Type Certificate Number H11NM

bearings, light bulbs, etc. This Warranty shall not apply to any helicopter, which has been crated for shipping un- less such crating is performed by RHC. RHC is not responsible for the cost of shipping parts under the terms of this Warranty. However, RHC will credit the RHC Dealership, which sold and delivered the new helicopter to its original owner, with an allowance for labor performed by that Dealership for removing and reinstalling the defec- tive part. No credit will be issued for trouble-shooting. RHC makes no Warranty with respect to batteries, instruments, avionics or other trade accessories since they are usually warranted separately by their respective manufacturers. New aircraft are equipped with new engines which have a separate Lycoming limited warranty. ADDITIONAL WARRANTY FOR MAIN & TAIL GEARBOXES In addition to the warranty specified above, an extended pro-rated warranty shall apply to the main and tail gear- boxes for the first 2200 hours of service or three years from the date of manufacture, whichever event occurs first. During this period, if a gearbox must be overhauled due to failure of a part which was defective when it left the factory, RHC will pro-rate the cost of the overhaul by dividing the hours in service by 2200 or the months in service by thirty-six (36), whichever fraction is greater. THE FOREGOING WARRANTY IS EXCLUSIVE AND IS GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES AND REPRESENTATIONS, EXPRESS, IMPLIED, OR STATUTORY, WHETHER WRITTEN OR ORAL, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR TRADE USAGE, THE REMEDIES OF THE BUYER SHALL BE LIMITED TO THOSE PROVIDED HEREIN. IN NO EVENT WILL THE MANUFACTURER BE LIABLE FOR LOSSES RESULTING FROM LOSS OF USE OF THE HELICOPTER, COLLATERAL, CONSEQUENTIAL OR SPECIAL DAMAGES, OR ANY OTHER COSTS. Warranty adjustments with respect to any helicopter or parts manufactured by RHC will be made only upon compliance with the following procedure: (1) The defective part or assembly, together with a written Warranty Claim, must be returned to RHC not later than thirty (30) days after discovery of the defect nor more than thirty (30) days after expiration of the Warranty period. (2) RHC will, after inspection, determine whether the material or part was defective when it left the factory and will respond accordingly. Final determination of a Warranty adjustment rests with RHC. ROBINSON HELICOPTER COMPANY, INC. 2901 Airport Drive Effective 1 February 2003 Torrance, California 90505 U.S.A. JUN 2014 Page v LIMITED PARTS WARRANTY Robinson Helicopter Company, Inc. (hereafter referred to as RHC) warrants each new helicopter part to be free from defects in material and workmanship appearing within one year from the date of delivery from the RHC fac- tory or during the first one thousand (1000) hours of operation, whichever event occurs first; provided, the part has been subjected to normal use and service. This Warranty is limited to repair or replacement on an exchange basis, as selected by RHC, of any part, which upon examination by RHC is deemed to have been defective when the part left the factory. A new warranty period is not established for parts replaced under the terms of this War- ranty. Such replacement parts are warranted only for the remainder of the original warranty period. RHC is not responsible for the cost of removing, shipping, or reinstallation of parts under the terms of this Warranty. This Warranty shall not apply to any part which has been repaired or altered outside the factory, and which, in RHC’s judgment, has affected the performance or reliability of the part. This Warranty shall not apply to any part which has been subject to corrosion, misuse, negligence or accident, nor to any parts normally replaced during routine maintenance, such as, air cleaners, skid shoes, rod end or spherical bearings, light bulbs, etc. RHC makes no Warranty with respect to batteries, instruments, avionics or other trade accessories since they are usually warranted separately by their respective manufacturers. ADDITIONAL WARRANTY FOR MAIN & TAIL GEARBOXES In addition to the warranty specified above, an extended pro-rated warranty shall apply to the main and tail gear- boxes for the first 2200 hours of service or three years from the date of manufacture, whichever event occurs first. During this period, if a gearbox must be overhauled due to failure of a part which was defective when it left the factory, RHC will pro-rate the cost of the overhaul by dividing the hours in service by 2200 or the months in service by thirty-six (36), whichever fraction is greater. THE FOREGOING WARRANTY IS EXCLUSIVE AND IS GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES AND REPRESENTATIONS, EXPRESS, IMPLIED, OR STATUTORY, WHETHER WRITTEN OR ORAL, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR TRADE USAGE, THE REMEDIES OF THE BUYER SHALL BE LIMITED TO THOSE PROVIDED HEREIN. IN NO EVENT WILL THE MANUFACTURER BE LIABLE FOR LOSSES RESULTING FROM LOSS OF USE OF THE HELICOPTER, COLLATERAL, CONSEQUENTIAL OR SPECIAL DAMAGES, OR ANY OTHER COSTS. Warranty adjustments with respect to any helicopter or parts manufactured by RHC will be made only upon compliance with the following procedure: (1) The defective part or assembly, together with a written Warranty Claim, must be returned to RHC not later than thirty (30) days after discovery of the defect nor more than thirty (30) days after expiration of the Warranty period. (2) RHC will, after inspection, determine whether the material or part was defective when it left the factory and will respond accordingly. Final determination of a Warranty adjustment rests with RHC. ROBINSON HELICOPTER COMPANY, INC. 2901 Airport Drive 01 June 06 Torrance, California 90505 U.S.A. Page vi JUN 2014 CONTENTS INTRODUCTION Section Title Page — Cover Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i — Subscription Order and Renewal Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii — Chapter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii — Recommended Change Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv — Limited Aircraft Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v — Limited Parts Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi — Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii CHAPTER 1 — GENERAL Section Title Page 1.000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.001 R44 Maintenance Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.002 R44 Maintenance Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.003 R44 Component Overhaul Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.004 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 1.005 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 1.006 Definitions and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2A 1.007 Service Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2B 1.008 External Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 1.009 Version Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3B 1.100 Helicopter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3D 1.101 Scheduled Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3D 1.105 Calibration of Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3D 1.110 Lubrication - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3D 1.115 Chip Detector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 1.120 Main Rotor Gearbox Drain and Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 1.130 Tail Rotor Gearbox Drain and Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 1.140 Clutch Actuator Lower Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . 1.8 1.150 Defueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 1.160 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8A 1.170 Hydraulic Reservoir Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8A 1.180 Draining and Flushing Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8B 1.190 Bleeding Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8C 1.200 Handling, Jacking, Hoisting, Leveling and Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 1.210 Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 1.211 Ground Handling Wheels Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 1.212 Ground Handling Wheels Installation - Float Ship Landing Gear . . . . . . . . . 1.10A 1.213 Moving the Helicopter on Ground Handling Wheels . . . . . . . . . . . . . . . . . 1.11 1.214 Main Rotor Blade Tie-Downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 1.215 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 1.216 Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 1.220 Jacking, Hoisting and Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 1.230 Weighing and CG Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 1.231 Helicopter Weighing Procedure . . . . . . . . . . . . . . . . . . . . . . 1.16 1.240 Ballast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 1.300 Fastener Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 JUN 2014 Page vii CONTENTS CHAPTER 1 — GENERAL (Continued) Section Title Page 1.310 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 1.320 Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 1.330 Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23 1.400 Approved Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 1.410 Paint Strippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 1.420 Solvents and Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 1.430 Fillers and Putty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.440 Torque Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.450 Primers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.455 Powder Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.460 Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31 1.470 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 1.480 Adhesives and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34 1.490 Storage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 1.500 (Reserved) 1.36 1.600 Part Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37 1.700 Special Instructions for Reassembling and Flight Testing R44 Series Helicopters After Crating for Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38 1.800 Replacement Component Identification (Data) Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 CHAPTER 2 — INSPECTION Section Title Page 2.000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.100 General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.110 Ball and Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.120 Push-Pull Tubes, Rod Ends, and Spherical Bearings . . . . . . . . . . . . . . . . . . . 2.2 2.121 Push-Pull Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 2.122 Rod Ends and Spherical Bearings . . . . . . . . . . . . . . . . . . . . . 2.2 2.125 Elastomeric Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 2.130 Telatemp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 2.200 Ground and Flight Check for 100-Hour / Annual Inspection . . . . . . . . . . . . . . . . . . . . . . 2.7 2.205 Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 2.210 Run Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 2.220 Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 2.230 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 2.300 Airframe Preparation for 100-Hour / Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 2.400 100-Hour / Annual Airframe Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 2.410 Inspection Procedures and Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 2.500 Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 2.501 Upper and Lower Clutch Actuator Bearings Inspection . . . . . . . . . . . . . . . . 2.39 2.502 C181 Lower Bearing Inspection . . . . . . . . . . . . . . . . . . . . . 2.39 2.503 C184 Upper Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . 2.40 2.507 V-Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.41 2.508 Lower Sheave V-Belt Wear Pattern Inspection . . . . . . . . . . . . . . . . . . . . . 2.43 2.510 Tail Skid Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45 2.520 Tail Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48 Page viii JUN 2014 CONTENTS CHAPTER 2 — INSPECTION (Continued) Section Title Page 2.530 Main Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49 2.540 Rotor/Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 2.550 Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.51 2.560 Penetrant Inspection of C020 Upper Steel Tube Frame . . . . . . . . . . . . . . . 2.53 2.561 Corrosion on C020 Upper Steel Tube Frame . . . . . . . . . . . . 2.54 2.570 Volcanic Ash Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55 2.580 Windshield Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56 2.590 Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56A 2.600 12-Year Inspection and Limited Overhaul Requirements . . . . . . . . . . . . . . . . . . . . . . . . 2.57 2.610 Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.57 2.620 (Reserved) 2.58 2.630 Component Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.59 2.700 2200-Hour Overhaul Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.60 2.710 Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.60 CHAPTER 3 — LIFE-LIMITED COMPONENTS Section Title Page 3.000 Life-Limited Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 3.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 3.002 Time-In-Service Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 3.003 Fatigue Life-Limited Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 3.100 Overhaul Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 3.110 Powerplant Overhaul Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 3.120 Aircraft Overhaul Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 3.200 Type Certificate Data Sheet (TCDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 3.300 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 CHAPTER 4 — AIRFRAME Section Title Page 4.000 Airframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.100 Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.110 Cabin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.111 Cabin Assembly Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.120 Windshield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 4.121 Windshield Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 4.122 Windshield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 4.123 Windshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 4.130 Door Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4.131 Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4.132 Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4.140 Fairing, Cowling and Inspection Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4.141 Engine Cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4.142 Mast Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 JUN 2014 Page ix CONTENTS CHAPTER 4 — AIRFRAME (Continued) Section Title Page 4.143 Upper Cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 4.144 Cabin Inspection Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 4.200 Steel Tube Frame Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 4.210 Lower Frame Assembly, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 4.211 Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 4.212 Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 4.220 Lower Frame Assembly, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 4.221 Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 4.222 Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 4.230 Upper Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 4.231 Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 4.232 Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 4.240 Strut Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 4.300 Tailcone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17 4.310 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19 4.400 Empennage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 4.410 Vertical Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 4.411 C042-1 Upper Vertical Stabilizer . . . . . . . . . . . . . . . . . . . . . 4.21 4.412 C043-1 Lower Vertical Stabilizer . . . . . . . . . . . . . . . . . . . . . 4.22 4.420 Horizontal Stabilizer(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 4.421 C044-1 Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . 4.23 4.422 (R44 Clipper) C050-2 Aux Stabilizer . . . . . . . . . . . . . . . . . . 4.23 4.430 Tail Rotor Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25 4.440 Tail Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26 CHAPTER 5 — LANDING GEAR Section Title Page 5.000 Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.100 Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.110 Landing Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.120 Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 5.200 Cross Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 5.210 Cross Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 5.220 Cross Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 5.300 Skid Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 5.310 Skid Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 5.320 Skid Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 5.330 Skid Shoe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 5.340 Ground Handling Wheel Support Replacement . . . . . . . . . . . . . . . . . . . . . 5.7 5.350 Skid Extension Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 5.400 Strut Fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 5.410 Strut Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 5.420 Strut Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 5.500 Utility Float Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Page x JUN 2014 CONTENTS CHAPTER 5 — LANDING GEAR (Continued) Section Title Page 5.510 Utility Float Landing Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 5.520 Utility Float Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 5.530 Utility Float Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 5.540 Utility Float Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 5.600 Emergency Pop-Out Float Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 5.610 Pop-Out Float Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 5.620 Pop-Out Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13 5.630 Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 5.640 Emergency Inflation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 5.650 Pop-Out Float Packing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18 5.660 Pressure Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21 5.665 Filling Pressure Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22 5.670 Pressure Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24 5.680 Inflation Lever Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27 5.690 Inflation Lever Shear-Rivet Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5.27 5.700 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29 CHAPTER 6 — POWERPLANT Section Title Page 6.000 Powerplant and Related Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 6.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 6.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 6.100 Powerplant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 6.110 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 6.120 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 6.200 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 6.210 Fanwheel and Scroll Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 6.220 Fanwheel and Scroll Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 6.230 (Reserved) 6.240 Fan Dynamic Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 6.300 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 6.310 Oil Cooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 6.320 Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 6.400 Induction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 6.410 Carburetor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 6.420 Carburetor Air Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 6.430 Carburetor Air Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 6.440 Carburetor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 6.450 Carburetor Heat Scoop Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 6.460 Carburetor Heat Scoop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 6.470 Fuel Injection Air Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 6.480 Fuel Injection Air Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 6.490 Fuel Control Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 6.495 Fuel Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 6.500 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20 6.510 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20 JUN 2014 Page xi CONTENTS CHAPTER 6 — POWERPLANT (Continued) Section Title Page 6.520 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20 6.600 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21 6.610 Low-Power Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21 CHAPTER 7 — DRIVE TRAIN Section Title Page 7.000 Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 7.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 7.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 7.100 Main Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 7.110 Main Rotor Gearbox Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 7.120 Main Rotor Gearbox Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 7.130 Leveling Main Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 7.140 C908-1 Yoke Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 7.141 Setting Hall Effect Sender Gap . . . . . . . . . . . . . . . . . . . . . . 7.6 7.150 Replacement of Main Rotor Gearbox Pinion Seal . . . . . . . . . . . . . . . . . . . . 7.6 7.155 Main Rotor Gearbox Sump O-Ring Replacement Procedure . . . . . . . . . . . . 7.8 7.160 Main Rotor Gearbox Overtemp Inspection . . . . . . . . . . . . . . . . . . . . . . . . 7.8A 7.170 Main Rotor Gearbox Chip Light Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 7.8A 7.200 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 7.210 Clutch Assembly Lubricant Inspection and Servicing . . . . . . . . . . . . . . . . 7.9B 7.211 C184 Bearing Assembly Removal . . . . . . . . . . . . . . . . . . . . 7.14A 7.212 C184 Bearing Assembly Installation . . . . . . . . . . . . . . . . . . 7.15 7.213 Clutch Assembly Seals Replacement . . . . . . . . . . . . . . . . . . 7.16 7.220 (Reserved) 7.17 7.230 Clutch Sheave Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 7.240 Clutch Shaft Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 7.250 Lateral Clutch Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 7.260 C907 Yoke Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24 7.270 C195 Yoke Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26 7.280 V-Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27 7.281 V-Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27 7.282 V-Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27 7.283 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30 7.290 C007 Fanshaft and Bearing Assembly, Starter Ring Gear Support, Lower Sheave, and Alternator Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7.30 7.291 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30 7.292 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30 7.300 Tail Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31 7.310 Tail Rotor Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31 7.320 Tail Rotor Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31 7.321 Adjustment of Damper Friction . . . . . . . . . . . . . . . . . . . . . . 7.33 7.330 Intermediate Flex Plate Installation and Shimming . . . . . . . . . . . . . . . . . . 7.36 7.340 Checking Tail Rotor Drive Shaft Runout . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37 7.350 Two-Piece Tail Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38 7.400 Tail Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41 Page xii JUN 2014 CONTENTS CHAPTER 7 — DRIVE TRAIN (Continued) Section Title Page 7.410 Tail Rotor Gearbox Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41 7.420 Tail Rotor Gearbox Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41 7.430 Tail Rotor Gearbox Chip Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41 7.440 Tail Rotor Gearbox Output Shaft Seal Replacement . . . . . . . . . . . . . . . . . . 7.41 7.450 Tail Rotor Gearbox Input Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . 7.44 7.500 Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46 7.510 Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46 7.520 Actuator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46 7.530 Actuator Gearmotor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.47 7.540 Adjustment of Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49 7.550 Switch and Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49 7.551 Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49 7.552 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51 7.600 Rotor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51 7.610 Rotor Brake Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51 7.620 Rotor Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51 7.630 Rotor Brake Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51 CHAPTER 8 — FLIGHT CONTROLS Section Title Page 8.000 Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 8.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 8.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 8.003 Hydraulic Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 8.004 Hydraulic Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 8.005 Hydraulic Reservoir Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 8.006 Hydraulic Servo Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 8.100 Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3B 8.110 Cyclic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3B 8.111 Cyclic Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3B 8.112 Cyclic Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . 8.5 8.120 Cyclic Grip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 8.121 Cyclic Grip Assembly Removal . . . . . . . . . . . . . . . . . . . . . . 8.7 8.122 Cyclic Grip Assembly Installation . . . . . . . . . . . . . . . . . . . . . 8.10 8.130 Longitudinal Cyclic Trim Elastic Cords (electric trim systems only) . . . . . . 8.11 8.131 Elastic Cord Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13 8.132 Elastic Cord Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14 8.140 Lateral & Longitudinal Cyclic Trim Assemblies (electric trim systems only) 8.15 8.141 Lateral Cyclic Trim Assembly Removal . . . . . . . . . . . . . . . . 8.15 8.142 Lateral Cyclic Trim Assembly Installation . . . . . . . . . . . . . . 8.16 8.143 Longitudinal Cyclic Trim Assembly Removal . . . . . . . . . . . . 8.16 8.144 Longitudinal Cyclic Trim Assembly Installation . . . . . . . . . . . 8.17 8.150 Cyclic Friction Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 8.161 Cyclic Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 8.160 C121-7 Push-Pull Tube (electric trim systems only) . . . . . . . . . . . . . . . . . 8.19 8.161 C121-7 Push-Pull Tube Removal . . . . . . . . . . . . . . . . . . . . . 8.19 JUN 2014 Page xiii CONTENTS CHAPTER 8 — FLIGHT CONTROLS (Continued) Section Title Page 8.162 C121-7 Push-Pull Tube Inspection / Repair . . . . . . . . . . . . . 8.20 8.163 C121-7 Push-Pull Tube Sleeve Installation . . . . . . . . . . . . . 8.20 8.164 C121-7 Push-Pull Tube Sleeve Inspection . . . . . . . . . . . . . . 8.21 8.165 C121-7 Push-Pull Tube Installation . . . . . . . . . . . . . . . . . . . 8.21 8.200 Collective Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24 8.210 Collective Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24 8.211 Collective Stick Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24 8.212 Collective Stick Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8.24 8.213 Pilot-Adjustable Collective Friction Adjustment . . . . . . . . . . 8.28 8.214 Fixed Collective Friction Adjustment . . . . . . . . . . . . . . . . . . 8.28 8.220 Collective Spring Assembly (manual controls only) . . . . . . . . . . . . . . . . . . 8.28 8.221 Collective Spring Removal & Servicing . . . . . . . . . . . . . . . . 8.28 8.222 Collective Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . 8.30 8.223 Collective Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . 8.31 8.230 RPM Governor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32 8.231 Governor Controller Removal . . . . . . . . . . . . . . . . . . . . . . . 8.32 8.232 Governor Controller Installation . . . . . . . . . . . . . . . . . . . . . . 8.32 8.233 Governor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 8.33 8.234 Governor Assembly Installation . . . . . . . . . . . . . . . . . . . . . . 8.33 8.239 Governor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 8.33A 8.300 Jackshaft and Support Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34 8.310 Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34 8.311 Jackshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34 8.312 Jackshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34 8.320 Strut Assembly (Jackshaft Support) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34 8.321 Jackshaft Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34 8.322 Jackshaft Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8.35 8.400 Swashplate and Main Rotor Pitch Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38 8.410 Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38 8.411 Swashplate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38 8.412 Swashplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38 8.413 Swashplate Tilting Friction Adjustment . . . . . . . . . . . . . . . . . 8.44 8.500 Tail Rotor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.44 8.510 Tail Rotor Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.44 8.511 Tail Rotor Pedal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.44 8.512 Tail Rotor Pedal Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8.45 8.520 C317 Bellcranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.46 8.521 C317-2 Lower Forward Bellcrank Removal . . . . . . . . . . . . . 8.46 8.522 C317-2 Lower Forward Bellcrank Installation . . . . . . . . . . . . 8.46 8.523 C317-1 Lower Aft Bellcrank Removal . . . . . . . . . . . . . . . . . 8.48 8.524 C317-1 Lower Aft Bellcrank Installation . . . . . . . . . . . . . . . 8.49 8.530 C316-1 Bellcranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.49 8.531 Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.49 8.532 Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.50 8.540 A331-4 Intermediate Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.50 8.541 Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.50 8.542 Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.50 Page xiv JUN 2014 CONTENTS CHAPTER 8 — FLIGHT CONTROLS (Continued) Section Title Page 8.550 A120-3 Aft Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.51 8.551 Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.51 8.552 Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.51 8.560 C031-1 Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.51 8.561 Pitch Control Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.51 8.562 Pitch Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.51 8.570 Tail Rotor Pitch Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.52 8.571 Tail Rotor Pitch Link Removal . . . . . . . . . . . . . . . . . . . . . . . 8.52 8.572 Tail Rotor Pitch Link Installation . . . . . . . . . . . . . . . . . . . . . 8.52 8.600 C203 Yoke and A205 Fork Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.54 8.610 Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.54 8.615 C648-2 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.54 8.620 B115-1 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.54 8.700 Hydraulic Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.61 8.710 Hydraulic Reservoir Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.61 8.720 Hydraulic Reservoir Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.61 8.730 Hydraulic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.62 8.740 Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.63 8.750 Hydraulic Servo Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.64 8.760 Hydraulic Servo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.65 CHAPTER 9 — ROTOR SYSTEMS Section Title Page 9.000 Rotor Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.100 Main Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.110 Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.111 Main Rotor Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.112 Main Rotor Blade Installation . . . . . . . . . . . . . . . . . . . . . . . . 9.3 9.113 Boot Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 9.114 Boot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 9.115 Filling Pitch Bearing Housing . . . . . . . . . . . . . . . . . . . . . . . . 9.7 9.116 Drilling Main Rotor Hub Bolts . . . . . . . . . . . . . . . . . . . . . . . . 9.7 9.120 Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 9.121 Main Rotor Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 9.122 Main Rotor Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 9.123 Main Rotor Hub Journal and Shim Calculations . . . . . . . . . . . . 9.11 9.124 Adjustment of Hinge Friction . . . . . . . . . . . . . . . . . . . . . . . . 9.13 9.125 Shifting the Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . 9.14 9.126 Main Rotor Hub Bearing Replacement . . . . . . . . . . . . . . . . . . 9.15 9.130 Inspection of Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17 9.131 Scratches and Corrosion on Blade Skins and Doublers . . . . 9.17 9.132 Dents and Local Deformations . . . . . . . . . . . . . . . . . . . . . 9.19 9.133 Root Fitting Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 9.134 Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21 9.140 Repair of Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 9.141 Trimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27 JUN 2014 Page xv CONTENTS CHAPTER 9 — ROTOR SYSTEMS (Continued) Section Title Page 9.142 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27 9.200 Tail Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29 9.210 Tail Rotor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29 9.220 Tail Rotor Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31 9.230 Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35 9.300 Tail Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38 9.310 Tail Rotor Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38 9.320 Tail Rotor Blade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38 9.400 Tail Rotor Blade Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41 9.410 Scratches and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41 9.420 Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41 9.430 Erosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.42 9.440 Root Fitting Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.42 9.450 Nicks and Notches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.42 9.460 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.45 9.500 Tail Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.47 9.510 Tail Rotor Hub Elastomeric Bearing Replacement . . . . . . . . . . . . . . . . . . . . 9.47 9.520 Tail Rotor Hub Spherical Bearing Replacement . . . . . . . . . . . . . . . . . . . . . 9.49 9.530 Tail Rotor Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.50 CHAPTER 10 — RIGGING, TRACK AND BALANCE Section Title Page 10.000 Rigging, Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 10.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 10.002 Rod End Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 10.100 Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 10.110 Main Rotor Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 10.111 Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 10.112 Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 10.113 Collective Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 10.120 Main Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 10.121 Cyclic Travel Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 10.122 Collective Travel Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 10.130 Tail Rotor Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 10.131 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 10.132 C316 Bell Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 10.133 A120-3 Bell Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 10.134 Tail Rotor Pitch Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 10.140 Tail Rotor Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 10.150 Throttle Correlation Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19 10.160 Actuator Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19 10.200 Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19 10.210 Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20 10.220 Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20 10.221 Main Rotor Equipment Installation . . . . . . . . . . . . . . . . . . . . . 10.20 10.222 Tail Rotor Equipment Installation . . . . . . . . . . . . . . . . . . . . . 10.24 Page xvi JUN 2014 CONTENTS CHAPTER 10 — RIGGING, TRACK AND BALANCE (Continued) Section Title Page 10.230 Main Rotor Track and Balance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 10.27 10.231 Main Rotor Balance Adjustments . . . . . . . . . . . . . . . . . . . . . 10.28 10.232 Main Rotor Pitch Link Adjustment . . . . . . . . . . . . . . . . . . . . 10.28 10.233 Main Rotor Blade Trim Tab Adjustment . . . . . . . . . . . . . . . . 10.32 10.234 Main Rotor Track and Balance Trouble-Shooting . . . . . . . . . . 10.33 10.240 Tail Rotor Balance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34 10.250 Autorotational RPM Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36 CHAPTER 11 — HEATING, VENTILATION AND AIR CONDITIONING Section Title Page 11.000 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 11.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 11.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 11.100 Cabin Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 11.110 Control Cable and Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 11.120 Muffler Shroud Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 11.200 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 11.210 Cabin Air Vent Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 11.220 Cabin Air Vent Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 11.230 Door Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 11.300 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7 11.301 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7 11.302 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7 11.310 System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9 11.320 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11 11.321 Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11 11.322 Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11 11.323 Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12 11.330 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13 11.331 Compressor Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . 11.13 11.332 Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13 11.333 Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14 11.340 Evaporator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16 11.341 Evaporator Assembly Removal . . . . . . . . . . . . . . . . . . . . . . 11.16 11.342 Evaporator Assembly Installation . . . . . . . . . . . . . . . . . . . . 11.17 11.343 Evaporator Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . 11.18 11.350 Full Throttle Cut-Out Switch Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20 11.400 Drive Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21 11.410 Drive Cartridge Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21 11.420 Drive Cartridge Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21 CHAPTER 12 — FUEL SYSTEM Section Title Page 12.000 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 12.100 Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 JUN 2014 Page xvii CONTENTS CHAPTER 12 — FUEL SYSTEM (Continued) Section Title Page 12.110 Main Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 12.111 Main Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 12.112 Main Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 12.113 Main Tank - Bladder Replacement . . . . . . . . . . . . . . . . . . . . 12.6 12.114 Main Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9 12.120 Aux Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10 12.121 Aux Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10 12.122 Aux Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11 12.123 Aux Tank - Bladder Replacement . . . . . . . . . . . . . . . . . . . . . 12.12 12.124 Aux Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15 12.200 Fuel Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17 12.210 Roll-Over Vent Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17 12.300 Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18 12.400 Fuel Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19 12.410 Fuel Quantity Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19 12.411 Fuel Quantity Sender Check . . . . . . . . . . . . . . . . . . . . . . . . 12.19 12.412 Fuel Quantity Indication Check . . . . . . . . . . . . . . . . . . . . . . 12.20 12.420 Low-Fuel Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20 12.500 Gascolator Assembly and Aux Fuel Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21 12.600 Minimum Fuel Flow Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25 12.700 R44 II Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.26 12.710 Flow Divider Internal Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.26 12.720 Injection Nozzle Comparative Flow Check . . . . . . . . . . . . . . . . . . . . . . . . 12.27 12.730 Pressure Relief Valve Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.27 CHAPTER 13 — INSTRUMENTS Section Title Page 13.000 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 13.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 13.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 13.100 Pitot-Static System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 13.200 Flight Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 13.210 Airspeed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 13.211 Pitot Line Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3 13.220 Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3 13.221 Static Line Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4 13.230 Vertical Speed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 13.240 Outside Air Temperature (OAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 13.300 Drive Train and Powerplant Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 13.310 Engine - Rotor Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 13.320 Manifold Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 13.330 Carburetor Air Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 13.340 Engine Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 13.341 Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 13.342 Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 13.343 Cylinder Head Temperature Gauge . . . . . . . . . . . . . . . . . . . 13.6 Page xviii JUN 2014 CONTENTS CHAPTER 13 — INSTRUMENTS (Continued) Section Title Page 13.344 Fuel Quantity Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 13.345 Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7 13.400 Trouble-Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7 13.500 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9 13.510 Aspen PFD and MFD Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9 CHAPTER 14 — ELECTRICAL AND AVIONICS SYSTEMS Section Title Page 14.000 Electrical and Avionics Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 14.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 14.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 14.100 Dual Tachometer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3 14.200 Low RPM Warning Unit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3 14.300 Police and Electronic News Gathering (E.N.G.) Version Equipment . . . . . . . . . . . . . . . . 14.3 14.310 (Nucomm) HD Microwave System . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3A 14.311 (Nucomm) HD Microwave System - Controller . . . . . . . . . 14.3A 14.312 (Nucomm) HD Microwave System - Transmitter . . . . . . . . 14.3A 14.313 (Nucomm) HD Microwave System - Pod Antenna . . . . . . . . 14.3B 14.314 (Nucomm) HD Microwave System - Power Amp . . . . . . . . 14.3B 14.320 (Vislink) HD Microwave System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3C 14.321 (Vislink) HD Microwave System - Control Panel . . . . . . . . 14.3C 14.322 (Vislink) HD Microwave System - L1600 Encoder Transmitter 14.3C 14.323 (Vislink) HD Microwave System - Pod Antenna . . . . . . . . 14.3D 14.324 (Vislink) HD Microwave System - Power Amp . . . . . . . . . 14.3D 14.330 Geneva Audio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3E 14.331 Geneva Audio System - Pilot Audio Panel . . . . . . . . . . . . 14.3E 14.332 Geneva Audio System - Co-pilot Audio Panel . . . . . . . . . . 14.3E 14.333 Geneva Audio System - Aft Audio Panels . . . . . . . . . . . . 14.3F 14.334 Geneva Audio System - Router . . . . . . . . . . . . . . . . . . . 14.3G 14.335 Geneva Audio System - Transmit Switch . . . . . . . . . . . . . 14.3I 14.400 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3J 14.405 A569 Low Rotor RPM Warning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3J 14.410 Electrical Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4 14.420 Instrument Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9 14.430 Clutch Actuator Electrical Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . 14.7 14.440 Electrically Powered Instruments Accuracy Check . . . . . . . . . . . . . . . . . . . 14.12 14.500 Electrical Load Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.15 14.600 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17 14.700 Electric Trim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21 14.710 Trim Controller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21 14.720 Trim System Electrical Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . 14.22C 14.800 Antenna Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25 14.900 Avionics Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.27 14.1000 Avionics for R44 Helicopter S/N 2363 & Subsequent and R44 II Helicopter S/N 13697, 13698, 13702, 13705 & Subsequent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.41 14.1010 C024 Electrical System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.41 OCT 2014 Introduction Page xix Page xx Introduction OCT 2014 CONTENTS CHAPTER 14 — ELECTRICAL AND AVIONICS SYSTEMS (Continued) Section Title Page 14.1020 C036 Electrical Components Installation . . . . . . . . . . . . . . . . . . . . . . . 14.41 14.1030 C058 Cyclic Grip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.49 14.1040 C800 Aspen PFD and MFD Installations . . . . . . . . . . . . . . . . . . . . . . . 14.49 14.1050 C802-2 COM Radio (Garmin GTR 225B) Installation . . . . . . . . . . . . . . . 14.51 14.1060 C803-1 ADS-B (Garmin GDL 88) Installation . . . . . . . . . . . . . . . . . . . . 14.53 14.1070 C804-15 Transponder (Garmin GTX 330 ES) Installation . . . . . . . . . . . 14.55 14.1080 C822-2 Audio Control (Garmin GMA 350H) Installation . . . . . . . . . . . . 14.57 14.1090 C831 GPS (Garmin GTN 600/700 series) Installation . . . . . . . . . . . . . . 14.59 CHAPTER 15 — FURNISHINGS Section Title Page 15.000 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 15.100 Seat Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3 15.110 Four-Point Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4 15.200 Seat and (Aft) Seat Back Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 15.210 Back Rest Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 15.300 Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7 15.310 Forward Cabin Floor Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7 15.320 Adhered Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7 15.400 Insulation and Headliner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7 15.500 Miscellaneous Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8 15.510 Pilot's Operating Handbook (POH) Strap Replacement . . . . . . . . . . . . . . . 15.8 15.520 License Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8 15.530 Map Pocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8 15.600 Emergency Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8 15.610 Emergency Locator Transmitter (ELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8 15.620 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10 CHAPTER 16 — SPECIAL TOOLS Section Title Page 16.000 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1 CHAPTER 17 — REVISION LOG Section Title Page — Revision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1 CHAPTER 1 GENERAL Section Title Page 1.000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.001 R44 Maintenance Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.002 R44 Maintenance Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.003 R44 Component Overhaul Authorization . . . . . . . . . . . . . . . . . . . . 1.1 1.004 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 1.005 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 1.006 Definitions and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2A 1.007 Service Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2B 1.008 External Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 1.009 Version Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3B 1.100 Helicopter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3D 1.101 Scheduled Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . 1.3D 1.105 Calibration of Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3D 1.110 Lubrication - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3D 1.115 Chip Detector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 1.120 Main Rotor Gearbox Drain and Flush . . . . . . . . . . . . . . . . . . . . . . . 1.4 1.130 Tail Rotor Gearbox Drain and Flush . . . . . . . . . . . . . . . . . . . . . . . . 1.7 1.140 Clutch Actuator Lower Bearing Lubrication . . . . . . . . . . . . . . . . . . 1.8 1.150 Defueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 1.160 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8A 1.170 Hydraulic Reservoir Filter Replacement . . . . . . . . . . . . . . . . . . . . . 1.8A 1.180 Draining and Flushing Hydraulic System . . . . . . . . . . . . . . . . . . . . 1.8B 1.190 Bleeding Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8C 1.200 Handling, Jacking, Hoisting, Leveling and Weighing . . . . . . . . . . . . . . . 1.9 1.210 Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 1.211 Ground Handling Wheels Installation . . . . . . . . . . . . . . . . . . . . . . . 1.9 1.212 Ground Handling Wheels Installation - Float Ship Landing Gear . . . 1.10A 1.213 Moving the Helicopter on Ground Handling Wheels . . . . . . . . . . . . 1.11 1.214 Main Rotor Blade Tie-Downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 1.215 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 JUN 2014 Page 1.i CHAPTER 1 GENERAL (Continued) Section Title Page 1.216 Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 1.220 Jacking, Hoisting and Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 1.230 Weighing and CG Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 1.231 Helicopter Weighing Procedure . . . . . . . . . . . . . . . . . . . . . . 1.16 1.240 Ballast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 1.300 Fastener Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 1.310 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 1.320 Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 1.330 Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23 1.400 Approved Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 1.410 Paint Strippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 1.420 Solvents and Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 1.430 Fillers and Putty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.440 Torque Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.450 Primers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.455 Powder Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.460 Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31 1.470 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 1.480 Adhesives and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34 1.490 Storage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 1.500 (Reserved) 1.36 1.600 Part Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37 1.700 Special Instructions for Reassembling and Flight Testing R44 Series Helicopters After Crating for Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38 1.800 Replacement Component Identification (Data) Plates . . . . . . . . . . . . . . . . 1.42 Page 1.ii JUN 2014 CHAPTER 1 GENERAL 1.000 Introduction The R44 Maintenance Manual contains instructions necessary for proper maintenance, servicing, and handling of R44-series helicopters certificated on U.S. FAA Type Certificate H11NM. The R44 Instructions for Continued Airworthiness (ICA) include the R44 Maintenance Manual (MM), R44 Illustrated Parts Catalog (IPC), R44/R44 II Pilot’s Operating Handbook (POH), R44 Service Bulletins (SB), R44 Service Letters (SL), Lycoming O-540/IO-540 Operator’s Manuals, applicable Lycoming technical publications, and applicable component manufacturer technical publications. Service Bulletins are issued by Robinson Helicopter Company (RHC), Lycoming, and component manufacturers. Service Bulletin compliance is mandatory. RHC technical publications are available on our website, www.robinsonheli.com, under the Publications tab. Recent technical publications are available from Lycoming at www.lycoming.com, and from Teledyne Continental Motors (TCM) at www.tcmlink.com. CAUTION Always read instructions completely before performing a task. 1.001 R44 Maintenance Manual Revisions Before using the R44 Maintenance Manual, verify it consists of effective pages. The list of effective pages is located in the Revision Log in Chapter 17. When a new manual is purchased, complete and submit the Subscription Service Form located in the Introduction. Subscription owners receive publication revisions for a one-year period. Renew subscriptions annually. The revision status for all RHC technical publications is available on our website, www.robinsonheli.com, under the Publications tab. 1.002 R44 Maintenance Authorization Only appropriately certificated mechanics who have successfully completed an R44 factory-sponsored maintenance course, or are under direct supervision of the above-stated mechanic, may perform maintenance, repairs, or inspections on the R44-series helicopter. Annual inspections of U.S.-registered light helicopters must be performed by holders of an Inspection Authorization (IA) or by repair stations certificated by the Federal Aviation Administration (FAA). The daily preflight and some preventive maintenance may be performed by the above-stated mechanics, or by the pilot/owner after receiving appropriate instruction in accordance with the R44/R44 II Pilot’s Operating Handbook and applicable aviation regulations. 1.003 R44 Component Overhaul Authorization Only appropriately certificated mechanics who have successfully completed an R44 factory- sponsored component overhaul course, and who possess special tools and technical data supplied by RHC, are authorized to disassemble and overhaul or repair major components as required by Chapter 3. JUN 2014 Page 1.1 1.004 Maintenance Record The Airframe Maintenance Record is available online at www.robinsonheli.com, under the Publications tab. Airframe Maintenance Record blank PDF forms may be used for R22-series, R44-series, and R66 Turbine helicopters. Component Record blank PDF forms may be used for life- limited or TBO components. Blank paper copies are available for purchase. A Component Record is a maintenance record of the removals, installations, or maintenance performed on a life-limited or TBO component. When a life-limited or TBO component is installed in the helicopter, the Component Record card is inserted in the Airframe Maintenance Record. When a life-limited or TBO component is removed from the helicopter, remove the Component Record card and keep the card with the Component. Major assemblies may contain one or more life-limited or TBO component. RHC encourages operators to utilize Component Record cards to assist in tracking time on interchangeable parts since service lives may be different between models. RHC does not create Component Record cards for spares, however, operators may create their own. RHC’s Repair Station does not require a Component Record card in order to perform work on a component, unlike a Component/Return Authorization form. If RHC’s Repair Station performs work on a component and the Component Record card is present, the Repair Station will date and make an entry on the card. RHC recommends using a toner-based laser, or a pigment-based inkjet, color printer and 65 lb white (96 bright) premium card stock for Maintenance Record or Component Record card production. Maintenance Record binders and tab sets are available separately. 1.005 Notations The following notations will be found throughout the manual: NOTE A NOTE provides emphasis or supplementary explanation. CAUTION Equipment damage can result if a CAUTION is not followed. WARNING Personal injury or death can result if a WARNING is not followed. Page 1.2 JUN 2014 1.006 Definitions and Abbreviations Refer to R44 or R44 II Pilot's Operating Handbook (POH) Section 1, as applicable, for additional definitions and abbreviations. A. Definitions 14 CFR § 27.602 Critical Part: A part identified as a 14 CFR § 27.602 critical part within this manual is subject to special inspection requirements. RHC Technical Support must be notified whenever the part fails to meet the special inspection requirements. 12 years: With respect to a 12 year inspection or life-limit, 12 years means 12 years from the date of the factory-issued airworthiness certificate or factory-issued authorized release certificate (FAA Form 8130-3, Airworthiness Approval Tag). Annually: With respect to an annual inspection, annually means within the preceding 12 calendar months. Datum: An imaginary vertical plane from which all horizontal measurements are taken for balance purposes with the aircraft in level flight attitude. Empty Weight: Empty Weight includes the weight of the airframe, powerplant, required and installed equipment, fixed ballast, hydraulic fluid, unusable fuel, and gearbox oil. Refer to R44-Series Type Certificate Data Sheet (TCDS) in Chapter 3. Refer to Equipment List/Weight and Balance Data Sheet (RF 134) and Weight and Balance Record in R44 or R44 II POH Section 6, as applicable, for installed equipment. Life-Limited Part: Refer to Chapter 3. Any part for which a mandatory replacement limit is specified in the type design, the Instructions for Continued Airworthiness, or the maintenance manual. Time in Service: With respect to maintenance time records, time in service means the time from the moment an aircraft leaves the surface of the earth until it touches it at the next point of landing. JUN 2014 Page 1.2A 1.006 Definitions and Abbreviations (continued) B. Abbreviations 14 CFR: Title 14 of the Code of Federal Regulations. The Federal Aviation Regulations (FARs) are part of the CFR. AOG: Aircraft on Ground ATA-100: Air Transport Association of America Specification No. 100 BL: Butt Line Station locations CO: Carbon Monoxide CRA: Component Return/Authorization ELT: Emergency Locator Transmitter FS: Fuselage Station locations HID: High Intensity Discharge LBL: Left Butt Line Station locations LED: Light Emitting Diode MRDS: Main Rotor Driveshaft MRGB: Main Rotor Gearbox OEM: Original Equipment Manufacturer R44 IPC: R44 Illustrated Parts Catalog R44 MM: R44 Maintenance Manual R44 POH: R44 Pilot’s Operating Handbook R44 II POH: R44 II Pilot’s Operating Handbook RHC: Robinson Helicopter Company SB: Service Bulletin SL: Service Letter TBO: Time Between Overhaul TCDS: Type Certificate Data Sheet TRDS: Tail Rotor Driveshaft TRGB: Tail Rotor Gearbox TS: Tailcone Station locations TSN: Time Since New TSO: Time Since Overhaul WL: Water Line Station locations 1.007 Service Directory Please visit www.robinsonheli.com and click on the Customer Support tab for a complete service directory. Procure parts from any R44 Dealer or Service Center, or order directly from assigned RHC Customer Service Representative via email, fax, or phone. Page 1.2B JUN 2014 JUN 2014 Page 1.3 1.008 External Dimensions Page 1.3A JUN 2014 1.008 External Dimensions (continued) JUN 2014 Page 1.3B 1.009 Version Description Refer to Section 3.200 for Type Certificate Data Sheet. WARNING Refer to R44 Illustrated Parts Catalog (IPC) for specific part number differences between versions. R44, “Astro”: 4-digit serial numbers 0002, 0004 thru 0760. Lycoming O-540-F1B5 carbureted engine derated to 205 horsepower maximum continuous power with 225 horsepower 5-minute takeoff rating. Manual controls (electric automatic trim and ground-adjustable collective trim); optional hydraulic cyclic & collective controls replace manual controls. Gross weight 2400 pounds. 14-volt electrical system standard; 28-volt optional. R44 “Clipper”: Fixed or pop-out float landing gear. Additional corrosion protection. Auxiliary horizontal stabilizer installed at base of lower vertical stabilizer. Drain valves installed in chin. Additional navigation lights atop mast fairing on fixed float versions. Marine radio package optional. Optional hydraulic cyclic & collective controls replace manual controls. R44, “Raven”, “Raven I”, “Clipper I”: Hydraulic cyclic & collective controls standard. Adjustable pilot-side pedals. Serial number 0761 and subsequent. R44 II, “Raven II”: 5-digit serial numbers 10001 and subsequent. Lycoming IO-540-AE1A5 fuel-injected engine derated to 205 horsepower maximum continuous power with 245 horsepower 5-minute takeoff rating. Gross weight 2500 pounds. 28-volt electrical system. Solid-state start booster for retard magneto. Second oil cooler. Rounded tip main and tail rotor blades. R44 II, “Clipper II”: Based on “Raven II.” Fixed or pop-out float landing gear. Instrument Trainer: R44 or R44 II configuration with 10-hole instrument panel. VMC operations only. E.N.G. (Electronic News Gathering): R44 or R44 II configuration. 28-volt electrical system. Nose-mounted gyro-stabilized camera with tailcone-mounted battery. Standard microwave capability. Police: R44 or R44 II configuration. 28-volt electrical system. Includes searchlight, police radio package, and nose-mounted gyro-stabilized infrared-capable camera with tailcone-mounted battery. Optional microwave capability. Perform maintenance & inspection per Lycoming Operator’s Manual.* • • • • • Perform Lycoming SI 1129B Methods of Checking DC Alternator and Generator Belt Tension. • • Perform Lycoming SI 1191A Cylinder Compression. • Perform Lycoming SI 1080C Maintenance Items for Special Attention. • • Perform Lycoming SB 301B* Maintenance Procedures and Service Limitations for Valves. • Perform Lycoming SB 366B Carburetor Throttle Body Screw Inspection. • Perform Lycoming SB 342F (IO-540 Only) Fuel Line (Stainless Steel Tube Assy.) and Support Clamp Inspection & Installation. Reference AD 2011-26-04. • Perform Lycoming SB 388C Procedure to Determine Exhaust Valve and Guide Condition. • • Perform Lycoming SB 480E I. Oil & Filter Change & Screen Cleaning / II. Oil Filter/Screen Content Inspection. • • • Perform TCM SB 643B Maintenance Intervals for All TCM & Bendix A/C Magnetos & Related Equipment. • • • Perform TCM SB 658 Distributor Gear Maintenance. • Perform TCM SB 663A Two-Wire Magneto Tach. Breaker Contact (Points) Assy. P/N 10-400507. • • Perform 100-hour/annual maintenance & inspection per § 2.400. • • Lubricate C181-3 bearing per § 1.140. • • Replace hydraulic filter per § 1.170. • Drain and flush gearboxes per § § 1.120 & 1.130. • Clean gearbox chip detectors per § 1.115. • • Perform clutch assembly lubricant inspection & servicing per § 7.210. • Service collective spring (manual controls) per § 8.221. • Verify magneto drive cushion pliability. • • Overhaul helicopter per § 2.700. • Inspect emergency locator transmitter (ELT) per 14 CFR § 91.207. • Perform pop-out float leak check per § 5.630. • Test and inspect transponder per 14 CFR § 91.413. • Perform pop-out float inflation check per § 5.640. • Perform pop-out float pressure cylinder hydrostatic test.* • Perform 12-year maintenance and inspection per § 2.600. • Pop-out float pressure cylinder maximum life. • * Shorter interval than published on referenced document/decal. First 10 hours First 25 hours First 100 hours Every 50 hours Every 100 hours Every 300 hours Every 500 hours Every 2200 hours Every 4 months Every 12 months Every 24 months Every 3 years Every 4 years Every 12 years Every 15 years TABLE 1 SCHEDULED MAINTENANCE AND INSPECTIONS Page 1.3C JUN 2014 1.100 Helicopter Servicing 1.101 Scheduled Maintenance and Inspections Required maintenance and inspection intervals are given in Table 1. Some aircraft may require maintenance and inspections in addition to the requirements in Table 1. Consult aircraft maintenance records, Service Bulletins (SB), aviation regulations, Airworthiness Limitations, and Airworthiness Directives (AD) for applicability. Publications listed are subject to revision. Preventive maintenance is required between scheduled inspections. Fluid leaks, discoloration, fretting, galling, chafing, nicks, scratches, dents, cracks, and corrosion all warrant further investigation. Unairworthy items must be replaced or repaired as allowed by RHC. 1.105 Calibration of Tools The dimensions and tolerances given in this maintenance manual are critical. RHC recommends measuring tools be calibrated at least once a year. This includes torque wrenches, micrometers, calipers, dial indicators, spring scales, protractors and balancing equipment. WARNING Proper torque is critical. Always use calibrated wrenches and undamaged, properly lubricated (where applicable) hardware. Ensure all clamping surfaces are clean, and clamp only bare metal or wet-primed surfaces. Improper torque or dirty or painted clamping surfaces may result in loss of clamp-up, hardware or part damage, and premature failure. 1.110 Lubrication - General Most bearings in the R44 are sealed or self-lubricated and do not require periodic lubrication; bearings with specific lubrication intervals are noted in Table 1. Engine lubrication requirements are contained in the Pilot’s Operating Handbook, Lycoming Operator’s Manual and Lycoming Service Instruction No. 1014 (current revision). Main and tail rotor gearboxes require additional oil when indicated by sight plug reading. WARNING The only approved lubricant for use in the main rotor and tail rotor gearboxes is A257-2 lubricant. When a new or overhauled gearbox is installed, it must be drained and the chip detector inspected after the first 4 hours of flight or first chip light, whichever occurs first. Thereafter, change gearbox oil at intervals per Section 1.101. Additionally, change gearbox oil and clean sight glass whenever oil becomes so dirty that its level cannot be determined. JUN 2014 Page 1.3D 1.115 Chip Detector Cleaning During normal gearbox operation, an insulating film of varnish can accumulate on a chip detector’s magnetic probe and prevent gearbox chip warning light illumination. Clean chip detector by: 1. Remove and discard safety wire (if applicable) securing chip detector. Disconnect chip detector wiring at quick-disconnect located several inches from chip detector. For tail rotor gearbox, place container beneath to catch oil. Remove chip detector from gearbox. 2. Clean and scrub chip detector with a toothbrush and cleaning solvent, followed by drying with compressed air or a lint-free cloth. 3. Check chip detector circuit function by connecting chip detector electrical wiring, turning battery switch on, and grounding detector’s central magnetic probe to airframe. Verify appropriate gearbox chip warning light illuminates. Turn battery switch off. 4. Install chip detector. Torque threaded-type chip detector per Section 1.330 and safety wire. Ty-rap chip detector electrical wiring as required. 5. Turn on battery switch. Check chip detector circuit function by grounding detector’s center terminal and verifying appropriate gearbox chip warning light illuminates. Turn battery switch off. 1.120 Main Rotor Gearbox Drain And Flush To drain and flush main rotor gearbox: 1. Ground run helicopter two to five minutes at 60-70% RPM to warm main rotor gearbox oil. 2. Disconnect chip detector wiring at quick-disconnect located approximately 10 inches from chip detector. Cut safety wire securing chip detector to main rotor gearbox sump attach bolt (not applicable to quick-release chip detectors). 3. Remove chip detector. Do not remove chip detector housing. NOTE After removing chip detector, check for oil leaking from chip detector housing. Leakage indicates housing is defective and must be replaced. If leakage occurs, immediately install main rotor gearbox drain assembly to minimize oil spillage. Page 1.4 JUN 2014