R44 MAINTENANCE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

1.180 Draining and Flushing Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . 1.8B 1.190 Bleeding Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8C 1.200 Handling, Jacking, Hoisting, Leveling and Weighing . . . . . . . . . . . . . . . . . . . 1.9 1.210 Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 1.211 Ground Handling Wheels Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 1.212 Ground Handling Wheels Installation – Float Ship Landing Gear . . . . . . . . 1.10A 1.213 Moving the Helicopter on Ground Handling Wheels . . . . . . . . . . . . . . . . . 1.11 1.214 Main Rotor Blade Tie-Downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 1.215 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 1.216 Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 1.220 Jacking, Hoisting and Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 1.230 Weighing and CG Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 1.231 Helicopter Weighing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 1.240 Ballast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.ii Chapter 1 General JAN 2021 CHAPTER 1 GENERAL (Continued) Section Title Page 1.300 Fastener Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 1.310 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 1.320 Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 1.330 Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23 1.400 Approved Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 1.410 Paint Strippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 1.420 Solvents and Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 1.430 Fillers and Putty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.440 Torque Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.450 Primers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.455 Powder Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29 1.460 Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31 1.470 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 1.480 Adhesives and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34 1.490 Storage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 1.500 (Reserved) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 1.600 Part Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37 1.700 Special Instructions for Reassembling and Flight Testing R44 Series Helicopters After Crating for Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38 1.800 Replacement Component Identification (Data) Plates . . . . . . . . . . . . . . . . . . 1.42 ROBINSON MAINTENANCE MANUAL R44 SERIES CHAPTER 1 GENERAL 1.000 Introduction The R44 Maintenance Manual contains instructions necessary for proper maintenance, servicing, and handling of R44-series helicopters. The R44 Instructions for Continued Airworthiness (ICA) includes the R44 Maintenance Manual (MM), R44 Illustrated Parts Catalog (IPC), R44 Service Bulletins (SBs), R44 Service Letters (SLs), Lycoming O-540- series and IO-540-series Operator’s Manuals, applicable Lycoming technical publications, and applicable component manufacturer technical publications. Service Bulletins are issued by Robinson Helicopter Company (RHC), Lycoming, and component manufacturers. RHC Service Bulletin compliance is mandatory; comply with other applicable Service Bulletins as directed. RHC technical publications are available online at www.robinsonheli.com. Recent technical publications are available from Lycoming at www.lycoming.com, and from Continental Motors, Inc. (CMI) at www.continentalmotors. aero. Kit instructions are issued for field installation of either optional or mandatory (due to Service Bulletin or parts obsolescence) equipment upgrades, or provisions for upgrades. Kit instruction issued by RHC either implement approved type design data, or are approved as type design data. A list of chapters is located in the Introduction. Chapters are separated by tab dividers and chapter contents are listed in the chapter front pages. CAUTION Always read instructions completely before performing a task. 1.001 RHC Maintenance Manual and Illustrated Parts Catalog Updates RHC Maintenance Manuals (MMs) and Illustrated Parts Catalogs (IPCs) are available digitally at www.robinsonheli.com, under the Publications tab. Access to these publications does not require an account and is free of charge. Viewing MMs & IPCs online is recommended to ensure use of current data. Viewing MMs & IPCs offline via paper or digital download requires verification that the data is current. Refer to the online MM or IPC Revision Log for the list of current pages. Sign up for free email notification of revisions to MMs & IPCs by sending an email to subscriptions@robinsonheli.com with “Subscribe email” in the subject line. Within the email, include name, email address, physical address, and helicopter model(s) of interest. JAN 2021 Chapter 1 General Page 1.1 ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.2 Chapter 1 General JAN 2021 1.002 R44 Maintenance Authorization Only appropriately certificated mechanics who have successfully completed an R44 factory-sponsored maintenance course, or are under direct supervision of the above-stated mechanic, may perform maintenance, repairs, or inspections on R44-series helicopters. Annual inspections of U.S.-registered light helicopters must be performed by holders of an Inspection Authorization (IA) or by repair stations certificated by the Federal Aviation Administration (FAA). The daily preflight and some preventive maintenance may be performed by the above-stated mechanics, or by the pilot/owner after receiving appropriate instruction in accordance with the R44/R44 II/R44 Cadet Pilot’s Operating Handbook and applicable aviation regulations. 1.003 Component Maintenance Authorization Only appropriately certificated mechanics who have successfully completed both a factory- sponsored maintenance course and component maintenance course, and who possess technical data supplied by RHC, are authorized to perform maintenance specified in the Component Maintenance Manual (CMM). Component maintenance may only be performed at an RHC-authorized Service Center that has required Component Maintenance special tools (ref. R44 SL-67). 1.004 Maintenance Record Blank, digital Airframe Maintenance Record forms are available online at www.robinsonheli.com. Airframe Maintenance Record blank PDF forms may be used for R22-series, R44-series, and R66 Turbine helicopters. Component Record blank PDF forms may be used for life- limited or TBO components. Blank paper copies are available for purchase (P/N R8478 Airframe Maintenance Record and P/N R8479 Component Record [pack of 20]). A Component Record is a maintenance record of the removals, installations, or maintenance performed on a life-limited or TBO component. When a life-limited or TBO component is installed in the helicopter, the Component Record card is inserted in the Airframe Maintenance Record. When a life-limited or TBO component is removed from the helicopter, remove the Component Record card and keep the card with the Component. Major assemblies may contain one or more life-limited or TBO component. RHC encourages operators to utilize Component Record cards to assist in tracking time on interchangeable parts since service lives may be different between models. RHC does not create Component Record cards for spares, however, operators may create their own. RHCs Repair Station does not require a Component Record card in order to perform work on a component, unlike a Component/Return Authorization form. RHC recommends using a toner-based laser, or a pigment-based inkjet, color printer and 65 lb white (96 bright) premium card stock for Maintenance Record or Component Record card production. Maintenance Record binders and tab sets are available separately (P/N R8656 Maintenance Record Binder and P/N R8650 Maintenance Record Tabs). ROBINSON MAINTENANCE MANUAL R44 SERIES JAN 2021 Chapter 1 General Page 1.2A 1.005 Notations The following notations will be found throughout the manual: NOTE A NOTE provides emphasis or supplementary explanation. CAUTION Equipment damage can result if a CAUTION is not followed. WARNING Personal injury or death can result if a WARNING is not followed. 1.006 RHC Maintenance Manual and Illustrated Parts Catalog References Maintenance Manual and Illustrated Parts Catalog Section and Figure references are subject to relocation and renumeration. Effort will be made at the time of RHC technical document revisions to correct superseded references, however, certain documents may not otherwise require revision and superseded references may remain. A keyword or part number search in online documents (Ctrl+F [PC] or Command+F [Mac]) may help to locate applicable data. ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.2B Chapter 1 General JAN 2021 1.007 Definitions and Abbreviations Refer to R44/R44 II/R44 Cadet Pilot's Operating Handbook (POH) Section 1, as applicable, for additional definitions and abbreviations. A. Definitions 14 CFR § 27.602 Critical Part: 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 R44 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 R44-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 R44/R44 II/R44 Cadet POH Section 6, as applicable, for installed equipment. Life-Limited Part: Refer to Chapter 3. Any part for which a mandatory replacement limit is specified in the type design, the Instructions for Continued Airworthiness, or the maintenance manual. Time in Service: With respect to maintenance time records, time in service means the time from the moment an aircraft leaves the surface of the earth until it touches it at the next point of landing. ROBINSON MAINTENANCE MANUAL R44 SERIES JAN 2021 Chapter 1 General Page 1.3 1.007 Definitions and Abbreviations (continued) B. Abbreviations 14 CFR: Title 14 of the Code of Federal Regulations. The Federal Aviation Regulations (FARs) are part of the CFR. AOG: Aircraft on Ground ATA-100: Air Transport Association of America Specification No. 100 BL: Butt Line Station locations CO: Carbon Monoxide CRA: Component Return/Authorization ELT: Emergency Locator Transmitter EMU: Engine Monitoring Unit FS: Fuselage Station locations HID: High Intensity Discharge HS: Horizontal Stabilizer Station locations ICA: Instructions for Continued Airworthiness LBL: Left Butt Line Station locations LED: Light Emitting Diode LH: Left-hand LRU: Line-Replaceable Unit MRDS: Main Rotor Drive Shaft MRGB or MGB: Main Rotor Gearbox or Main Gearbox OEM: Original Equipment Manufacturer R44 IPC: R44 Illustrated Parts Catalog R44 MM: R44 Maintenance Manual R44 POH: R44 Pilot’s Operating Handbook R44 II POH: R44 II Pilot’s Operating Handbook R44 Cadet POH: R44 Cadet Pilot’s Operating Handbook RBL: Right Butt Line Station locations RH: Right-hand RHC: Robinson Helicopter Company RS: Rotor Station locations SB: Service Bulletin SDS: Safety Data Sheet SL: Service Letter TBO: Time Between Overhaul TCDS: Type Certificate Data Sheet TRDS: Tail Rotor Drive Shaft TRGB or TGB: Tail Rotor Gearbox or Tail Gearbox TS: Tailcone Station locations TSN: Time Since New TSO: Time Since Overhaul WL: Water Line Station locations ROBINSON MAINTENANCE MANUAL R44 SERIES 1.008 Service Information A. Part Designation RHC parts are designated with an alphanumeric part number beginning with letter “A”, “B”, “C”, etc., followed by three digits and a dash number. A revision letter or letters follow(s) the stamped or ink-marked part number. Revision progression is A thru Z, followed by AA thru AZ, followed by BA thru BZ, etc. Unless otherwise specified, any revision of the same part number is interchangeable, such as “A101-1 A” and “A101-1 D”. A change in dash number indicates a change in form, fit, and/or function (e.g. part number C339-1 is not interchangeable with part number C339-10 even though both are jackshaft weldments for [hydraulic] R44s). Similarly, part numbers F049-6 and F049-06 are not interchangeable because the dash numbers are different. B. Returning Parts All parts shipped to RHC must include a signed Component Return/Authorization (CRA) Form available online at www.robinsonheli.com. C. Ordering and Shipping Procure parts from any R44 Dealer or Service Center, or order directly from assigned RHC Customer Service Representative via email, fax, or phone. D. Warranty Claims Complete CRA Form (refer to Part B) and, in the Warranty Claim section, indicate if rotorcraft or component is under warranty. If claim is for parts or for labor allowance due to a Service Bulletin issued against rotorcraft or component, write in “per SB-XX” adjacent to requested warranty action. E. Customer Support Please visit www.robinsonheli.com for Customer Support contact information. Page 1.3A Chapter 1 General JAN 2021 ROBINSON MAINTENANCE MANUAL R44 SERIES Intentionally Blank JAN 2021 Chapter 1 General Page 1.3B ROBINSON MAINTENANCE MANUAL R44 SERIES Page 1.3C Chapter 1 General JAN 2021 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 342 (IO-540 Only) Fuel Line (Stainless Steel Tube Assy.) and Support Clamp Inspection & Installation. Reference AD 2015-19-07. • Perform Lycoming SB 388* (also applies to replacement cylinders) Procedure to Determine Exhaust Valve and Guide Condition. • • Perform Lycoming SB 480 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. • • Perform main rotor blade tip maintenance per § 9.150. • • Lubricate C181-3 bearing per § 1.140. • • Replace hydraulic filter per § 1.170. • Drain and flush gearboxes per § § 1.120 & 1.130. • Clean gearbox chip detectors per § 1.115. • • Perform clutch assembly lubricant inspection & servicing per § 7.210. • Perform 2200-hour inspection per § 2.700. • Inspect emergency locator transmitter (ELT) per 14 CFR § 91.207. • Perform pop-out float leak check per § 5.630. • Test and inspect transponder per 14 CFR § 91.413. • Perform pop-out float inflation check per § 5.640. • Perform pop-out float pressure cylinder hydrostatic test.* • Pop-out float pressure cylinder maximum life. • * Shorter interval than published on referenced document. First 10 hours First 25 hours First 100 hours Every 50 hours Every 100 hours Every 300 hours Every 500 hours Every 2200/2400 hours Every 4 months Every 12 months Every 24 months Every 3 years Every 4 years Every 12 years Every 15 years TABLE 1 SCHEDULED INSPECTIONS Consult latest revision of listed publications for specific applicability. ROBINSON MAINTENANCE MANUAL R44 SERIES 1.100 Helicopter Servicing 1.101 Scheduled Maintenance and Inspections Required maintenance and inspection intervals are given in Table 1. Some aircraft may require maintenance and inspections in addition to the requirements in Table 1. Consult aircraft maintenance records, Service Bulletins (SB), aviation regulations, Airworthiness Limitations, and Airworthiness Directives (AD) for applicability. Publications listed are subject to revision. 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. 1.105 Calibration of Tools The dimensions and tolerances given in this maintenance manual are critical. RHC recommends measuring tools be calibrated at least once a year. This includes torque wrenches, micrometers, calipers, dial indicators, spring scales, protractors and balancing equipment. WARNING Proper torque is critical. Always use calibrated wrenches and undamaged, properly lubricated (where applicable) hardware. Ensure all clamping surfaces are clean, and clamp only bare metal or wet-primed surfaces. Improper torque or dirty or painted clamping surfaces may result in loss of clamp-up, hardware or part damage, and premature failure. 1.110 Lubrication - General Most bearings in the R44 are sealed or self-lubricated and do not require periodic lubrication; bearings with specific lubrication intervals are noted in Table 1. Engine lubrication requirements are contained in the Pilot’s Operating Handbook, Lycoming Operator’s Manual and Lycoming Service Instruction No. 1014 (current revision). Main and tail rotor gearboxes require additional oil when indicated by sight plug reading. WARNING The only approved lubricant for use in the main rotor and tail rotor gearboxes is A257-2 lubricant. When a new or overhauled gearbox is installed, it must be drained and the chip detector inspected after the first 4 hours of flight or first chip light, whichever occurs first. Thereafter, change gearbox oil at intervals per Section 1.101. Additionally, change gearbox oil and clean sight glass whenever oil becomes so dirty that its level cannot be determined. JUN 2014 Page 1.3D ROBINSON MAINTENANCE MANUAL R44 SERIES 1.115 Chip Detector Cleaning During normal gearbox operation, an insulating film of varnish can accumulate on a chip detector’s magnetic probe and prevent gearbox chip warning light illumination. Clean chip detector by: 1. Remove and discard safety wire (if applicable) securing chip detector. Disconnect chip detector wiring at quick-disconnect located several inches from chip detector. For tail rotor gearbox, place container beneath to catch oil. Remove chip detector from gearbox. 2. Clean and scrub chip detector with a toothbrush and cleaning solvent, followed by drying with compressed air or a lint-free cloth. 3. Check chip detector circuit function by connecting chip detector electrical wiring, turning battery switch on, and grounding detector’s central magnetic probe to airframe. Verify appropriate gearbox chip warning light illuminates. Turn battery switch off. 4. Install chip detector. Torque threaded-type chip detector per Section 1.330 and safety wire. Ty-rap chip detector electrical wiring as required. 5. Turn on battery switch. Check chip detector circuit function by grounding detector’s center terminal and verifying appropriate gearbox chip warning light illuminates. Turn battery switch off. 1.120 Main Rotor Gearbox Drain And Flush To drain and flush main rotor gearbox: 1. Ground run helicopter two to five minutes at 60-70% RPM to warm main rotor gearbox oil. 2. Disconnect chip detector wiring at quick-disconnect located approximately 10 inches from chip detector. Cut safety wire securing chip detector to main rotor gearbox sump attach bolt (not applicable to quick-release chip detectors). 3. Remove chip detector. Do not remove chip detector housing. NOTE After removing chip detector, check for oil leaking from chip detector housing. Leakage indicates housing is defective and must be replaced. If leakage occurs, immediately install main rotor gearbox drain assembly to minimize oil spillage. Page 1.4 JUN 2014 ROBINSON MAINTENANCE MANUAL R44 SERIES ROBINSON MAINTENANCE MANUAL MODEL R44 1 . 1 20 Main Rotor Gearbox Drain and Flush (cont'd) 4. Drain oil by installing main rotor gearbox drain assembly in chip detector housing with drain hose overboard into a suitable container. Slide wedge under drain assembly to open valve (see Figure 1-2). 5. Remove drain assembly. Remove and discard safety wire securing gearbox filler plug. Remove plug. 6. Fill gearbox with SAE30, SAE40, SAE50, or SAE20W50 straight mineral engine oil to level indicated by decal adjacent to sight gage. 7. Install filler plug, tighten, but do not safety wire. 8. Ground run helicopter for approximately five minutes at 60-70% RPM. 9. After shutting down helicopter, drain gearbox using drain assembly. 10. Remove drain assembly. Remove and discard safety wire on chip detector housing. Remove chip detector housing and immediately place a small container under gearbox to catch any residual oil. 11 . Clean chip detector with a toothbrush and cleaning solvent per Section 1. 11 5. Compressed air or masking tape may also be used to remove debris but scrubbing with solvent is mandatory to remove any varnish accumulation. Do not use a magnet to remove debris. Clean and visually inspect chip detector housing. 12. Verify chip detector function by connecting electrical leads, turning Master switch on, and touching detector's central magnetic probe to horizontal firewall. MR CHIP warning light should illuminate. Disconnect electrical wires. 13. Install chip detector housing into main rotor gearbox. Torque per Section 1.330, and safety wire. 14. Install chip detector into chip detector housing. Torque threaded-type chip detector per Section 1 .330 and safety wire. Connect chip detector electrical wires and ty-rap. 15. As required, remove sight gage and clean with solvent. Reinstall sight gage, torque per Section 1 .330, and safety wire. 16. Remove filler plug. Fill gearbox with Robinson A257-2 lubricant to level indicated on decal. Rotate rotor system by hand several revolutions and pull down tailcone several times. Recheck gearbox oil level. Adjust as necessary. 17. Torque filler plug per Section 1.330 (safety wire not required). Change 13: OCT 2006 Page 1.5 I I I ROBINSON MAINTENANCE MANUAL MODEL R44 1. 120 Main Rotor Gearbox Drain and Flush (cont'd) 18. Turn on MASTER switch. Check chip detector operation by grounding detector's center terminal and verifying MR CHIP warning light illuminates. Turn off MASTER switch. Page 1 .6 B7260 CHIP DETECTOR i \ \ \ \.______, ~ CHIP . .r ~~ DETECTO ~.. ·. ',: ----~~ HOUSING l \ ~" l \A ' ', < WEDGE ,, \ \ MT054-1 DRAIN ASSEMBLY FOR B7260 "QUICK-RELEASE" CHIP DETECTOR OR MT053-1 MAIN ROTOR GEARBOX DRAIN ASSEMBLY FOR A7260 THREADED CHIP DETECTOR FIGURE 1-2 DRAINING MAIN ROTOR GEARBOX Change 13: OCT 2006 ROBINSON MAINTENANCE MANUAL MODEL R44 1.130 Tail Rotor Gearbox Drain and Flush 1. Ground run helicopter for approximately five minutes at 60- 70% RPM to warm tail rotor gearbox oil. 2. Disconnect chip detector wiring at quick-disconnect located approximately 11 inches from chip detector. 3. Remove and discard safety wire securing chip detector to sight gage. 4. Place a container under tail rotor gearbox to catch oil and remove chip detector. 5. Remove and discard safety wire securing filler-vent plug to sight gage. Remove I filler-vent plug. 6. Install chip detector, torque per Section 1.330, but do not safety wire. Add approximately five ounces of SAE30, SAE40, SAE50, or SAE20W50 straight mineral engine oil. 7. Install filler plug, tighten, but do not safety wire. 8. Ground run helicopter at 60-70% RPM for approximately five minutes. 9. After shutting down helicopter, remove chip detector and drain mineral oil. 10. Clean and scrub chip detector with a toothbrush and cleaning solvent. Compressed air or masking tape may also be used to remove debris but scrubbing with solvent is mandatory to remove varnish accumulation. Do not use a magnet to remove debris. 11. Connect chip detector wiring. Turn on Master switch. Check chip detector operation by grounding detector's center terminal; TR CHIP warning light should illuminate. Turn off Master switch and disconnect chip detector wiring. 12. Install chip detector, torque per Section 1.330, and safety wire. Connect chip detector wiring and secure with Ty-raps® as required. 13. As required, remove sight gage and clean with solvent. Reinstall sight gage, torque I per Section 1.330, and safety wire. CAUTION Tail rotor gearbox sight plug glass must indicate correct oil level when aircraft is on level ground. 14. Fill gearbox with Robinson A25 7-2 lubricant to level indicated by sight glass decal. Install filler-vent plug, torque per Section 1.330, and safety wire. 15. Turn on Master switch. Check chip detector operation. Turn off Master switch. I Change 1 3: OCT 2006 Page 1.7 ROBINSON MAINTENANCE MANUAL MODEL R44 1. 140 Clutch Actuator Lower Bearing Lubrication NOTE Syringe suitable for the following procedure is included in kit Kl-115, available from RHC Customer Service. 1. Fill syringe with 4-5 grams of A257-12 grease (commercially available, see Section 1.4 70). Note: 5 grams of grease fills a 1 .0 inch (25 mm) long space inside a syringe body with a 0.63 inch ( 16 mm) inner diameter. 2. Remove screw from left side of C181-3 bearing housing. Screw may be covered by Telatemp; remove Telatemp as required to access screw. It is not necessary to replace Telatemp. Note: aft cowling may be removed to ease bearing access. 3. Using syringe, inject grease through screw hole. 4. Install B289-3 self-sealing cross-head screw, or thoroughly clean set screw and screw hole threads and then install set screw using B270-20 sealant, wet epoxy primer, or wet zinc-chromate primer on threads. Tighten set screw only until screw is flush with bearing housing. CAUTION Set screw hole is through to bearing housing cavity. Tightening set screw further than flush-with-housing can result in set screw contacting and damaging internal bearing assembly components. 5. Ground run helicopter at 102% RPM for two minutes, shut down, inspect bearing, and clean off any escaped grease. 6. Install aft cowling, if removed. 1 . 1 50 Defueling WARNING Defueling must be done in a well-ventilated area. No smoking within 100 feet of helicopter during defueling. NOTE Low-fuel sender check (see Section 12.270) may be performed when defueling helicopter. 1. Turn fuel valve off and disconnect flexible fuel line at carburetor. 2. Place end of fuel line in a suitable container. Ground container to helicopter and turn fuel valve on. 3. Turn fuel valve off when the container is full and repeat as necessary to complete draining. 4. Attach fuel line to carburetor, torque per Section 1 .330, and torque stripe. Page 1.8 Change 14: JUL 2008 ROBINSON MAINTENANCE MANUAL MODEL R44 1 . 1 60 Storage For long-term (greater than 30 days) storage: 1. Defuel aircraft per Section 1. 150. 2. Clean aircraft per Section 8 of R44 Pilot 1 s Operating Handbook. 3. Paint or wax bare metal areas of main and tail rotor blades. 4. Apply suitable non-drying corrosion preventative compound to C 1 66 clutch shaft adjacent to seals (where shaft enters and exits upper sheave). 5. Preserve engine in accordance with Lycoming Service Letter L 180 (current revision). 6. Remove battery and periodically check and adjust, as required, battery charge I status. Check fluid level and specific gravity of non-sealed batteries. 7. Store aircraft in a protected, dry (dehumidified) environment. 8. Periodically inspect aircraft for corrosion and correct as required. 1 .170 Hydraulic Reservoir Filter Replacement CAUTION Cleanliness of hydraulic fluid is vital to proper system operation. Use only clean fluid from sealed containers and avoid contamination from dirty funnels, tubing, etc. 1. Remove and discard safety wire from filter cap. Remove filter cap from bottom of I hydraulic reservoir. 2. Remove filter and examine. If debris is found, use a magnet to determine if ferrous or non-ferrous. NOTE Ferrous debris may indicate pump damage. Replace filter again after one flight hour. If more ferrous debris is found, replace hydraulic pump per Section 8 and flush hydraulic system per Section 1 . 1 80. 3. Clean filter cap and replace O-ring packing. Lubricate new O-ring with A257-15 fluid (see Section 1.470). 4. Lubricate O-ring in new filter with A257-15 fluid and install filter in reservoir. Install filter cap, torque per Section 1.330, and safety wire. 5. Adjust reservoir fluid level as required. Install filler-vent and torque per Section 1 .330. Safety wiring filler-vent is not required. Change 1 3: OCT 2006 Page 1.8A ROBINSON MAINTENANCE MANUAL MODEL R44 1 . 180 Draining and Flushing Hydraulic System (see Figure 8-1 A) CAUTION Cleanliness of hydraulic fluid is vital to proper system operation. Use only clean fluid from sealed containers and avoid contamination from dirty funnels, tubing, etc. NOTE Drain and flush hydraulic system if oil turns dark, or emits bad odor. 1 . Remove reservoir filler-vent. 2. Place a one-liter container for contaminated fluid beneath D500-1 hydraulic pump at main rotor gearbox. Remove caps from pump suction and pressure T-fittings. Allow fluid in reservoir to drain through suction line into container. Pour small amount of clean A257-15 fluid (see Section 1.4 70) into reservoir to purge suction line. Pressure line will drain in following step when filter cap is removed. 3. Replace hydraulic reservoir filter per Section 1. 170. 4. See Figure 1-2A. Connect MT384 (or similar) 0.8-1.2 gpm hydraulic test pump to T- fittings on D500-1 pump. Fittings are different sizes to ensure correct connection. 5. Dispose of drained, contaminated hydraulic fluid. Fill reservoir with A257-15 fluid. 6. Disconnect servo return line at reservoir forward elbow and place end in empty container for contaminated hydraulic fluid. Cap elbow on reservoir assembly (use cap from pump T-fitting). 7. Activate hydraulic test pump and inspect hydraulic system for leakage. 8. Simultaneously fully raise collective and move cyclic fully forward. Then simultaneously fully lower collective and move cyclic fully aft. Monitor reservoir fluid level and fill as required. Repeat procedure until return line fluid into container is clean. WARNING Stay clear of moving flight controls. Hydraulic forces can cause injury. 9. Simultaneously fully raise collective and move cyclic fully aft then simultaneously fully lower collective and move cyclic fully forward. Monitor reservoir fluid level and fill as required. Repeat procedure until return line fluid into container is clean. 10. Connect servo return line to reservoir forward elbow. Torque 8-nut per Section 1.330 and torque stripe. 11. Bleed hydraulic system per Section 1 .190. 12. Remove and inspect filter. If debris is found, repeat drain and flush procedure. If filter is clean, reinstall per Section 1 .170, steps 4 & 5. Page 1.88 Change 13: OCT 2006 ROBINSON MAINTENANCE MANUAL MODELR44 1. 190 Bleeding Hydraulic System (see Figure 1-2A} 1. Disconnect cap on D500-1 hydraulic pump pressure (aft} T-fitting and connect pressure line from MT384 hydraulic test pump (or similar 0.8-1.2 gpm unit}. Pressure and suction fittings are different sizes to assure correct connection. 2. Remove reservoir filler-vent and cover hole with finger to prevent fluid loss. Disconnect cap on hydraulic pump suction (forward} T-fitting and connect hydraulic test pump suction line. Fill reservoir as required. 3. Activate hydraulic test pump and inspect for leakage. 4. Simultaneously fully raise collective and move cyclic fully forward then simultaneously fully lower collective and move cyclic fully aft. Repeat procedure ten times. WARNING Stay clear of moving flight controls. Hydraulic forces can cause in Jury. 5. Simultaneously fully raise collective and move cyclic fully aft then simultaneously fully lower collective and move cyclic fully forward. Repeat procedure ten times. 6. Shut off hydraulic test pump. Verify no leaks in hydraulic system. 7. Cover reservoir filler-vent hole with finger to prevent fluid loss. Disconnect hydraulic test pump suction line from D500-1 pump forward T-fitting and install cap. Torque cap per Section 1.330 and torque stripe. 8. Disconnect hydraulic test pump pressure line from D500-1 pump aft T-fitting and install cap. Torque cap per Section 1.330 and torque stripe. 9. Adjust reservoir fluid level as required. Install filler-vent and torque per Section 1.330. Safety wire is not required. Change 10: JUL 2004 Page 1.8C ROBINSON MAINTENANCE MANUAL l \ .,, ' ,..- . _.•..-§g.·, ~..-:. ··--~ :·-. • ~ t ,;;.. A•-,,~ I ;,j i :: /•:-jj •II .--:~~:;~~ .;.a.--~.,,..- ,_ .. ~ ...... . ..... ......... .... _-,.. - ,--· •• , ' f.~ ··~ . ., .. '•,J'•·:r 1 1 - _..> -~ I* .•· ---------___:.~;~i.... - ~· -- ···· D500-1 HYDRAULIC PUMP PRESSURE FIGURE 1-2A MOOELR44 MT384-1 (115 VAC, 60 Hz) or MT384-2 (208-230 VAC, 50 Hz} HYDRAULIC TEST PUMP MT384 HYDRAULIC TEST PUMP CONNECTION Page 1.8D Change 7: 06 Dec 99 ROBINSON MAINTENANCE MANUAL MOOELR44 1.200 HANDLING. JACKING, HOISTING, LEVELING, AND WEIGHING 1 . 210 Ground Handling 1.211 Ground Handling Wheels Installation a) Extend the handle by depressing the handle locking pin and sliding the handle out until the pin snaps into the outer hole. Hold handle and wheel with the protruding spindle in its lowest position. Insert spindle into support mounted on skid (see Figure 1-3). NOTE If helicopter has not settled on its skids completely, the spindles may not go in all the way. In this case, pull down on the tail cone to spread the gear enough to allow installation. b) Make sure that the protruding spindle is all the way in with the widened end completely past the inside of the support (see Figure 1-3A). c) Pull handle over center to raise helicopter and lock wheel in position (see Figure 1-4). CAUTION When lowering the helicopter, the handle has a tendency to snap over. NOTE 70 psi maximum tire inflation pressure. Issued: 11 Jun 93 Page 1.9 ROBINSON MAINTENANCE MANUAL MOCELR44 FIGURE 1-3 FIGURE 1-3A SPINDLE --- i SUPPORT- FIGURE 1-4 Page 1.10 Issued: 11 Jun 93 ROBINSON MAINTENANCE MANUAL 1.210 Ground Handling (cont'd) 1.212 Ground Handling Wheels - Float Ship Landing Gear INSTALLATION: MODELR44 Align aft blocks adjacent to mark on skid tube and position forward blocks to remove cord slack. a) Pull tail down. Insert forward blocks at their lower height under both skids. b) Push tail up. Insert rear blocks at their lower height under both skids at marks. c) Pull tail down. Move forward blocks inward to their upper height under skid tubes. d) Push tail up. Slide rear blocks out (upper height of rear blocks is not used) and insert wheels under skids at rear marks. NOTE Wheels may be placed a few inches forward to reduce force required to pull tail down. e) Pull tail down and remove forward blocks. l~L_. ) ,---~- il--JL-- ) r---~-- 0---0 SKIDS rd~ '"/FRONT BLOCK POSITIONS FRONT BLOCK POSITIONS FIGURE 1-38 FLOAT SHIP GROUND HANDLING WHEELS INSTALLATION Change 4: 1 Jun 97 Page 1.10A ROBINSON MAINTENANCE MANUAL MODELR44 1.212 Ground Handling Wheels - Float Ship Landing Gear (cont'd) REMOVAL: a) Pull tail down. Insert forward blocks at their upper height at forward marks under skids. b) Push tail up. Remove wheels and insert rear blocks at their lower height (upper height on rear blocks is not used) at marks. c) Pull tail down. Position forward blocks under skids at their lower height. d) Push tail up. Remove rear blocks. e) Pull tail down. Remove front blocks. 0----0 SKIDS ~ ~,,/ FRONT BLOCK POSITIONS SKIDS d \..i 'le/FRONT BLOCK POSITIONS FIGURE 1-3C FLOAT SHIP GROUND WHEELS REMOVAL Page 1.108 Change 4: 1 Jun 97 ROBINSON MAINTENANCE MANUAL MODEL R44 1.213 Moving the Helicopter on Ground Handling Wheels Moving the helicopter on ground handling wheels requires two people: one person to hold the tail down and steer by holding the tail rotor gearbox and another person to push on primary structure. The steel tube frame inside the aft cowl door may be used as a hand hold for pushing. Keep feet clear of skid tubes during ground handling. CAUTION Do not move helicopter by gripping tail rotor guard, outboard portion of horizontal stabilizer, tail rotor, or tail rotor controls. 1.214 Main Rotor Blade Tie-Downs Install MT290-2 main rotor blade tie-downs as shown in Figure 1-5. Tie-down straps are I installed by removing slack from lines to prevent blade movement. I CAUTION Overtightening tie-down straps can damage main rotor blades. 1 .215 Parking Refer to Section 8 of the R44 Pilot's Operating Handbook for parking procedures. 1.216 Trailering Trailering the R44 is not normally recommended. Most trailers large enough to accomodate the helicopter are designed for much heavier loads; the trailer's springs and shock absorbers will not function properly when lightly-loaded. If trailering is unavoidable the following precautions should be observed: 1. Load trailer with ballast until it is at the average weight it is designed to carry. 2. Support tailcone, taking care to prevent chafing or abrasion at the support point. 3. Remove main rotor blades. If not practical to remove, support the main rotor blades so they will not bear on droop stops. Locate supports about 5 feet in from blade tips. Supports must be cushioned to prevent blade damage. 4. Restrain tail rotor to prevent teetering. Change 1 3: OCT 2006 Page 1.11 ROBINSON MAINTENANCE MANUAL MODEL R44 DETAIL - TIE AROUND THE BRACKET ABOVE THE CABIN AIR INLET. V . j ' ,1, , -"'~ -~'\., CAUTION Overtightening Tie-Down straps can damage blades. WRAP AROUND TAIL CONE IN FRONT OF LIGHT, AROUND TAIL CONE TO BACK OF LIGHT; THEN WRAP AROUND BASE TO ATTACH VELCRO. FIGURE 1-5 MAIN ROTOR BLADE TIE-DOWN INSTALLATION Page 1. 12 Change 13: OCT 2006 ROBINSON MAINTENANCE MANUAL MODEL R44 1. 21 6 Trailering (cont'd) e) Protect helicopter's windshield, tail rotor and other vulnerable parts from highway debris damage. f) After trailering, thoroughly inspect aircraft for possible damage, with particular Iattention to the steel tube structure and rotor systems. 1 . 220 Jacking, Hoisting and Leveling 1. Helicopter jacking is accomplished by placing a jack under each end of the aft cross tube 1 inch inboard of elbow fittings. CAUTION Care must be taken to prevent the helicopter from becoming dislodged from jacks. 2. Hoist helicopter using MT527-1 helicopter lifting fixture as shown in Figure 1-6A, or by passing one-inch diameter soft nylon rope through the lightening holes in main rotor hub and forming a double loop per Figure 1-68. Rope must have a minimum tensile strength of 2,500 lb. 3. Level helicopter using either of the following methods: a. Leveling using tailcone and aft landing gear cross tube: 1) Place a propeller protractor on top of forward bay of tailcone. When tailcone is 0. 7 degrees nose down ship is leveled longitudinally. 2) Level helicopter longitudinally by placing shims under landing gear skid tubes. 3) Verify aft cross tube is not bent. Place a bubble level in center of aft cross tube. 4) Level helicopter laterally by placing shims under landing gear skid tubes. 5) Recheck longitudinal level per steps 1) and 2) above. Repeat steps 1) through 4) as required. NOTE Jacks may be used under aft cross-tube 1 inch inboard from elbows. Change 12: JUL 2005 Page 1 .13 ROBINSON MAINTENANCE MANUAL MT527-l HELICOPTER ·~ LIFTING FIXTURE ~( VERTICAL FIREWALL Page 1.14 ' ' ,~? . /Tu ,/ I f .. -?' ~ i..../1/'. f· / ~y \ ' -C FIGURE l-6A HELICOPTER HOISTING TAIL ROTOR GEAR BOX TAILCONE \ ::::::-.... .. ·-,~-~MEASURE (r HERE y INSERT TUBE INTO HOLE AFT OF VERTICAL FIREWALL FIGURE 1-7 HELICOPTER C.G. DETERMINATION MODEL R44 FIGURE 1-6B HELICOPTER HOISTING X t Change 3: 5 May 95 ROBINSON MAINTENANCE MANUAL MODEL R44 1.220 Jacking, Hoisting, and Leveling (cont'd) b. Leveling at the main rotor hub: 1. Rotate main rotor until teeter hinge bolt is aligned with longitudinal axis of helicopter. Place a bubble level at location marked "level here". NOTE Level must be on top of main rotor hub and parallel to teeter hinge bolt. 2. Level helicopter longitudinally by placing shims under landing gear skid tubes. 3. Rotate main rotor until teeter hinge bolt is aligned with lateral axis of helicopter. 4. Level helicopter laterally by placing shims under landing gear skid tubes. NOTE Jacks may be used under aft cross tube 1 inch from elbow. 5. Recheck longitudinal level per preceding steps. Repeat steps as required to level helicopter. Change 1 3: OCT 2006 Page 1 .15 ROBINSON MAINTENANCE MANUAL MODEL R44 1.230 Weighing and C.G. Calculation NOTE The Equipment List/Weight and Balance Data form in the Pilot's Operating Handbook must be used to maintain a continuous record of the helicopter's weight and balance. NOTE Level must be on top of main rotor hub and parallel to teeter hinge bolt. 1.231 Helicopter Weighing Procedure 1. Drain all fuel, including gascolator and both fuel tank sumps. 2. Fill engine oil, hydraulic fluid (if applicable}, and gearboxes to full marks. 3. Install and secure all doors. 4. Position main rotor blades fore/aft and approximately level and center cyclic stick. 5. Be sure all checked items on Equipment list/Weight and Balance Data form are installed in their proper locations. Correct form as required. 6. Be sure aircraft is clean and remove any foreign items such as charts, tools or rags. 7. Hoist aircraft per Section 1 .220. Have one person hold tail of helicopter while it is being hoisted to stabilize aircraft. 8. With main rotor blades oriented approximately fore and aft, raise both blades off droop stops to allow hub to freely teeter. 9. With aircraft hanging freely and steadily, use a water level and measure difference in vertical height between centerline of tail rotor gearbox and cabin belly at vertical firewall. Refer to Figure 1-7. Record height difference to nearest tenth of inch: inches {no ballast) Page 1.16 Change 14: JUL 2008 ROBINSON MAINTENANCE MANUAL MODEL R44 1.231 Helicopter Weighing Procedure (cont'd) 10. Determine uncorrected longitudinal center of gravity: 114.34 - [0.32 x (difference in height, from Step 9)] inches 11 . Place a 1000-pound capacity scale under each skid. Locate center of scales approximately six inches forward of ground handling wheel mount centerline. 12. Lower aircraft until it rests entirely on scales. Aircraft must be well balanced on scales before releasing tail. Be sure aircraft is level laterally by placing level on center of aft landing gear cross tube. 13. Determine uncorrected empty weight: Right Scale indication plus Left Scale indication + minus Tare (such as lifting fixture, if installed) - Uncorrected Empty Weight 14. Determine CG with full fuel and 1 50 lb pilot: ----- ----- ----- ----- [(CG from Step 10) x (empty weight from Step 13)] + 38840 _- lb lb lb lb inches (empty weight from Step 1 3) + 451. 2 ---- 15. If CG from Step 14 is greater than 102.5 inches, determine required nose ballast as follows: [(CG from Step 10 - 102.5) x (empty weight from Step 13)] - 7408 = lb 95.5 ---- Round ballast weight up to nearest 0.25 lb and install nose ballast per Section 1.240. Record actual nose ballast installed: lb ---- Repeat steps 7 thru 15 and revise measurements and calculations. Change 14: JUL 2008 Page 1.17 ROBINSON MAINTENANCE MANUAL MODEL R44 1 . 231 Helicopter Weighing Procedure (cont'd) 16. Adjust weight and balance to correct for drained unusable fuel: WEIGHT CG MOMENT ITEM (lb) (inches from datum) (in.-lb) Ship as weighed X = (from Step 1 3) (from Step 10) Add unusable fuel +7.2 X 96.0 +691 Helicopter basic empty weight and CG (includes unusable fuel and full oil) X * - *CG location (arm) is determined by dividing total moment by total weight. Datum is located 100 inches forward of main rotor centerline CAUTION Following any modification which moves empty CG aft, calculate weight and balance with 1 50 lb pilot and full fuel. If calculation shows CG aft of aft limit, fixed ballast must be installed in nose to comply with minimum solo pilot weight limitation in Section 2 of the Pilot's Operating Handbook. 17. Determine lateral center of gravity using step 13 data: Lateral C G Arm = (Right Scale - Left Scale) (Right Scale + Left Scale) x41.20 = inch Page 1.18 Change 14: JUL 2008 ROBINSON MAINTENANCE MANUAL MOCEL R44 1. 240 Fixed Ballast Installation 1. Remove screws securing upper console and open console. 2. Remove landing light retainer and landing lights. 3. If required by Section 1 .231, install appropriate ballast per Figure 1-8, 1-8A, or 1-8B, as applicable. NOTE Maximum allowable ballast is 10 pounds. 4. Torque bolts per Section 1. 320 and torque stripe per Figure 2-1. 5. Close and secure upper console. 6. Reinstall landing lights and retainer. Function check landing lights. NAS428-3-1 2 * BOLT (4 places) AN97O-3 WASHER (4 places) C 361 -1 CONSOLE PANEL (Ref) * 2 threads minimum beyond nut. Change 14: JUL 2008 FIGURE 1-8 FIXED BALLAST INSTALLATION (with 4-hole ballast plates) Page 1 .19 ROBINSON MAINTENANCE MANUAL 1. 240 Fixed Ballast Installation {cont'd} NAS428-3A * or NAS6603* BOLT (4 places) MODEL R44 * Select NAS428-3A bolt length as required for 2 threads minimum beyond nut. Page 1.19A Select NAS6603 bolt length as required for 2 to 4 threads beyond nut. FIGURE 1-8A FIXED BALLAST INSTALLATION (with 6-hole ballast plates) Change 14: JUL 2008 ROBINSON MAINTENANCE MANUAL MODEL R44 1. 240 Fixed Ballast Installation (cont'd) /' 1// FORWARD * Bolt length as required for 2-4 threads beyond nutplate. FIGURE 1-8B FIXED BALLAST INSTALLATION (with 2-hole ballast plates, required with H.I.D. landing lights) Change 14: JUL 2008 Page 1 .19B ROBINSON MAINTENANCE MANUAL MODEL R44 1.300 FASTENER TORQUE REQUIREMENTS WARNING Proper torque is critical. Always use calibrated wrenches and undamaged, properly lubricated (where applicable) hardware. Ensure all clamping surfaces are clean, and clamp only bare metal or wet-primed surfaces. Improper torque or dirty or painted clamping surfaces may result in loss of clamp-up, hardware or part damage, and premature failure. 1.310 General Fasteners shall be torqued to standard dry values listed in Section 1 .320 unless otherwise specified. If torque is applied by rotating bolt, increase torque value by 10% to account for higher friction at bolthead and shank. For example, the torque wrench setting for an NAS1305 bolt used with an NAS1068 nutplate is determined as follows: NAS 1 305 bolt ( 5 indicates 5/ 1 6 inch size) dry torque per Table 1 Add 1 0% because torque must be applied at bolt head Torque wrench setting 240 in.-lb 24 in.-lb 264 in.-lb A secondary locking mechanism is required on all critical fasteners. B330 stamped nuts (palnuts) serve as secondary locking mechanisms in most areas on the helicopter, and are torqued per Table 1. The IPC lists secondary locking mechanisms for specific fasteners. 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 Never substitute AN bolts for NAS bolts. NAS bolts have higher tensile strength. NOTE A critical fastener is one which, if removed or lost, would jeopardize safe operation of the helicopter. This includes joints in the primary control system, and non-fail-safe structural joints in the airframe, landing gear, and drive system. Torque seal (paint) is applied to all critical fasteners after palnut installation in a stripe extending from the fastener's exposed threads across both nuts onto the component (reference Figure 2-1). Any subsequent rotation of the nut or bolt can be detected visually. Approved source for torque seal is given in Section 1 .460. Any nut damaged due to handling or whose nut drag has deteriorated appreciably must be replaced. Page 1.20 Change 14: JUL 2008 1.310 General (continued) WARNING Two threads minimum must be exposed beyond nut on any installation to insure proper locking of a threaded fastener; four threads maximum may be exposed. More than four threads exposed may allow nut to seat against fastener shank, resulting in insufficient joint clamping. CAUTION Never substitute AN bolts for NAS bolts. NAS bolts have higher tensile strength. Torque Requirements 1. Damaged hardware must be replaced. 2. Bolt and nut are to be clean and dry except when assembly procedure specifies anti- seize or thread-locking compound. 3. If chattering or jerking occurs, disassemble and re-torque fastener. 4. If special adapters which change effective length of torque wrench are used, final torque value must be calculated using formulas in Figures 1-9 and 1-10. 5. Proper thread engagement requires 2-4 threads exposed beyond primary self-locking nut (palnuts excepted). 6. Torque wrenches must be calibrated annually, when dropped, or when a calibration error is suspected. 7. Any self-locking nut whose drag has deteriorated appreciably must be replaced. 8. Replace palnuts when removed. JAN 2012 Page 1.21 ROBINSON MAINTENANCE MANUAL MODEL R44 FIGURE 1-10 SHORTENING TORQUE WRENCH EFFECTIVE LENGTH FIGURE 1-9 LENGTHENING TORQUE WRENCH EFFECTIVE LENGTH Given Symbols Y = Unknown Y = Torque wrench setting T = 135 in.-lb T = Torque applied to fastener L = 10 in. L = Length of torque wrench A = 1.5 in. A = Length of adapter When using an adapter that lengthens torque wrench effective length, calculate torque wrench setting using the formula below: EXAMPLE Solve for Y = T x L = 135 x 10 = 1350 = 117.39 L + A 10 + 1.5 11.5 Set torque wrench to 117 in.-lb to torque fastener to 135 in.-lb. Given Symbols Y = Unknown Y = Torque wrench setting T = 135 in.-lb T = Torque applied to fastener L = 10 in. L = Length of torque wrench A = 1.5 in. A = Length of adapter When using an adapter that shortens the torque wrench effective length, calculate torque wrench setting using the formula below: EXAMPLE Solve for Y = T x L = 135 x 10 = 1350 = 158.82 L – A 10 – 1.5 8.5 Set torque wrench to 159 in.-lb to torque fastener to 135 in.-lb. Page 1.22 JAN 2012 ROBINSON MAINTENANCE MANUAL MODEL R44 A --------1----------- L ----------;...... 1 L --------1...... 1 1.320 Standard Torques NOTE 1. Torque values include nut self-locking torque. 2. Increase torque values 10% if torqued at bolt head. 3. For elbow and tee fittings which require alignment, torque to indicated value, then tighten to desired position. 4. Tolerance is ± 10% unless range is specified. 5. Unless otherwise specified, thread sizes 8-32 and smaller are not used for primary structure and do not require control of torques. FASTENER SERIES SIZE EXAMPLE FASTENER DRY TORQUE NAS6603 thru NAS6608 Bolts NAS1303 thru NAS1308 Bolts NAS623 Screws NAS1351 & NAS1352 Screws NAS600 thru NAS606 Screws 10-32 NAS6603 50 in.-lb 1/4-28 NAS6604 120 in.-lb 5/16-24 NAS6605 240 in.-lb 3/8-24 NAS6606 350 in.-lb 7/16-20 NAS6607 665 in.-lb 1/2-20 NAS6608 995 in.-lb AN3 Bolts AN4 Bolts AN6 Bolts AN8 Bolts AN502 & AN503 Screws AN509 Screws AN525 Screws MS24694 Screws MS27039 Screws 10-32 AN3 37 in.-lb 1/4-28 AN4 90 in.-lb 3/8-24 AN6 280 in.-lb 1/2-20 AN8 795 in.-lb STAMPED NUTS (PALNUTS) 10-32 B330-7 (MS27151-7) 6–15 in.-lb 1/4-28 B330-13 (MS27151-13) 11–25 in.-lb 5/16-24 B330-16 (MS27151-16) 20–40 in.-lb 3/8-24 B330-19 (MS27151-19) 29–60 in.-lb 7/16-20 B330-21 (MS27151-21) 42–85 in.-lb 1/2-20 B330-24 (MS27151-24) 54–110 in.-lb TAPERED PIPE THREADS 1/8-27 N/A 60 in.-lb 1/4-18 N/A 85 in.-lb 3/8-18 N/A 110 in.-lb 1/2-14 N/A 160 in.-lb 3/4-14 N/A 230 in.-lb ROD END JAM NUTS (AN315 and AN316) 10-32 AN315-3 15 in.-lb 1/4-28 AN316-4 40 in.-lb 5/16-24 AN316-5 80 in.-lb 3/8-24 AN316-6 110 in.-lb AUG 2019 Chapter 1 General Page 1.22A ROBINSON MAINTENANCE MANUAL R44 SERIES Intentionally Blank Page 1.22B Chapter 1 General AUG 2019 ROBINSON MAINTENANCE MANUAL R44 SERIES 1.330 Special Torques Special torques supersede standard torques listed in § 1.320. NOTE 1. Torque values include nut self-locking torque. 2. Increase torque values 10% if torqued at bolt head. 3. For elbow and tee fittings which require alignment, torque to indicated value, then tighten to desired position. 4. Tolerance is ± 10% unless range is specified. 5. Unless otherwise specified, thread sizes 8-32 and smaller are not used for primary structure and do not require control of torques. AREA (QUANTITY) FASTENER TORQUE AIR CONDITIONING (2) AN824-8D nuts on D792-2 and D793-2 lines at firewall 360 in.-lb (3) D782-5 bolt, D782-4 bracket-to-engine 360 in.-lb D799-2 or -9 high pressure cutout switch 90 in.-lb D799-3 low pressure cutout switch 90 in.-lb MS21042L6 nut, compressor drive pulley retaining 300 in.-lb (4) nuts (engine mounting), D778-1 cartridge assembly 204 in.-lb nut, D792-2 line assy-to-evaporator 150 in.-lb wet w/ A257-20 nut, D793-2 line assy-to-evaporator 210 in.-lb wet w/ A257-20 nut, D794-1 hose assy-to-D793-2 line assy 210 in.-lb nut, D794-1 hose assy-to-D777-1 compressor assy 300 in.-lb wet w/ A257-20 nut, D810-1 or -2 line assy-to-D777-1 compressor assy 210 in.-lb wet w/ A257-20 nut, D810-1 or -2 line assy-to-D783-1 condenser 150 in.-lb wet w/ A257-20 nut, D811-1 or -2 line assy-to-D783-1 condenser 150 in.-lb wet w/ A257-20 nut, D811-1 or -2 line assy-to-D793-2 line assy 150 in.-lb (4) valve cores (on servicing and cutout switches fittings) 4 in.-lb CABIN (2) NAS1351-6H20P bolts securing B253-2 anchor 150 in.-lb CYCLIC STICK (2) NAS1352-3H14 screws, C683-4 damper (manual-controls) 40 in.-lb DRIVE SYSTEM C182-1 nut (2-inch socket) on C007-5 shaft assembly Note: Shaft assemblies with smaller nuts are obsolete 450–550 ft-lb wet w/ A257-9 (6) NAS6608-42H bolts, lower sheave 900 in.-lb EMPENNAGE (8) NAS6604-6 bolts, vertical stabilizer attach 185 in.-lb FANWHEEL C182-1 nut - see DRIVE SYSTEM (above) (16) NAS6603-6 bolts, cone-to-fanwheel 70 in.-lb (8) NAS6605-12, -13, or -14 bolts, hub 300 in.-lb AUG 2019 Chapter 1 General Page 1.23 ROBINSON MAINTENANCE MANUAL R44 SERIES 1.330 Special Torques (continued) AREA (QUANTITY) FASTENER TORQUE FLOATS, POP-OUT (10) inlet check valve base 75–85 in.-lb (10) inlet check valve pivot (hose fitting) retainer 110–120 in.-lb (22) nuts on D674-1, -2, -3, -4, -5, & -6 hoses 230–260 in.-lb (4) nuts on D674-7 hoses 110–130 in.-lb D770-1, -2, -3, & -4 valve assemblies 40 in.-lb FUEL SYSTEM (1) A457-11 adapter, gascolator outlet 285 in.-lb (1) B254-3 strainer assembly, main tank 150 in.-lb wet w/ A257-9 (1) B283-3 hose assembly, gascolator-to-carburetor (O-540) 120 in.-lb (1) B283-3 hose assembly, mechanical-to-electrical fuel pump (IO-540) 120 in.-lb (5) B289-1 bolts, fuel quantity sender, self-sealing 37 in.-lb (1) B330-5 palnut, fuel quanity sender, ground wire 9 in.-lb (1) B330-6 palnut, fuel quanity sender, center stud 11 in.-lb (2) B330-25 palnuts, electrical fuel pump elbows (IO-540) 75 in.-lb (1) C595-4 hose assembly, D321-1 valve assembly-to-D453-3 tee (IO-540) 120 in.-lb (1) C741-1 line assembly, gascolator-to-fuel valve 285 in.-lb (1) D205-28 or D205-38 hose assembly, main tank-to-fuel valve 120 in.-lb (1) D205-29 hose assembly or C595-2 hose assembly, aux tank-to-main tank 120 in.-lb (1) D205-30 hose assembly, main tank-to-drain 100 in.-lb (1) D205-31 hose assembly, D321-1 valve assembly-to-D453-3 tee (IO-540) 120 in.-lb; orient elbow horizontal ± 5° (1) D210-4 nut, A455-1 plug-to-gascolator 70 in.-lb (1) D321-1 valve assembly, aux tank 150 in.-lb; rotate connector so D205-31 hose fitting 80° ± 5° aft, or C595-4 hose fitting is 55° ± 5° aft (2) D452-6 nuts, electrical fuel pump elbows (IO-540) 150 in.-lb (1) AN316-7R nut, relief valve connector-to-firewall (IO-540) 150 in.-lb (1) AN815-3D union or A880-933 or -963 union, main tank 100 in.-lb (1) AN815-6D union or A880-936 or -966 union, main tank 200 in.-lb (1) AN924-3D nut or A880-1003 nut, A761-1 drain-to-D255-1 connector 100 in.-lb (1) AN924-5D or A880-1005 nut, low fuel switch assy-to-D250-1 cover assy 150 in.-lb (1) HTM-300 clamp, electrical fuel pump-to-D742-1 support assembly (IO-540) 100 in.-lb Page 1.24 Chapter 1 General AUG 2019 ROBINSON MAINTENANCE MANUAL R44 SERIES 1.330 Special Torques (continued) AREA (QUANTITY) FASTENER TORQUE FUEL SYSTEM (continued) (1) MS21900D6 adapter or D319-4 fitting, mechanical fuel pump (IO-540) 150 in.-lb (1) MS27769D2 plug, gascolator 60 in.-lb HYDRAULIC HOSES & FITTINGS (2) B330-19 palnuts 30 in.-lb (3) B330-21 palnuts 45 in.-lb (1) B330-25 palnuts 75 in.-lb (1) AN820-4 cap, AN834-4D tee at hydraulic pump 60 in.-lb (1) AN820-6 cap, AN834-6D tee at hydraulic pump 120 in.-lb (2) D452-3 nuts 60 in.-lb (3) D452-4 nuts 90 in.-lb (1) D452-6 nut 150 in.-lb (1) D205-3, (1) -12, (1) -14 hose assemblies & (2) AN815-3D unions 95–105 in.-lb (1) D205-7, (1) -11, (2) -16 hose assemblies & (3) AN815-4D unions 135–150 in.-lb (1) D205-15 hose assembly & (1) AN815-6D union 190–210 in.-lb HYDRAULIC PUMP Hydraulic pump-to-gearbox mounting nuts (see MAIN ROTOR GEARBOX) HYDRAULIC RESERVOIR (1) B563-3 sight gage 150 in.-lb (1) D487-3 vent asembly 100 in.-lb (1) D516-1 cap, filter 150 in.-lb (4) NAS1352-4-8P screw, reservoir-to-frame 80 in.-lb HYDRAULIC SERVOS MS27039C0806 screw attaching D200-2 scissors 25 in.-lb B330-6 palnut on above screw 5–10 in.-lb LANDING GEAR (8) B227-28 clamps, strut fairings 15 in.-lb (8) HTM-200 clamps, strut fairings 100 in.-lb wet w/ B270-10 (4) NAS6604-46 bolts, ground handling wheel supports 70 in.-lb (4) NAS6607P20 bolts, gear attach (earlier ships) Note: NAS6607-20 bolts are standard torque per § 1.320. 66 ft-lb MAIN ROTOR BLADE (2) A722-4 screws, tip balance weight 40 in.-lb wet w/ A257-9 (2) B289-2 bolts, self-sealing 70 in.-lb (1) C165-1 clamp, inner Tighten to 2.850 ± 0.005 inch outside diameter (OD) (2) NAS1351N3-12P screws, tip cover-to-blade 40 in.-lb wet w/ A257-9 AUG 2019 Chapter 1 General Page 1.25 ROBINSON MAINTENANCE MANUAL R44 SERIES 1.330 Special Torques (continued) AREA (QUANTITY) FASTENER TORQUE MAIN ROTOR GEARBOX (4) A650-4 fittings, gearbox mounting or (4) D210-10 nuts 50 ft-lb wet w/ A257-9, torqued from bolt head or nut (1) B563-2 sight gage 150 in.-lb (1) B566-1 chip detector housing 150 in.-lb chip detector (threaded type) Approximately 75 in.-lb (4) D210-4 nuts, hydraulic pump-to-gearbox (or cover) 40 in.-lb (1) AN320-8 nut, gearbox pinion (retains C908 yoke) 35–45 ft-lb (1) AN814-8D filler plug 150 in.-lb (6) NAS1352-4H screws, end cover (safety wire is required) 120 in.-lb (6) NAS1352-4 screws, end cover (safety wire not required) 140 in.-lb (6) NAS1352-4H16P screws, sump-to-housing (safety wire is required) 120 in.-lb at head (6) NAS1352-4-16 screws, sump-to-housing (safety wire not required) 140 in.-lb at head MAIN ROTOR HUB (1) NAS634-105 bolt, teeter hinge and (2) NAS634-105 bolts, coning hinges New bolt: 0.021–0.022 inch elongation, wet w/ A257-9 Used bolt: 0.020–0.022 inch elongation, wet w/ A257-9, and cotter pin holes must align PITCH LINKS 21FKF-813 self-locking jam nut, main rotor pitch link 300 in.-lb POWERPLANT (4) bolts, airbox-to-carburetor 30 in.-lb (2) bolts, engine-to-ground strap 96 in.-lb (6) bolts, D730-1 manifold weldment-to-engine 96 in.-lb (4) engine hardware, securing C592-3 mount assembly 204 in.-lb (6) engine nuts, securing C357-1 clips 96 in.-lb (1) hardware, securing alternator to B200-3 or D728-1 arm 204 in.-lb (4) nuts, carburetor-to-engine (O-540) 96 in.-lb initial, 204 in.-lb final; torque in crisscross pattern (1) nut, A457-9 tee 140 in.-lb (1) nut, A462 fitting on carburetor mixture control arm 25–30 in.-lb (12) spark plugs 420 in.-lb wet w/ A257-16 (1) A058-10 probe 36–48 in.-lb (1) A723-15 line assembly, nuts 40 ft-lb Page 1.26 Chapter 1 General AUG 2019 ROBINSON MAINTENANCE MANUAL R44 SERIES 1.330 Special Torques (continued) AREA (QUANTITY) FASTENER TORQUE POWERPLANT (continued) (1) B173 v-belt, tension at alternator 150–170 in.-lb initial drag at pulley (1) B283-7 hose assembly, nuts 140 in.-lb (1) B283-10 hose assembly, nuts 140 in.-lb (1) B283-11 hose assembly, nuts 140 in.-lb (1) C740-4 line assembly, nuts 30 in.-lb (1) D740-1 line assembly, nuts 30 in.-lb (1) D753-1 line assembly, nuts 40 ft-lb (1) D753-2 line assembly, nuts 40 ft-lb (2) MS20074-05-04 bolt, alternator 204 in.-lb (1) MS20074-05-11 bolt, alternator 204 in.-lb (1) MS20074-06-07 bolt, alternator 280 in.-lb (4) NAS1352-6H48P screw, securing C593-3 mount assy 280 in.-lb (3) STD-1411 nuts, securing C357-3 clips 96 in.-lb (12) 21FKF-518 nuts, exhaust flange 200–220 in.-lb (1) 3080-00038 cylinder head temperature probe 75 in.-lb STEEL TUBE FRAME (2) C722-2 5/8-inch internal-wrenching screws 120–125 ft-lb wet w/ A257-9 (2) S14119 screw and (2) A31007 nut 10 in.-lb SWASHPLATE (18) AN503-8-8 fillister-head screws 17 in.-lb (26) NAS1352-08H8P socket-head screws 30 in.-lb (26) NAS1352N08-8 screws 35 in.-lb wet w/ A257-9 (1) NAS6605-8 bolt clamping C203-1 yoke 190 in.-lb (opposite clamping bolt must be torqued first) TAIL ROTOR (1) NAS6606-53 bolt, elastomeric teeter (delta) hinge 420 in.-lb TAIL ROTOR GEARBOX (1) A610-1 vent assembly 100 in.-lb (1) B563-4 sight gage 150 in.-lb (1) B566-2 chip detector 100 in.-lb (1) D210-4 nut, securing C119-2 bumper to TRGB output shaft 120 in.-lb (1) D210-5 nut, pitch control housing stud 240 in.-lb (1) AN320-8 nut, C116-1 input yoke 35–45 ft-lb (4) MS20074-04-06 bolts, input cap 60 in.-lb (8) MS20074-04-06 bolts, input cartridge and output cap 100 in.-lb (4) NAS1352-5H12P drilled-head bolts, gearbox-to-tailcone attaching 200 in.-lb (4) NAS1352-5-12P bolts (undrilled), gearbox-to-tailcone attaching 240 in.-lb AUG 2019 Chapter 1 General Page 1.27 ROBINSON MAINTENANCE MANUAL R44 SERIES 1.400 Approved Materials The following items are available from the noted manufacturer(s) or their distributor(s). Check with appropriate regulatory authority(s) for allowable usage of materials. WARNING Refer to Safety Data Sheet (SDS) and observe precautions when working in proximity to hazardous materials. CAUTION Follow product manufacturer’s instructions for handling and storage. 1.410 Paint Strippers PRODUCT MANUFACTURER/SUPPLIER APPLICATION Cee-Bee Stripper A-292 McGean-Rohco: Cee-Bee Division Downey, CA Metal parts, except blades and flex plates. Plastic Media Blast- ing System Pauli & Griffin Co. Vacaville, CA Metal parts except blades and unsupported sheet metal less than 0.040 inch thick. 1.420 Solvents and Cleaners PRODUCT MANUFACTURER/SUPPLIER APPLICATION QSOL 220 Safety-Kleen Systems, Inc. Plano, TX General use and for cleaning prior to applying primer, topcoat, adhesive, or sealant. Benzene, 1-Chloro-4 (Trifluoromethyl) PCBTF Any “ “ Final Klean 3909S Du Pont Chemical Los Angeles, CA Remove adhesive residue on cabin and windshield. EM-Citro* LPS Laboratories, Inc. Tucker, GA “ “ Acetone Any “ “ Lacolene (Aliphatic Hydrocarbon) Any Windshield and plastic cleaning. Presolve LPS Laboratories, Inc. Tucker, GA Hydraulic components only. Tetrachloroethylene (Perchloroethylene) Any Vapor degreaser. 815 GD Brulin Corporation Indianapolis, IN Ultrasonic cleaning, general use.** SF50 L&R Mfg. Co. Kearny, NJ “ “ Page 1.28 Chapter 1 General AUG 2019 ROBINSON MAINTENANCE MANUAL R44 SERIES 1.420 Solvents and Cleaners (continued) PRODUCT MANUFACTURER/SUPPLIER APPLICATION #112 Ammoniated or #222 Nonammoniated cleaning & rinse solution L&R Mfg. Co. Kearny, NJ Ultrasonic cleaning, avionics components only. * May be used on acrylic plastic. ** Mix 5%-20% by volume; titration not required. 1.430 Fillers and Putty PRODUCT MANUFACTURER/SUPPLIER APPLICATION 315 Putty & Blue Cream Hardener DuPont Chemical Los Angeles, CA Minor surface imperfections. 05960 Acryl - Green 3M St. Paul, MN “ “ SBF1191 Gearhead Products Indianapolis, IN “ “ 1.440 Torque Seal PRODUCT MANUFACTURER/SUPPLIER APPLICATION F-900 (Any color except red) Organic Products Co. Irving, TX Torque seal. 1.450 Primers PRODUCT MANUFACTURER/SUPPLIER APPLICATION Gray epoxy CA 7422A/B/C or CA 7501A/B PRC - Desoto Int., Inc. Sylmar, CA Unlimited. Gray epoxy 4001PS001 with CS4902 curing solution AkzoNobel Waukegan, IL Aviation Primer, Green, A-702 (Aerosol)* Valspar Corporation Medina, OH Limited or touch-up use only. * Shelf life is two years. 1.455 Powder Coat PRODUCT MANUFACTURER 13-7004 Corvel Grey Zinc Rich Epoxy Powder* AkzoNobel Santa Fe Springs, CA 81-2158 Vitralon Grey Zinc Rich Epoxy Powder* Pratt & Lambert Chemical Coatings Buffalo, NY 39/80020 Smooth Matte Black Polyester Topcoat Powder* Tiger Drylac USA Cucamonga, CA * Shelf life is 12 months from date of manufacture at ambient temperature. JUN 2014 Page 1.29 ROBINSON MAINTENANCE MANUAL R44 SERIES ._____________._____ ______._____ _ ______.I I Page 1.30 JUN 2014 FIGURE 1-12 PAINT CODES (Refer to Chapter 9 for rotor blade paint dimensions. Exterior surface codes are D & F unless otherwise specified.) 1.455 Powder Coat (continued) PRODUCT MANUFACTURER 49/72460 Smooth Glossy Gray RAL 7043 Polyester Topcoat Powder* Tiger Drylac USA Cucamonga, CA 49/22460 Smooth Glossy Yellow RAL 1028 Polyester Topcoat Powder* “ “ PFWF104S9 White Polyester Topcoat Powder* Dupont Co. Wilmington, DE * Shelf life is 12 months from date of manufacture at ambient temperature. ROBINSON MAINTENANCE MANUAL R44 SERIES 0 D I E D A A D 1.460 Paints Refer to Figures 1-12 and 1-13 for paint code application. Paint codes for specific helicopter serial numbers are listed on the inside cover of factory-supplied maintenance record (logbook). NOTE Use fisheye eliminator, accelerator, or other additives per manufacturer's recommendations. CODE MATERIAL MANUFACTURER A Flat Black Imron 373-P-29950 Axalta Wilmington, DE Semi-gloss Black 3900-05 with 39-SG catalyst and water reducer Cardinal Industrial Finishes El Monte, CA Semi gloss Black 656-58-7038 with X-503 activator AkzoNobel Waukegan, IL B Dark gray Imron AF400/AF700 Axalta Wilmington, DE C Engine gray IE-8948 Randolph Products Co. Carlstadt, NJ Lycoming A219 gray engine enamel (aerosol can touch-up; shelf life 2 years) Tempo Products Cleveland, OH D White Imron AF400/AF700 Axalta Wilmington, DE E Yellow Imron AF400/AF700 “ “ F Imron AF400/AF700 Colors “ “ G Clear Imron AF740 Axalta Wilmington, DE H Semi-gloss Clear 656-58-9000 with X-503 activator AkzoNobel Waukegan, IL J White Imron 2.1 FT flat polyurethane enamel with FG-1333 activator and T-1021 or T-1022 thinner Axalta Wilmington, DE K White Cat-L-Ink 50-100R (shelf life 3 years) 20/A Catalyst (shelf life 2 years) Ethone, Inc. West Haven, CT Yellow Cat-L-Ink 50-202AR or BR (shelf life 3 years) 20/A Catalyst (shelf life 2 years) “ “ Med Red Cat-L-Ink 50-508R (shelf life 3 years) 20/A Catalyst (shelf life 2 years) “ “ L Red Imron AF400/AF700 Axalta Wilmington, DE M Orange Imron AF400/AF700 “ “ N Krylon 1311 (shelf life 2 years) Matte Clear (aerosol can) Krylon Div. of Borden Columbus, OH O Light gray Imron AF400/AF700 Axalta Wilmington, DE P Silver Bullet AM Tracer Black 20-452AM-F1 with 16-CURE-F4 activator Burke Industrial Coatings Ridgefield, WA JUN 2014 Page 1.31 ROBINSON MAINTENANCE MANUAL R44 SERIES FIGURE 1-13 PAINT CODES Page 1.32 JUN 2014 ROBINSON MAINTENANCE MANUAL I I B \ \ Exterior surfaces of fuel tank facing gearbox compartment D N B-1.--7: ),D -1 B - - ~-~--• -'l~ _ • • ~~:::::::=°=? , __ .. R44 SERIES I - j B ~•~ ~-:---J~ B B //, ~ c::::::::=~ -_} [l :::. .• , _.;-. ~ --1 !I I C . I C - (Carb heat scoop on exhaust collector RH side of aircraft) 1.460 Paints (continued) For limited touch-up of interior and landing gear only: CODE MATERIAL MANUFACTURER A Krylon 1613 (shelf life 2 years) Semi-Flat Black (aerosol can) Krylon Div. of Borden Columbus, OH NYBC 14 (shelf life 2 years) Semi-Flat Black New York Bronze Powder Co. Scranton, PA Cardinal A-2000-05 Flat Black (aerosol can) Cardinal Industrial Finishes So. El Monte, CA 1.470 Lubricants RHC PART NO. LUBRICANT TYPE MANUFACTURER’S PART NO. MANUFACTURER A257-1 Grease (general purpose) 101 Southwestern Petroleum Corp. Fort Worth, TX A257-2 Gear oil 201 SAE 90 Southwestern Petroleum Corp. Fort Worth, TX A257-3 Grease Aero Shell 14 MIL-G-25537 Shell Oil Co. A257-4 Oil (automatic transmission fluid) Dexron II or Dexron II/Mercon or Dexron III/Mercon Quaker State or Pennzoil A257-5 Grease (water resistant) 3120 11402 Sta-Lube, Inc. Compton, CA Lubrimatic Buffalo Grove, IL A257-6 Grease (fuel resistant) Fuelube EZ Turn Fleet Supplies Inc. Cleveland, OH United-Erie Div. of Interstate Chemical Co. Erie, PA A257-7 Dry film lubricant Lubri-Kote Type A 1040 CR Mealey Ind. Lubricants Cleveland, OH A257-8 Rubber lubricant P-80 International Products Corp. Trenton, NJ A257-9 Anti-seize Silver Grade Loctite Corp. Newington, CT A257-10 Substitute A257-16 A257-12 Grease Mobilgrease 28 MIL-PRF-81322 Exxon Mobil Corp. A257-15 Hydraulic fluid Per MIL-PRF-5606 Any A257-16 Engine oil Type M 20W-50, SAE J1966 Phillips 66 Co. Pasadena, TX JUN 2014 Page 1.33 ROBINSON MAINTENANCE MANUAL R44 SERIES 1.470 Lubricants (continued) RHC PART NO. LUBRICANT TYPE MANUFACTURER’S PART NO. MANUFACTURER A257-16 Engine oil Aviation oil 20W-50, SAE J1966 Exxon Mobil Corp. Fairfax, VA A257-17 Substitute A257-19 A257-18 O-ring lubricant 55 Dow Corning Corp. Midland, MI A257-19 Valve lubricant and sealant compound 111 Dow Corning Corp. Midland, MI A257-20 Pag oil Daphne Hermetic PR Apollo America Corp. Southfield, MI A257-21 Petrolatum lubricant P-16 Panef Corp. Milwaukee, WI 1.480 Adhesives and Sealants RHC PART NO. DESCRIPTION COLOR MFR. PART NO. MANUFACTURER B270-1 Sealant - polysulfide, fuel resistant (2-part) Sealant - polysulfide, fuel resistant (2-part) Sealant - polysulfide, fuel resistant (2-part) Gray Gray Gray FS-8907 B-2 WS-8032 B-2 AC-350 B-2 PPG Aerospace Glendale, CA Royal Adhesives & Sealants Wilmington, CA Advanced Chemistry & Technology Inc., Garden Grove, CA B270-2 Substitute B270-1 B270-4 Substitute B270-13 B270-5 Sealant - synthetic rubber putty (1-part) White Light Gray Q4-2805 94-031 Dow Corning Corp. Midland, MI B270-6 Sealant & lubricant - thread (1-part) Gray Titeseal 55 Radiator Spec. Co. Charlotte, NC B270-7 Substitute B270-14 B270-8 Adhesive - rubber, nitrile/acetone (1-part) Tan C 160 Stabond Corp. Gardena, CA B270-9 Adhesive - epoxy, structural, flexible (2-part) Gray 2216 B/A 3M Co. St. Paul, MN B270-10 Adhesive/sealant - threadlocker, anaerobic, tight-fits (1-part) Red 271 Henkel Loctite Corp. Rocky Hill, CT B270-11 Adhesive/sealant - threadlocker, anaerobic, loose-fits (1-part) Red 277 Henkel Loctite Corp. Rocky Hill, CT Page 1.34 JUN 2014 ROBINSON MAINTENANCE MANUAL R44 SERIES JAN 2021 Chapter 1 General Page 1.35 1.480 Adhesives and Sealants (continued) RHC PART NO. DESCRIPTION COLOR MFR. PART NO. MANUFACTURER B270-12 Sealant - electrical potting (2-part) Any color except red MIL-PRF-8516 Type II, Class 2, Category A or B Any B270-13 Sealant - silicone rubber, noncorrosive (1-part) Translu- cent 3145 Dow Corning Corp. Midland, MI B270-14* Adhesive - foam, neoprene/water (1-part) White Lavender 100 Neutral 100 Lavender 3M Co. St. Paul, MN B270-15 Adhesive - plastic, for vinyl (1-part) Clear 2262 3M Co. St. Paul, MN B270-16 Substitute B270-14 B270-17 Adhesive - cyanoacrylate, instant (1-part) Clear Super Bonder 495 Henkel Loctite Corp. Rocky Hill, CT B270-18 Adhesive - weather strip (1-part) Black 051135-08008 3M Co. St. Paul, MN B270-19 Adhesive - epoxy structural, rigid (2-part) Green 1838 B/A 3M Co. St. Paul, MN B270-20 Adhesive/sealant - threadlocker, anaerobic, non-permanent (1-part) Purple 222 or 222MS Henkel Loctite Corp. Rocky Hill, CT B270-21 Protectant - corrosion, non-drying (1-part) Lt. Amber LPS 3 LPS Laboratories, Inc. Tucker, GA B270-22 Protectant - corrosion, drying (1- part) Amber LPS Hardcoat LPS Laboratories, Inc. Tucker, GA B270-23 Sealant - gasket (1-part) Sealant - gasket (1-part) Brown Brown GM3H (Gasket Maker #4) JV66B Perfect Seal, Inc. Cincinnati, OH Dana Corp.; Churubusco, IN (Victor Reinz Brand) B270-24 Activator/Primer - Anaerobic adhesive (1-part) Translu- cent Green 7649 Henkel Loctite Corp. Rocky Hill, CT B270-25 Clear Coat - automotive touch up, brush in bottle (1-part) Clear Clear Coat Touch up Bottle Automotivetouchup Harahan, LA B270-26 Sealant - Polysulfide, window glazing (2-Part) Black AC-251B-1 Advanced Chemistry & Technology Inc., Garden Grove, CA * B270-8 may be substituted for B270-14. ROBINSON MAINTENANCE MANUAL R44 SERIES 1.490 Storage Limits 1. B283 hoses have a shelf storage life of 5 years. Hose service life is “on condition”, with a maximum of 12 years. 2. Elastic cords have a shelf storage life of 5 years. Elastic cord service life is “on condition”, with a maximum of 12 years. Use invoice or FAA Form 8130 date as start date. 3. Store V-belts at less than 85º F (30º C), with relative humidity below 70%. Avoid solvent and oil vapors, atmospheric contaminants, sunlight, and ozone sources (electric motors, arc welding, ionizing air purifiers, etc.). Belt shelf life is 4 years if preceding recommendations are followed. Use invoice date or FAA Form 8130 date as start date. 4. Oils and greases have a 5 year shelf life when stored and kept sealed in their original container. Use invoice date or FAA Form 8130 date as start date unless the manufacturer has marked container with manufacture date (in which case use manufacture date as start date). 5. Rubber o-rings, seals, and gaskets have a twenty (20) quarter, five (5) year shelf life from the indicated cure date. Fluorocarbon (Viton) and silicon rubber products shall adhere to manufacturer’s expiration date(s). Service life is “on condition” with a maximum of 12 years. 6. Store uninstalled fuel bladder in original container (if available) at 70°F to 80°F and below 70% humidity. Coat bladder with clean, non-detergent engine mineral oil to prevent rubber from drying out and cracking. Store bladder in relaxed condition free from tension, compression, or other deformation such as creases or folds. Page 1.36 Chapter 1 General JAN 2021 ROBINSON MAINTENANCE MANUAL R44 SERIES ROBINSON MAINTENANCE MANUAL MODEL R44 1.600 PART INTERCHANGEABILITY The following parts are interchangeable. Unless noted otherwise, whenever one part is referred to in this manual, its substitute part is also permitted. AN340 nut AN345 nut N364 nut AN507 screw AN509 screw AN515 screw AN515C screw AN515UB screw AN525 & AN526 screw AN814 & MS24391 plug AN81 5 & MS24392 union AN819 & MS20819 sleeve AN822 & MS20822 elbow AN823 & MS20823 elbow AN825 & MS20825 tee AN826 & MS20826 tee AN894 & MS24398 bushing AN900 gasket AN924 nut & MS24400 nut AN931 grommet AN936 lockwasher AN960-8L washer AN960-8 washer AN960-1 0L washer AN960-10 washer AN960-416L washer AN960-416 washer AN960-516L washer AN960-516 washer AN960-616L washer AN960-616 washer AV DEL 1 693 rivet MS20604ML4W1 rivet MS21 91 9DG clamp NAS1291 nut NAS 1303 thru NAS 1 320 bolt NAS487 instrument nut NAS679A nut NAS679C M nut NAS696 nutplate NAS698 nutplate NAS698 nutplate Interchangeable with: MS35649 nut per NASM35649 except brass nut MS35650 nut per NASM35650 MS21083 nut per NASM21083 MS24693 screw per NASM24693 MS24694 screw per NASM24694 MS35206 screw per NASM35206 MS51957 screw B567- screw MS27039C screw per NASM27039 AS5169 plug AS5174 union AS5176 sleeve AS5195 elbow AS5196 elbow AS5197 tee AS5198 tee AS5173 bushing MS35769 gasket per AS35769 AS5178 nut MS35489 grommet B332- lockwasher NAS 1149FN816P washer NAS1149FN832P washer NAS1149F0332P washer NAS 1149F0363P washer NAS 1149F0432P washer NAS1149F0463P washer NAS1149F0532P washer NAS1149F0563P washer NAS1149F0632P washer NAS1149F0663P washer A VDEL 1 691 rivet MS20604M4W1 rivet per NASM20604 AS21919 clamp MS21042 nut per NASM21042 NAS6603 thru NAS6620 bolt* MS33737 Instrument nut per NASM33737 NAS1291- nut NAS1291C M nut MS21071 nutplate per NASM21071 MS21073 nutplate per NASM21073 MS21073 nutplate per NASM21073 * The following bolts must be NAS 1300 series only: NAS1304-28, -35, -37, & -38, and NAS1305-35 Change 14: JUL 2008 Page 1 .37 ROBINSON MAINTENANCE MANUAL MODEL R44 1.700 SPECIAL INSTRUCTIONS FOR REASSEMBLING AND FLIGHT TESTING R44 SERIES HELICOPTERS AFTER CRATING FOR EXPORT REASSEMBLY: TO BE PERFORMED BY A CERTIFICATED MECHANIC 1. Remove top of cabin assembly crate. Remove wall marked "A" by removing lag bolts painted black. Remove empennage assembly. Remove remaining walls. Remove all parts, except cabin assembly, from crate base. Open main rotor blade and tailcone crate. 2. Reinstall main rotor hub per Section 9.122. 3. Assemble landing gear per Section 5.320. NOTE Do not install strut fairings at this time. 4. Attach a hoist to main rotor hub per Section 1.220. Lift aft end of crate while at same time taking up slack in hoist. When helicopter belly is in a horizontal position, lift with hoist until cabin is supported by hoist alone. Remove lag screws and carriage bolts attaching helicopter cabin to crate. Remove crate. CAUTION Do not lift heli.copter and attached crate using main rotor hub; damage to main rotor gearbox and frames could result. 5. Remove supports from landing gear attachment points and install assembled landing gear per Section 5. 1 20 or Section 5 (float landing gear). Install front cross tube cover panel. If desired, install strut fairings per Section 5 .420 (not applicable to utility float landing gear). 6. Remove tailcone cowling and install tailcone per Section 4.312. Install strobe light. Install communication, Loran, and GPS antennas (if equipped). Install tailcone cowling. CAUTION Make sure all foam packing material is removed from inside of tailcone before installation; damage to tail rotor drive shaft could result. 7. Install empennage assembly per Section 4.322. Install tail rotor guard per Section 4.330. 8. Fill tail rotor gearbox with A257-2 oil to full level. 9. Install tail rotor per Section 9.212. Match color coded markings on blades with pitch links. 10. Install fan and scroll per Section 6.220. Page 1.38 Change 13: OCT 2006 ROBINSON MAINTENANCE MANUAL MODEL R44 1.700 SPECIAL INSTRUCTIONS FOR REASSEMBLING AND FLIGHT TESTING R44 SERIES HELICOPTERS AFTER CRATING FOR EXPORT (cont'd) 11. Install engine exhaust per Section 6.520. 12. Install main rotor blades per Section 9. 112. Match color-coded markings on blades with markings on hub and pitch links. 13. Perform tail rotor drive shaft runout per Section 7 .340. 14. Fill main rotor gearbox with A25 7-2 oil to full level as required. 15. Fuel helicopter and drain a small amount of fuel through gascolator. 1 6. If ship is equipped with attitude horizon, directional gyro, turn coordinator, and/or vertical card magnetic compass, install as follows: Attitude Horizon, Direction Gyro, and Turn Coordinator: Remove warning lights from lower console. Pull out B 197 instrument face by removing six (6) securing screws. NOTE Place a piece of foam under B197-1 face to prevent scratching lower face. Install required instrument(s) by securing with hardware provided. CAUTION Directional gyro mount screws must not exceed 1 inch in length or unit will be damaged. Connect existing straight connector(s) to directional gyro and/or turn coordinator. Connect angle connector to attitude horizon, ensuring strain relief points down. Ensure connectors lock in place. Ty-rap excess wiring. Reinstall B197-1 face to console. Reinstall amber FUEL FILTER (10-540 only), AUX FUEL PUMP (10-540 only), ALT, & GOV OFF lights and red ENG FIRE & OIL warning lights. Vertical Card Magnetic Compass: Remove vertical card compass from foam-protected box. Install a 2-inch length of B 1 58-3 heat-shrink tubing over each compass wiring pin. Locate existing wires from windshield center bow. Connect pins from compass to existing sockets (polarity is not critical), cover connection with heat-shrink, then apply heat. Secure compass in mount with four screws and hide and secure wiring atop compass. Change 13: OCT 2006 Page 1.39 ROBINSON MAINTENANCE MANUAL MODEL R44 1.700 SPECIAL INSTRUCTIONS FOR REASSEMBLING AND FLIGHT TESTING R44 SERIES HELICOPTERS AFTER CRATING FOR EXPORT (cont'd) 1 7. Install battery (negative ground system). 18. Remove plastic dehydrator plugs from each cylinder's upper spark plug hole. 19. Lubricate provided upper spark plugs with A257-10 spark plug thread lubricant, install, and torque per Section 1 .330. 20. Connect ignition leads to upper spark plugs and install spark plug access covers. 21 . Disconnect ignition leads from lower spark plugs and remove lower spark plugs. 22. Place a small container under each cylinder's lower spark plug hole. With ignition switch in the OFF position, rotate engine by hand, several revolutions, to force excess preservation oil from cylinders. 23. Temporarily connect a grounding wire from each magneto's primary lead terminal to airframe ground. 24. Activate starter for no more than 1 2 seconds or until oil pressure is indicated on gage, whichever comes first. Allow starter to cool for 5 minutes after each activation. 25. After oil pressure is indicated remove temporary grounding wire from each magneto. 26. Lubricate lower spark plug threads with A257-10 spark plug thread lubricant, install, and torque per Section 1 .330. 27. Connect ignition leads to lower spark plugs. 28. Install belly, left, right, and aft cowling assemblies. 29 Perform Section 2.205 ground check. 30. Perform Section 2.210 run-up. Page 1 .40 Change 13: OCT 2006 ROBINSON MAINTENANCE MANUAL MODEL R44 1.700 SPECIAL INSTRUCTIONS FOR REASSEMBLING AND FLIGHT TESTING R44 SERIES HELICOPTERS AFTER CRATING FOR EXPORT (cont'd) NOTE 10-540 engines should idle at 58-62% rpm with engine warm, clutch engaged. 10-540 IDLE ADJUSTMENT PROCEDURE Idle rpm and mixture were set for sea-level standard conditions during factory flight test. If idle and off-idle throttle performance are not satisfactory upon reassembly, adjust as follows: First set idle rpm to 58-62% rpm with engine warm & clutch engaged. Then, with engine off, disconnect fuel control outlet hose, connect test hose if desired, and measure fuel flow rate at fuel control outlet with mixture full rich, throttle at idle, and electric fuel pump on (ignition key to PRIME position). Adjust idle mixture as required to obtain 1 6-1 8 pounds/hour fuel flow ( 1 70-1 90 cc/minute). Clockwise rotation of idle mixture adjustment wheel (viewed from aircraft right side) enriches mixture. Re-check idle rpm after mixture adjustment and repeat as required until both rpm and mixture are within limits. With rpm and mixture set, verify smooth acceleration from idle to 102% rpm with no engine hesitation or smoke from tailpipe. Also verify smooth needle split from 102% to idle with no engine roughness or erratic rpm indications and acceptable idle quality. Note that 1 6-1 8 pounds/hour fuel flow should produce acceptable idle quality and off-idle throttle performance under sea-level standard conditions. Richer mixtures may be required for cold temperature operation and leaner mixtures may be required for hot/high altitude operation. Deviate from 16-18 lb/hr recommendation as required for acceptable idle quality and off-idle throttle performance (smooth accelerations and needle splits). Change 13: OCT 2006 Page 1.41 ROBINSON MAINTENANCE MANUAL MODEL R44 1. 700 SPECIAL INSTRUCTIONS FOR REASSEMBLING AND FLIGHT TESTING R44 SERIES HELICOPTERS AFTER CRATING FOR EXPORT (cont1 d) FLIGHT TEST: TO BE DONE BY A QUALIFIED PILOT AND A CERTIFICATED MECHANIC 1 . Perform preflight inspection per the Pilot1 s Operating Handbook. 2. Balance fanwheel per Section 6.240. 3. Balance tail rotor per Section 10.240. 4. Perform hover checks per Section 2.220 Step 1. DO NOT proceed into forward flight at this time. 5. Track and balance main rotor per Section 10.200. 6. After completing track and balance, adjust autorotation RPM per Section 10.250. Avoid rotor overspeeds by avoiding higher gross weights and higher altitudes during autorotation checks. 7. While climbing at Maximum Continuous Power (MCP), 60 KIAS, and governor on: a. Evaluate roughness and controllability. b. Perform 30 degree left yaw to check for adequate directional control. 8. Level flight at 2000 feet density altitude (deviate as required for weather and terrain), MCP, and governor on, evaluate the following: a. Longitudinal and lateral cyclic control forces. b. Collective control forces. 9. Evaluate roughness at MCP and 130 straight and level flight. 10. Check all instruments, gauges, and avionics for proper operation. 11. During autorotation at 50 KIAS and 90% RPM, perform a 30 degree right yaw to check for adequate directional control. 1.800 REPLACEMENT COMPONENT IDENTIFICATION (DATA) PLATES In order to issue a replacement component identification plate for field installation, RHC must first receive the old identification plate in legible condition. If old identification plate is lost or destroyed, then RHC must have an original letter (photocopies or faxes are NOT acceptable) from customer1 s Civil Aviation Authority authorizing identification plate replacement AND stating component name, part number, and serial number for each requested identification plate. There is a charge for each plate issued. Page 1.42 Change 13: OCT 2006 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 . . . . . . . . . . . . . . . . . 2.3 2.121 Push-Pull Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2.122 Rod Ends and Spherical Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2.125 Elastomeric Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 2.130 Telatemp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 2.140 Torque Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 2.200 Ground and Flight Check For 100-Hour/Annual Inspection . . . . . . . . . . . . . . . 2.7 2.205 Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 2.210 Run Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 2.220 Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 2.230 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 2.300 Airframe Preparation For 100-Hour/Annual Inspection . . . . . . . . . . . . . . . . . . 2.13 2.400 100-Hour/Annual Airframe Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 2.410 Inspection Procedures and Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 2.500 Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 2.501 Upper and Lower Clutch Actuator Bearings Inspection . . . . . . . . . . . . . . . 2.39 2.502 C181 Lower Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 2.503 C184 Upper Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40 2.507 V-Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.41 2.508 Lower Sheave V-Belt Wear Pattern Inspection . . . . . . . . . . . . . . . . . . . . . 2.43 2.510 Tail Skid Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45 2.520 Tail Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48 2.530 Main Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49 2.540 Rotor/Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 2.550 Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.51 2.560 Penetrant Inspection of C020 Upper Steel Tube Frame . . . . . . . . . . . . . . 2.53 2.561 Corrosion on C020 Upper Steel Tube Frame . . . . . . . . . . . . . . . . . . . 2.54 2.570 Volcanic Ash Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55 2.580 Windshield Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56 2.590 Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56A 2.600 12-Year Inspection and Limited Overhaul Requirements . . . . . . . . . . . . . . . . 2.57 JAN 2021 Chapter 2 Inspection Page 2.i ROBINSON MAINTENANCE MANUAL R44 SERIES CHAPTER 2 INSPECTION (Continued) Section Title Page 2.610 Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.57 2.620 (Reserved) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.58 2.630 Component Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.59 2.700 2200-Hour Overhaul Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.60 2.710 Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.60 Page 2.ii Chapter 2 Inspection JAN 2021 ROBINSON MAINTENANCE MANUAL R44 SERIES CHAPTER 2 INSPECTION 2.000 Introduction The R44 hel