Publication No, CSP-023 Illustrated Parts List and Maintenance Instructions with Initial Installation Instructions FOR CYCLIC STICK GRIP KIT INSTALLATION Part No. 369H90129-31 PartNo. 369H90129-505 USED ON HUGHES 500D (MODEL 369D) HELICOPTERS 6 Hughes Helicopters aveon of amma coperaton cate ny catorsa oD775150 Issued 1 June 1977csP-023 Section Opt Eqpt Manual TABLE OF CONTENTS Page FOREWORD « ed Fe Purpose and Content of this Manual ........ Fel F-2. Applicability 2.00220 Fel F-3. Compatibility of Com- bined Optional Equipment. : F-4. Organization of Contents... 2.2.6.4. FHL F-5. Use of this, Manualss ss... teeee Fel Related Publications . | F-1 Literature Changes and Revisions ........F-1 ILLUSTRATED PARTS LIST .... 1-1 1-1. Scope and Contents... .. 1-1 1-2. Group Assembly Parts List... .. viel 1-8, Milustrations | | 11 Section 2 ‘Table of Contents Page MAINTENANCE INSTRUCTIONS... 2-1 2-1, General Information . 2-2. Description... . 2-3. Reference Data . |. 2-4, Operational Check. +... 2-5, Replacement of Cyclic Stick Grip Switches. 2-6, Wiring Diagram. . INSTALLATION INSTRUCTIONS. . 3-1 3-1, General Information... 3-1 3-2. Reference Data... 2. 3-1 3-3. Preparation... 11113-2 3-4. Removal of Cyclic Stick. . 3-2 3-5. Disassembly ot Cyclic Stick. . 3-2 8-8. Assembly of Cyel ie Stick Grip Kit . 3-7. Installation of Cyclic Stick. . . . 3-8. Weight and Balance,csP-023 Opt Eqpt Manual Foreword FOREWORD F-1. PURPOSE AND CONTENT OF THIS MANUAL. This manual supplements information contained in HMI - Vol 1 and 369D - IPC, and contains instructions for initial installation and continuing maintenance for the cyclie stick grip kit assemblies. Weight and balance data is included. This manual also contains parts lists for procuring replacement parts for the cyclic stick grip kit assemblies. F-2. APPLICABILITY. The cyclic stick grip kits are applicable for use on any Hughes 500D (Model 369D) helicopter. F-3. COMPATIBILITY OF COMBINED OPTIONAL EQUIPMENT. For compatibility information on which optional equipment may or may not be used in combination at the same time, refer to Section 21, HMI - Vol 1. F-4, ORGANIZATION OF CONTENTS. The con- tents of this manual are grouped into sections as outlined in the Table of Contents. Each section is organized to provide comprehensive coverage of entire systems, major equipment groupings, and major components that are similar or associated. (Procedures for each of these are presented in sequence as defined in Section 1, HMI - Vol 1.) F-5, USE OF THIS MANUAL. This manual is for use by operators of the Model 369D helicopter equipped with a cyclic stick grip kit. Although this manual is a separate publication, it should be kept with HMI - Vol 1, HMI - Vol 2, 369D - IPC and other handbooks listed in Section 1, HMI ~ Vol 1 that form the primary information file for the helicopter. F-6. RELATED PUBLICATIONS. Reference is made to applicable portions of HMI - Vol 1 and 369D - IPC as required to accomplish instructions contained herein. F-1, LITERATURE CHANGES AND REVISIONS. Changes and revisions to contents of this manual are made as defined in Section 1, HMI - Vol 1. F-1/F-2csP-023 Opt Egpt Manual Section 1 SECTION 1 ILLUSTRATED PARTS LIST 1-1, SCOPE AND CONTENTS. This illustrated parts list provides, by means of text (parts lists) and companion illustrations, a complete parts definition of the 369H90129-31 and 389H90129-505, Cyclic Stick Grip Kits, manufactured by Hughes Helicopters, Culver City, California. NOTE: The illustrated parts list is organized and presented in the same manner as the 369D Series Illustrated Parts List (369D IPC). (For information on use, refer to the 369D IPC.) 1-2. GROUP ASSEMBLY PARTS LIST. The parts Usts furnish information for procuring replace- ‘ment parts for the cyclic stick grip kits, and shall not be used for any other purpose. (For information or procurement of replacement parts for the standard cyclic stick refer to 369D - IPC.) 1-3, ILLUSTRATIONS. An isometric illustration is provided and includes a combined parts list, with variations noted, for both the 369H90129-31 and 369H90129-505 cyclic stick grip kits. The illustration is exploded to the extent necessary to show the parts relationship for the complete cyclic stick grip kits.CSP-023 Opt Eqpt Manual assembly kit 1. Cyclic stick grip Figure 1-csP-023 Opt Eqpt Manual Section 1 FIG.& unis INDEX PART DESCRIPTION PER ‘No. NO. ASSY 1-t- | 369H90129-31 CYCLIC STICK GRIP KIT (Complete assy) . REF 369H90129-505 CYCLIC STICK GRIP KIT (Grip only)... || REF -1 | XMRA20-0000F GASKET . A556 1 -2 |MSi-7603-16-20 | PIN (Component of $89H96129-31) | || || 20 ‘Ms100-2520P + PIN (Component of 369H90129-505) ||) | 20 -3 |MRAC20P-sTC6HS | . PLUG (Component of 369H90129-31) | | || 1 <4 | 22K1-048 + NUT (Component of 369H90129-31). 221112) 1 5 |Ms24665-151 + PIN, COTTER (Component of 369H9012-31) | | | 2 -6 | HS626-4-326 BUSHING (Component of 269H90129- ea). 1 1 | Ms20365-832 e NUTS nee j 1 -8 | ANOSOPDSL + WASHER! || ; 2 -9 | Ms27039-0824 + SCREW. 11! . ; 1 -10 | Msi782i-1-9 + STRAP (11) ee oe 1 -1 | TC-626 + MOUNTING PLATE, STRAP (Component of | | 1 369H90129-31) -12 | se9x90153, + GRIP, CYCLIC STICK. .... i -13 | NASI398B5-4 + RIVET (Component of S69H9011 7 -14 | 369027132 + TUBE ASSY (Component of 369H90129-31), 1 “15 | NAS561P2-5 + PIN (Component of 369H90129-31) .... . 1 -16 | AN960PDS16L + WASHER (Component of 369H90129-31) 4 -17 |Ms20470B3 + RIVET (Component of 369H90129-31) . 1 -18 | 36947129 + STUD (Component of 369H90129-31) . || | 1 -19. |369A7141 + SOCKET (Component of 369H90129-31) .... | | 1 1-3/1-4csP-023 Opt Eqpt Manual Section 2 SECTION 2 MAINTENANCE INSTRUCTIONS 2-1, GENERAL INFORMATION. A special cyclic stick grip assembly is provided for use when a combination of the cargo hoist /hook and emergency float kits are installed on the helicopter at the same time, 2-2. DESCRIPTION. The cyclic stick grip kit may be procured in two forms. The 369H90129-31 kit contains a complete pilot's cyclic stick assem- bly. The 369H90129-505 kit contains only the stick grip and required parts for installation on the existing pilot's cyclic stick. Each cyclic grip kits provides a four-way cyclic trim switeh, a two-position trigger type communication switch, and two guarded button switches for emergency Moats and cargo hook or hoist installations. A plug covers an opening which may be used for an additional switch if required. 2-3. REFERENCE DATA. Maintenance of the cyclic stick grip kits is similar to that of the standard cyclic stick and grip (Section 7, HMI - Vol 1). Refer to Section 20, HMI - Vol i for interfacing schematic and wiring diagrams, Differences in the grip switches and electrical wiring are discussed in the following paragraphs. 2-4. OPERATIONAL CHEC! a, Place BATT-OFF-EXT switch in the OFF position. Ensure that all electrical power is off. b. Disconnect electrical plug located near foorline aft of pilot's cyclic stick. ¢. Using ohmmeter, conduct continuity check of all switch circuits to ensure proper hookup of wiring and for switch operation. 4. Connect electrical plug to receptacle; safety with lockwire (3, table 3-1). ‘2, Energize electrical system. Check operation of four-way trim switch by momentarily activating switch and checking that both lateral and longitudinal trim actuators operate properly. . Check operation of RADIO/ICS switch as applicable to installed communications systems. CAUTION: Do not activate emergency float ‘switch or hoist cable cutter switch. h. If installed, check operation of emergency float and cargo hook/hoist switches in accordance with the applicable Opt Eqpt Manual. J. Remove electrical power; place BATT-OFF- EXT switch in OFF position. 2-5, REPLACEMENT OF CYCLIC STICK GRIP SWITCHES (see Figure 2-1). ‘@. Check that all electrical power is OFF. NOTE: Disassemble only to the extent required for the replacement of damaged or defective switches. The wiring through the grip assembly is tied with nylon cord (7, table 3-1) and covered with an insulating sleeve. Do not remove twine ties or insulating sleeves unless wire replacement is required. b. Remove screws securing affected switches. €. Unscrew RADIO/ICS trigger switch pin and carefully withdraw pin while holding switch in place. d. Unsolder wiring terminals on switch to be disconnected. If more than one switch is to be replaced, tag wires to ensure correct reinstalla~ tion. e. Solder wiring to terminal of replacement switches as applicable. Remove any wire identi- fication tags. {, Insert replacement switch in grip mounting receptacle; secure switches using original attack- ing hardware. NOTE: Make certain switch is properly positioned with applicable keyway, pin hole, ete, for proper alignment of matering parts. 2-6. WIRING DIAGRAM. Figure 2-2 contains a wiring diagram for the cyclic stick grip kit installation. Refer to Section 20, HMI - Vol 1 for wiring information on interfacing helicopter electrical systems.Section 2 Opt Eqpt Manual csP-023 CYCLIC TRIM sw (Sion, rrlooen Pw Hook sur | isa mi Guano. font stats ~ Hoist CUTTER : Suit isis9 arcs TeIGGeR DA ‘SWITCH (S112) _ ee GRIP ASSonaLy. Figure 2-1. Cyclic stick grip switches - replacement 2-2csP-023 Opt Eqpt Manual Section 2 (vOLIC STICK GRIP Oe 00 | ® a0 1. s 6-20- 1 x sa a Hse Sutrew v 1-20: I u +2 : . uit _,210 Fos + siz | iatcoer ses [Past os w v0 ol} °5 suite t 20 a ys A 92. ae f 10 eee | L cba 14-20- 1 . f B0- ' : 2 u I Sata suse . tae 7a 7 aoistiLoAT « 11-20- NO, ‘SWITCH : He nor 4 182 4 2 Nore IF THE MOIST IS BEING INSTALLED REMOVE WIRES. 11-20, 12-20, 17-29 AND JUMPER FROM SWITCH SI/S5 ‘AND CONNECT WIRES 13-20 AND 14-20 AS SHOWN Figure 2-2. Wiring diagram - cyclic stick grip kit 2-9/2-4csP-023 Opt Eqpt Manual Section 3 SECTION 3 INSTALLATION INSTRUCTIONS 3-1, GENERAL INFORMATION. The cyclic stick grip kit must be installed on any Hughes 500 Model 369D Series Helicopter when a combination of the 369190065 cargo hook kit, 369H90070 hoist kit, and/or 369H90121 emergency float kit are installed on a helicopter. ‘Two configurations of the cyclic stick grip kit are offered, the 369H90129-31 and the 369H90129-505, ‘The 369190129-31 kit consists of a factory assem= bled cyclic stick which is ready to install with a minimum of labor, whereas, the 369H90129-505 kit consists of all the components necessary for the owner or operator to assemble and install a cyclic stick grip on the helicopter. Procedures as given are to be utilized for install- ing a cyclic stick kit on a helicopter designated to receive any combination of the above mentioned optional kits. Information in the installation instructions is presented as additional procedures over and above those given in the body of the Handbook of Maintenance Instructions (HMI - Voll). Reference is made in the instructions to the applicable data in HMI - Vol 1 that is to be followed in order to accomplish the installation of a cyclic stick kit. 3-2, REFERENCE DATA, Table 3-1 lists consumable materials and expendable items required for installation. Items listed in the consumable materials and expendable items table are recommended items and are of a commercial nature that may be procurable locally. Alternate but equivalent items are acceptable, Table 3-2 lists special tools and equipment required to ‘accomplish installation, Table 3-1. Consumable materials and expendable items Item ‘Commercial Product No. Material Specification Name/No. Manufacturer 1 Tubing, MIL-I-631, Type F, 3/8 in. Commercial vinyl form U, grade A, class 1, category 1 2 Tubing, MIL-I-631, Type F, 1/2 in, Commercial Vinyl form U, grade A class 1, category 1 3 Lockwire Ms20995C CRES Safety Commercial wire (3) (diameter as required) 4 Solder SN6OWRP2 as required Commercial (QQ-8-571) 5 cord, No. 17 Flat Commercial Tying Air-Tect braid 6 ‘Tape, cresc Commercial VinytSection 3 Opt Eqpt Manual csP-023, Table 3-2. Special tools and equipment Item Nomenclature ‘Manufacturer 1 Removal tool, Winchester Electronics pin, No. 1071001 Division of Litton Industries Oakville, Conn, 2 Insertion tool, Winchester Electronics pin, No. 107-1015 Division of Litton Industries Oakville, Conn. 3-3. PREPARATION. Instructions in the follow- ing paragraphs are applicable to both cyclic stick grip kits. Preparation for installation of a grip kit includes the following: ‘@. Identify all components removed, including hardware, to gain access to work areas. Protect ‘components from damage and contamination. b. Disconnect battery. (1) Check that all electrical switches are in OFF position. CAUTION: Make certain BATT-OFF-EXT Switch is in OFF position. (2) Raise pilot compartment floor left-hand access door; remove screws and washers secur- ing battery to mounting brackets and remove (3) Disconnect electrical wiring harness male connector from battery receptacle located at inboard end of battery case, 3-4. REMOVAL OF CYCLIC STICK. Remove the pilot’s eyelic stick in accordance with the following instructions: a, Disconnect cyclic stick electrical plug located on pilot's lower seat structure. b. Remove the hardware that secures pilot's lateral control rod to stick socket; remove split bushing from aft bolt hole to avoid loss. NOTE: Retain all removed hardware, Tess cotter pin, for reuse. c. Remove the hardware that secures the lateral friction mechanism link to the cyclic torque tube. d. Remove the hardware that secures the stick socket to the end of the cyelic torque tube, Re- move stick assembly. 3-5. DISASSEMBLY OF CYCLIC STICK, Dis- assemble the pilot's cyclic stick only if 369H90129-505 grip kit is to be installed. Dis- assemble the cyclic stick as follow: a. Remove nylon strap that secures electrical wiring bundles to base of cyclic stick assembly. 3-2 b, Remove standard configuration cyclic stick grip from cyclic stick tube assembly as follows: (1) Using contact removal tool (1, table 3-2), disconnect removable contacts from electrical plug. (2) Remove retaining screw and lockwasher from base of grip. Separate grip from stick tube assembly. (3) Tie a "fish" string (5, table 3-1) to each wire bundle to aid reassembly. Push wire into wiring exit holes in stick socket while carefully pulling grip wiring from stick tube assembly. Remove grip and wiring. NOTE: Leave strings in tube to assist in reassembly. 3-6, ASSEMBLY OF CYCLIC STICK GRIP KIT. ‘The 369H90129-31 grip kit is shipped with as many parts assembled as practical, however, the 3691190129-505 grip kit will require assembly at installation. Assemble 369H90129-505 grip kit as follows: a, Remove retaining screw and lockwasher from the grip contained in the kit. b. Divide the grip kit wires into two approxi- mately equal bundles as follows: (1) Form one bundle with twisted shielded wires plus five additional wires, (2) Form a second bundle with remaining 11 wires, NOTE: Ensure a smooth flow of wires from switch contacts in grip. ¢. Cut two pieces vinyl tubing (1, table 3-1) to Tength of cyclic stick tube/socket assembly; allow approximately 6~inches excess on each piece. Insert wire bundles from grip through vinyl tubing. Slide tubing into grip approximately 2-inches. d. Attach "fish" strings to ends of grip wire bundles; carefully draw wire bundles through stick assembly and out wiring exit holes at base of stick socket (15, fig. 1-1).csP-023 NOTE: Push wire bundles at grip end while pulling vinyl covered bundles through exit holes in stick socket. €. Position grip assembly on cyclie stick tube assembly and install with lockwasher and retain= ing screw. {, Insert vinyl tubing (2, table 3-1) over ends of électrical wiring routed through base of cyclic tube assembly socket. Trim vinyl tubing as necessary. Push as much electrical wiring slack as possible back into the stick assembly. Secure wiring to tube assembly socket with nylon strap (10, fig. 1-1). 1h, Cut electrical wiring to approximately 16-inches in length from center of nylon strap. 1, Using solder (4, table 3-1) instas: contact pins (2, fig. 1-1) to ends of electrical sring. J. Using contact insertion tool (2, table 3-2), connect pinned ends of electrical wiring to plug (See fig. 2-2, Electrical Wiring Diagram). ik. Weap tape (6, table 3-1), a5 required around electrical wiring where 1/2-inch vinyl tubing commences at base of eyelic stick tube assembly socket. 1. Connect electrical plug to mating receptacle safety plug retaining screws with lockwire (3, table 3-1). 3-7. INSTALLATION OF CYCLIC STICK, Install the cyclic stick kit (369H9012Z9-31 or 369H90129- 505) as follows: Opt Eqpt Manual Section 3 a. Install washers (17, fig. 1-1), pin (18), and ise on lateral friction stud (19). b. Position cyclic stick to align with mating holes in cyclic torque tube; insert cyclic stick lateral friction stud into guide slot of lateral friction link. . Attach cyclic stick to cyclic torque tube using original hardware and replacement cotter pin (5). Install bolt head aft. 4. Install slotted bushing (6) in aft position of lower bolt hole in stick socket (15); align pilot's lateral control rod with socket (15) and install original hardware and replacement cotter pin (5). Install bolt head att. €. Assemble balance of lateral friction mechanism components on cyclic stick friction stud as follows: (1) Install spring retainer, spring, adjust- ment knob, and nut (4), (2) ‘Adjust friction knob nut (4) to stop {friction knob when spring reaches free length (00 compression) +1/32-inch. £, Insure sufficient slack in wire bundles between stick/socket wire exit holes and strap mounting plate (11, fig. 1-1); install strap (10, fig. 1-1) over end of 1/2-inch vinyl tubing and combined wire bundles. 3-8. WEIGHT AND BALANCE. The weight and balance changes resulting from installation of the 369H90129-31 or 369H90129-505 cyclic stick grip kits is negligible. However, record the addition of the grip kits in the basic weight and balance record in accordance with HMI - Vol 2. 3-3/3-4