KI-233 Revision E

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KI-233 Revision E KI-233-1 R44-series Chin Access Cover Installation Kit Instructions KI-233-2 R66 Turbine Chin Access Cover Installation Kit Instructions To comply with R44 Service Bulletin SB-102 or R66 Service Bulletin SB-35. NOTE Visit www.robinsonheli.com to verify kit instructions are current revision. Review instructions before installation; contact RHC Technical Support with questions. Verify kit contents match list; contact RHC Customer Service if parts are missing or damaged. NOTE Rivets included in kit are provided as a courtesy and at lengths most commonly used on production helicopters. Proper rivet length is determined by installer during installation. 1 KI-233Instr. Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 2 B526-6 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6 3 C795-1 Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 4 C795-2 Shingle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 5 MS20426AD3-4+ Rivet (Note: “+” in part number indicates 50-qty pack) . . . . . . . . . . 1 1 6 MS20470AD3-4.5+ Rivet (Note: “+” in part number indicates 50-qty pack) . . . . . . . . . . 1 1 7 MS20605R3W3 Rivet, blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 0 8 MS21069L08 Nutplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6 9 NAS1149FN232P+ Washer (Note: “+” in part number indicates 20-qty pack) . . . . . . . . 1 1 10 NAS1474A08 Nutplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 Consumables Refer to R44 Maintenance Manual (MM) § 1.400 or R66 MM § 20-70 approved materials list. • One pint of paint; C795-1 cover & C795-2 shingle are supplied primered only. Refer to the inside cover of factory-supplied maintenance record (logbook) for paint code(s) of specific helicopter serial number. NOTE C795-1 cover and C795-2 shingle may be painted before or after installation on helicopter. ITEM PART NUMBER KIT CONTENTS (R44) QTY PER KI-233-1 (R66) QTY PER KI-233-2 22 OCT 2021 Chin Access Cover Installation Kit Page 1 of 8 KI-233 Revision E Page 2 of 8 Chin Access Cover Installation Kit 22 OCT 2021 Special Tools • Blind rivet installation tool • Manual squeeze-type rivet installation tool • Thin-Kerf (or equivalent) cutting disc for fiberglass • Drum (cylindrical) sander, 1-inch (or smaller) diameter • Clecos (sheet metal fastener) size #40 (silver) and #18 (black) Kit Instructions CAUTION To minimize risk of electrical discharge: When disconnecting battery, disconnect negative (ground) cable from the battery first, then disconnect positive cable. When connecting battery, connect positive cable first, then connect negative (ground) cable. 1. Turn battery switch off. If nose battery installed, refer to R44 Illustrated Parts Catalog (IPC) Figures 96-19, 96-23, or 96-27 and R44 MM § 37-10. Using standard maintenance procedures, remove battery and battery box assembly & box drain. 2. Refer to Figures 1A, 1B, or 1C, as applicable. Lay out dimensions for access hole on chin as shown. Inspect proposed hole area for fasteners and note location(s). WARNING Refer to appropriate Safety Data Sheet (SDS) and take necessary safety precautions when working in proximity to hazardous materials. 3. Open upper console. Remove avionics as required and inspect proposed hole area for impediments such as, but not limited to: wiring, heater control cable & clamp(s), heater hose(s) & clamps, radar altimeter components, and antenna(e). Temporarily reposition or remove impediments as required. 4. Using cutting disc, create small hole within marked boundaries sufficient to allow passage of an inspection mirror. Simultaneous use of vacuum cleaner is recommended to minimize debris accumulation. 5. Using inspection mirror, inspect chin interior for impediments. Temporarily reposition or remove impediments as required. 6. Using cutting disc and drum sander, cut out hole to specified 4.00 inches by 8.00 inches dimensions with 0.5-inch radius corners. Simultaneous use of vacuum cleaner is recommended to minimize debris accumulation. 7. Refer to Figures 1A, 1B, or 1C, as applicable. Using C795-1 cover as template and a drill stop, lay out and drill (6) 0.169–0.175 inch diameter holes around access hole as shown. KI-233 Revision E 22 OCT 2021 Chin Access Cover Installation Kit Page 3 of 8 Kit Instructions (continued) 8. Layout C795-2 shingle installation rivet holes as shown in Figures 1A, 1B, or 1C. Postion shingle on chin at planned rivet holes and verify shingle will be centered on, and overlap cover. Using a drill stop, drill (3) 0.097–0.102 inch diameter holes. NOTE Ensure all nutplates are installed parallel with centerline of helicopter. a. For R44-series: Refer to Figure 2. Temporarily hold (2) NAS1474A08 nutplates in aft positions on exterior using screws. Using nutplates as template, drill (4) 0.097–0.102 inch diameter rivet holes. Remove nutplates and create 0.170–0.190 inch diameter, 100º countersinks on outside of chin. Install nutplates using (4) MS20426AD3-4 rivets, or MS20605R3W3 blind rivets, at installer’s discretion. Position (4) MS21069L08 nutplates in place on exterior with screws temporarily inside chin. Using nutplates as template, drill (8) 0.097–0.102 inch diameter rivet holes. Remove nutplates & screws and create 0.170–0.190 inch diameter, 100º countersinks on outside of chin. Install nutplates using (8) MS20426AD3-4 rivets. On R44 s/n 0357 and prior, the clamp securing the heater control cable may require minor repositioning and a new screw hole. If required: i. Remove and retain AN742-3 clamp (and hardware) securing cabin heat cable to belly of