R66 MAINTENANCE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR TRADE USAGE, THE REMEDIES OF THE BUYER SHALL BE LIMITED TO THOSE PROVIDED HEREIN. IN NO EVENT WILL THE MANUFACTURER BE LIABLE FOR LOSSES RESULTING FROM LOSS OF USE OF THE HELICOPTER, COLLATERAL, CONSEQUENTIAL OR SPECIAL DAMAGES, OR ANY OTHER COSTS. Warranty adjustments with respect to any helicopter or parts manufactured by RHC will be made only upon compliance with the following procedure: (1) The defective part or assembly, together with a written Warranty Claim, must be returned to RHC not later than thirty (30) days after discovery of the defect nor more than thirty (30) days after expiration of the Warranty period. (2) RHC will, after inspection, determine whether the material or part was defective when it left the factory and will respond accordingly. Final determination of a Warranty adjustment rests with RHC. Effective 01 June 2010 ROBINSON HELICOPTER COMPANY, INC. 2901 Airport Drive Torrance, California 90505 U.S.A. Page viii Introduction APR 2017 ROBINSON HELICOPTER COMPANY, INC. LIMITED PARTS WARRANTY Robinson Helicopter Company, Inc. (hereafter referred to as RHC) warrants each new and factory overhauled helicopter part to be free from defects in material and workmanship appearing within one year from the date of delivery from the RHC factory or during the first one thousand (1000) hours of operation, whichever event occurs first; provided, the part has been subjected to normal use and service. This Warranty is limited to repair or replacement on an exchange ba- sis, as selected by RHC, of any part, which upon examination by RHC is deemed to have been defective when the part left the factory. A new warranty period is not established for parts replaced under the terms of this Warranty. Such replacement parts are warranted only for the remainder of the original warranty period. RHC is not responsible for the cost of removing, shipping or reinstallation of parts under the terms of this Warranty. This Warranty shall not apply to any part which has been repaired or altered outside the factory, and which, in RHC’s judgment, has affected the performance or reliability of the part. This Warranty shall not apply to any part which has been subject to corrosion, misuse, negligence or accident, nor to any parts normally replaced during routine maintenance, such as, air cleaners, skid shoes, rod end or spherical bearings, light bulbs, etc. RHC makes no Warranty with respect to engines, batteries, instruments, avionics or other trade accessories since they are usually warranted separately by their respective manufacturers. ADDITIONAL WARRANTY FOR MAIN & TAIL GEARBOXES In addition to the warranty specified above, an extended pro-rated warranty shall apply to new and factory overhauled main and tail gearboxes installed, on all R22 & R44 helicopters for the first 2200 hours of service, on all R44 Cadet helicopters for the first 2400 hours of service, on all R66 helicopters for the first 2000 hours of service, or three years from the date of manufacture, whichever event occurs first. During this period, if a gearbox must be over- hauled due to failure of a part which was defective when it left the factory, RHC will pro-rate the cost of the overhaul by the hours in service or the months in service, whichever fraction is greater. THE FOREGOING WARRANTY IS EXCLUSIVE AND IS GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES AND REPRESENTATIONS, EXPRESS, IMPLIED, OR STATUTORY, WHETHER WRITTEN OR ORAL, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR TRADE USAGE, THE REMEDIES OF THE BUYER SHALL BE LIMITED TO THOSE PROVIDED HEREIN. IN NO EVENT WILL THE MANUFACTURER BE LIABLE FOR LOSSES RESULTING FROM LOSS OF USE OF THE HELICOPTER, COLLATERAL, CONSEQUENTIAL OR SPECIAL DAMAGES, OR ANY OTHER COSTS. Warranty adjustments with respect to any parts manufactured by RHC will be made only upon compliance with the following procedure: (1) The defective part or assembly, together with a written Warranty Claim, must be returned to RHC not later than thirty (30) days after discovery of the defect nor more than thirty (30) days after expiration of the Warranty period. (2) RHC will, after inspection, determine whether the material or part was defective when it left the factory and will respond accordingly. Final determination of a Warranty adjustment rests with RHC. Effective 01 June 2016 ROBINSON HELICOPTER COMPANY, INC. 2901 Airport Drive Torrance, California 90505 U.S.A. CHAPTER 1 GENERAL Section Title Page 1-00 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1-10 R66 Maintenance Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1-20 R66 Maintenance Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 1-30 Component Maintenance Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 1-40 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 1-50 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 1-60 Definitions and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 1-70 Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4A 1-71 Part Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4A 1-72 Returning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4A 1-73 Ordering and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4A 1-74 Warranty Claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4A 1-75 Customer Service Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4A 1-80 Assembly Instructions for R66 Helicopter Crated for Export . . . . . . . . . . . . . 1.5 APR 2017 Chapter 1 General Page 1.i Intentionally Blank Page 1.ii Chapter 1 General APR 2017 CHAPTER 1 GENERAL 1-00 Introduction The R66 Maintenance Manual contains instructions necessary for proper maintenance, servicing, and handling of the R66 helicopter. The R66 Instructions for Continued Airworthiness (ICA) includes the R66 Maintenance Manual (MM), R66 Illustrated Parts Catalog (IPC), R66 Pilot’s Operating Handbook (POH), R66 Service Bulletins (SB), R66 Service Letters (SL), RR300 Series Operation and Maintenance Manual (OMM), applicable Rolls-Royce technical publications, and applicable component manufacturer technical publications. Service Bulletins are issued by Robinson Helicopter Company (RHC), Rolls-Royce, and component manufacturers. RHC Service Bulletin compliance is mandatory; comply with other applicable Service Bulletins as directed. RHC technical publications are available online at www.robinsonheli.com. Rolls-Royce technical publications are available online at https://fast.aeromanager-online.com. Kit instructions are issued for field installation of either optional or mandatory (due to Service Bulletin or parts obsolescence) equipment upgrades, or provisions for upgrades. Kit instructions issued by RHC either implement approved type design data, or are approved as type design data. The R66 Maintenance Manual is formatted in Air Transport Association of America Specification No. 100 (ATA-100). Style, content, and structure deviates from ATA-100 when necessary for clarity, and for logic of presentation. A list of chapters and a complete list of contents is located in the Introduction. Chapters are separated by tab dividers and chapter contents are listed in the chapter front pages. CAUTION Always read instructions completely before performing a task. 1-10 R66 Maintenance Manual Revisions Before using the R66 Maintenance Manual, verify it consists of current effective pages. The list of effective pages is located in the Revision Log in Chapter 100. When a new manual is purchased, complete and submit the Subscription Order Form available online at www.robinsonheli.com. Subscribers receive publication revisions for a two-year period. Renew subscriptions annually. The revision status for all RHC technical publications is available online at www.robinsonheli.com. APR 2017 Chapter 1 General Page 1.1 1-20 R66 Maintenance Authorization Only appropriately certificated mechanics who have successfully completed an R66 factory-sponsored maintenance course, or are under direct supervision of the above- stated mechanic, are authorized to perform maintenance, repairs, or inspections on the R66 helicopter. Annual inspections of U.S.-registered light helicopters must be performed by holders of an Inspection Authorization (IA) certificate or by repair stations certificated by the Federal Aviation Administration (FAA). The daily preflight and some preventive maintenance may be performed by the above-stated mechanics, or by the pilot/owner after receiving appropriate instruction in accordance with the R66 Pilot’s Operating Handbook and applicable aviation regulations. 1-30 Component Maintenance Authorization Only appropriately certificated mechanics who have successfully completed both a factory- sponsored maintenance course and component maintenance course, and who possess technical data supplied by RHC, are authorized to perform maintenance specified in the Component Maintenance Manual (CMM). Component maintenance may only be performed at an RHC-authorized Service Center that has required special tools. 1-40 Maintenance Record The Airframe Maintenance Record is available online at www.robinsonheli.com. Airframe Maintenance Record blank PDF forms may be used for R22-series, R44-series, and R66 Turbine helicopters. Component Record blank PDF forms may be used for life- limited or TBO components. Blank paper copies are available for purchase (P/N R8478 Airframe Maintenance Record and P/N R8479 Component Record [pack of 20]). A Component Record is a maintenance record of the removals, installations, or maintenance performed on a life-limited or TBO component. When a life-limited or TBO component is installed in the helicopter, the Component Record card is inserted in the Airframe Maintenance Record. When a life-limited or TBO component is removed from the helicopter, remove the Component Record card and keep the card with the Component. Major assemblies may contain one or more life-limited or TBO component. RHC encourages operators to utilize Component Record cards to assist in tracking time on interchangeable parts since service lives may be different between models. RHC does not create Component Record cards for spares, however, operators may create their own. RHC’s Repair Station does not require a Component Record card in order to perform work on a component, unlike a Component/Return Authorization form. RHC recommends using a toner-based laser, or a pigment-based inkjet, color printer and 65 lb white (96 bright) premium card stock for Maintenance Record or Component Record card production. Maintenance Record binders and tab sets are available separately (P/N R8656 Maintenance Record Binder and P/N R8650 Maintenance Record Tabs). Page 1.2 Chapter 1 General APR 2017 1-50 Notations The following notations will be found throughout the manual: NOTE A NOTE provides emphasis or supplementary explanation. CAUTION Equipment damage can result if a CAUTION is not followed. WARNING Personal injury or death can result if a WARNING is not followed. 1-60 Definitions and Abbreviations Refer to R66 Pilot's Operating Handbook (POH) Section 1 for additional definitions and abbreviations. A. Definitions 14 CFR § 27.602 Critical Part: 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 § 6-20 for R66 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 R66 Turbine Type Certificate Data Sheet (TCDS) in § 4-30. Refer to Equipment List/Weight and Balance Data Sheet (RF 134) and Weight and Balance Record in R66 POH Section 6 for installed equipment. Life-Limited Part: Refer to § 4-10. Any part for which a mandatory replacement limit is specified in the type design, the Instructions for Continued Airworthiness, or the maintenance manual. Time in Service: With respect to maintenance time records, time in service means the time from the moment an aircraft leaves the surface of the earth until it touches it at the next point of landing. APR 2017 Chapter 1 General Page 1.3 1-60 Definitions and Abbreviations (continued) B. Abbreviations 14 CFR: Title 14 of the Code of Federal Regulations. The Federal Aviation Regulations (FARs) are part of the CFR. AOG: Aircraft on Ground ATA-100: Air Transport Association of America Specification No. 100 BL: Butt Line Station locations CRA: Component Return/Authorization ELT: Emergency Locator Transmitter EMU: Engine Monitoring Unit FCU: Fuel Control Unit FS: Fuselage Station locations GCU: Generator Control Unit HID: High Intensity Discharge HS: Horizontal Stabilizer Station locations LBL: Left Butt Line Station locations LED: Light Emitting Diode LRU: Line-Replaceable Unit MRDS: Main Rotor Drive Shaft MRGB: Main Rotor Gearbox OEM: Original Equipment Manufacturer PTG: Power Turbine Governor R66 IPC: R66 Illustrated Parts Catalog R66 MM: R66 Maintenance Manual R66 POH: R66 Pilot’s Operating Handbook RHC: Robinson Helicopter Company RR300 Series OMM: Rolls-Royce RR300 Series Operation and Maintenance Manual RS: Rotor Station locations SB: Service Bulletin SL: Service Letter TBO: Time Between Overhaul TCDS: Type Certificate Data Sheet TRDS: Tail Rotor Drive Shaft TRGB: Tail Rotor Gearbox TS: Tailcone Station locations TSN: Time Since New TSO: Time Since Overhaul WL: Water Line Station locations Page 1.4 Chapter 1 General APR 2017 APR 2017 Chapter 1 General Page 1.4A 1-70 Service Information 1-71 Part Designation Robinson parts are designated with a part number prefix “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”. 1-72 Returning Parts All parts shipped to RHC must include a signed Component Return/Authorization (CRA) Form available online at www.robinsonheli.com. 1-73 Ordering and Shipping Procure parts from any R66 Dealer or Service Center, or order directly from assigned RHC Customer Service Representative via email, fax, or phone. 1-74 Warranty Claims Complete CRA Form (refer to § 1-72) and, in the Warranty Claim section, indicate if rotorcraft or component is under warranty. If claim is for parts or for labor allowance due to a Service Bulletin issued against rotorcraft or component, write in “per SB-XX” adjacent to requested warranty action. 1-75 Customer Service Directory Please visit www.robinsonheli.com for a complete service directory. Intentionally Blank Page 1.4B Chapter 1 General APR 2017 1-80 Assembly Instructions for R66 Helicopter Crated for Export NOTE Aircraft assembly to be performed by a certificated mechanic. 1. Remove top of cabin assembly crate. Remove wall marked “A” by removing lag bolts painted black. Remove empennage assembly. Remove remaining walls. Remove all parts, except cabin assembly, from crate base. Open crate containing blades, skid tubes, and tailcone. 2. Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1. Install hardware securing forward and aft strut assemblies (cross tubes installed) onto skid tubes. Standard torque bolts per Section 20-32 and torque stripe per Figure 5-1. 3. Remove tailcone cowling per Section 53-23. Remove engine cowling per Section 53-21. 4. Remove shipping supports (ty-raps, foam, tape, etc.) from main rotor gearbox compartment, but leave cannon plugs taped and fluid line dust caps installed. Remove engine air intake cover by opening air filter bypass door and pulling string and cover through the door. Remove main rotor gearbox mounting hardware, nylon spacers, and upper frame strut assemblies. 5. Remove top of main rotor gearbox crate and position crate so gearbox is upright. Refer to Section 7-20. Install hoisting equipment and lifting fixture or nylon rope on main rotor hub. Remove hoist slack to support gearbox, remove lag bolts securing gearbox to wooden divider, and carefully hoist gearbox from crate (do not damage pitot tube). 6. Install main rotor gearbox per Section 63-20 steps 1 thru 9, but do not remove hoisting equipment and lifting fixture or nylon rope. 7. Perform (engine driveline) forward flex plate shimming per Section 63-11. 8. Refer to Section 7-20. Remove hoist slack to support cabin assembly, remove lag and carriage bolts securing metal angles to crate, and hoist cabin & attached metal angles off of crate base. CAUTION Do not lift helicopter and attached crate using main rotor hub; damage to main rotor gearbox and frames could result. 9. Remove metal angles from cabin assembly landing gear attach points. Install landing gear assembly per Section 32-10. SEP 2012 R66 Maintenance Manual Chapter 1 General Page 1.5 Page 1.6 Chapter 1 General R66 Maintenance Manual SEP 2012 FIGURE 1-1 ASSEMBLY INSTRUCTIONS FOR R66 HELICOPTER CRATED FOR EXPORT FIGURE 1-2 ASSEMBLY INSTRUCTIONS FOR R66 HELICOPTER CRATED FOR EXPORT 1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued) 10. For air-conditioned ships: a. Refer to Figure 1-1. Remove shipping supports (ty-raps, foam, tape, etc.) from G777- 1 compressor assembly. Install hardware securing G782-1 mount weldment to main rotor gearbox. Standard torque hardware per § 20-32 and torque stripe per Figure 5-1. Hook B774-3 spring in drilled hole of NAS1352-4H14 screw. Verify security. b. Refer to Figures 1-1 and 1-2. Verify B173-5 v-belt is in good condition. Fit belt around G779-1 pulley and compressor pulley, and install hardware securing compressor to G782-1 mount weldment. Standard torque bolts per § 20-32. c. Refer to Figure 1-2. Install hardware securing compressor to G781-1 arm weldment. Rotate compressor up and outboard to tension belt, then tighten hardware securing compressor to weldment. Verify belt is properly aligned on both pulleys. Adjust belt tension until 4.5-5.5 lb of force applied mid-span deflects belt 0.16-inch. Standard torque bolts per § 20-32. d. Connect compressor assembly wiring to airframe harness at connectors and install ty-raps as required. Cinch ty-raps until snug without over-tightening, and trim tips flush with heads. 11. Refer to IPC Figure 79-1. Remove F237-1 tailcone frame weldment and F305-5 (aft) inlet. Install tail rotor drive fan shaft (fanwheel installed) through scroll assembly. Install hardware securing aft inlet to scroll assembly. Verify security. 12. Refer to IPC Figure 65-1. Install hardware securing C947-3 plate assembly to F908-1 yoke and tail rotor drive fan shaft. Standard torque bolts and palnuts per § 20-32 and torque stripe per Figure 5-1. 13. Remove shipping supports (ty-raps, foam, tape, etc.) from tailcone assembly, and install tailcone per Section 53-40 steps 1 thru 7. Install strobe light. Install communication and GPS antennas (if equipped). 14. Install empennage assembly per § 53-50. Install aux stabilizer assembly per § 53-52. 15. Service tail rotor gearbox per § 12-21. Service main rotor gearbox per § 12-11. 16. Remove hydraulic reservoir shipping plug. Install D487-3 vent assembly, special torque vent to 100 in.-lb, and torque stripe per § Figure 5-1 (do not safety wire). 17. Install tail rotor assembly per § 64-10. Match color-coded markings on blades with pitch links. 18. Install main rotor blades per § 62-10. Match color-coded markings on blades with markings on hub and pitch links. 19. Inside engine compartment, remove anti-ice valve cap, starter-generator cap, inducer bleed hose cover, exhaust pipe cover and desiccant, and combustion case drain valve cap. Connect inducer bleed hose to box assembly and tighten clamp. Verify security. MAY 2015 Chapter 1 General Page 1.7 1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued) 20. If ship is equipped with attitude horizon, directional gyro, turn coordinator, and/or vertical card magnetic compass: A. Attitude Horizon, Directional Gyro, and Turn Coordinator Installation CAUTION Directional gyro mount screws must not exceed 1-inch in length. 1. Place a piece of foam under instrument face. Remove (6) screws securing face to console and gently pull face forward. Remove hardware securing instrument hole covers to face and remove covers. Install instruments and secure to face with hardware provided. 2. Connect straight connector(s) to directional gyro and/or turn coordinator. Connect angle connector to attitude horizon, ensuring strain relief points down. Ensure connectors lock. Ty-rap excess wiring. Install screws securing instrument face to console. B. Vertical Card Magnetic Compass Installation 1. Locate airframe wiring (in windshield center bow), install 2-inch length of B158-3 heat shrink over wiring, and connect compass pins to airframe sockets (polarity is not critical). Slide heat shrink over connection and apply heat. Install (4) screws securing compass to mount, securing wiring atop compass. 21. Connect battery per § 96-10. NOTE Check battery open circuit voltage and perform boost charging or capacity tests as required per Concorde Battery Instructions for Continued Airworthiness. 22. Perform pitot-static leak check per § 95-10. 23. Install Emergency Locator Transmitter (ELT) per § 25-61, as required. Install tailcone cowling assembly per § 53-23. 24. Install fire extinguisher per § 25-62, as required. 25. Fuel helicopter per § 12-41. 26. Verify all shipping supports (ty-raps, foam, tape etc.) have been removed from helicopter. Refer to § 6-70. Secure access panels and inspection doors. NOTE Flight checks to be performed by a qualified pilot and certificated mechanic. 27. Perform ground check per § 5-41 steps 2 thru 9. Page 1.8 Chapter 1 General MAY 2015 1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued) 28. Depreserve the engine after storage per RR300 Series Operation and Maintenance Manual (OMM). Install starter-generator cooling hose. Install engine cowling per § 53-21. 29. Install tail rotor dynamic balance equipment per § 18-21. 30. Perform run-up per § 5-42 steps 2 thru 16. 31. Perform tail rotor dynamic balance per § 18-20. 32. Remove tail rotor dynamic balance equipment. Install main rotor balance equipment per § 18-11. CAUTION Mast fairing, cowlings, and panels must be installed for flight. 33. Perform hover checks per § 5-43 step 1. DO NOT proceed into forward flight. 34. Track and balance main rotor per § 18-12. 35. While climbing at maximum continuous torque, 60 KIAS: a. Evaluate vibration level and controllability. b. Perform momentary 30° left yaw to check for adequate directional control. 36. Level flight at 2000 feet density altitude (deviate as required for weather and terrain), maximum continuous torque: a. Evaluate longitudinal and lateral cyclic control forces. b. Evaluate collective control forces. 37. Evaluate vibration level at maximum continuous torque and straight-and-level flight. 38. During autorotation at 50 KIAS and 90% rotor RPM, perform momentary 30° right yaw to check for adequate directional control. 39. Check all instruments, gages, and avionics for proper operation. MAY 2015 Chapter 1 General Page 1.9 Intentionally Blank Page 1.10 Chapter 1 General MAY 2015 CHAPTER 4 AIRWORTHINESS LIMITATIONS Section Title Page 4-10 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4-20 Additional Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 4-21 Parts with a Recommended Time Between Overhauls (TBO) . . . . . . . . . . . 4.3 4-22 Parts with a Recommended Replacement Time . . . . . . . . . . . . . . . . . . . . 4.3 4-23 Airframe and Engine Accessory Limits . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4A 4-24 Engine Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4A 4-30 Type Certificate Data Sheet (TCDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4A APR 2017 Chapter 4 Airworthiness Limitations Page 4.i Intentionally Blank Page 4.ii Chapter 4 Airworthiness Limitations APR 2017 SEP 2011 R66 Maintenance Manual Chapter 4 Airworthiness Limitations Page 4.1 4-10 Airworthiness Limitations The Airworthiness Limitations Section is FAA approved and specifies inspections and other maintenance required under 14 CFR §§ 43.16 and 91.403, unless an alternative program has been FAA approved. A. Fatigue Life-Limited Parts Part Number Description Maximum Service Life C023-21, -34, & -35 Tailcone Assembly . . . . . . . . . . . . . . 2000 Hours C044-1 Horizontal Stabilizer . . . . . . . . . . . . . . 2000 Hours C154-1 Main Rotor Hub . . . . . . . . . . . . . . . . . 2000 Hours C158-1 Main Rotor Spindle . . . . . . . . . . . . . . 2000 Hours C251-3 Main Rotor Shaft . . . . . . . . . . . . . . . . 2000 Hours C545-1 Gear Set, Tail Gearbox . . . . . . . . . . . . 2000 Hours C647-12 Bearing Set, Swashplate . . . . . . . . . . 2000 Hours D079-1 Tail Rotor Guard . . . . . . . . . . . . . . . . 2000 Hours D196-1 Tail Rotor Drive Shaft . . . . . . . . . . . . 2000 Hours F016-2 Main Rotor Blade . . . . . . . . . . . . . . . 2000 Hours or 12 years* F020-1 Upper Frame . . . . . . . . . . . . . . . . . . 2000 Hours F029-1 Tail Rotor Blade . . . . . . . . . . . . . . . . 2000 Hours or 12 years* F143-1 Pinion, Main Gearbox . . . . . . . . . . . . . 2000 Hours F146-1 Pinion, Main Gearbox . . . . . . . . . . . . . 2000 Hours F195-1 Yoke, Tail Rotor Drive Shaft . . . . . . . . 2000 Hours F235-13 Strut, Upper Frame . . . . . . . . . . . . . . 2000 Hours F252-1 Strut, Upper Frame . . . . . . . . . . . . . . 2000 Hours F263-1 Housing, Main Gearbox . . . . . . . . . . . 2000 Hours F270-1 Cartridge, Main Gearbox . . . . . . . . . . 2000 Hours G062-2 Tail Rotor Hub . . . . . . . . . . . . . . . . . 2000 Hours G201-1 Frame, Servo Support . . . . . . . . . . . . 2000 Hours * Whichever limit occurs first. FAA Approved: This page constitutes the Airworthiness Limitations Section in its entirety, is considered segregated from the rest of the document, and sets forth the FAA approved mandatory replacement times for the fatigue life-limited parts listed above. Intentionally Blank Page 4.2 Chapter 4 Airworthiness Limitations R66 Maintenance Manual SEP 2011 4-20 Additional Limitations 4-21 Parts with a Recommended Time Between Overhauls (TBO) Remove the following components for overhaul when they have accumulated 2000 hours time in service since new or since last overhaul. Maintenance procedures are listed for reference and are subject to revision. Part Number Description Reference C005-13 Main Rotor Blade & Spindle Assembly MM § 62-10 & IPC Figure 62-1 F006-1 Main Rotor Gearbox Assembly MM § 63-20 & IPC Figure 63-3 C017-6 Swashplate Assembly MM § 67-40 & IPC Figure 62-5 F018-1 Clutch Assembly MM § 63-12 & IPC Figure 63-1 C021-1 Tail Rotor Gearbox Assembly MM § 65-40 & IPC Figure 65-9 C649-4 Oil Cooler MM § 79-30 & IPC Figure 63-15 D211-3 Hydraulic Reservoir Assembly MM § 67-52 & IPC Figure 67-25 D212-5, -6 Hydraulic Servo Assembly MM § 67-53 & IPC Figures 67-29 & 67-33 D500-2, -3 Pump Assembly MM § 67-51 & IPC Figure 63-3 F649-1 Oil Cooler MM § 79-30 & IPC Figure 79-7 4-22 Parts with a Recommended Replacement Time Remove the following components when they have accumulated 2000 hours time in service since new. Maintenance procedures are listed for reference and are subject to revision. Part Number Description Reference A120-5 Bellcrank MM § 67-65 & IPC Figure 65-9 A215-015 O-Ring MM § 28-11 & IPC Figure 28-1 A522-10 Control Cable MM § 76-12 & IPC Figure 76-1 A522-11 Control Cable MM § 28-31 & IPC Figure 28-9 A522-14 Control Cable MM § 21-31 & IPC Figure 21-31 A729-68 Tube MM § 71-30 & IPC Figure 71-13 A785-37 Hose MM § 71-10 & IPC Figure 75-1 A785-38 Hose MM § 71-41 & IPC Figure 71-15 A918-5 Elastic Cord MM § 5-43 & IPC Figure 67-41 A947-2 Plate Assembly MM § 63-10 & IPC Figure 63-1 B173-5 V-Belt MM § 21-21 & IPC Figure 21-3 B277-12 Clamp MM § 21-30 & IPC Figure 21-33 B345-4 Pitch Link MM §§ 64-10 & 67-62 & IPC Figure 64-1 C031-1 Tail Rotor Pitch Control Assembly MM § 67-62 & IPC Figure 65-9 C119-2 Bumper MM § 64-10 & IPC Figure 64-1 C152-1 Thrust Washer MM §§ 62-10 & 62-20 & IPC Figure 62-3 C189-14 Nut MM §§ 62-10 & 62-20 & IPC Figure 62-3 C522-10 Control Cable MM § 76-11 & IPC Figure 76-1 APR 2017 Chapter 4 Airworthiness Limitations Page 4.3 4-22 Parts with a Recommended Replacement Time (continued) Part Number Description Reference C522-11 Control Cable MM § 76-21 & IPC Figure 76-5 C947-3 Plate Assembly MM § 65-10 & IPC Figure 65-1 D082-1 Tube Assembly MM § 53-53 & IPC Figure 53-21 D224 Tail Rotor Drive Shaft Assembly MM § 65-20 & IPC Figure 65-3 D918-1 Elastic Cord MM § 67-10 & IPC Figures 67-1 & 67-5 D918-2 Elastic Cord MM § 67-10 & IPC Figures 67-1 & 67-5 D918-3 Elastic Cord MM § 67-10 & IPC Figures 67-1 & 67-5 D930-2 Safety Spring MM § 76-10 & IPC Figure 76-1 F170-2 Fitting MM § 71-30 & IPC Figure 71-13 F173-1 Strut MM § 71-30 & IPC Figure 71-13 F579-1 Seal MM § 71-23 & IPC Figure 71-11 F642-6, -7 Engine Shaft Weldment MM § 63-10 & IPC Figure 63-1 F651-2 Element MM § 12-12 & IPC Figure 63-13 F651-3 Seal Kit MM § 12-12 & IPC Figure 63-13 F771-1 Filter MM § 71-21 & IPC Figure 71-9 F792-1 Dual Tachometer MM § 95-23 & IPC Figure 95-1 G727-1 Tube MM § 71-30 & IPC Figure 71-13 G732-3 Cap MM § 63-12 & IPC Figure 63-1 MS21919WCH12 Clamp MM § 71-30 & IPC Figure 71-13 MS24665-423 Cotter Pin MM § 62-10 & IPC Figure 62-3 MS28778-4 Packing MM § 79-30 & IPC Figure 79-7 MS28778-8 Packing MM § 79-30 & IPC Figure 79-7 MS29512-10 Packing MM § 28-11 & IPC Figure 28-1 NAS557-32A Grommet MM § 63-12 & IPC Figure 63-1 NAS617-12 Packing MM § 71-30 & IPC Figure 71-13 NAS634-105 Bolt MM § 62-10 & IPC Figure 62-3 NAS6604-67 Bolt MM § 63-12 & IPC Figure 63-1 Page 4.4 Chapter 4 Airworthiness Limitations APR 2017 4-23 Airframe and Engine Accessory Limits Refer to accessory manufacturer’s instructions for continued airworthiness for accessory limits. Remove accessories per R66 Maintenance Manual or RR300 Operation and Maintenance Manual (OMM) as required. 4-24 Engine Limits Refer to RR300 Operation and Maintenance Manual (OMM) for engine limits. Prepare engine for Rolls-Royce maintenance facility per § 71-11 as required. 4-30 Type Certificate Data Sheet (TCDS) The Robinson R66 Type Certficate Data Sheet (TCDS) reprinted on the following pages is subject to revision. Visit the FAA Aircraft Certification Regulatory and Guidance Library online databases for TCDS revision status at: http://rgl.faa.gov. APR 2017 Chapter 4 Airworthiness Limitations Page 4.4A Intentionally Blank Page 4.4B Chapter 4 Airworthiness Limitations APR 2017 MAY 2015 Chapter 4 Airworthiness Limitations Page 4.5 Page No. 1 2 3 4 5 Rev. No. 2 2 2 2 1 DEPARTMENT OF TRANSPORTATION FEDERAL AVIATION ADMINISTRATION R00015LA Revision 2 Robinson R66 March 10, 2015 TYPE CERTIFICATE DATA SHEET NO. R00015LA This data sheet, which is a part of Type Certificate No. R00015LA, prescribes conditions and limitations under which the product for which the type certificate was issued meets the airworthiness requirements of Title 14, Code of Federal Regulations. Type Certificate Holder: Robinson Helicopter Company 2901 Airport Drive Torrance, California 90505 I. Model R66 (Normal Category Rotorcraft), Approved October 25, 2010 Engine One Rolls-Royce 250-C300/A1, Type Certificate number E4CE Fuel Jet A or Jet A-1 conforming to ASTM D 1655 Jet B conforming to ASTM D 6615 JP-4 or JP-5 conforming to MIL-DTL-5624 JP-8 conforming to MIL-DTL-83133 Engine Limits Power Ratings at N 2 speed of 6016 rpm (100% rpm): Maximum continuous: 224 hp (83% Torque) Takeoff (5 minute): 270 hp (100% Torque) Maximum speeds: Output shaft (N 2): 101% (6076 rpm) Gas producer shaft (N 1): 105% (53519 rpm) Maximum Measured gas temperature: During start: 927° C (10 second limit above 810°C) 5 minute during operation: 782° C Continuous during operation: 706° C Rotor Speed Limits Transmission Torque Limits Condition Minimum Maximum ( rpm* ) ( % ) ( rpm* ) ( % ) Power On 404 99 412 101 Power Off 359 88 432 106 * Main Rotor Rating Max Torque at 100% N 2 ( ft-lb ) ( % ) Takeoff (5 min) 236 100 Max Continuous 196 83 Page 4.6 Chapter 4 Airworthiness Limitations MAY 2015 R00015LA Page 2 of 5 Airspeed Limits Sea level VNE values shown above. For reduction of VNE with altitude and temperature, see R66 Pilot’s Operating Handbook and FAA Approved Rotorcraft Flight Manual (RTR 661). Airspeed limit is 65 KIAS for power settings above 83% torque. Airspeed limit with inflated pop-out floats is 80 KIAS. Airspeed limit is 100 KIAS for any combination of doors off. Center of Gravity (C.G.) Range Notes: 1. Straight line variation between points shown 2. Lateral C.G. limits valid for all gross weights Empty Weight C.G. Range None. The aircraft’s empty weight and empty weight C.G. must be determined by the procedures in Section 8 of the R66 Maintenance Manual, RTR 660. Datum 100 inches forward of main rotor centerline. Leveling Means For weight and balance: Level placed laterally and longitudinally on aft tunnel cover immediately forward of aft middle seat. If cover is not straight, use keel panel upper flanges, accessed by removing aft tunnel cover. For rigging: Level placed on top of main rotor hub parallel with teeter bolt. Main rotor blades are aligned fore-aft for lateral levelling, and teeter bolt is aligned fore-aft for longitudinal levelling. Maximum Weight 2700 lb Minimum Crew 1 pilot in forward right seat. Takeoff Gross Weight or Configuration Power On V NE Power Off V NE ( KIAS ) ( KIAS ) Less than 2200 lb 140 100 2200 lb to 2700 lb Or Police Version * (any Gross Weight) Or Pop-out Floats * (Floats Stowed, any Gross Weight) 130 100 Gross Weight Longitudinal C.G. Forward Limit Aft Limit ( lb ) ( in ) ( in ) 1400 91.0 102.5 2300 102.5 2500 91.0 2700 92.0 98.0 Longitudinal C.G. Lateral C.G. Left Limit Right Limit ( in ) ( in ) ( in ) 91.0 -3.5 +3.5 100.0 -3.5 +3.5 102.5 -1.5 +1.5 MAY 2015 Chapter 4 Airworthiness Limitations Page 4.7 Page 3 of 5 R00015LA Number of Seats 5 (4 for Police Version) Seat Locations Pilot and forward occupant at STA 49.0 in Aft outboard occupants at STA 80.0 in Aft center occupant at STA 78.0 in Maximum Compartment Main baggage compartment Weights Maximum weight is 300 lb at STA 107.0 in Maximum loading density is 50 lb/ft2 Underseat baggage compartments Forward seats – Maximum weight is 50 lb at STA 42.0 in Rear seats – Maximum weight is 50 lb at STA 82.0 in Note: For any seat location, the maximum combined weight of the load on the seat (e.g., occupant) plus the weight of stowed items and any installed equipment in the underseat baggage compartment is 300 lb. Fuel Capacity Fuel tank capacity is 74.6 U.S. gallons Usable fuel quantity is 73.6 U.S. gallons at STA 102.5 in Note: Aircraft empty weight includes 1.0 U.S. gallon of unusable fuel. Oil Capacities Component Capacity (qt) STA ( in ) Engine 6 126.0 Main Rotor Transmission 2 100.0 Tail Rotor Transmission 0.11 327.0 Hydraulic Reservoir 0.65 110.8 Maximum Operating Altitude 14,000 feet Density Altitude. Maximum altitude above ground level is 9,000 ft. Rotor Blade and Control Movements Main Rotor Blades Collective Pitch 13.0° ±0.5° total travel Cyclic Pitch Forward 13.50° to 14.25° Aft 13.50° to 14.25° Left 7.5° to 8.5° Right 6.0° to 7.0° Note: Collective low pitch to be established in accordance with the Maintenance Manual and Instructions for Continued Airworthiness (RTR 660) procedures to obtain proper autorotation RPM. Tail Rotor Blades Collective Pitch Full right pedal 15.5° to 16.5° Full left pedal 8.5° to 19.0° All blade angles measured at 75% radius Manufacturer’s Serial Numbers 0002 and subsequent. Certification Basis 14 CFR part 27, dated February 1, 1965, as amended by Amendment 27-1 through Amendment 27-44. Equivalent Safety Finding: Number AT14992LA-R-S-1 RHC Note: Tail rotor blades collective pitch full left pedal should be "18.5° to 19.0°". Page 4.8 Chapter 4 Airworthiness Limitations MAY 2015 R00015LA Page 4 of 5 14 CFR part 27.695(a)(1), Power boost and power-operated control system. (see Note 7) Special Condition: No. 27-035-SC Robinson Model R66 Helicopter, Sec. 27.1309, Installation of HeliSAS Autopilot and Stabilization Augmentation System (AP/SAS). 14 CFR Part 36, dated December 1, 1969, as amended by Amendment 36-1 through Amendment 36-28. Compliance with the ditching requirements of § 27.801 was not demonstrated. Compliance with the ice protection requirements of § 27.1419 was not demonstrated. The R66 is approved for day and night VFR operations only. TC Application Date: September 06, 2006. TC Issue Date: October 25, 2010. Production Basis Production Certificate No. 424WE dated October 25, 2010. Equipment The basic required equipment as prescribed in the applicable airworthiness regulations (see Certification Basis) must be installed in the aircraft for certification. In addition, the following FAA-approved Rotorcraft Flight Manual is required: R66 Pilot’s Operating Handbook and FAA Approved Rotorcraft Flight Manual (RTR 661), dated October 25, 2010, or later approved revision. GENERAL NOTES NOTE 1. A current weight and balance report, including a list of equipment included in the certificated empty weight, and loading instructions when necessary, must be provided for each aircraft at the time of original airworthiness certification and at all times thereafter, except in the case of operators having an approved weight control system. NOTE 2. The following placard must be installed in clear view of the pilot: “THIS ROTORCRAFT APPROVED FOR DAY AND NIGHT VFR OPERATIONS” For additional placards, see the Rotorcraft Flight Manual. All placards required in the Rotorcraft Flight Manual must be installed in the appropriate locations. NOTE 3. Information essential to the proper maintenance of the helicopter, including retirement time of critical components, is contained in the Robinson R66 Maintenance Manual and Instructions for Continued Airworthiness (RTR 660). Retirement times are listed in the “AIRWORTHINESS LIMITATIONS” section. NOTE 4. Deleted as of March 10, 2015. NOTE 5. Any cockpit instruments installed by a 3 rd party must be marked with limit markings and range markings in accordance with Robinson’s marking scheme. NOTE 6. Deleted as of March 10, 2015. MAY 2015 Chapter 4 Airworthiness Limitations Page 4.9 Page 5 of 5 R00015LA NOTE 7. Exemption No. 9589, dated January 28, 2008, has been removed since Robinson Helicopter Company was granted an Equivalent Level of Safety (ELOS) finding to CFR §27.695(a)(1), Number AT14992LA-R-S-1, dated February 20, 2013. The exemption allowed a powered flight control system without considering the jamming of a control valve as a possible single failure. There is no impact to R66 helicopters that have been delivered or are in service. --- END --- Intentionally Blank Page 4.10 Chapter 4 Airworthiness Limitations MAY 2015 APR 2017 Chapter 5 Inspections Page 5.i CHAPTER 5 INSPECTIONS Section Title Page 5-10 Life-Limited Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5-11 Time-In-Service Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5-12 Retirement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5-20 Scheduled Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 5-30 Standard Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 5-31 Ball and Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 5-32 Push-Pull Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 5-33 Rod Ends and Spherical Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 5-34 Elastomeric Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 5-35 Telatemp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 5-40 Operation Checks for 100-Hour / Annual Inspection . . . . . . . . . . . . . . . . . . . . 5.8 5-41 Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 5-42 Run-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 5-43 Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 5-45 100-Hour / Annual Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . 5.13 5-50 2000-Hour Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39 5-55 12-Year Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39 5-60 Special Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41 5-61 Tail Skid Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41 5-62 Tail Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42 5-63 Main Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43 5-64 Rotor/Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44 5-65 Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47 5-66 Dye Penetrant Inspection of F020-1 Upper Frame . . . . . . . . . . . . . . . . . . . 5.48 5-67 Corrosion on F020-1 Upper Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48 5-68 Main Rotor Gearbox Overtemp Illumination . . . . . . . . . . . . . . . . . . . . . . . . 5.48 5-69 Main Rotor Gearbox (MR) Chip Light Illumination . . . . . . . . . . . . . . . . . . . . 5.49 5-70 Tail Rotor Gearbox (TR) Chip Light Illumination . . . . . . . . . . . . . . . . . . . . . 5.49 5-71 Main Rotor Gearbox Filter Bypass Indicator . . . . . . . . . . . . . . . . . . . . . . . . 5.49 5-72 Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 5-73 Pop-Out Float-Equipped Helicopter Water Landing with Tail Rotor Contact . . 5.50 Intentionally Blank Page 5.ii Chapter 5 Inspections APR 2017 CHAPTER 5 INSPECTIONS 5-10 Life-Limited Components 5-11 Time-In-Service Records It is the operator’s responsibility to maintain a record of time in service for the engine, airframe, and all life-limited components, as well as the number of start cycles for the engine. Two hourmeters are provided: the hourmeter on the console records all run time including ground idle and is provided for reference. The hourmeter located outboard of the pilot's seat is collective-activated and records run time only when the collective is raised off the down stop. Both hourmeters are connected to main rotor gearbox oil- pressure switch. The collective-activated hourmeter may be used to determine time in service for maintenance purposes, including time in service for all life-limited components. Calendar life begins on the date of the factory-issued airworthiness certificate or factory- issued authorized release certificate (FAA Form 8130-3, Airworthiness Approval Tag). Engine life is limited by engine time in service and accumulated start cycles. The engine is equipped with an electronic Engine Monitoring Unit (EMU), which may be used to verify time in service and accumulated start cycles. An official, independent record of start cycles must be maintained by the operator. When a life-limited replacement part or overhauled component is installed in the helicopter, record the part name, part number, serial number, and previous time in service in the aircraft maintenance record, including the installation date and helicopter total time. Previous time in service must be included when calculating remaining component life or time between overhaul (TBO). CAUTION Components with mandatory overhaul times or life-limits whose time in service is not reliably documented cannot be considered airworthy and must be removed from service. If a part is fatigue life-limited or has a mandatory overhaul requirement and is interchanged between an R44 and an R66 helicopter, and if the part life-limit or overhaul requirement is different between an R44 and an R66 helicopter, the shorter life-limit or overhaul requirement must be used. If a part is fatigue life-limited or has a mandatory overhaul requirement, and the accumulated cycles and/or time in service are known but the helicopter type is unknown, the shorter life-limit or overhaul requirement must be used. 5-12 Retirement Procedure The FAA-approved Airworthiness Limitations section in Chapter 4 lists the mandatory replacement time for affected components. Life-limited components must be removed from the helicopter at specified intervals and permanently retired from service by destroying or damaging each part beyond repair or beyond appearance of serviceable condition. APR 2017 Chapter 5 Inspections Page 5.1 * One-time maintenance after new or overhauled main rotor gearbox is installed. ** Recurring inspection not to exceed given interval. *** See § 1-60 Definitions and Abbreviations. TABLE 1 SCHEDULED INSPECTIONS Replace main gearbox oil filter per § 12-12. • • Perform 100-hour / annual inspection per § 5-45. • • As required by RR300 Series Operation and Maintenance Manual (OMM), perform maintenance and inspection. • • • • • Service inlet barrier filter per § 71-21. • • Replace main gearbox oil per § 12-12. • Drain and flush tail rotor gearbox per § 12-23. • Replace hydraulic filter per § 12-32. • Clean gearbox chip detectors per § 12-13 & 12-22. • • Perform 2000-hour maintenance and inspection per § 5-50. • Inspect emergency locator transmitter (ELT) per 14 CFR § 91.207. • Perform pop-out float leak check per § 32-64 Part A. • Test and inspect transponder per 14 CFR § 91.413. • Perform pop-out float inflation check per § 32-64 Part B. • Peform pop-out float pressure cylinder hydrostatic test. • Perform 12-year maintenance and inspection per § 5-55. • Pop-out float pressure cylinder maximum life. • First 100 Hours* 100 Hours** 200 Hours** 300 Hours** 400 Hours** 600 Hours** 2000 Hours** Annually *** 12 Months** 24 Months** 1 Year** 3 Years** 5 Years** 12 Years** 15 Years** 3000 Cycles** Page 5.2 Chapter 5 Inspections APR 2017 5-20 Scheduled Maintenance and Inspections The R66 helicopter required inspection intervals are given in Table 5-1. Required inspection intervals are maximum 100 hours time in service or 12 calendar months, whichever occurs first; the inspection interval may be extended up to 10 hours, without accumulation, if allowed by local regulations. Some aircraft will reach calendar intervals before accumulating the associated service time. Unless noted, use the more conservative inspection interval. Refer to § 5-45 for inspection procedures. Some aircraft may require maintenance and inspections in addition to the requirements in Table 5-1. Consult aircraft maintenance records, Service Bulletins (SB), aviation regulations, Airworthiness Limitations, and Airworthiness Directives (AD) for applicability. 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. MAY 2015 Chapter 5 Inspections Page 5.3 FIGURE 5-2 ROD END CENTERING Position rod ends for maximum rotation FIGURE 5-1 ROD END AND SPHERICAL BEARING PLAY LIMITS AND TORQUE STRIPE APPLICATION Page 5.4 Chapter 5 Inspections MAY 2015 5-30 Standard Inspection Criteria This section contains standard inspection criteria for 100-hour/annual maintenance and inspection. 5-31 Ball and Roller Bearings The first indication of bearing failure is usually an increase in bearing noise. Noise will almost always start several hours prior to bearing failure. Listen to drive system during start-up and shutdown. A failing bearing will produce a loud whine, rumble, growl, or siren sound. Upon hearing an unusual noise, thoroughly inspect all bearings before further flight. A failing bearing may have a distorted seal or be exuding a large amount of grease. Monitor bearings for increase in temperature, but do not rely on Telatemps to detect failing bearings as temperature increase may occur only seconds before bearing disintegrates. 5-32 Push-Pull Tubes 1. Nicks, cuts, or scratches in tube not more than 0.010 inch deep and not more than 1/4 of tube circumference may be polished out in lengthwise direction using 320-grit or finer wet-or-dry abrasive paper to 1 inch minimum blend radius. Replace push-pull tube if depth exceeds these limits. 2. Replace push-pull tube if tube is dented or flattened more than 5% of its diameter in unswaged area; dents or flattening is not permitted in swaged (tapered and threaded) ends of tubes. 5-33 Rod Ends and Spherical Bearings 1. Maximum axial play: 0.020 inch Maximum radial play: 0.010 inch 2. Looseness between bearing outer race and rod end housing is not permitted. 3. Rod ends not riveted in place must block passage of 0.020-inch diameter wire through witness hole. Refer to Figure 5-1 for maximum rod end extension when no witness hole is provided. 4. Rod end jam nuts and palnuts must be torqued per Section 20-32 and torque striped per Figure 5-1 at the most visible position for pre-flight inspection. Torque stripe must extend across nuts to both rod end shank and push-pull tube (or pitch link barrel, yoke, support, strut, etc.). Torque stripes are subject to deterioration and must be periodically renewed. 5. Refer to Figure 5-2. Rod ends must be centered, or positioned, to allow as much push- pull tube or link rotational movement as possible without binding. CAUTION Teflon-lined bearings must not be lubricated or solvent cleaned. WARNING Assembly of flight controls is critical and requires inspection by a qualified person. If a second person is not available, RHC recommends the installer take a 5-minute break prior to inspecting flight control connections he has assembled. SEP 2012 R66 Maintenance Manual Chapter 5 Inspection Schedule Page 5.5 Elastomer Fatigue Elastomer Oil Contamination FIGURE 5-3 ELASTOMERIC BEARING DAMAGE Elastomer Overload Page 5.6 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012 5-34 Elastomeric Bearings Refer to Figure 5-3. Elastomeric bearings are used in the G062-1 tail rotor hub. Fatigue, oil contamination, or overload can degrade the elastomer. Small surface cracks (fatigue cracks) and elastomer dust or “eraser crumbs” are normal and are not cause for replacement. As cracks grow, enough elastomer will be lost to cause reduced stiffness and increased vibration. Replace bearing if crack is deeper than 0.10 inch or cracks are present over more than 25% of elastomer face. Avoid elastomer exposure to oil, grease, hydraulic fluid, cleaning solvent, and rust- preventative fluids. Immediately wash off contaminants with detergent and water. Replace a contaminated bearing that exhibits swelling, wavy edges, or debonding. Overload occurs when elastomer’s tensile strength or rubber-to-metal bond strength is exceeded. This can occur when normal loads are applied to a bearing weakened by fatigue or oil contamination. Overload is indicated by large clean cracks or extrusions from elastomer. Elastomer may also separate (debond) from metal bushings. Replace bearing if separation exceeds 25% of bonded area. 5-35 Telatemp Indicators Refer to Figure 5-4. Self-adhesive Telatemp indicators record increases in operating temperatures of the hydraulic pump and tail rotor gearbox. To use a Telatemp, draw a reference line between the highest temperature square which has darkened during normal operation and the next undarkened square. During every check thereafter, determine if an additional block has blackened. If an indicated temperature increase cannot be accounted for by a change in operating conditions, subject component should be carefully examined before further flight. If no reference line is detectable and/or all indicator blocks are compromised, carefully examine part before further flight and replace Teletemp (after first flight, draw a reference line as described above). Part Number Temperature Range 110-2 60°C / 140°F — 88°C / 190°F 110-3 82°C / 180°F — 110°C / 230°F 110-4 104°C / 220°F — 132°C / 270°F FIGURE 5-4 TELATEMP WITH DRAWN REFERENCE LINE APR 2017 Chapter 5 Inspections Page 5.7 5-40 Operation Checks for 100-Hour / Annual Inspection Complete the following checklists in conjunction with 100-hour / annual inspection. Note and correct any discrepancies. 5-41 Ground Check (aircraft not running) 1. Twist Grip: Verify twist grip smooth rotation without binding in full up and full down collective position. Verify over center spring holds twist grip full open or closed. 2. Fuel Cutoff Valve: Verify smooth actuation without binding. Verify proper function of lock button. 3. Collective Control: Verify proper operation through full control travel with and without friction applied. With friction off, verify approximately one-half inch total free play before encountering hydraulic resistance. Verify normal hydraulic resistance throughout remainder of control travel. With friction on, verify increased resistance but no binding or locking of control. Verify power turbine governor rigging as follows: a. Turn battery switch on. With collective full down, hold beep switch actuator all the way down. Have a second person verify the PTG reads approximately 45°. b. With collective full down, hold beep switch actuator all the way up. Have a second person verify the PTG reads approximately 65°. Return actuator to nominal position. Turn battery switch off. 4. Cyclic Control: With friction off, verify approximately one-half inch total longitudinal and one inch total lateral free play before encountering hydraulic resistance. Verify normal hydraulic resistance throughout remainder of control travel. With friction on, verify increased resistance but no binding or locking of control. 5. Tail Rotor Pedals: Verify smooth actuation without binding. Verify proper pedal position for pilot and locking pin security. 6. Removable Controls (if installed): Verify proper operation and locking pin security. Page 5.8 Chapter 5 Inspections APR 2017 5-41 Ground Check (continued) 8. Lighting and Instruments: (Turn battery switch on.) ANNUNCIATOR PANEL a. Main rotor gearbox temperature / pressure segment illuminates. b. Engine oil segment illuminates. c. Generator segment illuminates. d. Rotor brake segment illuminates (if rotor brake is applied). e. Low RPM segment illuminates. f. Cowl door segment illuminates when one, two, or all of the following doors are open: fuel filler door, right side engine door, and/or baggage compartment door. g. All segments illuminate when test button is depressed (slight delay on low fuel light). INSPECTION LIGHTING a. Left side cowl door - verify LEDs illuminate main rotor gearbox and hydraulic reservoir sight gages when cowl door is open (battery switch on or off). EXTERIOR LIGHTING a. Position lights – check function. b. Anti-collision light – check function. c. Landing lights – check function. INTERIOR LIGHTING a. Panel lighting and dimmer control – check function (position lights must be illuminated to enable panel lighting and dimmer control). b. Map light – check function. c. Digital voltmeter – indicates approximately 24 volts. d. Oil temperature gage – slight needle deflection with engine cold. e. Fuel quantity gage – indication of fuel level. (Turn battery switch off.) APR 2017 Chapter 5 Inspections Page 5.9 5-41 Ground Check (continued) 9. Aircraft Documents: (Additional documents may be required in countries other than the US.) a. Inspect condition and verify R66 MT699-1 laminated pilot's checklist is current revision. Check revision status online at: www.robinsonheli.com. b. Inspect condition and verify R66 Pilot’s Operating Handbook is current revision and contains correct Equipment List/Weight & Balance Data. Check revision status online at: www. robinsonheli.com. c. Verify airworthiness certificate onboard & matches helicopter S/N. d. Verify registration certificate onboard & matches helicopter S/N and all registration markings. 5-42 Run-Up 1. Clean engine gas path, if required, per RR300 Series Operation and Maintenance Manual (OMM). 2. Perform Pilot's Operating Handbook (POH) Section 4 “Preflight” checklist. 3. Perform POH Section 4 “Before Starting Engine” checklist. 4. Prior to start, verify rotor brake locks out starter. 5. Perform POH Section 4 “Starting Engine and Run-Up” checklist. 6. Generator light off. 7. Verify N2/Rotor tachometer functions with battery and generator switches off. Return switches to on. 8. No unusual bearing noise when varying RPM through operating range. 9. Carefully beep N2 toward 104%. If N2 can be beeped above 104% (do NOT exceed 105%), adjust PTG rigging per MM §§ 76-21 and 76-22. 10. Verify tachometer needles are properly adjusted/governed. 11. Verify proper generator voltage. 12. Heater operates properly. 13. Verify acceptable instrument variation when transmitting on various frequencies. 14. Verify operation and adjustment of low rotor RPM warning light and horn. 15. Engine performance indications are within acceptable parameters. Page 5.10 Chapter 5 Inspections APR 2017 5-42 Run-Up (continued) 16. Check hydraulic system operation. Using cyclic-mounted hydraulics switch, turn hydraulics OFF. Using small longitudinal cyclic inputs, there should be approximately one-half inch of freeplay before encountering stiffness and feedback. Return cyclic to neutral. Turn hydraulics ON. Controls should be free with no feedback or uncommanded motion (“motoring”). Complete flight checks with hydraulics on. 17. Air conditioning (if installed): Verify system blows cold air on both low and high settings. Verify no EMI/RFI with other instruments and systems. After a flight with air conditioning on, verify water drains from drain tube in ship’s belly (may be little or no water in very dry conditions). 5-43 Flight Check 1. Hover: a. Verify normal gage indications. b. Verify controllability in left and right pedal turns. c. Verify hydraulic system zeros cyclic stick forces. d. Evaluate vibration levels; if unacceptable, measure imbalance and correct. 2. Level Flight: Conduct at typical cruise altitude (weather permitting) and maximum continuous torque. Loading to typical operating conditions or nominal weight and CG in middle of envelope will provide the most useful evaluation. a. Verify tail rotor pedal position when yaw string is centered. Right pedal 0.25 to 0.75 inch forward of left pedal. b. Verify tail rotor elastic trim cord zeros pedal forces (cord applies left pedal force). c. Verify hydraulic system zeros cyclic stick forces and collective is balanced with no feedback. d. Verify acceptable control forces (feedback) with hydraulics off. e. Evaluate vibration levels; if unacceptable, measure imbalance and correct. APR 2017 Chapter 5 Inspections Page 5.11 5-43 Flight Check (continued) 3. Power Assurance Check: Refer to R66 Pilot's Operating Handbook (POH) Chapter 5 power assurance chart. Conduct at typical cruise altitude (weather permitting) and maximum continuous torque (83%). Turn heater, generator, and anti-ice switches OFF. Stabilize N2/R at 100% (beep as required) and record the following values: a. N1 b. % Torque (83% nominal) c. OAT d. MGT e. Pressure altitude f. Oil pressure g. Oil temperature h. Determine max allowable MGT from power assurance chart. i. Calculate margin. Margin = Max allowable MGT - Indicated MGT. 4. Autorotation: a. Autorotate at 100 KIAS. Verify normal control forces and flying characteristics. 5. Shutdown: a. Perform POH “Shutdown Procedure” checklist. b. Verify rotor brake function and ROTOR BRAKE annunciator segment illuminates. Page 5.12 Chapter 5 Inspections APR 2017 5-45 100-Hour / Annual Maintenance and Inspection RHC recommends retaining a copy of the most recently performed 100-hour / annual checklist with the aircraft’s maintenance records to meet the requirement of 14 CFR § 91.417 (b)(1). R66 Serial No.: Technician Name: Registration No.: Technician Certificate Number: Collective-Activated (Time In Service) Hourmeter Indication: Helicopter Total Time In Service: A. Preparation Operation Checks: Perform ground and flight checks per § 5-40. Cleaning (required by 14 CFR Part 43, Appendix D, paragraph (a)): Note any fluid leakage before cleaning. Clean main and tail rotor blades, hubs, and airframe exterior with a mild soap and water solution per Chapter 20. CAUTION Do not spray main rotor hub, tail rotor gearbox vent, hydraulic reservoir vent, swashplate area, or bearing seals with high- pressure water or solvent as water or solvent may cause corrosion or breakdown of lubricants. See RR300 Series Operation and Maintenance Manual (OMM) for engine cleaning instructions and precautions. Access and Inspection Panels: Refer to R66 Illustrated Parts Catalog Chapter 6 for access and inspection panel locations. Remove or open necessary panels, doors, covers, fairings, and cowlings in accordance with 14 CFR Part 43, Appendix D, paragraph (a). NOTE If radio antennas are installed on removed panels, disconnect antenna lead and corresponding ground wire. Pull respective radio circuit breaker and tag circuit breaker with “Antenna Removed.” APR 2017 Chapter 5 Inspections Page 5.13 5-45 100-Hour / Annual Inspection (continued) B. Inspection CABIN FORWARD FOOTWELLS Tail Rotor Pedal Bearing Blocks: Remove pedal bearing block covers as required. Examine accessible portion with inspection light and mirror. Inspect condition. Check for looseness or play in pedal bearings. Maximum allowable play is 0.080 inch axially and 0.030 inch radially. Verify bearing block security. Adjustable Tail Rotor Pedals: Inspect condition. Verify no cracks in welds. Verify locking pins engage holes to secure adjustable pedals. Verify proper operating clearance and smooth actuation. Co-Pilot Removable Tail Rotor Pedals: Inspect condition. Verify no cracks in welds. Verify locking pins engage holes to secure removable pedals. Verify proper operating clearance and smooth actuation. Cabin Heater Diffusers: Inspect condition. Verify marking legibility. Verify no significant nicks, scratches or dents, or cracks in welds. Verify security. Fire Extinguisher and Mount: Inspect condition. Inspect fire extinguisher per manufacturer’s instructions. Verify no loss of charge or obstructions in extinguisher nozzle. Verify security. Map Holders: Inspect condition. Verify no defects, tears, or material deterioration. Remove foreign objects and verify security. License Holder: Inspect condition. Verify no defects, cracks in plastic, or material deterioration. Verify security. Cabin Chin and Floor: Inspect condition. Verify equipment security. Retrieve and discard trapped debris. CONSOLE Console Assembly: Inspect condition. Verify no significant nicks, scratches or dents; verify no cracks, corrosion, or loose rivets in lower console assembly. Verify hinge security. HID Landing Lights: Inspect condition. Verify proper installation and security of wiring and equipment. Flight & Engine Instruments: Inspect condition. Verify proper instrument markings per R66 POH Section 2. Verify proper installation and security of wiring and equipment. Page 5.14 Chapter 5 Inspections APR 2017 5-45 100-Hour / Annual Inspection (continued) CONSOLE (continued) Post Lights: Inspect condition. Verify proper function and equipment security. Fuel Cutoff Control and Guard: Inspect condition. Verify cable and mounting bezel security. Verify proper adjustment and smooth operation of knob. Verify guard is attached to console. Radios and Radio Trays: Inspect condition. Verify no cracks or corrosion. Verify proper installation and security of wiring and equipment. Pitot & Static Lines: Inspect pitot and static lines for obstructions, cracking, chafing, pinching or kinking. Verify integrity of pitot and static line connections. Verify line security. Tail Rotor Pedal Bearing Block Supports: Examine accessible portion with inspection light and mirror. Inspect both vertical sheet metal supports inside lower console and verify no cracks. Pay particular attention to area near NAS6603-13 bolts. Replace any cracked support prior to flight. Tail Rotor Controls: Examine accessible portion with inspection light and mirror. Inspect tail rotor control components for obvious defects. Verify operating clearance. Cabin Heater Hose: Inspect condition. Verify no collapsed areas or chafing. Verify hose clamp and hose security. Copper Bus Bars: Inspect condition. Verify no corrosion or bends in bus bar. Verify bus bar security and isolation from surrounding structure. Wiring: Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify neatness, proper routing and installation, and security. Fasteners & Torque Stripes: Inspect condition. Verify proper installation and security of fasteners. Renew deteriorated torque stripes per Figure 5-1. Close & Secure: Verify foreign objects are removed. Verify equipment security and cleanliness of interior. Close console and verify security. APR 2017 Chapter 5 Inspections Page 5.15 5-45 100-Hour / Annual Inspection (continued) PILOT-SIDE CONSOLE (Optional equipment) Pilot Avionics Support Weldment: Inspect condition. Verify no significant nicks, scratches, or dents on console shell. Verify no cracks in welds. Verify weldment mounting security. CIRCUIT BREAKER PANEL CAUTION Ensure BATTERY switch is turned off while circuit breaker panel is open. Panel Cover: Inspect condition. Verify no damage to nutplates and rails in panel interior. Verify marking legibility. Fuses and Fuse Holders: Inspect condition. Verify security and no corrosion. Verify correct fuse installation. Circuit Breakers: Inspect condition. Check airworthiness directive applicability. Verify proper installation and security. Copper Bus Bars: Inspect condition. Verify no corrosion or bends in bus bars. Verify bus bar security and isolation from surrounding structure. Wiring: Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify neatness, proper routing and installation, and security. Fasteners & Torque Stripes: Inspect condition. Verify proper installation and security of fasteners. Renew deteriorated torque stripes per Figure 5-1. Close & Secure: Verify foreign objects are removed. Verify equipment security. Verify cleanliness of interior and of access cover. Close cover and verify security. UNDER LEFT FRONT SEAT Lithium-Ion Battery Circuit Back-Up Batteries (required with optional Lithium-ion main battery): Inspect condition. Verify presence and proper orientation of (2) 9V back-up batteries. Verify security of battery trays and G468-1 mount assembly. Verify legibility of silkscreen lettering on mount. Inspect wiring for obvious damage. Page 5.16 Chapter 5 Inspections APR 2017 5-45 100-Hour / Annual Inspection (continued) HORIZONTAL CONTROL TUNNEL (Front seats; continued) Covers: Inspect condition. Verify marking legibility. Antenna Wiring & Connectors: Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify no damaged connectors. Verify neatness, proper routing and installation, and security. Cyclic Box Assembly: Inspect condition. Verify no nicks, scratches, dents, cracks, corrosion, or loose rivets. Verify no distortion or damage on cyclic stop sheet metal assembly. Verify security. Cyclic Stick Assembly: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Verify no cracks in welds. Verify security, proper operating clearance, and smooth actuation. Verify security of co-pilot control and locking pin. Cyclic Boot: Inspect condition. Verify proper locking function of boot snaps. Verify no defects, tears, or material deterioration. Verify security. Cyclic Friction Assembly: Inspect condition. Inspect link rod end bearings per § 5-33. Verify no excessive flaring at either end of friction spacer. Verify proper installation, security, and operation. Cyclic Pivot: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Inspect spherical bearings per § 5-33. Verify proper installation, security, and operating clearance. APR 2017 Chapter 5 Inspections Page 5.16A Intentionally Blank Page 5.16B Chapter 5 Inspections APR 2017 5-45 100-Hour / Annual Maintenance and Inspection [5 of 26 Pages] HORIZONTAL CONTROL TUNNEL (Front seats; continued) Cyclic Horizontal Torque Tube: Examine accessible portion with inspection light and mirror. Verify no nicks, scratches, dents, cracks, or corrosion. Verify no cracks around reinforcement blocks on both ends of torque tube. Verify proper installation, security, and operating clearance. Horizontal Push-Pull Tubes: Examine accessible portion with inspection light and mirror. Inspect condition per § 5-32. Verify no nicks, scratches, chafing, dents, cracks, or corrosion. Inspect rod end bearings per § 5-33; verify rod ends are centered and palnut and jam nut are tight. Check witness holes for proper thread engagement. Verify proper installation, security, and operating clearance. Collective Stick Assembly: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Verify no cracks in welds. Verify proper installation, security, and operation of collective micro switches. Verify security, proper operating clearance, and smooth actuation of both flight and throttle controls. Verify over center spring holds twist grip full open or full closed. Verify placard legibility. Collective Stick Torque Tube: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Collective Boot: Inspect condition. Verify proper locking function of boot snaps. Verify ty-rap is properly installed (loosely securing boot around collective stick). Verify no defects, tears, or material deterioration. Verify security. Fuel Valve Knob and Guard: Inspect condition. Verify cable and mounting bezel security. Verify proper adjustment and smooth operation of valve. Verify guard is present. Collective Friction & Stop Assembly: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion in stop assembly. Verify no bending or binding of stop through full control travel, with and without friction applied. Measure collective friction per § 67-22. Verify proper installation and security of collective friction lever and stop assembly. Co-Pilot Removable Collective Stick Assembly: Remove co-pilot collective stick assembly. Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Verify no damage to spring pin and safety wire at coupling. Firmly grasp coupling and rotate twist grip in each direction with opposite hand. Verify no free play of coupling or spacer relative to torque tube. Install removable collective stick in helicopter and verify both locking pins engage holes to secure stick. Verify security, proper operating clearance, and smooth actuation of both flight and throttle controls. Verify placard legibility. Co-Pilot Removable Collective Boot: Inspect condition. Verify proper locking function of boot snaps. Verify ty-rap is properly installed (loosely securing boot around collective stick). Verify no defects, tears, or material deterioration. Verify security. MAY 2015 Chapter 5 Inspections Page 5.17 5-45 100-Hour / Annual Maintenance and Inspection [6 of 26 Pages] HORIZONTAL CONTROL TUNNEL (Front seats; continued) Pitot & Static Lines & Drains: Inspect pitot and static lines for obstructions, cracking, chafing, pinching, or kinking. Remove drain plugs from tee fittings in each line and clear any moisture from system. Install drain plugs. Verify integrity of pitot and static line connections. Verify line security. Wiring: Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify neatness, proper routing and installation, and security. Fasteners & Torque Stripes: Inspect condition. Verify proper installation and security of fasteners. Renew deteriorated torque stripes per Figure 5-1. Antennas: Inspect condition. Verify no cracks where antennas mount to cowling. Verify security. Close & Secure: Verify foreign objects are removed. Verify equipment security. Verify cleanliness of interior and of inspection and access covers and cowlings. Connect ELT (if installed) wiring at connectors and anti-ice switch wiring terminals under cyclic box cover. Connect antenna leads and ground wires (if installed). Install covers and cowlings removed in preceding steps. Verify security. Verify security of removable and adjustable controls. Fasten cyclic, collective, and removable collective boot snaps. HORIZONTAL CONTROL TUNNEL (Aft seats) Covers: Inspect condition. Verify marking legibility. Antenna Wiring & Connectors: Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify no damaged connectors. Verify neatness, proper routing and installation, and security. Cyclic Yoke: Inspect condition. Verify no cracks, corrosion, or fretting. Inspect spherical bearings per § 5-33. Verify proper installation, security, and operating clearance. Cyclic Fork: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Inspect rod end bearings per § 5-33. Verify proper installation, security, and operating clearance. Cyclic Horizontal Torque Tube: Examine accessible portion with inspection light and mirror. Verify no nicks, scratches, dents, cracks, or corrosion. Verify no cracks around reinforcement blocks on both ends of torque tube. Verify proper installation, security, and operating clearance. Horizontal Push-Pull Tubes: Examine accessible portion with inspection light and mirror. Inspect condition per § 5-32. Verify no nicks, scratches, chafing, dents, cracks, or corrosion. Inspect rod end bearings per § 5-33; verify rod ends are centered and palnut and jam nut are tight. Check witness holes for proper thread engagement. Verify proper installation, security, and operating clearance. Page 5.18 Chapter 5 Inspections MAY 2015 5-45 100-Hour / Annual Maintenance and Inspection [7 of 25 Pages] HORIZONTAL CONTROL TUNNEL (Aft seats; continued) Fuel Cutoff and Throttle Control: Inspect condition. Verify proper fuel cutoff and throttle control clearance to installed equipment and surrounding structure. Verify proper installation and security. Cabin Heater Valve and Control: Inspect condition. Verify control clearance to installed equipment and surrounding structure. Verify heater valve security. Verify proper installation and smooth operation of valve. Flight Control Bellcranks: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Inspect spherical bearings per Section 5-33. Verify proper installation, security, and operating clearance. Bellcrank Support: Inspect condition. Verify no cracks or corrosion in welds. Verify no cracks where support mounts to keel panels. Verify proper installation and security. Evaporator and Blower Assembly (Air Conditioning; if installed): Remove middle seat assembly and cover, and inspect condition. Verify refrigerant line security, no damage, and clearance to adjacent structure. Verify no loose, chafed, frayed, or broken wires. Verify proper installation and security of blower and evaporator components. Evaporator Drain Tubes and Valve (Air Conditioning; if installed): Remove middle seat assembly and cover, and covers inside left and right seat compartments to access drain system. Verify tubes are unobstructed. Function- check drain system by simultaneously squeezing drain tube and sediment tube near tee-fitting and verify check-valve ball moves up momentarily. VERTICAL CONTROL TUNNEL Vertical Push-Pull Tubes: Examine accessible portion with inspection light and mirror. Inspect condition per Section 5-32. Verify no nicks, scratches, chafing, dents, cracks, or corrosion. Inspect rod end bearings per Section 5-33; verify rod ends are centered and palnut and jam nut are tight. Check witness holes for proper thread engagement. Verify proper installation, security, and operating clearance. Beep Switch Actuator: Inspect condition. Verify proper control clearance to installed equipment and surrounding structure. Verify proper actuator installation, security, and operation. Tunnel Interior: Verify general cleanliness of tunnel interior. Inspect for fluid leaks or seepage; investigate cause and correct. Seat Backs: Inspect condition. Verify upholstery cleanliness and security. SEP 2012 R66 Maintenance Manual Chapter 5 Inspection Schedule Page 5.19 5-45 100-Hour / Annual Maintenance and Inspection [8 of 25 Pages] CABIN BULKHEAD Blind Encoder & Engine Monitoring Unit (EMU): Inspect condition. Inspect wiring for obvious damage. Verify no cracks where units mount to bulkhead. Verify proper installation and security. Download EMU data as required per RR300 Series OMM. Fuse Block and Fuses (Air Conditioning; if installed): Inspect condition. Verify no corrosion. Verify correct fuse amperage and security. Antenna Wiring: Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify neatness, proper routing and installation, and security. Check grommets for proper installation. Pitot & Static Lines: Inspect pitot and static lines for obstructions, cracking, chafing, pinching, or kinking. Verify integrity of pitot and static line connections. Verify line security. Seat Back Interior: Verify general cleanliness of seat back interior. Inspect for fluid leaks or seepage; investigate cause and correct. Cabin Bulkhead: Examine accessible portion with inspection light and mirror. Verify no nicks, scratches, dents, cracks, corrosion, or loose rivets. Verify stiffener security. Verify upholstery cleanliness and security. Wiring: Inspect condition. Verify no loose, chafed, or broken, wires or terminals. Verify neatness, proper routing and installation, and security. Fasteners & Torque Stripes: Inspect condition. Verify proper installation and security of fasteners. Renew deteriorated torque stripes per Figure 5-1. Antennas: Inspect condition. Verify no cracks where antennas mount to cowlings. Verify security. Close & Secure: Verify foreign objects are removed. Verify equipment security. Verify cleanliness of interior and of inspection and access covers and cowlings. Connect antenna leads and ground wires (if installed). Install covers and cowlings removed in preceding steps. Verify security. BAGGAGE COMPARTMENT Door: Inspect condition. Verify proper operation of micro switch and COWL DOOR warning segment. Inspect hinges and latches for obvious defects. Verify security and proper latching/locking function. Carpet: Inspect condition. Verify no defects, tears, or material deterioration. Verify proper installation and security. Page 5.20 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012 5-45 100-Hour / Annual Inspection (continued) BAGGAGE COMPARTMENT (continued) Interior: Inspect condition. Verify no structural damage. Verify general cleanliness of baggage compartment. Verify any installed equipment or passenger cargo are secure. Generator Control Unit (GCU) & Wiring: Inspect condition. Verify no exposed, loose, chafed, or broken, wires & terminals. Verify proper installation and security of wiring covers and Generator Control Unit (GCU). BATTERY Lead-Acid Battery Installations: Inspect condition. Verify no cracks or corrosion on or near battery cable terminals. As required, perform capacity test or replace battery per manufacturer’s instructions. Verify battery cable security. Verify no corrosion in surrounding structure. Lithium-Ion Battery Installation (if equipped): Refer to § 96-12. Inspect condition. Verify no cracks or corrosion on or near battery terminals. Verify vent hose, comm connector wiring, and battery cable security. Perform scheduled maintenance as required. Verify no corrosion in surrounding structure. AUX FUEL SYSTEM (If equipped) Placards: Verify placard legibility, proper installation, and security. Aux Fuel Tank: Examine accessible portion with inspection light and mirror. Inspect condition of exterior and verify no leakage. Check bladder interior for foreign objects or debris. Verify security. Aux Fuel Tank Support: Examine accessible portion with inspection light and mirror. Inspect condition of exterior; verify no cracks or obvious damage. Verify security. Aux Fuel Hoses: Inspect condition. Verify no leakage, chafing, or obvious damage to fuel lines. Verify line clearance to installed equipment and surrounding structure. Verify security. Aux Fuel Gage Sender & Wiring: Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify proper installation and security of sender and wiring. Aux Fuel Pump Wiring: Inspect condition. Verify no loose, chafed, or broken wires. Verify proper installation and security of wiring. APR 2017 Chapter 5 Inspection Schedule Page 5.21 5-45 100-Hour / Annual Inspection (continued) AUX FUEL SYSTEM (If equipped; continued) Aux Fuel Cap: Inspect condition. Verify no damage or deterioration of gasket. Install cap and verify proper locking function. Verify security. Aux Fuel Tank Sump Drain: Inspect condition. Verify drain valve opens easily, drains fuel freely, springs closed, and seals completely. Inspect drain hose assembly for defects, tears, or material deterioration. Secure hose near drain valve at tab. MT183-1 Tool Kit: Inspect condition. Remove kit and verify kit contains loose parts listed in R66 Illustrated Parts Catalog. Clip kit to aux tank and verify security. MAIN ROTOR GEARBOX COMPARTMENT Cowling Doors: Inspect condition. Verify proper operation of fasteners. Antenna Wiring & Connectors: Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify no damaged connectors. Verify neatness, proper routing and installation, and security. Check grommets for proper installation. Placards: Verify placard legibility, proper installation, and security. Refer to Chapter 11. Fuel Tank: Examine accessible portion with inspection light and mirror. Inspect condition of exterior and verify no leakage. Check bladder interior for foreign objects or debris. Verify security. Fuel Gage Sender & Wiring: Inspect condition. Verify no loose, chafed, or broken, wires or terminals. Verify proper installation and security of sender and wiring. Low-Fuel Switch Assembly Warning: Turn battery switch on. With a clean wooden dowel, gently depress low-fuel sender float in fuel bladder and verify LOW FUEL warning segment illuminates after approximate 1-second delay. Turn battery switch off. Fuel Cap: Inspect condition. Verify no damage or deterioration of gasket. Install cap and verify proper locking function. Verify security. Page 5.21A Chapter 5 Inspection Schedule APR 2017 5-45 100-Hour / Annual Inspection (continued) MAIN ROTOR GEARBOX COMPARTMENT (continued) Fuel Tank Rollover Vents: Inspect condition. Inspect Tygon® tube for defects, tears, or material deterioration. Verify proper safety wire installation and security. Verify 0.25 inch minimum clearance between cable assembly and vent assembly Tygon® tube; adjust cable as required. Verify no obstructions in vents. Fuel Tank Sump Drain: Inspect condition. Verify drain valve opens easily, drains fuel freely, springs closed, and seals completely. Inspect drain tube and clamp for defects, tears, or material deterioration. Clear fuel from drain tube and install clamp. Fuel Valve: Inspect condition. Verify cable and component security. Verify proper installation and (smooth) operation of valve. Cabin Bulkhead: Inspect condition. Verify no deformation, buckling, wrinkling, nicks, scratches, dents, cracks, corrosion, fretting, or loose rivets. Verify no leakage from fuel tanks. Verify security. Main Rotor Gearbox: Inspect condition. Verify no damage, material deterioration, or deformation of gearbox mounts. Verify no leakage at mast tube-to-gearbox attachment. Inspect mast tube for cracks. With ship on level ground, verify correct oil level and cleanliness through sight gage and adjust or flush as required. Verify security of Hall Effect senders and yoke magnets. Inspect oil lines for leakage, chafing, or obvious damage. Inspect oil pump mounting and fittings for leaking or obvious damage. Inspect gearbox oil filter for leakage or for tripped bypass indicator. Verify oil system proper installation and security. NOTE At 600 hours time in service or annually, whichever occurs first, remove chip detector and clean off varnish build-up from detector’s magnetic probe and adjacent metal body (a toothbrush dampened with solvent works well). Service gearboxes, change oil and filter, and clean chip detectors at intervals recommended in § 5-20. Rotor Brake: Inspect condition. Verify integrity of brake pads and 0.030 inch minimum pad thickness. Verify brake pads are clear of engine shaft with brake released. Inspect micro switches for cracks. Verify no loose, chafed, or broken wires or terminals. Verify security. Inspect both pulleys (one at end of lever, one next to fuel tank) for cracks. Verify no frayed strands or binding of rotor brake activating cable. Verify proper routing and installation, security, and operation of brake and brake micro switch. APR 2017 Chapter 5 Inspection Schedule Page 5.21B Page 5.22 Chapter 5 Inspection Schedule APR 2017 5-45 100-Hour / Annual Inspection (continued) MAIN ROTOR GEARBOX COMPARTMENT (continued) Hydraulic Servo Support Frame: Inspect condition. Inspect rod ends per § 5-33. Use an inspection light and mirror to inspect all parts of each weld. Verify no cracks or corrosion in servo support. Verify proper installation and security. Jackshaft: Inspect condition. Verify no cracks or corrosion in welded assembly. Inspect jackshaft to vertical push-pull tube attachment. Inspect jackshaft aft support frame attachment and forward attachment rod end per § 5-33. Inspect C343-8 tube and rod ends linking jackshaft to aft servo. Verify security and proper operating clearance. 5-45 100-Hour / Annual Maintenance and Inspection [11 of 25 Pages] MAIN ROTOR GEARBOX COMPARTMENT (continued) Main Rotor Push-Pull Tubes: Examine accessible portion with inspection light and mirror. Inspect condition per Section 5-32. Verify no nicks, scratches, chafing, dents, cracks or corrosion. Inspect rod end bearings per Section 5-33; verify rod ends are centered and palnut and jam nut are tight. Check witness holes for proper thread engagement. Verify proper installation, security, and operating clearance. Tail Rotor Push-Pull Tube & Forward Bellcrank: Examine accessible portion with inspection light and mirror. Inspect condition per Section 5-32. Verify no nicks, scratches, chafing, dents, cracks, or corrosion. Inspect rod end bearings per Section 5-33; verify rod ends are centered and palnut and jam nut are tight. Check witness holes for proper thread engagement. Inspect bellcrank and bellcrank sheet metal mounting for nicks, scratches, dents, cracks, or corrosion. Inspect spherical bearings per Section 5-33. Verify proper installation, security, and operating clearance. Hydraulic Reservoir: Inspect condition. Verify no significant leakage. Replace filter and packing at intervals specified in Section 5-20. Drain and flush hydraulic system per Section 12-33 if oil has turned dark or emits bad odor. Add fluid as required. Verify security. CAUTION Cleanliness of hydraulic fluid is vital to proper system operation. Service hydraulic system with clean fluid from sealed containers. Verify funnels, tubing, and other service tooling is free of contaminants. Hydraulic Servos: Inspect condition. Inspect rod ends per Section 5-33. Verify approximately 0.040 inch total free play at servo valve input. Verify no significant servo leakage. Clean servo input rod end/clevis area with no-residue, non-alcoholic solvent as required. Verify no obvious defects and security of scissors at upper clevis of servos. Verify proper installation and clearance from surrounding structure through full control travel. CAUTION Use LPS PreSolve to clean hydraulic parts. Do not use alcohol. Hydraulic Hoses, Lines, & Fittings: Inspect condition. Verify no leakage, chafing, or obvious damage to hydraulic lines. Verify integrity of connections. Verify fluid line clearance to installed equipment and surrounding structure and sufficient fluid hose slack available through full control travel. Verify proper installation and security. Hydraulic Pump: Inspect condition. Inspect Telatemp per Section 5-35. Verify no significant leakage. Verify proper installation and security. SEP 2012 R66 Maintenance Manual Chapter 5 Inspection Schedule Page 5.23 5-45 100-Hour / Annual Maintenance and Inspection [12 of 25 Pages] MAIN ROTOR GEARBOX COMPARTMENT (continued) Upper Steel Tube Frame: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Verify no chafing where wires, hoses, or clamps attach to frame. Examine each weld for cracks with an inspection light and mirror. CAUTION Upper steel tube frame is fatigue loaded and therefore susceptible to fatigue cracks. Inspect all joints thoroughly. F908-1 (Tail Rotor Drive) Yoke Assembly: Inspect condition. Verify no cracks, corrosion, or fretting. Verify proper installation, security, and operating clearance. Verify security of magnets. G779-1 Pulley (Air Conditioning; if installed): Inspect condition. Verify no cracks, corrosion, or fretting. Verify no nicks or sharp edges in fins that could damage v-belt. Verify proper installation, security, and operating clearance. V-Belt (Air Conditioning; if installed): Inspect condition. Replace belt if exhibiting frayed edges, excessive cracking, heat damage, or rubber deterioration. Verify 4.5-5.5 lb of force applied mid-span deflects belt 0.16-inch; adjust as required per Section 21-21. Compressor Assembly (Air Conditioning; if installed): Inspect condition. Verify security of mounting. Verify no loose, chafed, frayed, or broken wires. Verify proper installation and security of pressure switches,