# SERVICE BULLETIN SB900-099R l

DAT E: 2 7 DECEMBER 2006 PAGE 1 OF 8 

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## THRUSTER EXTENSION AND VORTEX GENERATOR INSTALLATION * Supersedes Service Bulletin SB900

- 099 dated 09 May 2006. Revised to change time of 

# I
compliance and add a note for the installation of new thruster extension fairings. Aircraft that are in compliance with Service Bulletin SB900-099 meet the intent of this revision, please complete and return compliance form. 

### 1. PLANNING I NFORMA TION A. Aircraft Affected: All MD900 helicopters , serial number 900-0008 thru 900-0116. Serial numbers 900-0117 and subsequent will have the Thruster Extension and Vortex Generators installed prior to delivery
. B. Assembly/Components Mfected By This Notice: 90005420100-103, -105 Thruster Buildup Installation , 90001 3 00205-109 Tailboom Buildup Assembly, 90007610300-105 General Cowling and Fairing Installation , and 900F3441025-101 NOTAR ® Fan Felt Seal. C . Reason: To correct a discrepancy bet ween the helicopter capability and the Rotorcraft Flight Manual (RFM ) cont r ollabilit y en velop e (Ref. RFM Figure 2-2 ) by improving t h e low s p e ed controllabilit y characteristic s of the anti-torque control sy stem. Failure to comply with the requirements of part 1 and part 2 of this Bulletin may result in reduced anti

- torque control during certain combinations of high gross weight , density altitude , and wind critical conditions
. Also , the maximum gros s weight of the helicopter will be lowered if this Service Bulletin i s not complied with
. D. Description: Proce dure s in this Bulletin require owner s and operators to adju st direction al control system r igging, in s tall t he Thru ster E xten s i on Kit (which includes v ortex gen erators), and verify t h at t h e 900F 344 1025- 10 3 NOTAR® Fan Felt Seal is in stall e d
. P a rt 1 re quires r i ggin g a d j u stm en t of t h e directio n al control (fan a nd t hru s t er) syste m . Part 2 requires install ation of the Thruster Extension Kit and Fan Felt Seal part number verification. The Thruster Extension Kit requires installation of vortex generators on the tailboom, installation of the thruster extension and new fairings, installation of a new configuration tailboom bumper, directional control rod replacement, and adjust rigging of anti-torque fan and directional control thruster. E. Time of Compliance: Perform the requirements of this Bulletin according to the schedule indicated: Part 1 Adjust directional control system rigging no later than 09 July 2006. 

## I Part 2 Install Thruster Extension Kit and verify Fan Felt Seal part number no later than 28 February 2007. 

## I Copyright 1999-2006 by MD Heli copters Inc. This document may be reproduced and distributed provided no fee is charged, the text is not modified, and this copyright notice is included. 

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### IISB900-099Rl

DATE: 27 DECEMBER 2006 PAGE 2 OF 8 

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### II F. FAA Approval: The technical design aspects of this Bulletin are FAA Approved. 

### G. Manpower: Part 1 of this Bulletin requires approximately 8 man-hours to complete. Part 2 of this Bulletin requires approximately 32 man-hours to complete if the Fan Felt Seal requires replacement, 24 man-hours for the Thruster Extension Kit only. 

### H. Interchangeability: None I. 

### Material/Part Availability: Contact the MDHI Warranty and Repair Department. REPLACEMENT PARTS/SUPPLIES Nomenclature Part No. Qty. Source Thruster Extension Kit SBK-009 1 MD HI Felt Seal , NOTAR ® Fan 900F3441025-103 1 MD HI 

### NOTE: The following materials must be ordered in addition to the SBK009 Thruster Extension Kit to comply with part 2 of this Bulletin. MATERIAL Nomenclature Part No. Qty. Source Sealing Compound MDM16-1097T1 CB1/2 2 oz PRC Desoto International , Inc

. MIL-S-8802 T1 CB1/2 (60 cc) 5454 San Fernando Rd

. 890 Glendale , CA 91203 (818) 240-2060 Adhesive , Acrylic (Note 1) Loctite ® 330 TM 250ml kit Loctite Industrial Products 800-562-8483 or www . loctite

. com/int_henkel/loctite/entry

.cfm Adhesive , Epoxy (Note 2) MDM16-1068 C12 2 oz Dexter Adhesive & Coating Systems , Hysol EA9321 {60 cc) & Frekote Products One Dexter Dr

. Seabrook, NH 03874-4018 (800) 254-2636 Resin , Epoxy MDM16-1115 T3 AR Fiber-Resin Corporation Araldite 501 20701 Nordhoff St. Chatsworth, CA 91311 (800) 624-9487 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. 

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# SERVICE BULLETIN SB900-099Rl

DATE: 27 DECEMBER 2006 PAGE 3 OF 8 

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### II MATERIAL (Cont.) Nomenclature Part No. Qty. Source Solvent Cleaner Desoclean 45 16 oz PRC Desoto International, Inc
. or equivalent (473 cc) 5454 San Fernando Rd
. Glendale , CA 91203 {818) 240-2060 Sandpaper, Non Aluminum 180 Grit AR Commercial Oxide NOTES: (1) Preferred adhesive. Has a fixture time of 30 seconds to 5 minutes, full cure in 24 hours
. (2) Has a fixture time of 24 hours , full cure in 5 to 7 days. J. Warranty Policy: The MDHI Warranty and Repair Dept. will provide the Thruster Extension Kit SBK-009 and Fan Felt Seal at no cost to the operator. MDHI will also provide, to authorized Service Centers , up to 32 hours of labor warranty (spares credit) for installation of the Thruster Extension Kit and Fan Felt Seal. 

### NOTE: • Schedule parts from MDHI no later than 30 June 2006
. • Install the Thruster Extension Kit and Fan Felt Seal no later than 28 February 2007
. 

## I
• Submit to MDHI Warranty and Repair Department, the Service and Operations Report (SOR) form with parts removed, the ''Bulletin Compli ance Recording Form" completed and signed with the part invoice attached , within 30 days after accomplishing part 2 of this Service Bulletin
. K. Disposition of Parts Removed: Fax a mi2Y of the completed Service and Operations Report (SOR) form to MDHI Warranty Repair Dept. DATAFAX: (480 ) 346

- 6813. Ship removed parts ; old control rod and tailboom bumper (cut in half) , along with the (original ) completed Service and Operations Report (SOR) form to MDHI Warranty Repair Dept
. L. Tooling: TOOLS AND EQUIPMENT Nomenclatu re Source V

ortex Ge ne r ator L oc ati ng Te mpla te, M D

H

I (Incl ud e d in Thruster Extension Kit, PN 900053 1 OOOO -AT1 PN SBK-009)

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. 

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DATE: 27 DECEMBER 2006 PAGE 4 OF 8 

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### II M. Weight and Balance: Thruster Extension Kit installation moves the thruster assembly aft 21 in
. This results in the weight and balance change shown in the table below. Record the following weight and balance data in the helicopter Log Book. Weight Long Arm Lat Arm Long Moment Lat Moment Add/Subtract (lbs .) (inches) (inches) (inch-pounds) (inch-pounds) Add 13.83 475

. 56 0 6577 0 

### N. Electrical Load Data: N/A 

### 0. Other Publications Affected: CSP-900RMM-2, Rotorcraft Maintenance Manual , Reissue 1 , Revision 27 , or later revision incorporated. CSP-900IPL-4, Illustrated Parts List Reissue 2 , Revision 10 , or later revision incorporated. 

### P. Referenced Publications: CSP -900RMM-2, Rotorcraft Maintenance Manual, Reissue 1 , Revision 27 , or later revision incorporated. CSP-900SPM, Standard Practice Manual , Original Issue , Revision 14 , or later revision incorporated. Q. 

### Compliance Record: Make sure that compliance with Parts 1 and 2 of this Service Bulletin are recorded in the Compliance Record section of the helicopter Log Book and on the Bulletin Compliance Recording Form at time of completion of each Part. 

### R. 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. 

### 2 . ACCOMPLISHMENT INSTRUCTIONS A. Part 1. 

### Adjust Rigging: ( 1). Verify that revis i on 27 or later is incorporated into CSP-900RMM-2 , Rotorcraft Maintenance Manual. (2). Adjust rigging of anti-torque fan and direct ional contr ol thruster ( Ref. CSP-900RMM-2 , S ection 67-20-00 , Ant i-To r que/Dir ectional Control System Rigging). (3). Reco rd compli ance to P art 1 of thi s Bulletin in t h e Roto rcraf t Logb ook. (4). Complete Part 1 of the Bulletin Compliance a nd Re cordin g Form (attache d) a nd FAX to MDHI F ield Service D ept. 

### B. Part 2. Install Thruster Extensio n Kit and Verify Fan Felt Seal Part Numb er: 

### NOTE: • Step 1 of this Part applies to MD900 helicopters serial numbers 900-00008 thru 900-00047. • Aircraft serial numbers 900-000008, -00010, -00011, -00015, -00022, 00030, -00031, -00040 , -00041, and -00047 already comply with step 1 of this Part. 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. 

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### II ( 1). Verify that P IN 900F3441025-103 NOTAR® Fan Liner (Felt Metal Seal) is installed. (Ref. Figure 1 )

(a). If necessary, replace with a P/N 900F3441025-103 Fan Liner (Felt Metal Seal) (Ref. CSP-900RMM-2, Section 64-30-00).

# ~

0
.66 

# in_--+1 - --·-1 1 FORWARD EDGE OF MA
- (16.76 mm) "
- .**~** CHINED SURFACE 

# c -------------,

900F3441025-101 FAN FELT SEAL



# 0.42in 

# ----!-.--1 FORWARD EDGE OF MA· (10
. 67 mm) 

## I 

# _____.J <_ CHINED SURFACE 

# c ·----------------**~** 900F3441025-103 FAN FELT SEAL 9864-197 

### Figure 1. Fan Felt Seal Identification (2 ). Verify that revision 27 or later is incorporated into CSP-900RMM-2 , Rotorcraft Maintenance Manual. (3). Remo v e t ailboom covers and fai rin gs, SL1 , SR1 , S 2 , S 4 (Ref. C SP-900RMM- 2, S e ction 06-00-00 a nd 5 3 -40-00 ). (4). Rem ove T h r u ster A ss embly (Ref
. CS P-900RMM -2, Secti on 67

- 20

- 00 ). (5). Remove Tailboom Bumper (Ref. CSP

- 900RMM

- 2, Section 53

- 40

- 00). (6). Remove Rotating Cone Control Rod Assembly (Ref. CSP

- 900RMM-2, Section 67-20-00). (7). Install vortex generators on tailboom using vortex generator locating template, PN 90005310000-AT1 (Ref. CSP-900 RMM

- 2, Section 53

- 40

- 00, Vortex Generator Installation). (Instructions for template use provided with template.) 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. 

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### II (8). Modify thruster assembly
. (Ref. Figure 2)

(a). Trim thruster control rod pass thru hole per View D-D and View E-E and seal any exposed fibers with Epoxy Resin, refer to resin manufacturer's instructions. (b). Verify that installed thruster control sector assembly is PN 900C2010392-109
. If the PN is not correct, contact MDHI Field Service Department. (c). Using permanent ink, reidentify modified thruster assembly, at location of existing part number, as PN 90005310000-101. (9). Install new Tailboom Bumper (thruster extension) (Ref
. CSP-900RMM-2, Section 53-40-00). (10). Install new Rotating Cone Control Rod Assembly (thruster extension) (Ref. CSP-900RMM-2, Section 67-20-00). (11)
. Install Thruster Extension (Ref. CSP-900RMM-2, Section 53-40-00 )
. (12)
. Install Thruster Assembly (Ref. CSP-900RMM-2 , Section 67-20-00). 

## I NOTE: Make screw holes in new fairings SL8 and SR8 to match attach holes in helicopter
. (13). Install tailboom fairings, SL1, SR1, S2, S4, SL8, and SR8 (Ref. CSP-900RMM-2, Section 06-00-00 and 53-40-00). ( 14). Install vortex generators on thruster fairings and thruster extension fairings using vortex generator locating template, PN 90005310000-AT1 (Ref. CSP-900RMM-2, Section 53-40-00, Vortex Generator Installation). (Instructions for template use provided with tool.) (15). Adjust rigging of anti-torque fan and directional control thruster (Ref. CSP-900RMM-2, Section 67-20-00, Anti-Torque/Directional Control System Rigging). (16)
. Remove rotating cone assembly and verify there is clearance (no contact) between sector assembly and rotating cone control rod assembly through full directional control travel. Install rotating cone assembly. ( 17 ). Perform helicopter weight and balance calculation and record in helicopter Basic Weight and Balance Record. ( 18 )
. Record compliance to Part 2 of this Bulletin in the Rotorcraft Logbook. ( 19 ). Complete Part 2 of the Bulletin Compliance and Recording Form (attached) and FAX to MDHI Field Service Dept
. 

### NOTE: If owners and operators want to take advantage of the increased gross weight capabilit y of t h is configurati on , they mu s t comply with t h e late s t revis ion of SB900-102 , Incre a se d Gross Weight Cap ab ility 6251-6500 lb s With LH Middle Aft Truss A ssembly Replacem en t.

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. 

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### II

TAILBOO M BU M PER

2

.391N

. (60

.71 MM) DIRECTIONAL CONTROL ROD ASS Y
- THRUSTER EXTENSIONSCREW ( 32 PLCS) 

### _-'lb.,,,._ --..._

# ~..::c•**-..-- WA-S~Hl**  32 PLCSJ RH FAIRING ASSY (SR8) LH FAIRING ASSY (SL8) (NOT SHOWN FOR CLARITY)

THRUSTER CONTROL SECTOR

2

.881N

. ( 73

. 15 MM) 4 X R 0

.50 IN.

(12.7MM)

E XISTING CU T OU T VIEW D- D (LOOKING DOW N) VIEW E- E (LOOKING AFT) 

### Figure 2. Thruster Extension Modification Copyright 1999

- 2006 by MD Helicopte r s Inc
. This document may be reproduced and distributed provided no fee is charged, the text is not modified, and this copyright notice is included. 9b5 3-19 5



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# Bulletin Compliance Recording Form Service Bulletin SB900-099R1, Thruster Extension and Vortex Generator Installation 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 Name: Aircraft Serial No: Address:
Phone: PART 1 Completed Helicopter Total Time:

__________ Date : Location:

_____________________________ ___ Signature of Person Confirming Comp liance : ________________ _ PART 2 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 p r ovided no fee is charged , the text is not modi fied, and this copyright notice is included. 

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