Pilot’s Operating Handbook for Robinson R44

landing within 5 minutes in case of fire. Alternator, RPM governor, low rotor RPM warning system, OAT gage, and cyclic trim or hydraulic control system must be operational for dispatch. Minimum crew is one pilot. Solo flight from right seat only. Forward left seat belt must be buckled. Operation up to 100 KIAS approved with any combination of cabin doors removed. All seat belts must be buckled and loose items in cabin must be properly secured during doors-off flight. FAA APPROVED: 21 FEB 2014 2-6 ROBINSON MODEL R44 SECTION 2 LIMITATIONS KINDS OF OPERATION LIMITATIONS VFR day and night operations are approved. VFR operation at night is permitted only when landing, navigation, instrument, and anti-collision lights are operational. Orientation during night flight must be maintained by visual reference to ground objects illuminated solely by lights on the ground or adequate celestial illumination. Note: There may be additional requirements in countries outside the United States. FUEL LIMITATIONS APPROVED FUEL GRADES 1OOLL grade aviation fuel 100/130 grade aviation fuel FUEL CAPACITY Total Capacity US gallons (liters) Usable Capacity US gallons (liters) Tanks with bladders: Main tank Auxiliary tank Combined capacity 30.5 17.2 47.7 (115) (65) (180) 29.5 17.0 46.5 (112) (64) (176) Tanks without bladders: Main tank Auxiliary tank Combined capacity 31.6 18.5 50.1 (120) (70) (190) 30.6 18.3 48.9 (116) (69) (185) Note: Per R44 Service Bulletin SB-78B, fuel tanks without bladders should no longer be in service. FAA APPROVED: 21 FEB 2014 2-11 PLACARDS (cont’d) Near aux tank fuel gage: For bladder-style tank AUX: 17.0 US GAL For aluminum (non-bladder) tank AUX: 18.3 US GAL In clear view of pilot: MINIMUM SOLO PILOT WEIGHT 150 LB (SEE PILOT’S HANDBOOK) THIS ROTORCRAFT APPROVED FOR DAY AND NIGHT VFR OPERATIONS LOW-G PUSHOVERS PROHIBITED On removable cyclic grip: SOLO FROM RIGHT SEAT ONLY On aircraft without ashtray, in clear view of all occupants: NO SMOKING On aircraft with ashtray, in clear view of all occupants: NO SMOKING IN FRONT SEATS ROBINSON MODEL R44 SECTION 2 LIMITATIONS FAA APPROVED: 21 FEB 2014 2-12 ROBINSON MODEL R44 SECTION 2 LIMITATIONS PLACARDS (cont’d) Inside each baggage compartment: CAUTION DO NOT EXCEED ANY OF THE FOLLOWING: • COMPARTMENT CAPACITY: 50 LB MAX • COMBINED SEAT PLUS COMPARTMENT: 300 LB MAX • ROTORCRAFT GROSS WEIGHT LIMIT SEE ROTORCRAFT FLIGHT MANUAL FOR ADDITIONAL LOADING INSTRUCTIONS. FAA APPROVED: 21 FEB 2014 3-i ROBINSON MODEL R44 SECTION 3 EMERGENCY PROCEDURES SECTION 3 EMERGENCY PROCEDURES CONTENTS Page Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Power Failure - General . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Power Failure Above 500 Feet AGL . . . . . . . . . . . . . . . . 3-2 Power Failure Between 8 Feet and 500 Feet AGL . . . . . 3-2 Power Failure Below 8 Feet AGL . . . . . . . . . . . . . . . . . . 3-3 Maximum Glide Distance Configuration . . . . . . . . . . . . . 3-3 Minimum Rate of Descent Configuration . . . . . . . . . . . . 3-3 Air Restart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Emergency Water Landing - Power Off . . . . . . . . . . . . . 3-4 Emergency Water Landing - Power On . . . . . . . . . . . . . . 3-4 Loss of Tail Rotor Thrust During Forward Flight . . . . . . . 3-5 Loss of Tail Rotor Thrust During Hover . . . . . . . . . . . . . 3-5 Engine Fire During Start on Ground . . . . . . . . . . . . . . . . 3-6 Fire in Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Electrical Fire in Flight . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Tachometer Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Cyclic Trim Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Hydraulic System Failure . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Governor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Warning/Caution Lights . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Low RPM Horn & Caution Light . . . . . . . . . . . . . . . . . . . 3-10 FAA APPROVED: 21 FEB 2014 3-1 ROBINSON MODEL R44 SECTION 3 EMERGENCY PROCEDURES SECTION 3 EMERGENCY PROCEDURES DEFINITIONS Land Immediately - Land on the nearest clear area where a safe normal landing can be performed. Be prepared to enter autorotation during approach, if required. Land as soon as practical - Landing site is at pilot’s discretion based on nature of problem and available landing areas. Flight beyond nearest airport is not recommended. POWER FAILURE - GENERAL A power failure may be caused by either an engine or drive system failure and will usually be indicated by the low RPM horn. An engine failure may be indicated by a change in noise level, nose left yaw, an oil pressure light, or decreasing engine RPM. A drive system failure may be indicated by an unusual noise or vibration, nose right or left yaw, or decreasing rotor RPM while engine RPM is increasing. In case of power failure, immediately lower collective to enter autorotation and reduce airspeed to power-off V ne or below. CAUTION Aft cyclic is required when collective is lowered at high speed. CAUTION Do not apply aft cyclic during touchdown or ground slide to prevent possible blade strike to tailcone. FAA APPROVED: 21 FEB 2014 3-2 ROBINSON MODEL R44 SECTION 3 EMERGENCY PROCEDURES POWER FAILURE ABOVE 500 FEET AGL 1. Lower collective immediately to maintain rotor RPM. 2. Establish a steady glide at approximately 70 KIAS. (For maximum glide distance or minimum rate of descent, see page 3-3.) 3. Adjust collective to keep RPM between 97 and 108% or apply full down collective if light weight prevents attaining above 97%. 4. Select landing spot and, if altitude permits, maneuver so landing will be into wind. 5. A restart may be attempted at pilot’s discretion if sufficient time is available (See “Air Restart Procedure”, page 3-3). 6. If unable to restart, turn unnecessary switches and fuel valve off. 7. At about 40 feet AGL, begin cyclic flare to reduce rate of descent and forward speed. 8. At about 8 feet AGL, apply forward cyclic to level ship and raise collective just before touchdown to cushion landing. Touch down in level attitude with nose straight ahead. POWER FAILURE BETWEEN 8 FEET AND 500 FEET AGL 1. Lower collective immediately to maintain rotor RPM. 2. Adjust collective to keep RPM between 97 and 108% or apply full down collective if light weight prevents attaining above 97%. 3. Maintain airspeed until ground is approached, then begin cyclic flare to reduce rate of descent and forward speed. 4. At about 8 feet AGL, apply forward cyclic to level ship and raise collective just before touchdown to cushion landing. Touch down in level attitude and nose straight ahead. FAA APPROVED: 21 FEB 2014 3-3 ROBINSON MODEL R44 SECTION 3 EMERGENCY PROCEDURES POWER FAILURE BELOW 8 FEET AGL 1. Apply right pedal as required to prevent yawing. 2. Allow rotorcraft to settle. 3. Raise collective just before touchdown to cushion landing. MAXIMUM GLIDE DISTANCE CONFIGURATION 1. Airspeed approximately 90 KIAS. 2. Rotor RPM approximately 90%. 3. Best glide ratio is about 4.7:1 or one nautical mile per 1300 feet AGL. MINIMUM RATE OF DESCENT CONFIGURATION 1. Airspeed approximately 55 KIAS. 2. Rotor RPM approximately 90%. 3. Minimum rate of descent is about 1350 feet per minute. Glide ratio is about 4:1 or one nautical mile per 1500 feet AGL. CAUTION Increase rotor RPM to 97% minimum when autorotating below 500 feet AGL. AIR RESTART PROCEDURE CAUTION Do not attempt restart if engine malfunction is suspected or before safe autorotation is established. 1. Mixture - full rich. 2. Throttle- closed, then cracked slightly. 3. Actuate starter with left hand. FAA APPROVED: 21 FEB 2014 3-4 ROBINSON MODEL R44 SECTION 3 EMERGENCY PROCEDURES EMERGENCY WATER LANDING – POWER OFF 1. Follow same procedures as for power failure over land until contacting water. If time permits, unlatch doors prior to water contact. 2. Apply lateral cyclic when aircraft contacts water to stop rotors. 3. Release seat belt and quickly clear aircraft when rotors stop. EMERGENCY WATER LANDING – POWER ON 1. Descend to hover above water. 2. Unlatch doors. 3. Passengers exit aircraft. 4. Fly to safe distance from passengers to avoid possible injury by rotors. 5. Switch battery and alternator OFF. 6. Roll throttle off into overtravel spring. 7. Keep aircraft level and apply full collective as aircraft contacts water. 8. Apply lateral cyclic to stop rotors. 9. Release seat belt and quickly clear aircraft when rotors stop. TACHOMETER FAILURE If rotor or engine tach malfunctions in flight, use remaining tach to monitor RPM. If it is not clear which tach is malfunctioning or if both tachs malfunction, allow governor to control RPM and land as soon as practical. NOTE Each tach, the governor, and the low RPM warning horn are on separate circuits. A special circuit allows the battery to supply power to the tachs with the battery and alternator switches both OFF. CYCLIC TRIM FAILURE If the automatic cyclic trim fails to compensate for the cyclic feed-back force, land as soon as practical. If the trim generates undesirable forces, switch trim off and land as soon as practical. HYDRAULIC SYSTEM FAILURE Hydraulic system failure is indicated by heavy or stiff cyclic and collective controls. Loss of hydraulic fluid may cause intermittent and/or vibrating feedback in the controls. Control will be normal except for the increase in stick forces. 1. HYD Switch – verify ON. 2. If hydraulics not restored, HYD Switch – OFF. 3. Adjust airspeed and flight condition as desired for comfortable control. 4. Land as soon as practical. GOVERNOR FAILURE If engine RPM governor malfunctions, grip throttle firmly to override the governor, then switch governor off. Complete flight using manual throttle control. ROBINSON MODEL R44 SECTION 3 EMERGENCY PROCEDURES FAA APPROVED: 21 FEB 2014 3-7 FAA APPROVED: 21 FEB 2014 3-10 ROBINSON MODEL R44 SECTION 3 EMERGENCY PROCEDURES WARNING/CAUTION LIGHTS (cont’d) BRAKE Indicates rotor brake is engaged. Release immediately in flight or before starting engine. STARTER-ON Indicates starter motor is engaged. If light does not go out when ignition switch is released from start position, immediately pull mixture off and turn battery switch off. Have starter motor serviced. GOV-OFF Indicates engine RPM throttle governor is off. CARBON MONOXIDE Indicates elevated levels of carbon monoxide (CO) in cabin. Shut off heater and open nose and door vents. If hovering, land or transition to forward flight. If symptoms of CO poisoning (headache, drowsiness, dizziness) accompany light, land immediately. FULL THROTTLE (if installed) Indicates engine near full throttle. The governor will be ineffective because it cannot increase throttle to maintain RPM. Lower collective as required to extinguish light. LOW RPM HORN & CAUTION LIGHT A horn and an illuminated caution light indicate that rotor RPM may be below safe limits. To restore RPM, immediately roll throttle on, lower collective and, in forward flight, apply aft cyclic. The horn and caution light are disabled when collective is full down. FAA APPROVED: 21 FEB 2014 4-i ROBINSON MODEL R44 SECTION 4 NORMAL PROCEDURES SECTION 4 NORMAL PROCEDURES CONTENTS Page Recommended Airspeeds . . . . . . . . . . . . . . . . . . . . . . . 4-1 Daily or Preflight Checks . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Starting Engine and Run-Up . . . . . . . . . . . . . . . . . . . . . . 4-7 Takeoff Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Cruise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Doors-Off Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Practice Autorotation - Power Recovery . . . . . . . . . . . . 4-10 Practice Autorotation - With Ground Contact . . . . . . . . . 4-11 Hydraulics-Off Training . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Use of Carburetor Heat . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Use of Carb Heat Assist . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Approach and Landing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Noise Abatement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 FAA APPROVED: 21 FEB 2014 4-1 ROBINSON MODEL R44 SECTION 4 NORMAL PROCEDURES SECTION 4 NORMAL PROCEDURES RECOMMENDED AIRSPEEDS Takeoff and Climb 60 KIAS Maximum Rate of Climb (VY ) 55 KIAS Maximum Range 100 KIAS* Landing Approach 60 KIAS Autorotation 70 KIAS* * Certain conditions may require lower airspeeds. See placard on page 2-9. DAILY OR PREFLIGHT CHECKS Remove all covers and tiedowns. Remove even small accumulations of frost, ice, or snow, especially from rotor blades. Check maintenance records to verify aircraft is airworthy. An 8-foot step ladder is recommended for preflight inspection of the main rotor; however, main rotor hub may be reached by first opening right rear seat and stepping on seat support and then stepping on deck below the aux fuel tank. Check general condition of aircraft and verify no visible damage, fluid leakage, or abnormal wear. Verify no fretting at seams where parts are joined together. Fretting of aluminum parts produces a fine black powder while fretting of steel parts produces a reddish-brown or black residue. Verify Telatemps show no temperature increase that cannot be attributed to a change in operating conditions (mechanics draw a reference line to the right of the highest temperature square which has darkened in operation). Verify torque stripes on critical fasteners are not broken or missing. DAILY OR PREFLIGHT CHECKS (cont’d) 1. Upper Forward Cowl Doors - Right Side Battery switch . . . . . . . . . . . . . . . . . . . . . . . . . . . ON Oil pressure and alternator lights . . . . . . . . . . . . . . ON Warning light test switches . . . . . . . . . . . Push to test Fuel quantity . . . . . . . . . . . . . . . . . . . . . Check gages Battery switch . . . . . . . . . . . . . . . . . . . . . . . . . . . OFF Aux fuel tank quantity . . . . . . . . . . . . . . . . . . . Check Fuel filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . Tight Aux fuel tank . . . . . . . . . . . . . . . . . . . . . . . . No leaks Fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . No leaks Fuel tank sump, gascolator drains . . . . . . . . . . Sample Gearbox oil . . . . . . . . . . . . . . . . . . . . . . Full, no leaks Hydraulic system . . . . . . . . . . . . . . Fluid full, no leaks Rotor brake . . . . . . . . . . . . . . . . . . . Actuation normal Flex coupling . . . . . . . . . . . . . . . No cracks, nuts tight Yoke flanges . . . . . . . . . . . . . . . . . . . . . . . No cracks Gearbox, hydraulic pump Telatemps . . . . . . . . Normal Control rod ends . . . . . . . . . . . . Free without looseness Steel tube frame . . . . . . . . . . . . . . . . . . . . . No cracks All fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . Tight Tail rotor control . . . . . . . . . . . . . . . . . No interference 2. Main Rotor CAUTION Do not pull down on blades to teeter rotor. To lower a blade, push up on opposite blade. Blades . . . . . . . . . . . . . .Clean and no damage/cracks CAUTION Verify erosion on lower surface of blades has not exposed skin-to-spar bond line. Reference Rotor Systems description in Section 7. FAA APPROVED: 21 FEB 2014 4-2 ROBINSON MODEL R44 SECTION 4 NORMAL PROCEDURES FAA APPROVED: 21 FEB 2014 4-5 ROBINSON MODEL R44 SECTION 4 NORMAL PROCEDURES DAILY OR PREFLIGHT CHECKS (cont’d) 11. Fuselage Left Side Baggage compartments . . . . . . . . . . . . . . . . . . Check Removable controls . . . . . . . . . . . . . Secure if installed Collective control . . . . . . . . . . . . . . . . . . . . . . . . Clear Seat belts . . . . . . . . . . . Check condition and fastened Doors . . . . . . . . . . . . . . . . . . . . Unlocked and latched Door hinge safety pins . . . . . . . . . . . . . . . . . Installed Landing gear . . . . . . . . . . . . . . . . . . . . . . . . . . Check Ground handling wheel . . . . . . . . . . . . . . . . . Removed Position light . . . . . . . . . . . . . . . . . . . . . . . . . . Check Static port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear 12. Nose Section Pitot tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear Windshield condition and cleanliness . . . . . . . . Check Fresh air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear Landing lights . . . . . . . . . . . . . . . . . . . . . . . . . Check 13. Fuselage Right Side Baggage compartments . . . . . . . . . . . . . . . . . . Check Seat belts . . . . . . . . . . . Check condition and fastened Aft door . . . . . . . . . . . . . . . . . . Unlocked and latched Door hinge safety pins . . . . . . . . . . . . . . . . . Installed Landing gear . . . . . . . . . . . . . . . . . . . . . . . . . . Check Ground handling wheel . . . . . . . . . . . . . . . . . Removed Position light . . . . . . . . . . . . . . . . . . . . . . . . . . Check Static port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear 14. Cabin Interior Loose articles . . . . . . . . . . . . . . . Removed or stowed Instruments, switches, and controls . . Check condition Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functioning Adjustable pedals (if installed) . . . . . . . . . Pins secure CAUTION Remove left seat controls if person in that seat is not a rated helicopter pilot. FAA APPROVED: 21 FEB 2014 4-6 ROBINSON MODEL R44 SECTION 4 NORMAL PROCEDURES DAILY OR PREFLIGHT CHECKS (cont’d) CAUTION Fill baggage compartments under unoccupied seats to capacity before using baggage compartments under occupied seats. Avoid placing objects in compartment which could injure occupant if seat collapses during a hard landing. CAUTION Ensure all doors are unlocked before flight to allow rescue or exit in an emergency. CAUTION Shorter pilots may require cushion to obtain full travel of all controls. Verify aft cyclic travel is not restricted. BEFORE STARTING ENGINE Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastened Fuel shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ON Cyclic/collective friction . . . . . . . . . . . . . . . . . . . . . . . . OFF Cyclic, collective, pedals . . . . . . . . . . . . . . . Full travel free Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full travel free Collective . . . . . . . . . . . . . . . . . . . . . Full down, friction ON Cyclic . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral, friction ON Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral Rotor brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disengaged Circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Carb heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OFF Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full rich Mixture guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installed Trim and landing light switches . . . . . . . . . . . . . . . . . . OFF Avionics switch (if installed) . . . . . . . . . . . . . . . . . . . . . OFF Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disengaged Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set HYD and governor switches . . . . . . . . . . . . . . . . . . . . . ON FAA APPROVED: 21 FEB 2014 4-7 ROBINSON MODEL R44 SECTION 4 NORMAL PROCEDURES STARTING ENGINE AND RUN-UP Throttle twists for priming . . . . . . . . . . . . . . . . As required Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closed Battery, strobe switches . . . . . . . . . . . . . . . . . . . . . . . . ON Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear Ignition switch . . . . . . . . . . . . . . . . . . . . . . Start, then Both Starter-On light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Out Set engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 60% Clutch switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engaged Blades turning . . . . . . . . . . . . . . . . . . . Less than 5 seconds Alternator switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ON Oil pressure within 30 seconds . . . . . . . . . 25 psi minimum Avionics, headsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . ON Wait for clutch light out . . . . . . . . . . . . . Circuit breakers in Warm-up RPM . . . . . . . . . . . . . . . . . . . . . . . . . . 60 to 70% Engine gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green Mag drop at 75% RPM . . . . . . . . . . . 7% max in 2 seconds Carb heat . . . . . . . . . . . . . . . CAT rise/drop, set as required Sprag clutch check . . . . . . . . . . . . . . . . . . . . . Needles split Doors . . . . . . . . . . . . . . . . . . . . . . . . . . Closed and latched Limit MAP chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Cyclic/collective friction . . . . . . . . . . . . . . . . . . . . . . . . OFF Cyclic trim or hydraulic system . . . . . . . . . . . . . . . . . Check Governor On, increase throttle . . . . . . . . . . RPM 101-102% Warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Out Lift collective slightly, reduce RPM . . . . . Horn/light at 97% CAUTION On slippery surfaces, be prepared to counter nose-right rotation with left pedal as governor increases RPM. FAA APPROVED: 10 MAR 2015 4-9 ROBINSON MODEL R44 SECTION 4 NORMAL PROCEDURES CRUISE 1. Adjust carb heat if required. (See page 4-12.) 2. Verify RPM in green arc. 3. Set manifold pressure with collective for desired power. 4. For aircraft with manual controls, adjust cyclic trim to zero forces. 5. Verify gages in green, warning lights out. CAUTION If turbulence is expected, reduce power and use a slower than normal cruise speed. CAUTION In-flight leaning with engine mixture control is not allowed. Mixture must be full rich during flight. NOTE When loaded near aft CG limit, slight yaw oscillation during cruise can be stopped by applying a small amount of left pedal. DOORS-OFF OPERATION Maximum airspeed with any door(s) off is 100 KIAS. Warn passengers to secure loose objects and to keep head and arms inside cabin to avoid high velocity airstream. CAUTION Ensure all seat belts are buckled during doors-off flight. Rear seat bottoms may lift if not restrained and items in baggage compartments could be blown out. CAUTION Flight with left door(s) removed is not recommended. Loose objects exiting left doors may damage tail rotor. PRACTICE AUTOROTATION - POWER RECOVERY 1. Adjust carb heat if required. (See page 4-12.) 2. Lower collective to down stop and adjust throttle as required for small tachometer needle separation. CAUTION To avoid inadvertent engine stoppage, do not chop throttle to simulate a power failure. Always roll throttle off smoothly for small visible needle split. NOTE Governor is inactive below 80% engine RPM regardless of governor switch position. NOTE When entering autorotation from above 4000 feet, reduce throttle slightly before lowering collective to prevent engine overspeed. 3. Adjust collective to keep rotor RPM in green arc and adjust throttle for small needle separation. 4. Keep airspeed 60 to 70 KIAS. 5. At about 40 feet AGL, begin cyclic flare to reduce rate of descent and forward speed. 6. At about 8 feet AGL, apply forward cyclic to level aircraft and raise collective to control descent. Add throttle if required to keep RPM in green arc. CAUTION Simulated engine failures require prompt lowering of collective to avoid dangerously low rotor RPM. Catastrophic rotor stall could occur if the rotor RPM ever drops below 80% plus 1% per 1000 feet of altitude. FAA APPROVED: 10 MAR 2015 4-10 ROBINSON MODEL R44 SECTION 4 NORMAL PROCEDURES FAA APPROVED: 10 MAR 2015 4-13 APPROACH AND LANDING 1. Make final approach into wind at lowest practical rate of descent with initial airspeed of 60 knots. Adjust carb heat as required. 2. Reduce airspeed and altitude smoothly to hover. (Be sure rate of descent is less than 300 FPM before airspeed is reduced below 30 KIAS.) 3. From hover, lower collective gradually until ground contact. 4. After initial ground contact, lower collective to full down position. CAUTION When landing on a slope, return cyclic control to neutral before final reduction of rotor RPM. CAUTION Never leave helicopter flight controls unattended while engine is running. CAUTION Hold throttle closed if passenger is entering or exiting left front seat with engine running and left seat collective installed. ROBINSON MODEL R44 SECTION 4 NORMAL PROCEDURES FAA APPROVED: 21 FEB 2014 4-14 ROBINSON MODEL R44 SECTION 4 NORMAL PROCEDURES SHUTDOWN PROCEDURE Collective down, RPM 60-70% . . . . . . . . . . . . . Friction ON Cyclic and pedals neutral . . . . . . . . . . . . . . . . . Friction ON Trim switch (if installed) . . . . . . . . . . . . . . . . . . . . . . . . OFF CHT drop . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle closed Clutch switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Disengage Wait 30 seconds . . . . . . . . . . . . . . . . . . . . . . . Mixture OFF Mixture guard . . . . . . . . . . . . . . . . . . . . . . Back on mixture Wait 30 seconds . . . . . . . . . . . . . . . . . . . Apply rotor brake Clutch light . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extinguishes Avionics, alt, battery, and ignition switches . . . . . . . . . OFF CAUTION Do not slow rotor by raising collective during shutdown. Blades may flap and strike tailcone. NOTE During idle and after engine shutdown, pilot should uncover one ear and listen for unusual noise which may indicate impending failure of a bearing or other component. NOTE HYD switch should be left ON for start- up and shutdown to reduce possibility of unintentional hydraulics-off liftoff. Switch OFF only for pre-takeoff controls check or hydraulics-off training. SECTION 6 WEIGHT AND BALANCE CONTENTS Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Weight and Balance Record . . . . . . . . . . . . . . . . . . . . . . 6-2 Loading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 REVISED: 21 FEB 2014 6-i ROBINSON MODEL R44 SECTION 6 WEIGHT AND BALANCE REVISED: 21 FEB 2014 6-1 ROBINSON MODEL R44 SECTION 6 WEIGHT AND BALANCE SECTION 6 WEIGHT AND BALANCE GENERAL The helicopter must be flown only within weight and balance limits specified in Section 2. Loadings outside these limits can result in insufficient control travel for safe operation. The center of gravity may be adjusted by adding removable ballast (any appropriate item of mass) to any under-seat baggage compartment. Recalculate weight and balance after adding ballast, and verify ballast meets baggage compartment limits given in Section 2. Loaded helicopter weight and balance can be determined using the method given under LOADING INSTRUCTIONS. In accordance with FAA procedures, the detail weight and balance data of this section are not subject to FAA approval. The loading instructions of this section, however, have been approved by the FAA as satisfying all requirements for instructions on loading of the rotorcraft within approved limits of weight and center of gravity and on maintaining the loading within such limits. CAUTION Fuel burn causes CG to move forward during flight. Always determine safe loading with empty fuel as well as with takeoff fuel. Payload may be limited by forward CG as fuel is burned. WEIGHT AND BALANCE RECORD The following form should be used to maintain a continuous record of your helicopter’s weight and balance. Each time an item of equipment is removed or installed, an entry must be made and the new empty CG determined. The original factory weight and balance and an equipment list is supplied with each helicopter on a form which is inserted at the end of this section. This weight and balance provides the first entry in the Weight and Balance Record form. NOTE Calculated CG with full fuel and 150 lb pilot must be within CG limits. Following modification, ad- justment to fixed nose ballast may be required. See R44 Maintenance Manual. REVISED: 21 FEB 2014 6-2 ROBINSON MODEL R44 SECTION 6 WEIGHT AND BALANCE REVISED: 21 FEB 2014 6-3 ROBINSON MODEL R44 SECTION 6 WEIGHT AND BALANCE WEIGHT AND BALANCE RECORD (Continuous History of Changes in Structure or Equipment Affecting Weight and Balance) HELICOPTER MODEL R44 SERIAL NUMBER: DATE DESCRIPTION OF ARTICLE OR MODIFICATION WEIGHT CHANGE RUNNING BASIC EMPTY WEIGHT ADDED (+) REMOVED (—) WEIGHT (lb) LONGITUDINAL LATERAL (+ = RIGHT SIDE) WEIGHT (lb) LONGITUDINAL LATERAL Arm (in.) Moment (in.-lb) Arm (in.) Moment (in.-lb) Arm (in.) Moment (in.-lb) Arm (in.) Moment (in.-lb) HELICOPTER AS WEIGHED WEIGHT AND BALANCE RECORD (cont’d) REVISED: 21 FEB 2014 6-4 ROBINSON MODEL R44 SECTION 6 WEIGHT AND BALANCE LOADING INSTRUCTIONS The following table may be used when calculating loaded helicopter weight and CG position. COMMON ITEM WEIGHT & CG Item Weight (lb) Longitudinal arm (in.) Lateral arm (in.) (+ = right side) Pilot (right forward seat) 49.5* +12.2 Left forward passenger 49.5* —10.4 Baggage under forward seats 44.0 ±11.5 Aft passengers and baggage under aft seats 79.5 ±12.2 Main fuel** 106.0 —13.5 Aux fuel** 102.0 +13.0 Forward doors 7.5 each 49.4 ±24.0 Aft doors 7.0 each 75.4 ±23.0 Removable cyclic 0.6 35.8 —8.0 Removable collective 0.8 47.0 —21.0 Removable pedals (both pedals) 0.8 16.8 —9.5 * If additional backrest cushion is used, subtract thickness of compressed cushion. ** A longitudinal arm of 104.5 in. may be used for combined main and aux fuel. REVISED: 21 FEB 2014 6-5 ROBINSON MODEL R44 SECTION 6 WEIGHT AND BALANCE LOADING INSTRUCTIONS (cont’d) The following sample calculation demonstrates how to determine loaded helicopter weight and center of gravity. A worksheet is provided on the page following the sample calculation for a weight and balance calculation for your helicopter. These may be compared with the CG limits given in Section 2 to determine safe loading. Both takeoff and empty fuel conditions must be within limits. Lateral CG usually falls well within limits for conventional loadings. If an unusual lateral installation or loading occurs, lateral CG should be checked against the CG limits given in Section 2. The lateral reference datum is the aircraft centerline with items to the right positive and items to the left negative. REVISED: 21 FEB 2014 6-6 ROBINSON MODEL R44 SECTION 6 WEIGHT AND BALANCE LOADING INSTRUCTIONS (cont’d) SAMPLE LOADING CALCULATION Item Weight (lb) Location Moment Long. Arm (in.) Lat. Arm (in.) += Right Side Long. (in.-lb) Lat. (in.-lb) Basic empty weight 1460 106.2 0.2 155,052 292 Remove forward right door —7.5 49.4 24.0 —371 —180 Remove forward left door 49.4 —24.0 Remove aft right door 75.4 23.0 Remove aft left door 75.4 —23.0 Remove cyclic 35.8 —8.0 Remove collective 47.0 —21.0 Remove pedals (both) 16.8 —9.5 Pilot (forward right seat) 170 49.5 12.2 8415 2074 Left forward passenger 170 49.5 —10.4 8415 —1768 Aft right passenger 160 79.5 12.2 12,720 1952 Aft left passenger 130 79.5 —12.2 10,335 —1586 Baggage under forward right seat 10 44.0 11.5 440 115 Baggage under forward left seat 10 44.0 —11.5 440 —115 Baggage under aft right seat 79.5 12.2 Baggage under aft left seat 10 79.5 —12.2 795 —122 Zero usable fuel weight and CG* 2112.5 92.9 0.3 196,241 662 Usable main fuel at 6 lb/gal. 177 106.0 —13.5 18,762 —2390 Usable aux fuel at 6 lb/gal. 102 102.0 13.0 10,404 1326 Takeoff Gross Weight and CG* 2391.5 94.3 —0.2 225,407 —402 * CG location (arm) for loaded helicopter is determined by dividing total moment by total weight. ISSUED: 21 FEB 2014 6-7 ROBINSON MODEL R44 SECTION 6 WEIGHT AND BALANCE LOADING INSTRUCTIONS (cont’d) LOADING CALCULATION WORKSHEET Item Weight (lb) Location Moment Long. Arm (in.) Lat. Arm (in.) += Right Side Long. (in.-lb) Lat. (in.-lb) Basic empty weight Remove forward right door 49.4 24.0 Remove forward left door 49.4 —24.0 Remove aft right door 75.4 23.0 Remove aft left door 75.4 —23.0 Remove cyclic 35.8 —8.0 Remove collective 47.0 —21.0 Remove pedals (both) 16.8 —9.5 Pilot (forward right seat) 49.5 12.2 Left forward passenger 49.5 —10.4 Aft right passenger 79.5 12.2 Aft left passenger 79.5 —12.2 Baggage under forward right seat 44.0 11.5 Baggage under forward left seat 44.0 —11.5 Baggage under aft right seat 79.5 12.2 Baggage under aft left seat 79.5 —12.2 Zero usable fuel weight and CG* Usable main fuel at 6 lb/gal. 106.0** —13.5 Usable aux fuel at 6 lb/gal. 102.0** 13.0 Takeoff Gross Weight and CG* * CG location (arm) for loaded helicopter is determined by dividing total moment by total weight. ** A longitudinal arm of 104.5 in. may be used for combined main and aux fuel. Do not use combined main and aux fuel if calculating lateral arm. THIS PAGE INTENTIONALLY BLANK ISSUED: 21 FEB 2014 6-8 ROBINSON MODEL R44 SECTION 6 WEIGHT AND BALANCE ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 10 MAR 2015 7-i SECTION 7 SYSTEMS DESCRIPTION CONTENTS Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Rotor Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Powerplant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Removable Flight Controls . . . . . . . . . . . . . . . . . . . . . . . 7-5 RPM Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Automatic Cyclic Trim . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Control Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . 7-8 Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Clutch Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Audio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Optional Avionics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Pitot-Static System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Dual Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Warning and Caution Lights . . . . . . . . . . . . . . . . . . . . . . 7-23 Cabin Heating and Ventilation . . . . . . . . . . . . . . . . . . . . 7-24 Seats, Belts, and Baggage . . . . . . . . . . . . . . . . . . . . . . . 7-24 Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Rotor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Engine Primer System (Optional) . . . . . . . . . . . . . . . . . . 7-26 Carbon Monoxide Detector . . . . . . . . . . . . . . . . . . . . . . 7-27 Emergency Locator Transmitter (Optional) . . . . . . . . . . . 7-28 Optional Accessory Mounts . . . . . . . . . . . . . . . . . . . . . . 7-29 REVISED: 10 MAR 2015 7-1 SECTION 7 SYSTEMS DESCRIPTION GENERAL The R44 is a four-place, single main rotor, single engine helicopter constructed primarily of metal and equipped with skid-type landing gear. The primary fuselage structure is welded steel tubing and riveted aluminum sheet. The tailcone is a monocoque structure in which aluminum skins carry most primary loads. Fiberglass and thermoplastics are used in secondary cabin structure, engine cooling shrouds, and various other ducts and fairings. The cabin doors are also constructed of fiberglass and thermoplastics. Four right-side cowl doors provide access to the main gearbox, drive system, and engine. A left-side engine cowl door provides access to the engine oil filler and dip stick. Additional access to controls and other components for maintenance is provided by removable panels and cowlings. Stainless steel firewalls are located forward of and above the engine. The four cabin doors are removable. Refer to Section 8 for removal and installation procedures. ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 10 MAR 2015 7-2 ROTOR SYSTEMS The main rotor has two all-metal blades mounted to the hub by coning hinges. The hub is mounted to the shaft by a teeter hinge. The coning and teeter hinges use self-lubricated bearings. Droop stops for the main rotor blades provide a teeter hinge friction restraint which normally prevents the rotor from teetering while starting or stopping. Pitch change bearings for each blade are enclosed in a housing at the blade root. The housing is filled with oil and sealed with an elastomeric boot. Each blade has a thick stainless steel spar at the leading edge which is resistant to corrosion and erosion. The skins are bonded to the spar approximately one inch aft of the leading edge. Blades must be refinished if the paint erodes to bare metal at the skin-to-spar bond line. Bond may be damaged if bond line is exposed. The tail rotor has two all-metal blades and a teetering hub with a fixed coning angle. The pitch change bearings have self-lubricated liners. The teeter hinge bearings either have self-lubricated liners or are elastomeric. The tail rotor blades are constructed with aluminum skins and root fittings. Maintaining the paint finish will reduce corrosion and erosion. DRIVE SYSTEM A vee-belt sheave is bolted directly to the engine output shaft. Vee-belts transmit power to the upper sheave which has an overrunning clutch contained in its hub. The inner shaft of the clutch transmits power forward to the main rotor and aft to the tail rotor. Flexible couplings are located at the main gearbox input and at each end of the long tail rotor drive shaft. The main gearbox contains a single-stage spiral-bevel gear set which is splash lubricated. Cooling ducts under the gearbox are connected to the top of the engine cooling scroll. The main gearbox is supported by four rubber mounts. ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 21 FEB 2014 7-4 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION FLIGHT CONTROLS Dual controls are standard equipment and all primary controls are actuated through push-pull tubes and bellcranks. Bearings used throughout the control system are either sealed ball bearings which do not require lubrication or have self-lubricated liners. Flight control operation is conventional. The cyclic is center mounted with the left and right control grips mounted to a cross tube which pivots on the center cyclic post. On later aircraft, the pilot’s cyclic grip angle can be adjusted fore and aft relative to the cross tube by a mechanic to achieve the most comfortable hand position. The most forward position provides the most control clearance at aft cyclic for larger pilots. Pilots should always verify the ability to apply full control travel prior to flight. Collective operation is conventional. The engine throttle is correlated to collective inputs through a mechanical linkage. When the collective is raised, the throttle is opened and when the collective is lowered, the throttle is closed. The collective stick also incorporates a twist grip throttle control which is described in the Engine Controls section. CAUTION Above 4000 feet, throttle-collective correla- tion and governor are less effective. There- fore, power changes should be slow and smooth. CAUTION At high power settings above 4000 feet, the throttle is frequently wide open and RPM must be controlled with collective. On later aircraft, right-side tail rotor pedals are adjustable. To adjust, remove quick-release pin on each pedal by depressing button and pulling. Slide pedal fore or aft to most comfortable of three adjustment positions and reinstall quick-release pin. Verify pins are secure before flight. REVISED: 21 FEB 2014 7-5 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REMOVABLE FLIGHT CONTROLS Left seat pilot controls may be removed and installed by maintenance personnel or pilots as follows: 1. To remove cyclic grip, remove quick-release pin by depressing button and pulling, then pull outward on left grip while supporting cyclic center post. On aircraft with hydraulic controls, rotate right-side cyclic cross tube clockwise to stop, depress stop pin under cyclic pivot, and continue clockwise rotation one turn to wind up balance spring. To install removable cyclic grip, use reverse procedure. NOTE Later aircraft have a knurled ring next to the quick-release pin which may be hand tightened to eliminate freeplay. The ring must be loose (rotate counterclockwise looking inboard) to remove pin. CAUTION Overrotating cyclic cross tube in either wound or unwound direction will damage balance spring. CAUTION After removing cyclic grip, place plastic cap on exposed cyclic cross tube to prevent possible injury to left seat passenger. 2. To remove collective, push boot aft to expose locking pins. Depress locking pins and pull forward on stick. To install, use reverse procedure. It may be necessary to rotate stick slightly to allow pins to snap into place. CAUTION When collective is installed, ensure that both locking pins are fully engaged through holes on each side. 3. To remove tail rotor pedals, depress locking pin while twisting pedal counterclockwise, then pull up. To install, use reverse procedure. On later aircraft, a cover which is stowed under the floor scuff plate may be rotated up to cover the floor openings when the pedals are removed. REVISED: 10 MAR 2015 7-6 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION RPM GOVERNOR The governor maintains engine RPM by sensing changes and applying corrective throttle inputs through a friction clutch which can be easily overridden by the pilot. The governor is active only above 80% engine RPM and can be switched on or off using the toggle switch on the end of the right seat collective. The governor is designed to assist in controlling RPM under normal conditions. It may not prevent over- or under-speed conditions generated by aggressive flight maneuvers. CAUTION When operating at high density altitudes, governor response rate may be too slow to prevent overspeed during gusts, pull-ups, or when lowering collective. ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 10 MAR 2015 7-8 CONTROL FRICTION ADJUSTMENT Cyclic and collective controls are equipped with adjustable friction devices. The collective friction lever is located near the aft end of the pilot’s collective. It is actuated aft to increase friction and forward to release it. The cyclic friction knob is located left of the cyclic center post. Turning the knob clockwise applies friction to both longitudinal and lateral cyclic. CAUTION Control friction must be used with caution during flight. Excessive friction may make the helicopter difficult to control. The pedals actuate push-pull controls connected directly to the tail rotor pitch control and do not incorporate any friction devices. ENGINE CONTROLS A twist-grip throttle control is located on each collective stick. The controls are interconnected and actuate the throttle valve through a mechanical linkage. The engine throttle is also correlated to collective inputs through a mechanical linkage. When the collective is raised, the throttle is opened and when the collective is lowered, the throttle is closed. The electronic engine governor makes minor throttle adjustments by rotating the twist grip to maintain RPM within power-on limits. Manual manipulation of the twist grip is not typically required except during start up, shut down, autorotation practice, and emergencies. An overtravel spring located in the throttle linkage allows the pilot to roll throttle off beyond the idle stop prior to a ground contact (run-on) autorotation landing. This prevents the throttle from opening when the collective is raised. ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 21 FEB 2014 7-9 ENGINE CONTROLS (cont’d) Correct throttle linkage adjustment may be verified during preflight by rolling the twist-grip through the overtravel spring and holding against the hard idle stop. The carburetor throttle arm should just barely start to move when the collective is raised full up. Other engine controls include a mixture control located forward and to the right of the cyclic center post and a carburetor heat control located to the left of the cyclic. Later R44s are equipped with Carb Heat Assist which is described in Section 4. CLUTCH ACTUATOR After the engine is started, it is coupled to the rotor drive system through vee-belts which are tensioned by raising the upper drive sheave. An electric actuator, located between the drive sheaves, raises the upper sheave when the pilot engages the clutch switch. The actuator senses compressive load (belt tension) and switches off when the vee-belts are properly tensioned. The clutch caution light illuminates whenever the actuator circuit is energized, either engaging, disengaging, or retensioning the belts. The light stays on until the belts are properly tensioned or completely disengaged. Belt slack during engine start should be adjusted such that blades begin turning within five seconds of clutch engagement. Excessive slack may cause belts to jump out of sheave grooves during start. Periodic readjustment by a mechanic may be required as belts wear in service. A fuse located on the test switch panel prevents an actuator motor overload from tripping the circuit breaker and turning off the caution light prematurely. CAUTION Never take off while clutch caution light is on. ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 21 FEB 2014 7-10 FUEL SYSTEM The fuel system is gravity-flow (no fuel pumps) and includes main and auxiliary tanks, a shutoff valve control located between the front seats, and a strainer (gascolator). The fuel tanks have flexible bladders in aluminum enclosures. Fuel tank air vents are located inside the mast fairing. Plunger-style drain valves are provided for the gascolator and for each fuel tank sump. The gascolator is located on the lower right side of the firewall and is drained by pushing up on the plastic tube which extends below the belly. Valves for both tanks are located inside the right cowl door below the auxiliary tank. Fuel samples are taken by extending the plastic tubes clear of the aircraft and pushing on the plungers. Fuel should be sampled from all three locations prior to the first flight of the day and after refueling to verify no contamination and correct grade. The fuel gages are electrically operated by float-type transmitters in the tanks. When the gages read E the tanks are empty except for a small quantity of unusable fuel. The low fuel caution light is actuated by a separate electric sender located on the bottom of the main tank. The auxiliary tank is interconnected with the main tank and is located somewhat higher so it will become empty first while fuel still remains in the main tank. The fuel shutoff valve controls flow from both tanks to the engine. ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 21 FEB 2014 7-11 ELECTRICAL SYSTEM A 14-volt DC electrical system which includes an alternator and a sealed lead-acid battery is standard. A 28-volt electrical system is optional. The battery is located either in the engine compartment, under the left front seat, or beneath the instrument console. The circuit breaker panel is on the ledge just forward of the left front seat. Breakers are marked to indicate function and amperage and are of the push-to-reset type. The battery switch controls the battery relay which disconnects the battery from the electrical system. A wire protected by a fuse near the battery bypasses the battery relay to allow both tachometers and the clock to continue to receive battery power with the battery switch off. The alternator control unit protects the electrical system from overvoltage conditions. The ammeter indicates current to the battery (“—” indicates discharge). An ALT caution light or ammeter discharge indication in flight indicates low voltage and possible alternator failure. Turn off nonessential electrical equipment and switch alternator off then back on after one second to reset alternator control unit. If ALT light stays on or ammeter still indicates discharge, land as soon as practical. CAUTION Continued flight without functioning alterna- tor can result in loss of power to tachom- eters, producing a hazardous flight condition. NOTE Except for emergency procedures, do not operate alternator with battery switched off. The battery helps protect electrical equip- ment from voltage spikes. Later aircraft have an avionics master switch which controls power to the avionics bus. This allows all avionics to be switched on and off by a single switch. ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 21 FEB 2014 7-12 ELECTRICAL SYSTEM (EARLIER AIRCRAFT) ELECTRICAL SYSTEM (cont’d) ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 21 FEB 2014 7-13 ELECTRICAL SYSTEM (LATER AIRCRAFT) ELECTRICAL SYSTEM (cont’d) REVISED: 21 FEB 2014 7-14 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION CIRCUIT BREAKER PANEL – TYPICAL (EARLIER AIRCRAFT) ELECTRICAL SYSTEM (cont’d) REVISED: 21 FEB 2014 7-15 CIRCUIT BREAKER PANEL – TYPICAL (LATER AIRCRAFT) ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION ELECTRICAL SYSTEM (cont’d) REVISED: 21 FEB 2014 7-16 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION LIGHTING SYSTEM A red anti-collision light is installed on the tailcone and is controlled by the strobe switch. Position lights are installed on each side of the cabin and in the tail and are controlled by the nav lights switch. Post and internal lights (earlier aircraft) or a light at the top of the windshield (later aircraft) illuminate the instruments. Instrument lighting is active when the nav lights switch is on and lighting is dimmed via the knob above the nav lights switch. An overhead map light mounted on a swivel is controlled by an adjacent switch. The map light may be used for emergency lighting of the instrument panel. Two landing lights are installed in the nose at different vertical angles to increase the lighted area. One landing light switch controls both lights and is located on the cyclic center post. NOTE Landing lights operate only when clutch actuator switch is in the engage position. An optional flashing light may be mounted on the tailcone in addition to the standard anti-collision light. On earlier aircraft, the optional light is controlled by the strobe switch and the standard light is powered whenever the battery switch is on. On later aircraft, the optional light is controlled by a separate switch. REVISED: 21 FEB 2014 7-17 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION INSTRUMENT PANEL Standard primary instruments include an airspeed indicator, engine and rotor dual tachometer, altimeter, manifold pressure gage, and magnetic compass. Engine gages include an ammeter, oil pressure, oil temperature, cylinder head temperature, and fuel quantity for main and aux tanks. Also standard are a clock, a carburetor air temperature gage, and a digital outside air temperature gage. A collective-activated hourmeter is located right of the pilot’s seat and may be used for recording time in service. (Older aircraft may have an hourmeter activated by engine oil pressure.) Views of typical instrument panels are given on the following pages. Pilots should familiarize themselves with panel layout and equipment installations for each specific aircraft that they fly. REVISED: 21 FEB 2014 7-18 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION 1. VERTICAL SPEED INDICATOR 21. CLOCK 2. OPTIONAL INSTRUMENT 22. ENGINE INSTRUMENTS 3. AIRSPEED INDICATOR 23. PANEL LIGHTS DIMMER 4. ENGINE AND ROTOR TACHS 24. ROTOR BRAKE LIGHT 5. ALTIMETER 25. NAVIGATION LIGHTS SWITCH 6. OPTIONAL INSTRUMENT 26. STROBE LIGHT SWITCH 7. MANIFOLD PRESSURE GAGE 27. CLUTCH ACTUATOR SWITCH 8. CLUTCH ACTUATOR LIGHT 28. ALTERNATOR SWITCH 9. M.R. GEARBOX TEMP LIGHT 29. BATTERY SWITCH 10. M.R. GEARBOX CHIP LIGHT 30. IGNITION SWITCH 11. CARBON MONOXIDE LIGHT 31. CABIN HEAT 12. STARTER-ON LIGHT 32. INTERCOM 13. T.R. GEARBOX CHIP LIGHT 33. OUTSIDE AIR TEMP/VOLTMETER 14. LOW FUEL LIGHT 34. CABIN AIR 15. LOW RPM LIGHT 35. CARBURETOR HEAT 16. ALT LOW VOLTAGE LIGHT 36. CYCLIC FRICTION 17. ENGINE FIRE LIGHT 37. MIXTURE CONTROL 18. OIL PRESSURE LIGHT 38. ELT SWITCH (OPTIONAL) 19. GOVERNOR-OFF LIGHT 39. HEATED PITOT SWITCH (OPT’L) 20. CARBURETOR AIR TEMP INSTRUMENT PANEL – TYPICAL (EARLIER AIRCRAFT) (Exact panel configuration may vary with optional equipment and date of helicopter manufacture.) REVISED: 21 FEB 2014 7-19 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION OPTIONAL INSTRUMENT PANEL (EARLIER AIRCRAFT) (Exact panel configuration may vary with optional equipment and date of helicopter manufacture.) 1. ENGINE AND ROTOR TACHS 23. OIL PRESSURE LIGHT 2. AIRSPEED INDICATOR 24. ROTOR BRAKE LIGHT 3. ARTIFICIAL HORIZON 25. CARBURETOR AIR TEMP 4. ALTIMETER 26. CLOCK 5. MANIFOLD PRESSURE GAGE 27. ENGINE INSTRUMENTS 6. TURN COORDINATOR 28. PANEL LIGHTS DIMMER 7. HSI 29. NAVIGATION LIGHTS SWITCH 8. VERTICAL SPEED INDICATOR 30. STROBE LIGHT SWITCH 9. OPTIONAL INSTRUMENT 31. CLUTCH ACTUATOR SWITCH 10. OPTIONAL INSTRUMENT 32. ALTERNATOR SWITCH 11. MARKER BEACON 33. BATTERY SWITCH 12. M.R. GEARBOX TEMP LIGHT 34. IGNITION SWITCH 13. T.R. GEARBOX CHIP LIGHT 35. CABIN HEAT 14. M.R. GEARBOX CHIP LIGHT 36. INTERCOM 15. STARTER-ON LIGHT 37. OUTSIDE AIR TEMP/VOLTMETER 16. LOW RPM LIGHT 38. CABIN AIR 17. LOW FUEL LIGHT 39. CARBURETOR HEAT 18. CARBON MONOXIDE LIGHT 40. CYCLIC FRICTION 19. CLUTCH ACTUATOR LIGHT 41. MIXTURE CONTROL 20. GOVERNOR-OFF LIGHT 42. ELT SWITCH (OPTIONAL) 21. ALT LOW VOLTAGE LIGHT 43. HSI SLAVE CONTROL 22. ENGINE FIRE LIGHT INSTRUMENT PANEL – TYPICAL (LATER AIRCRAFT) (Exact panel configuration may vary with optional equipment and date of helicopter manufacture.) ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 10 MAR 2015 7-20 1. VERTICAL SPEED INDICATOR 22. IGNITION SWITCH 2. AIRSPEED INDICATOR 23. PILOT’S SIDE CONSOLE (OPT’L) 3. ENGINE AND ROTOR TACHS 24. ENGINE INSTRUMENTS 4. OPTIONAL INSTRUMENT 25. CARBURETOR AIR TEMP 5. ALTIMETER 26. CLOCK 6. MANIFOLD PRESSURE GAGE 27. PANEL LIGHTS DIMMER 7. CLUTCH ACTUATOR SWITCH 28. CABIN HEAT 8. CLUTCH ACTUATOR LIGHT 29. NAVIGATION LIGHTS SWITCH 9. M.R. GEARBOX TEMP LIGHT 30. ANTI-COLLISION LIGHT SWITCH 10. M.R. GEARBOX CHIP LIGHT 31. AVIONICS MASTER SWITCH 11. CARBON MONOXIDE LIGHT 32. ALTERNATOR SWITCH 12. STARTER-ON LIGHT 33. BATTERY SWITCH 13. T.R. GEARBOX CHIP LIGHT 34. CABIN AIR 14. LOW FUEL LIGHT 35. INTERCOM 15. LOW RPM LIGHT 36. OUTSIDE AIR TEMP/VOLTMETER 16. ALT LOW VOLTAGE LIGHT 37. AVIONICS STACK 17. ENGINE FIRE LIGHT 38. CYCLIC FRICTION 18. OIL PRESSURE LIGHT 39. CARBURETOR HEAT 19. GOVERNOR-OFF LIGHT 40. ELT SWITCH (OPTIONAL) 20. FULL THROTTLE LIGHT 41. MIXTURE CONTROL 21. ROTOR BRAKE LIGHT 42. PITOT HEAT SWITCH (OPT’L) ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 21 FEB 2014 7-21 AUDIO SYSTEM A four-place intercom/audio system is standard and is controlled by a small control panel above the avionics stack. The ICS volume knob controls intercom volume but does not affect radio volume. The VOX squelch knob is used to set the threshold volume at which the intercom is activated. When the VOX knob is turned fully clockwise, keying is required to activate the intercom. A toggle switch allows selection of PILOT ISO mode in which the pilot is connected only to the radio while the copilot and rear passengers remain connected to each other via the intercom. A music input jack is located on the aft seat console. This input is muted when the intercom is active, when transmitting, and during reception of radio signals. Headset jacks are located in the ceiling near each seat. The cyclic grips are equipped with either transmit and intercom buttons or trigger-style intercom/transmit switches. For the trigger-style switch, the first detent activates the intercom and the second detent transmits. Additional intercom buttons are located inboard of the rear seats and on the left forward floor. Audio control panels from several manufacturers are offered as options in place of the standard intercom system. Pilots should consult the manufacturer’s operating instructions if an audio panel is installed. OPTIONAL AVIONICS A wide range of optional avionics are available for the R44. It is not practical to provide a description of all equipment in this manual. All aircraft are delivered with the manufacturers’ operating manuals for each piece of installed equipment. Pilots are referred to the manufacturers’ manuals for detailed operating instructions. Good practice dictates becoming familiar with installed equipment before operating an aircraft. REVISED: 21 FEB 2014 7-22 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION PITOT-STATIC SYSTEM The pitot-static system supplies air pressure to operate the airspeed indicator, altimeter, and vertical speed indicator. The pitot tube is located on the front edge of the mast fairing. The static sources are located on each side of the cabin aft of the rear doors. Water can be drained from pitot-static lines by removing the plastic drain plugs which are accessible through the forward inspection panel on the underside of the cabin. Draining lines should be required only if the airspeed indicator or altimeter appears erratic. Pitot and static sources should be inspected frequently for bugs or other obstructions. DUAL TACHOMETER An electronic engine and rotor dual tachometer is standard. Engine tachometer signal is provided by magneto breaker points. Rotor tachometer signal is provided by two magnetic senders at the main gearbox drive yoke. Each tachometer is on a separate circuit with its own circuit breaker. With battery and alternator switches off, the tachometers continue to receive power from the battery through a bypass circuit as long as the clutch actuator switch is in the engage position. ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 21 FEB 2014 7-23 WARNING AND CAUTION LIGHTS Warning and caution lights include clutch, main gearbox over-temperature, main and tail gearbox chip, engine fire, starter on, low fuel, low RPM, alternator, low oil pressure, rotor brake, carbon monoxide, and full throttle (later aircraft). The clutch light indicates that the clutch actuator is operating. The low RPM light and horn indicate rotor RPM at 97% or below. The engine fire light is actuated by a temperature switch located at the forward end of the horizontal firewall. The low oil pressure and low fuel lights are actuated by sensors in those systems and are independent of the gage indicators. The alternator light warns of a possible alternator failure. The governor-off light indicates the governor is switched off. The main and tail gearbox chip detectors are magnetic devices located in the drain plug of each gearbox. When metallic particles are drawn to the magnets they close an electrical circuit, illuminating the caution light. Metal particles may be caused by a failing bearing or gear, thus giving warning of impending gearbox failure. The main gearbox over-temp light is actuated by a temperature switch located near the input pinion. The carbon monoxide light is actuated by a sensor above the pilot’s heater outlet and indicates elevated cabin carbon monoxide levels. The full throttle light is activated by a switch in the throttle linkage and indicates that the engine is near full throttle. ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION REVISED: 10 MAR 2015 7-24 CABIN HEATING AND VENTILATION Fresh air vents are located in each door and in the nose. Door vents are opened and closed using the knob near the vent door hinge. A rotating knob is provided to lock vents closed. For maximum ventilation, open door vents wide during hover but only one inch or less during cruise. The rotating knob can be used to hold vents partially open. The fresh air inlet in the nose is opened by pulling the vent handle on console face. Rotating the vent handle clockwise will lock its position. Air from the nose inlet is directed along inside surface of the windshield for defogging as well as for ventilation. The cabin heater consists of a muffler heat shroud, a control valve at the firewall, outlets forward of the tail rotor pedals and in the rear footwells, and interconnecting ducting. A heater control knob located on the console face actuates the valve which directs heat either into the cabin or out an overboard discharge on the cabin underside. CAUTION In case of an in-flight engine fire, cabin heat should be turned off to seal cabin area from engine compartment. SEATS, BELTS, AND BAGGAGE The seats are not adjustable but, on later aircraft, the pilot- side pedals are adjustable. Each helicopter is supplied with a cushion which can be placed behind the pilot to position him farther forward. This allows shorter pilots to reach the pedals, the cyclic grip in its most forward position, and controls on the center console. Each seat is equipped with a combined lap belt and inertia reel shoulder strap. The inertia reel is normally free but will lock if there is sudden movement as would occur in an accident. REVISED: 10 MAR 2015 7-25 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION SEATS, BELTS, AND BAGGAGE (cont’d) Four- or five-point harnesses are optional for the front seats. The lap belts on these harnesses should be adjusted to eliminate slack. On five-point harnesses, the lower strap should be adjusted as necessary to ensure that the buckle does not interfere with the cyclic grip in the full aft position. Later harnesses are equipped with a webbing stop located above the inertia reel. The stop limits shoulder strap retraction and should be adjusted so the straps are comfortable without excessive slack. A baggage compartment is located under each seat. Seat cushions hinge forward for access. LANDING GEAR A skid-type landing gear is used. Most hard landings will be absorbed elastically. However, in an extremely hard landing, the struts will hinge up and outward as the crosstube yields (becomes permanently bent) to absorb the impact. Slight crosstube yielding is acceptable. However, yielding which allows the tail skid to be within 30 inches of the ground when the helicopter is sitting empty on level pavement requires crosstube replacement. The four landing gear struts are fitted with aerodynamic fairings to reduce air drag. The helicopter is approved to fly with or without the fairings installed. Abrasion-resistant wear shoes are mounted on the bottom of the skids. These shoes should be inspected periodically, particularly if autorotation landings with ground contact have been performed. Have skid shoes replaced whenever the thinnest point in the wear area is less than 0.06 inches (1.5 mm). ISSUED: 21 FEB 2014 7-26 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION ROTOR BRAKE The rotor brake is mounted on the aft end of the main gearbox and is actuated by a cable connected to a pull handle located on the cabin ceiling. To stop the rotor, use the following procedure: 1. After pulling mixture off, wait at least 30 seconds. 2. Pull brake handle forward and down using moderate force (approximately 10 lb). 3. After rotor stops, it is recommended to use the rotor brake as a parking brake by hooking bead chain in slot in bracket. The brake must be released before starting the engine. When the brake is engaged, the starter is disabled. CAUTION Applying rotor brake without waiting at least 30 seconds after engine stops or using a force which stops rotor in less than 20 seconds may damage brake shoes. ENGINE PRIMER SYSTEM (OPTIONAL) The primer is used to improve engine cold starting. The primer pump is normally mounted to the steel tube frame and is accessible through the lower right cowl door. Some early R44s have the pump mounted in the control tunnel and a knob just forward of the pilot’s seat which actuates the pump via a push-pull cable. Engine priming is performed as follows: 1. Unlock pump handle and pump as required for priming (normally two to three strokes). Pull handle up slowly to allow time for fuel to fill pump. 2. After priming, push handle full down and lock. ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION ISSUED: 21 FEB 2014 7-27 CARBON MONOXIDE DETECTOR The carbon monoxide (CO) detector indicates elevated cabin CO levels. CO is an odorless, toxic gas present in engine exhaust which causes headaches, drowsiness, and possible loss of consciousness. CO levels may become elevated due to an exhaust leak or exhaust recirculation during prolonged hovering. The CO detector system consists of a sensor above the pilot’s heater outlet and a caution light. A system check (light flashes twice) is performed each time power is switched on. A sensor malfunction is indicated by a continuing flash every four seconds. If the caution light illuminates, shut off heater and open nose and door vents as required to ventilate the cabin. If hovering, land or transition to forward flight. If symptoms of CO poisoning (headache, drowsiness, dizziness) accompany caution light, land immediately. Have exhaust system inspected before next flight. Many chemicals can damage the CO sensor. Avoid use of solvents, detergents, or aerosol sprays near the sensor. Temporarily tape off openings in top and bottom of sensor housing when cleaning cabin interior. ISSUED: 21 FEB 2014 7-28 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION EMERGENCY LOCATOR TRANSMITTER (OPTIONAL) The Emergency Locator Transmitter (ELT) installation consists of a transmitter with internal battery pack, an external antenna, and a remote switch/annunciator. The transmitter is mounted to the upper steel tube frame and is accessible through the aft, upper cowl door. The remote switch/annunciator is located left of the cyclic stick. The ELT is operated by a switch on the transmitter and a remote switch in the cockpit. The transmitter switch has been secured in the AUTO or ARM position at installation and should always be in this position for flight. The remote switch/annunciator is a three position switch with indicator light. This switch should also be in the AUTO or ARMED (middle) position for flight. With both switches set to AUTO/ARM, the ELT will begin transmitting when subjected to a high “G” load. When the unit is transmitting, the red indicator light illuminates. Moving the remote switch to ON activates the transmitter. Use the ON position if an emergency landing is imminent and time permits. If the ELT is inadvertently activated, use the RESET position of the remote switch to stop transmission and reset the unit. The red indicator will extinguish when unit is reset. NOTE Earlier aircraft may have ELT installations without remote switch. For more detailed instructions on ELT operation, maintenance, and required tests, refer to manufacturer’s instructions supplied with the unit. ISSUED: 10 MAR 2015 7-29 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION OPTIONAL ACCESSORY MOUNTS Provisions for mounting small, portable items are an option. The provisions use mounting bars located forward of the pilot’s seat, the copilot’s seat, or both. The bars are fitted with one or more clamp assemblies which are compatible with a variety of commercially available accessory mounts. There is a 10 lb total weight limit for items attached to each bar. USB and cigarette-lighter-style power outlets are installed near the inboard end of the mounting bars. The power outlets are protected by the Aux Power circuit breaker and in-line fuses and are placarded with voltage/ current ratings. Wire clamps and a pocket for securing excess wire are also provided. The accessory mounts are intended to provide a safe means of mounting small items such as portable electronic devices. The mounting bar, clamp assembly, and power outlets are approved as part of the aircraft type design, but any items attached are the responsibility of the pilot in command under appropriate operating rules. Ensure that any items attached are secure and do not interfere with flight controls or primary field of view. Route any wires through the wire clamps or secure them to the bar with cable ties or tape. THIS PAGE INTENTIONALLY BLANK ISSUED: 10 MAR 2015 7-30 ROBINSON MODEL R44 SECTION 7 SYSTEMS DESCRIPTION SECTION 8 HANDLING AND MAINTENANCE CONTENTS Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Required Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Required Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Preventive Maintenance by the Pilot . . . . . . . . . . . . . . . 8-3 Alterations to Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Cabin Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Tail Rotor Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Cleaning Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 REVISED: 10 MAR 2015 8-i ROBINSON MODEL R44 SECTION 8 HANDLING AND MAINTENANCE REVISED: 10 MAR 2015 8-1 SECTION 8 HANDLING AND MAINTENANCE GENERAL This section outlines procedures recommended for handling, servicing, and maintaining the R44 helicopter. Every owner should stay in close contact with a Robinson Service Center to obtain the latest service and maintenance information. Owners should also be registered with the factory to receive service bulletins, changes to this handbook, and other helpful information as it becomes available. Federal Regulations place responsibility for maintenance of a helicopter on the owner and operator. The owner/ operator must insure that all maintenance is performed by qualified mechanics and in accordance with the R44 Maintenance Manual (Instructions for Continued Airworthiness), Service Bulletins/Service Letters, and FAA Airworthiness Directives. All limits, procedures, safety practices, time limits, servicing, and maintenance requirements contained in this handbook are considered mandatory. Authorized Robinson Service Centers will have recommended modification, service, and operating procedures issued by the FAA and by Robinson Helicopter Company. This information will be useful in obtaining maximum utility and safety with the helicopter. REQUIRED DOCUMENTS The Airworthiness Certificate (FAA Form 8100-2) must be displayed in the aircraft at all times. The following additional documents must be carried in the aircraft: 1. Registration Certificate (FAA Form 8050-3) 2. Pilot’s Operating Handbook 3. Current Weight and Balance ROBINSON MODEL R44 SECTION 8 HANDLING AND MAINTENANCE REQUIRED DOCUMENTS (cont’d) The following documents should not be carried in the aircraft, but must be available for use by any mechanic or pilot servicing the aircraft: 1. Aircraft Logbook 2. Engine Logbook NOTE Required documents may vary in countries other than the United States. REQUIRED INSPECTIONS Federal Regulations require most civil aircraft of U.S. registry to undergo a complete inspection every twelve months. This annual inspection must be signed off by a mechanic with Inspection Authorization (lA). In addition to the annual inspection, the R44 Maintenance Manual requires a complete inspection after every 100 hours of operation. The helicopter incorporates a number of fatigue life-limited components which must be retired at specified time intervals. A list of these components is contained in the Airworthiness Limitations section of the R44 Maintenance Manual and Instructions for Continued Airworthiness. The R44 helicopter includes many unique features. Without special training, Airframe and Powerplant (A&P) mechanics are not qualified to perform the above inspections. These inspections must be performed only by properly rated personnel who have successfully completed a factory- approved maintenance course of instruction on the R44 helicopter. REVISED: 10 MAR 2015 8-2 ROBINSON MODEL R44 SECTION 8 HANDLING AND MAINTENANCE PARKING 1. Place cyclic control in neutral and apply friction. 2. Put collective full down and apply friction. 3. Align rotor blades approximately fore and aft. Apply rotor brake. Use blade tie-downs in windy conditions. CAUTION If using rotor blade tie-downs, do not overtighten tie-down straps (5 lb max tension). Do not pull down on blades to teeter rotor. To lower a blade, push up on opposite blade. 4. During storm conditions, helicopter should be hangared or moved to a safe area. 5. If helicopter is hangared, turn fuel shutoff valve off. CABIN DOORS All four cabin doors may be removed and installed by maintenance personnel or pilots. To remove a door, disconnect door strut by lifting inboard end of strut while holding door in full open position, remove cotter rings in upper and lower hinge pins, and then lift door off. To install doors, use reverse procedure. Adjust weight and balance as required when removing or installing doors. REVISED: 10 MAR 2015 8-6 ROBINSON MODEL R44 SECTION 8 HANDLING AND MAINTENANCE REVISED: 10 MAR 2015 8-7 ENGINE OIL Recommended maximum oil quantity is nine quarts and minimum quantity for takeoff is seven quarts as indicated on the oil dipstick. The oil and filter should be changed at least every 50 hours or four months, whichever occurs first. If no oil filter is installed, change oil every 25 hours. Check alternator drive belt condition and tension and fan shaft bearing condition at each oil change. To change oil: 1. Ground run or fly helicopter to obtain normal operating temperature. 2. Remove engine side cowls and open quick drain on bottom of sump to drain oil into suitable container. 3. Cut safety wire from oil suction-screen cap located on centerline at accessory (magneto) end of sump. 4. Remove, inspect, clean, and reinstall oil suction screen. Re-safety cap. 5. Cut safety wire (if installed) from oil filter and break loose using wrench or loosen pressure-screen housing bolts. 6. Place suitable container below and inboard of magneto to catch oil retained in filter or screen housing and remove filter or screen housing slowly to allow oil to drain into container. Do not allow oil to drain on magneto housing. 7. Cut filter open to inspect, or inspect and clean pressure screen. 8. Install new filter per instructions printed on filter. Use only Champion CH48108, CH48108-1, Tempest AA48112, or Robinson B123-1 or -2 filter with Robinson filter adapter or use Champion CH48103 or CH48103-1 filter with early-style filter installation. Safety wire is not required on filter. If no filter is installed, re-install pressure screen and housing. Torque pressure-screen housing bolts to 96 in.-lb. ROBINSON MODEL R44 SECTION 8 HANDLING AND MAINTENANCE REVISED: 10 MAR 2015 8-8 ENGINE OIL (cont’d) 9. Close quick drain and fill sump with 9 quarts of appropriate grade oil as recommended below. 10. Start helicopter. Verify oil pressure within 30 seconds. Ground run for a few minutes, shut down, and verify no leaks. 11. Check oil level on dipstick. 12. Install cowlings. 13. Make appropriate maintenance record entries. The following grades of oil are recommended: Average Ambient Air Temperature Mineral Grades MIL-L-6082 or SAEJ1966 (Use first 50 hours) Ashless Dispersant Grades MIL-L-22851 or SAEJ1899 (Use after first 50 hours) All Temperatures — SAE15W50 or SAE20W50 Above 80°F SAE60 SAE60 Above 60°F SAE50 SAE40 or SAE50 30°F to 90°F SAE40 SAE40 0°F to 70°F SAE30 SAE30, SAE40, or SAE20W40 0°F to 90°F SAE20W50 SAE20W50 or SAE15W50 Below 10°F SEA20 SAE30 or SAE20W30 ROBINSON MODEL R44 SECTION 8 HANDLING AND MAINTENANCE REVISED: 10 MAR 2015 8-9 TAIL ROTOR GEARBOX OIL If oil is not visible in the sight gage with helicopter sitting level, oil must be added. To add oil: 1. Cut safety wire (if installed) and remove filler/vent cap located on top of gearbox. 2. Use only Robinson part number A257-2 oil. 3. Fill very slowly to center of sight gage. DO NOT overfill. (Less than a tablespoon of oil is usually required.) 4. Reinstall filler/vent cap. Be sure metal gasket or rubber o-ring is in place. Torque to 100 in.-lb. 5. Safety wire as before. (Safety wire not required if cap is sealed with an o-ring.) Be sure safety wire applies tension in direction which would tighten cap. HYDRAULIC FLUID If hydraulic fluid is not visible in reservoir sight gage with helicopter sitting level, remove filler/vent cap and add Robinson part number A257-15 fluid (MIL-PRF-5606) to center of sight gage. Torque filler/vent cap to 100 in.-lb. NOTE Sight gage reading will be higher with system hot. FUEL Approved fuel grades and fuel capacity are given in Section 2. A small quantity of fuel should be drained from the gascolator and from each tank using the quick drains prior to the first flight each day. Drain enough fuel to remove any water or dirt and check for approved fuel color. If fuel contamination is suspected, continue to drain fuel from gascolator and tank drains until all contamination is eliminated. ROBINSON MODEL R44 SECTION 8 HANDLING AND MAINTENANCE REVISED: 10 MAR 2015 8-10 BATTERY The battery is located in the engine compartment, under the left front seat, or beneath the instrument console. The battery is sealed and does not require fluid level checks. A discharged battery is NOT AIRWORTHY because it will not have the reserve capacity to operate the electrical system should the charging system fail in flight. Often, a 10 or 15 minute charge will improve battery condition enough to start the engine. If battery is located in the engine compartment, open left engine cowl access door and connect positive charger cable to positive (battery side) battery relay terminal. Then, connect negative charger cable to battery ground strap or engine. If battery is located beneath the instrument console, remove console hold down screws (one each side), lift console, remove battery box cover, and connect charger cables directly to battery posts (connect positive cable first). Use extreme caution not to short to console sheet metal. Later console installations are equipped with charging posts on the right side of the console. Charger cables may be connected directly to these posts without accessing the battery. If battery is located beneath the left front seat, open under- seat compartment, remove battery protective panel at forward end of compartment, and connect charger cables as described for engine compartment battery. After charging, disconnect cables (disconnect negative cable first), secure access panels or console as required, and attempt a normal start. If battery still has insufficient charge to start engine, service or replace battery before further flight. ROBINSON MODEL R44 SECTION 8 HANDLING AND MAINTENANCE REVISED: 10 MAR 2015 8-11 CLEANING HELICOPTER CLEANING EXTERIOR SURFACES The helicopter should be washed with mild soap and water. Harsh abrasives, alkaline soaps, or detergents could scratch painted or plastic surfaces or could cause corrosion of metal. Cover areas where cleaning solution could cause damage. Use the following procedure: 1. Rinse away loose dirt with water. 2. Apply cleaning solution with a soft cloth, sponge, or soft bristle brush. 3. To remove stubborn oil and grease, use a cloth dampened with aliphatic naphtha. 4. Rinse all surfaces thoroughly. 5. Any good automotive wax may be used to preserve painted surfaces. Soft cleaning cloths or a chamois should be used to prevent scratches when cleaning or polishing. CAUTION Never use high-pressure spray to clean helicopter. Never blow compressed air into main or tail rotor blade tip drain holes. CLEANING WINDSHIELD AND WINDOWS 1. Remove dirt, mud, and other loose particles from exterior surfaces with clean water. 2. Wash with mild soap and warm water or with aircraft plastic cleaner. Use a soft cloth or sponge in a straight back and forth motion. Do not rub harshly. 3. Remove oil and grease with a cloth moistened with isopropyl alcohol (rubbing alcohol) or aliphatic naphtha. ROBINSON MODEL R44 SECTION 8 HANDLING AND MAINTENANCE REVISED: 10 MAR 2015 8-12 CLEANING HELICOPTER (cont’d) CLEANING WINDSHIELD AND WINDOWS (cont’d) CAUTION Do not use gasoline, other alco- hols, benzene, carbon tetrachlo- ride, thinner, acetone, or window (glass) cleaning sprays. 4. After cleaning plastic surfaces, apply a thin coat of hard polishing wax. Rub lightly with a soft cloth. Do not use a circular motion. 5. Scratches can be removed by rubbing with jeweler’s rouge followed by hand polishing with commercial plastic polish. Use a figure eight motion when polishing. CLEANING UPHOLSTERY AND SEATS 1. Vacuum and brush, then wipe with damp cloth. Dry immediately. 2. Soiled upholstery, except leather, may be cleaned with a good upholstery cleaner suitable for the material. Follow manufacturer’s instructions. Avoid soaking or harsh rubbing. CAUTION Avoid use of solvents, detergents, or aerosol sprays near CO sensor. Tape off openings in top and bottom of sensor housing when cleaning cabin interior. 3. Leather should be cleaned with saddle soap or a mild hard soap and water. CLEANING CARPETS Remove loose dirt with a whisk broom or vacuum. For soiled spots and stains, use nonflammable dry cleaning liquid. ROBINSON MODEL R44 SECTION 8 HANDLING AND MAINTENANCE FAA APPROVED: 21 FEB 2014 9-i ROBINSON MODEL R44 SECTION 9 SUPPLEMENTS SECTION 9 SUPPLEMENTS OPTIONAL EQUIPMENT SUPPLEMENTS Information contained in the following supplements applies only when the related equipment is installed. CONTENTS Page Peak Beam Searchlight . . . . . . . . . . . . . . . 9-4.1 Fixed Floats . . . . . . . . . . . . . . . . . . . . . . . 9-5.1 Heated Pitot . . . . . . . . . . . . . . . . . . . . . . . 9-6.1 Police Version . . . . . . . . . . . . . . . . . . . . . . 9-7.1 ENG Version . . . . . . . . . . . . . . . . . . . . . . . 9-8.1 Garmin GPSMAP 225 . . . . . . . . . . . . . . . . 9-9.1 Pop-Out Floats . . . . . . . . . . . . . . . . . . . . . 9-10.1 ADS-B Equipment . . . . . . . . . . . . . . . . . . . 9-11.1 NON-U.S. SUPPLEMENTS The following supplements contain additional information required by certain countries: Canadian Supplement CIS Supplement Ukranian Supplement ROBINSON MODEL R44 SECTION 9 ADS-B EQUIPMENT SUPPLEMENT 9-11.1 FAA APPROVED R44 PILOT’S OPERATING HANDBOOK ADS-B EQUIPMENT SUPPLEMENT This supplement must be included in the FAA-approved Pilot’s Operating Handbook when ADS-B equipment is installed. The information contained herein supplements or supersedes . t n e m e l p p u s s i h t n i d e t s il s a e r a e s o h t n i y l n o l a u n a m c i s a b e h t For limitations, procedures, and performance information not contained in this supplement, consult the basic Pilot’s Operating Handbook. APPROVED BY: Manager, Flight Test Branch, ANM-160L Federal Aviation Administration, LAACO Transport Airplane Directorate DATE: LOG OF PAGES Page No. Date 9-11.1 9-11.2* 9-11.3* 21 Feb 14 21 Feb 14 21 Feb 14 Page No. Date 9-11.4 9-11.5 9-11.6* 21 Feb 14 21 Feb 14 21 Feb 14 *Manufacturer’s data, not FAA approved. ISSUED: 21 FEB 2014 9-11.2 SECTION 1: GENERAL INTRODUCTION This supplement contains the changes and additional data applicable when Automatic Dependent Surveillance- Broadcast (ADS-B) equipment is installed. ADS-B is divided into two categories – ADS-B “Out” and ADS-B “In”. ADS-B Out equipment transmits information to air traffic control to supplement radar/transponder information. The supplemental information allows optimization of flight plan routes and aircraft spacing. ADS-B Out equipment may be required for operation in certain airspace. The R44 ADS-B Out installation has been shown to meet the requirements of 14 CFR § 91.227. NOTE The R44 ADS-B Out system operates on frequency 1090 MHz. This frequency is also accepted for ADS-B Out equipment in most countries outside the United States. The ADS-B Out equipment consists of a GPS receiver connected to the transponder. The transponder has ADS-B broadcast capability and broadcasts GPS position as well as additional pre-programmed information such as aircraft identification and size to air traffic control. ADS-B In equipment receives traffic and weather information and displays the information for the pilot to aid situational awareness. ADS-B In equipment is not required for general aviation operations in the United States. ROBINSON MODEL R44 SECTION 9 ADS-B EQUIPMENT SUPPLEMENT ISSUED: 21 FEB 2014 9-11.3 ROBINSON MODEL R44 SECTION 9 ADS-B EQUIPMENT SUPPLEMENT SECTION 1: GENERAL (cont’d) INTRODUCTION (cont’d) The ADS-B In equipment consists of a receiver installed under the left, front seat connected to a moving map GPS. Most ADS-B data is broadcast from air traffic control ground stations. Symbols on the GPS screen indicate whether the receiver is within range of a ground station (refer to GPS manufacturer’s documentation). Other aircraft which have been equipped with ADS-B Out systems can broadcast their position directly to the receiver. The R44 may be equipped with only ADS-B Out or with both ADS-B Out and ADS-B In. FAA APPROVED: 21 FEB 2014 9-11.4 SECTION 2: LIMITATIONS PLACARDS On transponder when ADS-B Out equipment is installed: ADS-B OUT INSTALLED SECTION 3: EMERGENCY PROCEDURES No change. SECTION 4: NORMAL PROCEDURES ADS-B SYSTEM OPERATION ADS-B system operation is mostly automatic and requires little pilot action. The primary GPS, transponder, and ADS-B receiver (if installed) must all be powered and in normal operating modes for proper system function. ADS-B OUT The R44 ADS-B Out system is a single point of entry system. Mode 3/A codes, IDENT commands, and emergency codes are set on the transponder and are automatically incorporated in ADS-B Out broadcasts. The transponder should transition to ALT mode after takeoff for proper ADS-B Out broadcasts. ADS-B Out broadcasts may be selected off by using menus associated with the transponder FUNC key. NOTE ADS-B Out may be required in certain airspace. Do not turn off ADS-B Out unless directed by air traffic control. Malfunctions in the ADS-B Out system are annunciated by various messages on the GPS screen (refer to GPS manufacturer’s documentation) and by a “no ADS-B” indication on the transponder screen. ROBINSON MODEL R44 SECTION 9 ADS-B EQUIPMENT SUPPLEMENT FAA APPROVED: 21 FEB 2014 9-11.5 SECTION 4: NORMAL PROCEDURES (cont’d) ADS-B SYSTEM OPERATION (cont’d) ADS-B IN The ADS-B In receiver is mounted underneath the left, front seat and has no direct pilot interface. The receiver is powered by the Transponder/ADS-B circuit breaker. ADS-B In data is displayed on the primary GPS screen when the pilot selects traffic or weather menu pages. Some data may also be overlaid on the moving map page. Certain warnings such as traffic conflicts cause pop-up messages on the GPS display. Control of data display details is via GPS menu interface. Refer to GPS manufacturer’s documentation. Receiver malfunction will be annunciated on the GPS screen. SECTION 5: PERFORMANCE No change. ROBINSON MODEL R44 SECTION 9 ADS-B EQUIPMENT SUPPLEMENT ISSUED: 21 FEB 2014 9-11.6 SECTION 6: WEIGHT AND BALANCE No change. SECTION 7: SYSTEM DESCRIPTION ADS-B SYSTEM The ADS-B Out system consists of a GPS receiver connected to the transponder which broadcasts the aircraft’s position, identification, and certain other parameters to air traffic control. ADS-B data is broadcast via the Extended Squitter (ES) feature of the transponder on a frequency of 1090 MHz. Note that change of aircraft registration may require update of pre-programmed parameters by qualified maintenance personnel. Most of the data required for ADS-B broadcast such as aircraft type, ICAO address, and call sign are pre- programmed at installation. Flight-specific data such as Mode 3/A code and IDENT are entered using the transponder controls. The transponder uses these codes simultaneously for standard transponder as well as ADS-B broadcasts. There is no need to make a second code entry or to enter a code more than once. This is known as a “single point of entry” ADS-B system. The ADS-B In system consists of a receiver mounted under the left, front seat connected to a moving map GPS with software capable of displaying the received ADS-B In data. The receiver receives both approved US ADS-B frequencies (