 95 +/-3 inch-pounds plus previously noted drag torque. Reapply torque stripe 100 paint. (Applicable to Hughes tailbooms only) Inspect torque stripe on T/R swash plate locknut for any sign of 100 slippage. Remove M/R blades, use 5X magnifying glass to inspect M/R blade root fittings & M/R hub lead-lag links for broken or cracked lugs, etc. NOTE: 100 bushings for condition and slippage marks. (Applicable to Main Rotor blades -515 and prior dash numbers) (Applicable to links -31 and prior dash numbers)

M/R blade root end insp. Using a 10X magnifying glass, inspect for any indications of chord wise cracking emitting from the root end fitting edge on the blade doubler & skin. Insect blade for missing or cracked adhesive paint at the root end fitting to doubler. Inspect leading edge of tail rotor blades inboard of the abrasion strips for any evidence of cracking. No cracks allowed. Remove the fairing inspection button plug. Clean and inspect the area in and around the rivet hole for cracks. Use a bright light and a 10x or

100

100

100

Initial

Group of Companies

Hughes 500 Series Repetitive Airworthiness Directives and Service Bulletins A/C Reg.: ___________ A/C W.O. No.: ___________ A/C T.A.T.: _____________ Date: _______________  Denotes certification by approved pilots is acceptable

AD 77-21-04

DN 9.2 Part II

AD 81-26-01 R1 DN-99 AD 90-19-02 AD 90-19-02

November 9, 2007

HMI COM DN-164 HMI COM DN-164

higher magnifying glass. Terminating action: Aerometals struts Remove overrunning clutch subassembly and inspect ball bearing for excessive loss of grease, dryness or caking. Remove & Inspect M/R drive shaft splines for cracks (Applicable to 369D driveshaft only)

300 300

Inspect overrunning clutch assembly for condition of race inner clutch, race outer clutch & the sprag assembly.

300 Hook hrs

Inspect overrunning clutch assembly for condition of race inner clutch, race outer clutch & the sprag assembly.

Annual