R44 MAINTENANCE MANUAL and INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

washer evidences separation (8 places). D046-1 or -2 (LH), & D046-3 (RH) Strut Weldments Visually inspect for corrosion; replace if pitted. If non-pitting, surface corrosion is found, remove corrosion & paint per § 23-71 and MPI per § 23-41. Powder coat per § 23-76 (preferred), or prime & paint per §§ 23-75 & 23-77. D151-2 Stop (teeter, 2 each) Replace with new. D174-2 Fanwheel Perform 12-year service per § 2.620, or replace with new or overhaul exchange. D201-5 Support Assembly – Hydraulic Servos (fwd) Replace D201-5 with D201-6 support assembly. D203-1 Support Assembly – LH (aft servo) Visually inspect. If exterior corrosion is evident, record length, disassemble, and inspect tube interior. Repair or replace as required. D204-8 Support Assembly – RH (aft servo) Visually inspect. If exterior corrosion is evident, record length, disassemble, and inspect tube interior. Repair or replace as required. D207-1 Strut Weldment – Jackshaft, Forward Visually inspect. If exterior corrosion is evident, record length, disassemble, and inspect tube interior. Repair or replace as required. D208-1 Strut Weldment – Jackshaft, Aft Visually inspect. If exterior corrosion is evident, record length, disassemble, and inspect tube interior. Repair or replace as required. D211-1 or -2 Hydraulic Reservoir Perform 12-year service per § 2.660, or replace with new or overhaul exchange. D212-1 Hydraulic Servo Actuators Remove upper clevis, scissor, and D200-3 washer from servo, as applicable. Visually inspect threaded bore in piston shaft with borescope. Replace servo if corrosion is evident. D224-1 or -2 Tail Rotor Drive Shaft Remove yoke(s) and inspect shaft interior using borescope. Replace shaft if corrosion is evident. D278-1 or -2 Governor Controller Submit to RHC Repair Station for 12-year service, or replace with new or overhaul exchange. Page 1.3I Chapter 1 General APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES APR 2026 Chapter 1 General Page 1.3J 1.102 Additional Component Maintenance (continued) A. 12 YEARS (continued) Part Number Description Action D321-1 Valve – Pressure Relief (Fuel) Replace with new D321-1 or D321-4 valve assembly. D731-1 Bellcrank Assembly – Throttle, R44 II Visually inspect. If exterior corrosion is evident, remove and inspect tube interior. Verify bearings rotate smoothly without noise. Repair or replace as required. D731-9 Bellcrank Assembly – Throttle, R44 II (fuel control) Visually inspect. Replace if corrosion is evident. Verify bearing rotates smoothly without noise. D756-1 Bellcrank Assembly (forward, R44 II) Visually inspect. Replace if corrosion is evident. Verify bearing rotates smoothly without noise. D756-3 & -4 Bellcrank Assembly (forward & aft, R44) Visually inspect. Replace if corrosion is evident. Verify bearing rotates smoothly without noise. D778-1 Cartridge – Air Conditioning Pulley Drive (R44 II or Cadet only) Replace with new. D918-1 & -2 Elastic Cords – Cyclic Replace with new. NAS1149E0363R Washer (corrosion resistant, mixture arm, 2 each) Replace with new C141-26 washers, per R44 SL-80. 21FKF-518 Nut (exhaust riser, 12 each) Replace with new. 21FKF-813 or 27FKF-813 Jam Nut (MR pitch link, 2 each) Replace with new. ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.3K Chapter 1 General APR 2026 1.102 Additional Component Maintenance (continued) B. 2200/2400 Hours Perform action indicated on the following components when they have accumulated 2200 hours (R44 S/Ns 0001 thru 9999 & R44 II S/Ns 10001 thru 29999) or 2400 hours (R44 Cadet S/Ns 30001 & subsequent) time in service since new or since last overhaul: Part Number Description Action A120-3 Tail Rotor Bellcrank Replace with new. A130-21 Spacer (at R44 and R44 Cadet powerplant controls) Replace with new. A130-48 Spacer Replace with new, per R44 SL-80. A190-3 V-Belt Set Replace with new. A336-6, -9 Push-Pull Tube – Throttle (R44 II) Replace with new. A462-4 Fitting Replace with new. A522-7 Control Cable – Mixture (carburetor) Replace with new. A522-13 Control Cable – Mixture (fuel control) Replace with new. A595-1 Seal – Vertical Firewall (neoprene) Replace with new. A595-2 Seal – Vertical Firewall (Teflon®) Replace with new. A650-2 or -4 Fitting – MRGB Mount Visually inspect, including bore. Replace if worn or corroded. Magnetic particle inspect per § 23-41. A729-33 Tube (aux fuel pump drain) Replace with new. A785-6 Hose (bulkhead to MRGB) Replace with new. A785-7 Hose (alternator cooling) Replace with new. A785-10 Hose (carb heat scoop to airbox) Replace with new. A785-11 Hose (engine LH cowling to airbox) Replace with new. A785-12 Hose (scroll to muffler shroud) Replace with new. A785-13 Hose (muffler shroud to cabin heat inlet) Replace with new. A785-16 Hose (scroll to MRGB) Replace with new. A785-17 Hose (scroll to bulkhead) Replace with new. A785-19 Hose (magneto cooling) Replace with new. A785-28 Hose (bulkhead to hydraulic reservoir) Replace with new. A785-31 Hose (R44 II engine air intake) Replace with new. A918-1 thru -8 Elastic Cord – Tail Rotor Replace with new. Dash number is selected during flight test evaluation. A947-2 Flex Plate Assembly (intermediate) Replace with new. B173-2, -3, or -6 V-Belt – Alternator Replace with new. B173-4 V-Belt – A/C Compressor Drive Replace with new. B277-024 Clamp Replace with new. B277-036 Clamp Replace with new. ROBINSON MAINTENANCE MANUAL R44 SERIES 1.102 Additional Component Maintenance (continued) B. 2200/2400 Hours (continued) Part Number Description Action B283-1 Hose Assembly (oil pressure sender) Replace with new. B283-3 Hose Assembly (fuel; various) Replace with new. B283-7 Hose Assembly (fuel control to flow divider) Replace with new. B283-9 or -11 Hose Assembly (fuel return) Replace with new B283-11 hose assembly. B283-10 Hose Assembly (engine-driven pump to fuel control) Replace with new. B345-4 Pitch Link (tail rotor) Replace with new. B350-3 Spring Pin (fanwheel retaining nut) Replace with new. C005-4 C154-1 Main Rotor Hub Assembly Replace with new. C005-12 C016-7 Main Rotor Blade & C158-1 Spindle Assembly Replace with new or overhaul exchange C005-12 main rotor blade & spindle assembly, as required. C006-3, -6, or -8 Main Rotor Gearbox Assembly Replace with new or overhaul exchange C006-8 main rotor gearbox assembly. C007-5 Fanshaft Assembly Replace with new. C008-4 or -9 Tail Rotor Assembly Replace with new C008-9 tail rotor assembly. C014-X Landing Gear Assembly Perform 2200-Hour/2400-Hour service per § 2.650 Part B. C017-4 or -6 Swashplate Assembly Replace with new or overhaul exchange C017-6 swashplate assembly. C018-2 or -3 Clutch Assembly (C166-4 shaft) Replace with new or overhaul exchange C018-4 or -5 clutch assembly. C018-4 or -5 Clutch Assembly (C166-5 shaft) C020-1 Upper Frame Assembly (standard) Replace with new. C020-2 Upper Frame Assembly (with tie-downs) Replace with new. C021-1 Tail Rotor Gearbox Assembly Replace with new or overhaul exchange. C031-1 Tail Rotor Pitch Control Replace with new. C046-1, -19, -21, or -23 Lower Frame Assembly – LH Remove paint per § 23-71 and MPI per § 23-41. Powder coat per § 23-76 (preferred), or prime & paint per §§ 23-75 & 23-77. C046-2 Lower Frame Assembly – RH Remove paint per § 23-71 and MPI per § 23-41. Powder coat per § 23-76 (preferred), or prime & paint per §§ 23-75 & 23-77. C051-1 or -2 Clutch Actuator Assembly Replace with new or overhaul exchange. C106-X Journal, Main Rotor Hub Replace with new, or: Visually inspect using 10x magnification for obvious damage; magnetic particle inspect per § 23-41. APR 2026 Chapter 1 General Page 1.3L ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.3M Chapter 1 General APR 2026 1.102 Additional Component Maintenance (continued) B. 2200/2400 Hours (continued) Part Number Description Action C119-2 Bumper (tail rotor) Replace with new. C121-17 Push-Pull Tube (tailcone) Replace with new. C121-25 or -31 Push-Pull Tube Assembly – Swashplate Disassemble, remove paint per § 23-71, fluorescent penetrant inspect per § 23-42, and replace as required. Clean, prime, & paint per § 23-60. C152-1 Thrust Washer Replace with new, or: Visually inspect using 10x magnification for obvious damage; magnetic particle inspect per § 23-41. C169-1 or -35 Exhaust Muffler Assembly Replace with new C169-35 assembly. C169-31 or -37 Exhaust Muffler Assembly Replace with new C169-37 assembly. C174-1 Revision A thru F Support (engine mount at prop governor pad; constant 0.5-inch dia. vertical tube) Replace C174-1 support, C592-2 link & C592-3 mount with C174-7 support, C174-11 plate & C592-4 mount. C174-1 Revision G or subsequent Support (engine mount at prop governor pad; vertical tube lower portion is 0.562 inch dia.) Strip paint using § 23-71 approved materials. Magnetic particle inspect support per § 23-41. Powder coat per § 23-76 (preferred), or prime & paint per § 23-60. C174-7 Support Weldment Liquid-strip paint using § 23-71 approved materials only. Magnetic particle inspect support per § 23-41. Powder coat per § 23-76 (preferred), or prime & paint per § 23-60. Fill and drain tube interiors using B270-21 protectant. C174-11 Plate Weldment Strip paint using § 23-71 approved materials. Magnetic particle inspect plate per § 23-41. Powder coat per § 23-76 (preferred), or prime & paint per § 23-60. C182-1 Nut (fanwheel retaining) Replace with new. C189-14 Nut (MR hub bolt) Replace with new. C258-1 Main Rotor Pitch Link Assembly Replace with new C258-8 link assembly. C258-5 or -8 Main Rotor Pitch Link Assembly Replace with new C258-8 link assembly, or perform inspection per § 2.630 and magnetic particle inspect barrel. C339-1 or -10 Jackshaft Weldment Visually inspect. Repair or replace as required. C343-1*, -9, & -11 (*R44 SL-43 refers) Push-Pull Tube Assembly – Tail Rotor Visually inspect. If exterior corrosion is evident, record length, disassemble, and inspect tube interior. Repair or replace as required. ROBINSON MAINTENANCE MANUAL R44 SERIES 1.102 Additional Component Maintenance (continued) B. 2200/2400 Hours (continued) Part Number Description Action C348-5 Anchor Assembly – Seat Belt (Forward) Replace if seat buckle attaching lugs are less than 0.073 inch thick. Visually inspect. If exterior corrosion is evident, remove and inspect tube interior. Repair or replace as required. C480-1 Swashplate Boot Replace with new. C522-7 Control Cable – Carburetor Heat Replace with new. C568-1 Scoop Assembly (carburetor heat) Replace with new. C615-1 Gasket (airbox-to-carburetor) Replace with new. C627-4, -5, or -6 4-/5-point Harness Assembly Replace with new. C628-5, -6, -7, or -8 Connector Assembly Replace with new. C649-1 Oil Cooler Replace with new or overhauled C649-2 oil cooler. C649-2 & -3 Oil Cooler Flush & 400-psi pressure test or overhaul or replace with new. C749-1 Nozzle Assembly (MRGB cooling) Replace with new. C792-4 or -5 Dual Tachometer Replace with new or overhaul exchange. C907-1 or -2 Revision A thru G (weldment) Yoke – Clutch Shaft Forward (1.43-inch dia. center hole between arms) Replace with C907-1 or -2 Revision H or subsequent yoke. C907-1 or -2 Revision H or subsequent (forging) Yoke – Clutch Shaft Forward (1.471-inch dia. bore) Yoke is heat-treated steel & cadmium-plated; do not remove gold-colored cadmium plating. Replace with new, or comply with FAA AD 2025-11-07 (see current revision of R44 Service Letter SL-91). C918-15 Elastic Cord (collective) Replace with new A918-20 cord. C947-1 & -3 Flex Plate Assembly (forward & aft) Replace with new. D046-1 & -2 Strut Weldment – LH Remove paint per § 23-71. MPI per § 23-41. Powder coat per § 23-76 (preferred), or prime & paint per §§ 23-75 & 23-77. D046-3 Strut Weldment – RH Remove paint per § 23-71. MPI per § 23-41. Powder coat per § 23-76 (preferred), or prime & paint per §§ 23-75 & 23-77. D079-1 Tail Rotor Guard Assembly Replace with new. D082-1 Tube Assembly (weldment, TR guard) Replace with new, or: liquid-strip paint per § 23-71, MPI per § 23-41, & prime per § 23-60. D174-2 Fanwheel Replace with new or overhaul exchange. APR 2026 Chapter 1 General Page 1.3N ROBINSON MAINTENANCE MANUAL R44 SERIES 1.102 Additional Component Maintenance (continued) B. 2200/2400 Hours (continued) Part Number Description Action D201-5 Support Assembly – Hydraulic Servos (fwd) Replace with new D201-6 support assembly. D201-6 Support Assembly – Hydraulic Servos (fwd) Visually inspect including interior of tube for corrosion. If corrosion is found, replace with new. D203-1 Support Assy, LH – Aft Hydraulic Servo Remove paint per § 23-71. MPI per § 23-41. Clean, prime, & paint per § 23-60. D204-8 Support Assy, RH – Aft Hydraulic Servo Remove paint per § 23-71. MPI per § 23-41. Clean, prime, & paint per § 23-60. D211-1 or -2 Hydraulic Reservoir Replace with new or overhaul exchange. D212-1 Hydraulic Servo Actuators Replace with new or overhaul exchange. D224-1 & -2 Tail Rotor Drive Shaft Assembly Replace with new. D270-1 Governor Controller (with EMU) Replace with new or overhaul exchange. D278-1 or -2 Governor Controller Replace with new or overhaul exchange. D321-1 Valve – Pressure Relief (Fuel) Replace with new D321-1 or D321-4 valve assembly. D333-3 Fitting (carb heat control cable) Replace with new. D500-1 Hydraulic Pump Replace with new or overhaul exchange. D543-2 Spacer (fuel control throttle bellcrank) Replace with new. D730-8 Brace (fuel control) Replace with new. D735-1 Sleeve – Fuel Control Inlet Fitting (orange, insulated) Remove and discard. D743-1, -2, -3 or -4 Pump – Fuel (electric) Replace with new D743-3 pump. For helicopter S/N 13158 and prior equipped with D743-1, -2, or -4 aux fuel pump, also order KI-206-3 Provisions Kit. D778-1 Cartridge – Air Conditioning Pulley Drive (R44 II or Cadet only) Replace with new. D918-1 & -2 Elastic Cords – Cyclic Replace with new. D930-1 Mixture Spring (fuel control) Replace with new. F628-1 Connector Assembly Replace with new. F628-3 Connector Assembly Replace with new. F628-7 Buckle Assembly Replace with new. KI-6604 C017-5 Swashplate Installation Parts Kit Instructions Replace existing parts with kit parts. 21FKF-518 Nut (exhaust riser, 12 each) Replace with new. AN3-41A Bolt (oil cooler retaining) Replace with new. AN3-44A Bolt (oil cooler retaining) Replace with new. AN735-4 Clamp (mixture cable-to-C577-2 bracket) Replace with new. Page 1.3O Chapter 1 General APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES APR 2026 Chapter 1 General Page 1.3P 1.102 Additional Component Maintenance (continued) B. 2200/2400 Hours (continued) Part Number Description Action MS16562-4 Spring Pin (in D333-3 fitting) Replace with new. MS20002-24 Washer (thick, fanwheel retaining nut) Replace with new. NAS1149E0363R Washer (corrosion resistant, mixture arm, 2 each) Replace with new C141-26 washers, per R44 SL-80. NAS1149F2432P Washer (thin, fanwheel retaining nut) Replace with new. NAS634-105 Bolt (MR hub) Replace with new. C. Engine Maintenance Refer to latest revisions of Textron Lycoming Service Instruction No. 1009 and Lycoming Service Bulletin No. 240. D. Airframe and Engine Accessory Maintenance Refer to accessory manufacturer’s instructions for continued airworthiness for accessory maintenance. Remove accessories per R44 Maintenance Manual or accessory manufacturer’s instructions as required. ROBINSON MAINTENANCE MANUAL R44 SERIES 1.115 Chip Detector Cleaning NOTE During normal operation of gearboxes using A257-2 oil, an insulating film of varnish can accumulate on a chip detector’s magnet which could prevent metallic debris from illuminating the chip warning light. Proper cleaning of chip detectors per the following steps is critical to chip detector function. WARNING Review appropriate Safety Data Sheet (SDS) when working in proximity to hazardous materials. Specific recommendations for use of personal protective equipment are located in the SDS. 1. Remove and discard safety wire, if applicable, securing chip detector. Disconnect chip detector wiring from airframe harness at connectors. For tail gearbox, place suitable drain container below gearbox to catch oil and remove chip detector. 2. Clean chip detector using a toothbrush and approved solvent (refer to § 23-72). Remove debris using compressed air or masking tape; do not use a magnet. Dry chip detector using compressed air or a lint-free cloth. Inspect condition. 3. Connect chip detector wiring to airframe harness at connectors. Turn battery switch on. Touch detector’s magnet to airframe and verify appropriate gearbox caution light illuminates. Turn battery switch off. Disconnect chip detector wiring from airframe harness at connectors. 4. Install chip detector. Special torque threaded-type chip detector per § 23-33; install safety wire as required (refer to R44 SL-45). Connect chip detector wiring to airframe harness at connectors. 5. Turn battery switch on. Depress push-to-test button(s) and verify appropriate gearbox caution light illuminates. Turn battery switch off. 1.120 Main Rotor Gearbox Drain And Flush 1. Run-up helicopter for approximately five minutes at 60–70% RPM per applicable Pilot’s Operating Handbook (POH) Section 4 as required to warm oil and expedite draining. 2. Disconnect chip detector wiring from airframe harness at connectors. Remove chip detector from housing. 3. 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 Chapter 1 General APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES CHAPTER 2 INSPECTION Section Title Page 2.000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.100 General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.110 Ball and Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1A 2.120 Push-Pull Tubes, Rod Ends, and Spherical Bearings . . . . . . . . . . . . . . . . . 2.3 2.121 Push-Pull Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2.122 Rod Ends and Spherical Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2.125 Elastomeric Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 2.130 Telatemp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 2.140 Torque Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 2.530 Main Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49 2.540 Rotor/Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 2.550 Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.51 2.560 [Reserved.] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54 2.561 Corrosion on C020 Upper Steel Tube Frame . . . . . . . . . . . . . . . . . . . 2.54 2.570 Volcanic Ash Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55 2.580 Windshield Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.57 2.590 Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.58 2.595 C148 Bulkhead Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.59 APR 2026 Chapter 2 Inspection Page 2.i ROBINSON MAINTENANCE MANUAL R44 SERIES CHAPTER 2 INSPECTION (Continued) Section Title Page 2.600 2200-Hour/2400-Hour/12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2.60 2.610 Tail Rotor Gearbox 12-Year Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 2.62 2.620 Fanwheel 12-Year Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.63 2.630 C258-5 & -8 Main Rotor Pitch Link Assembly Inspection . . . . . . . . . . . . 2.64 2.640 Swashplate Assembly 12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . 2.65 2.650 Landing Gear Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.66 2.660 Hydraulic Reservoir 12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2.67 Page 2.ii Chapter 2 Inspection APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES APR 2026 Chapter 2 Inspection Page 2.3 2.120 Push-Pull Tubes, Rod Ends, and Spherical Bearings 2.121 Push-Pull Tubes 1. Nicks, cuts, or scratches in tube not more than 0.010 inch deep and not more than 1/4 of tube circumference may be polished out in lengthwise direction using 320-grit or finer wet-or-dry abrasive paper to 1-inch minimum blend radius. Replace push-pull tube if depth exceeds these limits. 2. Replace push-pull tube if tube is dented or flattened more than 5% of its diameter in unswaged area; dents or flattening is not permitted in swaged (tapered and threaded) ends of tubes. 3. Replace any C121 push-pull tube if tube threaded end allows insertion of inspection pin beyond allowable limits per following table: Thread Size Example Rod End Maximum Diameter Inspection Pin 10-32 A933-3 0.1730 inch diameter for first 0.09 inch of threads; 0.1670 inch diameter for remaining threads 1/4-28 A127-4 0.2300 inch diameter for first 0.11 inch of threads; 0.2240 inch diameter for remaining threads 5/16-24 A101-4 0.2880 inch diameter for first 0.13 inch of threads; 0.2820 inch diameter for remaining threads 3/8-24 D173-2 0.3520 inch diameter for first 0.15 inch of threads; 0.3440 inch diameter for remaining threads 2.122 Rod Ends and Spherical Bearings 1. Maximum axial play: 0.020 inch (for A104-4 bearing only: 0.035 inch axial play) Maximum radial play: 0.010 inch 2. Looseness between spherical bearing outer race & rod end housing, or between spherical bearing outer race & part, is not permitted. 3. Rod ends not riveted in place must block passage of 0.020-inch diameter wire through witness hole. Refer to Figure 2-1 for maximum rod end extension when no witness hole is provided. 4. Rod end jam nuts and stamped nuts must be torqued per § 23-32 and torque striped per Figure 2-1 at the most visible position for pre-flight inspection. Torque stripe must extend across nuts to both rod end shank and push-pull tube (or pitch link barrel, yoke, support, strut, etc.). Torque stripes are subject to deterioration and must be periodically renewed. 5. Refer to Figure 2-1A. Rod ends must be positioned (centered) to allow as much push-pull tube or link rotational movement as possible without binding. CAUTION Teflon-lined bearings must not be lubricated or solvent cleaned. WARNING Assembly of flight controls is critical and requires inspection by a qualified person. If a second person is not available, RHC recommends the installer take a 5-minute break prior to inspecting flight control connections the installer has assembled. ROBINSON MAINTENANCE MANUAL R44 SERIES FIGURE 2-2A ELASTOMER FATIGUE FIGURE 2-2C ELASTOMER OVERLOAD FIGURE 2-2B ELASTOMER OIL CONTAMINATION Page 2.4 Chapter 2 Inspection APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES \i \\ • ~ I \ \~ 114 //~ I 2.410 Inspection Procedures and Checklist (continued) 11. Rotor Hub Area (continued) Install Swashplate Boot Lower Ty-rap: Verify correct boot position and security and no boot damage. Hub: Inspect condition. Verify no nicks, scratches, gouges, or corrosion. If main rotor imbalance is suspected, check teeter and coning hinge friction per § 28-32. Verify no brown or black residue (indicates bearing wear). Hinge Bolts: Inspect condition. Verify cotter pins are in place and secure. Verify bolt heads and nuts are torque striped to thrust washers. Pitch Links and Rod Ends: Inspect condition. Inspect rod ends per § 2.122, including centering. Verify security, including jamnut tightness and proper safety wiring. Fasteners and Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per § 2.140. FIGURE 2-9 MEASURING UPPER SWASHPLATE SCISSOR AXIAL CLEARANCE APR 2026 Chapter 2 Inspection Page 2.31 ROBINSON MAINTENANCE MANUAL For scissors with C648-2 bearings: 0 . 002-0 . 010 inch total axial play per pivot . refer to Figure 8-13 . R44 SERIES 2.410 Inspection Procedures and Checklist (continued) 12. Main Rotor Blades Boots: Inspect condition. Verify no boot damage or oil leakage. Verify proper boot position and security. Verify sufficient clearance from hub assembly through full control travel. Blade Spindles & Root Fittings: Inspect area for damage per § 28-43. Verify proper installation and security of visible fasteners. Renew deteriorated torque stripes per Figure 2-1. Main Rotor Blade Tip Maintenance: Perform main rotor blade tip maintenance per § 28-60. Main Rotor Blade Inspection: Inspect skins and doublers for scratches and corrosion per § 28-41. Inspect blades for dents and local deformations per § 28-42 and for voids per § 28-44. As required, wax blades with soft cleaning cloths using carnauba-type wax (such as SC Johnson® Paste Wax). Ensure tip cover and blade tip drain holes are unobstructed. WARNING Structural damage may occur if compressed air is applied to blade tip drain holes. FIGURE 2-10 FANWHEEL ALIGNMENT MARKS Page 2.32 Chapter 2 Inspection APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES Alignment marks on fanwheel aligned with with spring pin /' , , , , , -✓ 0 . 041- inch diameter Safety wire astellated nut 2.620 Fanwheel 12-Year Maintenance 1. If installed, remove D174-2 fanwheel assembly per § 6.210. 2. Mark fanwheel assembly parts, including balancing hardware, for identical reassembly. 3. Refer to Figure 2-19. Loosen bolts securing C187-3 cone assembly and C186-1 hub to fanwheel. Verify hub axial play does not exceed 0.020 inch with hub bolts loose and NAS6603 bolts tight. 4. Remove hardware securing cone assembly, hub, and C178-2 spacer(s) to fanwheel and remove parts, noting relative locations for identical reassembly. 5. Visually inspect all components for obvious damage. Verify no elongation of fastener holes. Replace parts as required. 6. Assemble fanwheel wet with approved primer (chromate primer preferred; refer to § 23-75) between all clamping surfaces; while primer is wet, special torque D210 nuts per § 23-33. Apply B270-21 protectant to threads and tip of B660-1 bolts, if installed. FIGURE 2-19 D174-2 FANWHEEL ASSEMBLY APR 2026 Chapter 2 Inspection Page 2.63 ROBINSON MAINTENANCE MANUAL (16) NAS6603-6 Bolt ( 16) NAS 1149F0332P Washer (under head) ( 16) NAS 1149F0316P Washer (between cone assembly and fanwheel) (64) NAS 1149D0363J Washer (4 under each nut) (16) D210-3 Nut R44 SERIES (8, or 2@ 180° apart) NAS6605-12, -13, or -14 Bolt (as required for proper thread engagement per § 23-30 Part E) (6) B660-1 Bolts (optional , in two groups of 3; thread engagement limits do not apply) (8) NAS 1149C0516R Washer (between hub and cone assembly) (8) NAS 1149F0532P Washer (under nut) (8) D210-5 Nut C187-3 Cone assembly 0 . 020 inch Maximum axial play with hub bolts loose and NAS6603 bolts tight . C178-2 Spacer(s) - Fanwheel assembly 2.630 C258-5 & -8 Main Rotor Pitch Link Assembly Inspection 1. Temporarily mark each pitch link and associated swashplate ear with unique identifiers, such as different colors and/or X & O. Measure and record overall lengths of both links. 2. Remove pitch links. 3. R44 Service Letters SL-58 and SL-95 refer. Disassemble pitch links, keeping parts from each link separate from the other. 4. Evaluate rod ends per § 2.122 and replace as required. 5. Visually inspect parts with 10X magnification for obvious damage. Replace damaged parts. 6. Visually inspect interior of barrels with borescope for obvious damage. Replace damaged barrels. 7. Apply a light coat of A257-2 or -22 oil to rod end threads and assemble pitch links; adjust to recorded lengths. Torque jam nut & adjacent stamped nut per § 23-32. Special torque self-locking 21FKF-813 or 27FKF-813 jam nut per § 23-33. 8. Install pitch links to associated swashplate ear and, if installed, main rotor blade. Torque fasteners per § 23-32 and torque stripe per Figure 2-1. Page 2.64 Chapter 2 Inspection APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1A 8.005 Hydraulic Reservoir Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1A 8.006 Hydraulic Servo Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1B 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 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 8.151 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 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 APR 2026 Chapter 8 Flight Controls Page 8.i ROBINSON MAINTENANCE MANUAL R44 SERIES CHAPTER 8 FLIGHT CONTROLS (Continued) Section Title Page 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32A 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39 8.410 Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39 8.411 Swashplate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39 8.412 Swashplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39 8.413 Swashplate Tilting Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . 8.43 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 Page 8.ii Chapter 8 Flight Controls APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES ROBINSON MAINTENANCE MANUAL MODEL R44 23-- I· --~ 25 ,, • ' , { ~:~_L?) '} 26__..- 1~-c ___ ,;/ (._ ::~~ ?~) FORWARD FIGURE 8-9 JACKSHAFT INSTALLATION Change 14: JUL 2008 Page 8.37 Page 8.38 Chapter 8 Flight Controls APR 2026 FIGURE 8-10 SWASHPLATE INSTALLATION ROBINSON MAINTENANCE MANUAL R44 SERIES A255-3-- Counter weights ,FORWARD A205-7 Fork assembly Forward RH C121-31 push-pull tube .-~-·------------.... C115-1 ___ Spacers Lower, non-rotating swash plate C141-1 Safety washer FORWARD LUGS (3 PLACES) (VIEW LOOKING AFT) C769-2 Interrupter Aft C121-31 push-pull tube Forward LH C121-31 I-_;._+-;---- push-pull tube C 115-1 ___ Spacers Lower, non-rotating swashplate AFT LUG C141-1 Safety washer (VIEW LOOKING FWD) 8.400 Swashplate and Main Rotor Pitch Links 8.410 Swashplate 8.411 Swashplate Removal NOTE Rigging check is not required if push-pull tube rod end center-to-center dimension does not change. 1. Remove main rotor blades and hub per §§ 28-10 and 28-20. 2. Remove NAS6608 bolt & hardware securing C150-1 droop stops and D226-2 teeter stop brackets to C251-2 main rotor shaft. Remove droop stops and brackets. 3. Remove NAS6605 bolt & hardware, including journals & shims, securing upper C204-3 arm to C203-5 yokes. 4. Remove chord arm weights and securing hardware from C203-5 yokes. Record weights removed for reinstallation. 5. Remove hardware securing C203-5 yokes & A210-1 key to main rotor shaft and remove yokes and key. 6. Mark each swashplate ear to match C258-5 or -8 pitch link marking (ref. § 28-10). Remove hardware securing pitch links and A205-7 fork assembly to upper, rotating swashplate and remove from swashplate. 7. Cut & discard ty-raps securing swashplate boot and remove boot. 8. Remove hardware securing three C121-31 push-pull tubes’ upper rod ends and A205-7 fork assembly’s rod end to lower, non-rotating swashplate. 9. Carefully lift swashplate assembly off slider tube. 8.412 Swashplate Installation 1. If not previously accomplished, install hardware, journals, and shims securing C204- 2 lower arm to mast tube assembly. Standard torque bolt per § 23-32, then verify 0.002—0.010-inch axial play in pivot (ref. Figure 2-9); adjust C117 shim thickness between nut-side journal & thrust washer as required. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. 2. If not previously accomplished, install hardware, journals, and shims securing lower A205-7 fork assembly to C204-2 lower arm. Standard torque bolt per § 23-32, then verify 0.002—0.010-inch axial play in pivot (ref. Figure 2-9); adjust C117 shim thickness between nut-side journal & thrust washer as required. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. APR 2026 Chapter 8 Flight Controls Page 8.39 ROBINSON MAINTENANCE MANUAL R44 SERIES Page 8.40 Chapter 8 Flight Controls APR 2026 8.412 Swashplate Installation (continued) 3. Refer to Figure 8-10. Install hardware securing lower A205-7 fork assembly’s rod end, and aft C121-31 push-pull tube’s upper rod end, to lower swashplate. Standard torque bolts per § 23-32. Install stamped nuts and standard torque per § 23-32, and torque stripe per Figure 2-1. 4. Refer to § 8.413 and ensure swashplate tilting friction is within allowable limits; adjust swashplate friction as required. 5. Slide swashplate boot over main rotor drive shaft and set in place. 6. Refer to Figure 8-13. Install C203-5 yokes on C251-2 main rotor drive shaft’s upper flange; ensure round edge of A210-1 key is inserted into upper flange slot to index yokes to main rotor drive shaft. Finger tighten clamping hardware. CAUTION NAS6605 bolt securing A210-1 key between yokes must be fully torqued first to obtain proper clamping force. 7. Standard torque NAS6605 bolt securing A210-1 key between yokes per § 23-32. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. 8. Standard torque NAS6604 bolt opposite A210-1 key per § 23-32. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. A slight gap between yokes opposite A210-1 key is normal. 9. Install hardware securing retained chord arm weights (recorded during removal) to C203-5 yokes. Standard torque bolt per § 23-32. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. 10. If not previously accomplished, fill remainder of upper A205-7 fork assembly’s rod end threaded hole with B270-13 sealant (ref. § 23-79). 11. Refer to Figure 8-13. Install hardware, journals, and retained shims securing upper C204-3 arm to C203-5 yokes. Standard torque bolt per § 23-32, then verify 0.002—0.010-inch axial play in pivot; adjust C117 shim thickness between nut-side journal & thrust washer as required. Verify arm falls when released from horizontal position. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. 12. If not previously accomplished, install hardware, journals, and retained shims securing upper fork assembly to C204-3 arm. Standard torque bolt per § 23-32, then verify 0.002—0.010-inch axial play in pivot; adjust C117 shim thickness between nut-side journal & thrust washer as required. With arm held stationary, verify fork falls when released from horizontal position. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. ROBINSON MAINTENANCE MANUAL R44 SERIES APR 2026 Chapter 8 Flight Controls Page 8.41 8.412 Swashplate Installation (continued) 13. Refer to Figure 8-10. Install hardware securing two forward C121-31 push-pull tubes’ upper rod ends to lower swashplate lugs. Standard torque bolts per § 23-32. Install stamped nuts and standard torque per § 23-32, and torque stripe per Figure 2-1. 14. Align upper swashplate interrupter-side ear to upper A205-7 fork assembly. Install hardware securing upper fork assembly’s rod end and correctly matched C258-5 or -8 pitch link’s lower rod end to interrupter-side swashplate ear. Standard torque bolt per § 23-32. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. 15. Install hardware & two A255-3 counterweights securing correctly matched C258-5 or -8 pitch link’s lower rod end to non-interrupter-side swashplate ear. Standard torque bolt per § 23-32. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. 16. Position swashplate boot on upper, rotating swashplate and secure in place using MS3367-6-0 ty-rap. With boot upper lip contacting C203-5 yokes, secure in place using MS3367-7-0 ty-rap. Cinch ty-raps until snug without over-tightening, and trim tips flush with heads. CAUTION Do not drop NAS634-105 bolt or C106-5 journals when aligning droop stops. 17. Temporarily install teeter hinge bolt & nut finger tight with both journals in main rotor shaft. Press each journal against shaft for droop stop alignment. 18. Position C150-1 droop stops and D226-2 brackets & D151-2 teeter stops on main rotor shaft. Ensure droop stops are aligned to teeter bolt’s journals and install NAS6608 bolt & associated hardware securing stops and brackets to shaft. Ensure teeter stops are pressed against shaft, then standard torque bolt per § 23-32. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. 19. Install main rotor hub and blades per §§ 28-20 and 28-10. 20. Verify no interference with control movement throughout flight control travel, and swashplate movement corresponds with cyclic and collective movement. 21. Perform main rotor track and balance per § 10.230. ROBINSON MAINTENANCE MANUAL R44 SERIES Page 8.42 Chapter 8 Flight Controls APR 2026 FIGURE 8-11 MEASURING SWASHPLATE TILTING FRICTION ROBINSON MAINTENANCE MANUAL Align swashplate ears with right and left side of helicopter. ,FORWARD R44 SERIES APR 2026 Chapter 8 Flight Controls Page 8.43 8.413 Swashplate Tilting Friction Adjustment Swashplate tilting friction is established by C197-1 through C197-6 spacers controlling clamping force of Teflon-lined sleeves on the ball assembly. 1. Mark for reassembly and disconnect boot, pitch links and drive linkage (scissors) from upper swashplate. Disconnect two forward push-pull tubes from lower swashplate. 2. Refer to Figure 8-11. Align upper swashplate arms with lateral axis of helicopter and center cyclic stick. Using MT359-1 spring scale (or equivalent) connected to upper swashplate arm bolt hole, pull down and note scale reading while swashplate is moving; do not use breakaway reading. For C017-6, force required to tilt swashplate must be between 2 and 7 pounds. For C017-4, force required to tilt swashplate must be free-without-looseness minimum to 5 pounds maximum. 3. Refer to Figure 8-12. To adjust friction, remove outer screws from upper swashplate and raise and secure retainers to allow access to inner screws. Remove inner screws securing sleeve to lower swashplate. 4. Raise sleeve and measure thickness of C197 spacer stack. Adjust spacer stack thickness as required, but not exceeding 0.150 inch, to achieve proper tilting friction. Decreasing spacer stack thickness increases tilting friction while increasing spacer stack thickness decreases tilting friction. All inner screws must be installed and special torqued per § 23-33 prior to measuring friction. 5. As required, safety wire inner screws with 0.020 inch diameter safety wire. Secure retainers to upper swashplate with outer screws, special torque per § 23-33, and safety wire as required. 6. Refer to Figure 8-10. Install hardware securing two forward C121-31 push-pull tubes’ upper rod ends to lower swashplate lugs. Standard torque bolts per § 23-32. Install stamped nuts and standard torque per § 23-32, and torque stripe per Figure 2-1. 7. Align upper swashplate interrupter-side ear to upper A205-7 fork assembly. Install hardware securing upper fork assembly’s rod end and correctly matched C258-5 or -8 pitch link’s lower rod end to interrupter-side swashplate ear. Standard torque bolt per § 23-32. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. 8. Install hardware & two A255-3 counterweights securing correctly matched C258-5 or -8 pitch link’s lower rod end to non-interrupter-side swashplate ear. Standard torque bolt per § 23-32. Install stamped nut and standard torque per § 23-32, and torque stripe per Figure 2-1. 9. Position swashplate boot on upper, rotating swashplate and secure in place using MS3367-6-0 ty-rap. With boot upper lip contacting C203-5 yokes, secure in place using MS3367-7-0 ty-rap. Cinch ty-raps until snug without over-tightening, and trim tips flush with heads. ROBINSON MAINTENANCE MANUAL R44 SERIES Page 8.43A Chapter 8 Flight Controls APR 2026 FIGURE 8-12 SWASHPLATE ASSEMBLY ROBINSON MAINTENANCE MANUAL R44 SERIES 16x NAS 1 352N08H8 Screw (shown)} 16x NAS620-8L Washer (ref) C017-4 Torque 30 in .- lb (dry) Swashplate Safety wire with 0.020 assy only inch w ire. -OR- C 1 9 7- 1 --,-ir\~~P==~-- thru -6 Spacers 0.150 in. maximum stack 1Ox NAS 1 352N08H8 Screw (shown)} 1 Ox NAS620-8L Washer (ref) C017-4 Torque 30 in.- lb (dry) Swashplate Safety wire with 0 . 020 assy only inch wire . -OR- C64 7-12 Bearing set (ref) (inner race and outer race apex marks aligned and pointing down) I I I I 11 ~ ( ~ _)) C199-1 Uppecswashplate fref , C017-4 assy) ~ / 1 C 1 99-2 Upper swashplate (ref, C017-6 assy) C202-1 Sleeve assembly 7 _ ~f( C2 17-1 Seal fret) [0,040 loch th ick( (secured with B270-11 h4- 1 ~ adhesive) - 17 Data plate (ref) 11 C 198-2 Lower swashplate 'r'- --7'I , , (ref, C017-4 assy) 1 ' F198-1 Lower swashplate ' 1 ~_J==_ll~ (ref, C017-6 assy) i ' Intentionally Blank APR 2026 Chapter 8 Flight Controls Page 8.43B ROBINSON MAINTENANCE MANUAL R44 SERIES Page 8.44 Chapter 8 Flight Controls APR 2026 8.500 Tail Rotor Controls 8.510 Tail Rotor Pedals 8.511 Tail Rotor Pedal Removal 1. Remove carpet to access pedal covers per § 15.310 or § 15.320 as required. 2. Remove screws between pedals securing access plates to floor and remove plates. 3. Open or remove console as required per § 13-80. If applicable, disconnect intercom system controller and outside air temperature gage wiring. 4. Remove radios, radio face plate and radio rack by removing screws securing rack to sides of console. ROBINSON MAINTENANCE MANUAL R44 SERIES APR 2026 Chapter 8 Flight Controls Page 8.55 **Select a combination of C117-67, -68, and/or -69 shims (or combination of C105-4 or C105-5 journals – earlier R44s) to provide 0.002–0.010 inch axial play in joint (ref. Figure 2-9). *C105-6 journal (0.525–0.527-inch length) & shims** supersede earlier C105-4** & C105-5** journals without shims. FIGURE 8-13 R44 & R44 II CHORD ARM YOKE INSTALLATION (torque 2nd) (torque 1st) ROBINSON MAINTENANCE MANUAL C203-5 Yoke assembly (2 Req'd) D210-5 Nut R44 SERIES Fork assembly Intentionally Blank Page 8.56 Chapter 8 Flight Controls APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES Intentionally Blank APR 2026 Chapter 8 Flight Controls Page 8.57 ROBINSON MAINTENANCE MANUAL R44 SERIES Intentionally Blank Page 8.58 Chapter 8 Flight Controls APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES 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 Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 10.133 A120-3 Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 10.230 Main Rotor Track and Balance Procedure . . . . . . . . . . . . . . . . . . . . . . 10.29 10.231 Main Rotor Balance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31 10.232 Main Rotor Pitch Link Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 10.31B 10.233 Main Rotor Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 10.39 10.234 Main Rotor Track and Balance Troubleshooting . . . . . . . . . . . . . . . . 10.40 10.240 Tail Rotor Balance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42 10.250 Autorotational RPM Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47 APR 2026 Chapter 10 Rigging, Track and Balance Page 10.i ROBINSON MAINTENANCE MANUAL R44 SERIES Intentionally Blank Page 10.ii Chapter 10 Rigging, Track and Balance APR 2026 ROBINSON MAINTENANCE MANUAL R44 SERIES 10.231 Main Rotor Balance Adjustment WARNING A rotor which is smooth after balancing but goes out of balance within a few flights is suspect and must be examined by RHC before further flight. A. Tip Weights (Spanwise Balance Adjustment) 1. Remove screws securing tip cover to blade. Balance rotor assembly spanwise by adjusting tip weights as required per Figure 10-10. Washers may be trimmed. Refer to Figure 10-11. Apply light coat A257-9 anti-seize to threads and install screws securing tip weights to blade; special torque screws to 40 in.-lb. Apply light coat A257-9 anti-seize to threads and install screws securing tip cover to blade; special torque screws to 40 in.-lb. (1) AN960-10 or NAS1149F0363P Washer = (2) AN960-10L or NAS1149F0332P Washers (1) C298-2 Weight = (5) AN960-10 or NAS1149F0363P Washers (1) C298-3 Weight = (11) AN960-10 or NAS1149F0363P Washers (1) C298-4 Weight = (4) C298-3 Weights B. Teeter Hinge Bolt Shims (Chordwise Balance Adjustment - Coarse Adjustment) 1. Remove and discard teeter hinge nut cotter pin. Remove nut, thrust washer, and any shims. 2. Have two people cone the main rotor blades. Push out teeter hinge bolt (and any shims) with another bolt. 3. Balance rotor assembly chordwise by moving (or exchanging) existing teeter hinge shims to other side of bolt (under head or under nut) as required per Figure 10-10. Install teeter hinge bolt per § 28-10. C. Chord Arm Weight (Chordwise Balance Adjustment - Fine Adjustment) 1. Balance rotor assembly chordwise by adjusting chord arm weights or washers per Figure 10-10. Total weight not to exceed four A255-2 weights (or equivalent). (1) A255-1 Weight = (8) AN970-4 Washers (1) A255-2 Weight = (3) A255-1 Weights APR 2026 Chapter 10 Rigging, Track and Balance Page 10.31 ROBINSON MAINTENANCE MANUAL R44 SERIES Page 10.31A Chapter 10 Rigging, Track and Balance APR 2026 FIGURE 10-12A C258-8 MAIN ROTOR PITCH LINK ROBINSON MAINTENANCE MANUAL Coarse Length Adjustment -------< Rotate Upper Rod End Only • One-half turn of rod end changes blade angle 0.44° R44 SERIES D173-6 Rod End, 1.22 inch head diameter, coarse threads Upper, attaches to pitch horn When installing, apply light coat of A257-2 or -22 oil to threads . ---21 FKF-813 or 27FKF-813 Nut, Special torque per § 23-33 . o,_______ Witness Hole Fine Length Adjustment -------< Rotate Barrel Assembly Only • One-half turn of barrel changes blade track 0 . 20 inch • One-half turn of barrel changes blade angle 0.20° Medium Length Adjustment ----- Rotate Lower Rod End Only • One- half turn of rod end changes blade track 0.25 inch • One- half turn of rod end changes blade angle 0.24° After any adjustment, verify rod end threaded shank blocks passage of 0 . 020-inch dia lockwire . ....,.,.....__ C258-6 Barrel Assembly ----Witness Hole After any adjustment, verify rod end threaded shank blocks passage of 0 . 020- i nch dia lockwire . AN316-6R Jam Nut, Standard torque per§ 23 - 32 . ....,.,.....__ 8330-19 Stamped Nut, Standard torque per§ 23-32 . D173-3 Rod End, 0.90 inch head diameter, fine thread Lower, attaches to swashplate When installing, apply light coat of A257-2 or -22 oil to threads.