R22 MAINTENANCE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

1.001 R22 Maintenance Manual Revisions Before using the R22 Maintenance Manual, verify it consists of current effective pages. The list of effective pages is located in the Revision Log in Chapter 37. 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. OCT 2018 Chapter 1 General Page 1.1 Page 1.2 Chapter 1 General OCT 2018 1.002 R22 Maintenance Authorization Only appropriately certificated mechanics who have successfully completed an R22 factory-sponsored maintenance course, or are under direct supervision of the above-stated mechanic, may perform maintenance, repairs, or inspections on R22-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 R22 Pilot’s Operating Handbook and applicable aviation regulations. 1.003 R22 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. 1.004 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-series 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). OCT 2018 Chapter 1 General Page 1.3 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 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. Page 1.4 Chapter 1 General OCT 2018 1.007 Definitions and Abbreviations Refer to R22 Pilot's Operating Handbook (POH) Section 1 for additional definitions and abbreviations. A. Definitions 14 CFR § 27.602 Critical Part: A part identified as a 14 CFR § 27.602 critical part within this manual is subject to special inspection requirements. RHC Technical Support must be notified whenever the part fails to meet the special inspection requirements. 12 years: With respect to a 12 year inspection or life-limit, 12 years means 12 years from the date of the factory-issued airworthiness certificate or factory-issued authorized release certificate (FAA Form 8130-3, Airworthiness Approval Tag). Annually: With respect to an annual inspection, annually means within the preceding 12 calendar months. Datum: An imaginary vertical plane from which all horizontal measurements are taken for balance purposes with the aircraft in level flight attitude. Refer to § 16-20 for R22 datum location. Empty Weight: Empty Weight includes the weight of the airframe, powerplant, required and installed equipment, fixed ballast, unusable fuel, and gearbox oil. Refer to R22-series Type Certificate Data Sheet (TCDS) in Chapter 3. Refer to Equipment List/Weight and Balance Data Sheet (RF 134) and Weight and Balance Record in R22 POH Section 6 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. OCT 2018 Chapter 1 General Page 1.5 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 ATA-100: Air Transport Association of America Specification No. 100 BL: Butt Line Station locations CO: Carbon Monoxide CRA: Component Return/Authorization ELT: Emergency Locator Transmitter FS: Fuselage Station locations HID: High Intensity Discharge HS: Horizontal Stabilizer Station locations LBL: Left Butt Line Station locations LED: Light Emitting Diode LH: Left-hand LRU: Line-Replaceable Unit MRDS: Main Rotor Drive Shaft MRGB: Main Rotor Gearbox OEM: Original Equipment Manufacturer R22 IPC: R22 Illustrated Parts Catalog R22 MM: R22 Maintenance Manual R22 POH: R22 Pilot’s Operating Handbook RHC: Robinson Helicopter Company RH: Right-hand RS: Rotor Station locations SB: Service Bulletin SL: Service Letter TBO: Time Between Overhaul TCDS: Type Certificate Data Sheet TRDS: Tail Rotor Drive Shaft TRGB: Tail Rotor Gearbox TS: Tailcone Station locations TSN: Time Since New TSO: Time Since Overhaul WL: Water Line Station locations 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). B. Returning Parts All parts shipped to RHC must include a signed Component Return/Authorization (CRA) Form available online at www.robinsonheli.com. C. Ordering and Shipping Procure parts from any R22 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 Directory Please visit www.robinsonheli.com for a complete support directory. Page 1.6 Chapter 1 General OCT 2018 OCT 2018 Chapter 1 General Page 1.7 1.009 Assembly Instructions for R22-series Helicopter Crated for Export NOTE Aircraft assembly to be performed by a certificated mechanic. 1. Remove all components from tailcone crate and all accessible components from cabin crate. Assemble landing gear per §§ 5.220 (float gear only) and 5.320. CAUTION Do not lift helicopter and attached crate using main rotor hub; damage to main rotor gearbox and frames could result. 2. Attach a hoist to main rotor hub per § 17-20. Lift aft end of crate while taking up slack in hoist. When main rotor shaft is vertical, remove bolts at landing gear attach points and remove crate. Install landing gear per § 5.120. Lower helicopter on ground. 3. Install front cross tube cover panel. For float landing gear, set float pressure per Mariner supplement of Pilot’s Operating Handbook and verify float stabilizer is being used in place of tail skid. 4. Install tailcone per § 4.312. Install tail rotor visual warning guard. 5. Install empennage assembly per § 4.322. 6. Install exhaust system per § 6.520. Install lower half of cooling fan scroll. 7. Remove preservative plugs from engine cylinder upper spark plug holes. Install upper spark plugs and special torque per § 23-33. Connect ignition leads. 8. Fill engine oil to six quart mark on dipstick, as required. 9. Install main rotor blades per § 26-10. Match color coded markings on blades, hub bolts, hub, and pitch links. Attach upper end of pitch links to pitch horns. 10. Install tail rotor per §§ 9.212 or 9.213, as applicable. 11. If required, fill battery with electrolyte and charge. 12. Fill main and tail rotor gearboxes with A257-2 oil. For helicopters shipped “on-side”, inject 6 ounces A257-2 oil into aft vent hole atop main rotor gearbox static mast tube. 13. Fuel helicopter and drain a small amount of fuel through gascolator. 1.009 Assembly Instructions for R22-series Helicopter Crated for Export (continued) 14. If ship is equipped with artificial horizon, directional gyro, or vertical card magnetic compass, install as follows: Artificial Horizon and/or Directional Gyro: a. Remove amber ALT light and red OIL light from B050 console. Pull out A777-1, A981-1, or B197-1 instrument face by removing perimeter mounting screws. Place a pad under face to prevent scratches. b. Install required instrument(s) using screws provided. CAUTION Directional gyro mounting screws must not exceed 1 inch in length or unit will be damaged. c. Connect straight multi-pin connector to directional gyro and/or angled connector to artificial horizon ensuring that angled strain relief points down. Ensure that connectors lock in place. Ty-rap excess wiring. d. Install instrument face, ALT light, and OIL light. Vertical Card Magnetic Compass: Locate two wires extending from windshield bow. Slide one piece of heat-shrink tubing (provided) over each wire. Connect compass pins to wire sockets (polarity not critical). Position heat-shrink tubing over connections and apply heat. Install compass using two screws provided. 15. Install battery (Negative Ground System). NOTE This must be performed by a qualified pilot and a certificated mechanic. 16. Perform preflight inspection per Pilot’s Operating Handbook and inspection per §§ 2.205 and 2.210. 17. Check tail rotor balance per § 10.240. 18. Perform hover checks in § 2.220.1. DO NOT proceed into forward flight at this time. 19. Track and balance main rotor per § 10.230. 20. While climbing at takeoff power per placard and 50 KIAS: a. Evaluate roughness at maximum and minimum power-on RPM. b. At minimum power-on RPM perform 30° left yaw to check for adequate directional control. Page 1.8 Chapter 1 General OCT 2018 1.009 Assembly Instructions for R22-series Helicopter Crated for Export (continued) 21. During level flight at 3000 feet pressure altitude (if able), MCP, with right trim and governor on: a. Verify longitudinal and lateral cyclic control forces are neutralized (no tendency of cyclic to creep longitudinally or laterally). b. Verify collective control forces are neutralized (no tendency of collective to creep up or down). c. Verify throttle correlation. Set MAP to 22 inches and turn governor off. Without twisting throttle, lower collective to 12 inches MAP then raise it to 22.5 inches MAP. RPM must stay in green arc. 22. Evaluate roughness at minimum power-on RPM, takeoff power per placard, and Vne per placard. 23. Check all instruments, gauges, and avionics for proper operation. 24. During autorotation at 50 KIAS and 90% rotor RPM, perform 30° right yaw to check for adequate directional control. OCT 2018 Chapter 1 General Page 1.9 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 SI 1080 Maintenance Items for Special Attention. • • Perform Lycoming SB 301* Maintenance Procedures and Service Limitations for Valves. • Perform Lycoming SB 366, as applicable Carburetor Throttle Body Screw Inspection. • Perform Lycoming SB 388 (also applies to replacement cylinders) Procedure to Determine Exhaust Valve and Guide Condition. • • Perform Lycoming SB 480 I. Oil & Filter Change & Screen Cleaning / II. Oil Filter/Screen Content Inspection. • • • Perform CMI SB 643, as applicable Maintenance Intervals for All CMI/TCM/Bendix Magnetos & Related Equipment. • • • • Perform CMI SB 658 Distributor Gear Maintenance. • • Perform CMI SB 663 Two-Wire Magneto Tach. Breaker Contact (Points) Assy. P/N 10-400507. • • Perform CMI SB 670 Replacement and maintenance of Magneto Distributor Block. • • Perform 100-hour/annual inspection per § 2.400. • • Lubricate A181-4 Revision K, L, and M bearings per § 22-42. • • Lubricate A181-4 Revision N bearing per § 22-42. • • Lubricate A184 bearing per § 22-41. • • Perform clutch assembly lubricant inspection & servicing per § 22-30. • Drain and flush gearboxes per §§ 22-13 & 22-23. • Clean gearbox chip detectors per §§ 22-11 & 22-21. • • Perform FAA AD 88-26-01 R2 (A158-1 spindles only). • Perform 2200-hour inspection per § 2.600. • Inspect emergency locator transmitter (ELT) per U.S. 14 CFR § 91.207. • Test and inspect transponder per U.S. 14 CFR § 91.413. • Perform 12-year inspection per § 2.600.** • * Shorter interval than published on referenced document. ** 12-year inspection is only required for helicopters that have accumulated 12 years in service and less than 2200 hours time in service since new, since last 2200-hour inspection, or since last 12-year inspection. TABLE 1 SCHEDULED INSPECTIONS Consult latest revision of listed publications for specific applicability. First 25 hours First 100 hours Every 50 hours Every 100 hours Every 300 hours Every 500 hours Every 800 hours Every 2200 hours Every 4 months Every 12 months Every 24 months Every 4 years Every 12 years Page 1.10 Chapter 1 General OCT 2018 1.100 Helicopter Servicing 1.101 Scheduled Maintenance and Inspections Required maintenance and inspection intervals are given in Table 1. Publications listed are subject to revision. 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 ● 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. OCT 2018 Chapter 1 General Page 1.11 1.102 Additional Component Maintenance A. Remove the following components when they have accumulated 12 years time in service and less than 2200 hours time in service since new, since last overhaul, or since last 12-year maintenance: Part Number Description Action A005-4 A154-1 Main Rotor Hub & Bearing Assembly Perform inspection and repair per MM § 2.610, return to RHC for inspection and repair, or replace with new. A005-12 B370-1 Main Rotor Hub & Bearing Assembly A005-6 A016-4 Main Rotor Blade & A158-1 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 (as required), spindle bearing replacement (as required), pitch horn screw replacement, boot and o-ring replacement, and inspection. A005-7 A016-6 Main Rotor Blade & A158-1 Spindle Assembly A005-14 A016-6 Main Rotor Blade & A158-3 Spindle Assembly A006-1 & -6 Main Rotor Gearbox Assembly Submit to RHC-authorized component maintenance facility for 12-year maintenance, or replace with new or overhaul exchange. 12-year maintenance includes pinion seal replacement, o-ring replacement, sealed bearing replacement, rubber mount replacement, additional bearings replacement (as required), and inspection. A007-3 or -5 Fanshaft Assembly Replace with new A007-5 fanshaft assembly. A008-2 or -4 Tail Rotor Assembly Replace with new A008-4 tail rotor assembly. A014-8 Landing Gear Assembly originally installed on R22 S/N 0002 thru 0487. Replace with new. A017-2 Swashplate Assembly Submit to RHC-authorized component maintenance facility for 12-year maintenance, or replace with new or overhaul exchange. 12-year maintenance includes inspection and repair as necessary. A018-1 Clutch Assembly (anodized) Submit to RHC-authorized component maintenance facility for 12-year maintenance, or replace with new or overhaul exchange. 12-year maintenance includes seal and o-ring replacement, bearing replacement, and inspection. A018-2 Clutch Assembly (metalized) A020-2 Upper Frame Assembly S/N 0399 and prior (originally installed on R22 S/N 0002 thru 0311). Replace with new. Note: Frame replacement may require tailcone forward bay replacement. A021-1 Tail Rotor Gearbox Assembly Replace with new or overhaul exchange B021-1 tail rotor gearbox assembly. A031-1 Tail Rotor Pitch Control Replace with new. A041-11 or -12 Tail Rotor Drive Shaft Damper Bearing Assembly Replace with new A041-11 or -12 damper bearing as- sembly or replace with new B224-1 or -3 drive shaft. Page 1.12 Chapter 1 General OCT 2018 1.102 Additional Component Maintenance (continued) A. Remove the following components when they have accumulated 12 years time in service and less than 2200 hours time in service since new, since last overhaul, or since last 12-year maintenance (continued): Part Number Description Action A044-1 Horizontal Stabilizer Rev M and prior (originally installed on R22 S/N 0002 thru 0631). Replace with new. A051-1 or A051-3 Clutch Actuator Assembly (A051-1 includes gearmotor assembly) Replace with new or overhaul exchange. A120-1 Tail Rotor Bellcrank Replace with new. A169-1, -2, or -4 Muffler with Risers Rev J and prior (baffled muffler with straight tailpipe, originally installed on R22 S/N 0002 thru 0500) with subsequent revision. Replace with new. A169-6 or -35 Muffler with Risers (O-320 engine) Visually inspect muffler interior; verify no obvious loss of material. A169-24 or -37 Muffler with Risers (O-360 engine) Visually inspect muffler interior; verify no obvious loss of material. A190-1 or -2 V-Belt Set Replace with new A190-2 v-belt set. A193-2 Flex Plate Replace with new A947-2 flex plate assembly. A193-3 Flex Plate Replace with new A947-3 flex plate assembly. A197-1 thru -7 Tail Rotor Drive Shaft Assembly originally installed on R22 S/N 0002 thru 0747. Replace with B224-1 drive shaft & appropriate B223 yoke. A258-1 Main Rotor Pitch Link Assemblies Replace with new A258-1 or A258-5 link assembly. A258-5 Main Rotor Pitch Link Assemblies Disassemble. 10X visually inspect barrel; verify no corrosion. A480-1 Swashplate Boot Replace with new. A493-1 Lower Sheave Rev H and prior (anodized, originally installed on R22 S/N 0002 thru 0294) with subsequent (steel-sprayed) revision. Replace with new. A649-1, -2, or C649-1 Oil Cooler Replace with new or overhaul exchange C649-1 oil cooler. A785-1 Hose – Air (intake) Replace with new. A785-2 Hose – Air (hot air inlet) Replace with new. A785-6 Hose – Air (engine cooling) Replace with new. A785-7 Hose – Air (alternator cooling) Replace with new. A785-26 Hose – Air (hot air inlet) Replace with new. A785-32 Hose Replace with new. OCT 2018 Chapter 1 General Page 1.13 Page 1.14 Chapter 1 General OCT 2018 1.102 Additional Component Maintenance (continued) A. Remove the following components when they have accumulated 12 years time in service and less than 2200 hours time in service since new, since last overhaul, or since last 12-year maintenance (continued): Part Number Description Action A792-2 or -4 Dual Tachometer Replace with new or overhaul exchange A792-4 dual tachometer. B021-1 Tail Rotor Gearbox Assembly Perform 12-year maintenance per MM § 2.620, or replace with new or overhaul exchange. B173-1 V-belt – Alternator Replace with new. B174-1 Fanwheel (Rev “J” or subsequent) Perform 12-year maintenance per MM § 2.630, or replace with new or overhaul exchange. B283-1 Hose Assembly (fuel system) Revision A thru P Replace with new. B283-2 Hose Assembly (fuel system) Revision A thru P Replace with new. B283-6 Hose Assembly (fuel system) Revision A thru P Replace with new. B286-2 Governor Controller Replace with new or overhaul exchange. D756-2 (or A011-2) Bellcrank Assembly – Throttle Replace with new. 1.102 Additional Component Maintenance (continued) B. Remove the following components when they have accumulated 2200 hours time in service since new or since last overhaul: Part Number Description Action A005-4 A154-1 Main Rotor Hub & Bearing Assembly Perform inspection and repair per MM § 2.610, return to RHC for inspection and repair, or replace with new. A005-12 B370-1 Main Rotor Hub & Bearing Assembly A005-6 A016-4 Main Rotor Blade & A158-1 Spindle Assembly Replace with new or overhaul exchange A005-7 or A005-14 main rotor blade and spindle assembly. A005-7 A016-6 Main Rotor Blade & A158-1 Spindle Assembly A005-14 A016-6 Main Rotor Blade & A158-3 Spindle Assembly A006-1 & -6 Main Rotor Gearbox Assembly Replace with new or overhaul exchange A006-6 main rotor gearbox assembly. A007-3 or -5 Fanshaft Assembly Replace with new A007-5 fanshaft assembly. A008-2 or -4 Tail Rotor Assembly Replace with new A008-4 tail rotor assembly. A014-8 Landing Gear Assembly originally installed on R22 S/N 0002 thru 0487. Replace with new. A017-2 Swashplate Assembly Submit to RHC-authorized component maintenance facility for overhaul, or replace with new or overhaul exchange. A018-1 Clutch Assembly (anodized sheave) Replace with new or overhaul exchange. A018-2 Clutch Assembly (metalized sheave) A020-2 Upper Frame Assembly S/N 0399 and prior (originally installed on R22 S/N 0002 thru 0311). Replace with new. Note: Frame replacement may require tailcone forward bay replacement. A021-1 Tail Rotor Gearbox Assembly Replace with new or overhaul exchange B021-1 tail rotor gearbox assembly. A031-1 Tail Rotor Pitch Control Replace with new. A041-11 or -12 Tail Rotor Drive Shaft Damper Bearing Assembly Replace with new A041-11 or -12 damper bearing assembly or replace with new B224-1 or -3 drive shaft. A044-1 Horizontal Stabilizer Rev M and prior (originally installed on R22 S/N 0002 thru 0631). Replace with new. A051-1 or A051-3 Clutch Actuator Assembly (A051-1 includes gearmotor assembly) Replace with new or overhaul exchange. A120-1 Tail Rotor Bellcrank Replace with new. A121-17 Push-Pull Tube Assembly Replace with new. OCT 2018 Chapter 1 General Page 1.15 Page 1.16 Chapter 1 General OCT 2018 1.102 Additional Component Maintenance (continued) B. Remove the following components when they have accumulated 2200 hours time in service since new or since last overhaul (continued): Part Number Description Action A169-1, -2, or -4 Muffler with Risers Rev J and prior (baffled muffler with straight tailpipe, originally installed on R22 S/N 0002 thru 0500). Replace with new. A169-6 or -35 Muffler with Risers (O-320 engine) Replace with new A169-35 muffler. A169-24 or -37 Muffler with Risers (O-360 engine) Replace with new A169-37 muffler. A189-10 Nut – Double Lock Replace with new. A190-1 or -2 V-Belt Set Replace with new A190-2 v-belt set. A193-2 Flex Plate Replace with new A947-2 flex plate assembly. A193-3 Flex Plate Replace with new A947-3 flex plate assembly. A197-1 thru -7 Tail Rotor Drive Shaft Assembly originally installed on R22 S/N 0002 thru 0747. Replace with new B224-1 drive shaft & appropriate B223 yoke. A258-1 Main Rotor Pitch Link Assembly Replace with new A258-5 link assembly. A258-5 Main Rotor Pitch Link Assembly Disassemble; fluorescent penetrant inspect barrel. A426-6 Cap – Collective Spring Replace with new. A480-1 Swashplate Boot Replace with new. A493-1 Lower Sheave Rev H and prior (anodized, originally installed on R22 S/N 0002 thru 0294). Replace with new. A615-1 Gasket – Carburetor-to-Air Box Replace with new. A628-6 Connector Assembly – Harness Replace with new. A636-2 Support (O-320 engine) Replace with new. A649-1 or -2 Oil Cooler Replace with new or overhaul exchange C649-1 oil cooler. A723-1 Oil Line Assembly Replace with new A723-5 oil line assembly. A723-2 Oil Line Assembly Replace with new A723-6 oil line assembly. A780-33 Cable Assembly Replace with new. A785-1 Hose – Air (intake) Replace with new. A785-2 Hose – Air (hot air inlet) Replace with new. A785-6 Hose – Air (engine cooling) Replace with new. A785-7 Hose – Air (alternator cooling) Replace with new. A785-26 Hose – Air (hot air inlet) Replace with new. A785-32 Hose Replace with new. A792-2 or -4 Dual Tachometer Replace with new or overhaul exchange A792-4 dual tachometer. 1.102 Additional Component Maintenance (continued) B. Remove the following components when they have accumulated 2200 hours time in service since new or since last overhaul (continued): Part Number Description Action A947-1 Flex Plate Assembly – Forward Replace with new. A947-2 Flex Plate Assembly – Intermediate Replace with new. A947-3 Flex Plate Assembly – Aft Replace with new. B021-1 Tail Rotor Gearbox Assembly Replace with new or overhaul exchange. B173-1 V-belt – Alternator Replace with new. B174-1 Fanwheel (Rev “J” or subsequent) Replace with new or overhaul exchange. B224-1 Tail Rotor Drive Shaft Replace with new. B224-3 Tail Rotor Drive Shaft Replace with new. B283-1 Hose Assembly (fuel system) Replace with new. B283-2 Hose Assembly (fuel system) Replace with new. B283-6 Hose Assembly (fuel system) Replace with new. B286-2 Governor Controller Replace with new or overhaul exchange. B350-2 Pin – Spring (fanshaft nut) Replace with new. C636-2 Support (O-360 engine) Replace with new. C649-1 Oil Cooler Replace with new or overhaul exchange. D756-2 (or A011-2) Bellcrank Assembly – Throttle Replace with new. F628-8 Buckle Assembly Replace with new. KI-217-1 R22 Bladder Fuel Tank Installation Kit Required for helicopter S/N 0002 thru 4620 per R22 SB-109, if not previously accomplished. KI-2207 A017-1 Swashplate Installation Kit Replace existing parts with kit parts. KI-2208 R22 A057-2 Airbox Assembly Installation Kit Required for helicopter S/N 2571M thru 2664 if not previously accomplished. AN320-18 Nut – Fanshaft Replace with new. MS16562-15 Pin – Spring Replace with new. MS20002-18 Washer Replace with new. MS24665-355 Cotter Pin Replace with new. NAS1149F1832P Washer Replace with new. NAS630-80 Bolt Replace with new. NAS6604-38 Bolt Replace with new. OCT 2018 Chapter 1 General Page 1.17 1.102 Additional Component Maintenance (continued) C. Engine Limits Refer to latest revisions of Textron Lycoming Service Instruction No. 1009 and Lycoming Service Bulletin No. 240. D. Airframe and Engine Accessory Limits Refer to accessory manufacturer’s instructions for continued airworthiness for accessory limits. Remove accessories per R22 Maintenance Manual or accessory manufacturer’s instructions as required. Page 1.18 Chapter 1 General OCT 2018 CHAPTER 2 INSPECTION Section Title Page 2.000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.100 General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.110 Ball and Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.120 Push-Pull Tubes, Rod Ends, and Spherical Bearings . . . . . . . . . . . . . . . . . 2.1 2.121 Push-Pull Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.122 Rod Ends and Spherical Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 2.125 Elastomeric Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2.130 Telatemp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 2.140 Torque Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 2.200 Ground and Flight Check For 100-Hour/Annual Inspection . . . . . . . . . . . . . . . 2.7 2.205 Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 2.210 Run Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 2.220 Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 2.300 Airframe Preparation For 100-Hour/Annual Inspection . . . . . . . . . . . . . . . . . . 2.10 2.400 100-Hour/Annual Airframe Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 2.410 Inspection Procedures and Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 2.500 Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.41 2.501 Clutch Actuator Upper and Lower Bearings . . . . . . . . . . . . . . . . . . . . . . . 2.41 2.502 A181-4 Actuator Lower Bearing Inspection and Lubrication . . . . . . . . . . . . 2.41 2.503 A184 Actuator Upper Bearing Inspection and Lubrication . . . . . . . . . . . . . 2.42 2.507 V-Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.43 2.508 Lower Sheave V-Belt Wear Pattern Inspection . . . . . . . . . . . . . . . . . . . . . 2.45 2.510 Tail Skid Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.46 2.520 Tail Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.47 2.530 Main Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48 2.540 Rotor/Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49 2.550 Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.51 2.560 Steel Tube Frame Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.53 2.570 Main Rotor Blade Detail Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54 2.571 Spar Cover Adhesive Damage (A016-2 main rotor blade only) . . . . . . . . 2.54 2.572 Main Rotor Blade Sealant and Filler Cracking . . . . . . . . . . . . . . . . . . . . 2.56 2.573 Visual Inspection of Main Rotor Blade Root Area . . . . . . . . . . . . . . . . . 2.57 2.580 Float Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.58 2.590 Windshield Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.59 2.600 2200-Hour/12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.60 OCT 2018 Chapter 2 Inspection Page 2.i CHAPTER 2 INSPECTION (Continued) Section Title Page 2.610 Main Rotor Hub Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 2.62 2.620 Tail Rotor Gearbox 12-Year Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 2.64 2.630 Fanwheel 12-Year Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.65 2.640 Main Rotor Blade Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.66 2.700 Additional Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.69 2.710 Volcanic Ash Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.69 2.720 Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.70 Page 2.ii Chapter 2 Inspection OCT 2018 CHAPTER 2 INSPECTION 2.000 Introduction The R22 helicopter must be inspected periodically to verify it is in airworthy condition. Required inspection intervals are maximum 100 hours time in service or 12 calendar months (annually), whichever occurs first; the inspection interval may be extended up to 10 hours, without accumulation, if allowed by local regulations. 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. 2.100 General Procedures Unless otherwise specified, the following general procedures apply to R22 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. 2.110 Ball and Roller Bearings The first indication of bearing failure is usually an increase in bearing noise. Noise will almost always start several hours before bearing failure or any increase in bearing temperature. 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. Do not rely on Telatemps to detect failing bearings as temperature increase may occur only seconds before bearing disintegrates. Refer to § 22-40. The failure of either actuator bearing in flight could cause loss of power to the rotor system and could result in a serious accident. The actuator upper ball bearing is on the clutch shaft aft of the upper sheave; the actuator lower roller bearing is on the fanshaft aft of the lower sheave. Just before complete failure of an actuator bearing, the clutch light may flicker constantly (on and off in less than one second). This should not be confused with its normal on-off re-tensioning in flight (on for 1-8 seconds then off). Flight should not be resumed until cause of the flickering clutch light has been determined. OCT 2018 Chapter 2 Inspection Page 2.1 Page 2.2 Chapter 2 Inspection OCT 2018 FIGURE 2-1 ROD END AND SPHERICAL BEARING PLAY LIMITS AND TORQUE STRIPE APPLICATION FIGURE 2-1A ROD END CENTERING (Position rod ends for maximum rotation) 2.120 Push-Pull Tubes, Rod Ends, and Spherical Bearings 2.121 Push-Pull Tubes 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 and 1-inch minimum blend radius. If depth exceeds these limits, tube must be replaced. If tube is dented or flattened more than 5 percent of its diameter, it must be replaced. 2.122 Rod Ends and Spherical Bearings Refer to Figure 2-1. 1. Maximum axial play: 0.020 inch Maximum radial play: 0.010 inch 2. Looseness between bearing outer race and rod end housing is not permitted. 3. Rod ends not riveted in place must block passage of 0.020 inch diameter wire through witness hole, if provided. 4. Rod end jam nuts and palnuts must be torqued per § 23-32 and torque striped, per Figure 2-1, at the most visible position for pre-flight inspection. Torque stripe must extend across nuts to both rod end shank and push-pull tube (or pitch link barrel, yoke, support, strut, etc.). Torque stripes are subject to deterioration and must be periodically renewed. 5. Rod ends must be centered, i.e., rod ends should be positioned to allow as much movement as possible without binding. WARNING Assembly of flight controls is critical and requires inspection by a qualified person. If a second person is not available, the installer must take a 5-minute break prior to inspecting flight control connections he has assembled. CAUTION Teflon-lined bearings must not be lubricated or solvent cleaned. OCT 2018 Chapter 2 Inspection Page 2.3 FIGURE 2-2A ELASTOMER FATIGUE FIGURE 2-2C ELASTOMER OVERLOAD FIGURE 2-2B ELASTOMER OIL CONTAMINATION Page 2.4 Chapter 2 Inspection OCT 2018 2.125 Elastomeric Bearings Elastomeric bearings are used in the A062-1 tail rotor hub. Fatigue, oil contamination, or overload can degrade the elastomer. Small surface cracks (fatigue cracks) and elastomer dust or “eraser crumbs” (see Figure 2-2A) are normal and are not causes for replacement. As cracks grow, enough elastomer will be lost to cause reduced stiffness and increased vibration. If deep (greater than 0.10 inch) cracks are present over more than 25% of elastomer face, replace bearing. Avoid exposure to oil, grease, hydraulic fluid, cleaning solvent, and rust-preventative fluids. Immediately wash off any such contaminants with detergent and water. Contaminated bearings exhibit swelling, wavy edges, or debonding (see Figure 2-2B) and must be replaced. Overload occurs when elastomer’s tensile strength or rubber-to-metal bond strength is exceeded. This can occur when normal loads are applied to a bearing weakened by fatigue or oil contamination. Overload is indicated by large extrusions from and large clean cracks in elastomer as shown in Figure 2-2C. Elastomer may also separate (debond) from metal bushings. If separation occurs over more than 25% of bonded area, replace bearing. OCT 2018 Chapter 2 Inspection Page 2.5 Page 2.6 Chapter 2 Inspection OCT 2018 2.130 Telatemp Indicators Self-adhesive Telatemp indicators record changes in operating temperatures of bearings and gearboxes. To use a Telatemp, draw a reference line between the highest temperature square which has darkened during normal operation and the next undarkened square. During every check thereafter, determine if an additional square has blackened. If an indicated temperature increase cannot be accounted for by a change in operating conditions, carefully examine the component before further flight. NOTE Telatemps can indicate erroneously if contaminated by a petroleum product, typically appearing as white, unactivated square(s) between darkened squares at each end; replace any Telatemp indicating as such and clean area with acetone prior to installing. Part Number Temperature Range F110-2 60°C / 140°F — 88°C / 190°F F110-4 104°C / 220°F — 132°C / 270°F Usage F110-4 on A006-1 Main Rotor Gearbox F110-2 on A184-3 Upper Actuator Bearing (just aft of upper sheave) F110-2 on A181-4 Lower Actuator Bearing (just aft of lower sheave) F110-2 on A021-1 or B021-1 Tail Rotor Gearbox 2.140 Torque Stripes If, during inspection, the remaining torque stripe on a fastener is insufficient to determine joint integrity, then remove accompanying palnut as required and apply specified torqe to fastener. If fastener moves, disassemble joint and inspect parts for damage such as fretting, thread deformation, hole elongation, etc.; replace damaged parts. If fastener does not move, install new palnut as required & standard torque per § 23-32. Torque stripe fastener per Figure 2-1. 2.200 Ground and Flight Check for 100-Hour/Annual Inspection Complete the following checklists in conjunction with a 100-hour or annual inspection. Note and correct any discrepancies. 2.205 Ground Check 1. Throttle Control: Check for freedom of rotation with collective full down and full up. 2. Throttle Overtravel Spring: Check by twisting throttle past idle position to override stop. Release throttle and ensure it returns immediately to normal idle position. 3. Mixture Control: Check for smoothness of operation with no binding. Check press-to-unlock button for proper function. Verify 0.03 to 0.10 inch spring-back at full rich position. 4. Carburetor Heat Control: Check for smoothness of operation with no binding. Verify 0.03 to 0.10 inch spring-back at full off position. 5. Cyclic Control: Check freedom through full travel with friction and right trim off. Verify friction knob rotates 1/8 to 1 turn clockwise before adding friction. Check full travel with friction and right trim on. Verify 10 pounds maximum friction measured laterally at grip with right trim off, friction on, and MR blade pitch links fore and aft. 6. Collective Control: Check freedom through full travel with friction off. Check freedom through full travel with friction on; friction should be 12 to 20 pounds measured at grip. 7. Carb Heat Assist (if installed): With collective down and full carb heat, raise collective full up and verify carb heat off. Lower collective full down and verify carb heat full on. With collective friction off, push carb heat off and verify collective stays down. 8. Tail Rotor Pedals: Check for smooth operation with no binding. 9. Removable Controls: Verify security of attached fasteners. 10. Lighting and Instruments: Turn MASTER switch on and verify — a. Carbon Monoxide caution light blinks twice b. Carb Air Temp approximately same as Outside Air Temp c. ALT caution light on d. OIL pressure warning light on e. Fuel quantity gages – indication of fuel level f. Navigation and panel lights – check function g. Strobe light – check function OCT 2018 Chapter 2 Inspection Page 2.7 2.205 Ground Check (continued) 10. Lighting and Instruments: Turn MASTER switch on and verify — (continued) h. Landing lights – check function (clutch switch must be Engaged to check landing lights) i. Map light – check function j. Ammeter – shows discharge k. Oil temperature gage – slight needle deflection with engine cold l. Cylinder head temp gage – slight needle deflection with engine cold m. MR CHIP light – on when sender shorted or test switch depressed n. MR TEMP light – on when sender shorted or test switch depressed o. TR CHIP light – on when sender shorted or test switch depressed p. LOW FUEL light – on after approximately 1 second delay when low fuel sender in tank is depressed or when test switch depressed Page 2.8 Chapter 2 Inspection OCT 2018 ROBINSON MAINTENANCE MANUAL MODEL R22 2.210 Run Up 1 . Perform preflight inspection per POH. 2. Turn MASTER switch on. Apply rotor brake and verify BRAKE light on. With brake applied, verify starter does not activate when key is turned to START position. 3. Start engine and run up using POH checklist, except leave cyclic and collective frictions on and governor off before proceeding. After engaging clutch switch, verify blades turn within 5 seconds and CLUTCH light extinguishes within 100 seconds. 4. Ammeter indicates charge, AL T light off. 5. Both magnetos ground (momentarily off) at 60% RPM. 6. Select alternator and battery switches off and verify- a. Engine and rotor tachometers operate. b. All warning/caution lights extinguished, indicating proper function of tachometer bus isolation diode. 7. No unusual bearing noise when varying RPM through operating range. Mechanic to listen near V-belt drive for symptoms of failing bearing as described in Section 2.11 0. 8. Set RPM at 75%, governor on, Increase to 85%, release throttle and verify governor increases RPM to 104% ± 1.5%. Increase RPM to 106%, release throttle, and verify governor decreases RPM to 104% ± 1.5%. 9. Engine and rotor tachometer needles within 1% of each other at 104% RPM. 1 0. Verify alternator voltage as follows: 13.4 to 13.9 vdc for A942-3 alternator control unit 13.0 to 13.7 vdc for A942-1 or -2 alternator control unit 11. Heater operates properly (if installed). 12. Tachometer needles do not jump more than 2% when transmitting on 118.00, 125.00, and 136.975 MHz with governor on. 13. Raise collective control 0.5 inch at grip and slowly decrease RPM. Verify low rotor RPM warning horn and light activate at 97 to 96% RPM and remain on as RPM is decreased to idle. 14. Idle RPM with engine warm, clutch engaged, throttle closed: 53 to 57%. 15. Idle mixture with engine warm, clutch disengaged, throttle closed: 2 to 4% RPM rise as mixture is pulled slowly to idle cut-off. Adjust idle mixture screw as required. If unable to obtain rise, set idle mixture screw to nominal position of 1 Yz turns out from full-in then adjust as required for smooth idle. Change 26: APR 2007 2.9 ROBINSON MAINTENANCE MANUAL MODEL R22 2.220 Flight Check 1. Hover: a. All gages green b. Controllability in left and right pedal turns c. Vibration levels 2. Level flight: Approximately 3000 feet density altitude (if possible), maximum continuous power, governor on, right trim on, frictions off. a. Vibration levels b. Longitudinal cyclic trim - cyclic does not creep forward or aft c. Lateral cyclic trim - cyclic does not creep left or right d. Collective spring - collective does not creep up or down e. Tail rotor pedal position - 0.0 to 0.5 inch left 2.300 AIRFRAME PREPARATION FOR 1 00-HOUR/ANNUAL INSPECTION The airframe must be thoroughly cleaned prior to inspection in accordance with U.S. FAR 43, Appendix D, paragraph (a). Cleaning should include a wipe down of main and tail rotor blades, hubs, and airframe exterior with a mild soap and water solution. Refer to R22 POH Section 8 for cleaning instruction. Note any fluid leakage before cleaning. 2.10 CAUTION Do not spray magnetos, main rotor hub, tail rotor gearbox vent, or swashplate area with high pressure water as water may enter and cause corrosion and breakdown of lubricants. Change 25: JUN 2006 ROBINSON MAINTENANCE MANUAL MODEL R22 2.400 100-HOUR/ANNUAL AIRFRAME INSPECTION Perform 100 hour or annual airframe inspections per Section 2.41 0. RHC recommends keeping a copy of the most recently performed checklist with the aircraft's maintenance records. 2.410 Inspection Procedures and Checklist R22 Serial No.: Registration No.: Hourmeter Indication: Aircraft Total Time: Technician name: Technician Certificate number: Numbers in parentheses indicate access location per Figures 2-3A and 2-38. 1 . Remove Landing Light Retainer ( 1 A) NOTE Do not remove pedal bearing block cover plates ( 1 B) unless function check of pedals indicates a problem with bearing blocks. Landing Light Retainer and Support: Inspect condition. Verify support security. Tail Rotor Pedal Bearing Blocks: Use an inspection light and mirror to inspect bearing blocks. Maximum allowable play is 0.050 inch axially and 0.020 inch radially. Verify security. Tail Rotor Pedal Bearing Blocks Sheet Metal Supports: Use an inspection light and mirror to verify no cracks or fretting in bearing block vertical sheet metal supports. Tail Rotor Pedals: Inspect condition. Verify no cracks. Verify security and operating clearance. Push-Pull Tubes: Inspect condition. Verify no cracks at ends. Inspect rod ends per Section 2.120. Verify security and operating clearance. Sheet Metal Structure: Inspect condition. Verify no corrosion. No cracks. Battery Box (if installed in nose): Inspect drain attachment to battery box. Verify no electrolyte leakage. Chin Area: Verify no loose equipment or debris. Wiring: Inspect condition. Verify no loose, broken, or chafed wires. Verify neatness and security. Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. Change 25: JUN 2006 2.11 ROBINSON MAINTENANCE MANUAL MODEL R22 2.410 Inspection Procedures and Checklist (cont' d) FIGURE 2-3A ACCESS COVERS AND INSPECTION PANELS 2.12 Change 25: JUN 2006 OCT 2018 Chapter 2 Inspection Page 2.13 2.410 Inspection Procedures and Checklist (continued) FIGURE 2-3B ACCESS COVERS AND INSPECTION PANELS 2. Open Upper Console Assembly (2) or Lower Faceplate per Section 14.1020 (10-hole instrument console only) Upper Console Assembly: Inspect condition. Verify hinge security. Instruments and Instrument connections: Inspect condition. Verify security. Strobe Power Supply and Wiring (alternate locations – atop horizontal firewall or behind right seat back): Inspect condition. Verify no cracks in mounting area. Verify security. B255-1 Bracket (10-hole instrument console only): Inspect condition of grommet and bracket contacting brace assembly between windshields. Tail Rotor Push-Pull Tubes: Inspect condition of visible portions. Verify operating clearance. Battery and Box (if installed in nose): Inspect condition. Check battery cell fluid level and specific gravity (non-sealed battery only). Verify security of connections. Verify no corrosion in surrounding structure. Radio Tray(s): Inspect condition. Verify security. Verify no loose or poor wire connections. Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. Wiring: Inspect condition. Verify neatness, security, and no chafing. 2.410 Inspection Procedures and Checklist (continued) 3. Open Circuit Breaker Panel (3) WARNING Ensure electrical system remains off while circuit breaker panel is open. Wiring: Inspect condition. Verify neatness, security, and no chafing. Connections: Inspect condition. Verify security and no corrosion. Circuit Breakers: Inspect condition. Verify security. Check airworthiness directive applicability. Verify red button (collar) on CLUTCH circuit breaker button. Copper Bus Bars: Inspect condition. Verify no corrosion. Verify bus bars are not bent and will not contact surrounding structure. Circuit Breaker Box Interior: Inspect condition. Verify cleanliness. Close and Secure: Circuit breaker panel. 4. Remove Horizontal Cover (4A), Cyclic Box Cover (4B), Belly Panel (4C) and Vertical Panel (4D) To remove cyclic box cover, unscrew trim adjustment knob, remove spring pin in cyclic friction knob, and, on ships equipped with carburetor heat assist, unscrew carburetor heat knob. Covers: Inspect condition. Verify placard legibility. Cyclic Box Assembly: Inspect condition. Verify no cracks, loose rivets, or corrosion. Verify security. Cyclic Stick Assembly: Inspect condition. Verify no cracks in weld areas. Verify security and operating clearance. Verify no more than 0.015 inch wear in plates at bottom of stick from A121-1 push-pull tube’s forward rod end housing. Cyclic Pivot (forward end of torque tube): Inspect condition. Inspect bearings per § 2.120. Verify security and operating clearance. Cyclic Right Trim: Rotate main rotor blades until pitch links are located fore and aft. Grip cyclic and activate right trim. Trim should produce a right cyclic stick force. Move cyclic stick fully left and verify right trim spring coils do not bind. Verify security and operating clearance. Page 2.14 Chapter 2 Inspection OCT 2018 ROBINSON MAINTENANCE MANUAL MODEL R22 2.410 Inspection Procedures and Checklist (cont'd) 4. Remove Horizontal Cover (4A), Cyclic Box Cover (4B), Belly Panel (4C) and Vertical Panel (40) (cont'd) Cyclic Friction: Inspect condition. Inspect rod ends per Section 2.120. Cyclic Horizontal Push-Pull Tube: Inspect condition. Verify no cracks around reinforcement blocks at tube ends. Verify security and operating clearance. Tail Rotor Horizontal Push-Pull Tubes: Inspect condition. Verify no cracks at ends. Inspect rod ends per Section 2.120. Verify security and operating clearance. Tail Rotor Push-Pull tube Lower Bellcrank: Inspect condition. Verify security and operating clearance. Mixture Cable: Verify security. Carburetor Heat Cable: Verify security. Carburetor Heat Assist Bellcrank (if installed): Inspect condition. Verify security and operating clearance. Carburetor Heat Assist Push-Pull Tube (if installed): Inspect condition. Verify no cracks at ends. Inspect rod ends per Section 2. 120. Verify security and operating clearance. Pitot and Static Lines and Drains: Inspect condition. Verify no cracking, chafing, or kinking. Remove drain plugs from tee fittings in each line and drain any water. Install drain plugs. Elastic Trim Cord: Remove trim cord assembly and stretch it. While stretched, check cord for voids which may indicate broken strands. Slide both hooks back and verify security of locking rings. Install cord. Verify operating clearance. Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. NOTE Elastic trim cord is not required if cyclic does not need forward trim in cruise flight. Change 25: JUN 2006 2.15 ROBINSON MAINTENANCE MANUAL MODEL R22 2.410 Inspection Procedures and Checklist (cont'd) 4. Remove Horizontal Cover (4A), Cyclic Box Cover (4B), Belly Panel (4C) and Vertical Panel (40) (cont'd) 2.16 Electrical Wiring: Inspect condition. Verify no loose, broken, or chafed wires. Verify neatness and security. Tail Rotor Vertical Push-Pull Tube: Inspect condition. Verify no cracks at ends. Inspect rod ends per Section 2.120. Verify security and operating clearance. Cyclic Push-Pull Tubes: Inspect condition. Verify no cracks at ends. Inspect rod ends per Section 2.120. Verify security and operating clearance. Contact between A 121-3 & -7 push-pull tube lower ends is permitted when cyclic stick is in aft corners of cyclic box. Cyclic Bellcrank: Inspect condition. Verify security and operating clearance. Cyclic Yoke (aft end of torque tube): Inspect condition. Inspect bearings per Section 2.120. Verify security and operating clearance. Cyclic Fork (attaching bellcrank to collective stick): Inspect condition. Inspect rod end per Section 2.120. Verify security. Verify operating clearance. Throttle Overtravel Spring: Inspect condition. Inspect rod ends per Section 2. 120. Verify security and operating clearance. Contact between overtravel spring and A 1 21-1 push-pull tube is permitted when cyclic stick is in forward right corner of cyclic box. Collective Friction and Stop Assembly: Inspect condition. Verify no nicks, cuts, or scratches. Move collective up and down and verify no bending or binding. Verify security and operating clearance. Collective Boot: Inspect condition. Verify no tears. Ensure tie string ends are tucked into boot (if installed - current production aircraft use Ty-raps to secure boot around collective stick). Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. Change 25: JUN 2006 OCT 2018 Chapter 2 Inspection Page 2.17 2.410 Inspection Procedures and Checklist (continued) 5. Remove Seat Backs (5A & 5B) & Collective Spring Guard (5C under left seat) Seat Backs and Collective Spring Guard: Inspect condition. Verify upholstery security. Upper Frame Assembly: Inspect condition of visible portions. Verify security. Electrical and Antenna Wiring: Inspect condition. Verify security. Verify no chafing. Check grommets for proper installation. Pitot and Static Lines: Inspect condition. Verify no chafing or kinks. Collective Stick Assembly: Inspect condition. Inspect bearings per § 2.120. Verify security and operating clearance. Verify no cracks in welds. Verify security of removable stick (if installed). If applicable, verify A783-1 retainer is secured to collective stick with ty-raps per Figure 2-4. FIGURE 2-4 A783-1 RETAINER SECURITY Throttle Connecting Rod: Inspect condition. Verify no cracks. Verify security and operating clearance. Governor: Inspect condition. Inspect rod ends per § 2.120. Verify security and operating clearance. Verify sufficient wiring slack with full up collective. Collective Spring: Inspect condition. Inspect rod ends per § 2.120. Verify no binding or roughness during operation. Verify lubrication of guide rods. Verify spring coils do not touch each other when collective is full down. Verify no elongation of lower cap guide rod holes. Verify security and operating clearance. Page 2.18 Chapter 2 Inspection OCT 2018 2.410 Inspection Procedures and Checklist (continued) 5. Remove Seat Backs (5A & 5B) & Collective Spring Guard (5C under left seat) (continued) Firewall Drains: Inspect condition. Verify drains are unobstructed. Verify tubing clamps are not cutting tubing. Verify security. Governor Controller and Wiring: Inspect condition. Verify security. Main Fuel Tank Outlet & Fuel Line: Inspect condition. Verify no leakage. Verify security. Verify smooth operation of fuel valve. Fuel Shut-Off Valve: Inspect condition. Verify no leakage. Verify security. Verify smooth operation of fuel valve. Aux Fuel Tank Fuel Line: Inspect condition. Verify clearance to structure. Verify no leakage. Verify security. Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. 6. Open Cowling Door(s) (6A & 6B) & Remove aft Cowling (6C) Cowling Doors: Inspect condition. Verify proper operation of fasteners. Electrical Wiring: Inspect condition. Verify no loose, broken, or chafed wires. Verify neatness and security. Actuator Fuse(s) and Holder(s): Inspect condition. Verify no corrosion. Verify correct AGC-1½ fuse(s), twist-to-lock function, and security. Antennas and Connections: Inspect condition. Verify security of antenna(s) and antenna connection(s). Emergency Locator Transmitter (if installed): Inspect condition. Verify security. If applicable, comply with U.S. 14 CFR 91.207 (d). Pitot Line and Static Vent: Inspect condition. Verify no chafing, kinks, or tight bends. Verify static vent is clean and unobstructed. Fuel Tanks: Inspect condition of visible portion. Verify no leaks. Verify security. Check interior for foreign objects and cracks in baffle. Aux Fuel Tank Fuel Line: Inspect condition. Verify clearance to structure. Verify no leakage. Verify security. Fuel Gage Sender(s) and Wiring: Inspect condition. Verify no fuel leaks. OCT 2018 Chapter 2 Inspection Page 2.19 2.410 Inspection Procedures and Checklist (continued) 6. Open Cowling Door(s) (6A & 6B) & Remove Aft Cowling (6C) (continued) Fuel Tank Sump Drain(s): Inspect condition. Verify drain valve(s) open easily, drain fuel freely, spring closed, and seal completely. Low Fuel Warning: Turn battery on. With a clean wooden dowel, gently depress low fuel sender float in main fuel tank and verify LOW FUEL warning light illuminates after approximately 1 second delay. Turn battery off. Fuel Cap(s): Refer to Figure 2-4A. Verify A689-6 fuel cap is revision J or subsequent if bladder tanks are installed (revision J or subsequent caps may also be used on all-aluminum tanks). Inspect condition. Verify no deterioration of gasket(s). Verify security when closed. Refer to R22 SB-107; verify cap decal is legible and properly installed, and alignment marks on cap and tank align when cap is fully closed. Collective Jackshaft Supports: Inspect condition. Inspect rod ends per § 2.120. Verify no cracks or corrosion. Verify strut ends are sealed. Verify security. Collective Jackshaft: Inspect condition. Verify no cracks or corrosion. If open type, verify no internal corrosion. Verify security. Verify operating clearance. Swashplate Push-Pull Tubes: Inspect condition of visible portions. Verify no cracks at ends. Inspect rod ends per § 2.120. Verify no tears in, or wear through, heat-shrink sleeves on forward push-pull tubes. Verify security and operating clearance. Push-Pull Tube Guides or Rollers: Inspect condition. Verify cleanliness, no wear into metal, and free movement of rollers. Verify security. FIGURE 2-4A A689-6 FUEL CAPS Page 2.20 Chapter 2 Inspection OCT 2018 2.410 Inspection Procedures and Checklist (continued) 6. Open Cowling Door(s) (6A & 6B) & Remove Aft Cowling (6C) (continued) Tail Rotor Push-Pull Tube and Bellcrank (at forward end of A121-15 push- pull tube): Inspect condition. Inspect rod ends per § 2.120. Verify no cracks in tube ends. Verify no cracks at bellcrank sheet metal mounting. Verify security and operating clearance. Main Rotor Gearbox Cooling Air Duct and Nozzle: Inspect condition. Verify security. Verify no rips, holes, chafing, or obstructions. Inspect condition and verify security of horizontal firewall grommet around duct. FIGURE 2-4B A947-1 FLEX PLATE INSPECTION 2.410 Inspection Procedures and Checklist (continued) 6. Open Cowling Door(s) (6A & 6B) & Remove Aft Cowling (6C) (continued) Main Rotor Gearbox: Inspect condition, especially gearbox mounts, static mast tube-to-gearbox attachment, and mast tube lower casting (if applicable). Inspect Telatemp per § 2.130. Verify proper oil level with no leakage. Verify security. Verify security of Hall Effect senders. NOTE At 500 hours time in service or annually, whichever occurs first, remove chip detector and clean any varnish accumulation from detector’s magnetic probe and adjacent metal body using a toothbrush and approved solvent per § 22-11. Drain and flush gearbox at intervals not to exceed 500 hours time in service (refer to § 22-13). Rotor Brake: Inspect condition, including activating cable & pulley and microswitch. Verify integrity of brake pads and 0.030 inch minimum pad thickness. Verify brake pad clearance to input yoke when brake is off. Verify security and operating clearance. MRGB Input Yoke: Inspect condition. Verify security and operating clearance. Verify security of magnets. Forward Flex Plate: Refer to Figure 2-4B. Inspect condition. Verify no distortion, nicks, scratches, cracks, corrosion, or fretting. If fretting is detected, contact RHC Technical Support. Verify bonded washers are installed on both sides of each flex plate ear. Verify proper installation, security, and operating clearance. WARNING A193 flex plates, which do not have bonded washers, are obsolete and must be replaced with A947 flex plates having bonded washers. If a bonded washer separates from an A947 flex plate, flex plate is unairworthy and cannot be repaired. Ensure A947-1 forward flex plate is Rev E or subsequent (identified by letter, “E” or subsequent letter, on two adjacent arms of flex plate). Clutch Shaft Forward Yoke: Inspect condition. Verify no cracks, corrosion, or fretting. Verify security and operating clearance. Clutch Assembly: Inspect condition. Verify no oil leakage. Verify no clutch shaft corrosion, especially at shaft-to A966-1 seal junctures. Remove any light surface corrosion at shaft-to-seal junctures and apply wax or suitable corrosion preventative compound. Verify no cracks in seal retainer plates. NOTE Clutch assembly lubricant inspection and servicing (§ 7.214) is recommended every 500 hours time in service. OCT 2018 Chapter 2 Inspection Page 2.21 2.410 Inspection Procedures and Checklist (continued) 6. Open Cowling Door(s) (6A & 6B) & Remove Aft Cowling (6C) (continued) Upper Sheave: Inspect condition. Verify smoothness of drive belt contact surfaces. Replace any sheave having corrosion, pitting, flaking, roughness, sharp ridges, wear through anodized coating, or blistering of optional metalized coating. Upper Steel Tube Frame: Inspect condition. Verify no cracks or corrosion. If corrosion is found, inspect and repair per § 2.560. Use an inspection light and mirror to inspect all parts of each weld. CAUTION Upper steel tube frame is fatigue loaded and therefore susceptible to fatigue cracks. Inspect all joints very thoroughly. Horizontal Firewall: Inspect condition, especially where bolted to steel structure. Verify no cracks, buckling, or wrinkles. Cabin Aft Bulkhead: Inspect condition. Verify no corrosion, loose rivets, deformation, or cracks. Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. 7. Remove Side Skirts (7A, 7B, 7D, & 7E), Spark Plug Access Covers (7C & 7F), and Battery Box Cover (7G, alternate location under upper console or left seat) Engine: Refer to Lycoming Operator's Manual (Lycoming P/N 60297-12 or 60297-16, as applicable) Sections 4 and 5 and Lycoming Sl 1080 (current revision) for 100-hour or annual inspection and service procedure. Muffler: Open heater shroud (if installed). Inspect muffler condition. Verify no cracks or ruptures. Pay particular attention to tail pipe and riser attachment areas, welds, clamps, riser flanges and gaskets. Verify no internal obstructions. Muffler Leak Check: Pressurize muffler with low pressure air and inspect for leakage by applying soapy water to exterior and looking for air bubbles. Verify security. WARNING Exhaust system failure can result in carbon monoxide poisoning, partial loss of power, or fire. Heater Shroud (if installed): Inspect condition. Close and secure shroud and connect hoses. Engine Cooling Panels: Inspect condition. Pay particular attention to panel attached to oil cooler and panel attached to alternator cooling hose. Verify no cracks or missing or loose fasteners. Verify security. Page 2.22 Chapter 2 Inspection OCT 2018 2.410 Inspection Procedures and Checklist (continued) 7. Remove Side Skirts (7A, 7B, 7D, & 7E), Spark Plug Access Covers (7C & 7F), and Battery Box Cover (7G, alternate location under upper console or left seat) (continued) Alternator & Pulley: Inspect condition. Verify steel pulley (use magnet); aluminum pulley is not approved. Verify security. Alternator Wiring: Inspect condition. Verify no evidence of arcing. Verify security of output, aux, and field terminal studs. Verify no damage to insulating spacer at output stud. Verify wiring security. Alternator Belt: Inspect condition. Replace belt if there are any cracks, missing teeth or delamination. Check tension per Lycoming Service Instruction 1129 (current revision). Verify proper belt alignment. Emergency Spare Alternator Belt: Remove if installed. Alternator Cooling Hose: Inspect condition. Verify no obstructions or holes. Verify security. Vertical Firewall: Inspect condition. Verify no cracks, buckling, or wrinkles, especially around structural attachment points. Lower Steel Tube Frames: Inspect condition. Verify no corrosion or cracks, especially at welds. If corrosion is found, inspect and repair per § 2.560. Verify proper torque (see § 23-32) and safety wiring of drilled-head bolt at lower left frame-to-cabin-belly attachment. Engine Mounts: Inspect condition. Verify security. Replace rubber mounts exhibiting significant deflection or other than superficial cracks. Throttle Control: Verify carburetor butterfly bellcrank contacts idle rpm adjustment screw with collective full down and throttle grip at idle position. Verify bellcrank contacts full-open stop when throttle is opened with collective half-up. Inspect rod end per § 2.120. Verify operating clearance, especially at vertical firewall. Throttle Correlation Rigging: Check per § 10.150 and adjust as required. Full Throttle Switch Rigging: Check per § 33-60 and adjust as required. Carburetor Mixture Control: Verify carburetor mixture control moves carburetor mixture control arm stop to stop. Inspect condition and verify security of mixture control cable clamp(s) on air box bracket; push and pull cable housing to ensure it does not slip in clamp(s). Inspect condition and verify security of mixture control cable inner wire attachment to carburetor mixture control arm. Ensure freedom of rotation between mixture control arm and inner wire retention fitting (bolt) when arm moves. Verify mixture control safety spring is properly installed (so spring force moves mixture control arm to full-rich position if inner wire breaks). Engine Electrical Wiring, Alternator Control Unit: Inspect condition. Verify no wire chafing. Inspect connections. Verify security and no corrosion. OCT 2018 Chapter 2 Inspection Page 2.23 2.410 Inspection Procedures and Checklist (continued) 7. Remove Side Skirts (7A, 7B, 7D, & 7E), Spark Plug Access Covers (7C & 7F), and Battery Box Cover (7G, alternate location under upper console or left seat) (continued) Oil Lines & Elbows: Inspect condition. Verify clearance and no cracks or abrasions. Wires, ty-raps, and structure must not contact lines. Oil Line Clamps: Inspect condition. Verify no broken clamps. Oil Cooler: Inspect condition. Verify no cracks or leakage. Verify security. Verify airflow path through cooling fins is unobstructed. Gascolator: Inspect condition. With fuel valve in OFF position, remove and clean gascolator bowl and filter screen. Reinstall bowl, turn fuel valve ON. Safety wire retainer after ensuring no leakage. Verify drain valve opens easily, drains fuel freely, springs closed, seals completely, and is torque- striped per § 23-31. Fuel Hose: Inspect condition, verify security, clearance, no cracks, abrasion or leakage. Carburetor Air Box: Open air box. Inspect condition. Verify free movement of disk in drain valve (not applicable to Mariners). Verify security. If installed, verify free movement and full closure of spring-loaded alternate air door. Carburetor Heat Valve: Verify carburetor heat control fully opens and closes slider valve. Inspect condition and verify security of carburetor heat cable clamp on air box. Inspect condition and verify security of carburetor heat control cable inner wire attachment to slider valve. Air Filter: Clean B771-1 air filter per § 6.435. Close and secure air box. Carburetor Air Inlet Hose: Inspect condition. Verify no obstructions, leakage, or chafing. Verify security. Carburetor Heat Scoop and Hose: Inspect condition. Verify security. Verify no obstructions, leakage, chafing, or scoop cracks. Heater Hoses (if installed): Inspect condition. Verify security and no obstructions, leakage, or chafing. Verify security. Battery, Battery Cables, and Battery Box (alternate locations under upper console or left seat): Inspect condition. Check each battery cell electrolyte for quantity and specific gravity (non-sealed batteries only). As required, perform capacity test or replace battery per manufacturer’s instructions. Verify battery cable security and no cracked or corroded terminals. Verify security of, and no obstructions in, battery box drain tube (if installed). Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. Page 2.24 Chapter 2 Inspection OCT 2018 2.410 Inspection Procedures and Checklist (continued) 8. Remove Tailcone Fairing (8) Tailcone Fairing: Inspect condition. Upper Steel Tube Frame: Inspect condition. Verify no cracks or corrosion. If corrosion is found, inspect and repair per § 2.560. Use an inspection light & mirror to inspect all parts of each weld. CAUTION Upper steel tube frame is fatigue loaded and therefore susceptible to fatigue cracks. Inspect all joints thoroughly. Tailcone-to-Upper Frame Attachment: Inspect condition. Verify security. Upper Frame Protective Clamp: Inspect clamp protecting right side upper frame tube from drive belt contact; replace if wear has penetrated clamp. If clamp is not installed, verify no more than 0.0049 inch wear into frame tube due to drive belt rubbing. Protective clamp may be installed per Figure 2-4C on any R22 if desired. FIGURE 2-4C UPPER FRAME PROTECTIVE CLAMP INSTALLATION (View looking forward) OCT 2018 Chapter 2 Inspection Page 2.25 Page 2.26 Chapter 2 Inspection OCT 2018 2.410 Inspection Procedures and Checklist (continued) 8. Remove Tailcone Fairing (8) (continued) Actuator Upper Bearing: Inspect condition. Verify no more than 0.060 inch axial play. Verify no fretting between bearing inner race and clutch shaft. Verify bearing inner race has not slipped relative to clutch shaft. Inspect Telatemp per § 2.130. Perform § 22-41 bearing inspection if unexplainable Telatemp increase has occurred. CAUTION A184 bearing requires periodic lubrication per § 1.101. Actuator Upper Bearing Lubrication: Perform as required. Clutch Lateral Centering Strut Assembly: Inspect condition. Inspect rod ends per § 2.120. Verify security. Intermediate Flex Plate and Yokes: Refer to Figure 2-4B. Inspect condition. Verify no distortion, nicks, scratches, cracks, corrosion, or fretting. If fretting is detected, contact RHC Technical Support. Verify bonded washers are installed on both sides of each flex plate ear. Verify proper installation, security, and operating clearance. WARNING A193 flex plates, which do not have bonded washers, are obsolete and must be replaced with A947 flex plates having bonded washers. If a bonded washer separates from an A947 flex plate, flex plate is unairworthy and cannot be repaired. Tail Rotor Push-Pull Tubes and A331-1 Bellcrank: Inspect condition. Verify no cracks at tube ends. Inspect rod ends per § 2.120. Verify security and operating clearance. Drive V-Belts: Inspect per § 2.507. Fanshaft: Inspect condition. Perform 360° visual inspection of exposed fanshaft for cracks. Verify security and safety wiring of attaching bolts. Actuator Lower Bearing: Inspect condition, verify bearing inner race has not slipped relative to fanshaft. Inspect Telatemps per § 2.130. Perform § 22-42 bearing inspection if unexplainable Telatemp increase has occurred. CAUTION A181-4 bearing requires periodic lubrication per § 1.101. Actuator Lower Bearing Lubrication: Perform as required. Lower Bearing Brackets: Verify no looseness or cracking in A185 brackets which secure actuator lower bearing to scroll. Fiberglass Scroll: Inspect condition. Verify no damage to vane assembly in upper right scroll. Verify security. Verify drain hole is unobstructed. 2.410 Inspection Procedures and Checklist (continued) 8. Remove Tailcone Fairing (8) (continued) Scroll Metal Inlet Lips & Gap (if installed): Inspect condition. Verify 0.020 to 0.100 inch gap between lips and fanwheel inlet. (Attach holes in lips may be elongated to facilitate gap adjustment.) Fanwheel Assembly: Inspect condition. Verify no cracks or corrosion. Check leading edge of vanes for damage. Verify alignment of roll pin and slippage marks on fanwheel. If marks and roll pin do not align, remove fanwheel and inspect hub and shaft for damage. Verify security. Actuator (A051-1): Turn master switch on and engage clutch switch. While actuator is engaging, depress extension limit switch lever and verify gear motor stops; release lever and verify gear motor resumes running. Use an inspection mirror to observe column springs at end of belt-tensioning cycle; springs should snap outward simultaneously. Verify maximum engaged extension limit per Figure 7-15 is not exceeded. Verify security of attachment to A181 and A184 bearings. Verify gear motor security and minimum 0.030 inch clearance to upper frame. Actuator Spring Switches: Check using either of following two methods, as appropriate: Method 1 - (actuator electrical harness must be equipped with “Test” plug) CAUTION When using MT558-1 plug assembly (see Figure 2-5), if gear motor does not shut off when column springs snap outward then spring switch has failed in closed position; immediately remove MT558-1 to prevent actuator damage. a. Disengage actuator. Connect one end of MT558-1 to actuator test plug. Engage actuator and verify gear motor shuts off when column springs snap outward. b. Disengage actuator. Connect opposite end of MT558-1 to actuator test plug. Engage actuator and verify gear motor shuts off when column springs snap outward. c. MT558-1 pins 1-2 jumper tests the wire 98 spring switch; the pins 2-3 jumper tests the wire 91 spring switch (see Figure 14-4A). If either switch does not function properly, replace switch section per § 7.551 before further flight. OCT 2018 Chapter 2 Inspection Page 2.27 FIGURE 2-5 Page 2.28 Chapter 2 Inspection OCT 2018 2.410 Inspection Procedures and Checklist (continued) 8. Remove Tailcone Fairing (8) (continued) Actuator Spring Switches (continued): Method 2 - (use if actuator electrical harness is not equipped with “Test” plug) a. Refer to Figure 2-5A. Depress column springs on one side of actuator until springs snap inward (use large screwdriver or similar tool with several layers to tape over end to protect actuator). Hold springs inward for at least one second. Actuator motor should not run. If motor starts, allow motor to run approximately two seconds, then release pressure on column springs. Depress column springs again. If motor starts again, opposite spring switch does not function properly. b. Disengage and re-engage actuator. Repeat step a. on opposite-side column springs. c. If either switch does not function properly, replace switch per § 7.551 before further flight. FIGURE 2-5A ACTUATOR FUNCTION TEST Lower Sheave: Inspect condition. Verify smoothness of drive belt contact surfaces. Remove any surface corrosion and refinish with approved primer. Replace any sheave showing corrosion-pitting or flaking of metalized coating, roughness, or sharp ridges. 2.410 Inspection Procedures and Checklist (continued) 8. Remove Tailcone Fairing (8) (continued) Engine Height: Check per § 6.130 and adjust as required. Clutch Shaft Angle: Check per § 7.240. Replace drive belts as required. Sheave Alignment: Check per § 7.230 and adjust as required. Throttle Correlation Rigging: Check per § 10.150 and adjust as required. Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. 9. Remove 4 Tailcone Inspection Covers (9) : Verify nutplate self-locking feature when removing. Inspection Covers: Inspect condition. Tail Rotor Drive Shaft: Inspect condition. Verify no cracks, bends, or contact with inside of tailcone. Refer to Figure 7-12C for corrosion limitations. Check runout per § 7.340. Tail Rotor Push-Pull Tube: Inspect condition. Inspect rod ends per § 2.120. Verify wear does not exceed § 2.120 limits. Verify no cracks in ends. Verify operating clearance. Verify tail rotor guard mounting screw shanks clear push-pull tube. Damper: Inspect condition. Verify security. Verify bearing housing wear is within Figure 2-6 limits. Tailcone Interior: Inspect condition. Verify no loose rivets or corrosion. Verify no excessive wear in tail rotor push-pull tube bushings. Verify no cracks, especially at damper-to-tailcone attachment. Lower, Whip Antenna (if installed): Remove four screws securing antenna mounting plate to tailcone. Verify no cracks or corrosion on mounting plate or tailcone mount. Inspect antenna and wiring condition. Install antenna. Verify security. Upper Antenna(s) (if installed): Inspect antenna and wiring condition. Verify security and no cracks at attachment to tailcone. Tailcone Exterior: Inspect condition. Refer to Figures 2-7A and 2-7B for dent and scratch limits. Verify no cracks, corrosion, fretting between skin joints, or loose rivets. Verify drain hole at forward edge of each bay (except forward) is unobstructed. Tail Rotor Visual Warning Guard: Inspect condition. Verify no cracks or corrosion, especially at tailcone attachment. Verify security. Strobe Light: Inspect condition. Verify cleanliness and security. Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. OCT 2018 Chapter 2 Inspection Page 2.29 Page 2.30 Chapter 2 Inspection OCT 2018 FIGURE 2-6 DAMPER BEARING HOUSING WEAR LIMITS 2.410 Inspection Procedures and Checklist (continued) 9. Remove 4 Tailcone Inspection Covers (9) (continued) FIGURE 2-7A TAILCONE DENT LIMITS BAY 5: 0.00 to 0.10 inch deep — No repair required provided 4 inches minimum between dented stations. 0.10 to 0.25 inch deep — Repair per § 4.314. Greater than 0.25 inch deep — Replace bay (requires return to RHC). ANY OTHER BAY: Dents with 0.030 inch maximum depth, 1.25 inch maximum diameter, and 0.125 inch minimum bottom radius are acceptable if there is no more than one dent per station with 4 inches minimum between dented stations. Otherwise, replace tailcone or return to RHC for repair. FIGURE 2-7B TAILCONE SCRATCH LIMITS Allowable scratch depth varies with scratch angle to tailcone centerline as shown. For scratches within these limits, polish out scratches using 320-grit or finer abrasive paper and minimum 0.10 inch blend radius. Polish parallel to tailcone long axis. If scratches exceed limits, replace tailcone or return to RHC for repair. OCT 2018 Chapter 2 Inspection Page 2.31 2.410 Inspection Procedures and Checklist (continued) 10. Remove Plastic Cover (10) Plastic Cover: Remove and clean. Inspect condition. Replace as required and install. Verify nutplate self-locking feature when installing. Empennage: Inspect condition. Verify security. Verify no cracks or loose fasteners. Verify lower vertical stabilizer and tail skid drain holes are unobstructed. Refer to special inspection section for tail skid strike inspection criteria. Aft Navigation Light: Inspect condition. Verify cleanliness, clear lens, and security. Aft Flex Plate: Refer to Figure 2-4B. Inspect condition. Verify no distortion, nicks, scratches, cracks, corrosion, or fretting. If fretting is detected, contact RHC Technical Support. Verify bonded washers are installed on both sides of each flex plate ear. Verify proper installation, security, and operating clearance. WARNING A193 flex plates, which do not have bonded washers, are obsolete and must be replaced with A947 flex plates having bonded washers. If a bonded washer separates from a A947 flex plate, flex plate is unairworthy and cannot be repaired. Tail Rotor Gearbox: Inspect condition, including seals. Verify proper oil level and no leakage. Verify security and safety wire integrity. Verify output shaft cleanliness. NOTE At 500 hours time in service or annually, whichever occurs first, remove chip detector and clean any varnish accumulation from detector’s magnetic probe and adjacent metal body using a toothbrush and approved solvent per § 22-21. Drain and flush gearbox at intervals not to exceed 500 hours time in service (refer to § 22-23). Page 2.32 Chapter 2 Inspection OCT 2018 OCT 2018 Chapter 2 Inspection Page 2.33 2.410 Inspection Procedures and Checklist (continued) 10. Remove Plastic Cover (10) (continued) Tail Rotor Pitch Control Assembly and Aft Bellcrank: Inspect condition. Inspect spherical bearing in underside of pitch control per § 2.120; it is permissible to have a single radial crack in this spherical bearing ball. Verify no excessive looseness on output shaft (0.25 inch maximum rotational play measured at pitch link attaching bolt head). Verify operating clearance and assembly slides freely on output shaft. Verify no leakage at bearing seals. Verify security. WARNING A031-1 Rev. J or prior pitch control assemblies require repetitive inspection per R22 Service Bulletin SB-90A every 300 hours or annually, whichever occurs first. Pitch Links: Inspect condition. Inspect rod ends and spherical bearings per § 2.120. If pitch links are one-piece type, remove and reinstall with outboard end inboard and inboard end outboard as required to obtain maximum service life. Verify security and operating clearance. Tail Rotor Blades: Inspect condition. Refer to § 9.220 for damage limitations. Inspect bearings per § 2.120. Verify no looseness between feathering bearing outer races and root fittings. Verify security. Verify blade tip drain holes (2 per A029-1 blade, 1 per A029-2 blade) are unobstructed. Verify no corrosion. Tap test bonded areas per § 26-44. WARNING Structural damage may occur if compressed air is applied to blade tip drain holes. Tail Rotor Hub: Inspect condition. Inspect spherical teeter hinge bearings per § 2.120; inspect elastomeric teeter hinge bearings per § 2.125. Verify hub teeters without binding. Verify teeter hinge bearing balls (P/N A030-1 hubs only), spacers contacting output shaft, nuts, and bolt remain stationary when teetering hub. Verify no cracks or corrosion. Verify operating clearance. Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. Page 2.34 Chapter 2 Inspection OCT 2018 2.410 Inspection Procedures and Checklist (continued) 11. Open Mast Fairing (11) Mast Fairing: Inspect condition. Verify no cracks, dents, or corrosion. Verify no yielding or cracking of A665-1 restraint. Yielding can be caused by overtightening screws in restraint nutplates. Upper and Lower Ribs: Inspect condition. Verify security, especially tightness of lower rib clamp. Three Vertical Push-Pull Tubes (Two A121-7 and One A121-5): Inspect condition. Inspect rod ends per § 2.120. Verify no cracks at upper ends. With collective full up and cyclic full aft, verify no wear of A121-7 tubes or sleeves, especially where sleeves rub inside guide assembly. Verify security and operating clearance. Pitot Tube and Line: Inspect condition. Verify no cracking, chafing, or kinking. Ensure drain hole on bottom of elbow behind pitot tube is clear. Verify security. Fuel Tank Vent Metal Lines and Plastic Tubes: Inspect condition. Verify no kinking or obstructions. Verify security. Swashplate Upper Scissors: Inspect condition. Inspect rod ends and spherical bearings per § 2.120. Measure scissors play per Figure 2-8. Observe scissor linkage while having someone raise and lower collective. Verify bolt, journals (or spherical bearing balls and spacers), and arm rotate together at each scissor linkage pivot. Verify operating clearance. Swashplate Lower Scissors: Inspect condition. Inspect rod ends per § 2.120. Verify security. Swashplate Slider Tube: Inspect condition. Verify no cracks at rivet holes or corrosion on base. Verify no damage to, or wear through, anodized tube surface. When viewed under 10X magnification, minute “checkerboarding” of anodized surface is normal. Remove Swashplate Boot Lower Ty-rap: Lift boot from swashplate. Using an inspection mirror, inspect area between main rotor drive shaft and inside of slider tube. Verify no corrosion and no debris. Verify no boot damage. Swashplate: Inspect condition. Verify 0.020 inch maximum radial play between swashplate ball and slider tube. Rotate rotor by hand and verify operating clearance and no rough or dry bearings. Swashplate Shimming: Observe swashplate ball from below and have someone move collective stick slowly up & down. Verify swashplate ball immediately moves with swashplate when swashplate reverses direction. Movement of swashplate without attendant ball movement indicates axial play between ball and swashplate; shim swashplate per § 8.416. Install Swashplate Boot Lower Ty-rap: Verify correct boot position and security and no boot damage. Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. 2.410 Inspection Procedures and Checklist (continued) 11. Open Mast Faring (11) (continued) Main Rotor Drive Shaft: Inspect condition of accessible portion. Verify no corrosion. FIGURE 2-8 MEASURING UPPER SWASHPLATE SCISSORS PLAY (Identify scissors bearing type and measure as shown) OCT 2018 Chapter 2 Inspection Page 2.35 FIGURE 2-9 MAIN ROTOR BLADE TIP AND TIP COVER 2.410 Inspection Procedures and Checklist (continued) 12. Rotor Hub and Hinge Bolts Hub: Inspect condition. Verify no nicks, scratches, gouges, or corrosion. If main rotor imbalance is suspected, check teeter and coning hinge friction per § 26-32. Verify no brown or black residue (indicates bearing wear). Hinge Bolts (three): Inspect condition; corrosion is prohibited. Verify cotter pins are in place and secure. Verify bolt heads and nuts are torque striped to thrust washers. Pitch Links and Rod Ends: Inspect condition. Inspect rod ends per § 2.120, including centering. Verify security, including jam nut tightness and proper safety wiring. Fasteners & Torque Stripes: Inspect condition and verify security of all fasteners. Renew deteriorated torque stripes per Figure 2-1. 13. Main Rotor Blades Boots: Inspect condition. Verify no boot damage or oil leakage. Verify proper boot position and security. Verify sufficient clearance from hub assembly through full control travel. Blade Spindles & Root Fittings: Inspect area for damage per § 26-43. Comply with FAA Airworthiness Directive 88-26-01 (current revision) as required (A158-1 spindles only). Verify proper installation and security of visible fasteners. Renew deteriorated torque stripes per Figure 2-1. Page 2.36 Chapter 2 Inspection OCT 2018 OCT 2018 Chapter 2 Inspection Page 2.37 2.410 Inspection Procedures and Checklist (continued) 13. Main Rotor Blades (continued) A016-6 Main Rotor Blade Inspection: Remove tip covers. Remove corrosion and loose paint from tip covers, blade tips, and skin-to-spar bond lines. Epoxy prime, or prime and paint, any exposed bare metal on tip covers, blade tips, and skin-to-spar bond lines. Using an AN970-4 washer or 1965-or-later U.S. quarter-dollar coin, tap-test critical bond areas and verify no dull or hollow sounds. Visually inspect critical bond areas and verify no separation. Install tip covers, ensuring cover edges are flush with blade profile. A016-4 Main Rotor Blade Bond Inspection: Perform R22 SB-103A or subsequent. Main Rotor Blade Inspection: Inspect skins and doublers for scratches and corrosion per § 26-41. Inspect blades for dents and local deformations per § 26-42 and for voids per § 26-44. As required, wax blades with soft cleaning cloths using carnauba-type wax (such as SC Johnson® Paste Wax). Ensure tip cover and blade tip drain holes are unobstructed. WARNING Structural damage may occur if compressed air is applied to blade tip drain holes. 14. Cabin General: Verify no loose equipment that might interfere with controls. Seat Belts: Inspect condition. Verify no fraying, broken stitching, holes, or rotting. Verify no significant discoloration due to UV damage. Check inertia reels for proper operation. Check buckles for proper operation. Verify security. NOTE TSO tag not required on factory-installed harnesses. Windows: Minor defects or imperfections that do not impair pilot's visibility are considered acceptable. Acceptable defects include: One nick, no more than 0.010 inch deep and no larger than 0.25 by 0.50 inch per square foot. Scratches no more than 0.010 inch deep and 5 inches long. Any surface defect such as small spots or stains that can be removed with light polishing. For cracks and crazing adjacent to windshield edges refer to § 25-20. Yaw String: Inspect condition. Minimum 3 inches long each side. Verify security. Page 2.38 Chapter 2 Inspection OCT 2018 2.410 Inspection Procedures and Checklist (continued) 14. Cabin (continued) Exterior: Inspect condition. Verify no cracks, corrosion, or damage. Verify no loose rivets. Loose rivets may be indicated by cracked paint and/or black residue around heads. Left and Right Navigation Lights: Inspect condition. Verify red left, green right, lens cleanliness, and security. Doors