' . 

SERVICE BULLETIN 

SB900-100 

DATE: 05 APRIL 2006 

PAGE 1 OF 8 

II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II 

DIRECTIONAL PEDAL ASSEMBLY MODIFICATION 

1. PLANNING INFORMATION: 

A. Aircraft Affected: 

All MD900 helicopters, serial number 900-00008 thru 900-00111, 900-00113 and 

900-00114. . 

Serial numbers 900-00112 and 900-00115 and subsequent will have the intent of this 

bulletin accomplished prior to delivery. -

B. Assembly/Components Affected By This Notice: 

Pedal Assembly, Directional- Pilot Dual Controls (P/N 900C1012007-107, 109, -111, -113, 

900C60 12007 -111) 

Pedal Assembly, Directional- Co-Pilot Dual Controls (P/N 900C1012207-105, -107, 109, 

-111, -113) 

Pedal Assembly, Directional- Pilot, Single Control (PIN 900C1010007-107, -109, -111, 

-113, 900C60 10007 -111) 

C. Reason: 

MD Helicopters, Inc. (MDHI) has received a report of a directional pedal separating from 

the pedal shaft assembly in the area of the welds at the pedal support plate and the upper 

and lower pedal supports. 

Failure to comply with the requirements of this Bulletin could result in loss of directional 

control. 

D. Description: 

Procedures in this Bulletin provide owners and operators with information pertaining to 

modifying the Directional Pedal Assemblies by removing the existing pedals, removing the 

welded pedal support plate from the pedal shafts, installing a new pedal mount on the 

pedal shafts with rivets and reinstalling the pedals on the new pedal mounts. 

E. FAA Approval: 

The technical design aspects of this Bulletin are FAA Approved. 

F. Manpower: 

8.0 man-hours are required to complete this Bulletin on aircraft equipped with single 

controls. 

16.0 man-hours are required to complete this Bulletin on aircraft equipped with dual 

controls. 

G. Time of Compliance: 

The requirements of this Bulletin shall be accomplished no later than 30 days after receipt 

of parts and tools, but, no later than 03 October 2006. 

H. Interchangeability: 

None 

Copyright 1999-2006 by MD Helicopters Inc. 

This document. may be reproduced and distributed provided no fee is charged, 

the text is not modified, and this copyright notice is included. 

II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II 
SB900-100 

DATE: 05 APRIL 2006 

PAGE 2 OF 8 SERVICE BULLETIN 

II MANDATORY 111 11111111111 MANDATORY 1 1 111111111111 MANDATORY II 

I. Material/Part Availability: 

Contact the MDHI Warranty Repair Department to order the Directional Pedal 

Modification Kit. 

REPLACEMENT PARTS/SUPPLIES 

Nomenclature Part No. Qty. Source 

Directional Pedal Modification Kit SBK- 010 * MD HI 

Pedal Mount - Left 900C2010073- 101 1 (Included in Kit) 

Pedal Mount- Right 900C2010073-102 1 (Included in Kit) 

Rivet, Blind NAS1 919808803 12 (Included in Kit) 

Sealant MI L-S- 8802, 81/2 1 oz. Commercial * * 

Primer MI L- P-85582 AR Commercial * * 

Chemical Coating (Aiodine) MI L-C-5541 AR Commercial * * 

*One Kit is r equired for aircraft with single controls, two Kits are required for aircraft with 

dual controls. 

** Refer to CSP-SPM, Chapter 91-00-00 for manufacturer I supplier. 

J. Warranty Policy: 

The MDHI Warranty and Repair Dept. will provide Directional Pedal Modification Kits at 

no cost to the operator. MDHI will also provide, to authorized Service Centers, up to eight 

(8) hours of labor warranty (spares credit) for rework of each set of directional pedals. 

K. Tooling: 

Rivet Gun- Huck 2012 with Nose Assembly 99-2743 (tools available from MDHI). 

High-Speed Grinder. 

Reamer 0.256-0.261 (6.5024-6.6294 mm). 

L. Weight and Balance: 

N/A 

M. Electrical Load Data: 

N/A 

N. Other Publications Mfected: 

Rotorcraft Maintenance Manual (CSP-900RMM-2). 

Standard Practice Manual (CSP-SPM). 

0. Points of Contact: 

For further assistance, contact the Field Service Department at MDHI, Mesa, Arizona. 

Telephone 1-800-388-3378 or (480) 346-6387. DATAFAX: (480) 346-6813. 

Copyright 1999-2006 by MD Helicopters Inc. 

This document may be reproduced and distributed provided no fee is charged, the text is not modified, and this copyright notice is included. 

II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II 

. \ 
SERVICE BULLETIN 

SB900-100 

DATE: 05 APRIL 2006 

PAGE 3 OF 8 

II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II 

2. ACCOMPLISHMENT INSTRUCTIONS: 

A. Modify Directional Pedal Assembly 

(1). Remove chin windscreens (Ref. CSP-900RMM-2, Section 53-10-00, Windscreen 

Removal). 

NOTE: Application of heat, 180°F (82°C) maximum, will aid in removal of sealant. 

(2). Remove pedals (Ref. CSP-900RMM-2, Section 67-20-00, Directional Control Pedals 

Removal). 

(3). With 206E/207E Engines: Remove pedal potentiometer (Ref. CSP-900RMM-2, Section 

67-20-00, Potentiometer Removal). ' 

(4). Remove and retain directional control pedals and attaching hardware (Ref. Figure 1). 

(a). Remove cotter pin, nut, bolt and washers securing interconnecting rod to lower 

directional crank assembly. 

(b). Remove hardware securing pedal bracket assembly and lower FOD plate. 

(c). Remove sealant from around pedal bracket assembly. 

(d). Remove complete pedal assembly and lower FOD plate from aircraft. 

=~WASHER 

~NUT 

COTTER PIN 

NUT 

WASHER 

PEDAL BRACKET 

ASSEMBLY 

Figure 1. Pedal Assembly Removal I Installation 

Copyright 1999-2006 by MD Helicopters Inc. 

This document may be reproduced and distributed provided no fee is charged, 

the text is not modified, and this copyright notice is included. 

9G53-030 

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SB900-100 

DATE: 05 APRIL 2006 SERVICE BULLETIN PAGE 4 OF 8 

II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II 

(5). Modify each pedal shaft assembly (Ref. Figure 2). 

(a). Remove support plate by cutting through upper and lower supports. 

~ 

(b). Cut off welded cap, top 0.125 in. (3.18 mm) of pedal shaft. 

~:~!{~~~~~off remainder ofupper and lower support, do not grind into base metal 

/ 

(c). Grind off remainder upper and lower supports to allow new pedal mount to slip on 

pedal shaft. A slight interference fit is allowable. 

(d). Vacuum shavings from pedal assembly. 

(6). Install pedal mounts (Ref. Figure 2). 

NOTE: 

(a). Ensure both pedal adjusters are in the same adjustment holes. 

(b). Insert rig pin through mount bracket and pedal shafts. 

(c). Securely clamp pedal shafts to align evenly with each other. 

(d). Temporarily install left pedal mount (PIN 900C2010073-101) on left pedal shaft 

assembly and right pedal mount (PIN 900C2010073-102) on right pedal shaft 

assembly. 

(e). Align pedal mounts evenly and secure both pedal mounts with clamping device. 

• Observe pedal mounts to determine that they are aligned parallel and in proper plane to 

each other. 

• When drilling pedal shafts, ensure drill bit only goes through one wall of pedal shaft. 

(f). Match drill forward and aft rivet holes in mount through one wall of each pedal 

shaft and cleco in place. 

(g). Remove clamping devices from pedal shafts and pedal mounts. 

(h). Move pedal shafts to allow for access to inboard sides of pedal mounts. 

(i). Match drill one inboard rivet hole in mount through one wall of each pedal shaft. 

(j). Ream holes to 0.256-0.261 in. (6.5024-6.6294 mm). 

(k). Remove pedal mounts, deburr and clean debris from inside pedal tubes and pedal 

assembly. 

(l). Treat bare metal with alodine. 

(m). Install pedal mounts on pedal shaft and secure each mount with five rivets wet with 

primer. 

(n). Apply a fillet of sealant (C216: Ref. CSP-SPM, Section 91-00-00), per manufacturer's instructions, around pedal mount where it mates with pedal shaft assembly. 

(7). Prepare mating surfaces of retained directional control pedals and pedal mounts for 

class "L" electrical bond (Ref. CSP-SPM). 

Copyright 1999-2006 by MD Helicopters Inc. 

This document may be reproduced and distributed provided no fee is charged, the text is not modified, and this copyright notice is included. 

II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II 
SERVICE BULLETIN 

SB900-100 

DATE: 05 APRIL 2006 

PAGE 5 OF 8 

II MANDATORY 1111111 1111111 MANDATORY 11111111111111 MANDATORY I I 

/0 ~ PEDALSUPPORTPLATE 

~ PEDAL SHAFT ASSEMBLY 

PEDAL 

CUT/GRIND OFF 

SHADED AREAS 

(NOTE) 

I CAP 

0.1251N 

(3.18 MM) 

j_ 

T 

~ 

LOWER SUPPORT 

RIVET Q RIGHT PEDAL (2 REQ'D AFT SIDE) 

..........._,MOUNT 

CAP 

CUT/GRIND OFF 

SHADED AREAS 

(NOTE) 

~ 

~ .....,_______ RIVET j (1 REQ'D SIDE) 

C9 LEFT PEDAL 

COMPLETED ASSEMBLY 

RH SHOWN 

(TYPICAL ALL PEDALS) 

HQIE: DO NOT GRIND INTO BASE METAL OF PEDAL SHAFT. 

Figure 2. Directional Pedals Modification 

Copyright 1999-2006 by MD Helicopters Inc. 

This document may be reproduced and distributed provided no fee is charged, 

the text is not modified, and this copyright notice is included. 

9867-197 

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SB900-100 

DATE: 05 APRIL 2006 SERVICE BULLETIN PAGE 6 OF 8 

II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II 

(8). Install retained directional control pedals on pedal mounts with retained attaching 

hardware (Ref. CSP-900RMM-2, Section 67-20-00, Directional Control Pedals 

Installation). 

(9). Test directional control pedals for class "L" electrical bond (Ref. CSP-SPM). 

(10). Apply an environmental seal of sealant (C216: Ref. CSP-SPM, Section 91-00-00), per 

manufacturer's instructions, around pedals and pedal mount. 

(11). Touch up paint as required. 

(12). Reinstall directional control pedals and attaching hardware (Ref. Figure 1). 

(a). Prepare mating surfaces of directional control pedal mount and mounting bulkhead 

for class "L" electrical bond (Ref. CSP-SPM). 

(b). Position complete pedal assembly and lower FOD plate in aircraft. 

(c). Install hardware securing pedal bracket assembly and lower FOD plate. 

(d). Install bolt, washers, nut and cotter pin, securing interconnecting rod to lower 

directional crank assembly. 

(e). Test directional control pedal mount for class "L" electrical bond (Ref. CSP-SPM). 

(f). Apply a fillet of sealant (C216: Ref. CSP-SPM, Section 91-00-00), per manufacturer's instructions, around directional control pedal mount where it mates with 

mounting bulkhead. 

(13). With 206E/207E Engines: Install pedal potentiometer (Ref. CSP-900RMM-2, Section 

67-20-00, Potentiometer Installation). 

(14). With 206E/207E Engines: Verify pedal potentiometer rigging (Ref. CSP-900RMM-2, 

Section 67-20-00, Pedal Anticipator (Transducer) Rigging (902 CONFIG)). 

(15). Install chin windscreens (Ref. CSP-900RMM-2, Section 53-10-00, Windscreen 

Installation). 

(16). Touch up paint as required. 

3. IDENTIFICATION: 

Using permanent ink, ink stamp "90005340111-101" on each pedal shaft of modified 

directional pedal assembly. 

4. DISPOSITION OF PARTS REMOVED: 

N/A 

5. COMPLIANCE RECORD: 

Record compliance to this Service Bulletin in the Compliance Record section of the helicopter 

Log Book. 

Copyright 1999-2006 by MD Helicopters Inc. 

This document may be reproduced and distributed provided no fee is charged, 

the text is not modified, and this copyright notice is included. 

II MANDATORY 1111111 11111 1 1 MANDATORY 1111111 1111111 MANDATORY II 
SERVICE BULLETIN 

SB900-100 

DATE: 05 APRIL 2006 

PAGE 7 OF 8 

II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II 

Bulletin Compliance Recording Form 

Service Bulletin SB900-100, Directional Pedal Assembly Modification 

FAX this form to MDHI (480) 346-6813 or 

Email to ServiceEngineering@ mdhelicopters.com 

MD Helicopters, Inc. 

Field Service Department 

4555 E. McDowell Road 

Mesa, AZ 85215-9734 

800-388-3378 phone (U.S. and Canada) 

480-346-6387 phone (International) 

480-346-6813 Fax 

Dear Sir: 

This is to inform you that the Service Bulletin has been complied with as indicated below: 

Customer/Operator N arne: 

Aircraft Serial No. 

Address: 

Address: 

Phone: 

Completed 

Helicopter Total Time: _________ _ Date: __________________ __ 

Location: -------------------------------------------------------

Signature of Person Confirming Compliance -------------------------------

Copyright 1999-2006 by MD Helicopters Inc. 

This document may be reproduced and distributed provided no fee is charged, the text is not modified, and this copyright notice is included. 

II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II 
SB900-100 

DATE: 05 APRIL 2006 SERVICE BULLETIN PAGE 8 OF 8 

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Copyright 1999-2006 by MD Helicopters Inc. 

This document may be reproduced and distributed provided no fee is charged, the text is not modified, and this copyright notice is included. 

II MANDATORY 11111111111111 MANDATORY 11111111111111 MANDATORY II