R44 Maintenance Manual and Instructions for Continued Airworthiness

1.190 Bleeding Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8C 1.195 Lubrication of Swashplate Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8G 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 1.240 Fixed Ballast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 1.300 Fastener Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 1.400 Approved Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 FEB 2024 Chapter 1 General Page 1.i ROBINSON MAINTENANCE MANUAL R44 SERIES CHAPTER 1 GENERAL (Continued) Section Title Page 1.500 (Reserved) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 1.600 Part Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 1.700 Assembly Instructions for R44-series Helicopter Crated for Export . . . . . . . . . 1.14 Page 1.ii Chapter 1 General FEB 2024 ROBINSON MAINTENANCE MANUAL R44 SERIES CHAPTER 1 GENERAL 1.000 Introduction The R44 Maintenance Manual contains instructions necessary for proper maintenance, servicing, and handling of R44-series helicopters. The R44 Instructions for Continued Airworthiness (ICA) includes the R44 Maintenance Manual (MM), R44 Illustrated Parts Catalog (IPC), R44 Service Bulletins (SBs), R44 Service Letters (SLs), Lycoming O-540- series and IO-540-series 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. RHC Service Bulletin compliance is mandatory; comply with other applicable Service Bulletins as directed. RHC technical publications are available online at www.robinsonheli.com. Recent technical publications are available from Lycoming at www.lycoming.com, and from Continental Motors, Inc. (CMI) at www.continentalmotors. aero. Kit instructions are issued for field installation of either optional or mandatory (due to Service Bulletin or parts obsolescence) equipment upgrades, or provisions for upgrades. Kit instruction issued by RHC either implement approved type design data, or are approved as type design data. A list of chapters is located in the Introduction. Chapters are separated by tab dividers and chapter contents are listed in the chapter front pages. CAUTION Always read instructions completely before performing a task. 1.001 RHC Maintenance Manual and Illustrated Parts Catalog Updates RHC Maintenance Manuals (MMs) and Illustrated Parts Catalogs (IPCs) are available digitally at www.robinsonheli.com, under the Publications tab. Access to these publications does not require an account and is free of charge. Viewing MMs & IPCs online is recommended to ensure use of current data. Viewing MMs & IPCs offline via paper or digital download requires verification that the data is current. Refer to the online MM or IPC Revision Log for the list of current pages. Sign up for free email notification of revisions to MMs & IPCs by sending an email to subscriptions@robinsonheli.com with “Subscribe email” in the subject line. Within the email, include name, email address, physical address, and helicopter model(s) of interest. AUG 2022 Chapter 1 General Page 1.1 ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.2 Chapter 1 General AUG 2022 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 R44-series helicopters. 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/R44 Cadet Pilot’s Operating Handbook and applicable aviation regulations. 1.003 Component Maintenance Authorization Only appropriately certificated mechanics who have successfully completed both a factory- sponsored maintenance course and component maintenance course, and who possess technical data supplied by RHC, are authorized to perform maintenance specified in the Component Maintenance Manual (CMM). Component maintenance may only be performed at an RHC-authorized Service Center that has required Component Maintenance special tools (ref. R44 SL-67) and holds a Repair Station certificate (or foreign equivalent). 1.004 Maintenance Record Blank, digital Airframe Maintenance Record forms are available online at www.robinsonheli.com. 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 (P/N R8478 Airframe Maintenance Record and P/N R8479 Component Record [pack of 20]). 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. RHCs Repair Station does not require a Component Record card in order to perform work on a component, unlike a Component/Return Authorization form. 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 (P/N R8656 Maintenance Record Binder and P/N R8650 Maintenance Record Tabs). ROBINSON MAINTENANCE MANUAL R44 SERIES FEB 2024 Chapter 1 General Page 1.2A 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. 1.006 RHC Maintenance Manual and Illustrated Parts Catalog References Maintenance Manual and Illustrated Parts Catalog Section and Figure references are subject to relocation and renumeration. Effort will be made at the time of RHC technical document revisions to correct superseded references, however, certain documents may not otherwise require revision and superseded references may remain. A keyword or part number search in online documents (Ctrl+F [PC] or Command+F [Mac]) may help to locate applicable data. ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.2B Chapter 1 General FEB 2024 1.007 Definitions and Abbreviations Refer to R44/R44 II/R44 Cadet Pilot's Operating Handbook (POH) Section 1, as applicable, for additional definitions and abbreviations. A. Definitions 14 CFR § 27.602 Critical Part: C016-x main rotor blades & C029-x tail rotor blades are critical parts as defined by 14 CFR § 27.602 and are subject to special inspection requirements & reporting described in Chapters 28 & 30. Contact RHC Technical Support if questions arise concerning special inspection or reporting 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, – factory-issued authorized release certificate (FAA Form 8130-3, Airworthiness Approval Tag), or – last 12-year inspection. 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. Refer to § 16-20 for R44 datum location. Empty Weight: Standard empty weight of a standard helicopter including unusable fuel, full operating fluids, and full engine oil. Basic empty weight is standard empty weight plus weight of installed optional equipment. Refer to R44-series Type Certificate Data Sheet (TCDS) H11NM at: https://drs.faa.gov. Refer to helicopter’s Equipment List/Weight and Balance Data Sheet (RF 134) and Weight and Balance Record in R44/R44 II/R44 Cadet 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. ROBINSON MAINTENANCE MANUAL R44 SERIES FEB 2024 Chapter 1 General Page 1.3 1.007 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 Assy: Assembly (component consisting of more than one part) 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 EMU: Engine Monitoring Unit FS: Fuselage Station locations GPM: Gallons Per Minute HID: High Intensity Discharge HS: Horizontal Stabilizer Station locations ICA: Instructions for Continued Airworthiness LBL: Left Butt Line Station locations LED: Light Emitting Diode LH: Left-hand LRU: Line-Replaceable Unit MR: Main Rotor MRB: Main Rotor Blade MRDS: Main Rotor Drive Shaft MRGB or MGB: Main Rotor Gearbox or Main 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 R44 Cadet POH: R44 Cadet Pilot’s Operating Handbook RBL: Right Butt Line Station locations RH: Right-hand RHC: Robinson Helicopter Company RS: Rotor Station locations SB: Service Bulletin SDS: Safety Data Sheet SL: Service Letter TBO: Time Between Overhaul TCDS: Type Certificate Data Sheet TIR: Total Indicator Reading TR: Tail Rotor TRB: Tail Rotor Blade TRDS: Tail Rotor Drive Shaft TRGB or TGB: Tail Rotor Gearbox or Tail Gearbox TS: Tailcone Station locations TSN: Time Since New TSO: Time Since Overhaul WL: Water Line Station locations ROBINSON MAINTENANCE MANUAL R44 SERIES 1.008 Service Information A. Part Designation RHC parts are designated with an alphanumeric part number beginning with letter “A”, “B”, “C”, etc., followed by three digits and a dash number. A revision letter or letters follow(s) the stamped or ink-marked part number. Revision progression is A thru Z, followed by AA thru AZ, followed by BA thru BZ, etc. Unless otherwise specified, any revision of the same part number is interchangeable, such as “A101-1 A” and “A101-1 D”. A change in dash number indicates a change in form, fit, and/or function (e.g. part number C339-1 is not interchangeable with part number C339-10 even though both are jackshaft weldments for [hydraulic] R44s). Similarly, part numbers F049-6 and F049-06 are not interchangeable because the dash numbers are different. B. Returning Parts All parts shipped to RHC must include a signed Component Return/Authorization (CRA) Form available online at https://robinsonheli.com. C. Ordering and Shipping Procure parts from any R44 Dealer or Service Center, or order directly from assigned RHC Customer Service Representative via email, fax, or phone. D. Warranty Claims Complete CRA Form (refer to Part B) and, in the Warranty Claim section, indicate if rotorcraft or component is under warranty. If claim is for parts or for labor allowance due to a Service Bulletin issued against rotorcraft or component, write in “per SB-XX” adjacent to requested warranty action. E. Customer Support Please visit https://robinsonheli.com for Customer Support contact information. Page 1.3A Chapter 1 General FEB 2024 ROBINSON MAINTENANCE MANUAL R44 SERIES Intentionally Blank FEB 2024 Chapter 1 General Page 1.3B ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.3C Chapter 1 General FEB 2024 TABLE 1 SCHEDULED INSPECTIONS Consult latest revision of listed publications for specific applicability. First 10 hours First 25 hours First 100 hours Every 50 hours Every 100 hours Every 300 hours Every 500 hours Every 2200/2400 hours Every 4 months Every 12 months Every 24 months Every 3 years Every 5 years Every 12 years Every 15 years Perform inspection per Lycoming Operator’s Manual.* • • • • • Perform Lycoming SI 1129 Methods of Checking DC Alternator and Generator Belt Tension. • • Perform Lycoming SI 1191 Cylinder Compression. • Perform Lycoming SB 301* Maintenance Procedures and Service Limitations for Valves. • • Perform Lycoming SB 342 (IO-540 Only) Fuel Line (Stainless Steel Tube Assy.) and Support Clamp Inspection & Installation. Reference AD 2015-19-07. • Perform Lycoming SB 388* (also applies to replacement cylinders) Procedure to Determine Exhaust Valve and Guide Condition. • • Perform Lycoming SB 480 (and R44 SL-83, as applicable) I. Oil & Filter Change & Screen Cleaning / II. Oil Filter/Screen Content Inspection. NOTE: Oil filters on D723-1 adapters do not require safety wire. • • • Perform CMI SB 643, as applicable Maintenance Intervals for All CMI/TCM/Bendix Magnetos & Related Equipment. • • • Perform CMI SB 663 Two-Wire Magneto Tach. Breaker Contact (Points) Assy. P/N 10-400507. • • Perform 100-hour/annual inspection per § 2.400. • • Perform main rotor blade tip maintenance per § 28-60. • • 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. • Verify magneto (or EIS) drive cushion pliability (must tolerate 180° bend). • • Perform 2200-hour/2400-hour/12-Year inspection per § 2.600. • • Perform pressure relief valve leakage check per § 12-83. • Perform pop-out float leak check per § 5.630. • Perform pop-out float inflation check per § 5.640. • Perform pop-out float pressure cylinder hydrostatic test (per U.S. DOT-SP 10915). • Pop-out float pressure cylinder maximum life. • * Gray square indicates a shorter interval than published on referenced document. ROBINSON MAINTENANCE MANUAL R44 SERIES 1.100 Helicopter Servicing 1.101 Scheduled Inspections Required maintenance and inspection intervals are given in Table 1. Publications listed are subject to revision. Also consult the following for specific applicability, as some aircraft may require maintenance and inspections in addition to the requirements in Table 1: • Aircraft maintenance records • Manufacturers’ Service Bulletins (SBs) • Aviation regulations • Airworthiness Limitations • Airworthiness Directives (ADs) 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. NOTE If a component or an inspection is scheduled for hourly and calendar intervals, comply with whichever requirement comes first, then reset interval unless otherwise specified. AUG 2022 Chapter 1 General Page 1.3D ROBINSON MAINTENANCE MANUAL R44 SERIES 1.102 Additional Component Maintenance NOTE RHC-manufactured parts not listed in § 1.102 as requiring additional component maintenance, or replacement per § 3.300, are “on condition”. A. 12 YEARS Perform action indicated on the following components when they have accumulated 12 years calendar time and less than 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, since last overhaul, or since last 12-year maintenance: Part Number Description Action A120-3 Tail Rotor Bellcrank Assembly Replace with new. A130-48 Spacer Replace with new, per R44 SL-80. A190-3 V-Belt Set Replace with new. A336-6 or -9 Push-Pull Tube, Throttle (R44 II) Visually inspect. If exterior corrosion is evident, record length, disassemble, and inspect tube interior. Repair or replace as required. A462-4 Fitting (mixture control arm) Visually inspect. Replace if worn or corroded. A650-2 or -4 Fitting (MRGB mount) Visually inspect, including bore. Replace if worn or corroded. 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. A785-32 Hose (alternator cooling) 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 (bonded) Visually inspect with 10x magnification. Replace if any bonded washer evidences separation (8 places). Replace if corrosion is evident. Page 1.3E Chapter 1 General AUG 2022 ROBINSON MAINTENANCE MANUAL R44 SERIES 1.102 Additional Component Maintenance (continued) A. 12 YEARS (continued) Part Number Description Action B173-2, -3, or -6 V-Belt – Alternator Replace with new. B173-4 V-Belt – A/C Compressor Drive Replace with new. 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. B283-10 Hose Assembly (engine- driven pump to fuel control) Replace with new. B283-11 Hose Assembly (fuel return) Replace with new. C005-4 Main Rotor Hub (C154-1) & Bearing Assembly Perform inspection and repair per § 28-22, return to RHC for inspection and repair, or replace with new. C005-12 C016-7 Main Rotor Blade & C158-1 Spindle Assembly Submit to RHC-authorized component maintenance facility for 12-year service, or replace with new or overhaul exchange. 12-year maintenance includes blade replacement (as required), pitch horn screw replacement, boot and O-ring replacement, and inspection. C006-3, -6, or -8 Main Rotor Gearbox Assembly Submit to RHC Repair Station for 12-year service, or replace with new or overhaul exchange. 12-year maintenance includes pinion seal replacement, O-ring replacement, sealed bearing replacement, rubber mount replacement, and inspection. C007-5 Fanshaft Assembly Inspect C181-3 bearing per § 2.502 step 3. Lubricate per § 1.140. C008-4 Tail Rotor Assembly Replace with new C008-9 tail rotor assembly. C008-9 Tail Rotor Assembly Disassemble. Remove bushings and teeter hinge bearings. Inspect hub; verify no fretting or corrosion. Fluorescent penetrant inspect hub. Replace blades as required. Replace teeter hinge bearings and blade attach bolts. C011-2 & -3 Arm Assembly – Throttle (forward & aft, R44) Visually inspect. Replace with D756 if corrosion is evident. Verify bearing rotates smoothly without noise. C014-X Landing Gear Assembly Perform 12-year service per § 2.650 Part A. C015-1 Cabin Assembly Remove B270-1 sealant from aft-side of aluminum C259 panels at junction of steel horizontal firewall and inspect panels for corrosion. Repair as required. Replace sealant. C017-4 Swashplate Assembly Perform 12-year service per § 2.640, or replace with new or overhaul exchange C017-6 swashplate. SEP 2023 Chapter 1 General Page 1.3F ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.3G Chapter 1 General SEP 2023 1.102 Additional Component Maintenance (continued) A. 12 YEARS (continued) Part Number Description Action C017-6 Swashplate Assembly Perform 12-year service per § 2.640, or replace with new or overhaul exchange. 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) Submit to RHC-authorized component maintenance facility, or replace with new or overhaul exchange. 12-year maintenance includes plug, seal and O-ring replacement, C184 bearing lubrication, and inspection. C020-1 or -2 C020-1 (standard) or C020-2 (tie-down provisions) Upper Frame Assembly Visually inspect for corrosion. If corrosion is found, remove paint per § 23-71 and MPI per § 23-41. Powder coat per § 23-76 (preferred), or prime & paint per §§ 23-75 & 23-77. C021-1 Tail Rotor Gearbox Assembly Perform 12-year service per § 2.610, or replace with new or overhaul exchange. C031-1 Tail Rotor Pitch Control Replace with new. C041-11 Bearing Assembly – TRDS Damper Replace with new. C046-1, -19, -21, or -23 Lower Frame Assembly – LH Visually inspect for corrosion. If corrosion is found, 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 Visually inspect for corrosion. If corrosion is found, 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 Submit to RHC Repair Station for 12-year service, or replace with new or overhaul exchange. C119-2 Bumper – Tail Rotor Replace with new. C121-1, -3 or -30, -19, & -24 or -28 Push-Pull Tube Assembly – Main Rotor Visually inspect. If exterior corrosion is evident, record length, disassemble, and inspect tube interior. Repair or replace as required. C121-9, -15, & -17 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. C121-21 Push-Pull Tube Assembly – Throttle Visually inspect. If exterior corrosion is evident, record length, disassemble, and inspect tube interior. Repair or replace as required. C121-25 or -31 Push-Pull Tube Assembly – Swashplate Measure & record overall length. Remove rod ends and visually inspect, including tube interior. Replace if corrosion is evident. C169-3, -32, -36, or -38 Muffler Assembly Visually inspect muffler interior; verify no obvious damage and no loss of material. C174-1 Revision A thru F Support (engine mount at prop governor pad; constant 0.5-inch dia. vertical tube) Replace with new C174-1 Revision G or subsequent. ROBINSON MAINTENANCE MANUAL R44 SERIES 1.102 Additional Component Maintenance (continued) A. 12 YEARS (continued) Part Number Description Action C174-1 Revision G or subsequent Support (engine mount at prop governor; vertical tube lower portion is 0.562 inch dia.) Remove rod ends and visually inspect, including tube interiors. Replace if corrosion is evident. C258-1 Main Rotor Pitch Link Assembly Replace with new C258-5 link assembly. C258-5 Main Rotor Pitch Link Assembly Perform inspection per § 2.630, or replace with new. C315-9 Support Weldment – Lower Aft Flight Controls Visually inspect. If exterior corrosion is evident, remove and inspect tube interior. Repair or replace as required. C319-5 Torque Tube – Cyclic Visually inspect. If exterior corrosion is evident, remove and inspect tube interior. Repair or replace as required. C334-4 Bellcrank Assembly (Collective) Visually inspect. If exterior corrosion is evident, remove and inspect tube interior. Repair or replace as required. Verify bearings rotate smoothly without noise. C336-1 Push-Pull Tube Assembly, Throttle (R44) Visually inspect. If exterior corrosion is evident, record length, disassemble, and inspect tube interior. Repair or replace as required. 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. C343-8 Tube – Aft Servo Visually inspect. If exterior corrosion is evident, record length, disassemble, and inspect tube interior. Repair or replace as required. C348-1 Anchor Assembly – Collective Stop Visually inspect. If exterior corrosion is evident, remove and inspect tube interior. Repair or replace as required. 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. C608-1 Support Weldment – Throttle Bellcrank Visually inspect. If exterior corrosion is evident, remove and inspect tube interior. Repair or replace as required. 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. C792-4 or -5 Dual Tachometer Submit to RHC Repair Station for 12-year service, or replace with new or overhaul exchange. SEP 2023 Chapter 1 General Page 1.3H ROBINSON MAINTENANCE MANUAL R44 SERIES 1.102 Additional Component Maintenance (continued) A. 12 YEARS (continued) Part Number Description Action C907-1 or -2 Revision A thru G (weldment) Yoke – Clutch Shaft Forward (1.43-inch dia. center hole between arms) Replace with new C907-1 or -2 Revision H or subsequent yoke. C907-1 or -2 Revision H or sub- sequent (forging) Yoke – Clutch Shaft Forward (1.471-inch dia. bore) Visually inspect using 10x magnification for obvious damage; replace yoke if damaged. C918-15 Elastic Cord – Collective Replace with new A918-20 cord. C947-1 & -3 Flex Plate Assembly (bonded) Visually inspect with 10x magnification. Replace if corrosion is evident. Replace if any bonded washer evidences separation (8 places). D046-1 & -2 Strut Weldment – LH Visually inspect for corrosion. If light 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. D046-3 Strut Weldment – RH Visually inspect for corrosion. If light 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 with new D201-6 support assembly. Use NAS6604H16 bolt & NAS1149F0432P washer and safety wire (4 places) to secure servos. 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. Page 1.3I Chapter 1 General SEP 2023 ROBINSON MAINTENANCE MANUAL R44 SERIES SEP 2023 Chapter 1 General Page 1.3J 1.102 Additional Component Maintenance (continued) A. 12 YEARS (continued) Part Number Description Action D278-1 or -2 Governor Controller Submit to RHC Repair Station for 12-year service, or replace with new or overhaul exchange. D321-1 Valve – Pressure Relief (Fuel) Replace with new or overhaul exchange. 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 or overhaul exchange. 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 Jam Nut (MR pitch link, 2 each) Replace with new. ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.3K Chapter 1 General SEP 2023 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 as- sembly. 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. SEP 2023 Chapter 1 General Page 1.3L ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.3M Chapter 1 General SEP 2023 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 with new C174-1 Revision G or sub- sequent. C174-1 Revision G or subsequent Support (engine mount at prop governor; vertical tube lower portion is 0.562 inch dia.) Magnetic particle inspect support. 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 C258-5 link assembly. C258-5 Main Rotor Pitch Link Assembly Replace with new, 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. 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. C749-1 Nozzle Assembly (MRGB cooling) Replace with new. C792-4 or -5 Dual Tachometer Replace with new or overhaul exchange. ROBINSON MAINTENANCE MANUAL R44 SERIES 1.102 Additional Component Maintenance (continued) B. 2200/2400 Hours (continued) Part Number Description Action C907-1 or -2 Revision A thru G (weldment) Yoke – Clutch Shaft Forward (1.43-inch dia. center hole between arms) Replace with new C907-1 or -2 Revision H or subsequent yoke. C907-1 or -2 Revision H or sub- sequent (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: Liquid-strip paint using § 23-71 approved materials only. Visually inspect using 10x magnification for obvious damage; replace yoke if damaged or if cadmium plating is absent. Magnetic particle inspect per § 23-41. Chromate- epoxy prime, & topcoat non-clamping areas with white epoxy paint per § 23-60. 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. D201-5 Support Assembly – Hydraulic Servos (fwd) Replace with new D201-6 support assembly. Use NAS6604H16 bolt & NAS1149F0432P washer and safety wire (4 places) to secure servos. 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 or overhaul exchange. 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. SEP 2023 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 D730-8 Brace (fuel control) Replace with new. D735-1 Sleeve – Fuel Control Inlet Fitting (orange, insulated) Replace with new. 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 or overhaul exchange. 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. 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. Page 1.3O Chapter 1 General SEP 2023 ROBINSON MAINTENANCE MANUAL R44 SERIES Intentionally Blank AUG 2022 Chapter 1 General Page 1.3P 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 AUG 2022 ROBINSON MAINTENANCE MANUAL R44 SERIES ROBINSON MAINTENANCE MANUAL MOCEL R44 1 .120 Main Rotor Gearbox Drain and Flush (cont'd) 4. Drain oil by installing main rotor gearbox drain assembly in chip detector housing with drain hose overboard into a suitable container. Slide wedge under drain assembly to open valve (see Figure 1-2). 5. Remove drain assembly. Remove and discard safety wire securing gearbox filler plug. Remove plug. 6. Fill gearbox with SAE30, SAE40, SAE50, or SAE20W50 straight mineral engine oil to level indicated by decal adjacent to sight gage. 7. Install filler plug, tighten, but do not safety wire. 8. Ground run helicopter for approximately five minutes at 60-70% RPM. 9. After shutting down helicopter, drain gearbox using drain assembly. 10. Remove drain assembly. Remove and discard safety wire on chip detector housing. Remove chip detector housing and immediately place a small container under gearbox to catch any residual oil. 11. Clean chip detector with a toothbrush and cleaning solvent per Section 1.115. Compressed air or masking tape may also be used to remove debris but scrubbing with solvent is mandatory to remove any varnish accumulation. Do not use a magnet to remove debris. Clean and visually inspect chip detector housing. 12. Verify chip detector function by connecting electrical leads, turning Master switch on, and touching detector's central magnetic probe to horizontal firewall. MR CHIP warning light should illuminate. Disconnect electrical wires. 13. Install chip detector housing into main rotor gearbox. Torque per Section 1.330, and safety wire. 14. Install chip detector into chip detector housing. Torque threaded-type chip detector per Section 1 .330 and safety wire. Connect chip detector electrical wires and ty-rap. 15. As required, remove sight gage and clean with solvent. Reinstall sight gage, torque per Section 1.330, and safety wire. 16. Remove filler plug. Fill gearbox with Robinson A257-2 lubricant to level indicated on decal. Rotate rotor system by hand several revolutions and pull down tailcone several times. Recheck gearbox oil level. Adjust as necessary. 17. Torque filler plug per Section 1.330 (safety wire not required). Change 13: OCT 2006 Page 1.5 I I I I ROBINSON MAINTENANCE MANUAL MODEL R44 1 . 120 Main Rotor Gearbox Drain and Flush (cont'd) 18. Turn on MASTER switch. Check chip detector operation by grounding detector's center terminal and verifying MR CHIP warning light illuminates. Turn off MASTER switch. Page 1.6 87260 CHIP DETECTOR WEDGE MT054-1 DRAIN ASSEMBLY FOR 87260 "QUICK-RELEASE" CHIP DETECTOR OR MT053-1 MAIN ROTOR GEARBOX DRAIN ASSEMBLY FOR A7260 THREADED CHIP DETECTOR FIGURE 1-2 DRAINING MAIN ROTOR GEARBOX Change 13: OCT 2006 ROBINSON MAINTENANCE MANUAL MODEL R44 1.130 Tail Rotor Gearbox Drain and Flush 1. Ground run helicopter for approximately five minutes at 60-70% RPM to warm tail rotor gearbox oil. 2. Disconnect chip detector wiring at quick-disconnect located approximately 11 inches from chip detector. 3. Remove and discard safety wire securing chip detector to sight gage. 4. Place a container under tail rotor gearbox to catch oil and remove chip detector. 5. Remove and discard safety wire securing filler-vent plug to sight gage. Remove filler-vent plug. 6. Install chip detector, torque per Section 1.330, but do not safety wire. Add approximately five ounces of SAE30, SAE40, SAE50, or SAE20W50 straight mineral engine oil. 7. Install filler plug, tighten, but do not safety wire. 8. Ground run helicopter at 60-70% RPM for approximately five minutes. 9. After shutting down helicopter, remove chip detector and drain mineral oil. I I 10. Clean and scrub chip detector with a toothbrush and cleaning solvent. Compressed I air or masking tape may also be used to remove debris but scrubbing with solvent is mandatory to remove varnish accumulation. Do not use a magnet to remove debris. 11. Connect chip detector wiring. Turn on Master switch. Check chip detector operation by grounding detector's center terminal; TR CHIP warning light should illuminate. Turn off Master switch and disconnect chip detector wiring. 12. Install chip detector, torque per Section 1.330, and safety wire. Connect chip detector wiring and secure with Ty-raps® as required. 13. As required, remove sight gage and clean with solvent. Reinstall sight gage, torque I per Section 1.330, and safety wire. CAUTION Tail rotor gearbox sight plug glass must indicate correct oil level when aircraft is on level ground. 14. Fill gearbox with Robinson A25 7-2 lubricant to level indicated by sight glass decal. IInstall filler-vent plug, torque per Section 1.330, and safety wire. 15. Turn on Master switch. Check chip detector operation. Turn off Master switch. I Change 1 3: OCT 2006 Page 1.7 ROBINSON MAINTENANCE MANUAL MODEL R44 1 .140 Clutch Actuator Lower Bearing Lubrication NOTE Syringe suitable for the following procedure is included In kit Kl-115, available from RHC Customer Service. 1. Fill syringe with 4-5 grams of A25 7-12 grease (commercially available, see Section 1.4 70). Note: 5 grams of grease fills a 1 .0 inch (25 mm) long space inside a syringe body with a 0.63 inch ( 16 mm) inner diameter. 2. Remove screw from left side of C181-3 bearing housing. Screw may be covered by Telatemp; remove Telatemp as required to access screw. It is not necessary to replace Telatemp. Note: aft cowling may be rernoved to ease bearing access. 3. Using syringe, inject grease through screw hole. 4. Install B289-3 self-sealing cross-head screw, or thoroughly clean set screw and screw hole threads and then install set screw using B270-20 sealant, wet epoxy primer, or wet zinc-chromate primer on threads. Tighten set screw only until screw is flush with bearing housing. CAUTION Set screw hole is through to bearing housing cavity. Tightening set screw further than flush-with-housing can result in set screw contacting and damaging internal bearing assembly components. 5. Ground run helicopter at 102 % RPM for two minutes, shut down, inspect bearing, and clean off any escaped grease. 6. Install aft cowling, if removed. 1. 1 50 Defueling WARNING Defueling must be done in a well-ventilated area. No smoking within 100 feet of helicopter during defueling. NOTE Low-fuel sender check (see Section 12.270) may be performed when defueling helicopter. 1 . Turn fuel valve off and disconnect flexible fuel line at carburetor. 2. Place end of fuel line in a suitable container. Ground container to helicopter and turn fuel valve on. 3. Turn fuel valve off when the container is full and repeat as necessary to complete draining. 4. Attach fuel line to carburetor, torque per Section 1.330, and torque stripe. Page 1 .8 Change 14: JUL 2008 ROBINSON MAINTENANCE MANUAL MODEL R44 1 . 1 60 Storage For long-term (greater than 30 days) storage: 1. Defuel aircraft per Section 1. 150. 2. Clean aircraft per Section 8 of R44 Pilot's Operating Handbook. 3. Paint or wax bare metal areas of main and tail rotor blades. 4. Apply suitable non-drying corrosion preventative compound to C 166 clutch shaft adjacent to seals (where shaft enters and exits upper sheave). 5. Preserve engine in accordance with Lycoming Service Letter L 180 (current revision). 6. Remove battery and periodically check and adjust, as required, battery charge status. Check fluid level and specific gravity of non-sealed batteries. 7. Store aircraft in a protected, dry (dehumidified) environment. 8. Periodically inspect aircraft for corrosion and correct as required. 1. 170 Hydraulic Reservoir Filter Replacement CAUTION Cleanliness of hydraulic fluid is vital to proper system operation. Use only clean fluid from sealed containers and avoid contamination from dirty funnels, tubing, etc. 1. Remove and discard safety wire from filter cap. Remove filter cap from bottom of I hydraulic reservoir. 2. Remove filter and examine. If debris is found, use a magnet to determine if ferrous or non-ferrous. NOTE Ferrous debris may indicate pump damage. Replace filter again after one flight hour. If more ferrous debris is found, replace hydraulic pump per Section 8 and flush hydraulic system per Section 1 . 1 80. 3. Clean filter cap and replace O-ring packing. Lubricate new O-ring with A257-15 fluid (see Section 1.470). 4. Lubricate O-ring in new filter with A257-15 fluid and install filter in reservoir. Install filter cap, torque per Section 1.330, and safety wire. 5. Adjust reservoir fluid level as required. Install filler-vent and torque per Section 1 .330. Safety wiring filler-vent is not required. Change 1 3: OCT 2006 Page 1.8A ROBINSON MAINTENANCE MANUAL MOCEL R44 1 . 180 Draining and Flushing Hydraulic System (see Figure 8-1 A) CAUTION Cleanliness of hydraulic fluid is vital to proper system operation. Use only clean fluid from sealed containers and avoid contamination from dirty funnels, tubing, etc. NOTE Drain and flush hydraulic system if oil turns dark, or emits bad odor. 1 . Remove reservoir filler-vent. 2. Place a one-liter container for contaminated fluid beneath D500-1 hydraulic pump at main rotor gearbox. Remove caps from pump suction and pressure T-fittings. Allow fluid in reservoir to drain through suction line into container. Pour small amount of clean A257-15 fluid (see Section 1.4 70) into reservoir to purge suction line. Pressure line will drain in following step when filter cap is removed. 3. Replace hydraulic reservoir filter per Section 1. 170. 4. See Figure 1-2A. Connect MT384 (or similar) 0.8-1 .2 gpm hydraulic test pump to T- fittings on D500-1 pump. Fittings are different sizes to ensure correct connection. 5. Dispose of drained, contaminated hydraulic fluid. Fill reservoir with A257-15 fluid. 6. Disconnect servo return line at reservoir forward elbow and place end in empty container for contaminated hydraulic fluid. Cap elbow on reservoir assembly (use cap from pump T-f itting). 7. Activate hydraulic test pump and inspect hydraulic system for leakage. 8. Simultaneously fully raise collective and move cyclic fully forward. Then simultaneously fully lower collective and move cyclic fully aft. Monitor reservoir fluid level and fill as required. Repeat procedure until return line fluid into container is clean. WARNING Stay clear of moving flight controls. Hydraulic forces can cause injury. 9. Simultaneously fully raise collective and move cyclic fully aft then simultaneously fully lower collective and move cyclic fully forward. Monitor reservoir fluid level and fill as required. Repeat procedure until return line fluid into container is clean. 10. Connect servo return line to reservoir forward elbow. Torque B-nut per Section 1.330 and torque stripe. 11. Bleed hydraulic system per Section 1.190. 12. Remove and inspect filter. If debris is found, repeat drain and flush procedure. If filter is clean, reinstall per Section 1 .170, steps 4 & 5. Page 1.8B Change 13: OCT 2006 ROBINSON MAINTENANCE MANUAL MODELR44 1.190 Bleeding Hydraulic System (see Figure 1-2A) 1. Disconnect cap on D500-1 hydraulic pump pressure (aft) T-fitting and connect pressure line from MT384 hydraulic test pump (or similar 0.8-1.2 gpm unit). Pressure and suction fittings are different sizes to assure correct connection. 2. Remove reservoir filler-vent and cover hole with finger to prevent fluid loss. Disconnect cap on hydraulic pump suction (forward) T-fitting and connect hydraulic test pump suction line. Fill reservoir as required. 3. Activate hydraulic test pump and inspect for leakage. 4. Simultaneously fully raise collective and move cyclic fully forward then simultaneously fully lower collective and move cyclic fully aft. Repeat procedure ten times. WARNING Stay clear of moving flight controls. Hydraulic forces can cause InJury. 5. Simultaneously fully raise collective and move cyclic fully aft then simultaneously fully lower collective and move cyclic fully forward. Repeat procedure ten times. 6. Shut off hydraulic test pump. Verify no leaks in hydraulic system. 7. Cover reservoir filler-vent hole with finger to prevent fluid loss. Disconnect hydraulic test pump suction line from D500-1 pump forward T-fitting and install cap. Torque cap per Section 1.330 and torque stripe. 8. Disconnect hydraulic test pump pressure line from D500-1 pump aft T-fitting and install cap. Torque cap per Section 1.330 and torque stripe. 9. Adjust reservoir fluid level as required. Install filler-vent and torque per Section 1.330. Safety wire is not required. Change 10: JUL 2004 Page 1.8C ROBINSON MAINTENANCE MANUAL MODELR44 -.: ...... .. -- ,:•..l\' :> /&:~~ . .,(~~'°l!! ~..,f.• ,.,, ~ ·, .•· /~<~.;~?,~ :•.::~1 I ........ .·, ...... _ '.• !l I,,· .... ~ : . ., ~-· • "" ,. ..••·:·· "·•--,.. -... , ..... __,->. ~.l, -·· ... -. :, - -----~~J ....... " ... .. - D500-1 HYDRAULIC PUMP -\ MT384-1 (115 VAC, 60 Hz) or MT384-2 (208-230 VAC, 50 Hz} HYDRAULIC TEST PUMP -....;;;~~~~~=~~'l~ • I l) " PRESSURE "- FIGURE 1-2A MT384 HYDRAULIC TEST PUMP CONNECTION Page 1.8D Change 7: 06 Dec 99 Intentionally Blank DEC 2021 Chapter 1 General Page 1.8E ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.8F Chapter 1 General DEC 2021 FIGURE 1-2B C017-4 SWASHPLATE ASSEMBLY, AND C017-6 REV AA, AB, & AC SWASHPLATE ASSEMBLY, APPROVED B900-13 MODIFICATION ROBINSON MAINTENANCE MANUAL R44 SERIES C017-4 {16x NAS1352N08H8 Screw (shown) Swashplate 16x NAS620-8~ Washer (ref) assy only Torque 30 In.- lb (dry) (see text) Safety w i re w i th 0.020 inch wire. , - 1 Ox NAS 1 352N08H8 Screw (shown)} 1 Ox NAS620-8L Washer (ref) CO 1 7-4 Torque 30 in .- lb (dry) Swashplate Safety wire with 0.020 assy only inch w ire. -OR- 1 Ox NAS 1352N08-8 Scr ew (ref) } CO 17 -6 1 Ox NAS620-8L Washe r (ref) Rev AA, Torque 35 in .- lb wet AB, & AC w i th A257-9 ant i-se ize. Swashplate (Safety wire is not used on C017-6) assy only C647-12 Bearing set (ref) (inner race and outer race apex marks al igned and poi nt ing down) ',~ / C199-1 Upper swashp late (ref, C017-4 assy) C199-2 Upper swashp late (ref, C017-6 assy) I I I I II I I I 7C 198-2 Lower swashplate (ref, C017-4 assy) F1 98-1 Lower swashplate (ref, C017-6 assy) _J_==bh C217-1 Seal (ref) (0 . 040 inch th ick) Data plate (ref)