R66 MAINTENANCE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

servicing, and handling of the R66 helicopter. The R66 Instructions for Continued Airworthiness (ICA) includes the R66 Maintenance Manual (MM), R66 Illustrated Parts Catalog (IPC), R66 Service Bulletins (SB), R66 Service Letters (SL), RR300 Series Operation and Maintenance Manual (OMM), applicable Rolls-Royce technical publications, and applicable component manufacturer technical publications. Service Bulletins are issued by Robinson Helicopter Company (RHC), Rolls-Royce, 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. Rolls-Royce technical publications are available online at https://fast.aeromanager-online.com. 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 instructions issued by RHC either implement approved type design data, or are approved as type design data. The R66 Maintenance Manual is formatted in Air Transport Association of America Specification No. 100 (ATA-100). Style, content, and structure deviates from ATA-100 when necessary for clarity, and for logic of presentation. A list of chapters and a complete list of contents 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. 1-10 R66 Maintenance Manual Revisions Before using the R66 Maintenance Manual, verify it consists of current effective pages. The list of effective pages is located in the Revision Log in Chapter 100. When a new manual is purchased, complete and submit the Subscription Order Form available online at www.robinsonheli.com. Subscribers receive publication revisions for a two-year period. Renew subscriptions annually. The revision status for all RHC technical publications is available online at www.robinsonheli.com. APR 2019 Chapter 1 General Page 1.1 ROBINSON MAINTENANCE MANUAL R66 SERIES 1-20 R66 Maintenance Authorization Only appropriately certificated mechanics who have successfully completed an R66 factory-sponsored maintenance course, or are under direct supervision of the above- stated mechanic, are authorized to perform maintenance, repairs, or inspections on the R66 helicopter. Annual inspections of U.S.-registered light helicopters must be performed by holders of an Inspection Authorization (IA) certificate 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 R66 Pilot’s Operating Handbook and applicable aviation regulations. 1-30 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 special tools. 1-40 Maintenance Record The Airframe Maintenance Record is 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. RHC’s Repair Station does not require a Component Record card in order to perform work on a component, unlike a Component/Return Authorization form. 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). Page 1.2 Chapter 1 General APR 2019 ROBINSON MAINTENANCE MANUAL R66 SERIES 1-50 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. 1-55 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. JUL 2023 Chapter 1 General Page 1.3 ROBINSON MAINTENANCE MANUAL MODEL R66 Page 1.4 Chapter 1 General JUL 2023 1-60 Definitions and Abbreviations Refer to R66 Pilot's Operating Handbook (POH) Section 1 for additional definitions and abbreviations. A. Definitions 14 CFR § 27.602 Critical Part: F016-2 main rotor blades & F029-1 tail rotor blades are critical parts as defined by 14 CFR § 27.602 and are subject to special inspection requirements & reporting described in Chapters 62 & 64. 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 § 6-20 for R66 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 R66 Type Certificate Data Sheet (TCDS) R00015LA at: https://drs.faa.gov. Refer to helicopter's Equipment List/Weight and Balance Data Sheet (RF 134) and Weight and Balance Record in R66 POH Section 6 for installed equipment. Life-Limited Part: Refer to § 4-10. 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 MODEL R66 1-60 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 two parts) ATA-100: Air Transport Association of America Specification No. 100 BL: Butt Line Station locations CRA: Component Return/Authorization ELT: Emergency Locator Transmitter EMU: Engine Monitoring Unit FCU: Fuel Control Unit FS: Fuselage Station locations GCU: Generator Control Unit 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 PTG: Power Turbine Governor R66 IPC: R66 Illustrated Parts Catalog R66 MM: R66 Maintenance Manual R66 POH: R66 Pilot’s Operating Handbook RBL: Right Butt Line Station locations RH: Right-hand RHC: Robinson Helicopter Company RR300 Series OMM: Rolls-Royce RR300 Series Operation and Maintenance Manual 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 JUL 2023 Chapter 1 General Page 1.4A ROBINSON MAINTENANCE MANUAL MODEL R66 Page 1.4B Chapter 1 General JUL 2023 1-70 Service Information 1-71 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. 1-72 Returning Parts All parts shipped to RHC must include a signed Component Return/Authorization (CRA) Form available online at https://robinsonheli.com. 1-73 Ordering and Shipping Procure parts from any R66 Dealer or Service Center, or order directly from assigned RHC Customer Service Representative via email, fax, or phone. 1-74 Warranty Claims Complete CRA Form (refer to § 1-72) 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. 1-75 Customer Support Please visit https://robinsonheli.com for Customer Support contact information. ROBINSON MAINTENANCE MANUAL MODEL R66 1-80 Assembly Instructions for R66 Helicopter Crated for Export NOTE Aircraft assembly to be performed by a certificated mechanic. 1. Remove top of cabin assembly crate. Remove wall marked “A” by removing lag bolts painted black. Remove empennage assembly. Remove remaining walls. Remove all parts, except cabin assembly, from crate base. Open crate containing blades, skid tubes, and tailcone. 2. Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1. Install hardware securing forward and aft strut assemblies (cross tubes installed) onto skid tubes. Standard torque bolts per Section 20-32 and torque stripe per Figure 5-1. 3. Remove tailcone cowling per Section 53-23. Remove engine cowling per Section 53-21. 4. Remove shipping supports (ty-raps, foam, tape, etc.) from main rotor gearbox compartment, but leave cannon plugs taped and fluid line dust caps installed. Remove engine air intake cover by opening air filter bypass door and pulling string and cover through the door. Remove main rotor gearbox mounting hardware, nylon spacers, and upper frame strut assemblies. 5. Remove top of main rotor gearbox crate and position crate so gearbox is upright. Refer to Section 7-20. Install hoisting equipment and lifting fixture or nylon rope on main rotor hub. Remove hoist slack to support gearbox, remove lag bolts securing gearbox to wooden divider, and carefully hoist gearbox from crate (do not damage pitot tube). 6. Install main rotor gearbox per Section 63-20 steps 1 thru 9, but do not remove hoisting equipment and lifting fixture or nylon rope. 7. Perform (engine driveline) forward flex plate shimming per Section 63-11. 8. Refer to Section 7-20. Remove hoist slack to support cabin assembly, remove lag and carriage bolts securing metal angles to crate, and hoist cabin & attached metal angles off of crate base. CAUTION Do not lift helicopter and attached crate using main rotor hub; damage to main rotor gearbox and frames could result. 9. Remove metal angles from cabin assembly landing gear attach points. Install landing gear assembly per Section 32-10. SEP 2012 R66 Maintenance Manual Chapter 1 General Page 1.5 ROBINSON MAINTENANCE MANUAL MODEL RBS Page 1.6 Chapter 1 General R66 Maintenance Manual SEP 2012 FIGURE 1-1 ASSEMBLY INSTRUCTIONS FOR R66 HELICOPTER CRATED FOR EXPORT FIGURE 1-2 ASSEMBLY INSTRUCTIONS FOR R66 HELICOPTER CRATED FOR EXPORT ROBINSON MAINTENANCE MANUAL -~ I Comp assembly (Ref )~/ t I '/ MODEL R66 FORWARD 1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued) 10. For air-conditioned ships: a. Refer to Figure 1-1. Remove shipping supports (ty-raps, foam, tape, etc.) from G777-1 compressor assembly. Install hardware securing G782-1 mount weldment to main rotor gearbox. Standard torque hardware per § 20-32 and torque stripe per Figure 5-1. Hook B774-3 spring in drilled hole of NAS1352-4H14 screw. Verify security. b. Refer to Figures 1-1 and 1-2. Verify B173-5 V-belt is in good condition. Fit belt around G779-1 pulley and compressor pulley, and install hardware securing compressor to G782-1 mount weldment. Standard torque bolts per § 20-32. c. Refer to Figure 1-2. Install hardware securing compressor to G781-1 arm weldment. Rotate compressor up and outboard to tension belt, then tighten hardware securing compressor to weldment. Verify belt is properly aligned on both pulleys. Adjust belt tension until 4.5-5.5 lb of force applied mid-span deflects belt 0.16-inch. Standard torque bolts per § 20-32. d. Connect compressor assembly wiring to airframe harness at connectors and install ty-raps as required. Cinch ty-raps until snug without over-tightening, and trim tips flush with heads. 11. Refer to IPC Figure 79-1. Remove F237-1 tailcone frame weldment and F305-5 (aft) inlet. Install tail rotor drive fan shaft (fanwheel installed) through scroll assembly. Install hardware securing aft inlet to scroll assembly. Verify security. 12. Refer to IPC Figure 65-1. Install hardware securing C947-3 plate assembly to F908-1 yoke and tail rotor drive fan shaft. Standard torque bolts and palnuts per § 20-32 and torque stripe per Figure 5-1. 13. Remove shipping supports (ty-raps, foam, tape, etc.) from tailcone assembly, and install tailcone per § 53-40 steps 1 thru 7. Install strobe light. Install communication and GPS antennas (if equipped). 14. Install empennage assembly per § 53-70. Install horizontal stabilizer assemblies per §§ 53-60 & 53-80. 15. Service tail rotor gearbox per § 12-21. Service main rotor gearbox per § 12-11. 16. Remove hydraulic reservoir shipping plug. Install D487-3 vent assembly, special torque vent to 100 in.-lb, and torque stripe per § Figure 5-1 (do not safety wire). 17. Install tail rotor assembly per § 64-10. Match color-coded markings on blades with pitch links. 18. Install main rotor blades per § 62-10. Match color-coded markings on blades with markings on hub and pitch links. 19. Inside engine compartment, remove anti-ice valve cap, starter-generator cap, inducer bleed hose cover, exhaust pipe cover and desiccant, and combustion case drain valve cap. Connect inducer bleed hose to box assembly and tighten clamp. Verify security. SEP 2023 Chapter 1 General Page 1.7 ROBINSON MAINTENANCE MANUAL MODEL R66 1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued) 20. If ship is equipped with attitude horizon, directional gyro, turn coordinator, and/or vertical card magnetic compass: A. Attitude Horizon, Directional Gyro, and Turn Coordinator Installation CAUTION Directional gyro mount screws must not exceed 1-inch in length. 1. Place a piece of foam under instrument face. Remove (6) screws securing face to console and gently pull face forward. Remove hardware securing instrument hole covers to face and remove covers. Install instruments and secure to face with hardware provided. 2. Connect straight connector(s) to directional gyro and/or turn coordinator. Connect angle connector to attitude horizon, ensuring strain relief points down. Ensure connectors lock. Ty-rap excess wiring. Install screws securing instrument face to console. B. Vertical Card Magnetic Compass Installation 1. Locate airframe wiring (in windshield center bow), install 2-inch length of B158-3 heat shrink over wiring, and connect compass pins to airframe sockets (polarity is not critical). Slide heat shrink over connection and apply heat. Install (4) screws securing compass to mount, securing wiring atop compass. 21. Connect battery per § 96-10. NOTE Check battery open circuit voltage and perform boost charging or capacity tests as required per Concorde Battery Instructions for Continued Airworthiness. 22. Perform pitot-static leak check per § 95-10. 23. Install Emergency Locator Transmitter (ELT) per § 25-61, as required. Install tailcone cowling assembly per § 53-23. 24. Install fire extinguisher per § 25-62, as required. 25. Fuel helicopter per § 12-41. 26. Verify all shipping supports (ty-raps, foam, tape etc.) have been removed from helicopter. Refer to § 6-70. Secure access panels and inspection doors. NOTE Flight checks to be performed by a qualified pilot and certificated mechanic. 27. Perform ground check per § 5-41 steps 2 thru 9. Page 1.8 Chapter 1 General SEP 2023 ROBINSON MAINTENANCE MANUAL MODEL R66 1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued) 28. Depreserve the engine after storage per RR300 Series Operation and Maintenance Manual (OMM). Install starter-generator cooling hose. Install engine cowling per § 53-21. 29. Install tail rotor dynamic balance equipment per § 18-21. 30. Perform run-up per § 5-42 steps 2 thru 16. 31. Perform tail rotor dynamic balance per § 18-20. 32. Remove tail rotor dynamic balance equipment. Install main rotor balance equipment per § 18-11. CAUTION Mast fairing, cowlings, and panels must be installed for flight. 33. Perform hover checks per § 5-43 step 1. DO NOT proceed into forward flight. 34. Track and balance main rotor per § 18-12. 35. While climbing at maximum continuous torque, 60 KIAS: a. Evaluate vibration level and controllability. b. Perform momentary 30° left yaw to check for adequate directional control. 36. Level flight at typical cruise altitude (deviate as required for weather and terrain), maximum continuous torque: a. Evaluate longitudinal and lateral cyclic control forces. b. Evaluate collective control forces. 37. Evaluate vibration level at maximum continuous torque and straight-and-level flight. 38. During autorotation at 50 KIAS and 90% rotor RPM, perform momentary 30° right yaw to check for adequate directional control. 39. Check all instruments, gages, and avionics for proper operation. MAR 2025 Chapter 1 General Page 1.9 ROBINSON MAINTENANCE MANUAL MODEL R66 TABLE 1 SCHEDULED MAINTENANCE, DEFAULT*** Consult latest revision of listed publications for specific applicability. First 100 Hours* 100 Hours** 200 Hours** 300 Hours** 400 Hours** 600 Hours** 1000 Hours** 2000 Hours** 12 Months** 24 Months** 5 Years** 6 Years** 12 Years** 15 Years** 3000 Cycles** Replace main gearbox oil filter per § 12-12. • • Perform 100-hour / annual inspection per § 5-45. • • Perform main rotor blade tip maintenance per § 62-60. • As required by RR300 Series Operation and Maintenance Manual (OMM), perform maintenance and inspection. • • • • • Service inlet barrier filter per § 71-21. • • Replace both 9v back-up batteries under LH front seat (ships with Lithium-ion main battery only). • Replace main gearbox oil per § 12-11. • Drain and flush tail rotor gearbox per § 12-23. • Replace hydraulic filter per § 12-32. • Clean gearbox chip detectors per § 12-13 & 12-22. • • Lubricate swashplate bearings per § 12-90. • • Perform 2000-hour/12-year inspection per § 5-50. • • Perform main gearbox internal visual inspection per § 5-74. • Perform pop-out float leak check per § 32-64 Part A. • Replace cockpit camera battery per § 96-120 Part C. • Test and inspect transponder per 14 CFR § 91.413. (U.S.-registered helicopters only). • Perform pop-out float inflation check per § 32-64 Part B. • Perform pop-out float pressure cylinder hydrostatic test (per U.S. DOT-SP 10915). • Pop-out float pressure cylinder maximum life. • * One-time maintenance after new or overhauled main rotor gearbox is installed. ** Recurring inspection. *** Helicopters on a Part 91 Approved Inspection Program (AIP), a Part 135 Approved Aircraft Inspection Program (AAIP), or an equivalent foreign-approved inspection program, must refer to & comply with that program. Refer to current revisions of FAA Advisory Circulars 91-90 & 135-10. Page 1.10 Chapter 1 General MAR 2025 ROBINSON MAINTENANCE MANUAL MODEL R66 1-90 Helicopter Servicing 1-91 Scheduled Maintenance and 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 as allowed by RHC. JUL 2020 Chapter 1 General Page 1.11 ROBINSON MAINTENANCE MANUAL MODEL R66 1-92 Additional Component Maintenance NOTE RHC-manufactured parts not listed in § 1-92 as requiring additional component maintenance, or replacement per § 4-30, are "on condition". A. 12 YEARS Remove the following components when they have accumulated 12 years time in service and less than 2000 hours time in service since new, since last overhaul, or since last 12-year maintenance, and perform action indicated: Part Number Description Action A120-5 Bellcrank – Aft Replace with new. A785-36 Hose (engine gearbox vent; earlier ships) Install KI-258 Firewall Drain Tube Upgrade Kit. A785-37 Hose (inducer bleed) Replace with new. A785-38 Hose (starter-generator) Replace with new. A918-1 thru -8, -19, & -20 Elastic Cord Assembly Replace with new. Dash number is selected during flight test evaluation. B173-5 V-Belt – Compressor Drive (cabin air conditioning) Replace with new. C005-4 Main Rotor Hub (C154-1) & Bearing Assembly Perform inspection and repair per § 62-22, return to RHC for inspection and repair, or replace with new. C005-13 Main Rotor Blade and Spindle Assembly Submit to RHC-authorized component maintenance facility for 12-year maintenance, or replace with new or overhaul exchange. 12-year maintenance includes blade replacement, boot and o-ring replacement, spindle bearing replacement (as required), pitch horn screw replacement (as required), boot and o-ring replacement, and inspection. C008-10 Tail Rotor Assembly Replace with new. C017-6 Swashplate Assembly Perform 12-year inspection per § 5-52, or replace with new or overhaul exchange. C021-1 Tail Rotor Gearbox Assembly Replace input seal & o-ring, and output seal & o-ring, per § 65-40. During seal replacement, visually inspect exposed portion of bearings for corrosion; replace gearbox if corrosion is evident. C031-1 Tail Rotor Pitch Control Replace with new. C258-1 Main Rotor Pitch Link Assembly Replace with new C258-5 link assembly. C258-5 Main Rotor Pitch Link Assembly Perform inspection per § 5-51, or replace with new. Page 1.12 Chapter 1 General JUL 2020 ROBINSON MAINTENANCE MANUAL MODEL R66 1-92 Additional Component Maintenance (continued) A. 12 YEARS (continued) Part Number Description Action C343-8 Tube Disassemble and visually inspect exterior and interior. Verify no corrosion. D211-3 Hydraulic Reservoir Assembly Perform 12-year inspection per § 5-54, or replace with new or overhaul exchange. D212-5, -6 Hydraulic Servo Assembly Perform inspection per § 29-30 Part C. D918-1 Elastic Cord – Longitudinal (cyclic pivot) Replace with new. D918-2 Elastic Cord – Lateral (cyclic pivot) Replace with new. D918-3 Elastic Cord – (collective) Replace with new. F006-1, -6 Main Rotor Gearbox Assembly Submit to RHC for 12-year maintenance, or replace with new or overhaul exchange. 12-year maintenance includes seal replacement, o-ring replacement, sealed bearing replacement, rubber mount replacement, R66 SL-11 upgrade (as applicable), and inspection. F014 Landing Gear Assembly Perform 12-year inspection per § 5-53, or replace with new. F018-1 Clutch Assembly (Revision C & prior) Replace with new or overhaul exchange clutch assembly. F018-1 Clutch Assembly (Revision D & subsequent) Submit to RHC for 12-year maintenance, or replace with new or overhaul exchange. 12-year maintenance includes seal replacement, o-ring replacement, and inspection. F121-3, -5, & -7 Push-Pull Tube Assembly Disassemble and visually inspect exterior and interior. Verify no corrosion. F579-1 Engine Air Bellmouth Replace with new. F642-6 Engine Shaft Weldment Replace with new F642-7 weldment. F650-1, -2 Main Gearbox Mounting Bolts Visually inspect exterior and interior. Verify no corrosion. F651-2 Element – Main Gearbox Filter Replace with new. F651-3 Seal Kit – Main Gearbox Filter Replace with new. F771-1 Filter – Engine Air Intake (foam, standard) Replace with new. F771-4 Filter – Starter-Generator (cooling air) Replace with new. F771-7 Filter – G918-1 Box Assembly Replace with new. F792-1 Dual Tachometer Perform accuracy check per § 95-23 Part D. G201-1 Frame, Servo Support Remove B163-2 rod end. Visually inspect exterior and interior. Verify no corrosion. JUL 2020 Chapter 1 General Page 1.13 ROBINSON MAINTENANCE MANUAL MODEL R66 Page 1.14 Chapter 1 General JUL 2020 1-92 Additional Component Maintenance (continued) B. 2000 HOURS Remove the following components when they have accumulated 2000 hours time in service since new or since last overhaul, and perform action indicated: Part Number Description Action A120-5 Bellcrank – Aft Replace with new. A130-48 Spacer (at A462-4 fittings) Replace with new. A215-015 O-Ring (rollover valves) Replace with new. A462-4 Fitting – Control Cable Replace with new. A522-10 Control Cable (FCU fuel cutoff) Replace with new, or replace inner wire. A522-11 Control Cable (fuel valve) Replace with new, or replace inner wire. A522-14 Control Cable (heater valve) Replace with new, or replace inner wire. A729-68 Tube (black, earlier ships; used with G727-1 engine gearbox vent tube) Replace with new. A785-36 Hose (engine gearbox vent; earlier ships) Install KI-258 Firewall Drain Tube Upgrade Kit. A785-37 Hose (inducer bleed) Replace with new. A785-38 Hose (starter-generator) Replace with new. A918-1 thru -8, -19, or -20 Elastic Cord Assembly Replace with new. Dash number is selected during flight test evaluation. A947-2 Flex Plate Assembly (engine driveline) Replace with new. B173-5 V-Belt – Compressor Drive (cabin air conditioning) Replace with new. B277-32 Clamp (inducer bleed hose, at engine) Replace with new. C005-4 Main Rotor Hub (C154-1) & Bearing Assembly Replace with new. C005-13 Main Rotor Blade and Spindle Assembly Replace with new or overhaul exchange C005-13 main rotor blade and spindle assembly. C008-10 Tail Rotor Assembly Replace with new. C017-6 Swashplate Assembly Submit to RHC-authorized component maintenance facility for overhaul, or replace with new or overhaul exchange. C021-1 Tail Rotor Gearbox Assembly Replace with new or overhaul exchange tail rotor gearbox assembly. C031-1 Tail Rotor Pitch Control Replace with new. C119-2 Bumper – Tail Rotor 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 § 5-51 and magnetic particle inspect barrel. C522-10 Control Cable (FCU throttle) Replace with new. C522-11 Control Cable (PTG) Replace with new. ROBINSON MAINTENANCE MANUAL MODEL R66 MAR 2025 Chapter 1 General Page 1.15 1-92 Additional Component Maintenance (continued) B. 2000 HOURS (continued) Part Number Description Action C649-4 Oil Cooler (main rotor gearbox oil) Replace with new, or overhaul oil cooler. C947-3 Flex Plate Assembly (tail rotor driveline) Replace with new. D082-1 Tube Assembly (tail rotor guard mount) Magnetic particle inspect or replace with new. D211-3 Hydraulic Reservoir Assembly Replace with new or overhaul exchange reservoir assembly. D212-5 Hydraulic Servo Assembly Replace with new or overhaul exchange servo assembly. D212-6 Hydraulic Servo Assembly Replace with new or overhaul exchange servo assembly. D224-3 and -4 Tail Rotor Drive Shaft (D196-1) Assembly Refer to § 4-30. Replace with new D224-4 tail rotor drive shaft assembly, if required. D333-13 Fitting (PTG) Replace with new. D500-2 Hydraulic Pump Assembly Replace with new or overhaul exchange pump assembly. D500-3 Main Rotor Gearbox Oil Pump Assembly Replace with new or overhaul exchange pump assembly. D918-1 Elastic Cord – Longitudinal (cyclic pivot) Replace with new. D918-2 Elastic Cord – Lateral (cyclic pivot) Replace with new. D918-3 Elastic Cord – (collective) Replace with new. D930-2 Spring – Safety (FCU throttle input) Replace with new. F006-1, -6 Main Rotor Gearbox Assembly Refer to § 4-30. Replace with new or overhaul exchange F006-1 or F006-6 gearbox assembly, as required. F018-1 Clutch Assembly Replace with new or overhaul exchange clutch assembly. F101-4 Rod End, Elastomeric Replace with new. F170-1, -2 Fitting (engine gearbox vent) Replace with new F170-2 fitting. F173-1 Strut (exhaust weldment support) Replace with new. F453-5 Retainer (at firewall seal) Replace with new. F579-1 Engine Air Bellmouth Replace with new. F597-1 Seal – Firewall Replace with new. F642-6, -7 Engine Shaft Weldment Replace with new F642-7 weldment. F649-1 Oil Cooler (engine oil) Replace with new, or overhaul oil cooler. F651-2 Element – Main Gearbox Filter Replace with new. F651-3 Seal Kit – Main Gearbox Filter Replace with new. F771-1 Filter – Engine Air Intake (foam, standard) Replace with new. F771-4 Filter – Starter-Generator (cooling air) Replace with new. ROBINSON MAINTENANCE MANUAL MODEL R66 1-92 Additional Component Maintenance (continued) B. 2000 HOURS (continued) Part Number Description Action F771-7 Filter – G918-1 Box Assembly Replace with new. F792-1 or -2 Dual Tachometer Replace with new. G732-2 Cap (with C130-62 spacer) Replace with G732-3 cap. A880-908 or AN815-8D Union – Engine Oil Outlet (replaces CV26-77 check valve on helicopter S/N 0222 and prior) Replace with new. A880-908 or AN815-8D Union – Oil Tank Vent (at engine) Replace with new. A880-910 or AN815-10D Union – Engine Oil Inlet Replace with new. MS16562-4 Spring Pin (at D333-13 fitting on PTG lever) Replace with new. MS29512-10 Packing (left rollover valve) Replace with new. NAS1149E0363R Washer (at A462-4 fittings) Replace with new. NAS557-32A Grommet – Firewall (engine drive shaft weldment) Replace with new. NAS6604-67 Bolt (clutch assembly) Replace with new. Page 1.16 Chapter 1 General MAR 2025 ROBINSON MAINTENANCE MANUAL MODEL R66 1-92 Additional Component Maintenance (continued) C. Engine Maintenance Refer to RR300 Operation and Maintenance Manual (OMM) for engine maintenance. Prepare engine for Rolls-Royce maintenance facility per § 71-11 as required. D. Airframe and Engine Accessory Maintenance Refer to accessory manufacturer’s instructions for continued airworthiness for accessory maintenance. Remove accessories per R66 Maintenance Manual or RR300 Operation and Maintenance Manual (OMM) as applicable. JUL 2020 Chapter 1 General Page 1.17 ROBINSON MAINTENANCE MANUAL MODEL R66 Intentionally Blank Page 1.18 Chapter 1 General JUL 2020 ROBINSON MAINTENANCE MANUAL MODEL R66 CHAPTER 4 AIRWORTHINESS LIMITATIONS Section Title Page 4-10 Life-Limited Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4-11 Time-in-Service Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4-12 Fatigue Life-Limited Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 4-20 Type Certificate Data Sheet (TCDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 4-30 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 SEP 2023 Chapter 4 Airworthiness Limitations Page 4.i ROBINSON MAINTENANCE MANUAL MODEL R66 Intentionally Blank Page 4.ii Chapter 4 Airworthiness Limitations SEP 2023 ROBINSON MAINTENANCE MANUAL MODEL R66 CHAPTER 4 AIRWORTHINESS LIMITATIONS 4-10 Life-Limited Components 4-11 Time-In-Service Records It is the operator’s responsibility to maintain a record of time in service for the engine, airframe, and all life-limited components, as well as the number of start cycles for the engine. Two hourmeters are provided: the hourmeter on the console records all run time including ground idle and is provided for reference. The hourmeter located outboard of the pilot's seat is collective-activated and records run time only when the collective is raised off the down stop. Both hourmeters are connected to main rotor gearbox oil- pressure switch. The collective-activated hourmeter may be used to determine time in service for maintenance purposes, including time in service for all life-limited components. Calendar time in service for the airframe and engine begins on the date of the original RHC- issued Export (or Standard) Certificate of Airworthiness for the helicopter. For spares without a storage limit specified in § 10-20, calendar time in service begins on the date of the RHC-issued Airworthiness Approval Tag (Authorized Release Certificate) issued with the invoice. 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. Engine life is limited by engine time in service and accumulated start cycles. The engine is equipped with an electronic Engine Monitoring Unit (EMU), which may be used to verify time in service and accumulated start cycles. An official, independent record of start cycles must be maintained by the operator. When installing a life-limited part or a part with an overhaul requirement, record in the helicopter maintenance record the installation date, part number, part name, serial number, helicopter total time, and time in service accumulated by part since new or since last overhaul, as applicable. WARNING Components with mandatory overhaul times or life-limits whose time in service is not reliably documented cannot be considered airworthy and must be removed from service. JUL 2023 Chapter 4 Airworthiness Limitations Page 4.1 ROBINSON MAINTENANCE MANUAL MODEL R66 4-12 Fatigue Life-Limited Parts The Airworthiness Limitations Section (ref. § 4-30) lists the mandatory replacement schedule for fatigue life-limited parts. If a part is fatigue life-limited or has a mandatory overhaul requirement and is interchanged between an R44 and an R66 helicopter, and if the part life-limit or overhaul requirement is different between an R44 and an R66 helicopter, the shorter life-limit or overhaul requirement must be used. If a part is fatigue life-limited or has a mandatory overhaul requirement, and the accumulated cycles and/or time in service are known but the helicopter type is unknown, the shorter life-limit or overhaul requirement must be used. Listed items (ref. § 4-30) must be removed from the helicopter at the specified intervals and permanently retired from service, preferably by destroying or damaging each part so it cannot inadvertently be returned to service. 4-20 Type Certificate Data Sheet (TCDS) TCDS R00015LA is available at FAA Dynamic Regulatory System website: https://drs.faa.gov. Page 4.2 Chapter 4 Airworthiness Limitations JUL 2023 ROBINSON MAINTENANCE MANUAL MODEL R66 SEP 2024 Chapter 4 Airworthiness Limitations Page 4.3 4-30 Airworthiness Limitations The Airworthiness Limitations Section is FAA approved and specifies inspections and other maintenance required under 14 CFR §§ 43.16 and 91.403, unless an alternative program has been FAA approved. R66 Fatigue Life-Limited Parts Part Number Description Maximum Service Life C023-21, -24, -34, & -35 . . . Tailcone Assembly, Rev AV & Prior . . . . . . . . . . 2000 Hours C044-1 & -2 . . . . . . . . . . . . . Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . . 2000 Hours C154-1 . . . . . . . . . . . . . . . . Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . 2000 Hours C158-1 . . . . . . . . . . . . . . . . Main Rotor Spindle . . . . . . . . . . . . . . . . . . . . . . 2000 Hours C251-3 . . . . . . . . . . . . . . . . Main Rotor Shaft, Rev T & Prior . . . . . . . . . . . . . 2000 Hours C545-1 . . . . . . . . . . . . . . . . Gear Set, Tail Gearbox . . . . . . . . . . . . . . . . . . . 2000 Hours C545-2 . . . . . . . . . . . . . . . . Pinion, Tail Gearbox . . . . . . . . . . . . . . . . . . . . . 2000 Hours C647-12 . . . . . . . . . . . . . . . . . Bearing Set, Swashplate . . . . . . . . . . . . . . . . . . 2000 Hours D079-1 . . . . . . . . . . . . . . . . Tail Rotor Guard, Rev P & Prior . . . . . . . . . . . . . 2000 Hours D196-1 . . . . . . . . . . . . . . . . Tail Rotor Drive Shaft, Rev H & Prior . . . . . . . . . 2000 Hours F016-2 . . . . . . . . . . . . . . . . . Main Rotor Blade, Rev J & Prior . . . . . . . . . . . . . 2000 Hours or 12 years1 F016-2 . . . . . . . . . . . . . . . . . Main Rotor Blade, Rev K & Subsequent . . . . . . . 2000 Hours or 15 years1 F020-1 . . . . . . . . . . . . . . . . . Upper Frame, Rev G & Prior . . . . . . . . . . . . . . . . 2000 Hours F029-1 . . . . . . . . . . . . . . . . . Tail Rotor Blade, Rev H & Prior . . . . . . . . . . . . . 2000 Hours or 12 years1 F029-1 . . . . . . . . . . . . . . . . . Tail Rotor Blade, Rev I & Subsequent . . . . . . . . . 2000 Hours or 15 years1 F029-2 . . . . . . . . . . . . . . . . . Tail Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . 2000 Hours or 12 years1 F195-1 . . . . . . . . . . . . . . . . . Yoke, Tail Rotor Drive Shaft . . . . . . . . . . . . . . . 2000 Hours F263-1 . . . . . . . . . . . . . . . . . Housing, Main Gearbox, Rev H & Prior . . . . . . . . 2000 Hours F270-1 . . . . . . . . . . . . . . . . . Cartridge, Main Gearbox, Rev D & Prior . . . . . . . 2000 Hours G062-2 . . . . . . . . . . . . . . . . Tail Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 Hours G201-1 . . . . . . . . . . . . . . . . Frame, Servo Support, Rev N & Prior . . . . . . . . . 2000 Hours 1 Whichever limit occurs first. Calendar time starts on date of original RHC-issued Airworthiness Approval. (Continues) ROBINSON MAINTENANCE MANUAL MODEL R66 Page 4.4 Chapter 4 Airworthiness Limitations SEP 2024 Approved By: Date: 07 Jun 2024 Manager, Federal Aviation Administration West Certification Branch, AIR-770 FAA Approved: This and the previous page constitute the Airworthiness Limitations Section in its entirety, is considered segregated from the rest of the document, and sets forth the FAA-approved mandatory replacement times for fatigue life-limited parts. 4-30 Airworthiness Limitations (continued) R66 Fatigue Life-Limited Parts (continued) Part Number Description Maximum Service Life C023-21, -24, -34, & -35 . . . Tailcone Assembly, Rev AW & Subsequent . . . . 4000 Hours C251-3 . . . . . . . . . . . . . . . . Main Rotor Shaft, Rev U & Subsequent . . . . . . . 4000 Hours D079-1 . . . . . . . . . . . . . . . . Tail Rotor Guard, Rev Q & Subsequent . . . . . . . 4000 Hours D196-1 . . . . . . . . . . . . . . . . Tail Rotor Drive Shaft, Rev I & Subsequent . . . . 4000 Hours F020-1 . . . . . . . . . . . . . . . . . Upper Frame, Rev H & Subsequent . . . . . . . . . . 4000 Hours F050-2 . . . . . . . . . . . . . . . . . Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . . 4000 Hours F143-1 . . . . . . . . . . . . . . . . . Pinion, Main Gearbox . . . . . . . . . . . . . . . . . . . . 4000 Hours F146-1 . . . . . . . . . . . . . . . . . Pinion, Main Gearbox . . . . . . . . . . . . . . . . . . . . 4000 Hours F235-13 . . . . . . . . . . . . . . . . Strut, Upper Frame . . . . . . . . . . . . . . . . . . . . . . 4000 Hours F252-1 . . . . . . . . . . . . . . . . . Strut, Upper Frame . . . . . . . . . . . . . . . . . . . . . . 4000 Hours F263-1 . . . . . . . . . . . . . . . . . Housing, Main Gearbox, Rev I & Subsequent . . . 4000 Hours F270-1 . . . . . . . . . . . . . . . . . Cartridge, Main Gearbox, Rev E & Subsequent . . 4000 Hours G201-1 . . . . . . . . . . . . . . . . Frame, Servo Support, Rev O & Subsequent . . . 4000 Hours G950-2 . . . . . . . . . . . . . . . . Stabilizer, Pop-out Floats . . . . . . . . . . . . . . . . . . 4000 Hours ROBINSON MAINTENANCE MANUAL MODEL R66 Digitally signed by ERIC D ERIC D SCHRIEBER SCHRIEBER Date: 2024.06.07 10:45:37 -07'00' CHAPTER 5 INSPECTIONS Section Title Page 5-10 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5-20 [Reserved] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5-30 General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5-31 Ball and Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5-32 Push-Pull Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 5-33 Rod Ends and Spherical Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 5-34 Elastomeric Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 5-35 Telatemp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 5-36 Torque Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 5-40 Operation Checks for 100-Hour/Annual Inspection . . . . . . . . . . . . . . . . . . . . . 5.8 5-41 Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 5-42 Run-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9B 5-43 Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 5-45 100-Hour/Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13 5-50 2000-Hour/12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39 5-51 C258-5 Main Rotor Pitch Link Assembly Inspection . . . . . . . . . . . . . . . . . . 5.39A 5-52 Swashplate Assembly 12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5.39B 5-53 Landing Gear Assembly 12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . 5.39C 5-54 Hydraulic Reservoir 12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39D 5-60 Special Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41 5-61 Tail Skid Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41 5-62 Tail Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42 5-63 Main Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43 5-64 Rotor/Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44 5-65 Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47 5-66 Dye Penetrant Inspection of F020-1 Upper Frame . . . . . . . . . . . . . . . . . . . 5.48 5-67 Corrosion on F020-1 Upper Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48 5-68 Main Rotor Gearbox Overtemp Illumination . . . . . . . . . . . . . . . . . . . . . . . . 5.48 5-69 Main Rotor Gearbox (MR) Chip Light Illumination . . . . . . . . . . . . . . . . . . . . 5.49 5-70 Tail Rotor Gearbox (TR) Chip Light Illumination . . . . . . . . . . . . . . . . . . . . . 5.49 5-71 Main Rotor Gearbox Filter Bypass Indicator . . . . . . . . . . . . . . . . . . . . . . . . 5.49 5-72 Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 5-73 Pop-Out Float-Equipped Helicopter Water Landing with Tail Rotor Contact . . 5.50 5-74 Main Rotor Gearbox Internal Visual Inspection . . . . . . . . . . . . . . . . . . . . . 5.51 MAR 2025 Chapter 5 Inspections Page 5.i ROBINSON MAINTENANCE MANUAL MODEL R66 Page 5.ii Chapter 5 Inspections MAR 2025 CHAPTER 5 INSPECTIONS (Continued) Section Title Page 5-75 C148 Bulkhead Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52 ROBINSON MAINTENANCE MANUAL MODEL R66 CHAPTER 5 INSPECTIONS 5-10 Introduction The R66 helicopter must be inspected periodically to verify it is in airworthy condition; refer to Table 1. NOTE Helicopters on a Part 91 Approved Inspection Program (AIP), a Part 135 Approved Aircraft Inspection Program (AAIP), or an equivalent foreign-approved inspection program, must refer to & comply with that program. Refer to current revisions of FAA Advisory Circulars 91-90 & 135-10. Fluid leaks, discoloration, dents, scratches, nicks, cracks, galling, chafing, fretting, and corrosion all warrant further investigation. Unairworthy items must be replaced or repaired as allowed by Robinson Helicopter Company. This section contains procedures for performing the required periodic airframe inspections. NOTE Unless directed by Service Bulletin, parts which were not listed as requiring replacement during previous compliance with a 12- year or 2000-hour Inspection may remain in service until next 12-year or 2000-hour Inspection (whichever occurs first). 5-20 [Reserved] 5-30 General Procedures Unless otherwise specified, the following general procedures apply to R66 inspection. When required, magnetic particle inspection may be performed in accordance with ASTM E 1444 and MIL-STD-1907. Fluorescent penetrant inspection may be performed in accordance with ASTM E 1417 and MIL-STD-1907. 5-31 Ball and Roller Bearings The first indication of bearing failure is usually an increase in bearing noise. Noise will almost always start several hours prior to bearing failure. Listen to drive system during start-up and shutdown. A failing bearing will produce a loud whine, rumble, growl, or siren sound. Upon hearing an unusual noise, thoroughly inspect all bearings before further flight. A failing bearing may have a distorted seal or be exuding a large amount of grease. Monitor bearings for increase in temperature, but do not rely on Telatemps to detect failing bearings as temperature increase may occur only seconds before bearing disintegrates. MAR 2025 Chapter 5 Inspections Page 5.1 ROBINSON MAINTENANCE MANUAL MODEL R66 FIGURE 5-2 ROD END CENTERING Position rod ends for maximum rotation FIGURE 5-1 ROD END AND SPHERICAL BEARING PLAY LIMITS AND TORQUE STRIPE APPLICATION Page 5.2 Chapter 5 Inspections MAR 2025 ROBINSON .----HOUSING MAINTENANCE MANUAL NOTE FOR MAXIMUM ROD EXTENSION WHEN NO WITNESS HOLES IS PROVIDED: ROD END A 101-4 D163-1 D173-1 9max 1.10 in. 1. 40 in . 1. 30 in . I MAXIMUM RADIAL PLAY 0 . 010 INCH TORQUE STRIPE * F101-4 1. 10 in . -----+---- A PIECE OF 0 .020 INCH DIAMETER SAFETY WIRE MUST NOT PASS THROUGH THE WITNESS HOLE MODEL R66 COMPONENT AN316 JAM NUT BALL BEARING - ( :$ ) · ~-+330 PALNUl------l--Q_/ _ ______....., li ffl , - -0-~- TORQUE STRIPE * L TORQUE STRIPE * BOLT SAFETY I WASHER MAXIMUM AXIAL PLAY 0.020 INCH * Typical torque stripe location shown . Adjust location as required for maximum visibility during preflight & 100-hr inspection. 1/ A 115-1 OR C115-1 SPACER (SMALL DIAMETER OF SPACER) TO CONT ACT ROD END BALL) EXPOSED THREADS PALNUT LF-LOCKING NUT WASHER 5-32 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. 5-33 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 5-1 for maximum rod end extension when no witness hole is provided. 4. Rod end jam nuts and palnuts must be torqued per § 20-32 and torque striped per Figure 5-1 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 5-2. 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. JUL 2023 Chapter 5 Inspections Page 5.3 ROBINSON MAINTENANCE MANUAL MODEL R66 Elastomer Fatigue Elastomer Overload FIGURE 5-3 ELASTOMERIC BEARING DAMAGE Page 5.4 Chapter 5 Inspections JUL 2023 Elastomer Oil Contamination ROBINSON MAINTENANCE MANUAL MODEL R66 \j \\ • ~ ' \ \~ 11~\ //~ I