Training Reference Only

.&.-r , """~!j',I.TM SB369H-245 SB369D-201

SB369E-O95 SB369F-O79
SB500N-O23 SB600N-O31

SERVICE BULLETIN DATE: 15MAY 2001

PAGE 1 OF 2
II 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 b this Bulletin:
Main Rotor Blade Assembly (PIN 369A1100-501, -503, -505, -507, -511)
Main Rotor Blade Assembly (PIN 369D21100, -501, -503, -516, -517, -523)
Main Rotor Blade Assembly (PIN 369D21102, -503, -517, -523)
Main Rotor Blade Assembly (PIN 369D21120-501)
Main Rotor Blade Assembly (PIN 369D21121-501)
Main Rotor Blade Assembly (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.
II MANDATORY11111111111111 MANDATORY11111111111111 MANDATORYII
 SB369H-245
SB369E-O95
SB369D-201
SB369F-O79
~M.
~ ~'-
TM' . .

SB500N-O23 SB600N-O31
DATE: 15MAY 2001 SERVICE B
PAGE 2 OF 2 ULLETIN
II MANDATORY11111111111111 MANDATORY
11111111111111 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 or CSP-H-4, Section
04-00-00, Torque Event (TE».
(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 ~
(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.
II MANDATORY11111111111111 MANDATORY
11111111111111 MANDATORYII
l ""...J
.
.~'~.
~r. . -TM SL369H-132Rl*
SL369E-O63Rl*SL369F-O5 SL369D-II1Rl*

SL500N-OO8Rl*SL600N-OO5Rl*

SERVICE LETTER DATE: 15MAY2001

PAGE 1 OF 2

* Supersedes Service Letters SL369H-132, SL369D-l11, SL369E-O63, SL369F-O56,

SL500N-OO8, SL600N-OO5, dated 11 January 1999. I
MD HELICOPTERS MODEL 369/500N/600N
TORQUE EVENT/RETIREMENT INDEX NUMBER EXPLANATION
MD Helicopters, Inc. (MDHI) is currently establishing a new approach to tracking certain
retirement lives and inspection intervals of various helicopter components. This is being I
implemented to ensure safe operation of the helicopter within the widest range of helicopter
usage.
Components are assigned retirement lives based on flight test, fatigue test and field
experience. This life is based on a flight spectrum that is representative of maneuvers a
particular model helicopter is expected to see. A flight spectrum defines flight maneuvers and I
a percentage of time performing these maneuvers. Each maneuver produces different loads.
The number of times these loads are applied has a cumulative effect on component lives.
The MDHI flight spectrum is FAA approved and represents our knowledge of helicopter usage. .
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*
SL369E-O63Rl*SL369F-O56Rl*
SL500N-OO8Rl*SL600N-OO5Rl*

DATE: 15MAY2001 SERVICE

-='~.
"'7"'-.

LETTER
. -TM

PAGE 2 OF 2

I 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
I 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.
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) "IV
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.
 \..iOCJ:'-ttlVll-~ MD Helicopters, Inc.
" ," MAINTENANCE MANUAL

plus another adjustment factor times Hover taxi with no external load will
Torque Events. typically result in no TEs. -

When a component reaches 1,000,000 6. External Lift and Torque Event (TE)
RIN's, it has reached it's maximum life Requirements
and is to be scrapped. The 369D/E/F/FF -500/600N helicopters are

5. Torque Event (TE) multi-use helicopters.

primarily for If theorhelicopter
external lifts is used
training flights
.(high
A Torque Event (TE) 1S defined as: TE flights),
inspection intervalsthere may components.
of some be a reduction in

The transition to a hover from forward I-CAUT-ioN' For safe operation of the heli-
flight. '::--~~~~l~~ copter, TE's must be recorded in
the Rotorcraft Log Book. Each external lift
Any external lift operation. will be recorded as two (2) TE's.

NOTE: An external lift can either be on the car-
go hook, external hoist or in external bas-
kets.
.(2).operators, an external
For external lift
load is recorded as two (2) TE's (pick-
up and drop-off).
(1). Determin.e the num~er of TE's and
external lifts the h.elic°p.ter accumu-
lates per hour of flight time.
Record all TE's
and continue to in Rotorcraft
record Log Book
all TE's.
(3). Perform required TE inspections.

Page 6

Revision 29 04-00-00 FAA APPROVED

.MD Helicopters, Inc. CSP-HMI-2
..'
MAINTENANCE MANUAL

Table 1. Airworthiness Limitations Component Mandatory

Replacement Schedule

Component Part Number Finite Life Man datory

(1) Model (2) Hours Inspection
(1) Hours
Main Rotor System
Blade assembly, main rotor 3690/E(5)(6) 369021100 3530 (37) 25 (11)(20)
369021100-516 3530 (37) 100 (20)
369021100-517 2500 (31) 25 (22)
369021100-517 3530 (37) 100 (20)
369021120-501 3530 (37) 100 (20)
369021100-523 4000 (37) 100 (20)
369F/FF (6) 369021102 3430 (37) 25 (11) (20)
369021102-503 3430 (37) 100 (20)
369021102-517 2500 (31) 25 (22)
369021102-517 3430 (37) 100 (20)
369021121-501 3430 (37) 100 (20)
369021102-523 4000 (37) 100 (20) ~!
500N (6) 369021102-503 3430 (37) 100 (20)
369021102-517 2500 (31) 25 (22)
369021102-517 3430 (37) 100 (20)
369021121-501 3430 (37) 100 (20) ~
.369021102-523 4000 (31) 100 (20)
600N 369021102-517 (21) 1900 (32)(37) 100 (20) I
369021102-523 3200 (33)(37) 100 (20) i
Folding pin, main rotor blade attach 3690/E/F/FF 369A 1004 2850
369A1004-3 2850
369A1004-5 7600
500/600N 369A1004-5 7600
Hub subassembly, main rotor 3690/E/F/FF 369021201 8900
500N
Pitch housing assembly, main rotor hub 3690 369021300 9100
369021300-501 9100
369E/F/FF 369021300-501 9100
500N
Retention strap assembly, main rotor hub 3690 369021210 2770 100 (4)
369021210-501
369E/F/FF 369021210-501 2770 100 (4)
500/600N 369021210-501 2770 100 (4)
Bolt -lead-lag hub, main rotor 3690 369A1220 6120
3690/E/F/FF 369021220 6120
500N
600N 369021220 5400 (34)

Page 7
FAA APPROVED 04 -00 -00 Revision 29

~-~--
 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). I

Page 13/(14 blank)

FAA APPROVED 04-00-00 Revision 29
--

MD Helicopters, Inc. CSP-fil\tII':2.

MAINTENAJ.~CEMANUAL

Table 1. 100-Hour or Annual Inspection (Cont.)

Registration No. Serial No.
Helicopter Hours Torque Events
Model Requirement Chap/Sect Initial
WARNING: Do not leave pitot heater ON for more than one minute during next check; severe burns to
personnel may result.
ALL PITOT HTR switch ON for a few seconds. Heated pitot tube will feel warm to 95
the touch; turn switch to OFF after check.
600N Apply power to aircraft and disconnect CIT sensor (Ref. CIT (Compressor 76-00-00
Inlet Temperature) Sensor Replacement); Verify ECU FAIL light illuminates.
Re-connect CIT sensor.
ALL Clean battery and inspect for: 96
* Connector pins for evidence of corrosion.
* 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 97
systems and equipment. Do not actuate hoist guillotine or emergency floats.
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 96
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.
ALL Entire engine for: 71
* Loose bolts; loose or broken connections. 75
76
* Accessories for security and broken or missing lockwire.
* 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
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). 76-10-00
500N
369D/E/FF Clean and lubricate drive splines of starter-generator drive shaft, and female 96
500N splines in engine accessory gear case on dry spline installations.
369D/E/FF Anti-ice air tubes and compressor scroll for cracks or breaks at the anti-ice 75-10-00
500N air valve and bleed port. If cracks exist, check engine for possible vibration
causes (Ref. Engine Anti-icing System and applicable AJlison Engine
Operation and Maintenance Manual).

Page 9
Form HOEO05 (Rev 05/01) 05-20-00 Revision 29

"", ,..~
 \j~.t'-.t1.1Vll-~ MU MellcopIers, Inc.
.-': ~ MAINTENANCE MANUAL

Table 1. 100-Hour or Annual Inspection (Cont.) -

Registration No. Serial No.
Helicopter 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. 12
ALL Perform operational check of particle separator filter (Ref. Scavenge Air 71-10-10
Operational Check).
ALL Install or close all stressed panels, covers and trim panels removed or 52-50-00
opened for inspection. Check closure, fit and security. All loose equipment for
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. For troubleshooting
procedures, refer to applicable section of this manual.
100-HOUR OR ANNUAL 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 Refer to Section 04-00-00 for components
..requiring calculation of RIN's/TE's and
Table 2 IS to be used for calculating and information pertaining to calculation of
recording the Retirement Index Number (RIN) RIN's/TE's.
or Torque Events (TE) of components that are
affected by Torque Events (TE). .
Component must be scrapped when It reaches
This record ofRINs/TE's should be kept as a 1,000,000 RIN's or maximum TE's (Ref. Sec.
permanent record. 04-00-00).
Table 2. Permanent Record of Retirement Index NumbersiTorque Events
Component Part No. Serial No. Hours TE's RIN's Signature

ReVIsIon
Pag~ ~o 29
05 -- 20 00 Form HOEO05 (Rev 05/01)

,, c
 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 Reference Description Hours Initial

Check for T/R backlash or looseness by rocking the T/R back & forth in
DN143.1 its plane of rotation. The blade should not move in excess of 0.75 *DAILY
AD86-20-07
Part II inches at the blade tip without rotation of the main rotor (applicable to
Bendix couplings only)
Examine T/R Transmission. Installation by checking torque stripes for
DN-151 movement of the trans. (Cracks in the torque paint), fretting products, *25
AD88-17-09 R1 Part II gapping between faying surfaces &/or rotation of the nuts & studs.
Para. (a) (Applicable to Hughes tailbooms only)

DN-51.8 Insp. of main rotor blade root fitting assembly & m/r hub lead-lag link *25
Part II assembly for cracks, condition & slippage marks on bushings.
AD 95-03-13 (Applicable to Main Rotor blades -515 and prior dash numbers) *15 hrs
Note: (Applicable to links -31 and prior dash numbers)

35 Hrs or
SB 2100-3R3, Inspect M/R blades with a 10x magnifying glass for cracks on the first
AD 2005-21-02 200 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
Para C Part 1 with Para (a)-(l) of DN-154, Part I, Insp. Procedures. (Applicable to all
Note: our Aircraft) Compliance change with 2 failed laminates 25 hrs
DN-151 Check the torque of each T/R transmission-mounting nut to 95 +/-3
AD 88-17-09 R1 Part IV inch-pounds plus previously noted drag torque. Reapply torque stripe 100
Para (a)(b) paint. (Applicable to Hughes tailbooms only)
DN-185 Inspect torque stripe on T/R swash plate locknut for any sign of 100
AD 94-24-04
Part III 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
AD 95-03-13 DN-51.8
bushings for condition and slippage marks. (Applicable to Main Rotor
Part I
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
DN-188 indications of chord wise cracking emitting from the root end fitting edge 100
AD 96-10-09
Part II on the blade doubler & skin. Insect blade for missing or cracked
adhesive paint at the root end fitting to doubler.
CSP-HMI-2 Inspect leading edge of tail rotor blades inboard of the abrasion strips 100
SB369D-193 R1 64-10-00
for any evidence of cracking. No cracks allowed.
SB 369D-200 Remove the fairing inspection button plug. Clean and inspect the area
AD 2007-12-23 or in and around the rivet hole for cracks. Use a bright light and a 10x or 100
SB 369E-094
November 9, 2007
 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

higher magnifying glass.

Terminating action: Aerometals struts
DN 9.2 Remove overrunning clutch subassembly and inspect ball bearing for
AD 77-21-04 300
Part II excessive loss of grease, dryness or caking.
AD 81-26-01 R1 DN-99 Remove & Inspect M/R drive shaft splines for cracks (Applicable to 300
369D driveshaft only)
HMI COM Inspect overrunning clutch assembly for condition of race inner clutch, 300
AD 90-19-02 Hook hrs
DN-164 race outer clutch & the sprag assembly.
HMI COM Inspect overrunning clutch assembly for condition of race inner clutch,
AD 90-19-02 Annual
DN-164 race outer clutch & the sprag assembly.

November 9, 2007