Rotorway International Exec 90 Maintenance Manual

E11-3131 Landing Gear Skid 500 HR 2000 HR/OC I-4 Reference prints: E10-2000 E13-2000 6 SECTION I: AIRFRAME 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 (part no. E11-3141, refer to print E10-2000) 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 skid pants. 3. Removal of the two rear lower fiberglass panels (part no. E32- 7130 and E32-7140) will allow you access for a visual inspection of the Engine Mount Rubber, part no. E13-3120. 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 various 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 any cracks in the skid tube. Also, inspect the bolts for wear prior to reinstalling the skid back on to the landing gear shoe. 7 SECTION II: TAIL BOOM The main purpose of the tail boom in all conventional helicopters is to provide a source of mounting 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 in the tail boom is aircraft industry standard, grade T-3 aluminum and is .025 thick. The sheet is rolled in a cone shape to provide structural integrity. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E09-**** Tail Boom 100 HR 2000 HR/OC II-1 E09-6131 Horizontal Trim Fins 100 HR 2000 HR/OC * E00-2301 AN3-5A Bolt 100 HR 2000 HR Torque E00-2305 AN3-11A Bolt 100 HR 2000 HR Torque E09-6110 Vertical Trim Fin(Upper 100 HR 2000 HR/OC * E09-6120 Vertical Trim Fin(Lower 100 HR 2000 HR/OC * E09-3252 Vert. Trim Fin Bracket 100 HR 2000 HR II-2 E00-2414 AN4-23A Bolt 100 HR 2000 HR Torque E00-2309 AN3-17A Bolt 100 HR 2000 HR Torque E00-2432 AN4-12A Bolt 50 HR 2000 HR Torque E00-2303 AN3-6A Bolt 50 HR 2000 HR Torque E00-2300 AN3-4A Bolt 50 HR 2000 HR Torque E00-2307 AN3-13A Bolt 50 HR 2000 HR Torque Reference prints: E09-2000 E09-2001 * Rivet Inspection 8 SECTION II: TAIL BOOM SERVICE NOTES: 1. The tail boom is subject to most of its stress under the take off and landing condition. The skin and its associated parts are subject to high frequency vibration 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: Depending on the size and head diameter of the rivet, use the appropriate drill and drill out the head by rotating in an elliptical manner. This procedure will remove the head from the rivet before drilling through the hole to remove the rivet spud. Use a rivet shank or a small punch and knock out the remainder of the rivet spud. 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. 9 SECTION III: BODY The body for the EXEC 90 helicopter consists of several separate panels that when assembled make up a solid egg shape structure which 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. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E32-**** Body 100 HR OC III-1 E32-7210 Eyebrow Window, Pass. 100 HR OC III-2 E32-7220 Eyebrow Window, Pilot 100 HR OC III-2 E32-7231 Windscreen 100 HR OC III-2 E32-1300 Seat Upholstery 100 HR OC III-3 E32-1310 Headliner 100 HR OC III-3 E45-**** Skid Pants 100 HR OC III-4 E32-1281 Flex Hose 100 HR OC * E54-4010 Push/Pull Cable 100 HR OC ** E32-3130 Floor Pan/Instrument Pod 100 HR OC Insp E32-6110 Seat Bulkhead 100 HR OC Insp E32-7100 Tub 100 HR OC Insp E32-7111 Fuselage (Right Front) 100 HR OC Insp E32-7112 Fuselage (Right Rear) 100 HR OC Insp E32-7121 Fuselage (Left Front) 100 HR OC Insp E32-7122 Fuselage (Left Rear) 100 HR OC Insp E32-7130 Fuselage (Lower Right) 100 HR OC Insp E32-7140 Fuselage (Lower Left) 100 HR OC Insp E32-7152 Dog House (Front) 100 HR OC Insp E32-7272 Dog House (Rear) 100 HR OC Insp E32-1110 Cyclic Boot 100 HR OC Insp E32-7160 Bracing Panel 100 HR OC Insp E32-7170 Bracing Panel 100 HR OC Insp E32-7180 Roof Panel 100 HR OC Insp E32-7190 Fresh Air Collector 100 HR OC Insp Reference print: E32-2000 * Tighten hose clamps ** Oil/20w 10 SECTION III: BODY 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, prolonged exposure to gas and oil over long periods of time will eventually weaken that piece. Oil and gas should be wiped off of the panels using a dry cloth which will absorb or remove the petroleum. After removal of all foreign substances, take a cloth moistened with acetone and wipe the part clean from any residue. CAUTION should be used when using 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 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 over spray and oxidation and #9 should be used to preserve and protect the windscreen and to bring up a high gloss. B. Care should be taken so that the windscreen screws are not over tightened. This condition can cause stress cracks that could result in a major crack down or across the windscreen. If a stress crack appears, stop drill with the appropriate size drill bit. 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. Interior and headliner: 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. 11 SECTION IV: TAIL ROTOR DRIVE The tail rotor drive on the EXEC 90 helicopter utilizes a V belt design drive rather than a drive shaft with gear boxes to transmit power to the tail rotor. This design provides a simple effective drive train process with simplified low maintenance. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E18-6130 Idler Pulley Mt.Scissors 250 HR 2000 HR IV-1 E18-1130 Idler Pulley Brg. Assy. 250 HR 250 HR/OC IV-2 E18-2012 Tail Rotor Idler Pulley 100 HR 2000 HR/OC IV-3 E18-1150 Tail Rotor Belt 100 HR 250 HR E18-1160 Tail Rotor Belt 100 HR 250 HR Reference print: E09-2000 12 SECTION IV: TAIL ROTOR DRIVE 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 scissor mount 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 back to 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 another appropriate means to 225-275 degrees F. CAUTION: Do not exceed 300 degrees F or heat treating 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 making sure the correct spacers are in their proper place and torque the bolt. M. Rotate the pulley in its new bearing and check the feel with your fingers for ease of rotation and smoothness. 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. 13 *Rev. 1 12/99 SECTION V: 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. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E17-1260 FS3 PP Bearing 100 HR 250 HR/OC ** V-1 E17-1290 Snap Ring 100 HR 250 HR ** E00-2605 AN176-24A Bolt 100 HR 250 HR/OC ** E17-6125 Carriage Slider Assy. 100 HR 1000 HR/OC ** 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 Assy. 100 HR 500 HR/OC ** V-2 E17-5120 Pitch Actuator Arm Pivot 100 HR 2000 HR ** V-3 E17-1340 Bearing Assy. 100 HR 250 HR/OC Inspect E17-5110 Pitch Horn 100 HR 250 HR E17-1350 Slider Act. Arm Clevis 100 HR 2000 HR E17-6150 Tail Rotor Shaft 100 HR 2000 HR/OC ** E17-1360 Bearing Plt. 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 ** E17-1280 Thrust Bearing Assy. 50 HR 250 HR/OC ** V-4 E17-1270 Alignment Bearing Assy. 50 HR 250 HR/OC ** V-4 Reference prints: E17-2000 E17-2001 ** For replacement details refer to Construction Manual. * 14 SECTION V: TAIL ROTOR SERVICE NOTES: 1. Remove bolt (part no. E00-2605) 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 only enough so that the head of the bolt can be rotated slightly by 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 this 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 and indicate identity on the tail rotor barrel so reassembly will be the same to 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 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 below. 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 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 and spars, refer to the tail rotor balancing procedures in the Construction Manual. 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 actuator arm with bolt and check for security of nut with cotter pins. 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. 15 SECTION VI: CONTROL ASSEMBLIES The Control Assemblies of the EXEC 90 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 its maneuvers. INSPECTION CHART DIRECTIONAL INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E16-6131 Cross Shaft Bushing 1000 HR 2000 HR VI-1 E16-6130 Scissor Mt. Bushing 1000 HR 2000 HR VI-2 E16-1200 3/16" Female Rod End 100 HR 1000 HR/OC VI-3 E16-1130 1/4" Male Rod End 100 HR 1000 HR/OC VI-4 E16-1140 1/4" Female Rod End 100 HR 1000 HR/OC VI-5 E16-1212 Directional Control Cable 100 HR 2000 HR/OC VI-6 Reference prints: E16-2000 E17-2000 INSPECTION CHART CYCLIC INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E14-6131 Cross Shaft Mt. Bushing 1000 HR 2000 HR VI-7 E14-1241 Nylon Bushing 1000 HR 2000 HR VI-8 E14-1150 5/16" Male Rod End 100 HR 2000 HR/OC VI-9 E14-1210 Cyclic Control Cable 100 HR 2000 HR/OC VI-10 E14-1220 Cyclic Control Cable 100 HR 2000 HR/OC VI-11 Reference print: E14-2000 16 INSPECTION CHART COLLECTIVE INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E15-6131 Cross Shaft Mt. Bushing 1000 HR 2000 HR VI-12 E15-1230 5/16" Male Rod End 100 HR 2000 HR/OC VI-13 E15-6130 Collective Rod End Plug 100 HR 2000 HR/OC E49-1400 Collective Control Rod 100 HR 2000 HR/OC Reference print: E15-2000 E49-2002 INSPECTION CHART THROTTLE INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E15-3150 Pilot Throttle Shaft 1000 HR 2000 HR VI-14 E15-3170 Transfer Shaft 1000 HR 2000 HR VI-15 E15-3220 Main Throttle Shaft 1000 HR 2000 HR VI-16 E15-1150 1/4" Male Rod End 100 HR 2000 HR/OC VI-17 E24-7530 Throttle Cable Assy. 100 HR 500 HR/OC Reference print: E15-2000 17 SECTION VI: CONTROL ASSEMBLIES 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. Lift up on the end of the foot pedal cross shaft (part no. E16-3101) just enough to remove the cross shaft bushing. Clean and apply a small amount of grease on the bushing and reassemble. Re-torque the bolt and safety wire. Do 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 frame 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. 3. Remove bolt (part no. E00-2305) and the locking nut and rod end (part no. E16-1200). 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. See note VI-4 above. 6. CAUTION: Under no conditions should any type of lubrication or oil be used on the sliding inner cable. 7. Grease cross shaft pivot bushing. See Construction Manual for detailed procedures. 8. 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. 18 9. 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. 10. CAUTION: Under no conditions should any grease or lubricant be used on the sliding inner cable. 11. See Note VI-10 above. 12. Cut safety wire and remove bolt (part no. E00-2501). Lift 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 bushing, position collective control shaft and insert the bolt. Torque bolt and add safety wire. 13. 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. 14. 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. Reassemble the washer and “B” control arm in their respective positions. Reinstall the bolt in the control arm casting and torque. 19 15. 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. 16. Removal or inspection 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. 17. 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 C/L measurement. Confirm throttle settings by referring back to the Construction Manual. 20 *Rev. 1 12/99 SECTION VII: OIL SYSTEM The powerplant in the EXEC 90 utilizes a dry oil sump. The oil is circulated from the oil sump through the engine, to the oil coolers, through the oil filter, and back into the oil sump. This oil cooler design allows for lower operating oil temperatures providing longer oil and component lifetimes. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E28-7100 Oil Sump Assy. 50 HR OC VII-I E28-1190 Valve Cover Drain Hose 100 HR 500 HR/OC or 5 yrs E28-1230 Main Oil Drain Hose 100 HR 500 HR/OC or 5 yrs E28-1110 Oil Filter 25 HR 25 HR/OC VII-2 E28-6141 Hose 100 HR 500 HR/OC or 5 yrs E28-6111 Hose 100 HR 500 HR/OC or 5 yrs E28-6121 Hose 100 HR 500 HR/OC or 5 yrs E28-6132 Hose 100 HR 500 HR/OC or 5 yrs E28-1150 Oil Cooler Assy. 100 HR 2000 HR/OC VII-3 E36-1200 Oil Pressure Cap. Tube 100 HR 1000 HR/OC or 5 yrs E36-1170 Oil Pressure Gauge 100 HR OC Reference print: E37-2000 NOTE: All hoses are general change out one for one. Refer to Construction Manual. 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. * * * * * * * 21 SECTION VII: OIL SYSTEM SERVICE NOTES: 1. To change oil in sump: A. Run engine to achieve at least 140 degrees F on oil temperature gauge. Shut engine off. B. Remove drain plug and drain oil from sump. C. Replace drain plug and fill sump with recommended type and grade oil (see Engine Manual). Fill sump to 2-5/8" from the bottom of the tank. Helicopter must be on level ground when measuring. 2. To change the oil filter: A. Remove the lower right side body panel. B. Unscrew the oil filter and dispose of it properly. C. Spread a little clean oil around the o-ring on the filter with your finger tip. Fill the filter with oil of the appropriate grade and type. Screw the filter on to the mount. After the rubber gasket makes contact, turn the filter an additional 2/3 turn to insure proper seal. 3. Wash the outside only of the oil cooler assembly with a warm soap and water solution using a low to medium pressure. Rinse out with clean fresh water. If the radiator has oil deposits on or in between the cooling fins, use a degreaser first, then rinse out with clean fresh water. If any of the fins have been bent over or flattened to such a point so that air cannot flow through the coil, straighten the fins to allow proper airflow. 22 *Rev. 1 12/99 SECTION VIII: COOLING SYSTEM The EXEC 90 power plant is a water cooled engine. The water pump circulates coolant from the engine through the radiator system. A fan is located over the closed radiator system to force cooler outside air across the radiators for effective cooling. Utilization of a water 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. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E30-1160 Radiator 100 HR 2000 HR/OC VIII-1 E34-1180 Radiator Cap 100 HR 500 HR/OC or 2 yrs E34-1230 Hose 100 HR 500 HR/OC or 5 yrs E34-1191 Hose 100 HR 500 HR/OC or 5 yrs E34-1200 Hose 100 HR 500 HR/OC or 5 yrs E34-1221 Hose 100 HR 500 HR/OC or 5 yrs E34-1280 Hose 100 HR 500 HR/OC or 5 yrs E34-1150 Hose 100 HR 500 HR/OC or 5 yrs E29-1000 Water Pump 100 HR 1000 HR/OC VIII-2 E29-5100 Pulley 100 HR 2000 HR/OC VIII-3 E29-1130 Belt 100 HR 500 HR/OC Reference print: E37-2000 NOTE: The rubber coolant 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. * * * * * * * 23 SECTION VIII: COOLING SYSTEM SERVICE NOTES: 1. Spray the radiators with mild soapy water solution using soft to medium pressure. A hard stream of water may damage the fins. If radiators are covered with oil or grease, use a mild degreaser which will not harm or have any effect on plastic. Wash off with a mild soapy solution and dry. 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 shaft seal assembly. 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. E29-5100). Deburr the bolt hole as necessary. C. Remove the impeller housing by removing the 7 bolts on top of the water pump body. 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.) 24 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 alternator belt. 25 SECTION IX: ENGINE & EXHAUST SYSTEM The EXEC 90 Engine has been designed specifically for the RotorWay Helicopter. RotorWay International manufactures the entire engine. Refer to the Engine Manual for further information. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E24-9710 Exhaust Gasket 100 HR 500 HR/OC IX-1 E24-7530 Throttle Cable 100 HR 500 HR/OC E24-9840 Heat Wrap 100 HR 2000 HR/OC E24-9760 Battery 100 HR 2 yrs/OC IX-2 E24-9801 Stainless Steel Muffler 100 HR 2000 HR/OC E24-9810 Stainless Steel Header 100 HR 2000 HR/OC E24-9720 Electronic Ignition Units 100 HR 2000 HR/OC * E24-1250 Spring 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 E27-3110 Torque Link Assy. 100 HR 2000 HR/OC IX-3 E24-0162 Engine 25 HR * E24-9940 Spark Plug Wires 250 HR 500 HR E24-9948 Spk.Plug Wire Separator 100 HR 500 HR E24-9740 Spark Plug 50 HR 100 HR E24-7553 Air Filter 25 HR 250 HR E24-1600 Engine Pulley 100 HR 1000 HR Reference Prints: E25-2000 E27-2000 * See Engine Manual 26 SECTION IX: ENGINE & EXHAUST SYSTEM 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. Cut safety wire securing header flange bolts (part no. E00-2504). Remove the bolts and hold the header flange up high enough to slip a new gasket in place. Reinstall the bolts, torque and safety wire. 2. Replace battery every two years or when battery will not take or hold a charge. Check acid level periodically to insure battery plates are covered with acid. Keep terminal posts clean and free from corrosion and dirt. 3. 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 back into torque link attachment tube (part no. E27-3100). Reinstall the torque link and tighten and torque the bolts. Verify for correct engine clearance on the passenger side near the oil filter bracket and the pilot side near the valve oil drain fitting. 4. Check engine pulley for anodizing wear. (See Engine Manual for greasing and replacement information.) 27 *Rev. 1 3/03 SECTION X: 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. INSPECTION CHART PRIMARY INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E49-6172 Main Sprocket 100 HR 1000 HR/OC * X-1 E49-7010 Sprocket Hub 100 HR 1000 HR/OC * X-1A E00-2608 Bolt 3/8 x 3-1/8 500 HR 2000 HR Torque E00-2450 Bolt 1/4 x 1-1/4 100 HR 500 HR Torque E00-3410 Thin Locknut 100 HR 500 HR Torque E00-9028 Hose Clamp 500 HR 2000 HR * E24-5110 Upper Clevis 500 HR 2000 HR/OC * E24-5100 Upper Engine Mount Cup 500 HR 2000 HR/OC * Reference print: E49-2001 * Inspect INSPECTION CHART SECONDARY INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E23-1000 Secondary Pulley Assy. 100 HR 1000 HR/OC * X-2 E23-5000 Upper Bearing Assy. 25 HR 1000 HR/OC X-2A E23-1240 Lower Bearing 100 HR 100 HR/OC * X-3 E23-1210 Main Drive Belts 50 HR 500 HR/OC X-4 E23-7141 High Temp Fan 100 HR 2000 HR/OC X-5 E23-1170 Snap Ring 500 HR 2000 HR * E23-8000 Fan Pulley Assy. 500 HR 2000 HR/OC X-6 E23-1220 Fan Pulley Bearing 100 HR 100 HR/OC E23-6180 Key, Secondary Sprocket 1000 HR 2000 HR/OC X-7 E23-6190 Retainer Plate 1000 HR 2000 HR * Reference print: E23-2000 * Inspect * * 28 INSPECTION CHART OIL BATH INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E33-7100 Top Rear Cover 100 HR OC * E33-7121 Lower Oil Bath Pan 100 HR OC * E33-7110 Top Front Cover 100 HR OC * E33-1170 Rear Oil Seal Assy. 100 HR 500 HR/OC * X-8 E33-1140 Tension Spring 100 HR 2000 HR * E33-3000 Rain Shield 100 HR 2000 HR * Reference print: E33-2000 * Inspect INSPECTION CHART CHAIN INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E49-1290 Drive Chain W/Link 100 HR 100 HR/OC X-9 INSPECTION CHART CLUTCH IDLER ASSEMBLY INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E27-6100 Idler Pulley Assy. 100 HR 2000 HR/OC X-10 E27-6100B Idler Pulley Bearing 100 HR 500 HR/OC E27-1160 Rod End 100 HR 2000 HR/OC * E27-1210 Idler Spring 100 HR 1000 HR * ** E27-2160 5/16 Rod End 100 HR 2000 HR * E27-6131 Clutch Tube Assy. 100 HR 2000 HR/OC X-11 E27-3170 Pulley Mt. Arm Weldment 100 HR 2000 HR X-12 E27-5100 Clutch Arm Casting 100 HR 2000 HR/OC * E00-2522 Bolt 100 HR 2000 HR * Reference print: E27-2000 E49-2001 * Inspect ** Grease 29 *Rev. 1 3/03 SECTION X: DRIVE TRAIN 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 adjustment and work preformed must be done by the factory service center at RotorWay A. The upper bearing assy. (part no. E23-5000) should have 1 shot of Mystik JT-6 grease every 25 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. E23-1200, 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. The main drive belts are replaced by following the procedures listed below. Pay close attention because you will follow the reverse procedures for reassembly. A. Clean 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. * 30 Rev. 1 3/03 C. Remove radiator assembly by bracing the tail boom with a stand or other appropriate method. Remove the radiator hoses from the radiators and necessary oil lines. Refer to print E30-2000 and E37-2000. Remove the tail boom support tube bolts and remove the entire radiator assembly. Plug the oil lines and water inlet and outlet manifolds. Place the assembly out of the way until future installation. D. Index the fan to the fan hub assembly and remove the fan from the hub. 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. Remove bolts (part no. E00-2524) and lower the upper engine mount cup (part no. E24-5100) into the upper engine pulley on the engine. Loosen the belt tension by backing out the all thread adjustment bolt (part no. E00-2525). G. Remove bolts (part no. E00-2531 and E00-2416). Remove the upper frame clevis casting. 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 disassembly procedure in reverse. Follow the belt tensioning procedures shown in the Construction Manual. 5. Check 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 removing the lower snap ring and lowering the pulley. It may be necessary to use a puller, as the pulley was originally assembled using loctite. B. Remove snap rings on either side of the pulley. C. Preheat the pulley in oven at 250 to 275 degrees F. CAUTION: Do not exceed 300 degrees. D. Lightly press out the old bearing with a press or vise. Note which end of the bearing had the lock ring. 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. 31 Rev. 1 3/03 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. Check for close tolerance fit against the secondary shaft and secondary sprocket. 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. 10. Refer to Note X-6 for the same 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, replace the two rivets back in the existing rivet holes. Reconnect the clutch arm casting and check for smooth 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. 32 *Rev. 1 12/99 SECTION XI: FUEL SYSTEM The fuel system in the EXEC 90 helicopter has two fuel tanks. The fuel tanks are tied together so that both provide fuel to the power plant at the same time and remain equalized as the fuel is consumed. The fuel flows from the tanks through a shut off valve, and then through a filter. After the filter, the fuel flows through 2 electric fuel pumps piped in parallel to the fuel pressure regulator and then to the power plant. A fuel drain valve is provided for fuel contamination checks. There is a small screen filter on the carburetor (refer to Engine Manual). The fuel capacity is monitored by an electronic fuel sender and gauge that provides an accurate means of fuel verification for the pilot. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E25-6110 Fuel Tank, Passenger 100 HR 2000 HR/OC * E25-6101 Fuel Tank, Pilot 100 HR 2000 HR/OC * E25-6121 Fuel Gauge & Sender 100 HR OC E25-1191 Fuel Valve 100 HR 2000 HR * E25-1380 Fuel Pump 100 HR 1000 HR/OC * E25-1390 Fuel Hose 100 HR 500 HR/OC or 5 yrs E25-2101 Fuel Cap 100 HR 2000 HR/OC XI-1 E25-1370 Fuel Pressure Regulator 100 HR 2000 HR/OC XI-2 E25-1360 Fuel Filter 50 HR 100 HR/OC Reference print: E37-2000 * Inspect NOTE: The rubber fuel 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. * * 33 SECTION XI: FUEL SYSTEM SERVICE NOTES: 1. Check fuel cap for proper venting by placing a vacuum pump hose over the vent inlet. Turn the pump on. If the vent is inoperative, the vacuum pump will draw down. If the vent is good, the pump will remain at a constant speed and pressure. 2. Check the Engine Manual for fuel calibration procedures. Regulator should be set at 4 to 4.5 reading. 3. Replace the fuel filter every 100 hours or OC. Check for contamination by cutting the used fuel filter in half and inspect the inlet side of the filter element. If the element is contaminated, remove the fuel tanks and wash them out with gasoline until clean. Install the new filter in the proper flow direction and verify fuel flow as described in the Engine Manual. 34 SECTION XII: FAN DRIVE The fan drive system is a series of pulleys and belts providing the proper speed reduction for the fan design. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E31-1120 Bearings 100 HR 500 HR/OC XII-1 E31-1130 Belt (Upper) 100 HR 500 HR/OC XII-2 E31-1141 Belt (Lower) 100 HR 500 HR/OC XII-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 * Reference print: E31-2000 * Inspect 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. 35 *Rev. 1 10/00 SECTION XIII: 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 at specified intervals. After construction, the blades are quality inspected and measured at specific intervals. This allows two blades with the identical airfoils to be matched and sold as a pair. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E20-3000 Retention Strap Assy. 25 HR 1000 HR/OC ** E20-1010 Asymmetrical Rotor Blade 25 HR 1500 HR/OC XIII-1 E20-1011 Asymmetrical Rotor Blade 25 HR 1500 HR/OC XIII-1 E00-2800 Bolt (9/16) 100 HR 1000 HR/OC XIII-2 E00-3800 Nut (9/16) 100 HR 1000 HR/OC XIII-3 E20-3170 Tip Weight 25 HR 1000 HR XIII-5 E20-6000 Aligner Block Assy. 100 HR 1000 HR/OC XIII-6 E20-6180 Pitch Horn Clevis 100 HR 1000 HR ** E20-6190 Pitch Horns 500 HR 1000 HR ** E00-2523 Bolt 100 HR 1000 HR **Torque E20-1220 Aligner Block Bearing 100 HR 100 HR/OC ** Reference prints: E20-2000 E49-2000 ** Inspect * * 36 SECTION XIII: MAIN ROTOR BLADES SERVICE NOTES: 1. Check for blade skin delamination by taking a small solid metal object like a nickel and 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 delamination 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. 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. Inspect the elastomeric bearing (part no. E20-1400 and 1401) for signs of any delamination or separation. This bearing must be kept dry and free from grease, oil and solvents. If any question exists as to the condition of the bearing, 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. 37 6. 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. 38 SECTION XIV: WIRING & ELECTRICAL The Electrical System on the EXEC 90 requires little maintenance if inspected properly. The three largest problems are corrosion, vibration of connectors, and chafing of wires. INSPECTION CHART WIRING INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E35-8220 Inline Fuse Holder 100 HR OC XIV-1 E35-8230 Panel Mount Fuse Holder 100 HR OC XIV-2 E35-8240 Toggle Switch 100 HR OC XIV-3 E35-8320 Fuses 100 HR 2000 HR/OC * E35-8410 Battery Terminal Eyelet 100 HR 2000 HR/OC XIV-4 E35-8520 Starter Relay 100 HR 1000 HR/OC XIV-5 E35-8530 Starter Key Switch 100 HR 2000 HR/OC * E35-8540 Push Button Switch 100 HR 2000 HR * E35-8200 Plugs 100 HR 2000 HR/OC * E35-8595 LED Indicator Light(Grn) 100 HR 2000 HR/OC * E24-9760 12 Volt Battery 100 HR 2 yrs/OC XIV-6 Reference prints: E35-2000 E35-2001 * Inspect INSPECTION CHART ALTERNATOR INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E42-1301 Alternator Belt 100 HR 250 HR/OC XIV-7 E42-2021 Voltage Regulator 100 HR 1000 HR/OC XIV-8 E42-1000 Alternator Assy. 100 HR 2000 HR/OC XIV-9 Reference Print: E31-2000 39 SECTION XIV: WIRING & ELECTRICAL SERVICE NOTES: 1. Fuse holders 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. 2. See note XIV-1 above. 3. 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. Using a scale of high resistance, measure the in and out going controls of the switch. A 10% maximum loss is acceptable. If greater, replace the toggle switch. 4. Check the bottom and top of eyelets for corrosion. Poor contact will cause excessive heat buildup and could result in hard starting. 5. Check spade connections for corrosion and poor connections. Check relay for operating action. Do this by removing 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 a good grounding source is applied to the relay body or mounting bracket. If a problem still exists, replace the starter relay (part no. E35- 8520). 6. Replace battery every two years or when battery will not take or hold a charge. Check acid level periodically to insure battery plates are covered with acid. Keep terminal posts clean and free from corrosion and dirt. 7. Check for cracking and dry rot. Belt tension and alignment is important for longevity of belt operation. Refer to the Construction Manual for installation and alignment details.