Exec 162F Maintenance Manual

pan, top front cover, rear oil seal, tension spring, rain shield. Chain: drive chain with link. Clutch idler assembly: idler pulley assembly, idler pulley bearing, rod ends, idler spring, clutch tube weldment, pulley arm weldment, clutch arm casting, bolts. SECTION 11: Fuel System Page 31 Fuel cap, hoses, fuel shut-off valve cable, fuel pump, fuel filter, fuel pressure regulator, fuel shut-off valve/filter, fuel tanks, fuel gauge, fuel gauge sending unit. SECTION 12: Fan Drive Page 33 Bearings, belts, pulleys, shaft. SECTION 13: Main Rotor Blades Page 35 Retention strap assembly, rotor blades, 9/16 bolt and nut, elastomeric thrust bearings, tip weight, aligner block assembly, pitch horn clevis, pitch horns, bolts, aligner block bearings. RotorWay International Exec 162F Maintenance Manual 6 Rev. 2 6/04 SECTION 14: Electrical System Page 37 Battery, digital display monitor, engine control unit (ECU), ignition module, man/baro pressure sensor, 9 pin cable, fuse holder, toggle switch, fuses, battery terminal eyelet, starter relay, push button switch, LED indicator light, airframe wiring harness, overhead wiring harness, instrument wiring harness, FADEC wiring harness, voltage regulator, alternator assembly. SECTION 15: Instrumentation Page 39 Hour meter, water temperature gauge, oil temperature gauge, oil pressure gauge and sender, volt meter, dual engine/ rotor tach, altimeter, vertical speed indicator, air speed indicator, compass, manifold pressure gauge, full range tach, fuel pressure gauge, fuel pressure sender. SECTION 16: Ground Handling Wheels Page 41 Wheel and tire, tire track. SECTION 17: Ballast Weight Page 43 Support tube weldment, mount tube weldment, ballast weight tube, ballast weight pin, safety clip. SECTION 18: Paint Page 45 Paint. SECTION 19: Rotor Hub Page 47 Rotor hub assembly: rotor hub plate, teeter block assembly, teeter block bearing, delrin shim, stainless steel shim, bolts, main rotor drive pin, thin washer, snap rings, thrust blocks, thrust washer, thrust block alignment bearing, thrust block liner, rod ends, pitch link, set screws, pitch pins, main rotor shaft, grease fitting, dust cap. Swash plate assembly: Non- rotating swash plate, swash plate bearing, snap rings, rotating swash plate, slider ball adjustment collar, cyclic cable mount, cyclic mount bearing, slider ball, spherical bushing, slider ball clamp, slider ball O-ring, swash plate scissor, scissor clevis, rod ends, nylon scissor bushing, collective actuator fork, collective scissor, collective scissor mount, control “T”, counter balance, rod end spacer, spring bracket, tension spring, delrin washer, scissor spacer, dust boot, rubber shaft protector. Main shaft assembly: main thrust bearing, main bearing flange, main shaft safety spacer, lower main shaft bearing weldment. Rotor hub shimming procedures, Page 51 Slider ball adjustment collar, Page 60 SECTION 20: Doors Page 63 Doors, door stiffener, door hinge, body hinge, bolts, vents. SECTION 21: Torque Requirements Page 65 Torque requirements for hardware used on the helicopter. SECTION 22: Inspection Guide for Hard Landings, Tail Rotor Strike, or Roll Overs Page 67 SECTION 23: Hourly Service Charts Page 69 SECTION 24: Grease Requirements Page 91 RotorWay International Exec 162F Maintenance Manual 7 Rev. 1 10/01 Section 1: Airframe The airframe is constructed of various size tubes consisting of geometric shapes which will allow the airframe to flex at key areas during operation and still maintain a high structural integrity. The tubing is aircraft industry standard 4130 chrome- moly. Where tubing requires bending, a mandrel bender is used and tubes are scribed, cut, and coped to a tolerance of .062 inch. The oxygen acetylene gas method of welding is used and all weldments are air cooled to retain the original strength of the alloy. Reference prints: E10-2000, E13-2000 SERVICE NOTES: 1. Remove all inspection panels including the two upper panels that are held on by nut plates. Using a flashlight or a suitable source of illumination and a mirror, inspect for cracks on the round and square tubes, paying close attention to the welded areas. If a small hairline crack appears, remove the paint from the airframe at that position to further verify the crack. It may be necessary to apply a pressure or load in such a manner as to help open up the crack to verify. If close inspection verifies the crack, contact the factory for further assistance. If verification is negative, repaint the suspect area and reassemble. 2. Remove skid pants. Inspect the rear landing gear, gear gusset, the area 6 inches above and below the landing gear step, and the rear landing gear attachment bracket. These are critical inspection areas. Approximately 80% of the total aircraft weight is transferred on the rear gear. After inspection, reinstall the skid pants. The rear landing gear may spread with age or after a hard landing. The gear should be replaced if the distance between rear landing gear shoes, measured inside, is greater than 62 inches. 3. Removal of the two rear lower fiberglass body panels (part no. E32-7130 and E32-7140) will allow you access for a visual inspection of the Engine Mount Rubber Ring, part no. E13-3121. This part must be kept clean from oil and grease. Allowing the part to become contaminated will deteriorate the rubber over a short period of time, changing the alignment of the secondary to engine height. If in question, check secondary and engine alignment. The tolerance is plus or minus 1/8". Refer to the engine installation section of the Construction Manual for further assistance. 4. Because the helicopter can be operated in many different terrains and will experience a variety of landing conditions, the landing gear skid will remain an on-condition inspection item. Lift the front skid off the ground approximately 10 inches and block it up with a 2x4 board. Look for a flat wear area across the bottom of the skid. If a flat area appears and measures more than 1/2" in width, replace the skid tube. Keeping the helicopter in the upright condition, remove the two (2) front skid shoe bolts (part no. E00-2414) on the right front skid shoe and drop the skid 3" below the shoe. This will allow an inspection on top of the skid which is normally hidden by the shoe. Check the holes for an oblong condition and for any cracks in the skid tube. Also, inspect the bolts for wear prior to reinstalling the skid on the landing gear shoe. INSPECTION CHART PART NO. E10-1001 EXEC 162F Airframe 100 HR 2000 HR/OC 1-1 E00-2415 AN4-24A (1/4 x 2-1/2) Bolt 100 HR 2000 HR/OC Torque E00-2601 AN6-10A (3/8 x 1) Bolt 100 HR 2000 HR/OC Torque E11-9010 Rear Landing Gear 100 HR 2000 HR/OC 1-2 E13-3121 Engine Mount Rubber Ring 50 HR 2000 HR/OC 1-3 E00-2507 AN5-10A (5/16 x 1) Bolt 100 HR 2000 HR/OC Torque E11-3130 Landing Gear Skid (Pilot) 500 HR 2000 HR/OC 1-4 E11-3131 Landing Gear Skid (Passenger) 500 HR 2000 HR/OC 1-4 DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. RotorWay International Exec 162F Maintenance Manual 8 RotorWay International Exec 162F Maintenance Manual 9 Section 2: Tail Boom The main purpose of the tail boom in all conventional helicopters is to provide a mounting location for the anti-torque system or tail rotor. Its secondary purpose is to mount the vertical and horizontal trim fins which are used to stabilize the aircraft in forward flight, opposing aerodynamic forces from the windscreen and body. The material used for the tail boom skin is aircraft industry standard, grade T-3 aluminum and is .025 thick. The sheet is rolled in a cone shape to provide structural integrity. Reference prints: E09-2000, E09-2001 SERVICE NOTES: 1. The tail boom is subject to most of its stress during take off and landing. The skin and its associated parts are subject to high frequency vibrations that can cause stress cracks and generate loose rivets and bolts. A. Stress cracks: Upon inspection of the tail boom skin, if you find that stress cracks have started, drill a small hole at the very end of the crack. This hole will stop any further migration of the crack. The size of the drilled hole will depend on the severity of the crack. B. Loose rivets: Using the appropriate sized drill bit (depending upon the size and head diameter of the rivet), drill out the head of the rivet by rotating the drill in an elliptical manner. This will remove the head without drilling through the rivet hole. Then use a rivet shank or a small punch to knock out the remainder of the rivet. Clean the area and deburr the hole if necessary. Replace the rivet using the original type and size. 2. Inspect the Vertical Fin bracket at bend areas for cracks. Also inspect the mounting holes outward to the edge of the bracket. INSPECTION CHART PART NO. E09-9000 Tail Boom 100 HR 2000 HR/OC 2-1 E09-9010 Vertical Trim Fin 100 HR 2000 HR/OC Rivet inspection E09-9021 Horizontal Trim Fins 100 HR 2000 HR/OC Rivet inspection E09-3252 Vertical Trim Fin Bracket 100 HR 2000 HR 2-2 E00-2300 AN3-4A (3/16 x 1/2) Bolt 50 HR 2000 HR Torque E00-2301 AN3-5A (3/16 x 5/8) Bolt 100 HR 2000 HR Torque E00-2303 AN3-6A (3/16 x 3/4) Bolt 50 HR 2000 HR Torque E00-2305 AN3-11A (3/16 x 1-1/8) Bolt 100 HR 2000 HR Torque E00-2306 AN3-12A (3/16 x 1-1/4) Bolt 50 HR 2000 HR Torque E00-2307 AN3-13A (3/16 x 1-3/8) Bolt 50 HR 2000 HR Torque E00-2308 AN3-15A (3/16 x 1-5/8) Bolt 50 HR 2000 HR Torque E00-2309 AN3-17A (3/16 x 1-7/8) Bolt 100 HR 2000 HR Torque E00-2414 AN4-23A (1/4 x 2-3/8) Bolt 100 HR 2000 HR Torque E00-2432 AN4-12A (1/4 x 1-1/4) Bolt 50 HR 2000 HR Torque SERVICE REFERENCE INSPECTION INTERVAL R.C.O. RotorWay International Exec 162F Maintenance Manual 10 RotorWay International Exec 162F Maintenance Manual 11 Section 3: Body The body of the EXEC 162F helicopter consists of several separate panels that when assembled make up a solid egg shape structure. This provides for a very efficient and aerodynamic airflow. Each panel is made using the hand lay-up squeeze method to give the piece the maximum strength to weight ratio. A gel coat is applied to the mold prior to the fiberglass lay-up so that the parts are ready for light sanding and paint. Reference print: E32-2000 SERVICE NOTES: 1. Care of the body panels is very minimum. However, two factors which may damage them are heat and prolonged exposure to gas and oil from lack of cleaning. When doing pre- and post-flight inspections, avoid exposing any removed panels to excess heat or direct sunlight. Stand the panels upright and avoid placing them in an abnormal position. Prolonged exposure to excessive heat or sunlight in an abnormal position could result in a deformed panel. Fiberglass is resistant to most chemicals; however, panels that are exposed to gas and oil over long periods of time will eventually be weakened. Wipe off oil and gas with a dry cloth. Then clean off any remaining residue using a cloth moistened with acetone. Use CAUTION when working with acetone because of its high flammability. Check to make sure that all metal parts protruding through the fiberglass have a minimum of 1/4" clearance. If the clearance requires enlarging, this process can be done by using a round or flat file or an air or electric grinder. 2. Care and cleaning of Plexiglass parts: A. Cleaning: A mild soap and water solution on a cloth can be used to remove dirt and fingerprints. A plastic cleaner such as Meguiar’s #2 can be used to remove overspray and oxidation and #9 should be used to preserve and protect the windscreen and to bring up a high gloss. INSPECTION CHART PART NO. Body 100 HR OC 3-1 E32-7210 Eyebrow Window, Pilot 100 HR OC 3-2 E32-7220 Eyebrow Window, Passenger 100 HR OC 3-2 E32-7231 Windscreen 100 HR OC 3-2 E32-1301 Seat Upholstery 100 HR OC 3-3 Skid Pants 100 HR OC 3-4 E32-1111 Cyclic Boot 100 HR OC E32-3131 Floor Pan/Instrument Pod 100 HR OC E32-6111 Seat Bulkhead 100 HR OC E32-7102 Bottom Tub 100 HR OC E32-7111 Fuselage (Right Front) 100 HR OC E32-7113 Fuselage (Right Rear) 100 HR OC E32-7122 Fuselage (Left Rear) 100 HR OC E32-7123 Fuselage (Left Front) 100 HR OC E32-7130 Fuselage (Lower Right) 100 HR OC E32-7140 Fuselage (Lower Left) 100 HR OC E32-7152 Doghouse (Front) 100 HR OC E32-7160 Bracing Panel 100 HR OC E32-7170 Bracing Panel 100 HR OC E32-7180 Roof Panel 100 HR OC E32-7272 Doghouse (Rear) 100 HR OC E54-4010 Push/Pull Cable 100 HR OC Oil (20 W) DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. RotorWay International Exec 162F Maintenance Manual B. Care should be taken so that the windscreen screws are not over tightened (see “Working With Plexiglass” in the Standard Construction Procedures of the Construction Manual). This could cause stress cracks that may result in a major crack down or across the windscreen. If a stress crack appears, stop drill the crack with the appropriate size drill bit. C. If a cover is used while trailering, make sure the cover has a soft inside lining and fits tight enough to the body to avoid flapping. 3. Use any commercially available upholstery cleaner on the seats or cabin interior if they become soiled. Carefully read the instructions on the cleaner to obtain desirable results. This will help prevent any shrinkage from occurring. 4. Check to make sure that the skid pants do not chafe against the body tub or the landing gear. If contact is present, file the fiberglass to make clearance between the two parts. 12 RotorWay International Exec 162F Maintenance Manual 13 Rev. 1 7/98 Section 4: Tail Rotor Drive The tail rotor drive of the EXEC 162F utilizes a V-belt design, rather than a drive shaft with gear boxes, to transmit power to the tail rotor. This design provides a simple and effective drive train with low maintenance. Reference print: E09-2000 SERVICE NOTES: 1. Remove the two bolts (part no. E00-2405) that attach the idler pulley assembly to the tail boom and slide the idler pulley mount scissors down and out of the tail boom. (See note 2 below for inspection of idler pulley assembly.) Place a small amount of grease on each of the mating surfaces and reinstall the pulley in its original position. Tighten the nuts on the bolts only enough to hold the part firmly. The part should not swing loosely but require slight pressure to move it. (Refer to Construction Manual.) 2. Tail Rotor Idler Pulley Assembly (part no. E18-2012) A. Remove the pulley by removing bolt part no. E00-2604. B. Remove two (2) snap rings. C. Heat the pulley in an oven or other appropriate means to 225-275 degrees F. CAUTION: Do not exceed 300 degrees F or the heat treatment of the pulley will be affected. D. Using appropriate tools, fixtures, and presses, press out the old bearing. E. Let the pulley air cool, then clean the inner mating service with acetone. F. Clean the outer surface of the bearing with acetone and position the bearing ready for reinstallation. G. Apply a thin even film of Loctite #609 to the outer surface of the bearing only. (Do not use your fingers.) H. Install one snap ring. I. Heat the pulley to 225-275 degrees and drop the bearing in place. If a press is necessary, use light pressure to insure contact of the bearing to the snap ring. (When using a press, press only on the outer race of the bearing and not the inner race.) Wipe off remaining Loctite. J. Install the second snap ring and let the assembly cool. K. Check to see that both snap rings have seated completely and that there is no play between the bearing and the pulley. L. Install the pulley, make sure the spacers are in their proper place and torque the bolt. M. Rotate the pulley on its new bearing and check the feel with your fingers for smoothness and ease of rotation. 3. Inspect for wear and anodizing on the pulley. Also inspect for cables and wires that may have shifted or come loose in the tail boom, allowing them to rub on the pulley. 4. Visually inspect and check tension of the tail rotor drive belts at every pre-flight and post-flight inspection. Detailed procedures regarding proper installation, tension and maintenance of these belts are given in the Flight Manual and in Section 25 of the Construction Manual (Rigging Procedures). Thoroughly inspect the condition of the belts every 100 hours. Replace the tail rotor drive belts at 250 hours of operation, or at 2 years, or on condition, whichever comes first. Shelf life, or time before entering service, is not included if the belts have not been exposed to the environment and have not been affected by aging. Conditional replacement includes damage resulting from excessive slipping, oil absorption, cracking, glazing, abnormal wear, or any other damage. INSPECTION CHART PART NO. E18-6130 Idler Pulley Mounting Scissors 250 HR 2000 HR 4-1 E18-1131 Idler Pulley Bearing Assembly 250 HR 250 HR/OC 4-2 E18-2012 Tail Rotor Idler Pulley 100 HR 2000 HR/OC 4-3 E18-1150 Tail Rotor Belt Pre/post flight 250 HR/OC or 2 yrs 4-4 E18-1160 Tail Rotor Belt Pre/post flight 250 HR/OC or 2 yrs 4-4 DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. RotorWay International Exec 162F Maintenance Manual 14 RotorWay International Exec 162F Maintenance Manual 15 Rev. 1 6/04 Section 5: Tail Rotor The tail rotor’s function is to counter the torque of the power plant and keep the aircraft from rotating. It also provides the ability to turn the aircraft while hovering by adjusting the pitch of the tail rotor blades through use of the directional controls. Note: Refer to the Construction Manual for replacement details of these components. Reference prints: E17-2000, E17-2001 SERVICE NOTES: 1. Remove bolt (part no. E00-2604) from the tail rotor barrel. Using a knife or a tool with a sharp edge, pry under the lip of the bearing (part no. E17-1260) removing the bearing from the barrel. Replace with new bearings and insert the bolt, tightening it just enough so that the head of the bolt can be rotated slightly with your fingers. Check end play by using your hand and fingers, pushing the barrel from side to side to confirm proper end play. 2. Use the following procedure to remove tail rotor blades (part no. E17-6000) and pitch pins (part no. E17-6173): A. First, mark each blade and pitch horn assembly as A and B. Indicate identity on the tail rotor barrel so reassembly will be the same. This will maintain tail rotor balance. B. Remove the two bolts that hold the blade to the pitch pin (part no. E00-2305 and E00-2308). C. Carefully grasp the tail rotor blade and barrel with your hand and rotate while pulling outward. D. Remove the snap rings and deburr the snap ring hole if needed. CAUTION: Be careful while doing this procedure not to mark or scratch the inner surface of the tail rotor barrel. E. Grasp the pitch pin and pull it out of the barrel. It may be necessary to insert a bolt in the tail rotor pin to lightly tap on for removal. NOTE: A slide hammer may be fabricated to facilitate the removal of the pitch pin. See drawing on the next page. F. After removal of the pitch pin, remove the alignment bearing assembly (part no. E17-1270) and the thrust bearing assembly (part no. E17-1280). Immerse the parts in a solvent to clean and remove the grease. After inspection of parts, reassemble according to original procedures as outlined in the Construction Manual and on prints E17- 2000 and E17-2001. NOTE: When changing out the tail rotor blades, refer to the tail rotor balancing procedures in the Construction Manual. INSPECTION CHART PART NO. E17-1260 FS3 PP Bearing 100 HR 500 HR/OC 5-1 E17-1290 Snap Ring 100 HR 500 HR E00-2604 AN6-24A (3/8 x 2-1/2) Bolt 100 HR 500 HR/OC E17-6126 Carriage Slider Assembly 25 HR 1000 HR/OC 5-5 E17-1300 Carriage Slider Bearing 100 HR 500 HR/OC E17-1210 Rod End 5/16 Teflon 100 HR 1000 HR/OC E17-6000 Tail Rotor Blade Assembly 100 HR 500 HR/OC 5-2 E17-5120 Pitch Actuator Arm Pivot Casting 100 HR 2000 HR 5-3 E17-1340 Bearing Assembly 100 HR 250 HR/OC E17-5110 Pitch Horn 100 HR 500 HR E17-9010 Slider/Actuator Arm Clevis 100 HR 2000 HR E17-6150 Tail Rotor Shaft 100 HR 2000 HR/OC E17-1360 Bearing Plate Slider Rail 100 HR 2000 HR E17-5101 Tail Rotor Pulley 100 HR 2000 HR/OC E16-1200 Female Rod End 100 HR 1000 HR/OC E17-1270 Alignment Bearing Assembly 50 HR 500 HR/OC 5-4 E17-1280 Thrust Bearing Assembly 50 HR 500 HR/OC 5-4 E17-6100 Tail Rotor Barrel 50 HR 2000 HR/OC 5-4 DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. RotorWay International Exec 162F Maintenance Manual 16 Rev. 1 6/04 3. Remove bolt (part no. E00-2311) and two washers. Then slide the actuator arm to one side and place a small amount of grease on the bolt hole in the pivot casting. Reassemble the actuator arm, install bolt, and check the nut with cotter pins for security. 4. Every 50 hours, add grease to the fitting on the tail rotor barrel until the grease comes out near the pitch horns, and wipe off excess. Drill a 3/16 inch hole in each blade tip cap so that grease thrown out by centrifugal force will not build up inside the blade. 5. Slowly inject one shot of Mystik JT-6 grease while moving the slider back and forth to spread the grease evenly. Add grease again every 25 hours of operation or as needed. RotorWay International Exec 162F Maintenance Manual 17 Section 6: Control Assemblies The Control Assemblies of the EXEC 162F helicopter transfer control inputs from the pilot and passenger to the associated location on the helicopter. The four areas that require control inputs are: A. Directional Controls B. Cyclic Controls C. Collective Controls D. Throttle Controls Coordinated inputs of these controls allow the pilot to maintain control of the helicopter throughout all maneuvers. Reference prints: E14-2000, E15-2000, E16-2000, E17-2000, E17-2001, E49-2002 SERVICE NOTES: 1. Remove the cross shaft bushing (part no. E16-6131) by clipping the safety wire from the bolt (part no. E00-2501) and then removing the bolt. Drill out the rivets that attach the bushing to the bracket on the airframe. Lift up on the end of the foot pedal cross shaft (part no. E16-3101) just enough to remove the cross shaft bushing. Clean the bushing, apply a small amount of grease and reassemble. Re-torque and safety wire the bolt, and pop rivet the bushing to the bracket. Perform this procedure for both pilot and passenger sides. 2. Remove the scissor mount bushing (part no. E16-6130) by removing bolt (part no. E16-2406). Lower the bushing away from the scissor beam (part no. E16-3120). Clean, grease lightly, and reassemble. Check clearance between head of bolt (part no. E16-2406) and front airframe tube. There should be a minimum of 1/16" clearance. If proper clearance cannot be obtained, shim under nylon scissor beam pivot bushing (part no. E16-6120) to achieve clearance. INSPECTION CHART PART NO. Directional Control E16-6131 Cross Shaft Bushing 1000 HR 2000 HR 6-1 E16-6130 Scissor Mount Bushing 1000 HR 2000 HR 6-2 E16-1200 3/16" Female Rod End 100 HR 1000 HR/OC 6-3 E16-1130 1/4" Male Rod End 100 HR 1000 HR/OC 6-4 E16-1140 1/4" Female Rod End 100 HR 1000 HR/OC 6-4 E16-1212 Directional Control Cable 100 HR 2000 HR/OC 6-5 Cyclic Control E14-6131 Cross Shaft Bushing 1000 HR 2000 HR 6-6 E14-1241 Nylon Bushing 1000 HR 2000 HR 6-7 E14-1150 5/16" Male Rod End 100 HR 2000 HR/OC 6-8 E14-1211 Cyclic Control Cable 100 HR 2000 HR/OC 6-9 E14-1221 Cyclic Control Cable 100 HR 2000 HR/OC 6-9 Collective Control E15-6131 Cross Shaft Mount Bushing 1000 HR 2000 HR 6-10 E15-1230 5/16" Male Rod End 100 HR 2000 HR/OC 6-11 E15-6130 Collective Rod End Plug 100 HR 2000 HR/OC E49-1400 Collective Control Rod 100 HR 2000 HR/OC Throttle Control E15-3150 Pilot Throttle Shaft 1000 HR 2000 HR 6-12 E15-3170 Transfer Shaft 1000 HR 2000 HR 6-13 E15-9021 Throttle Shaft Weldment 1000 HR 2000 HR 6-14 E15-1150 1/4" Male Rod End 100 HR 2000 HR/OC 6-15 E24-7531 Throttle Cable Assembly 100 HR 500 HR/OC DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. RotorWay International Exec 162F Maintenance Manual 18 3. Remove bolt (part no. E00-2305) rod end (part no. E16-1200) and jam nut. Then count the number of turns to remove, and install the new rod end with the same number of turns. Tighten the locking nut, replace the bolt and verify the cable travel. Refer to the Construction Manual for detailed procedures. 4. Remove bolts (part no. E00-2406) and remove both rod ends. Using calipers, measure and note the distance from center to center. Reinstall the new rod end with the same measurement. Refer to the Construction Manual for detailed procedures. 5. CAUTION: Under no conditions should any type of lubrication or oil be used on the sliding inner cable. 6. Grease the cross shaft pivot bushing. Refer to the Construction Manual for detailed procedures. 7. Remove bolt (part no. E00-2414) and the two large fender washers. Place a small amount of grease (Mystik JT-6) on the bolt, bushing and mating surfaces. Reinstall the bolt and two fender washers. Tighten the bolt enough to hold firmly while still allowing the cyclic clevis to move easily without any end play. 8. Remove bolt (part no. E00-2510) and pull the rod end away from clevis. Loosen the locking nut and on the rod end and unscrew it, counting the number of turns. Install the new rod end with the same number of turns. Tighten locking nut and install bolt. Refer to the cyclic control section and rigging procedures for the elastomeric rotor hub in the Construction Manual to verify adjustments. 9. CAUTION: Under no conditions should any grease or lubricant be used on the sliding inner cable. 10. Cut safety wire and remove bolt (part no. E00-2501). Drill out the rivets that attach the bushing to the bracket. Lift the collective control shaft (part no. E15-3120) enough to remove the cross shaft mounting bushing (part no. E15-6131). Clean and lightly grease with Mystik JT-6 grease. Reassemble the bushing, position the collective control shaft in the bracket and insert the bolt. Torque and safety wire the bolt, then pop rivet the bushing to the bracket. 11. Refer to prints E49-2002 and E15-2001. A. Remove the bolt (part no. E00-2516) that holds the rod end to the collective actuator fork. B. Remove the rod end spacer (part no. E49-1410) and spring bracket (part no. E49-1470). Relax spring tension. C. Remove bolt (part no. E00-2514) from the “G” control arm. Remove the collective control rod (part no. E49-1400) from the helicopter. D. Measure and remove the old rod ends from the collective control rod, counting the number of turns it takes to remove them. E. Reinstall the new rod ends using the same number of turns as in step D, then confirm this position by measurement. F. Reconnect the lower rod end first and torque the bolt. G. Inspect the upper bolt (part no. E00-2516) then reassemble the spring bracket and rod end spacer and align the hole in the rod end to the hole in the actuator fork. H. Pull the spring assembly and insert the bolt. Reinstall the remaining rod end spacer and torque the bolt. I. Reconfirm collective pitch setting by reviewing collective rigging procedures in the Construction Manual. J. Make sure rod end lock nuts are firmly in place. 12. Remove bolt (part no. E00-2306). Remove “B” control arm (part no. E15-5110). Remove washer (part no. E00-4600) and slide pilot throttle shaft (part no. E15-3150) out toward the front of the helicopter. Lightly grease the throttle shaft where the nylon bushing makes contact on the shaft. Reassemble by inserting the throttle shaft through the bushing. Replace the washer and “B” control arm in their respective positions. Reinstall the bolt in the control arm casting and torque. 13. Remove bolt (part no. E00-2306). Remove both “B” control arm castings (part no. E15-5110), marking their position. Remove washer (part no. E00-4600) and slide the transfer shaft (part no. E15-3170) out toward the front of the helicopter. Lightly grease the transfer shaft where the nylon makes contact on the shaft. Reassemble by inserting the transfer shaft back through the bushing the washer and both “B” control arm castings in their respective positions. Insert bolts back through the castings and torque. RotorWay International Exec 162F Maintenance Manual 14. Removal of the throttle grip is easily done by placing an air hose nozzle into the hole on the front of the rubber grip and blowing air into the grip at a high velocity. The grip will expand and can be pulled off. Note: Do not cut off any length of the rubber grip. The part of the grip that extends past the throttle and onto the non-rotating part of the collective stick will help act as a friction lock for the throttle. Removal of the throttle shaft is done by removing the bolt (part no. E00- 2306) and the “B” control arm castings (part no. E15-5110). Slide the throttle shaft completely out of the pilot collective stick. Place a small amount of grease on the throttle shaft (part no. E15-3150) and also on the plastic bushings. Re- install the throttle shaft back in the collective stick and rotate several times until the throttle moves freely. Finish assembly. 15. Remove bolts (part no. E00-2407). Measure center of rod ends on Throttle Connector (part no. E15-3160). Loosen lock nuts and count the number of turns to remove the rod ends(part no E15-1150). Install new rod ends using the same number of turns and check center line measurement. Confirm throttle settings by referring back to the Construction Manual. 19 RotorWay International Exec 162F Maintenance Manual 20 RotorWay International Exec 162F Maintenance Manual Section 7: Oil System The oil sump/heat exchanger is a combined sump tank and oil cooler. Oil is drawn from the sump tank into the oil pump. From the oil pump it circulates through the oil filter, then through the engine. It then drains back into the sump tank and flows over the heat exchanger, where it is cooled by circulating engine coolant. A dipstick is attached to the oil filler cap as a means of easily checking the oil level. Engine oil and oil filter should be changed every 25 hours. Refer to the engine manual for these procedures. Reference prints: E13-2000, E30-2000, E37-2000 SERVICE NOTES: 1. CAUTION: Do not overfill the oil sump. If too much oil is added, the sump must be drained and then re-filled to the proper level. If any oil is spilled, it must be cleaned up before flight. 2. Rubber hoses used in the oil system should normally be replaced at 500 hours, the specified number of years, or on condition, whichever comes first. Shelf life, or time before entering service, is not included if the hoses have not been exposed to the environment and have not been affected by aging. 3. NOTE: THE STEEL BRAIDING ON THE OIL HOSES IS EXTREMELY ABRASIVE. THE HOSES MUST BE POSITIONED SO THAT THEY DO NOT CONTACT OR RUB ON ANYTHING ELSE. CAUTION: Teflon lined steel braided hoses have a tendency to “set” after being exposed to heat and pressure. Attempting to change the curvature of a hose after it has set may cause the lining to crack. INSPECTION CHART PART NO. E28-7150 Oil Sump/Heat Exchanger 100 HR OC 7-1 E28-1192 Valve Cover Drain Hose 100 HR 500 HR/OC or 5 yrs 7-2 E28-1230 Main Oil Drain Hose 100 HR 500 HR/OC or 3 yrs 7-2 E28-1110 Oil Filter 25 HR 25 HR/OC E28-6112 Hose Assembly 100 HR 2000 HR/OC 7-3 E28-6122 Hose Assembly 100 HR 2000 HR/OC 7-3 E28-6142 Hose Assembly 100 HR 2000 HR/OC 7-3 DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. 21 Rev. 2 10/01 RotorWay International Exec 162F Maintenance Manual 22 RotorWay International Exec 162F Maintenance Manual Section 8: Cooling System The RI 162F power plant is a liquid cooled engine. The water pump circulates coolant from the engine through the radiator. A fan is located over the closed radiator system to force cooler outside air across the radiator for effective cooling. Utilization of a liquid cooled system (as opposed to air cooled) allows the operating temperature of the power plant to be maintained at a constant level, providing consistent horsepower and power plant longevity. Reference prints: E30-2000, E31-2000, E37-2000 NOTE: Rubber hoses used in the cooling system should normally be replaced at 250 hours, 5 years, or on condition, whichever comes first. Shelf life, or time before entering service, is not included if the hoses have not been exposed to the environment and have not been affected by aging. The Water pump/alternator belt should normally be replaced at 500 hours, or at 5 years, or on condition, whichever comes first. Shelf life, or time before entering service, is not included if the belt has not been exposed to the environment and has not been affected by aging. Conditional replacement includes damage resulting from excessive slipping, oil absorption, cracking, glazing, abnormal wear, or any other damage. SERVICE NOTES: 1. IT IS EXTREMELY IMPORTANT to follow the cooling system bleeding procedures outlined in the Engine Manual, and to use ONLY the recommended type of coolant. NEVER use tap water or well water in the cooling system. Failure to follow these guidelines could result in overheating and corrosion problems that may severely damage the engine and cooling system. To clean the outer surfaces of the radiator, spray it with a mild soapy water solution using soft to medium pressure. A hard stream of water may damage the fins. 2. If the helicopter is stored for a long period of time without operation, place a small amount of oil (#10W non-detergent) on the water pump shaft seal. For replacement of the water pump, refer to the Construction Manual and prints E30- 2000 and E31-2000. For replacement of the water pump seal and bearings, follow these procedures: A. Remove the water pump. B. Remove the water pump pulley (part no. E29-5150). Deburr the bolt hole as necessary. C. Remove the impeller housing by removing the 7 bolts on top of the water pump body. INSPECTION CHART PART NO. E30-1161 Radiator 100 HR 2000 HR/OC 8-1 E34-1180 Radiator Cap 100 HR 500 HR/OC or 5 yrs E34-1300 Hose 50 HR 250 HR/OC or 5 yrs E34-1310 Hose 50 HR 250 HR/OC or 5 yrs E34-1320 Hose 50 HR 250 HR/OC or 5 yrs E34-1330 Hose 50 HR 250 HR/OC or 5 yrs E34-1340 Hose 50 HR 250 HR/OC or 5 yrs E34-1350 Hose 50 HR 250 HR/OC or 5 yrs E34-1360 Hose 50 HR 250 HR/OC or 5 yrs E34-1370 Hose 50 HR 250 HR/OC or 5 yrs E29-1001 Water Pump Assembly 100 HR 2000 HR/OC 8-2 E29-5150 Water Pump Pulley 100 HR 2000 HR/OC E29-1131 Water Pump/Alternator Belt 100 HR 500 HR/OC or 5 yrs E34-5000 Thermostat 250 HR 250 HR/OC or 5 yrs 8-3 DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. 23 Rev. 1 7/98 RotorWay International Exec 162F Maintenance Manual 24 D. Place the pulley end of the shaft in a soft jaw vise. Using a belt wrench or appropriate tool, turn the impeller counter clockwise to remove it from the shaft. BEFORE REMOVING THE IMPELLER, NOTE HOW THE SEAL IS INSTALLED SO THAT THE REPLACEMENT CAN BE REINSTALLED IN AN IDENTICAL MANNER. Be careful not to damage the impeller or shaft. (A bolt may be inserted into the pulley bolt hole of the shaft to help keep the shaft from rotating.) E. Determine if the bearings need replacement by checking the smoothness of operation and the side-end play. Also examine the condition of the shaft itself checking for excessive corrosion or other damage. The shaft and bearings are an assembly and are replaced as such. If you determine the shaft assembly to be bad, it must be replaced using water pump shaft and bearing, part no. E29-2100. Before removing the shaft, measure the distance from the “face” of the water pump body to the end of the shaft where the impeller “bottoms” when installed. Record this number for use when installing the replacement shaft assembly. Proceed to step F below if the shaft assembly is to be replaced. If the shaft assembly appears to be in good condition, proceed to step H. F. Place the water pump body in an oven and heat to 250-275 degrees F. CAUTION: DO NOT EXCEED 300 DEGREES F. Remove the water pump body and place it on a surface where the shaft assembly can be pressed out of the casting. Do not use excessive force as it could damage or crack the aluminum casting. (The seal will be pressed out with the shaft assembly.) G. Install the new shaft assembly by first cleaning the water pump body thoroughly. Pre-coat the bearing O.D. and the body I.D. with a light film of Anti-seize. The shaft must be reinstalled by using light pressure ONLY. You will need to fabricate a bushing which allows you to press ONLY on the outer race of the bearing. Do not install by pressing on the shaft itself. Press the shaft assembly in until the height dimension recorded in step F is matched. Proceed to step I. H. Using fine emery cloth or equivalent, sand and deburr the shaft eliminating any corrosion and burrs. Hold the water pump body in a vise and carefully tap out the seal assembly using a punch and hammer. (Be careful not to damage the shaft or water pump body.) I. Before installing the new seal (part no. E29-1150), thoroughly clean the shaft and water pump body. Put a light coat of silicone on the seal surface which will contact the body. Install the seal until the outer flange of the seal bottoms and sets flat. Wipe off excess silicone. J. The shaft, seat counter bore, and rubber members of the seat should be lubricated with a light oil or grease. Check seal surfaces to be sure they are free of any dirt or grit. CAUTION: Do not damage seal contact surfaces. K. Carefully position and align the two mating seal pieces. L. Fill the threads of the impeller with silicone. Screw the impeller on clockwise until tight; check for proper alignment of the seal during this process. It must remain centered on the shaft as the impeller is installed. Using a belt wrench, tighten the impeller and wipe off any excess silicone. (Be careful not to damage or scratch the impeller.) M. Place a new gasket (part no. E29-1140) on the body and install the impeller housing using four bolts only. Fabricate a shim by cutting and bending a strip of shim stock to measure the clearance between the impeller and impeller housing. This clearance should be .015" to .025". If the clearance is out of tolerance, special thickness gaskets are available to achieve the proper clearance. Call a factory service representative for assistance. NOTE: Have current gasket thickness and the assembled impeller clearance measurements at hand when you call. N. Prior to installing the remaining three bolts, apply a coating of silicone to the threads, then install and torque to 120 in. lbs. Remove the four bolts initially installed for taking the clearance measurement and reinstall them using the same procedure as used on the last three bolts. O. Install the water pump pulley and tighten the bolt. P. Install the water pump assembly. Refer to the Construction Manual for installation details. Q. Install water pump/alternator belt. 3. Replace the thermostat, engine coolant, and hose clamps when changing the hoses. CAUTION: Use ONLY a RotorWay supplied thermostat for replacement. The correct type of thermostat was determined after many hours of testing at the factory. Use of the wrong thermostat could damage the engine and cooling system. RotorWay International Exec 162F Maintenance Manual 25 Rev. 2 6/04 Section 9: Engine and Exhaust System INSPECTION CHART PART NO. E24-9710 Exhaust Gasket 100 HR 500 HR/OC 9-1 E24-9840 Heat Wrap 100 HR 2000 HR/OC E24-9011 Muffler/Tailpipe 100 HR 2000 HR/OC E24-9001 Header Weldment 100 HR 2000 HR/OC E24-1251 Spring, Exhaust Knuckle 100 HR 1000 HR/OC E24-9831 Heat Shield 100 HR 2000 HR E27-1160 Rod End 100 HR 1000 HR/OC E27-1240 Rubber Insert 100 HR 2000 HR/OC or 3 yrs E27-9000 Torque Link Weldment 100 HR 2000 HR/OC 9-2 A24-162F R.I. 162F Engine 25 HR E24-9950 Spark Plug Wires 100 HR 500 HR E24-9948 Spk.Plug Wire Separator 100 HR 500 HR E24-9740 Spark Plug 50 HR 100 HR E24-7560 Air Filter W/Clamp 25 HR OC A24-1601 Main Drive Pulley Assembly 50 HR 1000 HR 9-3 ACIS Components (Optional) E38-3000 Supercharger Assembly 100 HR OC E38-5010 Stepper Motor 100 HR OC E38-6010 Air Filter 25 HR OC E38-6300 Mounting Bracket Weldment 100 HR 2000 HR/OC E38-6420 Oil Drain Hose 100 HR 500 HR/OC or 5 yrs 9-4 E38-6430 Oil Drain Hose 100 HR 500 HR/OC or 5 yrs 9-4 E38-6600 ACIS Oil Cooler 100 HR 2000 HR/OC E38-6610 Hose Assembly, Engine to Oil Cooler 100 HR 2000 HR/OC 9-5 E38-6620 Hose Assembly, Oil Cooler to Supercharger 100 HR 2000 HR/OC 9-5 E38-6640 Belt 100 HR 500 HR/OC or 5 yrs 9-6 DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. The RI 162F Engine has been designed specifically for the RotorWay Helicopter. RotorWay International manufactures the entire engine. Refer to the Engine Manual for further information. Reference prints: E25-2000, E27-2000 SERVICE NOTES: 1. Check around exhaust gasket for leaks when engine is idling. Failure to replace a leaky gasket can result in water hose failure and other engine related items. Remove the header flange bolts (part no. E00-2532) and hold the header flange up high enough to slip a new gasket in place. Reinstall and re-torque the bolts. WARNING: All four gaskets should be replaced at the first hint of flange leakage. Any type of exhaust system leak may allow carbon monoxide fumes to enter the cabin area. Exposure to these fumes can be fatal and any indication of leakage must be corrected before operation is continued. 2. Remove the bolt (part no. E00-2517) that holds the torque link and remove the rod end bolt (part no. E00-2513). Remove the torque link assembly and inspect for cracks. If replacing rubber insert (part no. E27-1240), remove the aluminum insert (part no. E27-6160). Remove old rubber and insert new rubber around the aluminum insert and press it back into torque link. Reinstall the torque link and tighten and torque the bolts. Verify for correct engine clearance on the pilot side near the valve cover oil drain fitting. 3. Check engine pulley for anodizing wear. (See Engine Manual for greasing and replacement information.) RotorWay International Exec 162F Maintenance Manual 26 Rev. 1 12/99 4. The rubber oil drain hoses should normally be replaced at 500 hours, five years, or on condition, whichever comes first. Shelf life, or time before entering service, is not included if the hoses have not been exposed to the environment and have not been affected by aging. 5. NOTE: THE STEEL BRAIDING ON THE OIL HOSES IS EXTREMELY ABRASIVE. THE HOSES MUST BE POSITIONED SO THAT THEY DO NOT CONTACT OR RUB ON ANYTHING ELSE. CAUTION: Teflon lined steel braided hoses have a tendency to “set” after being exposed to heat and pressure. Attempting to change the curvature of a hose after it has set may cause the lining to crack. 6. The supercharger belt should normally be replaced at 500 hours, or at 5 years, or on condition, whichever comes first. Shelf life, or time before entering service, is not included if the belt has not been exposed to the environment and has not been affected by aging. Conditional replacement includes damage resulting from excessive slipping, oil absorption, cracking, glazing, abnormal wear, or any other damage. RotorWay International Exec 162F Maintenance Manual Section 10: Drive Train The drive train is a series of reduction pulleys and sprockets that transmit power from the engine to the main rotor system. No transmissions, gear boxes or drive shafts are used. The system is simple to monitor and maintain. Reference prints: E23-2000, E27-2000, E33-2000, E49-2001 PART NO. Primary E49-6172 Main Sprocket 100 HR 1000 HR/OC 10-1 E49-7010 Sprocket Hub 100 HR 1000 HR/OC 10-1A E00-2608 AN176H (3/8 x 3-1/8) Bolt 500 HR 2000 HR Torque E00-2450 AN4H12 (1/4 x 1-1/4) Bolt 100 HR 500 HR Torque E00-3410 Thin Locknut 100 HR 500 HR Torque E00-9028 Hose Clamp 500 HR 2000 HR E24-5110 Upper Engine Mount Clevis 500 HR 2000 HR/OC E24-5100 Upper Engine Mount Cup 500 HR 2000 HR/OC Secondary E23-1002 Secondary Pulley Assembly 100 HR 1000 HR/OC 10-2 E23-5001 Upper Bearing Assembly 50 HR 500 HR/OC 10-2A E23-6125 Secondary Shaft 100 HR 500 HR/OC 10-2 E23-2552 Lower Bearing 100 HR 100 HR/OC 10-3 E23-1210 Main Drive Belts 50 HR 500 HR/OC or 5 yrs 10-4 E23-7141 High Temp Fan 100 HR 2000 HR/OC 10-5 E23-1170 Snap Ring 500 HR 2000 HR E23-3001 Fan Pulley Assembly 500 HR 2000 HR/OC 10-6 E23-1221 Fan Pulley Bearing 100 HR 100 HR/OC 10-2B, 10-7 E23-6191 Retainer Plate 1000 HR 2000 HR Oil Bath E33-7101 Top Rear Cover 100 HR OC E33-7121 Lower Oil Bath Pan 100 HR OC E33-7111 Top Front Cover 100 HR OC E33-1170 Rear Oil Seal Assembly 100 HR 500 HR/OC 10-8 E33-1140 Tension Spring 100 HR 2000 HR E33-3000 Rain Shield 100 HR 2000 HR Chain E49-1290 Drive Chain W/Link 25 HR 100 HR/OC 10-9 Clutch Idler Assembly E27-6100 Idler Pulley Assembly 100 HR 2000 HR/OC 10-10 E27-1231 Idler Pulley Bearing 100 HR 500 HR/OC 10-10 E27-1160 Rod End 100 HR 2000 HR/OC E27-1210 Idler Spring 100 HR 1000 HR Grease E27-2160 5/16 Rod End 100 HR 2000 HR E27-9020 Clutch Tube Weldment 100 HR 2000 HR/OC 10-11 E27-9010 Pulley Arm Weldment 100 HR 2000 HR 10-12 E27-5100 Clutch Arm Casting 100 HR 2000 HR/OC E00-2522 AN5-30A (5/16 x 3) Bolt 100 HR 2000 HR DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. 27 Rev. 6 3/03 INSPECTION CHART RotorWay International Exec 162F Maintenance Manual SERVICE NOTES: 1. Inspect the main drive sprocket for any noticeable wear around the teeth. First indication of wear will be an abnormal amount of aluminum flakes and dust in the oil bath and oil lubrication. Contact the factory for further inspection and instructions. A. Check sprocket hub for backlash against the main drive shaft. This can be done by grabbing the main rotor shaft and applying pressure against the standard rotation of the rotor system. Monitor the relationship of the main rotor shaft to the sprocket hub for any movement. If any movement is apparent, contact the factory. 2. The secondary unit comes as a complete assembly and should not be tampered with or opened at any time. A visual inspection and a lock up inspection of the overrunning clutch should be done during the pre-flight inspection. Any other adjustments or work performed must be done by the factory service center at RotorWay, with the exception of the following: A. The upper bearing assembly (part no. E23-5001) should have 1 shot of Mystik JT-6 grease every 50 hours. B. At the 100 hour inspection intervals, inspect the lower secondary shaft. This requires removal of the fan pulley, tail rotor drive pulley and lower mount bearing from the secondary shaft. Both the fan pulley bearing and the lower mount bearing should have been Loctited to the shaft during construction. A gear puller and heat will be needed to remove these bearings. Excessive heat should be avoided, which may damage the shaft or other components (the shaft can be damaged if shaft temperatures exceed 400 degrees Fahrenheit). Bearings should not be reused on reassembly. The shaft should be visually inspected for surface imperfections and also by using a dye penetrant, looking for surface cracks. Recommended penetrant inspection kits are Met-L-Check Penetrant Kit or Magnaflux Spotcheck Test Kit, available from suppliers such as Aircraft Spruce. Either kit will last for many years. Your local FBO may also be able to supply the kit or inspect the shaft. 3. The lower bearing, part no. E23-2552, is removed at 100 hour intervals for lower secondary shaft inspection. The bearing must be replaced at 100 hours; do not re-use the old bearing. See Service Note 10-2B above. 4. Replace the main drive belts at 500 hours of operation, or at 5 years, or on condition, whichever comes first. Shelf life, or time before entering service, is not included if the belts have not been exposed to the environment and have not been affected by aging. Conditional replacement includes damage resulting from excessive slipping, oil absorption, cracking, glazing, abnormal wear, or any other damage. The main drive belts are replaced by following the procedures listed below. Pay close attention because you will follow the reverse procedures for reassembly. See also Service Note 10-2B above. A. Clean the new belts with a clean rag lightly saturated with acetone. B. Cut old belts off with aviation shears or a sharp knife. Be careful not to damage any of the parts. C. Remove the radiator assembly (refer to print E30-2000 and E37-2000). Remove the radiator hoses from the radiator. Plug all water openings. Place the assembly out of the way until reinstallation. D. Index the fan to the fan pulley assembly and remove the fan from the pulley. Remove the fan pulley assembly from the shaft by loosening the set screws, removing the snap ring and lowering the pulley. The bearing was installed with Loctite; use a puller and if necessary apply heat to the bearing to release it from the shaft. CAUTION: Too much heat can damage the shaft or other components. See Service Note 10-6 for bearing replacement. Remove any burrs on the shaft caused by the set screws, then remove the tail rotor drive pulley. E. Remove the two bolts that hold the lower bearing flange to the square drive tube. Then remove the two bolts that hold the lower bearing flanges together so you can lower the bottom flange, and move it from the square drive tube. F. Disconnect the torque link. Loosen the belt tension by backing out the all thread adjustment bolt (part no. E00- 2525) on the upper engine mount clevis. Remove bolts (part no. E00-2524) and lower the upper engine mount cup (part no. E24-5100) into the upper engine pulley. G. Remove bolts (part no. E00-2531 and E00-2416). Remove the upper engine mount clevis. H. Take one of the four belts and slip the belt between the secondary unit and the square drive frame tube. Pull the belt forward, up and over the pulley. CAUTION: Do not damage the belts. Repeat this procedure with the remaining three belts. Align all belts in the correct order on both the engine and secondary unit pulleys. I. Reassemble all parts by following the above procedure in reverse. Follow the belt tensioning procedures shown in the Construction Manual. 28 Rev. 5 6/04 RotorWay International Exec 162F Maintenance Manual 29 Rev. 2 3/03 5. Check the high temp fan for stress cracks on blades. Do not confuse stress cracks with excess resin cracks. Stress cracks will penetrate the fiberglass and resin cracks will be on the surface only. 6. Check pulley for wear of anodizing and for chip or sand erosion. For bearing replacement do the following: A. Remove the fan pulley assembly by loosening the set screws, removing the snap ring and lowering the pulley. It may be necessary to use a puller, as the pulley was originally assembled using Loctite. If necessary, use a file or fine sandpaper to remove the burrs on the shaft from the set screws. B. Remove snap rings on both sides of the pulley bearing. C. Heat the pulley in oven at 250 to 275 degrees F. CAUTION: Do not exceed 300 degrees. D. Note which end of the bearing has the set screws, so that the new bearing will be installed in the same position. Lightly press out the old bearing with a press or vise. E. Clean the pulley inner surface with acetone and then clean the new bearing. F. Again reheat the pulley to 250-275 degrees F. G. Insert snap ring into the pulley groove and make sure it is seated. H. Place the pulley on a flat surface and apply a thin coat of Loctite #609 to the inner surface of the pulley and the outer surface of the bearing. I. With the bearing in the correct position, lightly press the bearing into the pulley until the bearing contacts and sits against the snap ring. CAUTION: If a press is required, make sure you press against the outer race of the bearing and not the inner race. J. Replace the second snap ring in the pulley and let air cool. NOTE: Use Loctite upon final assembly of this part to the secondary shaft assembly. 7. The fan pulley bearing, part no. E23-1221, is removed at 100 hour intervals for lower secondary shaft inspection. The bearing must be replaced at 100 hours; do not re-use the old bearing. See Service Note 10-2B and 10-6 above. 8. For removal of rear oil seal: A. Remove chain and secondary shaft. B. With heat gun or propane torch, heat surrounding area where glue exists. CAUTION: Use only enough heat to pop the seal out with a screwdriver. C. Clean the lower oil bath pan with acetone and lightly sand any glue or uneven protrusions from the pan. D. Sand mating surface of the seal with 400 grit paper and clean with acetone. CAUTION: Do not touch the rubber seal with sand paper. E. Mix blade glue at the proper ratios and apply to both parts. F. Place a little oil on the rubber seal and shaft. G. Slide the oil seal down (correct side up) pressing down with light finger pressure until the seal seats on the oil bath. Oil seal pressure must be applied evenly. H. Wipe off excess glue with a dry rag. Let the glue cure for 12 hours. 9. Refer to print E49-2001 and chain installation instructions in the Construction Manual. Chain tension should be set to 1/2 inch movement at 10 pounds pull with a spring scale midway between sprockets. Re-check chain tension at every 25 hour inspection. Some stretching of the chain normally occurs after the first 25 to 30 hours of operation. A shim (no more than .025 inch) may be added between the lower mainshaft bearing flange and the airframe tube to achieve the correct chain tension. The shim should be removed upon installation of a new chain. NOTE: Shims should ONLY be added between the lower mainshaft bearing flange and airframe to correct for chain stretching. Initial chain tension is achieved by adding shims at the secondary shaft bearing mount locations. 10. Refer to Service Note 10-6 for bearing removal procedure. Also refer to the Construction Manual and print E27-2000. 11. Inspect at every 100 hours. Grease at every 500 hours. Remove pop rivets on the end of the clutch spring tube and unbolt the rod end from the clutch arm casting (part no. E27-5100). Remove the clutch tube piston (part no. E27- 6131). Make a visual inspection for wear. Grease the piston and clutch spring tube. Compressing the piston a slight amount, install two pop rivets in the existing rivet holes. Reconnect the clutch arm casting and check for smoothness of operation. 12. Remove the pulley mounting arm bolt (part no. E00-2522). Place a thin film of grease on the bolt and mating surfaces. Reinstall the bolt and tighten it enough to allow the swing arm to pivot. RotorWay International Exec 162F Maintenance Manual 30 RotorWay International Exec 162F Maintenance Manual 31 Rev. 1 1/01 Section 11: Fuel System The RI 162F engine is equipped with RotorWay’s FADEC electronic fuel injection system. In this system, gasoline is delivered to the injectors at a very high pressure (up to 60 PSI). Braided stainless steel hoses and high quality fittings are used throughout the system. Reference prints: E25-2000, E25-2001, E37-2000 SERVICE NOTES: 1. The fuel tank caps are vented. If the vent becomes stuck or plugged, the engine may be starved for fuel and the fuel tanks may partially collapse. Remove the cap and inspect the plastic valve in the underside of the cap. To restore venting, heat a piece of welding rod or wire and push it through the valve. 2. Check routing and security of all hoses. They should be routed so that they curve smoothly without being kinked or sharply bent. The steel braided hoses are EXTREMELY ABRASIVE. When the engine is running, vibrations will cause the braid to wear through whatever it comes in contact with, just like a file. Verify that all braided hoses are positioned so that they do not contact or rub against anything else. Inspect all hoses and fittings for leaks. Run your finger under each connection to verify that fuel is not slowly leaking out. After performing any maintenance that requires hoses or fittings to be uncoupled, perform a pressurized leak check. To do this, tighten all fittings, turn on the fuel pumps and check carefully for leaks. CAUTION: The fuel system operates at a VERY high pressure. When performing this check, wear eye protection and have a fire extinguisher at hand. Check the system regularly in the first few hours of operation. Refer to the Engine Manual for further details. CAUTION: Teflon lined steel braided hoses have a tendency to “set” after being exposed to heat and pressure. Attempting to change the curvature of a hose after it has set may cause the lining to crack. INSPECTION CHART PART NO. Directional Control E25-2101 Fuel Cap 100 HR 2000 HR/OC 11-1 E25-4011 Hose Assembly 100 HR 2000 HR/OC 11-2 E25-4020 Hose Assembly 100 HR 2000 HR/OC 11-2 E25-4030 Hose Assembly 100 HR 2000 HR/OC 11-2 E25-4040 Hose Assembly 100 HR 2000 HR/OC 11-2 E25-4050 Hose Assembly 100 HR 2000 HR/OC 11-2 E25-4061 Hose Assembly 100 HR 2000 HR/OC 11-2 E25-4071 Hose Assembly 100 HR 2000 HR/OC 11-2 E25-4080 Hose Assembly 100 HR 2000 HR/OC 11-2 E25-4110 Hose Assembly 100 HR 2000 HR/OC 11-2 E25-4121 Hose Assembly 100 HR 2000 HR/OC 11-2 E25-4570 Fuel Valve Cable 100 HR 2000 HR/OC E25-4600 Fuel Pump 100 HR 1000 HR/OC E25-4630 Fuel Filter 100 HR 100 HR/OC 11-3 E25-4640 Fuel Pressure Regulator 100 HR 1000 HR/OC E25-4660 Shut-off Valve/Filter 100 HR 2000 HR/OC 11-4 E25-6102 Fuel Tank, Pilot 100 HP 2000 HR/OC E25-6112 Fuel Tank, Passenger 100 HR 2000 HR/OC E25-6130 Fuel Gauge (W/light) 100 HR OC E25-6122 Fuel Gauge Sending Unit 100 HR OC 11-5 DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. RotorWay International Exec 162F Maintenance Manual 3. Replace the fuel filter every 100 hours or OC. Check for fuel contamination by cutting the used filter in half and inspecting the inlet side of the filter element. If the element is contaminated, inspect and clean the pre-filter in the fuel shut-off valve/filter assembly (see note 4 below). When installing the new filter, be sure to replace the two crush washers (12MM part no. E25-4740, 14MM part no. E25-4750) and note proper flow direction. 4. After the first 25 hours of operation, check the pre-filter for any particles or debris that may have washed out of the fuel tanks. Clean as necessary. Every 500 hours, disassemble, clean and inspect the fuel shut-off valve/filter assembly. Replace O-rings as necessary. Refer to the Engine Manual for complete procedures. 5. If the needle on the fuel gauge stays above the full mark when the tank is not full, check the following: water in fuel tank, meter not grounded properly, sender wire is touching negative terminal or wiring, center rod of the sender is touching the outside tube, or sender is not calibrated. If the needle stays at empty, check the following: no power to sender, no power to gauge, sender not connected to gauge. If the needle fluctuates, check for loose or corroded wiring connections. 32 RotorWay International Exec 162F Maintenance Manual Section 12: Fan Drive The fan drive system is a series of pulleys and belts providing the proper speed reduction for the fan design. Reference print: E31-2000 SERVICE NOTES: 1. A. Remove the fan assembly from the helicopter. B. Loosen set screws from the locking collar, tap with hammer and punch in the opposite direction from the original set position. C. With a torch or heat gun, lightly heat the bearing so the Loctite will release the bearing from the shaft. D. Clean the shaft and install new bearings (part no. E31-1120) on the shaft in the correct position. Loctite the new bearings to the shaft, allowing time for the Loctite to cure before tightening the lock rings and set screws. E. Reassemble the fan assembly on the helicopter following the procedures in the Construction Manual and print E31-2000. 2. New belts should be cleaned with acetone and properly tensioned following the procedures outlined in the Construction Manual. Replace the fan drive belts at 500 hours of operation, or at 5 years, or on condition, whichever comes first. Shelf life, or time before entering service, is not included if the belts have not been exposed to the environment and have not been affected by aging. Conditional replacement includes damage resulting from excessive slipping, oil absorption, cracking, glazing, abnormal wear, or any other damage. INSPECTION CHART PART NO. E31-1120 Bearings 100 HR 500 HR/OC 12-1 E31-1130 Belt (Upper) 100 HR 500 HR/OC or 5 yrs 12-2 E31-1141 Belt (Lower) 100 HR 500 HR/OC or 5 yrs 12-2 E31-5100 Pulley (Upper) 100 HR 2000 HR/OC E31-5120 Pulley (Lower) 100 HR 2000 HR/OC E31-6100 Shaft 500 HR 2000 HR/OC DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. 33 Rev. 1 7/98 RotorWay International Exec 162F Maintenance Manual 34 RotorWay International Exec 162F Maintenance Manual 35 Section 13: Main Rotor Blades The main rotor blades are one of the key components of the helicopter. Proper maintenance and care of the main rotor blades will increase their longevity. The main rotor blades are made from aluminum alloys, and are constructed from 3 pieces: the main spar (C section) and an upper and lower aluminum skin. The spar is an aluminum alloy extrusion with a series of various heat treatments. The skins are of T6 aluminum and are bonded to the spar with a high strength adhesive, then riveted. After construction, the blades are quality inspected and measured at specific intervals. This allows two blades with identical airfoils to be matched and sold as a pair. Reference prints: E20-2000, E49-2000 SERVICE NOTES: 1. Check for blade skin delamination using the tap test hammer. Tap along the rivet line (the seam where the skin is bonded to the spar) the full length of the blade on both the upper and lower skins. You should notice a solid sound resonating from the blade. Tap repeatedly along the seam listening for noticeable sound changes. If the sound changes from a solid to hollow sound, the blade skin may have delaminated from the spar at that location and the factory should be notified. The tap test should be performed once every 25 hours, every three months, or after flying in violent weather conditions. A low rotor RPM on the helicopter can cause a wrinkling of the blade skins to the outboard side of the fiberglass doublers. If these conditions have occurred, contact the factory for further information. Blade fatigue is very difficult for a new and low time pilot to sense. Listed are some symptoms of blade fatigue: A. Change in blade droop (while in its static position) from previous inspection. B. Flight response controls seem sluggish and insensitive. C. During an autorotation flare the blade will develop a shake that will not stop until collective pitch can be reduced. D. Blade tracking seems to keep moving in and out and cannot stabilize. CAUTION: Blade fatigue is a dangerous condition and can result in a serious incident if left undetected. Newly painted blades can develop paint blisters or have blade paint erosion due to the type of conditions the helicopter is flown in. This can cause out of tracking conditions or a vibration in the rotor system. Keeping the leading edge smooth can be done by wet sanding the edge of the blade with 400 grit wet and dry sand paper and feathering the paint to a smooth edge. Tracking and vibration should return to a normal condition. 2. It is important to keep this bolt torqued to 65-70 ft. lbs. INSPECTION CHART PART NO. E20-3000 Retention Strap Assembly 25 HR 1500 HR/OC E20-9010 Asymmetrical Rotor Blade 25 HR 1500 HR/OC 13-1 E20-9011 Asymmetrical Rotor Blade 25 HR 1500 HR/OC 13-1 E00-2800 NAS1309-54 (9/16 x 4-1/4) Bolt 100 HR 1000 HR/OC 13-2 E00-3800 AN365-918A (9/16-18) Fiberlock Nut 100 HR 1000 HR/OC 13-3 E20-1400 Elastomeric Thrust Bearing 100 HR OC or 10 yrs 13-4 E20-1401 Elastomeric Thrust Bearing 100 HR OC or 10 yrs 13-4 E20-3170 Tip Weight 25 HR 1500 HR 13-5 E20-6000 Aligner Block Assembly 100 HR 1000 HR/OC 13-6 E20-6180 Pitch Horn Clevis 100 HR 1500 HR E20-6190 Pitch Horns 500 HR 1500 HR E00-2522 AN5-30A (5/16 x 3) Bolt 100 HR 1500 HR Torque E00-2523 AN5-32A (5/16 x 3-1/4) Bolt 100 HR 1500 HR Torque E20-1220 Aligner Block Bearings 100 HR 200 HR/OC 13-6 DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. RotorWay International Exec 162F Maintenance Manual 36 3. After the nut has been removed four or more times, it should be replaced with a new nut (part no. E00-3800). Torque to specs. 4. The elastomeric bearings (part no. E20-1400 and 1401) are comprised of thin layers of rubber and metal sandwiched together. Inspect for signs of any delamination or separation. These bearings must be kept dry and free from grease, oil and solvents. Many factors determine how long the bearings will last, such as age, hours used, climate, etc. As the bearings deteriorate and the rubber loses it’s elasticity, the controls will lose smoothness, require more pressure to move, and may not completely return to their original position. If any question exists as to the condition of the bearings, the factory should be contacted. 5. Check tip weight bolts (part no. E00-2404) for tightness every 25 hours. It is not necessary to remove the end plug from the blade unless the bolts become loose. 6. A simple tool can be made to add grease to the aligner block bearings (part number E20-1220) as shown in the drawing below. This tool will enable you to grease the bearings with the blades removed and the aligner blocks in place on the blade straps. Make the tool from steel or aluminum. Using this tool at the 100 hour maintenance interval will allow you to increase the recommended change out time of the bearing from 100 hours to 200 hours or on condition. Insert the tool into the bearing. Pump the grease until it visibly comes out of the bearing, purging out the old grease. Wipe away the excess grease, then rotate the inner race of the bearing (using a deep socket on the grease fitting) to spread the new grease and to make sure the bearing turns freely. Removal of aligner block bearing (part no. E20-1220) is as follows: A. Remove the blades from the helicopter. B. Remove the aligner block bolts (part no. E00-2523). Loosen the adjustment bolt (part no. E00-2417) two to three turns counter clockwise and remove the aligner block assembly. C. Place in oven and heat to 225-250 degrees F. CAUTION: Do not exceed 300 degrees F. D. Place on a press and press out the bearing with light pressure. Do not back out the adjustment bolt more than 2 or 3 turns because of damage to aluminum block threads. E. Clean bearing hole in the aligner block with acetone. F. Clean the new bearing (part no. E20-1220) with acetone and prepare to reinstall bearing into aligner block. G. Place a small amount of Loctite on the outer race of the bearing with a Q-tip. Press the bearing into the block with light pressure, leaving the bearing protruding .050" from the face of the block. (Check for all thread bolt clearance of bearing.) H. Let the block assembly air cool. Then reinstall the block on the blade according to the directions in the Construction Manual. ADDITIONAL NOTES: Check the lead-lag pin on the root end of the main rotor blades. If this pin is deformed and shows signs of the lead-lag bolts being over torqued, contact the factory for further information. RotorWay International Exec 162F Maintenance Manual 37 Section 14: Electrical System The Electrical System of the EXEC 162F requires little maintenance if inspected properly. The three most common problems are corrosion, vibration of connectors, and chafing of wires. Reference prints: E31-2000, E35-2000, E35-2001 SERVICE NOTES: 1. Replace the battery when it will not take or hold a charge. Check acid level periodically to insure battery plates are covered. Keep terminal posts clean and free from corrosion and dirt. 2. The digital display monitor, engine control units (ECUs), ignition modules, and man/baro pressure sensors are NOT user serviceable. Refer to the Engine Manual for information on these parts. If these components malfunction, contact the factory. 3. Inspect the FADEC wiring harness for security and corrosion. Inspect all wires and plugs. Refer to the Engine manual for further information. If a problem with this wiring harness is suspected, contact a factory service representative before attempting to make repairs. 4. The fuse holders on the overhead switch panel and throughout the wiring harness can develop corrosion, resulting in poor connections. Remove the fuse from the holder and make a visual inspection. If corrosion is found, clean or replace the fuse holder and fuse. 5. Check the toggle switch by first disconnecting the power leads from the battery terminals. Then actuate the toggle switch on and off. The switch should have a good solid snap action in both directions. If in doubt, check the switch with a an ohm meter. 6. Check the top and bottom of the battery and ground cable eyelets for corrosion and clean as necessary. Poor contact will cause excessive heat buildup and could result in hard starting. INSPECTION CHART PART NO. E24-9760 12 Volt Battery 100 HR OC 14-1 E35-4000 Digital Display Monitor 100 HR 2000 HR/OC 14-2 E35-4011 Engine Control Unit (ECU) 100 HR 2000 HR/OC 14-2 E35-4030 Ignition Module 100 HR 2000 HR/OC 14-2 E35-4060 Man/Baro Pressure Sensor 100 HR 2000 HR/OC 14-2 E35-4080 9 Pin Cable 100 HR 2000 HR/OC E35-8231 Fuse Holder 100 HR 2000 HR/OC 14-4 E35-8240 Toggle Switch 100 HR 2000 HR/OC 14-5 E35-8321 Fuses 100 HR 2000 HR/OC E35-8410 Battery Terminal Eyelet 100 HR 2000 HR/OC 14-6 E35-8520 Starter Relay 100 HR 2000 HR/OC 14-7 E35-8540 Push Button Switch 100 HR 2000 HR/OC E35-8596 LED Indicator Light 100 HR 2000 HR/OC E35-9002 Airframe Wiring Harness 100 HR 2000 HR/OC 14-8 E35-9013 Overhead Wiring Harness 100 HR 2000 HR/OC 14-8 E35-9022 Instrument Wiring Harness 100 HR 2000 HR/OC 14-8 E35-9031 FADEC Wiring Harness 100 HR 2000 HR/OC 14-3 E42-2021 Voltage Regulator 100 HR 2000 HR/OC 14-9 E42-1002 Alternator Assembly 100 HR 2000 HR/OC 14-10 DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. RotorWay International Exec 162F Maintenance Manual 38 7. Check spade connections on the starter relay for corrosion and poor connections. Check relay by unplugging the spade terminal that goes to the starter solenoid and activate the starter button. The relay should have a small clicking action (be sure the battery is connected and the key switch is on). If the relay chatters, check the voltage going to the relay. Voltage should be a strong 12 volts from the battery. Then check to see if the relay is properly grounded. If a problem still exists, replace the starter relay. 8. Inspect all wiring harnesses and cable assemblies to make sure there are no loose wires or connectors. Check that all wires are secured away from moving parts, and that no wires are chafing against other components. Plugs, pins, wires and other components may be replaced individually if necessary. 9. To check the voltage regulator for normal operation, monitor the voltage meter during a normal run-up of the helicopter. If the regulator is working, a voltage jump will be noticed on the meter during the run-up procedure. If the meter does not show a positive voltage charge, check the following: A. Alternator switch is on. B. Volt meter is working. C. Water pump/alternator belt is on and turning. D. Fuse is not blown on output side or field side. If all of the procedures above are determined to be in normal operating condition, replace the voltage regulator. If a problem still continues, it is possible the alternator is defective. See Note 14-10. 10. Check the alternator output with the helicopter in full operating condition and with the alternator switch on. The output should be 13.5 to 15.0 volts, with a 16 volt maximum. If proper output cannot be achieved, the alternator will need to be removed and serviced or repaired. NOTE: This alternator is reworked at the factory to achieve our specifications and requirements. Replace only with a RotorWay supplied part. RotorWay International Exec 162F Maintenance Manual 39 Rev. 3 6/04 Section 15: Instrumentation Instrumentation on the EXEC 162F is normally maintenance free. It is, however, extremely important to keep it in perfect operating condition. The instrumentation provides the pilot continuous information on all the helicopter systems conditions. NOTE: If a transponder is used, a static air port must be incorporated into the system. (Check transponder installation information.) SERVICE NOTES: 1. To check the water temp or oil temp sender: A. Make certain all connections are clean and secure. B. Disconnect the sender leads from the gauge, cool or heat the probe to a known temperature then check the resistance. See the chart below. 32 deg f = 9800 ohms 70 deg f = 3570 ohms 100 deg f = 740 ohms 212 deg f = 212 ohms C. To test the operation of the gauge, disconnect the sender leads from the gauge and substitute the sender with a resistor of the appropriate value that you wish to check from the list above (i.e. 615 ohms is 150 deg f.) D. If sender lead goes to ground, meter should peg full scale. E. If sender lead is open (broken) or sender is open internally meter should peg hard to the left. Slight needle movement to the left is normal when the temperature is below the starting point of the gauge. INSPECTION CHART PART NO. E36-1100 Hour Meter 100 HR OC E36-1120 Water Temperature Gauge 100 HR OC 15-1 E36-1160 Oil Temperature Gauge 100 HR OC 15-1 E36-3110 Oil Pressure Gauge 100 HR OC E36-3120 Oil Pressure Sender 100 HR OC E36-1220 Volt Meter 100 HR OC E36-3002 Dual Engine/Rotor Tach 100 HR OC E36-4010 Altimeter 100 HR OC E36-4020 Vertical Speed Indicator 100 HR OC E36-4030 Air Speed Indicator 100 HR OC E36-4040 Compass 100 HR OC E36-4050 Manifold Pressure Gauge 100 HR OC E36-4111 Full Range Tach 100 HR OC E36-3050 Fuel Pressure Gauge 100 HR OC E25-4940 Fuel Pressure Sender 100 HR OC E36-1230 Secondary Temp Gauge 100 HR OC E36-1240 Secondary Temp Gauge Sensor 100 HR OC DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R.C.O. RotorWay International Exec 162F Maintenance Manual 40