R44 Maintenance Manual - Complete n6ii

ROBINSONF\44 e

MAINTENANCtr MANI.]AL AND INSTRUCTIONS FORCONTINUED AIRWORTHINESS

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ROBINSONHELICOPTERCOMPANY,TORRANCE.CALIFORNIA

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CONTENTS

ClassS RevisionServiceform ComponentReturn/Authorization form RecommendedChangeReportform Limited Warranties 1.000

Ge n e ra l

2.000

Inspection

3.000

Life-LimitedComponentsand OverhaulSchedules AirworthinessLimitations

4.000

Airframe

5.000

L a n d i n gGe a r

6.0O0

Powerplant

7.000

DriveTrain

8.000

FlightControls

9.000

Rotor Systems

10.000

Ri g g i n g T , ra ck a n d B a l ance

1 1.000

Heating,Ventilation,and Air Conditioning

12.00O

Fuel System

13.0O0

I nstru me n ts

14.000

Electricaland Avionics Systems

15.000

Furnishings

16.000

S p e ci a T l ools

17.000

Re vi si o nL o g

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ClassS RevisionService

ClassS revisionserviceis requiredto ensurethis manualremainscurrent. ClassS subscribers will receivefuture issuesof the followingfor a periodof one year:

Safety Notices Revisionsto R44 Pilot'sOperatingHandbook R44 ServiceBulletins R44 Service Letters Revisionsto R44 MaintenanceManual& lllustratedPartsCatalog

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lf you wish to order class s revisionservice,pleasesend a check {drawn on U.s. bank} o r mo n e y o r d e rfo r U S $ 3 0 .0 0to : R OB INSON HELICOPTER COMPANY Attn: Publications 2901 Airport Drive T o r r a n c eC, A 9 0 5 0 5 - 6 11 5 UNITEDSTATES

Pleaseprint your name,completeaddress,and phonenumberin the spaceprovided below and returnthis page with your check or money order.

JtL

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lf you own an R44 helicopter,pleaseindicateship seriarnumber

Change 7r O6iDec 99

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Robinson Helicopter Go.tRHCI 2901 AirportDrive T o r r a n c eC,A 9 0 5 0 5 - 6 1 1 5U, S A

Phone:{31O}539-0508 F a x :( 3 1 0 )5 3 9 - 5 1 9 8 FAA CRSYV3RO1 2M

COMPONENT RETURN/AUTHORIZATION A copy of this form must accompanyANY parts or componentsreturned to RobinsonHelicopterGompany. A.O.G.

I acceptthe expeditingcharge($50.00 U.S., $60.00 Foreign),to insurethat work is commencedwithin (1) work day.

SUBMITTED BY: Name: Company

Name:

Telephone:

Fax No:

Email: COMPONENTDATA: Componentor Part No: SerialNo: Hours in Service: Date of last repair: Reasonfor return:

ROTORCRAFT DATA: RotorcraftS/N: Total Hours: RegistrationNo: edOwner:

R22

R44

WORKREOUESTED: None (seewarrantyclaim section)

Repairestimateonly

Overhaulin accordancewith RHC price list

Repairas necessary, cost not to exceed $

Core credit. Core chargedon RHCinvoiceno. WARRANTYCLAIM: work requestedor replaceunderwarranty _Perform credit. Replacementpart purchasedon RHCinvoiceno. _lssue THE ABOVE WARRANTYIS BASEDON: Rotorcraftlistedabove is under warranty C o m p o n e npt u rch a se dw i th i n one ( 1) yearon RHCinvoiceno. SHIPPINGINFORMATION: Address:

Carrier: URGENT- SHIPNEXTDAY AIR URGENT- SHIP2ND DAY AIR

I certifv that the above componentand rotorcraft data is correct in accordancewith FAR 91.417 and hereby authorizethe above work to'be comoletedincludinqorocurementand installationof necessarvmaterials.RHC employeesmay operatethe compondntat my risk foi tne purposeof testing, adjusting,inspeclion,or delivery. RHC is not responsiblefor loss or damageto the componentin case of theft, fire, accident,or any other causes beyond the control of RHC. A mechanic'slien on the componentto securethe amount of repairsand storage and will chargesis herebygranted.Any componentleft at RHCbeyondsix monthswill be consideredabandoned be disposedof . I agreeto pay the full amount in cash upon deliveryof the component.RHC will retainall scrapped or replacedparts.The abovecost estimatemay not be exceededwithout my approval.

PRINTNAME:

DATE:

SIGNATURE: Change13r OCT 2006

RSF 205 REV F

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R OB IN S ON HELICOPTER COM PANY PUBLICATIONS T E C H NICAL

R E C OMMENDED CHANGEREPORT Periodicrevisionsof this manual will be made to incorporatethe latest information.lf, in the opinion of the reader,any informationhas been omitted or requiresclarificationor correction,pleasedirect your comments to RHC using this form {or a duplicate}.Such informationwill be includedin future revisions. Send recommendations to: Technical RobinsonHelicopterCompany 2901 Airport Drive T o rra n ceCalifor , nia90505- 6115 UNITEDSTATES P h o n e :( 3 1 0 ) 5 3 9 - 0 5 0 8 Fax: { 3 1 0 )5 3 9 - 5 1 9 8 ldentification: He l i c o p t e M r odel:

!

-

Ser ialNum ber :

Remarks/Recommendations:

Change 7: OB Dec 99

tx

ROBINSON HELICOPTER COMPANY, INC. LIMITED AIRCRAFT WARRANTY Effective R22 S/N 3318 & on; R44 S/N | 2O2 & on RobinsonHelicopter Company, lnc. (hereafter referred to as RHC) warrants each new helicopter to be free from defects in material and workmanship appearing within two years from the date of delivery from the RHC factory or during the first one thousand (lOO0 hours of operation, whichever event occurs first; provided, the aircraft has been subjected to normal use and service. This Warranty is limited to repair or replacement on an exchange basis, as selected by RHC, of any part, which upon examination bV RHC is deemed to have been defective when the aircraft left the factory. A new warranty period is not established for parts replaced under the of this Warranty. Such replacement parts are warranted only for the remainder of the original warranty period. This Warranty shall not apply to any helicopter or part which has been repaired or altered outside the factory, and which, in RHC's judgment, has affected the performance or reliability of the helicopter or part. This Warranty shall not apply to any helicopter or part which has been subject to corrosion, misttse,negligence or accident, nor to any parts normally replaced during routine maintenance, such as, air cleaners, skid shoes,rod end or spherical bearings,light bulbs, ete. This Warranty shall not apply to any helicopter, which has been crated for shipping unless sueh crating is performed by RHC. RHC is not responsible for the cost of shippingparts under the of this Warranty. However, RHC will credit the RHC Dealership, which sold and delivered the new helicopter to its original owner, with an allowance for labor performed by that Dealership for removing and reinstalling the defective part. No credit will be issued for trouble-shooting. RHC makes no Warranty with respect to batteries, instruments, avionics or other trade accessories since they are usually warranted separately by their respective manufacturers. New aircraft are equipped with new engines which have a separate Lycoming limited warranty. ADDITIONAL WARRANTY FOR MAIN & TAIL GEARBOXES ln addition to the warranty specified above, an extended pro-rated warranty shall apply to the main and tail gearboxes for the first 22OO hours of service or three years from the date of manufacture, whichever event occurs first. During this period, if a gearbox must be overhauled due to failure of a part which was defective when it left the factory, RHC will pro-rate the cost of the overhaul by dividing the hours in service bV 22OO or the months in service by thirty-six (36), whichever fraction is greater. THE FORGOING WARRANTY IS EXCLUSIVE AND IS GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES AND REPRESENTATIONS. EXPRESS. IMPLIED. OR STATUTORY. WHETHER WRITTEN OR ORAL, INCLUDING WITHOUT LIMITATION FITNESS FOA A PARTICULAR ANY IMPLIED WARRANTIES OF MERCHANTABILITY. PURPOSE OR TRADE USAGE, THE REMEDIES OF THE BUYER SHALL BE LIMITED TO THOSE PROVIDED HEREIN. IN NO EVENT WILL THE MANUFACTURER BE LIABLE FOR LOSSES FESULTING FROM TOSS OF USE OF THE HELICOPTER. COLLATERAL, CONSEAUENTIAL OR SPECIAL DAMAGES, OR ANY OTHER COSTS. Warranty adjustments with respeet to any helicopter or parts manufactured by RHC will be made only upon compliance with the following procedure: (1)

The defective part or assembly, together with a written Warranty Claim, must be returned to RHC not later than thirty (3O) days after discovery of the defect nor more than thirty (3O16sr" after expiration of the Warranty period.

A

RHC will, after inspection, determine whether the material or part was defective when it left the factory and will respond accordingly. Final determination of a Warranty adjustmenf resfs with RHC.

Effective 1 February 2OO3

Change9: FEB2OO3

ROBINSON HELICOPTER COMPANY. INC. 29Ol Airport Drive Torrance, California 90505 U.S.A.

X]

COMPANY'INC. HELICOPTER ROBINSON LIMITEDPARTSWARRANTY RHq warrants each new helicopter RobinsonHelicopter company, lnc. (hereafter referred to as one year from the part to be free from defects in material and workmanship appearing(l.within hours of operation' O)q thousand date of detivery from the RHC factory i, Jirirg the firs.tone to normal use and service' subiecte-d been p"art has proviAeJ, iie whichever event occurs first; as selected bY BHC' of basis-, This warranty is limited to repair or replacement on an exchange when the part left defective have been nV-hii it de.e.1t9d any part, which upon .to parts reppcgd under the of this "*u.in'ation period'is not establishedfor the factory. A new warranty parts ,r" iurrunted only for'the remainder of the originalwarrantY Warranty. Suchreplacement reinstallation of parts under period. RHC is not responsiblefor th.tecost of removing, shipping, or which has been repaired This warranty shattno-t ipply'io the of this wiiiritv. "hy.part in RHC's iudgment, has affected the perfarmance or altered outside ln" fu"tory, anA iiici, part which has been subiect to or retiabirity of the part. This warranly- i'nail not appty {o any parts.normally replace! !u1ing- routine corrosion, misuse, negligence or accident, nor to any rod eid or spherical bearings, light bulbs, etc' uii ai, c,teaners,ikid maintenan"", "hor", "u"h avionics or other trade aceessories RHC makesno warranty with respectto batteries,instruments, manufacturers' since they are urrutly warranted separately by their respective ADDITIONAL WARRANTY FOR MAIN & TAIL GEARBOXES pro-rated warranty shall applY.to the tn addition to the warrantY specified above, an extended or three years from the date of main and tail gearbor", ior'the first )2OtO hours of service period' if a gearbox must be overhauled manufacture, whichever event o""uu irrt. During thls the factory, RHC will pro-rate the cost teft it due to failure or a pari which was dife,ctive whei the months in service by thirty-six of the overhaul by dividing the houis ii ""lrui"" by 22oo or (36), whichever fraction is greater. AND ACCEPTED IN LIEU THE FORGOING WARRANTY IS EXCLUSIVE AA!? IS GIVEN ExPREss'IMPLIED'

oF ANy ANDALLorHER wARRiiiifes-nno REPRESENTATIONS' wt.THour LtMtrATtoN oc oa,a, N0LU_D\NG 'rnEnciaNTABiLITy, oR srATUToRy, qHETHERwRiiiEi FtrNE-lsFoR ABEPART,,ULAR ANy tMpLtEDwARRANTtEsoi LtMtrEDTo 9HALL BUYER rHE or puRposEoR nRADE(tsAGE,rnE'tiEuEoiies BE LIABLE THosE pRovtDED HEREIN. w'aii-Ev-Eni wttt THE MANUFACTURER COLLATERAL' HELI0OPTER' oF THE FoR LossEsaEsuLTtNGFRIM'ioss- o'r usE oR ANY oTHERcosrs' coNsEaUENnAI-oi ipecnL DAMAGES, by RHC will be ma Warranty adjustments with respect to anY helicopter or parts manufactured onty upon compliance with the following procedure: (1)

e)

Claim' must be The defective part or assembly, together wilh a written Warranty the defect nor of discovery (3O) after days returned to RHC not later than thirty period' Warranty more than thirty (3O) days after expiration of the part was defective RHC will, after inspection, determine whether the material or determination of a Finat when it teft the factory ana iitt respond accordingly. Warranty adiustmenf resfs with RHC'

Ol June 06

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ROBINSONHELICOPTERCOMPANY' INC. 2901 AirPort Dfive Torrance, California 90505 U-S.A'

Change13: OCT 2006

1. GENERAL

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SECTION 1 GENERAL 1.OOOINTRODUCTION 1 . 0 0 1 M a n u a lN o ta ti o n s 1 . 0 0 2 M a n u a lR e vi si o n s 1.003 MaintenanceAuthorization 1.004 OverhaulAuthorization 1.O05 Customer 1 . 0 0 6 Ex t ern aD l i me n si o n s 1.OO7 VersionDescription 1 .1O OH E L I C OP T ESRE R V IC IN G O

1 . 1 0 1 S c h e d u l e dMa i n te n a n ce a n d Inspections 1. 1 0 5 C a l i b ra ti o n of Tools - Ge n e ra l 1 . 11 O L u b ri ca ti o n 1.1 15 Chip DetectorCleaning 1 . 1 2 O M a i n R o to rGe a rb o xD ra i nand Flush 1. 1 3 0 T a i l Ro to rGe a rb o xD ra i na nd Flush 1 . 1 4 0 C l u tch -A ctu a toLr o w e r B e ar ingLubr ication 1 . 15 0 D e fu e l i n g 1. 1 6 0 S t o r a g e 1 .170 HydraulicReservoirFilterReplacement 1. 1 8 0 D r a in i n ga n d F l u sh i n gH yd r aulicSystem 1 . 1 9 0 B l e ed i n gH yd ra u l i cS yste m 1.200 HANDL|NG,JACK|NG H ,O t S T t N GL, E V E L T NAGN D W E | G H | N G 1 . 2 1 O G r o u n dH a n d l i n g 1 . 2 1 1 G r o u n dH a n d l i n gWh e e l sl nstallation- Standar dLandingGear - FloatShip LandingGear 1 . 2 1 2 G r o u n dH a n d l i n gWh e e l sInstallation 1 . 2 1 3 M o vi n gth e H e l i co p teor n Gr oundHandlingW heels 1 . 2 1 4 M a i n R o to rB l a d eT i e -D o wns 1.215 Parking 1.216 Trailering

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AND WEIGHING(CONt,d) HOISTING,LEVELING,

'1.22OJacking, Hoisting,and Leveling 1 . 2 3 O W e i g h i n ga n d C G C a l cu l a ti on 1.231 HelicopterWeighingProcedures 1.24O BallastInstallation T OR OU ER E OU IR EM ENTS 1 . 3 O 0 F AS T EN E R 1.31O General 1.32O StandardTorques l o rq u e s 1 . 3 3 O S p e ci a T 1.4OO APPROVEDMATERIALSLIST 1. 4 1 O Pa i n tS tri P P e rs 1 . 4 2 O S o l v e n tsa n d C l e a n e rs 1 . 4 3 O F i l l e rsa n d P u ttY 1 . 4 4 O T o r qu eS e a l 1.45O Primers 1 . 4 5 5 P o w d e rC o a t 1 . 4 6 0 P a i nts 1 . 4 7 O L u b r i ca n ts 1 . 4 8 O Ad h e si ve sa n d S e a l a n ts 1.490 StorageLimits 1 . 5 O O( R E S E R V E D ) 1 . 6 0 0 P A R TI N T E R C H A N GE A B IL ITY 1 . 7 O O I N S T R U C T I O NFSO RU N C R A T I N GR,E A S S E M B L I NAGN, D F L I G H TT E S T I N GR 4 4 S E R I E SH E L IC OP T E R S ( DATA)PLATES IDENTIFICATION R E P L AC E ME NCTOMP ON E NT

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SECTION 1 GENERAL 1.OOO INTRODUCTION This manualcontainsreferencematerialnecessaryfor the properservicing,maintenance. and handlingof the R44-serieshelicopter.This manual is to be used in conjunctionwith the R44 and R44 ll Pilot'sOperatingHandbooks(POH),R44 lllustratedPartsCatalog(lPC), R44 ServiceBulletins,R44 ServiceLetters,Lycoming0-5401 lO-540 Operator'sManuals and enginemaintenancepublications,and applicabletechnicaldata suppliedby component manufacturers. As necessary, Service Bulletins are issued by Robinson Helicopter Company (RHC), Lycoming, and component manufacturers.Service Bulletin compliance is mandatory. RecentR44 ServiceBulletins(SB)and ServiceLetters(SL)are availableon the internetat www.robinsonheli.com.RecentLycomingServiceBulletinsare availableat www.lycoming. textron.com and recent Teledyne Continental Motors (TCM) ignition systems Service Bulletinsare availableat www.tcmlink.com. O

Always read instructionscompletelybefore beginninga task. 1.001 ManualNotations The following notationswill be found throughoutthe manual: WARNING Personal injury or death can result if a WARNING is not followed. CAUTION Equipmentdamagecan result if a CAUTIONis not followed.

NOTE A NOTEprovidesemphasisor supplementaryexplanation. 1.002 ManualRevisions Beforeusing this manual, be sure it includesall current revisions.A list of all applicable be sureto complete revisionsis containedin Section17.OOO. lf a new manualis purchased, and mail the revisionserviceapplicationfound in the front of the manual;this will insure that you receiverevisionsfor a one-yearperiod.A list of all current Robinsonpublication revisionscan be accessedon the internetat www.robinsonheli.com. 1.003 MaintenanceAuthorization Only appropriatelycertificatedmechanicsthat have successfullycompleteda factorysponsoredmaintenancecourse, or are under direcr!supervisionof such mechanic, may perform maintenance,repairs,or inspectionEiescribedin this manual. The daily preflightmay be accomplishedby the above-statedmechanicsor pilot/ownerafter careful study of the appropriatesections of the Pilot's OperatingHandbook,Some preventive maintenancemay be performed by the pilot after receivingappropriateinstructionsin Regulations. with the Pilot'sOperatingHandbookandapplicable FederalAviation accordance C h a n g e1 4 : JU L 2 OO8

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1.004 OverhaulAuthorization RHC factory Only appropriatelycertificatedmechanicsthat have completedspecial and coursesfor overhluringipecific componentsand possessspecia.ltools technical o"ti-i"ppii"o uv CnCuj" authorizebto disassembleand overhaul or repair major componentsas requiredby Section3. 1.005 Customer

.

T e l e p h on e : (3 1 0 ) 5 3 9 -0 5 0 8 - Main Switchboar d ( 3 1 0 )5 3 9 - 5 1 9 8 Fax: Technical: E-mail:

sion' Exten

customerservicb@robinsonheli'com

Po?'" r o robinsonheIi.com ltr1o l"iil#J.9ifl: [H"J$"ii"3iri,

208

Chris Sennett,[email protected]'com

Includethe following informationwhen ingTechnical: Helicoptermodel H e l i co p tese r ri a ln u mb e r Helicoptertotal time (TT) Helicoirtertime since overhaul(TSOH) Componentname ComponentPart number Comironenttime since repairor sinceoverhaul Parts Ordering: - par tsilndacc- epsor yor der ing -[l-isp a re s@ro b insonheli.com E - ma i l : (habla'espafiol), [email protected] E-mail: Ex te n si o n : 2 0 9 Ma l l o rYKohler P a g e1 . 2

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1.OOOEXTERNALDIIIENSIONS

R O T O RR A D 1 9 8 I N .

(30 INCHES t'tINIMUM TAIL SKID HEIGHTI'IEASURED FROM LEVELGROUND UP)

353 lN. 459 IN. OVERALL

29 lN, I

Fla4 & Fl44 II I

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1 2 9 I N . STANDARD LANDING GEAR. 1 3 0 . 5I t . FLoAT0R HrGH(EXTENDED) LANDING GEAR)

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353 lN. 459 IN. OVERALL

Fl44&rro t(44

Clq',r- II

(shown with fixed utilitYfloats) E X T E R N A LD I M E N S I O N S

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1.007 VersionDescription(alsosee Type CertificateData Sheet in Section3) R44, "Astro":

4-digit serial numbers 0002, OOO4 thru 0760. Textron Lycoming O-54O-F185engine derated to 2Ob horsepower maximum horsepower; 225 horsepower 5-minute takeoff rating. Manual controls (electricautomatic trim and groundadjustablecollectivetrim). Grossweight 24OOpounds.14-volt electricalsystemstandard;28-volt optional.optionalhydraulic cyclic & collectivecontrolb.

R44 "Clipplr", "C l i p p e rl " :

Basedon "Astro". Fixedor pop-outfloat landinggear.Additional corrosionprotection.Auxiliaryhorizontalstabilizerinstalledat base of lower verticalstabilizer.Drainvalvesinstailedin chin. Additional navigationlights atop mast fairing on fixed froat versions. Marine radio package optional. optional hydraulic cyclic & collectivecontrols. Hydraulic cyclic & collective controls standard. Adjustabre pilot-sidepedals.Serialnumber0761 and higher.

R44, "Raven", "R a v e nl "

WARNING R44 ll (fuel injectedl helicopters require two A2Ob-7 forks, A600-6 manifold pressule gage, two C0Ob-8 main rotor blade & spindle assemblies (two C016-5 main rotor blades & two C157-2 pitch horns), COO6-5main rotor gearbox, COO8-4tail rotor assembly {two CO29-2 tail rotor blades),two C016-5 main rotor blades,CA17-4swashplate,three C121-31 push-pull tubes, two C2O3-5 yokes, C2O4-2arm (stainlesssteel, lowerl, C2O4-3 arm tstainlesssteel, upper!, CT9Z-4 dual tachometer, D201-5 weldment (forward hydraulic servos), and D2O4-8 suppoft weldment (aft hydraulicservo). R 4 4 l l , " R a ve nl l " :

5 -d i g i tser ialnum ber s1OOO1&later .Longerchor d main r otor blades.Textron LycominglO-540-AE1A5fuel-injectedengine derated to 2O5 horsepower maximum continuous power; 245 horsepowerS-minutetakeoff rating. Gross weight 2bOO pounds. 28-volt electricalsystem. Solid-statemagneto start booster. Second oil cooler. Roundedtip main and tail rotor b l a d e s.

R 4 4 l l , " C l i p p e rl l " : S i mi l a rto R44 "Clipper ",but basedon "Ravenll" InstrumentTrainer: R44 or R44 ll configurationwith 1O-holeinstrument . VMC operationsonly. E. N . G .(E l e ctro n i c R44 or R44 ll configuration.28-volt electricalsystem. NoseN e w s Ga th e ri n g ): mountedgyro-stabilized camerawith tailcone-mounted battery. Standardmicrowavecapability. Police: R44 or R44 ll configuration.28-volt electricalsystem.Includes searchlight,police radio package, and nose-mountedgyrostabilized infrared-capablecamera with tailcone-mounted battery. Optionalmicrowavecapability. C h a n g e1 4 : J U L 2 0 0 8

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1 . 1 O O H E L I COP T ESRE R V IC IN G a nd Inspections 1 . 1 0 1 S c he d u l e dMa i n te n a n ce Somehelicoptersrequirefurthermaintenanceand inspectionsin additionto the following new f,eiicopt.lq. Coniult aircraft maintenance records, minimum requ-ii6nie-irt-i-toi Limitations.,and Airworthiness ServiceBulet'riisJ$Bi;-;"i;iion reguiaiiori+_nirworthiness

listedaresubjectto revision. Publications Direii'r"'iAijii;;;ii"riiTC ippiiEJuitltV-F l i g h tT i m e First 29 hours:

Change oil and filter and inspect oil suction screen and filter per Lycoming SB48OE. Check alternatorbelt tension per Lycoming ServiceInstruction{Sl}1 1 298' Inspect and service engine per Lycoming Operator's Manual, EverybO hours: S l 1 O8 OCa, n d ( as r equir ed)AD 2008- 06- 51. Changeoil, oil fi l ter , and inspect oil suction screen and removed filter per Lycoming S B 4 8 OE . Drain and flush gearboxe's per Sections 1'120 & 1 . 1 3 0 . First 1Oo-hour Check engine exhaust valve guide clearance per LVcominO lnspection: a sB388C. per Lycoming Ev e r y1 O 0 h o u rs: Inspectper Section2.400. Inspectand serviceengine Sl11298, andSB342E( l O- 540 o p e ra to r,sManual,s8366, Sl1O8OB, only). As required,inspect and serviceTCM ignitioncomponents p e r T C M 5 8 6 438. Every30O hours: L u b ri ca teC 181- 3 bear ingper Section1.14O.Replacehydr au l i cf i l ter p e r S e cti o n1 .170. Inspectvalvesand check engineexhaus tv al v e g u i d e cl e a ra nceper LycomingSB3O1B,SB388C, and Ope r ator 's Manual. Every5OOhours: D ra i n a n d fl u sh gear boxesper Sections1 .120 & 1.130. C l ean gearbox chip detectors per Section 1.115. magneto drive iushion pliability. Service collective spring assembly (manual controfsonly) per Section8.221. As required,inspectand service TCM ignitioncomponentsper TCM 58658 and 586634' Every22OOhours: Overhaulhelicopterper Section2-7OO. Calendar(in additionto precedingrequirements) Every4 months: Change oil, oil filter, and inspect oil suction screen and removed filter per LycomingSB48OE. Ev e r y1 2 mo n th s: Inspectper Section2.400. Cleangearboxchip detectorsper Section 1 .1 15. Inspectemergencylocatortransmitter(ELT)per 14 CFRPart 91.2O7.Inspectoptionalpop-outfloats per Section5.630. Every24 months: T e st a n d i n specttr ansponderper 14 CFRPar t91' 413' L u b ri ca teC 1 81- 3 bear ingper Section1.140. Inspectoptio nalpopEvery3 years: out floats per Section5.640. Hydrostatictest pressurecylinder' OverhaulTCM magnetosper TCM 586438. magnetodrive Every4 years: cu sh i o np l i a bility. Perform 12-yearinspectionand limitedoverhaulper Section2.600, E v e r y1 2 y e a r s : Section2.7OO. l o r o ve rh a u per

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1.105 Calibrationof Tools The dimensionsand tolerancesgiven in this maintenancemanual are critical. RHC recommendsmeasuringtools be calibratedat least once a year. This includestorque wrenches,micrometers,calipers,dial indicators,springscales,protractorsand balancing equipment. WARNING Proper torque is critical. Always use calibrated wrenches and undamaged, properly lubricated (where applicable) hardware. Ensure all clamping surfaces are clean, and clamp only bare metal or wet-primed surfaces. lmproper tolque or dirty or painted clamping surfaces may result in loss of clamp-up, hardware or and prematurefailure. 1 . 1 1 0 L u b ri ca ti o n- Ge n e ra l Most bearings in the R44 are sealed or self-lubricatedand do not require periodic lubrication;bearingswith specificlubricationintervalsare noted in Section1.101 . Engine lubricationrequirementsare contained in the Pilot's OperatingHandbook, Lycoming Operator'sManual and LycomingServiceInstructionNo. 1O14 (currentrevision).Main and tail rotor gearboxesrequireadditionaloil when indicatedby sight plug reading. WARNING The only approved lubricant for use in the main rotor and tail rotor qearboxesis Robinson A257-2lubricant. When a new or overhauledgearboxis installed,it must be drainedand flushedafter the first 4 hours of flight or first chip light, whicheveroccurs first, and again at the next 1OO-hour inspectionafter installation.Thereafter,drain and flush gearboxesat intervals per Section 1.101. Additionally,changegearboxoil and cleansight plug glasswhenever oil becomesso dirty that its level cannot be determined.

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MIfEIEL

H44

1 .1 15 Chip DetectorCleaninq Duringnormalgearboxoperation,an insulatingfilm of varnishcan accumulateon a chip dltector,s magnetirobe and preventgearboxchip warning light illumination. CleanchiP detectorbY: 1. Removeand discardsafety wire (if applicable)securingchip detector. Disconnecr locatedseveralinchesfrom chip detector. chip detectorwiring at quick-disconnect For tail rotor gearbox,place containerbeneathto catch oil. Removechip detector from gearbox. by 2. Cleanand scrub chip detector with a toothbrushand cleaningsolvent,followed drying with compressedair or a lint-freecloth' wiring, 3. Check chip detector circuit function by connectingchip detectorelectrical probe to magnetic turning MASTERswitch on, and groundingdetector's central MASttb airframe. appropriategearboxchip warning light illuminates.Turn switch off . and 4. Installchip detector. Torque threaded-typechip detector per Section 1.330 safety wire. Ty-rap chip detectorelectricalwiring as required. by grounding b. Turn on MASTER switch. Check chip detector circuit function warning light detector,s center terminal and ing appropriategearbox chip illuminates.Turn MASTERswitch off' |

1.120 Main RotorGearboxDrainAnd Flush To drain and flush main rotor gearbox: rotor gearbox 1. Groundrun helicoptertwo to five minutesat 60-700/oRPMto warm main oil.

o

1o inches 2. Disconnectchip detector wiring at quick-disconnectlocated approximately gearboxsump from chip detector. Cut safety *ir" r"ruring chip detectorto main rotor chip detectors). attach bolt (not applicableto quick-release 3. Removechip detector. Do not removechip detectorhousing' NOTE After removing chip detector, check for oil leaking from chip detector housing. Leakage indicates housing is defective and must be replaced.lf leakageoccurs,immediatelyinstallmain rotor gearboxdrain assemblyto minimizeoil spillage' P a g e1 . 4

C h a n g e1 3 : O C T 2 0 0 6

FIGIBINSEIN

MATNTENANcE MANUAL

MC'EIEL

F'44

1.120 Main Rotor GearboxDrainand Flush(cont'd) 4, Drain oil by installingmain rotor gearboxdrain assemblyin chip detector housing with drain hose overboard into a suitable container. Slide wedge under drain assemblyto open valve (seeFigure1-2l'. 5. Remove drain assembly.Removeand discard safety wire securing gearbox filler plug. Removeplug.

6 . Fill gearboxwith SAE3O,SAE4O,SAE50,or SAE20W5Ostraight mineralengineoil to level indicated by decal adjacentto sight gage.

7 . Installfiller plug, tighten, but do not safety wire. 8 . Groundrun helicopterfor approximatelyfive minutesat 60-700/oRPM. 9 . After shutting down helicopter,drain gearboxusingdrain assembly. 1 0 . Removedrain assembly.Removeand discardsafety wire on chip detectorhousing. Remove chip detector housing and immediatelyplace a small container under gearboxto catch any residualoil. 1 1 . C l e an ch i p d e te cto r w i th a toothbr ushand cleaningsolvent per Section 1.115. Compressedair or maskingtape may also be used to removedebris but scrubbing with solventis mandatoryto removeany varnishaccumulation.Do not use a magnet to removedebris.Cleanand visuallyinspectchip detectorhousing.

1 2 . chip detectorfunction by connectingelectricalleads,turning Master switch on, and touchingdetector'scentralmagnetirobeto horizontalfirewall. MR CHIP warning light should illuminate. Disconnectelectricalwires.

1 3 . Installchip detector housinginto main rotor gearbox.Torque per Section 1.330. and safety wire. 14. Installchip detectorinto chip detectorhousing.Torquethreaded-typechip detector per Section1.330 and safetywire. Connectchip detectorelectricalwires and ty-rap. 15. As required,removesight gage and cleanwith solvent. Reinstallsight gage,torque per Section 1.330, and safety wire. 16. Removefiller plug. Fill gearboxwith RobinsonA257-2 lubricantto level indicated on decal. Rotate rotor system by hand severalrevolutionsand pull down tailcone severaltimes. Recheckgearboxoil level.Adjust as necessary. 1 7 . T o r q u efi l l e rp l u g p e r S e cti on1.33O( safetywir e not r equir ed) . C h a n g e1 3 : OC T 2 OOo

P a g e1 . 5

I I

MOEIEL

MATNTENANcE MANUAL

FlclBINEiON

H44

1.120 MainRotorGearboxDrainandFlush{cont'd) by.grounding--dglqlt9f: .opera.tion. 1g. Turn on MASTERswitch. check chip detec.tor Turnoff MASTER iltuminates. tijtrt warning centerterminallnJu"iiiving MCCHIF switch.

\

\-\,----= .r,J

DETECTOR HOUSING

r\+ \'\

87260 CHIP DETECTOR

MTO54.1DRAINASSEMBLYFOR87260 CHIPDETECTOR "OUtCK-RELEASE" OR WEDGE

MTO53-1MAIN ROTORGEARBOX DRAINASSEMBLYFORA7260 CHIPDETECTOR THREADED

GEARBOX GA I NR O T O R F I G U R1 E- 2 D R A I N I NM

P a g e1 . 6

Change1 3 : O C T 2 0 0 6

FICIEIINSICIN

MATNTENANcE MANUAL

MOEIEL

R44

1 .130 Tail Rotor GearboxDrainand Flush 1. Groundrun helicopterfor approximatelyfive minutesat 60-7o0/oRPMto warm tail rotor gearboxoil. 2. Disconnect chip detector wiring at quick-disconnectlocated approximately11 . inchesfrom chip detector. 3. Removeand discardsafety wire securingchip detectorto sight gage.

I

4. Placea containerundertail rotor gearboxto catch oil and removechip detector. 5. Removeand discardsafety wire securingfiller-ventplug to sight gage. Remove I filler-ventplug. 6. lnstall chip detector, torque per Section 1.330, but do not safety wire. Add I approximatelyfive ounces of SAE3O, SAE4O, SAE5O, or SAE20W5O straight I m i n e r a le n g i n eo i l . 7. Installfiller plug, tighten, but do not safety wire. 8. Groundrun helicopterat 60-7Oo/o RPMfor approximatelyfive minutes. 9. After shutting down helicopter,removechip detectorand drain mineraloil. 1O. Cleanand scrub chip detectorwith a toothbrushand cleaningsolvent. Compressed I air or maskingtape may also be used to removedebrisbut scrubbingwith solvent is mandatoryto remove varnish accumulation.Do not use a magnet to remove debris. 1 1 . Connectchip detectorwiring. Turnon Masterswitch. Checkchip detectoroperation b y g r o u n d i n gd e te cto r'sce n te rter minal;TR CHIPwar ninglight shouldillum i nate. Turn off Master switch and disconnectchip detectorwiring. 12. Indtall chip detector, torque per Section 1.330, and safety wire. Connect chip as required. detector wiring and securewith Ty-raps@ 13. As required,removesight gage and cleanwith solvent. Reinstallsight g?g€,torque p e r S e c ti o n1 .3 3 O,a n d sa fe ty wir e.

I

CAUTION Tail rotor gearboxsight plug glassmust indicatecorrectoil level w h e n a i rcra fti s o n l e ve lqr ound. 14. Filfgearboxwith RobinsonA257-2lubricantto levelindicatedby sight glass decal. I I l n s t a l lf i l l e r-ve n pt l u g ,to rq u ep er Section1,330, and safety wir e. 1 5 . T u r n o n Ma ste rsw i tch . C h e ckchip detectoroper ation.Tur n off Masterswitc h.

C h a n g e1 3 : O C T 2 0 0 6

P a g e1 . 7

I

FICIEIINSCIN

MAINTENANcE

MANUAL

MOE EL ]t44

in kit Svrinqe suitable for the following procedureis included ftot RHC Cuttottt Sttui* [l'-i i"5; "u.iiiuit

;ee section avpirabre, grease(c_ommerciaily 1 . Fiilsyringewith 4-b gramsof A2b7-12 i""f''iiS mm)lonbspice insidea syringe 1.47O1.Note:b gramsof greasetillt . rlO rilov,iiitt i o.os inch(16 mm) innerdiameter'

may be covered housing.sc.r.eyv 2 . Removescrew from left side of c181-3 bearing necessaryto not is lt adcessscrew' by Telatemp;,e.ove Telate.p .f itquiied toremoved access' bearing to ease replaceTelatemp.-;.t;t"';ii cowfingriiay be 3 . Using syringe,inject greasethrough screw hole'

l-

screw and ,glean.set wet epoxy lnstall 8289-3 self-sealingcross-headscrew, or,Ihorltughly B27o-2o :9119nt, screw hote threa"d;;"d i"n"n lnrtull set screw q!!n.g only until screw primer, or wet tin?-.iiio."aie'primei on tfrreaOs'Tig6ten set screw i s f l u s h w i th b e a ri n gh o u si n g '

o

cavity. Tightening Set screw hote is throughto bearing.housing further thai flush-with-housingcan result in set ;;i r;;* assemblY tii"t i'ib-nta"iing and damaging internal bearing minutes,shut down, inspect bearing' 5 . G r o u n dru n h e l i co p te ra t 1 0 2oloRPM for two and clean off anY escaPedgrease' 6 . I n s t a l la ft co w l i n g ,i f re mo ved' 1 . 15 O D e fu e l i n g WARNING No smoking Defueling must be done in a well-ventilatedarea'

;iifriil"i 6d'i;;i oi treticopt

be Low-fuelsendercheck (seeSection12.27O1maY Performed when defuelinghelicoPter' car bur etor ' 1 . T u r n f u e l va l ve o ff a n d d i sconnectflexiblefuel line at r tur n . oundcontaine' toher icopteand 2 . p r a c ee n d o f fu e r ri n ei n a su itabr econtainerGr f u e l v al ve o n . repeat as necessaryto complete 3. Turn fuel valve off when the containeris full and draining. 1 .330, and tor questr ipe' 4. Attach fuel line to carburetor,tor queper Section C h a n g e1 4 : J U L 2 0 0 8 P a g e1 . 8

FIEIBINSCIN

MATNTENANeE MANuAL

MOEIEL

F|44

1. 1 6 0 St o r a se For long-term (greaterthan 3O days) storage: 1 . Defuelaircraftper Section 1 .150. 2. Cleanaircraftper Section8 of R44 Pilot'sOperatingHandbook. 3. Paintor wax bare metal areasof main and tail rotor blades. 4. Apply suitablenon-dryingcorrosionpreventativecompound to C166 clutch shaft adjacentto seals(whereshaft entersand exits upper sheave). 5. Preserve engine in accordance with Lycoming Service Letter L180 (current revision). 6. Remove battery and periodicallycheck and adjust, as required, battery charge status. Check fluid level and specific gravity of non-sealedbatteries. environment. 7. Store aircraftin a protected,dry (dehumidified) 8. Periodicallyinspectaircraftfor corrosionand correct as required. 1 . 1 7 0 H v dra u l i cR e se rvo iFr i l te rReplacem ent CAUTION of hydraulicfluid is vital to propersystem operation. Cleanliness Use only clean f luid from sealed containers and avoid contaminationfrom dirty funnels,tubing, etc. 1 . Removeand discardsafety wire from filter cap. Removefilter cap from bottom of hydraulicreservoir.

2 . Removefilter and examine.lf debrisis found, use a magnet to determineif ferrous or non-ferrous. NOTE Ferrousdebrismay indicatepump damage.Replacefilter again after one flight hour. lf more ferrous debris is found, replace hydrauliump per Section 8 and flush hydraulicsystem per S e cti o n1 .18 0 .

3 . Cfeanfifter cap and replaceO-ring packing.Lubricatenew O-ring with 4257-15 f l u i d ( s e eS e cti o n1 .4 7 0 1 .

4 . LubricateO-ringin new filter with A257-15fluid and installfilter in reservoir.Install filter cap, torque per Section 1.330, and safety wire. 5. Adjust reservoirfluid level as required.Install filler-vent and torque per Section 1.330. Safety wiring filler-ventis not required.

C h a n g e1 3 : O C T2 0 0 6

P a g e1 . 8 A

FICIBINSICIN

MAINTENANtrE

MANUAL

MOE'EL

F|44

(seeFigure8-1A)

Cleanlinessof hydraulicfluid is vital to propersystem operation' ti1iialior r.it"O containersandavoidcontamination Ur" dirty funnels,tubing, etc. from";iy;f"un

Drain and flush hydraulicsystem if oil turns dark, or emits bad

filler-vent. 1. Removereservoir fluid beneathD5O0-1hydlaqliump at 2. placea one-litercontainerfor contaminated itot..puTq suctionandpressureT-fittings'-Allow mainrotor gearbox. Remove "u-pJ tineintocontainer.Poursmallamountof clean 'tri" orjin ir.riorgh"Su"iion fluidin ,"r"-oiito linewittj S"Jti"n i.i7Ot inio r"i"ruoirto purgesuctionline. Pressure nzSj-15ftuid ariin in followingstepwhenfiltercap is removed' 3 . Repface hydraulicreservoirfilter per Section 1'17O' pump to T4. See Figure 1-2A. ConnectMT384 (or similar)O.S-1.2 gpm hydraulic.test connection' iitti,.tb;;;

OSOO-1p"rj.

fittittgt ai" Ait"t"nt sizesto ensurecorrect

fluid' 5 . Disposeof drained,contaminatedhydraulicfluid. Fill reservoirwith A257-15 in empty container returnline at reservoirforwardelbow and placeend 6 . Disconnectservo'hydr;;ii; (usecap from pump for contaminated T-fitting).

flrio. Cap elbow on reservoirassembly

7 . Activate hydraulictest pump and inspecthydraulicsystem for leakage' fully forward. Then simultaneglsly 8 . Simultaneouslyfully raisecotlectiveand move-cyc_l'1c fluid level and fill as coliectiveand move cyciic iutty gft: . Monitor reservoir friiliil;i until ieturn linefluid into containeris clean. i"qlitiO. Repeat-pioceOurJ WARNING Stay clear of moving flight controls. Hydraulicforces can cause fully aft then simgltaneously-{ully g. Simultaneouslyfuily raisecollectiveand move cycLic 'Monitor reservoirfluid level and fill as tor*ard.. lower cottectirieinl moue .y"li" iuliv is clean. into container fluid i'"ifrir"O. nepelipio"eduru irntil retdrnline per Section 1 '33O 10. Connectservo return tineto reservoirforward elbow. Torque B-nut and torque striPe. 1 1. Bleedhydraulicsystemper Section1.190. procedure. lf filter 12. Removeand inspectfilter. lf debrisis found, repeat drain and flush 5' & is clean,reinstaliper Section1.170, steps4 Change13: O C T 2006 P a g e1 . 8 B

FICIEIINSiCIN

MAINTEI\ANcE

MANUAL

M(fEIEL

14.44

1.190 Bleeding Hydraulic System(seeFigure1-2Al 1. Disconnect cap on Db00-1 hydrau.liump pressure (aft) T-fitting and connect pressure tine from MT3g4 hfdrautic te.st'ptimp (or iimiiar o.e_i.z gpm-unit). Pressureand suctionfittings are-differentsizesto assurecorrectconnection]' 2. Remove reservoir filler-vent and cover hole with finger to prevent fluid toss. Disconnectcap on. hydrauliump suction (forward)f-i''i:ting-ani nyOrauft test pump suction line. Fillreservoiras required. "onnr"t

3 . Activatehydraulic test pumpandinspectfor leakage. 4. s.imu.ltaneous.ly - I-rlly raise collective and move cyclic fullv forward then simultaneously fully lowercollectiveand movecyclicfully aft. Rep'eat procedure ten times. WAR stay clear of moving flight contrors. Hydraulicforces can cause Inturv. 5 . Simultaneouslyfully raise collective and move gvclic futly aft then simultaneously fully lower collectiveand move cyclic futly forward.' Repeatprocedureten times. 6 . shut off hydraulictest pump. no leaksin hydraulicsystem. 7 . Cover reservoirfiller-venthote with finger to, preventfluid loss. Disconnecthydraulic test pump suction line from D5O0-1.pumpforward T-fitting and install cap. 'forque cap per Section1.330 and torquestripe. 8 . Disco.nnecthydraulictest qump pressureline from D5OO-1pump aft T-fitting and installcap. Torquecap per Seciion 1.330 and torque stripe. 9 . 49jy"^tre_se_rvoir fluid_level as required. tnstallfitler-ventand torque per Section 1.330. Safety wire is not required.

C h a n g e1 0 : JU L 2 0 0 4

P a g e1 . 8 C

F|E|BINSiEIN

MAINTENANcE

MOEIELF44

MANUAL

MT384-l,(115 VAC,60 Hzl or MT384-2 (208-230 VAC, 5O Hzl TESTPUMP HYDRAULIC

!: :t ll

=ll

I II

' ..ti

II

l ?r.rrr

r'',/

I I -Z(\.

\

'":.7=

jrii " I D500-1 HYDRAULIC PUMP PRESSURE

1-2A FIGURE

P a g e1 . 8 D

Change7: 06 Dec99

FIGIBINSCIN

MAINTENANeE MANUAL

MtlOELH'44

AND WEIGHING LEVELING, JACKING,HOISTING. 1.200 HANDLING, 1.210 GroundHandling 1.211 GroundHandlingWheelsInstallation the handlelockingpin andsliding a) Extendthe handleby depressing the handleout untilthe pin snapsintothe outerhole.Holdhandle andwheelwith the protrudingspindlein its lowestposition. Insert Spindleinto mountedon skid {seeFigure1-3}. NOTE lf helicopterhas not settledon its skidscompletely,the spindles may not go in all the way. In this case,pull down on the tail cone to spreadthe gearenoughto allowinstallation.

bl Make sure that the protrudingspindleis all the way in with the widenedend completelypastthe insideof the (seeFigure 1-34).

c) Pull handleover centerto raise helicopterand lock wheel in position(seeFigure1-4).

CAUTION When loweringthe helicopter,the handlehas a tendency to snapover.

NOTE 70 psi maximumtire inflationpressure.

l s s u e d 1: 1 J u n 9 3

P a g e1 . 9

FICIBINSiCIN

MATNTENANeE MANUAL

MOEIEL'|'44

F I G U R1E- 3

F I GU R1E-3 A

SPINDLE

1- 4 FIGURE

P a g e1 . 1 O

l s s u e d1 : 1 Jun93

FIGIBINSC|N

MAINTENANci

MO6ELF44

MANUAL

1.210 GroundHandling(cont'dl 1.212 GroundHandlingwheels- Floatship LandingGear INSTALLATION:

, Align aft blocks adiacentto mark on skid tube and position forward blocks to removecord slack. SKIDS

/\

Pulltail down. lnseft forward blocks at their lower height underboth skids.

a)

bl

Pushtail uP. lnsert rear blocks at their lower heightunderboth skids at marks.

c)

Pulltail down. Move forward blocksinward to their upper heightundei skid tubes.

d)

l.-!

_.

f

I

t,

\,/ FBOTT BLOCK POSTTIONS

/> SKIDS

:l

\/

FRONT ELOCK POSITIoNS

Pushtail up. Sliderear blocks out (upperheight of rear blocks is not used)and insertwheels underskids at rear marks. NOTE Wheelsmay be placeda few inchesforward to reduceforce requiredto pull tail down.

e)

Pulltail down and remove forward blocks.

Hl

INSTALLATION WHEELS HANDLING F IGU R 1 E-3 8 FLOATSHIPqROUND Change4: 1 Jun 97

P a g e1 . 1 0 A

MATNTENANcE MANUAL

FIClEIINSlclN

M('EIEL1f,,44

1.212 GroundHandlingWheels- FloatShipLandingGear{cont'd} REMOVAL: a)

b)

Pulltail down. Insert forward blocksat their upperheightat forward marks underskids.

c,,> SKIDS

\/

FBOUT BLOCK PO$T|ol|S

Pushtail up. Removewheels and insert rear blocksat their lower height (upperheight on rear blocks is not used) at marks. sKtos

cl

Pulltail down. Positionforward blocksunder skids at their lower height.

d)

Pushtail up. Removerear blocks.

e)

Pulltail down. Removefront blocks.

FROlIT BLOCK POSITIONS

WHEELS REMOVAL FIGURE1-3C FLOATSHIPGROUND

P a g e1 . 1 0 8

Change4: 1 Jun 97

FICIBINEiCIN

MATNTENANeE MANUAL

MC'EIEL

F'44

1 . 2 1 3 M o vi n gth e H e l i co p teor n Gr oundHandlingW heels Moving the helicopteron ground handlingwheels requirestwo people:one personto holdthe tail down and steer by holdingthe tail rotor gearboxand anotherpersonto push on primarystructure. The steel tube frame insidethe aft cowl door may be used as a hand hold for pushing. Keepfeet clear of skid tubes during ground handling. CAUTION Do not move helicopterby grippingtail rotor guard, outboard portionof horizontalstabilizer,tail rotor, or tail rotor controls. 1 . 2 1 4 M ai n R o to rB l a d eT i e -D o wns InstallMT29O-2main rotor bladetie-downsas shown in Figure1-5. Tie-downstrapsare installedby removingslackfrom linesto preventblade movement. CAUTION Overtightening tie-down strapscan damagemain rotor blades. 1.215 Parkins Referto Section8 of the R44 Pilot's OperatingHandbookfor parkingprocedures. 1.216 Trailering Traileringthe R44 is not normallyrecommended. Mosttrailerslargeenoughto accomodate the helicopterare designedfor much heavier loads; the trailer's springs and shock absorberswill not function properlywhen lightly-loaded.lf traileringis unavoidablethe following precautionsshould be observed: 1. Loadtrailerwith ballastuntil it is at the averageweight it is designedto carry. 2. tailcone,taking care to preventchafing or abrasionat the point. 3. Removemain rotor blades. lf not practicalto remove,the main rotor blades so they will not bear on droop stops. Locate s about 5 feet in from blade tips. smust be cushionedto preventblade damage. 4. Restraintail rotor to preventteetering.

C h a n g e1 3 : OC T 2 0 0 6

P a g e1 . 11

FIC|BINSiEIN

MAINTENANeE

MANUAL

MODEL

]I44

DETAIL. TIE AROUNDTHE BRACKETABOVETHE

CAUTION OvertighteningTie'Down straps can blades.

WRAPAROUNDTAIL CONEIN FRONT OF LIGHT,AROUNDTAIL CONETO BACKOF LIGHT;THENWRAPAROUND BASETO ATTACHVELCRO.

FIGURE1-5 MAIN ROTORBLADETIE-DOWW

P a g e1 . 1 2

C h a n g e1 3 : O C T 2 0 0 6

FICIBINSCIN

MATNTENANeE MANUAL

MOE'EL F|44

1.216 Trailering(cont'd) e) Protect helicopter's windshield, tail rotor and other vulnerable parts from highway debrisdamage. inspectaircraftfor possibledamage,with particular I f) After trailering,.thoroughly attention to the steel tube structure and rotor systems. 1.220 Jacking, Hoistingand Leveling 1. Helicopterjacking is accomplishedby placinga jack undereach end of the aft cross tube 1 inch inboardof elbow fittings.

CAUTION Care must be taken to preventthe helicopterfrom becoming from jacks. dislodged 2. Hoist helicopterusing MT527-1 helicopterlifting fixture as shown in Figure 1-6A, or by ingone-inchdiametersoft nylon rope throughthe lighteningholesin main rotor hub and forming a double loop per Figure 1-68. Ropemust have a minimum tensilestrengthof 2,50O lb. 3. Levelhelicopterusing either of the following methods: a. Levelingusing tailconeand aft landinggear cross tube: 1) Placea propellerprotractoron top of forward bay of tailcone.When tailcone is 0.7 degreesnose down ship is leveledlongitudinally. 2) Level helicopter longitudinallyby placing shims under landing gear skid tu b e s. 3) aft cross tube is not bent. Place a bubble level in center of aft cross tube. 4) Levelhelicopterlaterallyby placingshims under landinggear skid tubes. 5) Rechecklongitudinallevelper steps 1) and 2) above. Repeatsteps 1) through 4) as required.

NOTE Jacks may be used underaft cross-tube1 inch inboard from elbows.

C h a n g e1 2 : J U L 2 0 0 5

P a g e1 . 1 3

FICIBINSGIN

MODEL

MAINTENANcE MANUAL

F|44

-L vr[527 HELICOPTER LIFTING FIXTURE

1.6A HELICOPTER FIGURE

HOISTING

TAIL ROTOR

\t 1.68 HELICOPTER FIGURE HOISTIN G

BOX

f-\-

\

/o

VERTICAL FIREWALL

o

-\..

TAILCONE

)

lj

o

rfr:;

;URE RE

ffi 1

INSERTTUBEINTO HOLEAFT FiREI.IALL OF VERTICAL

o

IN TUBEAT WATER BELLY CABiN

1- 7 FIGURE C.G. DETERMINATION HELICOPTER

P a g e1 . 1 4

Change3: 5 MaY 95

FICIB|NSiCIN

MATNTENANcE MANuAL

MIIEIEL

F44

{cont'd} b. Levelingat the main rotor hub: 1. Rotatemain rotor until teeter hinge bolt is alignedwith longitudinalaxis of helicopter. Placea bubbleleverat locationmarked ,,levelhere',.

NOTE Levelmust be on top of mainrotor hub and parallelto teeter

hinqe bolt.

2 . Levelhelicopterlongitudinallyby placingshims under landinggear skid tubes.

3 . Rotatemain rotor until teeter hinge bolt is alignedwith lateralaxis of helicopter.

4 . Levelhelicopterlaterallyby placingshims under landinggear skid tubes. NOTE Jacksmay be usedunderaft crosstube 1 inchfrom elbow. 5. Rechecklongitudinallevel per precedingsteps. Repeatsteps as requiredto level helicopter.

C h a n g e1 3 : O C T 2 O O o

P a g e1 . 15

FlClElINEiClN

MlfElEL

MAINTENANcE MANUAL

F44

1 . 2 3 0 W e ish i n ga n d C .G. C a l cu l ation

Pilot's The EquipmentListAtreightand BalanceData form in the continuous a Operaiing Handbookmust be used to maintain recordof the helicopter'sweight and bqlanc

Level must be on top of main rotor hub and parallelto teeter

r i g h i n gP rocedur e 1 . 2 3 1 H e l i co p teWe 1 . D r a i na l l fu e l , i n cl u d i n gg a s colatorand both fuel tank sumps' , gear boxesto full m ar ks' 2 . F i l len g i n eo i l , h yd ra u l i cfl uid { if applicable)and 3 . l n s ta l la n d se cu rea l l d o o rs. 4.

level and center cyclic Position main rotor blades fore/aft and approximately stick.

BalanceData form are 5. Be sure all checkeditems on Equipmentlist/Weightand i n s ta l l e di n th e i r p ro p e rl o c ations' Cor r ectform as required. such as charts, tools 6. Be sure aircraft is clean and remove any foreign items r a gs.

or

of helicopterw hi l e i t 7 . H o i st a i rcra ftp e r se cti o n 1.22O. Haveone per sonholdtail is being hoistedto stabilizeaircraft'

raiseboth blad", ofl 8. With main rotor bladesorientedapproximatelyfore and aft, droop stops to allow hub to freely teeter' measuredifference L With aircraft hangingfreely and steadily,use a water level and belly at vertical cabin in verticalheight between centerlineof tail rotor gearboxand firewall. Referto Figure1-7. Recordheight differenceto nearesttenth of inch:

P a g e1 . 16

inches(no ballast)

Change1 4 : J U L 2 O O B

FIclBINSiclN

MATNTENANcE MANuAL

MOEIEL

'''44

1.231 HelicopterWeighingProcedure(cont'd) 1O. Determineuncorrectedlongitudinalcenterof gravity: 114.34 - t0.32 x (differencein height,from Step g)l = 't1.

inches

Place a 1OOO-pound capacity scale under each skid. Locate center of scales approximatelysix inchesforward of groundhandlingwheel mount centerline.

12. Lower aircraft until it rests entirely on scales. Aircraft must be well balancedon scales before releasingtail. Be sure aircraft is tevel laterallyby placing level on center of aft landinggear crosstube. 13. Determineuncorrectedempty weight: Right Scaleindication

tb

plus Left Scaleindication +

tb

minus Tare (such as lifting fixture, if installed) -

tb

UncorrectedEmptyWeight = 14. DetermineCG with f ull fuel and 150 lb pilot: [(CGfrom Step tO) x (emptyweight from Step 13)] + 3gg4o (emptyweight from Step 13) + 451.2

inches

15. lf CG f rom Step 14 is greaterthan 102.5 inches,determinerequirednose ballastas follows: [ ( C Gt r o m S te p 1 O - 1 0 2 .S )x (e

ht fromStep13)J - 74oB

95.5

bl

Roundballastweightup to nearest0.2b lb and install nose ballast per Section 1.240. Recordactualnoseballastinstalled:

tb

Repeatsteps 7 thru 15 and revisemeasurements and calculations.

C h a n g e1 4 : J U L 2 0 0 8

P a g e1 . 1 7

FICIBINSCIN

MAINTENANeE

M('EIEL

MANUAL

F44

Procedure(cont'd) unusablefuel: 16. Adjust weight and balanceto correctfor drained CG (inchesfrom datum)

WEIGHT (tb)

ITEM

MOMENT (in.-lb)

X

Shipas weighed

Add unusablefuel

(from Step 13)

(fromStep 1O)

+7.2

96.0

Helicopterbasic empty weight and CG (includes unusablefuel and full oil)

+691

*_

*cG location(arm)is determinedby dividingtotal moment by total weight' Datum is located 1OOinchesforward of main rotor centerline

CAUTION Followingany modificationwhich moves empty cG aft, calculate lf calculation weight und buluncewith 150 lb pilot and full fuel' in nose to shows CG aft of aft limit, fixed ballastmust be installed Section 2 of comply with minimum solo pilot weight limitationin Handbook. the Pilot'sOPer 17. Determinelateralcenterof gravityusingstep 13 data: (RightScale- Left Scale) L a t e r aCl G A r m =

P a g e1 . 1 8

(RightScale + Left Scale)

x 41.2O =

inch

C h a n g e1 4 : J U L 2 0 0 8

FIClElINSiClN

MATNTENANeE MANuAL

MC'EIEL

F'44

1.24O Fixed BallastInstallation 1. Removescrews securingupper consoleand open console. 2. Removelandinglight retainerand landinglights. 3. lf requiredby Section 1.231, installappropriatebatlastjrer Figure 1-8, 1-8A, or 1 - 8 8 , a s a p p l i ca b l e .

NOTE Maximumallowable ballastis 1 0

s.

4. Torqueboltsper section1.32o andtorquestripeper Figure2-1. 5 . Closeand secureupper console. 6 . Reinstalllandinglights and retainer. Functioncheck landinglights.

i! /--- --oo---

'li,(.".,,' -A\.,'i '', eT:i-fjl'..^',) t.

i_--l:;-...

.

MS21o42L3 '{Rrs-

(4 ptaces)

/-\

\

\ NASl't49F0332P WASHER (4 places)

rq

*oo

.-'

\./ i"r \\

r\ \l \l

A941-2 BALLAST PLATE

il

( 0.25r b)

Grl ll

A941-3 BALLAST PLATE ( 1 . 0 0t b )

\\ \)

c361-1 C O N S O LPEA N E L {Ref) *2 threadsminimumbeyondnut.

FIGURE 1-8 FIXEDBALLASTINSTALLATION (with -holeballasrplatesl C h a n g e1 4 : J U L 2 O O 8

P a g e1 . 19

FIclEtINSCIN

MOE'EL

MANUAL

MAINTENANCE

1t44

1.240 Fixed BallastInstallation(cont'd)

ii:tQ ,':::"j -'-'$[=i\""1'

'; o42Lg

f,MS21 '\N UT .-

\

I t

(.---,)-'.--

'l-'

)

\.'. i "r.tt. i tr\. \. \

,/0,,, '

\.'.'.. '.. i 4,

\l'

'.-

Sf

b'\'tl

Q)-,. G,

"-.. l:

or NAS6603*

\

!

\

t-

---

\

\

-

''-r

BOLT (4 places)

\ NASl 149F0332P WASHER (8 Places)

-s\\

t

\

(4 Places)

A941-2 BALLASTPLATE (0.25lb)

tl

li

tt.

..--l

.-a\ --'. r - \\'=))-.

NASl 149FO332P WASHER

'.

'j.'-o)-'

A941-3 BALLASTPLATE ( 1 . O 0l b )

c361-1 C O N S O LPEA N E L (Ref)

*Select NAS42B-3A bolt length as requiredfor 2 threads minimum beyond nut' Se|ectNAS66o3bo|t|engthasrequiredfor2|o4threadsbeyondnut.

FIGURE1.8A FIXEDBALLASTINSTALLATION (with 6-hole ballast Plates)

P a g e1 . 1 9 A

C h a n g e1 4 : J U L 2 O O B

FIclBINSiClN

MATNTENANcE MANUAL

MOEIEL

F,44

(cont'd) L240 Filqd Ballast_lnstallation

c 3 6 1 /,1

7 A941-6

FORWARD

*Boft length as requiredfor 2-4 threads beyond nutplate.

FIGURE1-8B FIXEDBALLASTINSTALLATION (with 2-holeballastplates,requiredwirh H.l.D.landinglightsl

C h a n g e1 4 : J U L 2 O O 8

P a g e1 . 1 9 8

F|clEIINSiclN

MAINTENANeE MANUAL

MOEIEL

844

REOUIREMENTS TOROUE 1.3OOFASTENER

P r o p e r t o r q u e i s c r i t i c a | . A | w a y s(where u s e c a applicablel | i b r a t e d w r hardware. enchesand undamaged, proplii/ -fuUricated_. - are clean' and climp-only bare metal Ensureall clampingsurfaces

or wet-primedt uftil" J' r".'nloq 1 -iq'l ll : I gi*v* :,:.l,ii:t"^1 or hardware ot-ctamp-up, in'los, ,"ruii i.,"v ;i#;il'Hil.]"l oart damaqe, and Premature t

1. 3 1 0 G e n e r a l fistedin Section 1.320 unlessotherwise Fastenersshail be torquedto standarddry.va.rues torque value by 10o/oto soecified.rf torque-ir'"ppfiLl-uv *ri'gii"j nJt,]ncr"as" 6t-hi;h;; friction at boltheadand shank' Forexample,thetorquewre.nchsettingforanNASl3O5boltusedwithanNASl063 nutplateib determinedas follows: 240 in.- l b tor queper Table 1 N A S 1 3 O 5b o l t (5 i n d i ca te s5 /1 6 i nch size)dr ybolt head 24 in .- l b Add 1O% becaut"-i"tqJi must be appliedat 264lnLE Torque wrench setting on at criticalfasteners.B33o stampednuts -r.'i"ir'inismq A secondaryrockingmechanismis required andare heticopter,

in ''ost areasonthe (parnuts) serveur"JX"oriiuoi^r9."i.i"e fasteners' for specific mechanisms torquedperTabteT.-in"tpc tists;;;;;J;;tlo.t ing a inspgction.by Assembly of flight controls is criticaland requires. insta||er the -;;f. pers.onis not avai|ab|e, qua|ifiedpe]son. lr '""ond " prror to inspecting fright control drust take a #ffi*"

bolts have higher Never substituteAN bolts for NAS bolts. NAS tensile strength.

or lost' would A critical fasteneris one which, if removed. tsin includes This ;;";;;ai;; tii" oplruiionot trt" heficopter. structuralts in the primarycontio"l';;;i;;' "lq l"li?il:{" ear, and drive sYStqlL th e b i rfra me l, a n d i after palnut installationin a stripe Torque seal (paint)is appliedto all criticalfasteners boih nuts.ontothe component acrosr extendingtro,i'ir,'" irii"n"r,, q;'io;i-t'iit^"udr ot bolt can be detected rotatio;-;-th;-nut (referenceFigure 2-1). An_y,rbd.qu"nt 1.460. given in section visually.npprou"olour"" tbr t-qud seal is has deterioratedappreciablymust Any nut damageddue to handlingor whose nut drag b e r e p l a ce d . C h a n g e1 4 : J U L 2 0 0 8 P a g e1 . 2 O

FICIBINSiCIN

MATNTENANeE MANuAL

MOEIEL

H44

1 . 3 1 0 G e n e r a{l c o n t ' d ) WARNING Two threads minimum must be exposed beyond nut on any installation to insure proper locking of fastener. Four threads maximum may be exposed. More than,fourthibads exposedmay allow nut to seat against bolt shank, resultingin insufficientt clamping. Torquingrequirements: 1. Bolt and nut are to be cleanand dry exceptwhen assemblyprocedurespecifiesantiseizeor thread-lockingcompound.

2 . lf chatteringor jerking occurs,disassembleand re-torquefastener. 3 . lf specialadapterswhich changeeffective length of torque wrench are used, final torque value must be calculatedusingformulabelow. 4. Properthreadengagementrequires2-4 threadsbeyondprimaryself-lockingnut (palnuts excepted). 5. Torque wrenchesmust be calibratedannually,when dropped,or when a calibration error is suspected. WHENUSINGA TOROUE WRENCH ADAFTER WHICH CHANGESTHEDISTANCEFROMTHETOROUEWRENCH DRIVETO THEADAPTERDRIVE,APPLYTHEFOLLOWING TO MAINTAINTHECORRECTED FORMULAS TOROUE HEADING:

T. Y. L. E.

TOROUE ACTUAL.{DESIRED} (INDICATED} APPARENT TOROUE EFFECTIVE LENGTHLEVER EFFECT1VE LENGTHOF EXTENSION

TOROUEWRENCH

SHORT OPEN-END ADAPTER

))

<J-TOROUEWRENCH

\u/

OPEN{NDWRENCH ADAFTER

ADAPTERDRIVE CENTERLINE

/n U

WBENCHDRIVE CENTERLINE

Al---/A

e---v)

serscREw ADAPTER

*l .

)a &/./ I tLY

HOSECLAMP ADAPTER

FLARE.NUT WRENCH ADAPTER

F o R M U T A I. ' ! L+E

-v

'E'AS PLUSDIMENSION) EXAMPLE: WITH

T = l3srb-in.

t-

Y = UNKNOWN L - loin. E = 1 . 6i n .

1 3 5 x 1 0 - l - 9 , ! , 9=. trz.gg l0 + 1.5 11.5 Y= 1171b-in.

FoRMULA,ftL L+E

=v

(WITH'E" AS MINUSDIMENSION) EXAMPLE:

T=135lb-in, Y = UNKNoWN L - 10.0in.

.T, = - =1 -3=5xr c160. 8 2 1 3 5 0 8.5 10 + 1.5

,'6a

61L14 '-----t/ SPANNERWRENCH ADAFTER

Y - 1 5 9| b - i n .

E = 1 . 5i n .

F IGU R E1 .9 C A L C U LATING TOROUE ADJUSTMENT FOREXTENSION C h a n g e1 3 : OC T 2 0 Oo

P a g e1 . 2 1

FICIBINSCIN

MOE EL H.44

MAINTENANeE MANUAL

1.320 StandardTorques TOROUES WRENCHING STANDARD SERIES FASTENER

NAS 13OOBolts NAS 660OBolts NAS600 THRU606 Screws NAS623 Screws NAS 1351 Screws NAS 1352 Screws AN3 Bolts AN4 Bolts AN6 Bolts AN8 Bolts AN5O2Screws AN5O3Screws ANSO9Screws AN525Screws MS24694Screws MS27039Screws

slzE

NAS6603

5O,

N/A

1t4-28

NAS6604

120

N/A

5t16-24

NAS6605

240

N/A

3t8-24

NAS6606

350

N/A

7t16-20

NAS6607

665

N/A

1t2-20

NAS6608

995

N/A

10-32

AN3

37

N/A

1t4-28

AN4

90

N/A

3t8-24

AN6

280

N/A

1t2-20

AN8

795

N/A

10-32

51-7) 8330-7(MS271

6to15

N/A

5t't6-24

N/A

2Oto 40

N/A

8 3 3 0 - 1 6( M S 2 7 1 5 1 - 2 6 )

N/A

7t16-2OI esso-zt(MS27151-211 42to 85

N/A

1t8-27

RODENDJAM NUTS ( A N 3 1 5a n d A N 3 1 6 )

8 3 3 0 - 1 3( M S 2 7 1 5 1 - 1 3 ) 1 1 t o 2 5

B 3 3 O - 1(9M S 2 7 1 5 1 - 1 9I ) 2 9 t o 6 O

3t8-24

1t2-20

PIPE TAPERED THREADS

WET DRY TOROUE TOROUE {tN.-LBl (tN.-LB)

10-32

1t4-28 STAMPEDNUTS (PALNUTS)

EXAMPLE FASTENER

B33O-24(MS27151-241 5 4 t o 1 1 O 60 NiA

N/A N/A

1t4-28

N/A

85

N/A

3/8-18

N/A

110

N/A

112-14

NIA

160

N/A

3t4-14

N/A

230

N/A

10-32

AN315-3

15

N/A

1t4-28

AN316-4

40

N/A

5tI6-24

AN316-5

80

N/A

3t8-24

AN316-6

110

N/A

Notes: 1, Valuesincludenut self-lockingtorque 2. lncreasevalues 1O% if torqued at bolt head value, then tighten to desiredposition 3. For elbow and tee fittings which requir" iiinrn"na, torque to indicated specified is range 4. Values * 1O% unless g-32 and smaller are not used for primary structure and do not require 5. Unlessotherwise specified, thread sizes control of torques.

Page1,22Change13:oCT2oo6

FICIEI|NSiCIN

MATNTENANcE MANuAL

MOEIEL

F,44

1 . 3 3 0 S p eci a T l o rq u e s Thesetorques are non-standardand supersedethose in Section 1.320.

AREA

FASTENER (21AN824-8D nuts on D792-2 and D793-2 tinesat firewalt

D799-2highpressure cutoutswitch D799-3 low pressurecutout switch MS21O42L6nut, compressordrive pulleyretaining

TOROUE 150 90 90 300

nut, D792-2 line assy-to-evaporator

150 wet wl A257-2O

nut, D793-2 line assy-to-evaporator

210 wet wt A257-20 210

nut, D794-1hoseassy-to-D777-1 compressor assy

3OOwet wl A257-2O

nut, D81O-1hose assy-to-D777-1 compressorassy

210 wet wl A257-2Q

nut, D810-1 hose assy-to-D783-1condenser

150 wet wl A257-20

nut, D811-1 hoseassy-to-D783-1 condenser

150 wet wl A257-20

AIR CONDITIONINGnut, D794-1 hose assy-to-D793-2lineassy

nut, D811-1 hoseassy-to-D793-2 lineassy (41valve cores (on servicingand cutout switches fittings)

150

1 (21NAS135l-6H2OPbolts securing8253-2 anchor 150 CYCLICSTICK (2) NAS1352-3H14screws,C683-4 damper(manual-controls) 40 C182-1 nut (2-inchsocket)on C0O7-5shaft assembly DRIVE 450-550 ft-tb wet Note: Shaft assemblieswith smallernuts are obsolete SYSTEM (6) NAS6608-42H bolts, lower sheave 900 EMPENNAGE {8) NAS6604-5 bolts, verticalstabilizerattach 170 C182-1 nut - see DRIVESYSTEM(above) CABIN

FANWHEEL (16) NAS66O3-6bolts, cone-to-fanwheel ( 8 ) N A S 6 6 0 5 - 1 2o r - 1 3 b o l t s ,h u b (10) inlet checkvalve base FLOATS, (1O)inlet check valve pivot (hosefitting) retainer EMERGENCY (22)nutson D674-1, -2, -3,-4, -5.& -6 hoses POP-OUT (4) nuts on D674-7 hoses on next page Notes: 1. 2. 3. 4. 5' 6. 7.

70 290-310 75-85 11 0 - 12 0 230-260 110-130

Values in inch-poundsunlessotherwisespecified. Valuesincludenut self-lockingtorque. Increasevalues 10% it torqued at bolt head Wet indicatesthreadslubricatedwith 4257-9 Anti-Seize For elbow and tee fittings which requirealignment,torqueto indicatedvalue, then tighten to desiredposition Values + 1Oo/o unlessrange is specified Unlessotherwisespecified,thread sizes8-32 and smallerare not used for primarystructureand do not require control of toroues.

C h a n g e1 4 : J U L 2 0 0 8

P a g e1 . 2 3

FIClEIINEiclN

MAINTENANcE MANUAL

MIIEIEL

H.44

(cont'd) J.330 SpecialTorques thosein Section1'320' and supersede Thesetorquesare non-standard

It OtnNgOSnuts,fuelprimerlines{0-540) 100, wet with B27O-1Oadhesive

clamp,electricfuel PumP(lO'540) fuel controlinlet reducer(lO-54O)

(2)fue|hosenuts,engine.drivenfuelpump.to-fuelcontro|in|ettee

ilo-540); (2) fuel hosenuts,fuet control inlet tee-to-reliefvalve (lO-540); (2) fuel hosenuts,fuel control-to-flowdivider(lO-540) (0-540) (2) fuel hosenuts,gascolator-to-carburetor tank; (2) fuel line nuts, auxiliary-to-main (2) fuel line nuts, main tank-to-fuelvalve;

FUEL SYSTEM

13 5 - 15 0

110-130 110-130

iziru"tline nuts,reliefvalve-to"@

(2) fuel line nuts, fuel valve-to-gascolator (5) fuel quantity senderbolts, self-sealing sendercenter stud terminalnut

jam nut, electricfuel pump inlet elbow flO-540); jur nut, electricfu"l pu.p ortl"t t"" jam nut, low-fuel warning sender tee, fuel control inlet (lO-540) fuel pump (lO-540) inlet adapter,engine-driven (0-540) (4) bolts, airbox-to-carburetor gascolatordrain valve on next Page Notes: 1. Values in inch-poundsunlessotherwisespecified' 2. Values includenut self-lockingtorque. if torqued at bolt head 3. Increasevalues 1Oo/o 4. Wet indicatesthreadslubricatedwith A257-9 Anti-Seize value,then tighten to desiredposition s. For elbow and tee fittings which requirealignment,torque to indicated 6. Values t 1O% unlessrangeis specified used for primarystructureand do not require 7. Unlessotherwisespecified,thread sizes8-32 and smallerare not control of torques,

P a g e1 . 2 4

C h a n g e1 4 : J U L 2 O O 8

FIClBINSiclN

MATNTENANcE MANUAL

F|44

MOEIEL

1.330 SpecialTorques(cont'd) Thesetorques are non-standardand supersedethose in Section 1.320.

FASTENER

AREA

TOROUE

(4) 8330-19 palnuts, reservoirpressureelbow {if installed}& , servo pressureT-fittings (2) 8330-21 palnuts, reservoirpressureinlet elbow & pump pressureT-fitting (if installed) (4) B33O-21palnuts,return elbows (if installed)& T-fittings

30

(2) 8330-25 palnuts,pump suctionT-fitting & reservoirsuction elbow (if installed)

75

cap, pump pressureT-fitting

60

cap, pump suction T-fitting

120

(if installed)& HYDRAULIC (4) D452-3 iam nuts, servo pressureelbows servo return T-fittings HOSES & FITTINGS l2l D452-4 iam nuts, pump pressure T'fitting & reservoir pressureinlet elbow (if installed)

45 45

60 90

(41 D452-4 jam nuts, return elbows (if installed)& T-fittings

90

el D452-Oiam nuts, pump suctionT-fitting & reservoirsuction elbow (if installed)

150

pressurehose (2) nuts, pump-to-reservoir

13 5 - 15 0

(6) nuts, pressurehosesto servos(exceptpump)

9 5 -10 5

(2) nuts, reservoir-to-pump suctionhose

190-210

(61nuts, return hosesfrom servos

135-150

HYDRAULIC Hydrauliump-to-gearboxmounting nuts (see MAIN ROTOR GEARBOX} PUMP (41attach bolts, reservoir-to-f rame

60

filler-vent HYDRAULIC RESERVOIR filter cap

100

sight gage

150

scissors HYDRAULIC MS27039CO806screw attachingD2OO-2 SERVOS 8330-6 palnut on above screw LANDlNG GEAR

(8) clamps,strut fairings (4) NAS6604 bolts,groundhandlingwheels nuedon next p a g e

150

25 5-10 100 wet with B27O-10 thread locking adhesive

70

Notes: 1. Valuesin inch-poundsunlessotherwisespecified. 2. Values includenut self-lockingtorgue. 3. Increasevalues 11o/oit torqued at bolt head 4. Wet indicatesthreadslubricatedwith A257-9 Anti-Seize position 5. For elbow and tee fittings which requirealignment,torque to indicatedvalue,then tighten to desired 6. Values + lOo/ounlessrangeis specified thread sizes8-32 and smallerare not used for primarystructureand do not require 7 . Unlessotherwisespecified-, control of torques.

C h a n g e1 4 : J U L 2 O O B

P a g e1 . 2 5

MAINTENANcE MANUAL

FICIBINEiCIN

Mt)E EL F,44

1 . 3 3 0 Sp eci a T l o rq u e s(co n t'd ) Thesetorques are non-standardand supersedethose in Section 1.320.

FASTENER

AREA MAIN ROTOR BLADE

l2l 8.289-2bolts, self-sealing l2l C722-3 screws, tip balanceweight t+t AGSO-+fittings, gearboxmountingor l4l NAS1291-1O nuts AN32O-Bnut, gearboxpinion {retainsC908 yoke) chip detector housing

MAIN ROTOR GEARBOX

chip detector (threadedtYPe)

90 ft-lb, dry, torqued from bolt head or nut 35-45 ft-lb Approximately15O Approximately75

(4) NASl 291-4 nuts, hydrauliump-to'gearbox(or cover)

40

(6) NASl 352-4 screws, end cover

120

(1) NAS634-105bolt, teeterhinge and (2) NAS634-105bolts, coninghinges 12)21FKF-813self-lockingjam nuts, main rotor pitch links line ( 1 ) A N 8 1 8 n u t , m a n i f o l dp r e s s u r e (4) or (6) AN818 nuts, oil coolerlines (2) bolts, engine-to-groundstraP {4) bolts, intake manifold-to'sump(lO'54O} (1) nut, A462 fitting on carburetormixture control arm POWERPLANT

55

150

sight gage

PITCHLINKS

60-80

fillerplug

(6) NASl 352-4H16P screws, sump-to-housing

MAIN ROTOR HUB

TOROUE

(O-540) (4) nuts, carburetor-to-engine (12) nuts, exhaustflange ( 12 ) s p a r kplugs (4) bolts, airbox-to-carburetor

12O at head 150 New bolt: O.O21-O.O22 inch elongation,wet Used bolt: 0.O20-O.022 inch elongation,wet, and cotter pin holes must align

300 25 to 30

450 to 500 96 90-10O, torque center bolts first

25-30 96 initial, 2O4 final, torque in crisscross pattern

200-220 42O, wet with A25710 sparkplug thread lubricant

25-35

Notes: 1. Valuesin inch-poundsunlessotherwisespecified. 2, Valuesincludenut self-lockingtorque. 3. lncreasevalues 10% if torqued at bolt head 4. Wet indicatesthreadslubricatedwith A257-9 Anti-Seize to desiredposition b. For elbow and tee fittings which requirealignment,torque to indicatedvalue,then tighten range specified is 6. Values t 107o unless and do not require 7. Unlessotherwise specified,thread sizes8-32 and smallerare not used for primarystructure control of torques.

P a g e1 . 2 6

c h a n g e1 4 : J U L 2 O O 8

FIclBINEiClN

MATNTENANcE MANuAL

M(fElEL

F.44

1 . 3 3 0 Sp e ci a T l o rq u e s(co n t'd ) Thesetorques are non-standardand supersedethose in Section 1.320.

AREA

FASTENER

screws STEEL TUBE Ql C722-2 5/8-inchinternal-wrenching FRAME ( 2 ) S 1 4 11 9 s c r e w a n d A 3 1 O O 7n u t (18l AN503-8-8fillister-head screws (26) NASl 352-O8HBPsocket-headscrews SWASHPLATE (1) NAS6605-8bolt clampingC2O3-1yoke TAIL ROTOR NAS66O6-53bolt, elastomericteeter (delta)hinge (4) bolts, input cap

TOROUE 120 to 125 ft-lb wet I to 1O 17

30 190 (oppositeclampingbolt must be torquedfirst) 380 60

(8) bolts, input housingand output cap

100

chip detector

100

filler-ventplug

100

input yoke retainingnut TAIL ROTOR GEARBOX MS21O42L5nut, pitch controlhousingstud

35-45 ft-tb

240

(4) NAS1352-5H12Pdrilled-headbolts, gearbox-totailconeattaching

200

(4) NAS1352-5-12P bolts (undrilled), gearbox-totailconeattaching

240

sight gage

150

Notes: 1. Valuesin inch-poundsunlessotherwisespecified. 2. Valubsincludenut self-lockingtorque. 3. Increasevalues 10o/oif torquedat bolt head 4. Wet indicatesthreadslubricatedwith A257-9 Anti-Seize 5. For elbow and tee fittings which requirealignment,torque to indicatedvalue,then tighten to desiredposition 6. Values + 1O% unlessrangeis specified 7. Unlessotherwisespecified,thread sizes8-32 and smallerare not used for primarystructureand do not require control of torques.

C h a n g e1 4 : J U L 2 0 0 8

P a g e1 . 2 7

I l

FICIBINSiCIN

MAINTENANcE

MANUAL

MOE'EL

FI44

1.4O0 APPROVEDMATERIALSLIST or their distributor(s). The following items are availablefrom the noted manufacturer(s) of primers,solvents, Check with appropriateregulatoryauthority(s)for allowableusage cleaners,fillers,putty, strippers,and paints'

CAUTION Follow product manufacturer'sinstructionsfor handling and storage. 1 . 4 1 0 Pa i n tS tri P P e rs PRODUCT

MANUFACTURER/SUPPLIER

APPLICATION

Cee-BeeStripper A-292

McGean-Rohco Cee-BeeDivision 9520 Cee Bee Drive Downey, CA 90241 T e l : 5 6 2 -803- 4311 F a x: 5 6 2 -803- 6701

Metal parts, except blades and flex plates

PlasticMedia BlastingSystem

P a u l i& Gri ffinCo. 907 Cotting Lane V a ca vi l l e CA , 95688 Tel: 7O7-447-7000 Fax: 707-447-7036

Metal parts excePt blades and unedsheet metal less than O.O4Oinch thick

P a g e1 . 2 8

C h a n g e1 3 : O C T 2 0 0 6

FIGIBINSCIN

MATNTENANcE MANUAL

]f,,44

M(IEIEL

1.42O Solventsand Cleaners PRODUCT

osoL220 Benzene,1-Chloro-4 (Trifluoromethyl) PCBTF

APPLICATION

MANUFACTURER/SUPPLIER

Safety-KleenSystems,Inc. General use for cleaning and prior to applyingprimer, P l a n o ,TX adhesive "t ",:.:"t Any Any

Acetone

Any Lacoline (AliphaticHydrocarbon)

Acrylic plasticcleaneronly

Dupont Lacquer& En a m e C l l e a n e r3 9 3 9 5 o r K w i k C l e a n3 9 4 9 5 *

Dupont Los Angeles,CA

and Cleaning,degr easing, removingsandingdust prior to primingor top coat

Presolve

LPS

Clean hydrauliccomponents only.

Tetrachloroethylene (Perchloroethylene)

FederalSpec

Vapor degreaser

815 GD

BrulinCorporation lN In d i a napolis,

cleaning lmersion/ultrasonic

o-T-236

*containswater; do not use on steel. 1.430 Flllersand Putty PRODUCT

APPLICATION

MANUFACTURER/SUPPLIER

229OSPutty 22915 (Hardener)

Dupont Los Angeles,CA

0 5 1 1 4 4 - 0 5 9 6 0A c r y l Green Spot Putty

3M St Paul,MN

Minor surfaceimperfections

US Chemical& Plastics E a s yW h i t e 1OO1O (Bodyfiller with hardener) Canton,OH 1 . 4 4 O T o r q u eS e a l PRODUCT

F-9OOWhite

C h a n g e1 4 : J U L 2 0 0 8

MANUFACTURER/SUPPLIER

OrganiroductsCo. P.O.Box428 lrving,TX 75060

APPLICATION

Torque Seal-White

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MAINTENANcE

FIEIBINEICIN

MC?E'EL F'44

MANUAL

1.450 Primers PRODUCT

MANUFACTURER/SUPPLIER

APPLICATION

GrayepoxyCA 75O1with Desoto AerosPaceCoatings, Unlimited PRC-DesotoInt., Inc. C A 7 5 0 1 B a cti va to r Gl e n dale,CA I AluminumPartsand Gray epoxy 44-GY-79 Deft, Inc. assemblies,and fiberglass with 44-GY-79 activator l rvi n e,CA components Aviation Primer,Green, A9O2* (Aerosol)

ValsparCorporation Me d i na,OH

Limitedor touch-upuse only.

* shelf life two years 1.455 PowderCoat (steelparts only)

1,'J3i8;ar,";'S:#1;:l':*s'erectrostatica n'li?:ffi ffi ffiil*i{;"33:'ilfl MANUFACTURER PRODUCT

1 3 - 7 0 0 4 C o ve lZ i n c-R i chGre y Epoxy Powder

Morton International Reading,PA

81-2158 VitralonZinc-RichGreY Epoxy Powder

Pratt and LambertChemicalCoatings Buffalo,NY

appliedwith total coatingthicknessof O.OO3 For topcoating,RHCuseselectrostatically to O.006 inch (primerand topcoat): PRODUCT

MANUFACTURER

Series 49-RAL 7043 High Gloss GreY Tiger Drylac USA RanchoCucamonga,CA PolyesterWeatherResistantPowder. 39-80040 Semi GlossBlack PolyesterWeatherResistantPowder

Tiger Drylac USA

Eachstep is bakedfor 1O-15minutes.Curingtemperaturefor all of the abovemust noO exceed4OOdegreesF.

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FICIBINSICIN

MATNTENANcE MANUAL

M('E,EL

F'44

1.460 Paints Paintcode numbersfor specifichelicopterserialnumbersare listedon the insidecover of factory guppliedmaintenancerecord (log book). Use fisheyeeliminator,accelerator,or other additivesper manufacturersrecommendations. MATERIAL

MANUFACTURER

A Flat Black lmron 373-P-29950 Polyurethaneenamel Dupont with 193S or 89OgSactivatorand 86855 reducer Los Angeles,CA Semi-glossBlack3900-05-1GKwith 39-SG CardinalIndustrialFinishes catalyst and water reducer(landinggear only) El Monte, CA B Dark gray lmron DSO2OHKPolyurethaneenamelwith Dupont 193S or 89095 activatorand 86855 reducer c Lycoming engine gray (high temperature)#76448* Textron Lycoming (enginecaseand cylinders) Williamsport,PA Lycoming engine gray E-8948 (cooling s and RandolphProductsCo. carburetorheat shroud) Carlstadt,NJ Lycomingenginegray enamel#A,219 Tempo Products (aerosolcan, for touch up)* Cleveland,OH D WhitelmronK0774HKPolyurethane enamelwith193S Dupont or 89095 activatorand 86855 reducer E Yellow lmron KO6SOHKPolyurethaneenamel with 193S or 89095 activatorand 86855 reducer F lmron 5000/6000 Polyurethaneenamel tint{s} with 193S or 89095 activatorand 86855 reducer G Clearlmron 24005 with 193S or 89095 activator H Cfearlmron24005 (1-part)and RK-P-19478(11-parts) with 193S or 89095 activator(4-parts) J White #23OOlatex flat exterioracrylic Vista PaintCo. (for landinggear floats) Long Beach,CA K White Cat-L-lnk#50-1OOR(shelflife 3 years) Ethone,Inc. A2O Catalyst* tfor silk screenletters) West Haven,CT Yellow Cat-L-lnk#5O-2O2BR(shelflife 3 years) A2O Catalyst* (for silk screenletters) L Red lmron K0759HKPolyurethane enamelwith 193S or 89095 activatorand 86855 reducer N K r y f o n# 1 3 1 1 * Matte clear (aerosolcan; for silk screenletters) For limitedtouch-upof interiorand landinggearonly: A Krylon#1613 Flat Back(aerosolcan)* NYBC#14 FlatBack (aerosolcan)*

Dupont KrylonDiv. of Borden Columbus,OH KrylonDiv. of Borden New York BronzePowderCo. Scranton,PA

"Shelf life two years C h a n g e1 4 : J U L 2 0 0 8

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FIclBINSiClN

MoEIEL H44

MAINTENANcE MANUAL

SURFACEPAINTING E X T E RNAL See approvedmaterialslist for detail informatibn on each letter finish code. See Section9.130 for specificbladepaint pattern d i me n si o n s, All exteriorsurfacesare code D & F unlessotherwisespecified. F IGU R E1 -1 1 A PAINTFINISHCODELOCATIONS P a g e1 . 3 1 A

C h a n g e1 4 : J U L 2 O O B

FIClBINEiclN

MATNTENANcE MANuAL

MC'EIEL ;f,.44

l

I

l

i

II

EXTERIORSURFACEOF FUELTANK FACINGGEARBOX COMPARTMENT

/.___

I

I

,

i I

I

l

I

I I

I

t

C - (CARBHEAT SCOOPON EXHAUST COLLECTOR RH SIDEOF AIRCRAFT)

F IGU R E1 -1 1 8 PAINTFINISHCODELOCATIONS

C h a n g e1 4 : J U L 2 0 0 8

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MATNTENANeE MANUAL

FICIBINSiCIN

MOE'EL

F|44

1.470Lubricants

A257-1

Mo l y Gre a se1 O1

Southwestern Petroleum Corp. Fort Worth, TX

A257-2

Ge a rL u b e2 0 1 gear oil

SouthwesternPetroleum Corp.

A257-3

Aero Shell 14 MIL-G-25537

ShellOil ComPanY Houston,TX

A257-4

Dexronll or Dexronll/Merconor Dexronlll/Mercon automatictransmissionfluid

State Pennzoil-Quaker Divisionof ShellOil Co. Houston,TX

A257 -5

Sta-Lube3120 water-resistantgrease

Sta- Lube,Inc. Compton,CA

A257-5

1 1 4O2 water-resistantgrease

Lubrimatic BuffaloGrove,lL

A257 -6

Fuelubef uel-resistantgrease

FleetSuppliesInc. Cleveland,OH United-ErieDiv. of lnterstateChemicalCo. Erie,PA

A257 -6

A257 -7

Lubri-KoteTYPeA 1040 CR drY film lubricant

Mealey Lubricants Cleveland,OH

A257 -8

P-8O,rubberlubricant

lnternationalProducts Trenton,NJ

A257 -9

Anti-seize767

Loctite CorP. Newington,CT

A257 -10

2612, spark plug thread lubricant

ChampionSPar kPlug Toledo,OH

A257 -10

T-556

Union Industries FL Jacksonville,

A257-12

2 8 g rease Mo b i l g re a se

Exxon-MobilCorP. Fair fax,VA

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IICIBINSGIN

MATNTENANeE MANuAL

M('E

EL F|44

L4ZQ lubricants(cont'd) RHC PART NO.

MFR. PART NO.

MANUFACTURER

4257-15

Mil-H-s606 hydraulicfluid

Any

4257 -16

Type M 20W-50, S A EJ 1 9 6 6

Phillips66 Co. Pasadena,TX

t

A257-16 Aviation Oil 2OW-50, S A EJ 19 6 6 ,

ExxonMobilCorp. Fairfax,VA

4257 -18

55 O-ringlube

Dow CorningCorp. Midland,Ml-

A257-19

111 Valvelube& Sealant

Dow CorningCorp. Midland,M l

A.25720

SP.15 PAG OiI

SandenCorp. Wylie,TX

A257 2 1

P-16 PetrolatumLube

PanefCorp. Milwaukee,Wl

Ch a n g e1 3 : OC T 2 OOo

Pa ge1.33

FIGIEIINSE|N

MOEIEL

MAINTENANeE MANUAL

'f,,44

1.480 Adhesivesand Sealants

ide, B.270-1 Sealant-PolYsulf

Gray

FS-8907B-2

PPGAerospace Glendale,CA

ide, B.270-1 Sealant-polvsulf

Gray

AC-35082

Advanced ChemistrY & TechnologyInc., GardenGrove,CA

B'270-2 Sealant-metal( 1-Part)

Silver

2084

3M St. Paul,MN

fuel resiitant (2-part) fuel resiitant (2-Part)

rubber Translucentscs 1201 B.270-4 Sealant-silicon ( 1 -p a rt)

GeneralElectric Waterford, NY

B.270-5 Sealant-synthetic

Black

04-2805 94-031

3M

B.270-6 Sealant& lubricant-

Cream

Titeseal55

RadiatorSpec. Co. Charlotte,NC

B.270-7 Adhesive-foam&

Amber

74

3M

B27A-8 Adhesive-rubber,

Brown

c 160

StabondCorP. Gar dena,CA

B,270-9 Adhesive,epoxy,

Gray

2216 BlA

3M

rubberputty (1-Part)

thread (1-part)

fabric (aerosol) nitrile/solvent {1 -p a rt)

structural,flexible (2-part)

B.270-10Adhesive/sealant-

Red

Loctite CorP. Newington,CT

B.270-11Adhesive/sealant

Red

Loctite Corp.

B,270-12Sealant-electrical

Tan

FlamemasterCorP. Chem Seal Division Sun Valley,CA

thread-locking {tight-fits) ( 1-part)

thread-locking (loose-f its) (1-Part) potting (2-part)

B,270-13Sealant-silicone,

Translucent 3 14 5

electronicuse (1-part)

8,270-14Adhesive-foam,

neoprene/water (1-part)

B.270-15Adhesive-Plastic,

Dow Cor ningC or P. Midland,Ml

100 Neutr al 3 M White Lavender lOO Lavender Clear

2262

3M

fo r vi n yl (1 -p a rt)

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FICIE|INSiCIN

MATNTENANeE MANUAL

MOEIEL

H'44

1.480 Adhesivesand Sealants(cont'd) RHC PART NO.

DESCRIPTION

COLOR

MFR. PARTNO.

MANUFACTURER

8270-17 Adhesive-

Clear

SuperBonder Loctite Corp. 495 Newington,CT

8270-18 Adhesive- Weather-strip

Black

05113508008

3M

8,270-19 Adhesive- Epoxy,

Green

1838 B/A

3M

Purple

222 or 222M5 Loctite Corp.

cyanoacrylate, Instant (1-part) (1 -p a rt)

Structural,rigid (2-part) B.270-20 Adhesive- Thread locking,Non-permanent (1-part)

8270-21 Protectant- Corrosion, Non-drying(1-part) B.270-22 Protectant- Corrosion, Drying{1-part) B.270-23 Sealant- Gasket (1 -p a rt)

B270-23 Sealant- gasket, (1-part)

8270-24 Activator/PrimerAnaerobicAdhesive (1-part)

B.270-25 Clear Coat - Automotive Touch-up,brushin bottle (1-part)

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Lt. Amber LPS3

LPSLaboratories,Inc. Tucker,GA

Amber

LPS Hardcoat LPS

Brown

GM3D

P . O . B .I,n c . , Cincinnati,OH

Brown

JV66B

DanaCor p. Chur ubusco, lN (Victor ReinzBrand)

Translucent7649 Green Clear

Loctite

ClearCoat Automotive- Touch Touch up bottle up

Page1.35

FICIBINSiCIN

MAINTENANeE

MANUAL

MOEIEL

F44

1.49O StorageLimits 1 . P / N 8 2 8 3 - x h o s e s h a . ; e a s h e | f s t o r a g e | i f e o f s y e a r s . H o s e s e r v occurs i c e | i f efirst' is,,on hOurs,whichever 22OO years or 1 2 of maximum a with condition,,, years. Erasticcord servicelife is "on 2. Erasticcords have a sherf storagerife of 5 or FAA Form 8130 date as condition",with a maximumof i 2 years. Use invoice start date. F (3O degreesC)' with 3 . Store drive and alternatorV-beltsat less than 85 degrees atmospheric and oir vapors, rerativehumidity berow 70 percent. Avoid sorvent (electricmotors' arc welding' ionizing contaminants,sunlight,and ozonesources precedingrecommendationsare air purifiers,etc.). Belt shelf life is 4 years if as start date' followed. use invoicedate or FAA Form 8130 date

and kept sealedin their 4 . Oils and greaseshave a 5 year shelf life when stored date as start date unless originalcontainer. Use invoicedate or FAA Form 8130 date (in which caseuse the manufacturerhas markedcontainerwith manufacture manufacturedate as start date). life of 20 quarters (5 5 . Rubbero-rings, seals, and gaskets have a shelf storage year s' Usecur e date y e a r s). S e rvi cel i fe i s " o n condition"with a m aximumol 12 on packageas start date. 1 . 5 O O( R E S E R V E D }

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FIOBINEiCIN

MATNTENANcE MANIIAL

MoETEL lr.44

1.600 PARTINTERCHANGEABILITY --

The following parts are interchangeable.Unlessnoted otherwise, whenever one part is referredto in this manual,its substitutepart is also permitted. Part

Interchangeablewith

AN34O nut AN 3 4 5 n u t N364 nut AN5O7 screw AN509 screw AN 5 1 5 s c r e w A N 5 1 5 Cs c r e w AN 5 1 5 U Bs c re w AN 5 2 5 & A N 5 2 6 scre w A N 8 1 4 & M S 2 4 3 9 1p l u g A N 8 1 5 & M S 2 4 3 9 2u n i o n A N 8 1 9 & M S 2 0 8 1 9s l e e v e AN 8 2 2 & M S2 0 8 2 2 e l b o w A N 8 2 3 & M S 2 0 8 2 3e l b o w AN 8 2 5 & M S 2 0 8 2 5 te e AN 8 2 6 & M S 2 O8 2 6te e AN 8 9 4 & M S 2 4 3 9 8 b u sh i n g AN 9 0 0 g a s k e t AN 9 2 4 n u t & MS 2 4 4 OOn u t AN 9 3 1 g r o m me t AN936 lockwasher A N 9 6 O - 8 Lw a s h e r AN 9 6 0 - 8 w a sh e r AN 9 6 O - 1 O Lw a sh e r A N 9 6 O - 1 Ow a s h e r AN96O-416Lwasher AN 9 6 0 - 4 1 6 w a sh e r A N 9 6 O - 5 1 6 Lw a s h e r A N 9 6 O - 5 1 6w a s h e r AN 9 6 O - 6 1 6 Lw a sh e r A N 9 6 O - 6 1 6w a s h e r AV D EL 1 6 9 3 ri ve t MS2O604ML4W1rivet M S 2 1 9 1 g D Gc l a m p NAS1291 nut NA S1 3 O 3t h r u N A S 1 3 2 Ob o l t NAS487 instrumentndt NAS679A nut NAS679C M nut NA S6 9 6 n u t p l a te NA S6 9 8 n u t p l a te NA S6 9 8 n u t pl a te

MS35649 nut per NASM35649 except brass nut M S35650 nut per NASM 35650 M S 2 1 O 8 3n u t p e r N A S M 2 1 0 8 3 MS24693 screw per NASM24693 MS24694 screw per NASM24694 M S352O6scr ew per NASM 35206 M S 5 1 9 5 7s c r e w 8567- scr ew M S27O39Cscr ew per NASM27O39 A S 5 1 6 9p l u g A S 5 1 7 4u n i o n A S 5 1 7 6s l e e v e AS5195 elbow A S 5 1 9 6e l b o w AS5197 tee AS5198 tee AS5173 bushing M S35769 gasketper 4535769 AS5178 nut M S35489 gr om m et 8332-_ lockwasher N A S 11 4 9 F N 8 1 6 Pw a s h e r NAS1149FN832Pwasher NAS1149F0332Pwasher N A S 11 4 9 F 0 3 6 3 Pw a s h e r NAS1149FO432Pwasher NAS1149F0463Pwasher N A S 11 4 9 F 0 5 3 2 Pw a s h e r NAS1149F0563w P asher NAS1149F0632Pwasher NAS1149F0663w P asher AVDEL 1691 r ivet MS2O6O4M4W1rivet per NASM2O6O4 A S 2 1 9 1 9c l a m p MS21O42 nut per NASM21042 NAS6603thr u NAS6620 bolt* MS33737 Instrumentnut per NASM33737 N A S 1 2 9 1 - _n u t N A S 12 g 1 C - _ Mn u t M S21O71nutplateper NASM 21071 M S21073 nutplateper NASM 21073 M S21073 nutplateper NASM21O73

* T h e f o l l o w i n gb o l ts mu st b e N A S 1 300 ser iesonly: N A S 13 0 4 - 2 8 , - 3 5 , - 3 7 , & - 3 8 , a n d N A S 1 3 0 5 - 3 5 C h a n g e1 4 : J U L 2 0 0 8

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FIElBINSiclN

MAINTENANeE

MOE,EL 1r'44

MANUAL

R44 SERIES AND FLIGHTTESTING lNSTtuerlo.NSFORREASSEMBLTNG 1.700SPEC|AL I

MECHANIC BY A CERTIFICATED REASSEMBLY:TO BE PERFORMED

"A" by removinglag bolts 1. Removetop of cabin assemblycrate. Removewall marked walls' Removeall remaining assembly' Remove paintedblack. Remove blade and tailcone rotor "tp"|nug" baie. open main tr"i" parts, "r"t" crate. """"ii'"rnin "ri".tiiv, 2.

Reinstallmain rotor hub per Section 9'122'

3. Assemblelandinggearper Section5'320'

Do not installstrut f

at this time.

end of crate while at same 4 . Attach a hoistto main rotor hub per section 1.22o. Lift aft horizontalposition'lift with time taking up slack in hoist. when r',"ri"opt"tq",,t is in a screws and carriagebolts hoist until cabin is edby hoiit alone. Removelag attachinghelicoptercabinto crate' Removecrate' CAUTION lift helicopterand attached crate using box and frames could to main rotor points and install assembledlanding 5. Removesfrom tandinggear attachme.nt lnstallfront crosstube cover gearper sectionl.l2o or seclio'ns (ttoutlandinggear).(not applicableto utilitv float inrt"tt ,trrt f.;;"d t"; Sectioi 6.qZO . tt Oesir-ed, landinggear). per section 4;312' Install strobe 6. Remove tailcone cowling and install tailcone Loian,-anaGPS antennas(if equipped)'Installtailcone light. Instalt "o.nrrni"uiion, cowling.

inside of Make sure all foam packing materialis removedfrom could shaft drive tailconebeforeinstallation;damageto tail rotor 7 . lnstallempennageassemblyper Section4'322' 4.330.

Installtail rotor guard Per Section

8 . Filltail rotor gearboxwith A257-2 oil to full level. markingson bladeswith 9 . lnstalltail rotor per Section9-212. Match color coded links.

pitch

1 0 . lnstallf a n a n d scro l lP e rS e cti on6.22O' Page1 . 3 8

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FIG|E|INEiC|N

MATNTENANcE MANUAL

MOEIEL

F|44

INSTRUCTIONS FORREASSEMBLING TESTING R44SERIES 1.700SPECIAL AND FLIGHT (cont'd) AFTERCRATING HELICOPTERS FOREXPORT 1 1. Installengineexhaust per Section6.520. 12. fnstall main rotor blades per Section9.112. Match color-codedmarkingson blades with markingson hub and pitch links. 13. Performtail rotor drive shaft runout per Section7.34O. 14. Fallmain rotor gearboxwith A257-2 oil to full level as required. 15. Fuelhelicopterand drain a smallamountof fuel throughgascolator. 16. lf ship is equipped with attitude horizon,directionalgyro, turn coordinator,and/or verticalcard magneticcom,installas follows: I Attitude Horizon,DirectionGyro, and Turn Coordinator: Remove warning lights from lower console. Pull out 8197 instrument face by removingsix (6) securingscrews. NOTE Placea piece of foam under 8197-1 face to prevent scratching lower face. Installrequiredinstrument(s)by securingwith hardwareprovided. CAUTION Directionalgyro mount screws must not exceed 1 inch in length or unit will be damaged. Connect existing straight connector(s)to directionalgyro and/or turn coordinator. Connect angle connectorto attitude horizon,ensuringstrain relief points down. Ensureconnectorslock in place. Ty-rap excess wiring. Reinstall8197-1 face to console. Reinstallamber FUELFILTER(lO-54Oonly), AUX FUEL PUMP (lO-54O only), ALT, & GOV OFFlights and red ENGFIRE& OIL warning lights. VerticalCard MagneticCom: Removeverticalcard comfrom foam-protectedbox. Installa 2-inch length of 8158-3 heat-shrinktubing over eachcomwiring pin. Locateexistingwires from windshieldcenter bow. Connectpins from comto existingsockets (polarityis not critical),cover connectionwith heat-shrink,then apply heat. Securecomin mount with four screws and hide and securewiring atop com.

Change13: OCT20Oo

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rl

FIEIE|INSCIN

MATNTENANcE MANUAL

MOE'EL

]',44

AND FLIGHTTESTINGR44 SERIES FORREASSEMB.LING INSTRUCTIONS 1.700 SPECIAL (cont'd) 17. Installbattery (negativegroundsystem)' upper spark plug hole' 1g. Removeplasticdehydratorplugsfrom each cylinder's plug thread lubricant'install' 19. Lubricateprovideduppersparkplugswith A257-1O spark and torque PerSection1.330. spark plug accesscovers' 20. Connectignitionleadsto upperspark plugs and install and remove lower spark 21. Disconnectignitionleadsfrom lower sparkplugs

plugs'

spark plug hole' Wlth ignition 22. Placea small containerunder each cylinder's lower revolutions'to force excess switch in the OFFposition,rotate engineby hand, several preservationoil from cYlinders. magneto's primary lead terminalto 23. Temporarilyconnect a groundingwire from each airframeground. oil pressureis indicatedon gage, 24. Activate starterfor no more than 12 secondsor until after each activation' whichevercomes first. Allow starterto cool for 5 minutes groundingwire from each magneto' 25. After oil pressureis indicatedremovetemporary plug thread lubricant' install' 26. Lubricatelower spark plug threadswith A257-10 spark and torquePerSection1.330. 27. Connectignitionleadsto lower spark plugs' 28. Installbelly, left, right, and aft cowling assemblies' 29 PerformSection2.205 groundcheck' 30. PerformSection2.210 run-up'

Page 1.4O

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FICIBINEiCIN

MATNTENANEE MANuAL

MOEIEL

F|44

1.700 SPECIAL INSTRUCTIONS FORREASSEMBLING AND FLIGHTTESTING R44 SERIES (cont'd) HELICOPTERS AFTERCRATING FOREXPORT NOTE fO-540enginesshouldidle at 58-620/o rpm vrdthenginewarm, clutch enqaqed. IO-54OIDLEADJUSTMENT PROCEDURE ldle rpm and mixture were set for sea-levelstandardconditions during factory flight test. lf idle and off-idle throttle performanceare not satisfactory upon reassembly,adjust as follows: First set idle rpm to 58-62% rpm with enginewarm & ctutch engaged. Then, with engineoff, disconnectfuel controloutlet hose,connecttest hose if desired, and measurefuel flow rate at fuel control outlet with mixture full rich, throttle at idle, and electricfuel pump on {ignitionkey to PRIMEposition}. Adjust idle mixtureas requiredto obtain16-18 pounds/hour fuel flow {170-190 cc/minute). Clockwiserotationof idle mixture adjustmentwheel (viewedfrom aircraft right side)enrichesmixture. Re-checkidlerpm after mixtureadjustmentand repeatas requireduntil both rpm and mixtureare within limits. With rpm and mixtureset, smooth accelerationfrom idle to 1O2o/o rpm with no enginehesitationor smoke from tailpipe. Also smooth needlesplit from 1O2o/o to idle with no engineroughnessor erraticrpm indicationsand acceptableidlequality. Notethat 16-18 pounds/hourfuel flow shouldproduceacceptableidle qualityand off-idle throttle performanceunder sea-levelstandardconditions. Richermixtures may be requiredfor cold temperatureoperationand leanermixturesmay be required for hot/high altitude operation. Deviatefrom 16-18 lb/hr recommendationas requiredfor acceptableidle quality and off-idle throttle performance(smooth accelerationsand needlesplits).

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Page1.41

FICIBINSCIN

MOEIEL

MATNTENANeE MANUAL

F|44

AND.FLIGHTTESTINGR44 SERIES FOR.REA-SSEMBLING 1.700 SPECIALINSTRUCTIONS (cont'd)

MECHANIC ptLor ANDA cERTtFtcATED TEST:To BEDoNEBy A ouALFED FLTGHT Handbook' perthe Pilot'soperating inspection preflight 1. Perform 2. Balancefanwheel per Section6'240' 3. Balancetail rotor per Section1O'240' DO NOT proceedinto forward flight 4. Performhover checks per section2-220 Step 1' at this time.

5 . Track and balancemain rotor per Section10'2OO' t i o n higher R P M paltitudes e r S e c t i oduring n10.250. 6 . A f t e r c o m p | e t i n g t r a c k a n d b a | a n c e , a d j u s t a u t o r o t a and Avoid rotor overrfiJt autorotationchecks.

by avoidinghigher gross weights

(M),60 KIAS' and governoron: 7 . while climbingat MaximumcontinuousPower a. Evaluateroughnessand controllability' directionalcontrol' b. Perform3O degreeleft yaw to checkfor adequate (deviateas requiredfor weather and terrain)' 8 . Levelflight at 2OOOfeet density altitude gou"tnor on, evaluatethe following: M, ",id a. Longitudinaland lateralcyclic controlforces' b. Collectiveeontrolforces. flight' 9 . Evaluateroughnessat M and 130 straightand level properoperation' 1 0 . check all instruments,gauges,and avionicsfor perform a 30 degree right yaw to 1 1 . During autorotationat 50 KIAS and 9o% RPM, check-foradequatedirectionalcontrol'

(DATA)PLATES IDENTIFICATION COMPONENT 1.8OOREPLACEMENT plate-for field installation'RHC ln order to issue a replacementcomponentidentifjcation lf old identification ftut" in regibrecondition.. must first receive the ord identiil;i;; or faxes (photocopies letter plate is rost o|. a"riroyed, then RHC must have an original Authority authorizingidentification are Nor acceptabre)from customer's civir Aviation and serialnumberfor each plate replacementAND statingcomponentname,part number' plate issued' i"qr"rtLO identificaiionplate.-Thereis a chargefor each Pa g e1 . 4 2

Change13: OCT 2006

2. INSPECTION

FIGIBINSCIN

MATNTENANcE MANUAL

MI,E'EL

F,44

2 SECTION INSPECTION 2 . O O OI N T R OD U C T ION

PROCEDURES 2.100 GENERAL 2 . 1 1 A B a l la n d R o l l e rB e a ri n g s 2.120 Push-PullTubes, Rod Ends,and SphericalBearings ll ubes 2 . 1 2 1 P u sh -P u T 2 . 1 2 2 R o d E n d sa n d S p h e ri calBear ings 2.125 ElastomericBearings 2.130 TelatempIndicators 2 . 2 0 0 G R O U N pA N D F L T GH T C H F CKFOR1OO- HOUR/ANNUAL tNSpECTtON 2.205 GroundCheck 2 . 2 1 0 R u nU p 2.220 Flight Check 2.230 Shutdown 2 . 3 0 0 AI R F RA MEP R E P A R A T ION F OR 1OO- HOUR/ANNUAL INSPECTION 2 . 4 O O 1O O . H OU R /A N N U AALIR F R AM EINSPECTION 2.41O InspectionProceduresand Checklist 2 . 5 0 O S P E C IA LIN S P E C T ION S 2.541 Clutch Actuator Upperand Lower BearingsInspection 2 . 5 0 2 C 1 8 1 L o w e r B e a ri n gInspection 2 . 5 0 3 C 1 8 4 U p p e rB e a ri n gInspection 2.507 V-Belt Inspection Ch a n g e1 4 : J UL 2 OO8

Page2.i

I

FICIEIINSGIN

MAINTENANeE MANUAL

MOE EL F|44

S n t'd) 2 . 5 0 0 SP E C I A LIN S P E C T ION(co 2.5oSLowerSheaveV-Be|tWearPattern|nspection 2 . 5 1 O T a i l S ki d S tri ke 2.520 Tail Rotor Strike 2.530 Main Rotor Strike OversPeed 2.540 Rotor/Engine 2 . 5 5 0 H a r dL a n d i n g 2.560 penetrantInspectionof co2o Upper steel Tube Frame

I I

2.561 Corrosionon CO20 Upper SteelTube Frame

|

2.57O {Reserved} 2.580 WindshieldInsPection

2.600 2 . 6 1 0 I n s Pe cti o nP ro ce d u re 2.620 (Reserved) 2.630 ComponentInspectionProcedure

) z.too 22oo-Houn avrnHnulneoutnenn a

P ro ce d u re 2 . 7 1 0 I n s Pe cti o n

Pa g e2 . i i

Change14: JUL 2008

FICIBINSCIN

MATNTENANcE rraANUAL

MCIDEL

1l.44

SECTION2 INSPECTION

2.000 TNTROpUCT|ON The R44 helicoptermust be inspectedperiodically to it is in airworthycondition. Required inspectionintervalsare maximum 1OOhourstime-in-service or 12 calendarmonths (annually), whichever occurs first; the inspectioninterval may be extended up to 10 hours, without accumulation,if allowed by local regulations. Preventivemaintenanceis requiredbetween scheduledinspections. Fluid leaks, discoloration,dents, scratches,nicks, cracks, galling, chafing, fretting, and corrosionall warrant further investigation. Unairworthy items must be replacedor repairedas allowed by RobinsonHelicopterCompany.This section contains proceduresfor performingthe requiredperiodicairframeinspections.

)

z.1oo GENERAL PROCEDURES When required,magnetiarticleinspectionmay be performedin accordancewith ASTM E 1444 and MIL-STD-19O7.Fluorescentpenetrantinspectionmay be performedin accordance with ASTM E 1417 and MIL-STD-1907.Unlessotherwisespecified,the followinggeneral proceduresapply to R44 inspection. 2.110 Balland RollerBearings The first indicationof bearingfailureis usuallyan increasein bearingnoise.Noisewill almost always start severalhours before bearingfailure or any increasein bearingtemperature. Listento drive system during start-upand shutdown.A failingbearingwill producea loud whine, rumble,growl; or siren sound. Upon hearingan unusualnoise,thoroughlyinspect bearingsbefore further flight. A failing bearingmay have a distortedseal or be exuding a largeamount of grease.Do not rely on Telatempsto detect failingbearingsas temperature increasemay occur only secondsbeforebearingdisintegrates.Referto Section2.5O1 for bearinginspectionand lubrication. The failureof eitheractuatorbearingin flight couldcauselossof power to the rotor system and could result in a seriousaccident.The actuator upper roller bearingis on the clutch shaft aft of the upper sheave;the actuator lower roller bearingis on the fanshaft aft of the lower sheave.Just beforecompletefailureof an actuatorbearing,the clutch light may flicker constantly (on and off in less than one second). This should not be confusedwith its normal on-off retensioningin flight (on for 1-8 secondsthen off). Flight should not be resumeduntil causeof the flickeringclutch light has beendetermined.

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Pa ge2.1

FIC|BINSiCIN

MAINTENANcE

MANUAL

M(fE EL F44

2.120 Push-PullTubes,Rod Ends,and sphericalBearings ll ubes 2 . 1 2 1 P u sh -P u T and not more 1. Nicks, cuts, or scratchesin tube not more than O'O1Oinch deep using direction than 1/4 of tube circumferencemay be polishedout in lengthwise blend radius' 32O-gritor finer wet-or-dry abrasivepaper and 1-inch minimum Replacetube if depth exceedsthese limits' it must be 2. lf tube is dented or flattened more than 5 percent of its diameter, replaced. ings( seeFigur e2- 1l' l 2 . 1 2 2 Ro d E n d sa n d sp h e ri ca Bear 1 . M a x i mu ma xi a lP l a Y : O.O2 Oinch M a x i mu mra d i a lP l a Y :O.O1 Oinch not permitted' 2. Loosenessbetween bearingouter race and rod end housingis inch diameterwire 3. Rod ends not riveted in place must block ageof o.o2o through witness hole. 1.32O and torque 4 . Rod end jam nuts and palnuts must be torqued Pgt section inspection' pre-flight ;'ir'|ffi,-fi"i eigrt" 2-1', at the moit-uisiUlti position for push-pull tube and Torque stripe must extend acrossn,1. tJboth'rod end shank to subject are (or pitch link barrel, yoke, , itrut, etc-)-Torque stripes and musi be periodicallyrenewed' Oetdrioration or.positio.ned'.toallow as 5 . Refer to Figure 2-1A. Rod ends must be centered, possiblewithout binding' much push-pulltuue or link rotationalmovementas

Teflon-lined bearings must not be lubricated or solvent

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FIclBINSiclN

MATNTENANcE MANUAL

MOEIEL

]i44

2 . 1 2 2 R o d E n d sa n d S p h e ri calBear ings( cont' d)

RODEND !r."

NOTE

FORMAXIMUM RODEXTENSIONA 1 0 1 - 4 :i'.10in. WHENNOWITNESS HOLEIS D l 6 3 - 1 1 . 4 0i n . PROVIDED: D 1 7 3 - 1 1 . 3 0i n .

HOUSING

RACE

p

MAXIMUM RADIAL PLAYO.O1O INCH TOROUE STRIPE*

A PIECEOF O.O2OINCHDIAMETERSAFETYWIRE MUSTNOTTHROUGH THEWITNESS HOLE.

AN316JAMNUT B33OPALNUT EXPOSED THREADS TOROUE STRIPE*

BOL

MAXIMUM AXIAL PLAYO.O2OINCH WASHER *Typicaltorquestripelocationshown. Adlust locationas requiredfor maximum visibilityduringpreflightinspection.

A 1 1 5 -01RC 1 1 5 -S1P A C E R (SMALLDIAMETER OFSPACER TO RODENDBALL)

FIGURE2.1 ROD END AND SPHERICAL BEARINGPLAY LIMITS AND TOROUESTRIPEAPPLICATION

Positionrod ends for maximum rotation

FIGURE2-1A ROD END CENTERING Ch a n g e1 3 : OC T 2 0 0 6

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FIClBINSlclN

MAINTENANeE MANUAL

n{tfEIEL F,44

2.1 25 ElastomericBearings oil contamination, Etastomericbearingsare used in the D062-1 tail rotor hub. Fatigue, or overloadcan degradethe elastomer. crumbs" (seeFigure Smallsurfacecracks(fatiguecracks)and elastomerdust or "eraser grow, enoughelastomer z-2$lare normaland are not causesfor replacement.As cracks deep (greaterthan will be lost to cause reduced stiffness and increasedvibration. lf face, replacebearing. o.1o inch) cracks are presentover more than 25o/oof elastomer rust-preventative Avoid exposure to oit, grease, hydraulic fluid, cleaning solvent, and off any such contaminants with detergent and water. fluids. lmmediatety *"rt (see Figure 2-2Bl contaminatedbeaiingsexhibit swelling,wavy edges, or debonding and must be rePlaced. bond strength Overload occurs when elastomer's tensile strength or rubber-to-metal bearingweakenedby is exceeded.This can occur when normalloads are appliedto a from and large fatigue or oil contamination. Overtoadis indicatedby large extrusions clean cracks in elastomeras shown in Figure2-2C' separationoccurs over Etastomermay also separate(debond)from metal bushings.lf more than 25o/oof bonded area,replacebearing'

Page2.4

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FIOBINEiCIN

MclE EL n'44

MATNTENANcE MANUAL

2.1 25 ElastomericBearings(cont'd)

Figure2-2A - ElastomerFatigue

Figure2-28 - ElastomerQil Contaminat_ion

o \

Figure2-2C - ElastomerOvedqad

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MAINTENANeE

MOE'EL

MANUAL

H44

2 . 1 3 0 T e l a te mpl n d i ca to rs

I

of bearings, self-adhesiveTelatempindicatorsrecordincreasesin operatingtemperatures temperature highest the gearboxes,etc. To useTelatemp,draw a referencelinebetween square' Jqrrru which has darkenedduring normaloperationand the next undarkened block has See Figure 2-3. During every check thereafter,determineif an additional for by a change blackened.lf an indicatedtemperatureincreasecannot be ed beforefurther in operatingconditions,subjectcomponentshouldbe carefullyexamined flight.

"fi il nn

telatemp TEMPERATURERECOROER ',127 116

121

1320C

oF22O 230 240 t MOD E 1 L 1 0 -4

250

2700F

Referenceline

Telatemp 110-4 1 1 O - 2o r 1 1 0 -3 110-2 1 1o-4

ComPonent Main Rotor Gearbox U p p e rA ctu a to rBear ing( justaft of uppersheave) Tail RotorGearbox Hydrauliump (if installed)

TelatempP/Ns & TemperatureRanges: 6 O d e g re e sC /1 4 0 d e gr eesF - 88 degr eesC/190 degr eesF 110-2 8 2 d e g re e sC /l 8 0 d e gr eesF - 1 1OdegreesC/23OdegreesF 11 0 - 3 104 degrees Cl22O degreesF - 132 degreesCl27O degreesF 110-4

P a g e2 . 6

C h a n g e 1 3 : O C T2 0 0 6

FIG|BINSiCIN

MATNTENANeE MANUAL

MCICIEL F44

INSPECTION 2.200 GROUNDAND FLIGHTCHECKFORlOO.HOUR/ANNUAL Completefollowing checklistsin conjunctionwith a 1OO-houror annualinspection. Note and correct any discrepancies. 2.205 GroundCheck (Aircraftnot running) I

1. Throttle Control: Check for freedom of rotation with collective full down and full up.

2 . Throttle OvertravelSpring: Check by twisting throttle past idle position to overridestop. Releasethrottle and ensureit returnsto normal idle position.

3 . Mixture Control:Check for smoothnessof operationwith no binding. Check press-to-unlock button for properfunction. O.O3to 0.10 inch spring-backat full rich position.

4 . Carburetor Heat Control (0-540 onlyl: Check for smoothness of operationwith no binding. 0.03 to O.1Oinch spring-backat full off position.

5 . Cyclic Control:With trim motors {if installed)in neutralposition,

freedom thru full travel with friction off. friction knob rotates 1/8-to-1 full turn beforeaddingfriction. For hydrauliccontrols: approximatelyone-halfinch total longitudinaland one inch total lateral freeplay before encountering resistance. normal hydraulic resistancewith no bindingor abnormalfeel throughoutcontroltravel.

6 . CollectiveControl: freedom through full travel with friction off and on. For non-hydraulic aircraft, friction knob moves 0.3-0.6 inch beforeaddingfriction.For hydrauliccontrols: approximately one-halfinch total freeplaybefore encounteringresistance.With carb heat assist (if installed)locked and friction lever fully off, C334 friction (between rear seats) within freeplay range is 4-5 pounds average measuredat grip. With friction lever fully on, 18-22 pounds measuredat grip. normal hydraulicresistancewith no bindingor abnormalfeel throughoutcontroltravel. 7 . Carb Heat Assist {if installedl:With collectivedown and full carb heat, raise collectivefull up and carb heat off. Lower collectivefull down and carb heat full on. With collectivefriction off, push carb heat off and collectivestays down. 8 . Tail Rotor Pedals:Checkfor smooth operationwith no binding. 9 . RemovableControls: securityof attach fasteners.

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MANUAL

844

2.205 GroundCheck(cont'd) 10. Lightingand Instruments: (MasterSwitch on) a.cARBoNMoNoXIDEwarning|ightflashestwice(ifinsta||ed}. b.CarbAirTempapproximatelysameasoutsideAirTemp. c.

ALT warninglight on'

d.

warninglight on' OIL Pressure

f.

AUX FUELPUMPwarninglight on (lO-54Oonly)' Fuelquantitygages- indicationof fuel level'

g.

Navigationand lights - check function'

h.

Strobelight- checkfunction'

i.

Landinqlights- check function (clutchswitch must be engaged to chedki-andinglights)'

j.

MaP light - check function'

k.

Ammeter- shows discharge' cold' oil temperaturegage - slight needledeflectionwith engine

e.

l. m.

engine cylinderheadtemp gage- slightneedledeflectionwith c ol d .

n.MRTEMP|ight-onwhensendershortedortestswitch depressed. o.MRcH|P|ight-onwhensendershortedortestswitch depressed -p . E N G | N E F | R E l i g h t - o n w h e n s e n d e r s h o r t e d o r t e s t s w i t c h depressed. q' . T R c H l P | i g h t - o n w h e n s e n d e r s h o r t e d o r t e s t s w i t c h dePressed. T . L o W F U E L | i g h t - o n ( s | i g h t d e | a y i s n o r m a l } w h e . n rod . l o worf u e | send"i in lunt is depreJieOwith'clean, non-sparking when test switch di:Pressed' (lo-54O s. FUELFILTERlight - on when test switch depressed o n l y). (referto 1 1. aircraftchecklistlaminatedcard is currentrevision S e c t i o n1 .OO2 )'

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MOE EL ]t44

2 . 2 1 0 R u nU p 1.

PerformPOHSection4 'Preflight" checklist.

2.

Perform"BeforeStartingEngine"checklist.

3.

lO-54O engine: AUX fdel PUMP light extinguishesduring prime and illuminatesafter priming. fuel drains from sniffle valve.

NOTE Significantprimemay be requiredbeforefuel drainsfrom sniffle

valve. Wait for valve to stop draining before starting engine. Enginewill be hard starting/floodedwhile valve is draining. 4.

Perform "Starting Engine and Run-Up" checklist. lf less than 15 minuteshas elapsedsince Step 3, use minimumor no prime.

5.

Checkclutchengagement time - maximum70 seconds.

6.

Ammeter indicatescharge,ALT light off.

7.

Both magnetosground (off momentarily)at 600/oRPM.

8.

Tachometeroperateswith alternatorand battery switches off.

9.

No unusualbearingnoisewhen varying RPMthrough operatingrange (mechanicto listen near V-belt drive). Referto Section2.110 and 2 . 5 0 1 th ru 2 .5 0 3 .

O

10. Set RPM at 75o/o,governor on. Increaseto 85o/o,releasethrottle, and governorincreasesRPM to 101 to 1O2o/o.IncreaseRPM releasethrottle, and governordecreasesRPMto 101 to 1O4o/o, t o 1 O2 o /o . 1 1. Engineand rotor tach needleswithin 1o/oof each other at 1O2olo RPM. 12. alternatorvoltageas follows: 13.4 to 13.9 vdc for A942-3 alternatorcontrol unit 27.75 to 29.25 vdc for A942.4 alternatorcontrol unit 13. Heateroperatesproperly. 14. Tachometerneedlesdo not jump more than 2o/owhen transmittingon 1 1 8 .OO,1 2 5 .0 0 , a n d 1 3 6 .975MHz with gover noron. 15. Raisecollectivecontrol O.5 inch at grip and slowly decreaseRPM. low-rotor-RPMwarning horn and light activateat g7o/oto 96% RPMand remainon as RPMis decreased to idle. C h a n g e1 4 : J U L 2 O 0 B

P age2.9

FIGIBINSCIN

MAINTENANeE

MANUAL

MOEIEL ]r44

2 . 2 1 0 R u nU P (co n t'd ) 16. ldle RPM with enginewarm, clutch engaged,throttle closed0-540 engine: 53o/o- 57o/o fO-540engine: 58o/o- 620/o ldle mixture with enginewarm, clutch engaged,throttle closed' pulledslowly to o-54O engine: 2o/oto 4% RPMrise as mixtureis i d |e cu t-o ff.Adjustidlemixtur escr ewasr equir ed. |funabletoobtainrise,setid|emixturescrewlTz turnsoutfromfu||yinthenadjustasrequiredfor smooth idle. 23. |0-540 engine: Adjust id|emixtureper Section6.495, Step mounted 1 8 . check hydraulicsystem (if installed)operation. using cycliccyclic hydraulicsswitch, turn hydraulicsOFF. Usingsmalllongitudinal freeplaybefore inputs,there shouldbe approximatelyone-halfinch of Controls encounteringstiffness and .Turn hydraulicsON' ("motoring")' shouldbe freewith no or uncommandedmotion Completeflight check with hydraulicson' low and high 1 9 . Air Conditioning: system blows cold air on both systems' After settings. no fUtiRfi with other instrumentsand draintube in a flight with air conditioningon, water drainsfrom ship;s belly (may be little or no water in very dry conditions)'

17.

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FIEIBINSCIN

MATNTENANcE MANUAL

MOEIEL

F|44

2.220 FlightCheck 1.

2.

3.

Hover: a.

All gagesgreen.

b.

Controllabilityin lett,andright pedalturns.

c.

Cyclic electrictrim (or hydraulics)zeroscyclic stick forces.

d.

Vibration levels satisfactory.

Levelflight Typicalcruisealtitude(if possible,deviateas requiredfor weather and regulations),maximumcontinuouspower, governoron. a.

Vibrationlevelssatisfactory.

b.

Cyclic electrictrim {or hydraulics}zeroscyclic stick forces.

c.

Collectivetrim spring (electrictrim system only) zeroscollective forces. For hydrauliccontrols: no and collectiveis balanced.

d.

Fixedcollectivefriction adequateto prevent "bounce" but not excessive(electrictrim system only).

e.

Tail rotor pedalpositionwhen yaw string is centered: 0.25 to 0.75 inch right for adjustablepedals,within 0.25 inch of neutral pedals. for non-adjustable

f.

Tail rotor elastictrim cord zerospedalforces (cord appliesleft pedalforce).

g.

For hydrauliccontrols: Turn hydraulicsOFFand no excessiveforces.

Autorotateat lOO KIAS with station 99 or greaterCG. electrictrim (or hydraulics)zeroscyclic stick forces.

2.230 Shutdown 1.

rotor brakefunctions and ROTORBRAKElight illuminates.

2.

Completeshutdown per POHchecklist.

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MAINTENANeE

MANUAL

MoEIEL n'44

I

blank Intentionally

P a g e2 . 1 2

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HCIE|INSC|N .

MATNTENANtrE MANuAL

MOE EL 1|'44

2.300 AIRFRAME PREPARATION FORl OOHR/ANNUAL INSPECTION Thoroughly cleanairframepriorto inspection.Wipedown mainand tail rotorblades,hubs, andairframeexteriorwith a mildsoapand watersolution. CAUTION Do not spray magnetos,main rotor hub, tail rotor gearboxvent, hydraulicreservoirvent, swashplatearea, or bearingseals with high-pressure water or solventa-swater or solventmay enter and causecorrosionand breakdownof lubricants.

2.400 1OOHR/ANNUAL AIRFRAME INSPECTION NOTE Numbersin parenthesesindicatelocationas illustrated in Figures 2-4 and 2-44. CAUTION lf pop-outfloats are installed,ensuresafety on pilot's red inflation lever is in LOCKEDpositionwhen working on helicopter. WARNING Pop-out float pressure cylinder contents are under extreme pressure. lf pop-out floats are installed, install locking pin in pressurecylindervalve (see Figure5-6) when working in forward left baggagecompartment,during cylinderremovalor installation, when worKrng workin-gon floats or inflation Inflauon noses. hoses. . Hemove Remove tocKtng and wnen ano lq"Lilg pin when work is completed. Avoid excessive heat (> 200 degreesF) as thermal relief valve will activate. Perform1OOhour or Annual inspectionper Section2.410. 2.410 InspectionProceduresand Checklist R44 SerialNo.: RegistrationNo.: Hourmeterlndication: Aircraft Total Time:

Technicianname: Technician Certificatenumber:

1. Tail Rotor PedalBearingBlocks NOTE Do not removepedalbearingblockcoverplates(1) unlessfunction check of pedals indicates possibleproblem with pedal bearing blocks. To removecover plates(1) peel back carpetingand removescrews holding plates.Use an inspectionlight and mirrorto inspectbearingblocks. Inspect for conditionand loosenes5 or play. Maximumallowableplay is 0.080 inch axiallyand 0.030 inch radially. Inspectall weld areasin pedalcontrols. Change13: OCT 2006

P a g e2 . 13

MAINTENANeE

FIGIBINEiC|N

MOEIEL

MANUAL

FI44

./

,ffi co-PILOT'S SEAT 10 ..48 il

\ 4H

3E

co-PlLoTs SEAT

4I (ENGONLY)

,,$ FORWARD

S FIGURE2.4 ACCESSAND INSPECTION P a g e2 . 1 4

Change1 3 : O C T2 0 0 6

MATNTENANeE MANUAL

FICIBINSiCIN

MOE'EL

N44

-*--.Ho--" /

BATTERY TAILCONE (POLICE andENG versionsonly)

l=m

:J

6B

FIGURE2-4A ACCESSAND INSPECTIONS NUMBER PART NUMBERDESCRIPTION NUMBER PART NUMBER DESCRIPTION Face (ENGonly) 4r D3B3-1 Deflector(LH) 1 81B9-4 (RH) A412-2 and Cover and Deflector Seat BackAssy (RH) 5 C003-10 8189-2 Seat Back Assy (LH) co03-11 CowlingAssy (LH) 6A c337- 1 ConsoleAssy 2 8050 CowlingAssy (RH) 6 B c378- 1 Cover Assy 3A c445-1 Cowling Assy - Belly 6C DO41-1 3 B c445-3 Cover

3C 3D 3E 4A 48 4C 4D 4E 4F

c444-1 c398-1 c794-1 c680-1 c461-1 c464-1 c463-1 co54-1 c474-2

Cover CoverAssy

4G

c474-1

Cover

4H

c794-2 c794-3 c794-2 c794-3

(without scoop) Assy (with scoop) (without scoop) Assy (with scoop)

4H

Cover Assy Cover Tray Cover Cover Assy Cover

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6D 7A

78 8A 88 I 10

DO40-1 DA42-4 DO42-4

C706-1 A231-1 4558-2 C261,1 co82-2 c082-3 co82-4 co82-5 11 C045 12 D412-1 (Police or ships) D347-1

Aft Cowling Assy Door Assy Door Assy TailconeCowling Assy Plug Assy Cover Mast FairingAssy FairingAssy (FWD,RH) FairingAssy (FWD, LH) FairingAssy (AFT, RH) FairingAssy (AFT, RH) Circuit Breaker Fairing(lnframetrics Camera) Fairing(FSlCamera)

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FIClElINSiClN

MAINTENANcE MANUAL

MIfEIEL

F|44

2.410 InspectionProceduresand Checklist(cont'd) 2. Upper Gonsole(21 Console(2), is openedby removingone screw on each side. With console open, inspectthe following: Pitot-static system: check pitot and static lines for cracking,chafing, for security. pinchingor kinking. check all-connections Flightand EngineGages: Checkall gaugesfor security' Inspectwiring and connectionson all gages. RadioTray(sl: Checkconditionand security. Tail Rotor Controls:Check accessibleportionsof TR pedal assembliesfor defects. operatingclearance. (3Cl' -' RemoveForward Tunnel Covers (3A & 3Bl, -GyclicSto.p.Go.ver 3. (3El Bdlly (3D1, Forward and inUoirAColtectiveCover NOTE lf radio antennasare installedon removeds,disconnect lead and any groundwire. Pullrespecliveradio circuit "nt"tnt with "AntennaRemoved"' Ur"ili". andtaq ciicuit-Ureaker Cyclic Box Assembly: Inspect lYclic box assemblyfor defects' Check (deterioration, ;i;ldsiop sheetrrtli ass"inblyfor cracksand otherdefects distortion,loose rivets, corrosion). Cyclic Stick Assembly: Inspectcyclic stick assemblyfor defects' Inspect welds for cracks. CAUTION (manualcontrolsl

Do not disturbclearsiliconecoatingprotectingstrainq.?9.9s,.9r or wiringwill disable .ti."f't"a *iiing. Any damageto stra-in-gages trim system. Cyclic Trim (manualcontrolsl: Turn masterand cyclic trim switches on. Mbve cyclic iaterattystop to stop and longitudinallystop tP :!9l uld_check Cr'ecirtrim moiors, springsand elastic cords for ljp"iiti.i" oi tiirn rbtliri ci"arunlu from atl wire bundlesand fuselagestructure during movement and at travel limits. Cyclic LateralTrim Actuator (manuatcontrolsl: Turn master and cyclic trim switches on.--Fu;h ;^d hold cyclic stick againstright stop until motor stops then turn trim off . Move-cyclic stick to left stop to compresssprlng' il;p;"i expoieO ponion of st'tuttfor wear and.galling.Do not glga.sqrod on springassemblies,bearingis seH-lubricating. neu H una'subse{ueniCOSO-t inipi,ti CtbO-t S'uiuthanespacbr{s--topl.Checksecurityof attachmentto cyclic pivot. Cyclic LongitudinalTrim Actuator (man-ualcontrols): Insp.ectC.130-13 u*thin" rfacer trioii. bfteit
Change13: OCT 2006

FICIBINEiCIN

MATNTENANcE MANUAL

MCICIEL ]|44

2.410 InspectionProceduresand Checklist(cont'd) 3. RemoveForward Tunnel Covers (3A & 3Bl, Cyclic Stop Cover (3C1, InboardCollectiveCover {3D} and Forward Belly (3El (cont'd)

'

Cyclic Friction: Check for excessiveplay or loosenessin links and rod ends connectedto cyclic stick. no excessiveflaringat eitherend of C13O-2spacer. Cyclic Push-PullTube and TorqueTube: InspectC319 torquetube paying specialattentionto area around blocksand end of torque tube for cracks. Inspect C121-1 push-pulltube rod end palnut and jam nut for tightness. Check witness holeson push-pulltubes. Checkrod ends and bearingsfor excessive play and looseness. Check accessibleportionsof cyclic pushpull tube and torque tube for defects, includingscratches. Pay particular attentionto top of torquetube immediatelybelow C348-1 anchorassembly. Inspectall nuts and bolts in cyclic controlsfor rotationand looseness. Tail Rotor Push-PullTube: Inspectaccessibleportionsof C121-9 tail rotor push-pulltube. Look for defects such as cracks, bends, scratches,or chafing. Checkrod ends for excessiveplay and looseness. GollectiveFrictionand Stop: Inspectcollectivestop condition;no nicks, cuts or scratchesare allowed. Check collectivefriction lever for security and operation. Move collective up and down and no bending or bindingof stop. collectiveboot's lace cannot entanglestop. Throttle OveftravelSpring: Inspect operationof overtravelspring while operatingthrottle. lt should move freely without any bindingor jerkiness. Check play in upper and lower rod ends. Checkrod ends for binding. Wiring Harness: Inspectfor chafingand clearancefrom controls. Pitot and Static Lines: Inspect pitot and static lines for security and any evidenceof cracking,chafing,pinchingor kinkingfrom sharpbends. Open drainsand check for moisture;closedrains. ElasticTrim Cord(sl: With cyclic forward-right,feel forward elastic trim cord(s)for voids which may indicatebrokenstrands. HeaterHose: Check heaterhose for collapsedareasand chafing. Fastenersand Torque Stripes:Inspectconditionand securityof all fasteners. Renewdeterioratedtorque stripesper Figure2-1

I

Remove Outboard Collective Cover (4A), Collective Torque Tube Cover (481,Tray (4C1,Mid Tunnel Covers (4D & 4El, Aft Tunnel Covers (4F & 4Gl, Aft BellyCover (4H), and RearConsole(41,ENGshipsonlyl NOTE lf radioantennais installedon removed,disconnectantenna lead and correspondinggroundwire. Pull respectiveradio circuit breakerand tag circuit breakerwith "antennaremoved". C h a n g e1 4 : J U L 2 0 0 8

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MOE'EL

1f,'44

2.410 InspectionProceduresand Checklist(cont'd) (4Bl' 4. RemoveOutboardColtectiveCover (4A1,CollectiveTorqueTube Cover (4F & 4G)' Aft Tray l4C), Mid Tunnel Covers (4D & 4E), Aft Tunnel Covers (cont'd) Belly Gover (4H1,and RearConsole{4I, ENGships onlyl welds CollectiveStick: Inspectconditionof collectivestick. Inspectall giving special for cracks. Inspect C328-1 connectingrod assembly governor attention to points of attachment. Inspectgovernormotor and micro motor arm for loosenessor binding. Inspect collective-activated switch for cracks or loosewires. CollectiveStick TorqueTube: no corrosionpitting. Apply a corrosionpreventativecompound such as LPS 2, ACF-50, or Corrosion-Xto any governor unpainted,phosphate-coatedarea while avoidingcontaminating openfriction clutch (a foam-typeapplicatorworks well). Ensureinteriorof ,,box,' structuresat inboardattach point and at A2O5 fork connection end are also treated. tube Aft End of Cyclic Torque Tube and Yoke Assembly: Inspect torque specialattentionto areaaroundblocksand end of torque and yoke, paying -crreck playin bellcrankbearingsper Section2.12Q.Inspect tube for cracks. swaged bearingfor movementin yoke' PushAft End of Cyclic push-PullTube 1C121-1)and Lower Endsof Vertical Pu||Tubes|C121-7|:|nspectpush-pulltubesforcracks.Checkrodend rod end jam nuts and palnuts for tightnessand rod ends for play' Check -bearings for bearings for looseness. Inspectfork assemblyareas' Check looseness. Check between bearingsand swage for evidenceof fretting. Check Aft End of (C121-1gl Tait Rotor Push-PullTubeand Lower Bearing: on welds witnesshole. Checklower bellcrankbearingfor play. Inspectall metal assemblyfor lower bellcrankand inspectsurroundingsheet area for cracks. Check CollectivePush-PullTube (Cl21-19): Check for bindingor nicks' play' for end rod witness holes.check jam nuts and palnutfor tightnessand

I

for tightness CollectiveFriction Assembly: Check jam nuts and palnuts and and rod endsfor play. Inspectall welds on bellcrankassembly inspect surroundingsheet metal for cracksand corrosion. up CollectiveSpring Assembly (ManualControlsOnly): Move collective not touch and down and no bindingor cracking. spring coils must when collectiveis full down. jam nut and palnut tightness' lf requiredby rod ends play within limits. guide rods are greased' Section1.101, serviceassemblyper Section8'221' fittings for FuelValve and FuelLine: Inspectfuel linefor damageand valve on fuel leakage(leakageis indicatedby a blue or greenresidue,depending used,or odor of fuel). no chafingof fuel lines. security' FuelValve-to-KnobTorqueTube: lnspectcondition. attaching P a g e2 . 1 8

C h a n g e1 4 : J U L 2 O O 8

FlClBINSlClN

MATNTENANcE MANUAL

MC'EIEL

F.44

2.410 InspectionProceduresand Checklist(cont'd) 5. RemoveAft Seat Back Assemblies(51 Wiring: Check wiring for securityand properinstallation. Pitot and Static Lines: Checkfor security,chafing,and kinks. Air Conditioning Refrigerant Lines (if installedl: security and no damage. tubesareunobstructed. EvaporatorDrainTubesandValve(ifinstalledl: Placea containerundersediment-tubeprotrudingfrom bottom of tee-fitting into right-aft baggagecompartment. Removeplug from sediment tube and allow any accumulatedmoisture and debristo drain. Reinstallplug. Simultaneouslysqueezedrain tube and sedimenttube near tee-fittingand check-valveball moves up momentarily. StrobePowerSupply&AlternatorControlUnit:Inspectstrobepower supply and alternatorcontrol unit wiring. Inspectmountingsfor cracks. Blind Encoder& GovernorController: Inspectblind encoderand governor controllerwiring. lnspectmountingsfor cracks. Fastenersand TorqueStripes:Inspectconditionand securityof all fasteners. Renewdeterioratedtorque stripesper Figure2-1. 6. Remove EngineAft (6D1,Belly {6G1,and both side (6A & 68l Cowlings Vertical Firewall: Inspect vertical firewall condition, especially around structuralattachmentpoints, no cracks,bucklingor wrinkles. Fuse{slandFuseHolder(sl(if installedon verticalfirewall}: security and no corrosion. correct fuses: -66 wire requiresAGC-3 fuse, -1601 l-1602 wires requireAGC-Sfuse. lf installed, -1226 wire requires AGC-3 fuse. Wiring: security,properinstallation,and no deterioration. Electric Fuel Pump (lO-54O onlyl: security, proper installation, unobstructeddrain tube, and no leakage. FuelLine & Hoselsl: Inspectcondition. security,properinstallation, no leakage,& (lO-54Oonly) good conditionof spirapinsulationon fuel line betweenfirewall & gascolator. Lower SteelTubeFrames:Thoroughlyinspectlower steeltubestructurefor corrosionand inspectall welds for cracks. Ensureframesare not chafedby wires, hoses,clamps,etc. Engine Cooling s: Inspect cooling s for cracks and missing fasteners. Oil Gooler(s):Inspectoil cooler(s)and fittingsfor damage,leaks,cleanliness, and security. Checkoil coolermountingarea(s)for cracks. C h a n g e1 4 : J U L 2 0 0 8

P a g e2 . 19

FIClEIINEiclN

MAINTENANeE MANUAL

MC]E'EL

F'44

2.410 InspectionProceduresand Checklist(cont'd) (6A & 68l Cowlings 6. Remove Engine Aft (6D), Belly {6G}, and both side (cont'd) Oil Lines: Inspectentirelengthof all oil tinesand no cracks,abrasion, or broken clamps. clearance;wires, ty-raps,and structuremust not lines. Gascolator: With fuel valve OFF, remove and clean gascolatorbowl and filter screen. no deteriorationof gasket. lf gascolatorbowl is secured grease. by threadedcollarand ring,lightlylubethreadsand ring with A257-6 Reassembleand turn fuel valve ON. Safety wire after ensuringno leaks occur. drain valve is secureand torque-striped' Mixture Gontrol: mixture control moves mixture control arm stop to stop. Inspectconditionand securityof mixture control cable clamps on bracket;push and pullcablehousingto ensureit doesnot slip in clamps. Inspect condition and security of mixture control cable inner wire attachment to mixture controt arm. Ensurefreedom of rotation between mixture control arm and innerwire retentionfitting {bolt)when arm moves. (so spring force mixture control safety spring is properly installed holds mixture control arm at full-richpositionif inner wire breaks). Air Box & Alternate Air Door: Ensurecarburetorheat slider valve {if (lubricatinglOapplicabte)movesfully from stop to stop. Replaceair filter b4O air filter rubber with A2s7-B rubberlubricantwill facilitatesealing). Check air box for conditionand security. spring-loadedalternate air door opens without bindingand closescompletely. rips' EngineAir Inlet Hose: correct iristallation& security' no holes,or collapsedareas. Ensurehose is not chafingframe. for Carburetor Heat Scoop and Hose (0'540 engines only): Inspect conditionand securitYHeaterHose: Inspectfor conditionand security' Battery and Battery Box (alternatelocations under upper console or under left, front seat): check cable terminals for cracks. check each cell electrolyte for quantity and specific gravity if equippedwith non'sealed battery. As required,performcapacitytest per manufacturer'sinstructions or replacebattery. securityand no obstructionsin drain tube' (9) 7. Open Cowling Doors t7A), RemoveTailconecowling {7Bl & Mast Fairing Cowling Door: Inspecthingesand latchesfor conditionand security' rivets' Tailconecowling: no cracks,air inlet obstructions'or loose and no Electricaland Antenna wires: Inspect condition. security c h a f i n g ,ki n kso r ti g h t b e n d s. operating MRGB Input Yoke: lnspect condition. security and c l e a r a n ce .V e ri fy se cu ri tyo f magnets' P a g e2 . 2 O

C h a n g e1 4 : J U L 2 O O 8

FICIBINSiCIN

MATNTENANcE MANUAL

MCIE EL F,44

2.410 InspectionProceduresand Checklist(cont'd) 7. Open Cowling Doors {7A1,RemoveTailconeCowling (78} & Mast Fairing(91 (cont'd) Forward Flex Plate: Inspectcondition, particularlyedges. security. bonded washers are securely bonded to both sides of each flex plate arm. operatingclearance.

Give specialattentionto these areasfor cracks

Inspectentire peripheryfor cracks and corrosion. Inspectthis area for cracks. Inspectarea around washers for fretting. FIGURE 2-5 FLEX PLATE INSPECTION

ClutchShaft ForwardYoke:Inspectcondition. no cracks,corrosion, or fretting. securityand operatingclearance. Rotor Brake: Inspectcondition,includingactivatingcable & pulleysand microswitch. integrityof brakepads and 0.030 inch minimumpad thickness. brake pad clearanceto input yoke when brake is off. securityand operatingclearance. Jackshaft: Inspect entire welded assemblyfor cracks and corrosion. Inspectjackshaftingstrut and tube weldmentsfor security,cracks and corrosion. Main Rotor Push-PullTubes: Inspect condition of viewable portions. V e r i f y no cra cks a t e n d s. In spectr od ends per Section2.120. Ver ify no tears in sleeves(manualcontrolsonly). securityand operating clearances. Main Rotor Push-PullTube Rollers & Bushings: (manual controls orllyl' Inspect condition. cleanliness,no wear into metal, and fr-ee movementof rollers.

Ch a n g e1 4 : J UL 2 OO8

Pag e2.21

FIclElINEiClN

MAINTENANcE MANUAL

MOE EL Fl44

2.410 InspectionProceduresand Checklist(cont'd) (91 7. Open GowlingDoors {7A1,RemoveTailconeCowling {78} & Mast Faidng (cont'd) pushTail Rotor Push-PullTube and upper Bellcrank: lnspect c121-15 pull tube, especiallyat ends, for cracks. Check iam nut for tightness or and rod end for looseness.lnspectbellcrankand mountingfor cracks other defects. Main Rotor Gearbox Cooling Hoses: Inspect both ends for security' Inspectfor rips, holes, and chafing. around Main Rotor Gearbox: Inspect main rotor gearbox, especially cracks' for gearboxmounts, cap mounting lugs, and mast tube no contaminationand no detertration of rubbermounts. security of Hall Effect senders. check Telatempfor overtempindications. oil Main Rotor GearboxOil: With ship on level ground, correct u si n g si ght gage. lf r equir edby Section 1' 101, l e v e l a n d cl e a n ti n e ss d r a i na n d fl u sh g e a rb o xp e r S ection1' 120' Main Rotor GearboxChip Detector: lf requiredby Section 1'101' clean c h i p d e t e c t o rP e rS e c t i o n1 . 1 1 5 . to inspect Upper Steel Tube Frame: Use an inspectionlight and mirror each weld, no cracksor corrosion'

andthereforesusceptible Uppersteeltubeframeis fatigue-loaded to fatique cracks. I HorizontalFirewall: Inspect upper and lower surfaces of horizontal firewall, especiallywhere boltedto steel structure,for cracks' buckling' (fuel residue)' or wrinkles. Inspectfirewall underfuel tank for leakage FuelTanks: Inspectconditionof visibleportion. no leaks' security. to Auxiliary Fuel Tank Fuel Line: Inspect condition' clearance structure. no leakage. security' FuelReturnLines& PressureReliefValve(lO-540only): Inspectcondition' no leakage. Veri{y security' leaks' Fuel GageSenders& wiring: lnspectcondition. no FuelTank vents: check vent tube connectionsfor security. drain.fuel Fuel Tank Sump Drains: both drain valves open easily, clamp freely,springclosed,and seal completely. D663-1 shut-off for tube and and inspect clamp on aux tank drain tube seals "otpi"t"ly, damageand deterioration. dowel' Low Fuelwarning: Turn MASTERswitch on. with a cleanwooden FUEL gentlydepresslow-fuelsenderfloat in mainfueltank and LOW irurning light illuminates.Turn MASTERswitch off' C h a n g e1 4 : JU L 2OOB Pa g e2 . 2 2

FICIBINSCIN

MATNTENANeE MANUAL

MC,EIEL F'44

2.410 InspectionProceduresand Checklist(cont'd) 7. Open Gowling Doors (7A1, RemoveTailconeGowling (7Bl & Mast Fairing(91 (cont'dl Fuel Caps: Inspect condition, to include gasket. security when closed. alignmentmarks on cap and tank align when cap is fully closed. Nuts and Bolts: Inspectall nuts and bolts in this area for movement and looseness. Cabin Bulkhead & Forward Hydraulic Servo Mounts: Inspect bulkhead and servo mounts (if installed)for corrosion,looserivets, deformationand cracks. Clutch Assembly: Inspectends of drive shaft and sealson sheavefor oil leakage.Inspect shaft for corrosion,especiallyat shaft-to-sealjunctures. Removeany light surfacecorrosionat shaft-to-sealjunctures,and apply a suitablecoriosion-inhibitor. Upper Sheave: Inspect sheave grooves. Replaceany sheave showing corrosionpitting or flakingof metalizedor anodizedcoatings,wear through anodizedcoatings,roughness,or sharpridges. Ddve V-Behs (see Section 2.5071: Inspect V-belts. no breakage, deteriorationof rubber,cuts, fraying,oil, grease,or foreignobjects. Actuator Fuses& Holders: Inspectcondition. no corrosion. correct fuses (14-voltsystemsrequireAGC-3fuses while 28-volt systems requireAGC-1% fuses). twist-to-lockfunction and security. Actuator Upper Bearingand Strut: lnspect seals on both sides of bearing for damage. Inspect strut, includingboth rod ends, and check witness holes. Check for fretting between bearinginner races and clutch shaft. Bearinginner races should be torque striped to clutch shaft. lf stripes are broken or misaligned,shaft is unairworthy. Check bearingTelatemp. Perform bearinginspectionper Section 2.503 if Telatemp indicationhas increasedwithout correspondingincreasein ambienttemperature. Actuator Lower Bearing: Inspect as much of bearing as can be seen. Inspect fiberglassscroll area at bearingattachment brackets for signs of cracking. Check bearingseals.forevidenceof deterioration. Inspect lower bearingbracketsfor loosenessor wear. lnspectbearingper Section 2.502 if discrepancies are found IntermediateFlex Plate and Forward End of Tail Rotor Drive Shalt (see Figure 2-51:. Inspect flex plate for cracks and fretting. Inspect yoke-todrive shaft weld for cracks (steelshafts). Tailcone Attachment: Thoroughly inspect all welds in this area for cracks, corrosion,and securityof attachingfasteners. Inspecttailcone mountingareafor cracks.

C h a n g e1 4 : J U L 2 0 0 8

Pag e2.23

FICIBINEiCIN

MtfEIEL

MATNTENANcE MANUAL

]l44

2.410 InspectionProceduresand Checklist(cont'd)

Belt TensionActuator Test Plug

VIEW LOOKING INBOARD

1_... Aft Cowl Door

FIGURE2.6 MT558.1 TOOL INSTALLATION

FIGURE2-6A ACTUATORSWITCHTEST P a g e2 . 2 4

C h a n g e1 4 : J U L 2 0 0 8

FICIBINS|CIN

MATNTENANcE MANUAL

MOEIEL

R44

2.41O InspectionProceduresand Checklist(cont'd) 7. Open Cowling Doors (7A1,RemoveTailconeCowling tTBl & Mast Faidng(9) (cont'd) Actuator (CO51l: clearanceto structure and drive train when fully disengaged.Turn masterswitch on and engageclutchswitch. Whileactuator is engaging,depressextensionlimit switch lever {seeFigure7-15) and gearmotorstops; releaseleverand gearmotorresumesrunning. integrity of activatingcable for extensionlimit switch. Use an inspection mirror to observe column springs at end of belt-tensioningcycle; springs should snap outward simultaneously. maximum engagedextension limit per Figure7-15 is not exceeded. clearanceto structureand drive train when fully engaged. down-limitstop screw jam nut is tight. Check actuatorfor failed-closedspring switch using either of the following two methods: Method 1 - (actuatorelectricalharnessmust be equippedwith "Test" plug per Figure2-6) a. With MASTERswitch on and actuatorfully engag€d,connect one end of MT558-1 tool to actuatortest plug and gearmotorremainsoff. CAUTION lf gearmotoractivateswhen installingMTs58-1 toolthen a sprin switch has failedin closedposition;immediatelyremoveMTs58to preventactuatordamage. b . DisconnectMT558-1 tool, connect oppositeend to actuator test plug, and gearmotorremainsoff . Disengageclutch and turn MASTERswitch off. d. MT558-1 pins 1-2 jumpertests wire 98 springswitch; pins 2-3 jumper testswire 91 springswitch (seeFigure14-1D). Replaceany malfunctioning switch per Section7.551 beforefurther flight. Method 2 - (actuatorelectricalharnesswithout "Test" plug) a. Referto Figure2-6A. With MASTERswitch on and actuatorfully engaged, depresscolumn springson one side of actuatoruntil springssnap inward (uselargescrewdriveror similartool with severallayersto tape over end to protect actuator). Hold springsinward for at leastone second. Actuator motor shouldnot run. lf motor starts, allow motor to run approximately two seconds,then releasepressureon columnsprings. Depressand hold columnspringsagain. lf motor starts again,oppositespringswitch does not function properly. b. Disengageand re-engageactuator. Repeat Step a. on opposite-side columnsprings. c. Replaceany non-functioningswitch per Section 7.551 before further flight.

Ch a n g e1 4 : J UL 2 0 OB

Page2.25

FIGIBINSiC|N

MAINTENANcE

MANUAL

Mc?E EL F.44

2.410 InspectionProceduresand Checklist(cont'd) Fairing(91 7. Open Cowling Doors (7A), RemoveTailconeCowling t7B) & Mast {cont'd) showing Lower Drive Sheave: Inspectlower sheave. Replaceany sheave roughness' grooves' wear coating, corrosionpitting ot it.t inb of metalized or sharpridges. Adjust as SheaveAlignment: sheave alignmentper Section 7 '23O' required. Hydraulic Reservoir: Inspect condition. security^and.no significant by Section1.101, replacefilter per Section1'1.7O' teakage.lt requireO dark or Drainand flush hydraulicsystem per Seciion 1.180 if oil has turned emits bad odor. Add fluid as required' CAUTION cleanlinessof hydraulicfluid is vital_toproper system operation' Cl".n tfiiO tiom seatedcontainersaridavoidcontamination Ur" ""iV etc. from dirtv funnels, is secure HydraulicReservoirCooling Hose: lnspect condition' hose anOi. directedat centerof reservoircoolingfins' shouldnot Hydrauliump: Inspectcondition. Pumptemperatureindication significant exceed gearboxtu,iipttuture indication' security and no leakage. per Section ForwardHydraulicServos: Inspectcondition. Inspectrod ends rod servo--input 2.120. ,."rtity and no significantleakage. solvent end/clevisareais clean;cleanseaiea with no-residue,non-alcoholic valve servo at freeplay total inch as iequireO. Verity apiroximately O.O4O controls input. valve ciearanceto surroundingstructurewhile flight security are movedthroughfull rangeof travel. lnspectconditionand of scissorsat upperclevis of servos.

parts' Oo not UseLPSPresolveto cleannydrautic per section Aft Hydraulicservo: Inspectcondition. Inspectrod ends input 2.120. r""uiit' ind no significantleakage.. servo clean;cleanseareawith no-residue,non-alcoholic - rod end/clevisarea is approximately0.040 inch total freeplayat ,oiu"nt as required. while servo valve input.- valve clearanceto surroundingstructure flight controlsare moved through full rangeof travel. Aft Hydraulicservo: Inspectrod ends per section.?'120. Inspect attachmentto Sheetmetal, no cracks. security' to HydraulicLines& Fittings:Inspectcondition. valve clearance range full surroundingstructur" *iil" flight controlsare moved through inch 0.25 minimum . of travel. security and io leakage. clearancebetweenpump hosesand aux fuel tank' of all Fastenersand TorqueStripes:Inspectconditionand verif,ysecurity fasteners.Renewdeterioiatedtoique stripesper Figure2-1. C h a n g e1 4 : J U L 2 0 0 8 P a g e2 . 2 6

FICIBINSiCIN

MATNTENANcE MANUAL

MtfE'EL

r|'44

2.410 InspectionCriteria(cont'd) 8. RemoveTailconePlugs{8Al & Aft PlasticCover (8Bl NOTE Aft plastic cover (88) is secured with two MS27039C0806 screws on Rev L and subsequenttailcones. On Rev K and prior tailconesensurescrewssecuringplasticcover are short enough to prevent interferencein aft flex plate area. Tail Rotor Drive Shaft: Inspect condition of that section of shaft that can be seen through each hole, looking for obvious defects such as cracks, bends,bows in shaft or corrosionor with insideof tailcone. Check runout per Section7.34O. Inspecteach end of drive shaft for cracks and corrosion. CAUTION Bends, bowing, dents, cracks and corrosion are cause for immediatereplacementof tail rotor drive shaft. Damper: Inspecttail rotor drive shaft damper{C041-1}. lnspectbearing and housingfor cracks,corrosion,wear (see Figure 2-81,and bearingseal deterioration.Inspectarms and bearingsfor cleanliness,cracks, bendsand corrosion. Inspectbearing'sinner race-to-driveshaft torque stripe. TailconeExterior: Inspecttailconeexteriorfor nicks, scratches,corrosion, fretting between skin ts, loose rivets and dents. Inspect tailcone for cracks in vicinityof antennamounts and battery (if installedon tailcone). Strobe Light: Inspectlensand strobe light mount for cracks, looserivets, and security. lf split red/clearlensis installed, clearhalf of lensfaces aft. Antennas: Inspectall antennasfor conditionand security. TailconeBattery {if installedl: Inspecttailcone-mountedbattery condition and security. no debrisbetweenbattery box cover and tailcone. Tailcone Interior: Inspect tailcone interior, especiallyaround rivets, for cracks,fretting, and corrosion. TailconeAttachment: Inspectconditionand securityof four bolts attaching tailconeto upperframe. Empennage:Inspectentireempennageand attachmentpoints for damage, cracks, and loose fasteners. Check tail skid for evidenceof tail strike. lf evidenceof tail strike is found, refer to specialinspectionsection. Float Stabilizer(if installed): Inspectconditionand security. Aft Flex Plate(SeeFigure2-51: Inspectflex plate for cracks, fretting, and distortion. lf fretting is detected, RHC Technical. Inspect securityof flex plate fasteners. Tail Rotor Drive Shaft Aft Yoke: Using inspectionhole, check yoke for cracks,fretting, and corrosion. TailRotorGuard:Inspectfor security.Checkforwardmountfor cracksaround welded area. Inspectareaaroundaft mount for crackingand fretting.

C h a n g e1 4 : J U L 2 0 0 8

Page2.27

FIC|BINSiCIN

MATNTENANeE MANUAL

M|lE

EL ]?'44

Criteria(cont'd) 2.41O Inspection

FWD

MAXIMUM ALLOWABLEWEA 0.040 inch

V IE W L OOK IN GA F T

FIGURE2-8 TAIL ROTORDRIVESHAFT DAMPERBEARINGINSPECTION

Page 2.28

C h a n g e1 3 : O C T 2 0 0 6

FIGIBINSC|N

MATNTENANtrE MANUAL

MOE'EL

F'44

2.41O lnspectionCriteria(cont'd) 9. Tail Rotor Gearboxand Tail Rotor Input Shaft Yoke: Inspectflange and weld for cracks and corrosion. Input Seal: Inspectfor leakage. Gearbox: Inspectgeneralcondition. Look for leakage. Checkoil quantity and cleanlinessthroughsight gage and adjust or flush as required. Check gearbox-to-tailcone mounting security. Inspect output shaft for nicks, scratchesand corrosion. Check safety wire on applicablegearboxbolts. CheckTelatemp. NOTE At 500 hourstime-in-serviceor annually.whicheveroccurs first, removechip detectorand cleanvarnishfrom detector'smagnetic probe and adjacent metal body (a toothbrush dampened with solventworks well). Also, drain and flush gearboxesat intervals not to exceed500 hourstime-in-service(ref Section 1.101). Pitch ControlAssemblyand G121-17 Push-PullTube: Check pitch control assemblyfor free movementthroughoutits entire rangeand for looseness on output shaft (0.25 inch maximumrotationalplay measuredat pitch link attach bolt). Inspectbellcrankfor cracks and ensurefree movement. Pay specialattentionto sphericalbearingatop stud protrudingfrom underside of pitch control;it is permissibleto have a singleradialcrack in the spherical bearingball. Inspectaft end of C121-17 push-pulltube for cracks and check rod end for excessivelooseness(Ref R44 SB 43A). PitchLinks: Checkrod endsfor excessivelooseness.lf equippedwith onepiecepitch links,disconnectand rotate inboardend outboardas requiredto obtainmaximumservicelife. Tail Rotor Blades: Inspect blade surfaces for excessiveerosion. nicks, scratches,cracks,or corrosion. Checktail rotor bladeroot fitting bearings for fretting and looseness. Loose bearing outer race in root fitting is unairworthy,requiringreplacementof blade. CO29-1bladesonly: remove tip covers,inspectfor debrisand corrosion,& reinstallcovers. Hub Plates and Hub: Inspect for cracks and corrosion, paying special attentionto areasaroundbladeand hub mountingbolts. Ensureteeterhinge bearingouter racesmove with hub and bearinginnerballsand retainingnut and bolt remainstationarywhen hub is teetered. Hub should move freely on bearingswithout stiffnessor jerkiness. Checkteeter hinge bearingsfor excessiveplay. For elastomericbearingsinspectper Section2.125. Fastenersand TorqueStripes:Inspectconditionand securityof all fasteners.Renewdeteriorated torquestripesper Figure2-1. C h a n g e1 4 : J U L 2 O O 8

P a g e2 . 2 9

F|clBINSiClN

MAINTENANcE MANUAL

MC'E,EL

N44

2.41O InspectionProceduresand Checklist(cont'd) 10. Open Mast Fairing{9} ribs' Mast Fairing: Inspect condition, especiallywhere stiffeners intersect end Lower SwashplateScissors: lnspect conditionof scissors. Check rod and bearingPlaY. Checkjam nut. For Vertical push-pullTubes: Inspectfor generalcondition and corrosion. guide' and rollers at manualcontiols, i;tp""t pusir-pulttude sleeves Rod Ends: check push-pulltube rod ends per section 2.120. and Plastic Rollers and Guide {manual controlsl: Inspect plastic rollers deterioration' grid" fot cleanliness,security,and PitotTube: Inspectpitot lineandtube, givingspecialattentionto connecting hole area,tor n"nii[g, Liatr.ingandkinkind. pitot tube elbow drain is unobstructed. tube Fuel Tank Vents: Inspect conditionand security of fuel tank,vent tube Check clamps. Ensuie-pitofiine is noi chafing fuel vint tubes' and are not kinked, pinched, connectionr.-V"?ity tubes are unobstruc-ted or chafing. tube Mast Fairing Ribs: Inspect for cracks especially around mast attachments. 11. RotorHub Area rod ends per Swashplate Lower Scissors: Inspect condition. Inspect S e c t i o n2 .1 2 0 . V e ri fYse cu ri tY. rod ends and Swashplate Upper Scissors: lqsqq"^tcondition. Inspectplay per Figure sprrliic'alU""rii6i'pEi Siltion i.'12O. Measurescissors and lower 2-8. obs"ru""sEirSor linkage while having someone raise spacers)' coilective. V"tiii'UoIi, jortnlft (or sphericai'bearingballs a.ndoperating and arm rotate'toglther ut uu"h rcirsor linkagepivot. c l e a r a n ce . at rivet holes SwashplateSliderTube: In-spectcondition. no cracks anodized through, wear or to, or corrosior,on urle. Veritv no durnage tube surface. swashplate' Remove swashplate Boot Lower Ty-rap: Lift boot from drive shaft rotor main lnspeit .i"u'U"t*een Using insp"cfion-16irror, "n no corrosionand no debris. no Veriiy tube. slider and inside of boot damage. radialplay swashplate: Inspectcondition. 0.920 inch maximum

verifv between,*uri.,-ilriduirri"o riiori tr'uu.Rotaterotorby handand il;;;tilg-clearanceandno roughor dry bearings'

ball from below and have SwashplateShimming:Observeswashplat^e swashplate someonemove collectivesticl-siowty up & down. reverses swash.plate when swasfrptate ball immeOiai"fy1.11ou6t-witfr movement ball without.attendant of swashplate direction. fVfou6ment per indicatesu*il'i pr"v ultw#n-uJtl ana swashplate;shim swashplate S e c t i o n8 . 4 1 6 . position and Install Swashplate Boot Lower Ty-rap: correct boot securitYand no boot damage' C h a n g e1 4 : J U L 2 0 0 8 P a g e2 . 3 O

M(lElEL n44

MATNTENANcE MANUAL

FICIBINS|CIN

2.410 InspectionProceduresand Checklist(cont'd) 11. Rotor Hub Area (cont'd) Hub: Inspectcondition. no nicks,scratches,gouges,or corrosion. check teeter and coning hinge lf main iotor imbalanceis iuspected, '5). no brown or black residue friction per Section 9.124 al (indicatesbearingwear). HingeBolts:Inspectcondition. cotter pins are in placeand secure. bolt heacisand nuts are torque stripedto thrust washers. Pitch Linksand Rod Ends:Inspectcondition.Inspectrod ends per Section 2.120, includingcentering. security, includingjamnut tightness and propersafety wiring. Fasteners & Torque Stripes: lnspect condition and security of all fasteners. Renewdeterioratedtorque stripesper Figure2-1 For scissors with C648-2 bearings: - O . O 1 Oi n c h O.OO1 total axial play per pivot. Referto Figures8-134 & 8-138.

i FeelerGauge /';"

o

,'

fI\

-----4

S-_

For scissors with 8115 spherical bearinqs:

o,,,,^I*(ccL(---6 i

HoldingTool

FIGURE2-9 MEASURINGUPPERSWASHPLATEROTATIONALPLAY (ldentify scissorsbearingUpe and measureas shownl C h a n g e1 4 : J U L 2 0 0 8

P a g e2 . 3 1

FICIBINSiCIN

MATNTENANcE MANUAL

MtfE

EL F'44

2.410 InspectionProceduresand Checklist(cont'd) 12. Main Rotor Blades(Referto Section9.130 for damageand repairlimits) CAUTION Main rotor bladeskinscan be dented;exercisecare when working on or aroundblades. Inspectvisibleportion. no corrosion. Boots: Inspect condition. security.apd n9 .oil leakage.. clearancebetweenboots and main rotor hub at full-up and full-down collectiveat cyclic travel extremes. Nicks, Scratches,Buckling,and Dents: no nicks, scratches,or buckling. any dents are within limits. Areas: Referto Figures9-9 & 9-9B: Usinga 1965Adhesive-Bonded or-i"i"t U.S. qratter-dollarcoin, taf-test..all.critical bond areas and u"iity no dull'or hollow sounds. Visually^inspectbond areas and no separation,Referto section9.13O.h.for void limits. 5x--1Oxmagnification,visuallyinspect Skin-to-sparbond line: Using --no. separation and no cracks in 'Refinish Jf.in-to-"par bonded ireas. any exposed {bare metal) pii"iit"hg skin-to-sparbond [n"-. 'bond line in accordancewith R44 ServiceLetter SL-32. Remove tip covers: no_corrosionor foreign material in blade Refelto Figure9-9. Using.a 1965-or-laterU'S' iipJ o. o.t iip and no "ou"it. skin]to-tipcap b-ond.areas tap-test qliti"t-Ooiiir-coin, inspect ciullor hollow sounds. Using 5x-1Ox magnification,_visually no 9-9} and Figure areas {see bondid eJge-of siin+o+ip cap bn.yexposedbare Telgl -Ensure s"iar"tion. epoxy prir", or p.rimeand p_aint, tip cover and bladetip cover. tip *f,icf, may conta6t'inJtaited drain holesare unobstructed. WARNING Structuraldamagemay occur if compressedair is appliedto blade drain holes. INSPECTTHESEAREAS FOR SIGNS OF SEPARATIONSUCH AS BLISTERS

AND BULGES.

HONEYCOMB

P a g e2 . 3 2

\ SPAR

INSPECTION FIGURE2.1O MAIN ROTORBI-ADESKIN.TO-SPAR c h a n g e1 4 : J U L 2 O O B

FICIBINEiCIN

MATNTENANcE MANUAL

MOEIEL

H,44

2.41O InspectionCriteria{cont'd) 12. Mdn Rotor Blades(Referto Section9.130 for damageand repairlimits) (cont'd)

Installtip covers: security. & TorqueStripes:Inspectconditionand securityof Fa{iteners

all fasteners. Renewdeterioratedtorque stripesper Figure2-1 13. ScrollArea FanwheelAssembly: Cleanand inspectfanwheelassemblyfor cracks and corrosion. Checkleadingedge of vanesfor damage. spring pin andfanwheelalignmentmarksarealigned(seeFigure2-11l';remove fanwheel and inspect mating surfacesfor darnageif misalignmentis evident. FiberglassScroll: Inspectfiberglassscrollfor cracksand marks from fanwheel. Inspectflexibleseal aroundscroll inlet for any rips or damage.Inspectvane assemblyin right upperscrollfor damage. drainhole is unobstructed. ScrollMetalInletLips&Gap: 0.030 / O.O9Oinchgap betweenlips and fanwheel inlet (elongatelip attach holesas requiredto adjustgap). 14. Engine Referto Section 1.101. Refer to LycomingOperator'sManual (P/N 60297-1O sections 4 and 5), LycomingSl 1O8OB,and applicable enginecomponentmanufacturer'smaintenancepublications for 1OOhour or annualinspectionand serviceprocedure. Engine Cooling s:Inspect condition. Pay particularattention to (s)mounting oil cooler(s)and attachedto alternator cooling hose. no cracks or missingor loose fasteners. security. Alternator & Pulley: Inspect condition. steel pulley (use magnet); aluminum pulley is not approved. security. electricalwiring security. AlternatorBelt:Inspectcondition.Replacebelt if thereareany cracks, missingteeth, or delamination.Checktensionper LycomingService Instruction1129 (latestrevision). properbelt alignment. EmergencySpare Alternator Belt: Removeif installed. AlternatorCoolingHose:Inspectcondition. no obstructionsor holes. security. Air Gonditioning Refrigerant Lines (if installedl: security, no damage,and clearanceto adjacentstructure. dust caps installedon servicingfittings at verticalfirewall. Air ConditioningCompressor(if installedli security. Air Conditioning Gompressor Drive Belt (if installedl: Inspect condition. 4.5/5.5 pounds force appliedat mid-spanof belt c au se s0 .1 1 /0 .1 7 i n ch b elt deflection;adjustas r equir ed. Muffler Elbow & Tailpipe Shields: no cracks in shieldsand shieldattachingbrackets. clamp security. C h a n g e1 4 : J U L 2 0 O B

P a g e2 . 3 3

FICIEIINSCIN

MAINTENANeE

MOE EL F|44

MANUAL

2.410 InspectionCriteria(cont'd)

0 . 0 4 1 I N C HD I A M E T E R STEEL STAINLESS SAFETYWIRE

S P R I N GP I N

A L ] G N M E NM T A R K SO N A F A N W H E E LL I G N E D PIN W I T HS P R I N G

NUT CASTELLATED

FANWHEEL

ALIGNMENTMARKS FIGURE2-11 FANWHEEL

Page2.34

C h a n g e1 3 : O C T 2 O O o

FIGIEIINSCIN

MATNTENANeE MANUAL

MODEL

Fl44

2.410 InspectionProceduresand Checklist(cont'd) 15. ExhaustSystem Removemuffler heatershroud screws, and open shroud. Inspect muffler outer wall for cracks, deformation,and ruptures.Pay particularattention to tailpipe and riser attachment areas, welds, clamps, s, riser. flangesand gaskets.Pressurizemuffler with low pressureair and'inspect for leakage. Closeand secureheatershroud. 16. LandingGear Skids and Shoes:Inspectleft and right landinggear skids and skid shoes; minimum allowable shoe thickness is O.O5 inch. drain holes are open (not applicableto float landinggear). Struts and Elbows (open fairings if installedl: lnspect for cracks and corrosion,especiallyat elbow ts. Inspect weld area at bottom of strut for cracks. Landing Gear Fairings (if installed): Inspect for cracks and loose rivets. security. Grosstubes:Inspect,especiallyat elbow ts, for cracks and corrosion. With helicopteron level ground, measuredistance from ground to tail skid. lf dimensionis lessthan 30 inches,one or both cross tubes must be replaced(seeSection5). LandingGearAttach Points: Check forward attach points for loose rivets, cracks, buckling,and fretting. Check bearingmounts for loose swages and worn bearings. Utility Floats (if installed): Inspect for damage. Refer to Pilot's Operating Handbookfor properinflationpressure. Pop-out Floats (if installed)PressureCylinder & Valve: Inspect condition. security. pressuregageindicatescorrectpressurefor ambient temperature;refer to placardon cylinderfor limits. Pop-outFloats (if installedl Inflation Manifold: Inspect condition. no chafingor pinchingof hoses,especiallywhere hosesthru structure. Pop-out Floats (if installedl: Inspect condition of stowed floats. no holes, cuts, tears, abrasionthru, or unravelingof, float covers. lf cover damage is found, inflate and inspect floats. all float cover snaps and hook-and-loopfasteners are properly secured. float-to-skid attachment security. NOTE Annuallyapply A257-7 dry-filmlubricant(seeSection 1.47O) to float cover snap mating surfaces. AnnuallyperformSection 5.630 leak check. Everythree years,performSection5.640 inflationtest. Ch a n g e1 3 : OC T 2 OOo

Page2.35

FIGIBINSCIN

M.fDEL

MAINTENANeE MANUAL

F|,44

2.410 InspectionProceduresand Checklist(cont'd) 17. Cabin no looseequipmentthat might foul controls' floats are Static ports: Inspect static ports for obstructions. lf fixed utility ports' installed, air dam installedaft of both static RearSeat-Bottomsuspensionstraps: Inspectcondition and security' stitching. SeatBeltsand ShoulderHarnesses:Inspectforfraying and broken quicklyto Checkinertiareelsfor properoperationby pullingharness reel lockingfunction. ctrect bucklesfor properoperation.check belt and attach points for securitY.

on factory installedharnesses. TrimController(Manualflightcontrolsonly):Adjusttrimcontrollerper Section14.710. indicate Wndows: Minor damagethat does not impairpitot's visibilityor impendingstructuralfailure is acceptable.For cracks and crazing adiacent to windshieldretainerstrips,referto Section2'580' Acceptabledamageincludes: not a. one nick, not more than o.o1o inch deep and occupyingan area largerthan 0.25 by O.5Oinch per squarefoot' b. scratchesnot more than o.o1o inch deep and 5 incheslong' removed c. Any surfacedefect such as smallspots or stainsthat can be with light Polishing' d. Minor polarizationfaults in smallareasof windshieldnear edges' skin: Inspectskinfor damage.Inspectfor looserivets,indicatedby cracked paint and/or black residuearoundheads' for Doors: lnspect for cracks around hinges and latches' Check vents tightness operation.Ensurehingepins are securedwith cotter pins' check of hinge mounting .Jr"*r. proper operationof door latching and lockingmechanisms. Chin Drains (R44 Clipper): no obstructions' 18. Special Equipment(if installedl by Peak Beam searchlight: check for proper operation. Align beams at wall a focusingboth lightsto smaltestspot possibleand shiningagainst least 1OOfeet u*ty. both spots hit same point within one foot' units Nose Gimbal and Monitors: Turn power on and infrared time' complete cool down sequence in manufacturer'srecommended focus gimbal steers smoothly in azimuth and elevation' check and zoom of infrared/video.check for clear imageson monitors' retractablemonitor retractswithout interference. Pa g e2 . 3 6

Change13: OC T 2006

FIclElINEiClN

MATNTENANcE MANUAL

MOEIEL

F|44

(cont'd) Procedures 2.410 Inspection and Chec.klist 18. SpecialEquipment(if installedl SpectrolabSearchlight: light starts and cooling fan operates. searchlightsteerssmoothlyin azimuthand elevation. For slavedunits,turn on slavingand light follows nose gimbalapproximately. FM Radios: radiostransmit and receiveproperlyand control head programsradiosproperly. VideoTape Recorder: all videotape recordermodesoperateproperly and remote control correctlycontrolsmodes. OverheadLight: overheadlight on/off. TransmitandIntercomSwitches: properoperationof specialtransmit and intercomswitches. Talent Light: talent light on/off, acceptablefriction. Micro Cameras: all micro camerasareselectablefrom videoswitcher and producefocused,uprightimageson monitors. TV Tuner: TV tuner receivesbroadcasts(videoclear on monitors, audio clear in headset). MicrowaveAntenna: omnidirectionalmicrowaveantennaextends/ retractsproperly. up/down indicatorlights function properly. Electromagnetic and Radio Frequency Interference: With all special equipment turned or, check for EMI/RFIwith tach, COM, intercom, com,or other systems. 19. Life-limitedParts, Airworthiness Directives,& Service Bulletins Life-LimitedParts: S/Ns of installedparts correspondwith those listed in maintenancerecordsand all installedparts have adequateservice lives remaining. AirworthinessDirectives:Check status of applicableairframe, engine, and accessoryAirworthinessDirectives,includingcompliancemethod. Some aircraftmay have AirworthinessDirectiveswhich requirerecurring inspections at less than 1OO-houror annual intervals. Recent U.S. AirworthinessDirectivesmay be accessedon the internetat: http: //www 1.f aa.gov/certification/aircraft/ Service Bulletins: Check status of applicableairframe, engine, and accessoryServiceBulletins,includingcompliancemethod. Some aircraft may have ServiceBulletins,which requirerecurringinspectionsat less than 1OO-houror annualintervals. RecentRHCServiceBulletinscan be accessedvia the internetat: www. robinsonheli.com/. htm 2O. RequiredDocuments and Placards Documents:Check that requireddocuments(AirworthinessCertificate, Registration, applicable Radio Station License, Pilot's Operating Handbook,EquipmentList/Weight& BalanceData)are on board,legible, and current. Placards:lnsureallrequiredplacardsareinstalled,legible,andcurrent;refer to Section 2 of Pilot'sOperatingHandbookfor placardrequirements. Ch a n g e1 3 : OC T 2 OOo

Page2.37

FIElBINEiclN

MAINTENANcE MANUAL

MOEIEL

F|'44

and Checklist(cont'd) 2.410 . InspectionProcedures 2O. Inspectionand AccessCovers rags, and ForeignObiectsRemoved: all tools'.lggt" hardware, aircratt" otherioreiin objectsare removedfrom all inspectionand accesscovers coversclosedand secure:Instatl/close t"rJ""a in piecedingsteps.securityof all accesscovers' with clipper I Airbox sealed:Ensureair box cover perimeteris sealed I modelsonly)' aluminumtape {Clipper Records 21. Maintenance records are current and MaintenanceRecords:EnsuremaintenanCe adjustments'oil '.nO i;n' replacement, correct.Entermaintenanc"(sucii'i; inip'"ction'data.Datamust includea change,O""tinJlrbti""tionf date,aircrafttotal timeto, worti performed-, descriptionof, or reference return in-service,righiiri";;;d ;.dificate humberof personapproving to service.

P a g e2 . 3 8

C h a n g e1 3 : O C T 2 0 0 6

FIC|BINEiC|N

MATNTENANcE MANIIAL

MI]EIEL

F44

2 . 5 O O S P E C IA LIN S P E C T ION S 2.501 Upper and Lower ClutchActuator BearingsInspection The actuator upper bearingis locatedon the clutch shaft, and the actuator lower bearing is located on the fanshaft. Failureof either actuator bearingin flight could cause loss of power to rotor system and result in a serious'accident.Refer to Section 2.110 for generalindicationsof bearingfailure.In addition,just before failure of an actuator bearing,the clutch light may flicker (on and off in less than one second)constantlyor iltuminatefor longer than normal in-flight retensioningtime of up to 8 seconds,then off). Flight should not be resumeduntil causeof abnormalclutch light illuminationhas been determined. Performthe following bearinginspectionswhenever an actuator bearingdiscrepancyis suspectedor fanwheel is removed: 2 . 5 0 2 C l 8 1 L o w e r B e a ri n gIn sp ection 1 . R e m o vescro l la n d fa n w h e e lp er Section6.210. 2. clutch drive shaft aft of sheave. Disconnectlower end of belt tension actuatorfrom bearinghousing. 3. Rotate bearinghousingwith finger tips. no roughness,scrapingor excessive l o o s e n e ss(O.O1 Oi n ch ma xi mum axial play) . Ver ify no seal dam ageand no heat d a m a g e . L u b ri ca teb e a ri n gp er Section1.140. 4. Carefully inspect inner race bearingson fanshaft. Forward bearing inner race is torque-stripedto fanshaft two places 18O degreesapart; crackedor brokentorque stripes indicatemovement.No movementor fretting is allowed between inner race and fanshaft. no distortion due to bearingouter races rotating in housing. Replacefanshaft & bearingassemblyif indicationsof movementare noted. 5. Reinstallfanwheelper Section6.220. 6. Check and adjust fanwheeldynamic balanceper Section6.24O.

Ch a n g e1 4 : J UL 2 OO8

Page2.39

FIclBINSiClN

vIATNTENANcE MANUAL

M(]E,EL

'l,44

2.503 C184 UpperBearingInspection housing' 1. Disconnectlateralcenteringstrut from left side of bearing its furl disengagepositionby 2. Disconnectbearinghousingfrom actuator.Runa-ctuatorto 7-15. Do not allow upper adjustingu.tuiior-oown-tiirit,"ir* ,p*"rd. Referto Figure other' and lower scissors;ittaching screw headsto each of any roughness'scraping' or 3. Rotate bearinghousing and check for sound or feel Vbrify no suatdamage,loss of lubricantor heat damage' excessivetooJeneJs-. bearinginnerraceis torque4. Carefullyinspectinnerracesof bearingson clutchshaft. Aft or brokentorque stripes stripedto clutl-hr6uii two-placeiiab-u"gr"es apart; cracked racesandshaft.Verifvno indicate*ou"i.,"if. V";iit 'io trliting n"ifi""q b6aringinner Removebearingsand distortiondue to bearingouter r"""irT rotatingin beariig hou.sing. of movementare noted' inOications ;;;f,tiiit inri"dfUetid down-limit b. Connect centeringstrut and actuator to bearinghousing. Adjust.actuator secbndsbeiween clutch engagementand stop screw ir,"ltuir-i oetay "oduringstart-up. "il"ii-tin-5 rotor turning

Pa g e2 . 4 4

C h a n g e1 4 : J U L 2 O O 8

FIClBINEiclN

MATNTENANeE MANUAL

F|44

MOEIEL

2.5O7 V-Belt Inspection lf any of the following conditions are observed, replace V-Belts in a. matched set per Section7.28O. 1 . Bottom of belts cracking.

cAusE' Belt slippingcausing heat build-upand gradualhardeningof undercord.

REMEDY

Returnactuatorto RHC for servicing.

2. Top of tie bandfrayedor damaged. CAUSE

structure Surrounding with normal interfering of belt. operation

\N

Foreignmaterial ingbelt.

REMEDY

Repositionaffected sheavefor proper clearanceand align sheavesper Section 7.230. Removeforeign material

3. Top of tie band blisteredor perforated. CAUSE

Foreignmaterial accumulatingbetween belts.

REMEDY

Checkfor and remove foreignmaterial.

FIGURE2-12 V-BELTDISCREPANCIES

Ch a n g e1 3 : OC T 2 OOo

Page2.41

FIClElINEiclN

MATNTENANeE MANUAL

M('EIEL

]I44

(cont'd) 2.507 V-BeltInspection 4. BELTCUTON BOTTOM Cause Belt ran over sheave and came off, or belt forced over sheave flangeduring installation without properslack. Foreignmaterialfell into belt drive makingbelt come off.

Remedv Check belt tensionper Section7.283 and upper sheavealignmentPer Section7.23O. Removeforeignmaterial if any. lnstallnew belts properlyper Section 7.280

5. BELTRIDINGOUTSIDESHEAVEGROOVE V-belt has jumped one grooveforcing belt out of sheave

CAUTION lf belt condition shown is allowed to run in specified condition, failure would progress as shown below. Cause One belt separatedfrom tie band

Remedv Both belts separated from tie band

Cause lmproperbelt tension, of sheaves misalignment and/orforeignobject struck belt forcing it from it normalPath.

Remedy ReplaceV-beltsPer Section7.280; align upper sheaveper Section7.23O.

DISCREPANCIES 2-12A V-BELT FTGURE

Page2.42

C h a n g e1 3 : O C T 2 0 0 6

FIG|BINSCIN

MATNTENANeE MANUAL

MOEIEL

Fl44

2.508 Lower SheaveV-BeltWear PatternInspection Observewear patterns in paint primer in all eight groovesof lower V-belt sheave.Wear patternson both sidesof all eight groovesshouldappearvery similar.Wear patternswhich vary in width lessthan a 3-to-1 ratio grooveto grooveare acceptable. lf wear pattern is noticeablydifferentfrom grooveto groove, inspect sheavegroovesfor roughnessor excessivewear and replabeV-beltsper Section 7.28O. lf wear patternsare all similar and alignmentand conditionof belts and sheavesare satisfactory,no further action is required.

DRIVEBELTS

/\

WEARPATTERN RATIOIN GROOVES N OTMORETHAN3:1

r,4

FIGURE 2-13 LOWER SHEAVE V-BELT WEARPATTERN

Ch a n g e1 3 : OC T 2 0 0 6

Page2.43

F|OBINSiEIN

MAINTENANeE

MANUAL

MclE EL n44

blank IntentionallY

Page2.44

Change13: OCT 2006

FICIBINEiCIN

MATNTENANcE MANUAL

MC'E EL Fl44

2.51O Tail Skid Strike The tail skid strike inspectionis listed in two parts, A and B. Part A concernsscuffing of tail skid. Part B is concernedwith bendingor breakingof tail skid and/orbucklingof lower verticalstabilizer. A. lf evidence of scuffing is found on.the tail skid, inspect the rotorcraft as follows: 1 . Vi s ua l l yinspect tail rotor blades for evidenceof solid object or ground . lf tail rotor damage is found, inspect tail rotor per Section 2.520.

2 . Visuallyinspectverticalstabilizerfor evidenceof buckling,cracksor loose rivets at tail skid and lower verticalto horizontalstabilizerattach points.

3 . Visuallyinspecttail rotor guardfor bendingor crackingat attach mounts. 4 . Visually inspect the horizontal stabilizerto tailcone attach points for evidenceof buckling,loose rivets or cracking. 5. Visually inspect tailcone for damage and tailcone to upper steel tube structureattach points for bucklingand looseattach bolts. B. For skid bendingor breakage,or bucklingof lower verticalstabilizer,perforrn the following inspectionsin additionto those listedin Step A. 1 . Inspecttail rotor drive shaft run-outper Section7.340. 2 . Removetailconeand dye check CO2Ouppersteeltube structureat tailcone attach points per Section2.560. 3 Visually inspect tailcone attachment points for elongatedholes (0.454 inch-diametermaximum.) 4. Remove the stabilizerassembly and dye penetrant inspect the tailcone casting. a) Removepaint from tailconecastingin areasshown iri Figures2-14 and 2-14A usinga suitablepaint removerper Section1.410. b) Dye penetrantinspect using instructionsprovidedby manufacturerof dye penetrantinspectionkit.

Ch a n g e1 4 : J UL 2 0 0 8

Page2.45

I

t; | |

:t t I ltl

i,!

I i\!\l

I \ I

Page2.46

,,\

l|l

I

],'44

1l

I lt r

I

M('E'EL

ta

I ttl I tl I

DYE

MANI.IAL

MAINTENANcE

FIG|BINSIG|N

I :,i=

r -4t

t I t I

l,^

F|GURE2.14TA|LCoNEcAsT|NGToPAFTV|EW AREASAFTERPAINTREMOVAL INSPECTDESIGNATED PENETRANT

C h a n g e1 3 : O C T 2 0 0 6

FICIBINSIC|N

MATNTENANeE MANUAL

MOE EL N44

FIGURE2.14A TAILCONECASTINGBOTTOMFWD VIEW DYE PENETRANTINSPECTDESIGNATEDAREASAFTERPAINT REMOVAL

C h a n g e1 3 : O C T 2 0 0 6

Page2.47

FIclBINEiclN

MATNTENANeE MANUAL

MI:'EIEL

F|44

2.510TailSkidStrike(cont'd) as follows: stabilizer 5. tnspecthorizontal attach pointsfor elongated a) Visuallyinspecthorizontalstabilizer looserivetsor buckling. maximum) diameter 6oiJJtb.Sg6-inch lowerverticalstabilizerfrom horizontaland visually b) Disassemble inrp""i ittach points on verticaland horizontalstabilizersfor diametermaximum),buckling,cracks ;ffig;td-hol"r iO.ZOO-inch of ofio"oi" rivets. bJcklingand cracksare causefor replacement tn" *ii. Looserivetsm-aybe drilledout and replaced' Removetail rotor guard. Removepaint from forward and aft utti"f,*"ni points 5nd dye penetrantinspect using instructions inspectionkit' Remove dye penetrantpiouiO"Oby manufacturer'of 10-32 screws and four rdmovins by tiorn t"itione 6;;;J;;"hf step' above as same dye penetrantinspect 2.52O Tail Rotor Strike Tail rotor strike inspectionis listedin two parts,{.and B. PartA concernsdamagereceived obiect UV a tiif roto, blaile due to with a small stone, tall grass, or some small rotor tail of stopp?ge sudden with concerned B is iotor Uf"O"ln ir"" air. Part blade or "6ni."iing Ar" to gr6unO-orsolid object causingbendingor shearingof a tail rotor blades. A. tnspectper Section9.220 and completepart B item 1' -' lf one or both tait rotor blades ground or a solid obiect causing B. UtaOesa tail rolor sudden stoppage inspection U"nAingoi she;ilg;i must b"eperformedl Inspectper following procedure: 1 ) Check tail rotor drive shaft run-out per Section 7.34O' lf run-out exceeds 0.025 inch at any location'the shaft must be -replacedor Strip p;fif U""L ai least 2 inchesfrom welds at forward end ;A;;;J. b.y.manufacturer oi-Oiivesfritf inO dye check per instructions.su-pplied drive shaft must found, is of cracks [it. ff'ity evidence OV" "ft"tL"i be replaced. 2l Visuallyinspectdrive shaft for evidenceof twisting, nicks, dents or scratches.Nicts and scratchesmay be polishedout to a maximum of O.OO3inches Oe"p. Evidenceoi twiiting or dents is cause for replacementof the drive shaft. 3) Removeyoke (c195-5) located at aft end of tail rotor drive shaft. inip""t fiofui io. uny elongalion. Strip.paint and dye check per int[tu"iioni supplied6y manufacturerof dye check kit' 4l Removetait rotor and tail rotor gearbox and return them to an RHC apJio"eOoverhaulfacility for overhauland/orrepair' 5 ) Always replaceaft and intermediateflex platesafter tail strike' 6) Visually inspecttailcone and empennagefor evidenceof a tail rotor bladestrike. 7l Visuallyinspectmain rotor system.

Page2.48

Change13: OC T 2006

FICIBINEiCIN

MATNTENANcE MANUAL

MOEIEL

H44

2.530 MainRotorStrike The mainrotor strikeinspectionis listedin two partsA and B. PartA concernsof mainrotorbladeswith objectin freeair suchas smallstones,brush,smallbirds,etc. Part B is concerned with suddenstoppageof mainrotordueto groundor solidobject. A. lf mainrotorbladehaseda smallobjectin freeair suchas smallstones,brush, small birds, etc the main rotor bladesshouldbe inspectedas follows: 1. Main rotor bladesshouldbe inspectedfor evidenceof nicks,scratches, dents, etc. per Section9.1 30. 2. Visually inspect trailing edge of blade for evidence of buckling or bending. This will be most evident near root of blade.

CAUTION lf evidenceof buckling is found on a main rotor blade it will be consideredto havesuddenstoppageandsuddenstoppageinspection must be used to inspect the entire rotorcraft B. lf main rotor blade or bladeshave edground or a solid object, they must be inspectedfor suddenstoppage. Suddenstoppageis evidentwhen bucklingor bending of the main rotor blades has occurred. Use the following procedurefor inspecting rotorcraftafter main rotor suddenstoppagehas occurred: 1. Checkthe tail rotor drive shaft run-outSection7.34O. 2. Removethe followingcomponentsand returnto a RobinsonHelicopter Companyapprovedoverhaulfacility for inspectionand/orrepair. COOSMain RotorSystem COOOMain RotorGearbox CO18ClutchAssembly C947-1 Forward Flex Plate C907 and C9O8Yokes 3. Inspect engine for sudden stoppage per engine manufacturer's instructions. 4. Dye penetrant inspect upper rotating swashplatefor cracks and/or deformation.

Ch a n g e1 3 : OC T 2 OOo

Page2.49

FIGIBINEiC|N

MOE'EL

MAINTENANeE MANUAL

F|'44

2.540 Rotor/EngineOversPeed Inspectionis listed in overspeed inspectionsare determinedby severity of overspeed' system ijue to overspeed three parts: A, B, and C. Part A concerns inspectionof rotor part B is concernedwith inspectionof rotor system due to between 1og% and 114o/o. overspeedinspections' overspeedsat or above 114o/o.Part C is concernedwith engine A. For rotor overspeedsbetween 108 and 114o/o:

Referto Part C if a pre-overspeedand 1. Check main rotor and tail rotor dynamic batance' Compare I post-overspeedbalance'

CAUTION rotor dynamicbalancegreater than 0.3 iPs

on per Part B.

outer blade 2 . Remove main rotor blades. Drain pitch bearing housings' Remove no to boot clamps and fold boots away from pitch horns. Rotate spindles brinellingof Pitch bearings. NOTE Bearingshave a high preload;slightdrag is normal.lf roughness is evident,return UjadeJnOsbinJleassJmblyto RHC-authorized overhaulfacilitYfor rePair. 3. Visuallyinspectmain and tail rotor blades' 4. Checktail rotor drive shaft run-out per section 7.340. changesor B. tf an overspeedat or above 114o/ois reportedor suspectedor if balance to Part A' roughnessis evident,performfollowing inspectionsin addition pitch bearing

Referto Part C if a power-onoverspeedoccurs' 1. PerforminsPectionPer PartA. bent bolts. 2, Checkconinghingeboltsfor evidenceof bending' ReplaceanY insPected' 3. Coning hinge bolts, washers,and journalsmust be magnetic Particle Replaceany crackedbolts,journalsor washers' Pa g e2 . 5 0

Change13: OC T 2006

FIGIBINSCIN

MATNTENANeE MANUAL

MOE EL Fr44

2.540 RotorlEngineOverspeed(cont'd) 4. Visually inspect hub and dye penetrant inspect any areas suspectedof having cracks. Dye penetrant inspectionsare performedusing instructionssuppliedby manufacturerof penetrantkit. ,''

5. Reinstallbladesand check balance. lf a changein balanceis evident,rotor system should be returned to an approved RHC overhaul facility for inspectionand/or repair. C. Determinepercentengineoverspeedfrom enginetachometerindicationusingfollowing formula:

percentengineoverspeed=

Enginetachometerindication x 2665 1O0 28OO

NOTE 1O2o/aenginetach indicationequals 2718 actual engine RPM. The ensine is rated at 2800 RPM Referto LycomingServiceBulletin369 (currentrevision)for engineoverspeedinspection requirements.

2.550 Hard Landing The hard landing inspectionis listed in two parts: A and B. Part A concernsyielding (bending)of the cross tubes due to hard landingsuch as hoveringautorotationsor run-on landingsthat do not applyside loadsto the landinggear. Part B is concernedwith hard landingsthat, in additionto yieldingof cross tubes, has yieldingof steel tube frames or fuselageprimarystructure. NOTE Side loadsshow up in the airframeas bucklesand bent steeltube structure. Ch a n g e1 3 : OC T 2 0 0 6

Page2.5" 1

FICIBINSICIN

MODEL

MAINTENANcIE MANUAL

F|44

2.550 Hard Landins(cont'd) A. Yieldingof cross tube due to hard landingwith no side loads:,

:l

1. Checktail rotor drive shaft run-outper section 7.340. See Section 2. Visuallyinspectmain rotor btadesfor oil canningof skins and buckling. blades. g.i ao ior irispectionand repairof main rotor serviceablelimit. Placerotorcraft 3. Checklandinggearcrosstubesfor yieldingb.gVond ground. lf lessthan 30 inches, to on level ground,and measut" tior iip otiait itciO one orU5th cross tubes must be replaced' 4.Checkandadjustsheavea|ignmentperSectionT.23o 5. Inspectfront seat structurefor yielding' and no gap 6. Inspect aft seat structure for yielding.. Open aft seat bofioms irounO foam spacer at aft end of seat bottom structure' inspect rotorcraft as B. lf yielding of steel tube frame(s) oR fuselage has occurred, follows: 1. PerformPan A insPections. particularattention -2. Visuallyinspect steel tube framesfor yielding.and cracks. Pay to att ,iertiiaiittrt of lower steeltube structure'

No frameyieldingis allqwed' 3. Visually inspect fusetage,landinggear attach points, and firewalls cracks.

for bucklingor

Vertical firewall attach points for susceotibleto cracksdue to hard lan

4. Dye check upper steeltube structureand all welded

ts'

5 . Visuallyinspecttailconefor bucklingor looserivets. points for bending and 6 . Visually inspect landing gear skid tube-to-strut attach cracks. by tail skid strikes,tail rotor strikes' main rotor 7 . Hard landingscan be accompanied. i1t"!" conditions, refer to the a.ppropriateportion blade strikes, rt". To-inip"&l; permitt-ed.Any cracks, of section 2.5oo. Minor sheet rulul-r"pairs to.cabin are for replacement'

;i"fiild;i

or"lling'il;L;i

irur stiJctui'eor tailconearecause

parts and assemblies' Major defects *"y-u" factory-repairedby replacementof

Page2.52

Change13: OCT 2OOo

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MATNTENANcE MANUAL

Mt'EIEL

H'44

2.560 PenetrantInspectionof CO20 UpperSteelTube Frame 1. Carefullyclean all paint, primer, oil, grease,etc from steel tube structurearound and adjacentto four tailconemounts (seeFigure2-15). 2, Apply epoxy paint remover and allow the softeningaction to complete (temperature affects time required). 3. Removesoftened paint by hand using a wire brush. Be sure steel structure is perfectly clean beforeapplicationof dye penetrant. 4. Carefullycheckfor cracksin and aroundeachweld beadand alongeachsteeling tube for at leasttwo inchesaway from weld beads.Replaceany frame exhibitingcrack indications. 5. lf no cracks are found, clean all inspectionmaterialsfrom steel tubing. 6. Prime with good quality zinc chromate or epoxy primer and allow adequatedrying time. 7. Refinishareawith gray epoxy top coat or equivalent. 2.561 Corrosionon C02O UpperSteelTube Frame 1. Polishout corrosionon steelframe tube . a. Polishout light surface corrosionon frame using Scotchbriteor 40O grit wet-or-drysandpapersubjectto dimensionallimitationsshown in Figure216. b. Polishout corrosionpitting using320-grit wet-or-drysandpapersubjectto dimensionallimitationsshown in Figure2-16. NOTE For large areasof corrosion,it may be necessaryto removeentire upperframefrom aircraftand strip off paintto adequatelydetermine extent of damage. 2. Primebare metal with a good qualityzinc chromateor epoxy primer. 3. Refinisharea with gray epoxy top coat or equivalent. 2.570 Reserved

Change13; OCT2006

Page2.53

FICIBINSiCIN

MAINTENANcE

MOE EL F|44

MANUAL

INSPECTFORCRACKS AT THIS LOCATION (TYPICALBOTH SIDES)

CHECKTHIS AREA FORCRACKS (TYPICALBOTH SIDES)

z'rN

/I-E/

\

l./

,/-

CHECKEACHWELDBEAD 2 IN. AREAFORCRACKS FROM EACHDIRECTION T H EJ O I N T .

FRAM EINSPECTION 2 .1 5 UPPER F IGU R E

Page2.54

C h a n g e1 3 : O C T 2 0 0 6

FICIE|INS|GIN

MATNTENANcE MANUAL

LIGHTSURFACECORROSION: 0.002 in. MAX. DEPTHAFTERREWORK

MOE'EL

F|44

0.10 in. MAX DIA -PITTING: 0.004 in. MAX. DEPTH AFTERREWORK

O.5Oin. MlN. SEPARAT BETWEENAREASOF PITTING

FIGURE2-16 UPPERFRAMECORROSION REMOVALLIMITATIONS

C h a n g e1 3 : O C T 2 0 0 6

P a g e2 . 5 5

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MtfElEL

MAINTENANeEMANUAL

H44

2.580 WindshieldInsPection strips usingthe following Inspectwindshieldfor cracks and crazingadjacentto retainer per section 4'120 windshields criteria. lf cracks exceedthese limits, re"place

CENTER RETAINER

STIFFENER

I

TOTAL CRACKSMUST NOT BE MORE T H A N2 I N . I N L E N G T H .N O S I N G L E CRACKTO BE MORETHAN 1 IN. IN LENGTH.

r itrt.tvtttt.cLEARAREABETWEEN PATCHESOF CRAZING

LOWER - LEFT RETAINER

I

o . 2 5 l N . OR LESS /;\

\y

INSPECTION 2 -1 7 W INDSHIELD F IGU R E P a g e2 . 5 6

Change13: OCT 2006

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H44

OVERHAUL REOUIREMENTS INSPECTION AND LIMITED 2.600 12-YEAR but 12 yearsor morehaveelapsedsincehelicopter ff lessthan 2200 hourstime-in-service, proceedas follows: was new or lastoverhauled, NOTE This Section does not supersede 2200-hour inspection and overhaul requirementscontainedin Section 3. Section 3 must be compliedwith basedon componentservicelives regardlessof was completed. when a 12-veari 2.61O InspectionProcedures 1. Groundcheckand run up aircraftper Sections2.205 and 2.210. component overhaul 2. Removefollowing componentsand return to an RHC-authorized facility for disassembly& inspectionper Section2.630.

C005-x C005-x COO6-x c007-5 C0O8-x CO17-x C018-x c021-1 C051-x C792-x D174-2 D211-1 D212-1 D278-x

Main rotor hub assembly Main rotor bladeand spindleassembly Main rotor gearboxand mast assembly Fanshaftand bearingassembly Tail rotor assembly Swashplateassembly Clutch assembly Tail rotor gearboxassembly Belt tensionactuatorassembly Tachometer Fanwheelassembly HydraulicReservoir Hydraulicservo actuators Governorcontrollerassembly

3. Replacefollowing parts with new or overhaulexchangeparts:

4120-3 A190-3 4785-x 8173-x 8283-x c o 11 - 2 c031-1 c 0 4 1 - 11 c480-1 c653-1 c653-2 C792-x D756-x

Tail rotor bellcrank V-belts Hoses,air ducts (variousdash numbers) Alternator belt Hoseassemblies{variousdash numbers) Arm assembly Tail rotor pitch control Bearingassembly Swashplateboot Mount Mount DualTachometer Bellcrankassembly

4. Removeengine and comply with current revisionof LycomingSl 1009. Flush and pressuretest oil cooler. Overhaulor inspect, as required,magnetos, alternator,and carburetoror fuel injectioncomponentsper appropriatemanufacturers'maintenance publicationsand servicebulletins. Ch a n g e1 3 : OC T 2 0 0 6

Page2.57

FICIEIINSON

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MATNTENANcE MAr\luAL

EL F|44

2.61O InspectionProcedures(cont'd) corrosion, b. Removehorizontaland verticalstabilizers.Visuellyinspect. no cracks, loose rivets, dents, or deformation. Dye penetrantinspect suspect areas' to struts), 6. Remove landing gear assembly,disassembletelbows to remain attached Magnetic removepaint, andvisuallyinspect.no cracks,corrosion,or deformation. 1'4OOsection paint using prime, and particleand fluorescentpenetrantinspect.clean, approvedmaterials. visuallyinspect. 7. Removesteeltubeframes.Removepaintfrom framesnot replaced,and prime, and paint using no cracks or corrosion.Magnetiarticleinspect.clean, Section 1.4OO-approvedmaterials. g. Inspectairframewiring condition. no corrosion,insulationdeterioration,or other damage. 9. lnspectand pressuretest fuel tanks per section 12.120. 1O.Replaceadditionalparts as requiredper AirworthinessLimitations. 1 1. Assembleaircraft.Rig flight controlsand rotor systems per Section 1O'1OO' 12. Weighhelicopterand calculateC.G. per Section1.231. As required,reviseEquipment Listryeight & Balancedata in Section 6 of helicopter'sPilot's OperatingHandbook. 13. Inspectaircraftper Section2.4OO. 14. Groundcheck and run up aircraftper Sections2.2O5 and 2'210'

NOTE Extendedlow-poweroperationwith new pistonrings may prevent properpiston ring seating. 15. Balancefanwheelper Section6.240. 16. Balancetail rotor per Section1O-24O. 17. Trackand balancemain rotor per Section1O'20O' 18. Flightcheck aircraftper Section2-220. s Sections1.120 and 1.130. 1 9 . D r a i n ,f l u sh ,a n d fi l l g e a rb o xeper 20. Filland bleedhydraulicsystem(if equipped)per Section1' 190' 2.620 (Reserved) P a g e2 . 5 8

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H'44

2.63O ComponentInspectionProcedures An RHC-authorized componentoverhaulfacility shallperformnoted procedure.

PART NUMBER DESCRIPTION COO5-x

NOTES

Removebearings.Visually inspect hub. no fretting, corrosion,or obvious damage.Fluorescent Main rotor hub assembly penetrant inspect hub. Magnetic particle inspect journalsand thrust washers. Replacebladesdueto possibilityof internalcorrosion and adhesive deterioration. Replace pitch horn screws, boots, and O-rings. Pitch horn, spindles, and other hardwaremay be reusedafter inspection and ingno damage. Replacepinionsealand all O-rings(mast tube base, input shaft, end cover, sump, chip detector, chip detectorhousing,andsightgage).Replacesealedball bearingatop mast tube. Replacerubbermounts.

COO5-x

Main rotor blade& spindleassembly

COO6-x

Main rotor gearboxand mast assembly

cooT-5

Fanshaftand bearing assembly

ReplaceC181-3bearingassemblywith factorynew or overhaulexchangepart. Inspectfanshaft.

COO8-x

Tail rotor assembly

Replacebladesdue to possibilityof internalcorrosion and adhesivedeterioration.Remove teeter hinge bearings.lnspect hub and hub plates; no fretting or corrosion.Fluorescentpenetrantinspect hub and hub plates.Replaceteeter hinge bearings and bladeattach bolts.

CO17-x

Swashplateassembly

clean, inspect, regrease,or replace {as required) swashplateduplexbearings.

CO18-x

Clutch assembly

clean,and inspect.Replaceall seals, Disassemble, O-rings, and lubricant. Replace C184-2 bearing assemblywith factory new or overhaul exchange part.

CO51-x

Belt tensionactuator assembly

Return to factory for lubrication and calibration check.

D174-2

Fanwheelassembly

Disassemble,clean, inspect. no cracks or corrosion.

Change13: OCT 2OOo

FICIEIINEiCIN

MC'EIEL t44

MATNTENANcE MANUAL

REOUIREMENTS OVERHAUL 2.700 22OO.HOUR proceedas follows: 22OOhourstime-in-service, hasaccumulated Whenhelicopter NOTE Kit R7543 containsthe majority of parls required.for a 22OOfor current f,out overhaul;check www.robihsonheli.com/public may componen-ts replaced airworthy kit contents. Previously 'accirmulating years 12 or hours 22OO ;;-.;il l; service until whichever ocCurs first, since new or slnce time-in-Service, 'neter io Airworthiness Limitations section for f.rf ou"tftaul. parts requiringr additional 2.7 10 InspectionProcedure 1. Groundcheck and run up aircraftper Sections2.205 and 2.210' 2. Replacefollowing parts with new or overhauledexchangeparts:

COO5-x COO6-x c007-5 COOS-x CO17-x CO18-x co21-1 CO23-x co31-1 CO51-x co56-1 C627-x C628-x c792-2 D174-2 D211-1 D212-1 D268-x

Main rotor blade and spindleassembly. Main rotor qearboxesdnd mast assembly Fanshaftani bearingassemblY Tail rotor assemblY SwashplateassemblY Clutch assembly Tail rotor gearboxassemblY Tailcone(RevM&Prior) Tail rotor pitch control Actuator assemblY Sorinqassemblv +lpoitt Harness& Buckleassemblies Harness& Buckleassemblies DualTachometer FanwheelassemblY Hydraulicreservoir Hydraulicservo actuators GovernorController

3. On all aircraft,replacefollowing parts with new parts:

A120-3 A190-3 A723-x A78O-x A785-x A947-2 8173-x 8283-x c121-17 C169-x c258-1 c480-1 c918-7 c947-1 c947-3 D079-1 D224-1 Various P a g e2 . 6 0

Tail rotor bellcrank V-Belts Oi l l i n e s(va ri o usdash num ber s) Batterycables Hoses,air ducts (variousdash numbers) Flex plate assemblY Alternator belt Hoseassemblies(variousdash numbers) Tail rotor push-pulltube assembly Muffler with risers Main rotor pitch link assemblies Swashplateboot Etjstic'trim cord {electrictrim system only) F l e xp l a te a sse mblY F l e xp l a te a sse m blY Tail rotor guard Tail rotor driveshaft E n g i n eco o l i n gs( consultIPC)

C h a n g e1 4 : J U L 2 O O 8

FICIBINE|CIN

MATNTENANcE MANUAL

MOE EL F|44

2.71O InspectionProcedure{cont'd} 4. Removeengineand overhaulor inspectas requiredby Lycoming.Flush and pressure test oil cooler. Overhaulor inspect,as required,magnetos,alternator,and carburetor or fuel injectioncomponentsper appropriatemanufacturers'maintenancepublications and servicebulletins. 5. Removehorizontaland verticalstabilizers.Visuallyinspect. no cracks,corrosion, looserivets, dents, or deformation.Dye penetrantinspectsuspectareas. removepaint, and visuallyinspect. 6. Removelandinggear assembly,disassemble, no cracks, corrosion, or deformation. Magnetic particle and fluorescent penetrant inspect.Clean,prime, and paint usingSection1.400 approvedmaterials. 7. Removesteeltubeframes.Removepaintfrom framesnot replaced,and visuallyinspect. no cracks or corrosion.Magnetiarticleinspect.Clean,prime, and paint using Section 1.4OO-approvedmaterials.

O

or other deterioration, 8. Inspectairframewiringcondition.no corrosion,insulation damage. 9. Inspectand pressuretest fuel tanks per Section 12.120. 10. Replaceadditionalparts as requiredper AirworthinessLimitations. 1 1. Assembleaircraft. 12. Rigflight controlsand rotor systemsper Section1O.1OO. 13. lnspectaircraftper Section2.4OQ. 14. Pertormweight and balanceper Section1.23O. 15. Groundcheckand run up aircraftper Sections2.205 and2.2"10. NOTE Extendedlow-poweroperationwith new piston ringsmay prevent r piston ri 16. Balancefanwheelper Section6.240 17. Bafancetail rotor per Section"1O.24O. 18. Trackand balancemain rotor per Section1O.2O0. 19. Flightcheckaircraftper Section2.220. 20. Drain,flush, and f ill gearboxesper Sections1.120 and 1.130. 21 . F.lland bleedhydraulicsystem(if equipped)per Section1.190. Change13: OCT 2006

Page2.61

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MAINTENANeE

MANUAL

MoEIEL pt44

Intentionallyblank

Page2.62

Change13: OC T2006

o 3. LIFE LIMITBD COMPONENTS

o

FIOBINSICIN

MATNTENANcEMANUAL

MoEtEL p.arr

sEcTtoN 3 LIFE.LIMITED COMPONENTS 3.OOOLIFE.LIMITED COMPONENTS 3.OOl

tntroduction

3.002

Time-ln-ServiceRecords

3.003

FatigueLife-LimitedParts

3.100 OVERHAUL REOUIREMENTS 3.110

PowerplantOverhaulRequirements

3.120

Aircraft OverhaulRequirements

TYPECERTIFICATE DATA SHEET SECTION AIRWORTHINESS LIMITATIONS

Change4: 1 Jun 97

Page3.i

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MoEIELn,4

This pageintentionallyleft blank.

Pag e3 . i i

l s s u e d1: 1 J u n 9 3

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MATNTENANeE MANuAL

rv|(,EIEL ]l'44

SECTION 3 LIFE-LIMITED COMPONENTS 3.OOOLIFE-LIMITED COMPONENTS 3.O01 lntroduction This section lists fatigue life-limitedparts and specifiedoverhaulrequirementsfor the R44 helicopter. 3.OO2 Time-ln-ServiceRecords It is the operator's responsibilityto maintainaccuratetime-in-servicerecords for the airframe,engine, and life-limitedcomponents. An hourmeteractivated by engine oil pressureis standardequipmenton earlierR44 helicoptersand is an acceptablemeans of recordingtime in service. Laterhelicoptersareequippedwith an hourmeteractivated by a combinationof oil pressureand up collective;the hourmeterwill recordtime only when engineoil pressureexists and the collectiveis raised. When installing a life-limitedpart, record in the helicoptermaintenancerecords the installationdate, part number, part name, serialnumber,helicoptertotal time, and all of usedlifeprevioustime-in-service accumulatedby the part. All previoustime-in-service limited parts must be includedin orderto safelydetermineretirementrequirements. When installingan overhauledpart, record in the helicoptermaintenancerecordsthe installationdate, part number, part name, serialnumber,helicoptertotal time, and all previoustime-in-serviceaccumulatedby the part sincelast overhaul. All previoustimein-servicesincelast overhaulmust be includedin orderto safelydeterminenext overhaul requirement. WARNING Components with mandatory overhaul or retirement intervals whose time-in-serviceis not reliably documented cannot be consideredairworthv and must be removedfrom service. 3.OO3 FatigueLife-LimitedParts Thef ollowingAirworthinessLimitationsSectionliststhe mandatoryreplacementschedule for fatigue life-limitedparts. Listed items must be removedfrom the helicopterat the specified intervals and permanentlyretired from service by destroying or damaging each part so it cannot inadvertently be returned to service. Fallge lives are based upon normal f light service,inctuding6 rotor stop-start" and 1O autoidGi'ronentrids per hour. Ch a n g e1 4 : J U L 2 0 0 8

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MOEIEL ]''44

3 . 1 O 0 O V E R H A U LR E OU IR E ME N T S 3.1 1O PowerplantOverhaulRequirements with the enginemanufacturer'soverhaul The enginemust be overhauledin accordance latest reiision of rextron Lycoming to Refer recommendationsand proci;;;;ServiceInstructionsNo. 1OO9' 3.1 2O Aircraft OverhaulRequirements

I

control system' and The complete airframe, including-rotor s.ystems,drive sylle.T' Companywhen Robinson'Heticopter fuselage,.nu.rn" oveirrautedir-inrtru"t'eo uy any of the following occur: since new or since last a) When the helicopterhas been operatedfor 22OOhours o v e r ha u l . subsurfacecorrosionin b) When an inspectionof the helicopterindicatesextensive system' the primarystructure,drive system or control can no longer c) when the helicopterconditionhas deterioratedso the helicopter given in the Pilot's specifications or safety meet the perfor;;;";;;;itori"uiriiv OperatingHandbook. years since new or since last d ) when the aircrafthas been in servicefor twelve overhaul,regardlessof the hoursflown'

WARNING

in Partsremovedfrom damagedaircraftare not to be reinstalled with rogjther RHC, tii n"en returnedto ;t;ir;;;itunr".r-p"rt and is found by RHCto be history,-foiinspection iti O"-uge

Pa g e3 . 2

C h a n g e1 3 : O C T 2 O O o

DEPAPTMENT OF TRANSPORTATION FEDERAL AVIATION INISTRATION

HIINM Revision5 Robinson Rt4 R44 tl February23,2007

TYPE CERTIFICATE DATA SHEETNO. HIINM This datasheet,which is a parl of Type CertificateNo. Hl lNM, prescribes condirionsand linitations underwhich the product for which the type certificatewasissuedmeetsthe airworthiness requirements of theFederalAviationRegulations. Type CertificateHolder:

RobinsonHelicopterConrpany 2901AirportDrivc Tonunce.Califomia90505

I. Modcl R44 (Normal CategoryRotorcraft), Approved December10, 1992 Engine

OneLyconringO-540-FIB5,TypeCtertificate nurnberE-295

Fuel

100LL minimumgradeaviationgasoline 100/130 milinrumgradeaviationgasoline

EngineLimits

Maximumcontinuous: Takeoff(5 minute):

205hp ar2718rpnr(102o/o) 225hpat 2718rprn(102o/A

See R44 Rotorcraft Flight Manual (RTR 461) foL maximum manifold pressure corresponding to horsepower rating.

PowerOn (RotorTach) Maxinrunr:408 mm ( | 02o/o\ Minimum:396 rpm ( 99%)

RotorSpeedLimits

PorverOff(Rotor Tach) Maximum:432mm (108%) Minimum:360mm (90%)

AirspeedLimits

VyB (neverexceedspeed) at sealevelis 130KIAS (120KIAS rvithfixedfloats;lqt takcoffgross weightsof 2200lb. or less.Vpg at sealevelis 120KIAS (l l0 KIAS with fixed floats)for takeoffgrossweightsover2200lb. PorverOff (Autorotation)Vyg at sealevelis 100KIAS. For reductionof Vyg with altitudeandtemperaturc, seeR44 RotorcraftFlight Manual (RTR46r). Airspeedlinritat powersettings aboveMaximurnClontinuous Poweris 100KIAS. Airspeedlimit witlr intlatedpop-outfloatsis 80 KIAS. Airspeedlimit for anycombinalion of DoorsOff is 100KIAS.

PaseNo. Rev. No.

I 5

., 5

3 5

C h a n g e1 4 : J U L 2 O O 8

4 5

5 5

6 5

P a g e3 . 3

Page2 of6

HI INM

Dccember10,1992,(qq!qg)

Centerof Graviry (C.G.)Range

C.G.@ggLonsitudinal Gross Aft Forward Weight (in.) (in.) 0b.)

I 550 2000 2200 2400

92.0 92.0 92.0 93.0 Note: ffi;

102.s 102.5 r00.25

LateralC.G.\q1g9Long.

c.c. (in.)

92.0

rm.0 102.5

Left (in.)

Right (in.)

-3.0 -3.0

+3.0 +3.0

-1.5

+1.5

98.0 trnetartationbetweenpointsshown'

EruptyWeiShtC.C' Range

102'5or forward' C.G.with150lb.pilotandfull fuelrnustbeSTA Calculated

MaximunlWeight

2400lb.

MininrunrCrew

I pilot in forward right seat.

Numberof Seats

4 (3 for Police and ENG Version) Pilot and Forward engerat STA 49'5 Seat Locations: Aft engersat STA 79'5

MaximuurBaggage

FuelCapacity

in any baggage conrpaflnent' For any 50 pounds of baggage and installed equipment of lhe seat load' baggage' and installed seat location, the nraxitnutn cornbinetl u'eight equipmentis 300 Pounds.

Tank Main Auxiliary

CapacitY (sal.)

Us$le (eal.)

Location (STA)

30.6

| 06.0 102.0

31.6 18.5

18.3

Oil Capacity

MaximumOperatiou Altitude

DensityAltitudeLimit 14.000ft' landingwithin 5 Maxinrunraltitudeabovegloundlevelis 9000ft' to allow fire. of minutesirr case

Manufacturer'sSerialNttmbers

0002.0004thru9999.excePtll40

CertificationBasis

|4cFRPart27,datedFebruaryl,1965,irrc|udingArnendments2T.|throughz7-z4' and2?' 1305(q)'and ExemptionNo. 54?3oatediuli 2, 199J,to 827'?5^5-(aX7) to ei"tption No. 6692datedOctober17,1997 $27'695' 36-2014CFRPart36 Anrendment SafetyFindine: Eouivalent NurnberTD I 0352LA-R/S-1 AnticollisionLight Svstem 14CFRPart 27.1401(d).

P a g e3 . 4

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HI INM

Page3 of6

l. lVlodelR44 (Normal Equipment

Deccmber10,1992,(cont'd) The basicrequiredequipmentasprcscribedin the applicableairworthiness regulations (seeCertificationBasis)nrustbe installedin theaircraflfor certifi-cation.In addition, thefollowingFAA-approvedRotorcraftFlight Manualis required: R44RotorcraftFlight Manual(RTR461)dalcdDeccnrber10, 1992,or laterrevision ( S e e N O T E4S, 5 , & 6 ) .

ll. Model R44 ll (Normal CategoryRotorcraft), Approved Ocrober9,2002 The R44 Il helicopterincludesa fuel injectedenginewith a 245 hp takeoffratinganda maxiumweightof 2500lb. Engine

OneLycominglO-540-AElA5, TypeCertilicatenumberlE4

Fuel

100LL minimumgradeaviationgasoline 100/l30mininrumgradeaviationgnsoline

EngineLinrits

Maximumcontinuous: Takeoff(5 minute):

205hp ar2718rpm (102o/o) 245hp at 27l8 rpm (l02Yo)

SeeRzMII RotorcraftFlight Manual(RTR462),datedOctober3.2002 or laterFAA approvedrevision.for nraximummanifoldpressure corrc'sponding to horsepower rating. PowerOn (RotorTach) Maximum:408mm ( l02o/o\ Minimum:404 rpm(l0l%)

RotorSpeedLimits

PorverOIT(RotorTach) (108%l Maximum:432rom Minimunr:360rnm (907o)

AirspeedLimits

Vyg (neverexceedspeed)at sealevelis 130KIAS ( 120KIAS with fixedfloats)for takeoffgross weightsof 22Q0lb.or less.VpB at sealevelis 120KIAS (l l0 KIAS with fixed floats)for takeoffgrossweightsover2200lb. PorverOfT(Autorotation)Vyg at sealevelis | 00 KIAS. For reductionof Vpg with altitudeandtenrperature, seeR44 II RotorcraftFlightManual (RTR462)datedOctober3,2002,orlaterFAA approved revision. Airspeedlimit at powel'settings Poweris 100KIAS. aboveMaxinrurnContinuous Airspeedlimit with inflatedpop-outfloatsis 80 KIAS. Airspeedlimit for any conrbination of DoorsOff is 100KIAS.

Centerof Gravity(C.G-)Range

l-ateral C.G. Range

Iinal C.G. .ange

Gross Weight ilb.)

Long. Forward (in.)

Aft (in.l

r600

92.0

t02.5

2t00 2300 2500

92.0 92.0

102.5 t00.25 98.0

93.0

I

c. c.

Left

(in.) 92.0

(in.)

r00.0

-3.0 -3.0

102.5

-1.5

I |

Right (in.)

+3.0 +3.0 +1.5

Notc: Straightline varialion betweenpoints shown

EmptyWeightC.G.Range

C h a n g e1 4 : J U L 2 0 0 8

Calculated C.G.with l50 lb. pilot antllhll fucl mustbe STA 102.5or lbnvard.

P a g e3 . 5

i

r . , I I l -

_ "

_ " _ _ j

|

- '

ApptonudOttobut 3' 2002'(tont'd)

"ft)' MaximumWeight

2500lb. waterlandingsrvithfixedor pop-outfloats' 2400lb. for inrentional

Minimunt(lrew

l pilot in for*'ardrightwt.

Nunrberof $wts

4 (3 for PoliceandENG Versions) at STA 49'5 SeatLocations: PilotandForwardenger al STA 79'5 Aft engers

MaximumBaggage

FuelCapacity

F'orany compartnrent'. in any baggage andinstalledequipnrent 50 poundsof baggage installed and loact, baggage. seat the of combineo'weight seatlocation,thenraximum is 300 Pounds' equiprnent Capacity (sal.)

Usable (nal.1

Main

3r.6

Auxiliarv

r8.5

30.6 18.3

Tank

Oil Capacity

ComDonent

Location (STA)

r06.0 t02.0

Capacity (qt.)

Location (STA)

9 2

I t0.0

F-npirre

Miin RotorTransnrission Tail Rotor Transmission Hvdraulic Reservoir

0 . 1I

0.65

t00.0 327.O I t7.o

MaxirnutnOperatton Altitude

DcnsityAltitudeLinrit' 14.000f1. within5 Maximumaltitudeabovegroundtcvclis 9000ft' to allowlanding rninutcsin caseof fire.

Manufacturer's Serial Nuntbcrs

I 140,10001arrdsubsequent

CertificationBasis

27-l through7-21'and t4 CFR Part2l datedFebruaryl. 1965.includingAmendmcnts to l'1 October $2?'695' dated ,1991 No.6692, Exenrption 36-24' 14CFRPart 36 Amendment EquivalentSatbtvFintlinq,: I NurnberTD I 035ZLA-R/SLightSystent Anticollision l4 CFRPart 2?.1401(d),

Equipment

regulations airworthiness in the.applicable asprescribed equipment Thebasicrequired addition' In certifi-catio'' lbr aircraft Saiisi mustbelnstalledin the lseeCerrificarion required: is Manual Flight Rotorcraft ilrefotlo*iug FAA-approvetl (See FlightMantral(RTR462)datedoctober3, 2002'or laterrevision R44|| Rotorcraft NOTES7 & 8).

DATA PERTINENTTO ALL MODELS Datunr

| 00 in. forward of main rolor centerline'

Mcans L,eveling

Manual antl Instructionsfor continued Airworthiness Rcfer to the R44 N,laintenance (RTR 460).

P a g e3 . 6

C h a n g e1 4 r J U L 2 O O B

HI INM

Page5 of6

RotorBladeand ControlMovenrents

Main Rotorblatleanglesat ?5%radius: CollectivePitch: 12.5o+l .0ototaltravel Note: Collectivelow pitchto be established in accordance with the Maintenance ManualandInstructionsfor ContinuedAirworthiness(RTR 460)procedures to obtain properautorotationRPM. Cycliitch:

Forward Aft Left Right

I3.50oto 14.25o 13.500 to 14.250 7.5o to 8.5" 6.(F to 7:()"

Tail Rotorbladeanglesat 75%o radius: ColleotivePitch:

ProductionBasis

O

Thrustto left Thrustto right

15.5"to 16.5o | 8.5oto 19.0o

ProductionCertificateNo. 424WE,datedFebruaryI l. 1993.

.ENERALN.TES NOTE l.

NOTE2.

.

A currentweightandbalancereport,includinga list of equipment includedin thecertificated onpty weight, and loadingirrstructions rvhennecessary, nrustbe providcdfor eachaircraftat thetime of original air-rvorthiness certificationandat all tinresthcreafter,exceptin thecaseof operatorslravingan approved weightcontrolsystem. Tlrcfollowingplacardmustbe installedin clearviewof thepilot: APPROVEDFOR DAY ANIDNICHT VFR OPERATIONS" "THIS ROTORC'RAFT Foradditionalplacards, seetheRotorcraftFlightManual.All placards requiredin theFAA-approved RotorcraftFlight Manualmustbe installedin theappropriate lcrcations.

NOTE 3.

Informationessentialto the propermaiutenance of thehelicopter.includingretirementtine of critical components. is containedin theRobinsonR44 Maintenancre MamralandInstructionsFor Continued Airworthiness(RTR 460). Retirementtimesarelistedin theFAA-approved"AIRWORTHINESS LIMITATIONS" section.The valuesof retirementor servicclife and inspectionintervalscannotbe changed withoutFAA Engineering approval.

NOTE 4.

R44 RotorcraftFlight ManualSupplement revisionis requircd 5 datcdJuly | 7, 1996.or laterFA.A-approved whenfloatlandinggearis installed.

NOTE 5.

R44 Rotoroafl Flight N{anualSupplementl0 datedJune10, 1999,or laterFAA-approvedrevisionis requiredwhenenrergency (pop-out)floatsareinstalled.

NOTE 6.

R44RotorcraftFlight Manualv,'ithFAA-approvedrevisionsthroughNovember5, 1999,or laterFAAapprovedrevisionis requiredrvhenhydraulically-boostecl nrainrotorflight controlsareinstalled.

NOTE 7.

R44 ll RotorcraliFlight ManualFixedFloatsSupplement datedOctober3,2002,or laterFAA-approved revisionis requiredwhentixed-floatlandinggearis installed.

NOTE 8.

R44 Il RotorcrattFlight ManualPop-OutFloatsSupplenrent datedOctober3,2002,or laterFAA-approved revisionis requiredwhenpop-outfloatsareinstalled.

C h a n g e1 4 : J U L 2 0 0 8

Page3.7

HIINM

NOTE 9.

Page6 of6

typecertificate(TC)' to the typedesignof this helicopterby meansof an anrended Any clranges for continuedairworthiness instructions Sig'requiring typecertiRcalifiicj, supplemental (ACo) for reviewandacceptance ".**to{ office certification ptoj".t tirlgi tii" (lCA,s)musrbe subnrirted l*.oll offrce (FSDo) prior to Flight standards,District by the Fort worth -Aircranrvat-uationGroup(FTW-AEC) theaffectedaircraftfor certificate oi*-otthin"tt standard first the theaircraltdelivery,or uponissuanceof repairsor (major changes Type design whicheveroccurslater* pt"r.tiU.a UyTitle t4 CFR21.50. ICA's reviewed those have nrust ICA's iequire that by meansof a iAn form 132(field approval) alterations) FSDO' by the field aPProving

END

P a g e3 . 8

C h a n g e1 4 : J U L 2 O O 8

A IRWORTHINESSLIMITATI O NS

FIclBINSON

MAINTENANCE

MANUAL

MODEL

H44

AIRWORTHINESS LIMITATIONS TheAirworthiness Limitations section': andspecifies inspections andother g-i.+oe,;;b';; 14cFn f44 lrpproved

il:tt'::;?'fi',i?ff"ilder

5543.16-;J

iiternatiuet's;;;

FATIGUE LIFE-LIMITED PARTS

Part -

c023-1

TailconeAssembly, RevM andprior

C01S2,-5,and-7 C020-1and-2 C029-1and-2

Maximum Service Life 2000Hours

MainRotorBlade 2200Hours or 12years* UpperFrame 2200Hours TailRotor Blade 2200Hoursor 12years* TailRotor HubAssembly 2200Hours GearSet,MainRotorGearbox 2200Hours MainRotorHub 2200Hours MainRotorSpindle 2200Hours TailRotorDriveShaft 2200Hours Sump,MainRotorGearbox 2200Hours Housing, MainRotorGearbox 2200Hours GearSet,TailRotorGearbox 2200Hours Bearing Setin C017-6SwashplateAssembly 2200Hours TailRotorHub 2200Hours TailRotorGuard 2200Hours

c030-'l -5 C1461and c154-1 c158-1 c196-1 C263-1 and-2 C2U-1and-2 c545-1 c6,47-12 D062-2 D079-1

A7s6-6 CyclicGrip 4400Hours c023-1 TailconeAssembly, RevN andSubsequent 4400Hours -3,4,-14,and-15 Tailcone C023-2, Assembly 4400Hours c044-1 Horizontal Stabilizer 4400Hours C198-1 and-2 LowerSwashplate 4400Hours c251-1 MainRotorShaft 4400Hours c319-3 CyclicTorque Tube 4400Hours c320-1 CyclicStick 4400Hours c337-1 Jackshaft 4400Hours D196-1 TailRotorDriveShaft 4400Hours * Wfrichever limitoccursfirst. Approved By:

Manager, Federal Aviation istration /' flTiffi LosAngeles !,5'"i?l3J'1"# AircraftCertification L? A1'Til3lifl'j"^ Office

' /O ' a' Dateof Approvat: FAAApproved:Thispageconstitutes theAinruorthiness t-iritrti*, S..tionin itsentirety, is considered segregated fromthe restof the document, and setsforththe FM-approved mandatory replacement timesfor thefatiguelife-limited parlslistedabove. Te m p o r a r R y e vi si o n0:1 MA R 2 0 1 1 l_l

Page3.9

FIclBINSiClN

MATNTENANcE MANUAL

MIfEIEL

]''44

SECTION 4 AIRFRAME 4.OOOAIRFRAME 4.001 Introduction 4.OO2 Description 4.100 FUSELAGE 4 . 1 1 0 C a bi nA sse mb l y 4 . 1 1 1 C a b i nA sse mb l yR e p a ir s 4 . 1 2 0 W i nd sh i e l dA sse mb l y 4 . 1 2 ' , Wi n d sh i e l dR e mo va l 4 . 1 2 2 W i n d sh i e l dR e p l a ce ment 4.123 WindshieldInstallation 4 . 1 3 0 D o or R e mo vaal n d In sta l l ation 4 . 1 3 1 Do o r R e mo va l 4 . 1 3 2 Do o r In sta l l a ti o n 4 . 1 4 0 F a i ri n g C , o w l i n ga n d In sp ections 4 . 1 4 1 E n g i n eC o w l i n g 4 . 1 4 2 Ma st F a i ri n g 4 . 1 4 3 U p p e rC o w l i n g t

4 . 1 4 4 C a b i nIn sp e cti o nP a n e ls 4 . 2 O O W E L DE DS T E E LT U B EF R A MEASSEM BLIES 4 . 2 1 0 L o w e r F ra meA sse mb l y,L .H. 4 . 2 1 1 F ra meR e mo va l 4 . 2 1 2 F ra meIn sta l l a ti o n 4 . 2 2 0 L o w e r F ra meA sse mb l y,R.H. 4 . 2 2 1 Fra meR e mo va l 4 . 2 2 2 F ra meIn sta l l a ti o n

Ch a n g e1 4 : J UL 2 OOB

Page4.i

FIClElINEiElN |

I |

MAINTENANeE

MANUAL

MC'E'EL

F.44

(cont'd) TUBEFRAMEASSEMBLIES STEEL 4.200 WELDED +.ZzO UPPerFrameAssemblY 4.231 FrameRemoval 4.232 FrameInstallation 4.240 Strut AssemblyRemovaland Installation

AND EMPENNAGE 4.300 TAILCONE 4.310 Tailcone 4 . 3 1 1 T a i l c o n eR e m o v a l 4.312 TailconeInstallation 4 . 3 1 3 T ai l co n eR e P a i r AssemblY 4.32O EmPennage Removal 4.321 EmPennage Installation 4.322 EmPennage 4,323 UpperStabilizerReplacement 4.324 Lower StabilizerReplacement 4.325 HorizontalStabilizerReplacement 4.326 Float Ship (R44 Clipper)COSOStabilizerRemoval 4.327 Float Ship (R44 Clipper)COsOStabilizerInstallation 4.330 Tail RotorGuardReplacement 4.340 Tail Skid RePlacement

P a g e4 . i i

C h a n g e1 4 : J U L 2 O O B

FICIE|INS|CIN

MATNTENANcE MANuAL

MOEIEL

]t44

SECTION4 AIRFRAME

4.OOO AIRFRAME 4.001 Introduction This section contains proceduresfor removaland installationof cabin components,steet tube structures,tailconeand empennage. 4.OO2Description The R44 is a four-place,single-main-rotor, single-engine helicopterconstructedprimarilyof metal and equippedwith skid-typelandinggear. Primarystructure of fuselageis welded steel tubing and rivetedaluminum. The tailcone is a semi-monocoquestructurein which aluminumskins carry most of the primaryloads. Fiberglassand thermosetplasticsare used in the secondarystructureof the cabin,engine coolingsystem and in variousother ducts and fairings. Cabindoors are removable. Four hingedcowl doors on right side provideaccessto main rotor gearbox,drive system and engine.A hingedcowl door on left sideprovidesaccessto engineoil filler, dip stick, and battery {if installedhere). For additionalaccessto controls and other components,there are removablesbetweenseat cushionsand seat backs, on each side and aft of enginecompartment,undercabinand forward of tailcone. The instrumentconsolehingesup and aft for accessto wiring and instrumentconnections and battery (if installedhere). Small removableplug buttons are located on tailcone for internalinspection. One stainlesssteel vertical firewall is forward of engine and a stainlesssteel horizontal firewall is above engine. 4. 1 0 OF U SE L AGE 4 . 1 1 OC a b i nA sse mb l v The cabin assemblyis a non-field-replaceable assembly. 4.111 CabinAssemblyRepairs 1. Verticalfirewall replacementmust be performedat the factory in a jig. Firewall repairs may be accomplishedin accordancewith U.S. FAA Advisory Circular 4 3 . 1 3 - 1 8 . F i r e w a l lm a t e r i a li s 0 . 0 1 6 - i n c ht h i c k , type 301, one- quar terhar d corrosion-resistant {CRES}steel. 2. Keelreplacementmust be performedat the factory in a jig. Keelrepairs may be accomplishedin accordancewith U.S. FAA AdvisoryCircular43.13-18. Keelmaterialis O.O25-inch thick, 2O24-T3clad aluminumsheet. 3. To preservecrashworthiness,repairsto seat structureare limitedto replacement of damagedcomponentsonly.

Ch a n g e1 4 : J UL 2 0 0 8

P a g e4 . 1

FIGIEIINSclN

MAINTENANCE

M(fE EL r|'44

MANUAL tt

t

I t t

,, ilt

.II

I

I

I

_){r

o

t>=

12

FIGURE4-1 WINDSHIELDINSTALLATION

1 2 3 4 5 6 7 I I 10 11

Page 4.2

c 2 7 4 - 1 ,1 3 * c367-10 c274-2,-4*

Windshield(1.H.)

AN526832R7

Retainer Windshield(R.H.)

c367-5 AN960-81 NAS1291-08 c367-11

Stiffener c367-12 Retainer(R.H.) c367-8 Retainer c367-7 Retainer(L.H.) c367-6 2 1 Screw AN526C832R Retainer c366-2 Bracket c366-5 A N 5 2 6 C 8 3 2 R 9 Screw

Screw Retainer Washer Nut Tape

Change1 1: JA N 2005

FIclB|NEiClN

MATNTENANeE MANUAL

MC'E'EL

F|44

4.120 WindshieldAssembly The C274 windshieldis made of transparentacrylic set in a weather-tightsiliconesealer and is screwed to cabin structure. 4.121 WindshieldRemoval a

1. Removeforwarddoor and hinges. NOTE To prevent scratching windshield, a protective cover should be taped to the inside and outside of the windshield prior to removal. 2. Removescrews and side retainerholdingwindshield. 3. Reinstallhingesand doors for cabin structurewith window removed. 4. Removescrews and retainers(upper,lower and middle)holdingwindshield. 5. Cleansiliconesealantfrom retainers. 6. Cleansiliconesealantfrom windshieldfor re-installation. 4. 122 WindshieldRepl_acement 1. Removeall old sealanton cabin and retainersif they are to be reused. 2. Clecoall window retainingstrips in place,checkingfor properalignment. 3. Installhingesand doors in door frames and secure.Removebottom and center retainingstrips, leavingside retainingstrip to hold door and door frame in position. 4. Hold windshieldin place by hand, and align it with frame accordingto contourof frame and windshield. 5. Mark windshieldfor trim using non-permanentmarker,such as greasepencilor maskingtape. 6. Trim to mark. A band saw is recommended.Bandsaw bladeshouldcontainat least 24 teeth per inch.

Ch a n g e1 3 : O C T 2 0 0 6

Page4.3

FIclBINEiClN

MOEIEL

MAINTENANGE MANUAL

FI44

4.1 22 WindshieldReplacement(cont'd)

of Tape cardboard to band saw table to prevent scratching and blade saw of windshield. Saw-cat.iull' to preventbinding crackingwindshield. 7. Hold windshieldin placeand check for fit. Re-trimas necessary' smooth' 8. After windshieldis fitted, carefullysand or scrapeedges 9. See Section4.123 WindshieldInstallation'

4.123 Windshieldhqlallqilg! a) Removeall old sealantfrom cabin,retainersand windshield' -4314-inchwide white polyvinyl b) Tapebottom and aft edgesof windshieldwith A7o1 chloridetaPe (3M #47U. c) Installwindshieldand cleco retainerstrips' tape' This will d) Mask windshieldalong edge of retainerstrips with 1/2" masking strips. catch siliconerubbersqueeze-outon installationof retainer e) RemoveretainerstriPs. entire edge of f) To ensurea properseal,run a beadof B27O-4siliconerubberalong tape line. lower) g) while holdingwindshieldin place, cleco retainerstrips (center,upper and into place. Then tighten h) With doors installedand closed, tighten center retainer strip first. tighten nuts upper and lower retainingstrips. A secondpersonwill be requiredto insideshiP. i)

and hinges When center,upperand lower retainingstrips are secure'removedoor for side striP installation.

j)

lnstallside retainerstriP.

k) Reinstallhingesand door. Ensureall fastenersare tight. f)

Page4.4

Fiffany gap betweenretainerand window with B27O-4sealant'

Change13: OCT 2006

FIclBINEiClN

MATNTENANeE MANUAL

MCIE'EL

]l.44

4.123 WindshieldInstallation{cont'd) m)

Removemasking tape next to retainers. Be careful not to smear wet sealant.

n)

Cleanany sealantoff windshieldafter it has been allowedto dry.

4.1 30 Door Removaland Installation 4 . 1 3 1 D o o r R e mo va l 1.

Disconnectaft door(s)gas.springby holdingdoor full open and lifting up firmly on gas spring'sinner attach point.

2.

Removecotter pins and/or cotter rings from both hinge pins.

3.

Removedoor by openinglatch and lifting door to disengagehinges.

4.

lf required,door hingesmay be removedby removingmountingscrews.

4 . 1 3 2 D o o r In sta l l a ti o n 1.

I n s ta l ld o o r h i n g e si f re moved.

2.

I n s ta l ld o o r b y a l i g n i n gh i ngepins and slidedoor down to engagehinges .

3.

Installcotter pins or rings in both hingepins of door. WARNING Failureto install a cotter pin or ring in each door's two hinge ns mav allow door to depart aircraft in fliqht.

4.

Reconnectaft door's gas spring.

4 . 1 4 0 F a i ri n g C , o w l i n ga n d In sp ections MS27O39COBscrews are used for fastening all removablecowlings and inspection s. 4 . 1 4 1 En g i n eC o w l i n g Enginecowling includesleft-handand right-handcowling assemblies,belly cowling assembly,and the aft cowling assembly. The lower edge of both engine cowling assembliesare ed by removable channels. The air intake hose is attachedto right engineside assembly,which may be removedor connectedthrough door in . Lower left slat in aft cowling assemblymay be removed for accessto clean out anything that may have fallen through slats.

Ch a n g e1 4 : J UL 2 OOB

Pa ge4.5

FICIBINEiCIN

MAINTENANGE MANUAL

MOE EL F|44

4 , 1 4 2 M a st F a i ri n g

must be installedfor fli rotor gearbox at swashplate The c261 mast fairing upper rib is mountedto main gearboxmast assembly' tube assembly. t-owei rib is clampedto main rotor The pitot tube is mountedon lower front of mast fairing. rib and attach to middle The fuel tank vents are installedthroughgrommetsin lower push- pulltubeis m ounted r i b o f m a st fa i ri n g .T h e C 6 6 5 -2guideJttttOl' for C121- 5 preloadon push-pulltube' to center rib. lt shouldbe adjustedto minimize 4 . 1 4 3 U p p e rC o w l i n g behind and below auxiliary cowling above horizontalfirewall includes DO42doors cowling' tank, cg47 saroundmast tube, and c706-1 tailcone

All cowlins must be installeO&fllight.

Page4.6

C h a n g e1 4 : J U L 2 0 0 8

FICIBINSCIN

MATNTENANeE MANUAL

MOEIEL

F|44

4.144 CabinInspections CAUTION tnspectionsmust be instaltedfor riight.All smay be left off for run-up.All must be installedfor flight.

The cabin inspectionsincludethe following: 1.

C794-1forwardbellyandC794-3aft bellyassembly.

2.

C465-1and C465-2att seat back s.

3.

C474-1 between the aft seat backs and C474-2 betweenthe aft seats.

4.

C463-1 cover underthe C464-1 tray.

5.

C445-1 and C445-3 covers between the forward seats and CM4-1 cyclic box cover.

6.

C461-1 collectivecrosstube cover behindthe left forward seat.

Change4: 1 Jun 97

Page4.7

F|CIE|INEiCIN

MAINTENANeE MANUAL

MOEIEL

F'44T

WARNING All welded steel tube frames used in the R44 are stress are permissibleoutside Robinson iJii"ueO.ruo-weiO-iepairs HelicoPterComPanY. The followingsteeltube framesare requiredon the R44z C02O-1 UpperFrameAssemblY L.H. CO46-1 LowerFrameAssemblY, CO46-2 LowerFrameAssemblY,R.H. CO46-3 Strut AssemblY C237-1 FrameAssemblY L.H. 4.210 LowerFrameAssembly, 4.211 FrameRemoval a) Removeall cowling. b) Removemain rotor gearbox,includingboth fuel tanks, per Section 7.110. tailconeandclutchassembly,perSectionO including c) Removepowerplant, 6.110. d) Removebatteryand batterybox. e) Removeleft aft seatback. tligur" a-?Lt DetailsD, f) Disconnectrhe threeforwardmounting_.pointq (Figure 4-28, DetailH). E, anOF) and tne at mountingpoint g) Disconnect the left aft NAS1307landinggearmountingbolt' screw connectingJhg h) Removethe NASO604-2bolt and the C722-2 cap (Figure 4-2, DetailsA & aisemOly foweifettlrime frame to'ine upper B).

P a g e4 . 8

Change4: 1 J un 97

FICIE|INEiCIN

MATNTENANeE MANUAL

MC'EIEL ]''44

NAS6604-2 BoLT (2 REQ'0.) AN960-4161 WASHER NUT NAS679A4 ( 2 P L ' C S) . c020-1 UPPER FRME c046-2 LOt,IER FMME

BoLT NAS6604-2 '0. (4 REQ I.IASHER AN95O-4161 ) (2 NUT REQ',D.) NAS679A4

c046-6 TUBE

NAS6605.21 BOLT

NAS6604-2 BoLT (2 REq,D.) WASHER AN960-5161 ( 2 R E Q ' ,) D . NAS679A5 AN96O-4161 WASHER NUT NAS679A4 NUT (2 PL,CS.) (3 PL'CS.) c020-1 UPPER FRAI4E /\ /

c722-z scREbr +l Mszooozclo *rT-/ BoLT NAS6605-4 (2 REQ'D) I'IASHER 4N960-5161 NAS679A5 NUT ( 4 P L ' C S) .

I

.\

.

LO!\lER FRME

AN960-416or 4J.61WASHER AS REQUIRED FORSHIMMING (2 MAXTMUM)

INSTALLATION 4-2 STEELTUBEFRAME FIGURE

C h a n g e5 : 1 5 J u n 9 8

Page4,9

MAINTENANcE

FIC|BINSiCIN

MANUAL

MOEIEL ]r44

B0LT NAS6604-2 (2 REQ'D-) Ang6o-qrotttAsHER c632-1 ANGLE

NUT NAS679A4 ( 2 P L ' , C )S .

BoLT NA.S6604-4 (2 REQ'0.) WASHER AN96O-4161 NUT NAS679A4

(z pr-'cs. )

BoLT NAS6604-2 (2 REq'D.) Anioo-qtot!',ASHER NUT NAS679A4 (2 PL'CS.)

c046-1 L0l,lER FRAME

BoLT NAS6604-3 (2 REQ'D.) WASHER AN960-4161 NUT NAS679A4 (2 PL',CS.) BoLT NAS6604-3 A N 9 5 0 - 4 1W 6 1A S H (E2RR E Q ' D . )

NAS66O4-2 BOLT (2 REQ.D. I,IASHER ) AN960.4161 I

NAS679A4NUT ( 4 P L ' C S) .

NUT NAS579A4

(z PL'cs.)

t

B0LT NAs6605-24

(2 REQ' D.) [ijei[:iroi t^tnsHrn NUT NAS679A5 ( 2 P L ' C S) .

BoLT NAS6605-23 A N 9 6 0 - 5 1W 6 1A S H (E2RR E Q ' D . ) NUT NAS679A5

TUBEFRAMEINSTALLATION 4-2A STEEL FIGURE

P a g e4 . 1 O

l s s u e d1 : 1 Jun93

FIClEIINsic|N

MAINTENANGE

MOEIEL H,44

MANUAL

c046-3 STRUT

Y\

@'

BENTTUBE c237-l FRAME

c046-2 LO!||ER FRA}IE ltAs6605-4BoLT

(2 REq'0.)... NASg5O-5161WASHER NAS679A5 NUT a B33O-16PALNUT

tii t' t \ \ \

\

c020-1 UPPER FMME

(R.H.) c384-6ANGLE (1.H., SHol,lN) c384-7ANCLE

BoLT NAS6607-24

c020-1 c141-4WASHER (2 REQ'D.) UPPER FRAME

c237-r BOLT NAS66O5.4 c046-1 WASHER AN96O-5161 LOl,|ER NUT NAS679A5 FRAME 8330.16PALNUT ( 2 P L ' C S) . VIEI,ILOOKING FORI.IARD ( 1 . H).

FRAME

NAS679A7 NUT 8330.21PALNUT ( 4 P L ' C S) .

o /

c023-1 TAIL CONE ASSEMBLY

ANDTAIL CONEINSTALLATION FIGURE 4 - 2 8 S T E E LT U B EFRAME

Change2: 12 Dec 94

Pa ge4.11

FIGIEIINSiC|N

MAINTENANeE MANUAL

MOE EL F'44

4,211 FrameRemoval(cont'dl

I I |

il

Removethe left frame assemblY'

'il

RemovetheCOl4-7landinggearandD31O-5cowlingbracketfrom the left frame assemblY'

4.212 FrameInstallation bracketper al Installthe col4-7 landinggears-upqgftgnlisto-5 cowling Figuie5-1, DetailB. Torqueper Section1'3zo' B, -D;E; Installall hardwareper Figure4-2, Detailall b) Positionframefor installation. Install H. oetait +2B., Fisure ind' F;;"d Fiqure+z1:;-D;iaits ha-rdwarebeforetorquing.

c l T o r q u e a l l N A S 6 6 0 0 b - o - ! t s p e r S e c t i othe n l ' 3c385-1 2 0 ' T g firewall lqg":hP C7?2-2Cap doubler screw per secii6n-i.$o-lrio-tateii wire to with 0.b41 inchdiameterwire. mountingbolt per Figure5-1, DetailB, and d) InstallNAS66O7landin_g-gear torqueper Section1.320. el Installpowerplantper Section6.120' fl

fnstalltailconeper Section4,312,

gl Installmain rotor gearboxper Section7 '12O' hl fnstallclutch assemblyper Section7'22O' il

InstallbatterYbox and battery.

il

all mountinghardwareis torquedand instatlleft aft seat back

'

kl lnstallall cowling.

P a g e4 . 1 2

Change2: 12Dec 94

FICIBINSCIN

MATNTENANeEMANuAL

MOEIEL F44

4.22O Lower FrameAssemblv.R.H. 4.221 FrameRemoval a) Removeall cowlipg. bl Removemainrotor gearbox,includingboth fuel tanks,per Section7.110. cl Removepow_erplqnt, includingtailcone,CO46-3strut, and clutch assembly, per Section6.110. dl Removeright rear seatback. el Disconnectthe aft NAS66O7landinggear nxrunting bolt from the right landinggear. fl

Disconnectthe tv\roforward mountingpoints (Figure+2A, DetailsC and El.

gl Removethe NAS66O4-2bolt and the C722-2 cap screw connectingthe upperframe to the lower right frame assembly(Figure4-2, DetailsA and Bl. hl Rernovethe right frame assembly. il

Removethe C014-7landinggearandthe D310-6bracketfrom the right frame assembly.

4.222 FrameInstallation al Installthe CO14-7landinggearand D310-6 bracketper Figure 5-1. Torqueper Section1.320. bl Positionframe for installation.Installall hardwareper Figure4-2, Details A and B and Figure+2A, DetailsC and E. Install all hardwarebefore torquing. c) Torque all NAS66fi) bolts per Section 1.32O. Torque the c722-2 eap screw per Section 1.33O and safety wire to the C385-1 firewall doubler with O.041 inch diametersafety wire.

Change2: 12 Dec 94

Page4,13

MtfEIELF,44

MAINTENANcEMANUAL

FICIBINSCIN

4,222 FrameInstallation(cont'd)

, per Figure5-1 and torqueper dl InstallNAS66O7landinggearrK)untingbolt Section1.320. e) Installpowerplantper Section6'120' fl

Installtailconeper Section 4'312'

gl fnstall main rotor gearboxper Section7 '12O' hl lnstallclutch assemblyper SectionT'22O'

aft seat back o i) all mountinghardwareis torquedand installright . il

Installall cowling.

4.23O UpnerFrameAssembly 4.231 FrameRemoval powerplantmust Beforethe upperframe is disconnectedand removed,the be either removedor ed' CAUTION Extensivedamageto the firewall and lower frame isiembties *itidccui ii powerplantis not ed or if is dislodged. al Removeall cowling. b) Removeclutch assemblyper Section7 '21O' per section7'110' cl Removemainrotor gearbox,includingboth fuel tanks, dl Removetailconeper Section4.311' e) powerplantor removeper Section6'11O'

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Change2: 12 Dec 94

FICIBINEIC|N

MATNTENANeE MANUAL

MOtrlEL H'44

4.231 FrameRemoval(cont'dl f)

Removethe right and left aft seat backsand betweenseatbacks.

g) RemoveC316-1uftperbellcrankper Section8.531 and removethe C12115 push-pull tube. h) Removethe C723 bulkheadassembliesat the aft end of the horizontal firewall. i)

Removethe NAS6605-4boltsat the aft outboardcornersof the horizontal firewall(Figure4-2B.,DetailsH).

it

Removeall NAS6600 bolts and the C722-2cap screwsshown in Figure 4-2, DetailsA and B.

k) Removeupperframe. l)

RemoveC329-1bearingblockassemblyand 4331-4 bellcrankassembly from upperframe.

4.232 FrameInstallation a) Cleanupperframeand mountingpointsof all sealant,greaseandoil. Install C329-1 bearingblock assemblyusing AN5O9-8R11screws,AN960-8L washers,and NAS1291-08nuts, 3 places.Install A331-4 bellcrankassemblyper Section8.542. b) Positionupperframe for installation.lnstall all hardwareper Figure4-2, DetailsA and B and Figure+2B, DetailH. Installall hardwarebefore torquing. c) Torqueall NAS66OObolts per Section 1.320. Torque the C722-2 cap screwsper Section1.330 and safety wire to the C385-1 firewalldoubler with 0.041 inch diameterwire. a

d) Sealfirewaltsusing B27O-1sealantto preventfuel seepage. e) Installthe C723 bulkheadassemblies. perSection8.532andinstallthe C121f) Installthe C316-1upperbellcrank 15 push-pull tube. g) fnstallpowerplant,if removed,per Sections6.120. h) fnstalltailconeper Section4.312.

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I

F|ClBINSiclN

MAINTENANeE MANUAL

MOEIELFI44

4.292 Framelnstallation(cont'dl j2O' il lnstallmain rotor gearboxper section7 per i) Installclutchassembly SectionT'22O' aft seat back and k) all mountinghardwareis torquedand install centers. ll Installall cowling. 4.24O- Strut AssemblvRemovaland lnstallation To removethe C046-3 strut: a)Removerightenginesidepane|andaftenginecow|ing. lower frames' b) enginefrom below to reducethe load on the c}Removeupperand|owermountingbo|tsandremovestrut. To installthe strut: G and a) Installstrut and hardwareas shown in Figure4'2F.,Details

H'

bl Torquebolts PerSection1'320' c) Removeengines' d) Installcowling. AND EMPENNAGE 4.300 TAILCONE 4.31O Tailcone 4.311 TailconeRemoval a) Removec7o6-1 tailconecowlingand DO4O-1.tft cowlingassemblies' chipdetector) b) Disconnectwiring (antenna,strobe,tail positionlight,and to tailcone. c) Mark tail rotor drive shaft and A947-2 flex plate for reinstallation.

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Change4: 1 J un 97

FIClBINEiclN

MATNTENANcE MANUAL

MtfEtEL

F'44

4 . 3 1 1 T a i l co n eR e mo va (co l n t' d) d) Disconnecttail rotor drive shaft at intermediateflex plate. Use a rag or foam rubber to and protect forward end of drive shaft in taitcone. e) Disconnectforward end of C121-17 push-pulltube. f) Remove four bolts that hold tailcone to steel tube frame (see Figure 4-28, D e ta i ll l . g) Carefullyremovetailcone. 4 . 3 1 2 T a i l co n eIn sta l l a ti o n ' 1. C237-1 frame assemblyis installedin upperframe with bent tube down and tabs to right per Figure 4-28. tail rotor drive shaft damper bearing i s i n co rre ctp o si ti o np e r Figur e7- 11.

2 . Install tailcone onto upper frame. Ensure wiring exiting tailcone forward

frame is not pinched.Standardtorque bolts per Section1.320. Installiralnuts, standardtorque per Section 1.320, and torque stripe per Figure2-1.

3 . Connect C121-17 att push-pulltube to A331-4 intermediatebellcrankas

shown in Figure8-14. Standardtorque bolt per Section1.320. Installpalnut, standardtorque per Section 1.32O,and torque stripe per Figure2-1.

4 . Installand shim intermediateflex plate per Section7.330. 5 . Checktail rotor drive shaft runout per Section7.34O. 6 . PullStrobecircuitbreaker.Connectelectricalconnectionsfor strobe,antenna,tail

positionlight, and TR chip detector.Individuallytest and correct function of tail positionlight and TR chip light circuits.Turn NAV LTS switch off.

7 . Push Strobe circuit breakerin. Individuallytest and correctfunction of strobe light. 8 . Ty-rap wiring as required. 9 . InstallC7O6tailconecowling and D04O aft cowling assemblies.

Ch a n g e1 4 : JUL 2OO8

P a g e4 . 1 7

FICIBINBCIN

MAINTENANcE

MOE EL F44

MANUAL

4 . 3 1 3 T a i l co n eR e P a i r refinishing. Repairstotai|coneare|imitedtob|endingoutscratchesand

D E N T SIN T A T L C ON E : bottom radius:O'125 No dents greaterthan O.O3Oinch deep, Dent minimum inch. fotut affecteddiameter: 1.25 inch max' stations:4 inches One dent p"r rtriioi, ,nini-ur dirtun"e between No sharp iricksor cracks allowed' repair'

iiJv-onoir1r""li-iti reprui"t"il"on. or returnto RHcfor 0 . 0 1 Oi n c h d e e P (Lessthan 15o from tailconecenterline)

Q Tailcone

O.OO5inch deep ( M o r et h a n 1 5 o f r o m tailconecenterline)

T AI L C ON ES C R A T C HL IMITS: to tailconecenterlineare Allowablescratchdepthsconsideringorientationrelative of thatsectionof RHcreplacemert asshown.scratche" "*"""iiili;iir;q;i* oui; ,"e r ninim umO.1Oinch blendradi us ' st Oe' UTenOed t a i l co n e . S cra tch e smu A sse mb l Y 4.32O Empennage e e mo va l 4 . 3 2 1 E mP e n n a g R a ) Re mo veD O7 9 -1ta i l ro tor guar d' b ) Di sco n n e ctta i l p o si ti o nlight wir e' c)Removetwoattachbo|tsattailconecastingand a sse mb l Y . P a g e4 . 1 8

r em ove empennage

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FIC|ElINSiclN

MATNTENANcE MANUAL

MIfEIEL

F44

4.322 EmpennageInstallation 1. Installempennageassemblyonto tailconecasting. 2. Install attachingbolts with washers as requiredunder each nut to maintain properthread engagement. Standardtorque bolts per Section1.320. Install 'palnuts, standardtorque per Section 1.320, and torque stripe per Figure2-1. 3 . Co n n e ctta i l p o si ti o n l i ght wir e and install MS21919 clam ps for tai l r otor gearboxchip detector and position light wiring. Ty-rap wiring as required. Individuallytest and correct function of tail position light and TR chip light circuits. 4. Installtail rotor guard per Section4.330. 4.323 VerticalStabilizerReplacement 1. RemoveDO79tail rotor guard if replacinglower verticalstabilizer. 2. Removefour bolts and screw at trailingedge and removeverticalstabilizer. 3. C554 clip at trailingedge may be reusedby drillingout two rivets. 4. Fit new verticalstabilizer. Fileskin as requiredfor a 0.030-to-0.120inch gap to horizontalstabilizer. 5. Installverticalstabilizer.Attach C554 clip to horizontalstabilizer.Match drill clip to vertical stabilizerwith #30 drill and rivet using MS2047OAD4rivets; N A S 1 9 1 9 B 0 4 Sb l i n d ri vet is optionalin for war dhole. 6. Specialtorque verticalstabilizerattach bolts per Section 1.330 and torque stri p ep e r F i g u re2 -1 . 7. lf removed,installtail rotor guard per Section4.330.

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FICIEIINSiC|N

MAINTENANcE MANUAL

MOE EL ]''44

4.325 HorizontalStabilizerReplacement lower vertical.stabilizers' 1. RemoveDO79-1tail rotor guard and upperand remove N1S21919clamps from 2. Disconnect tail position light wiring and horizontalstabilizer. 3. Removehorizontalstabilizer' washersundereach nut 4. Installnew horizontalstabilizerusingNASl 149F0663Pbolts per Section1'32O' EqiqnA nut' Torque as requireAiii i:qthreads per Figure2-1' """pot"O Installpatnuts,torque p"t S"5i''J;l:420, ;nd torque stripe to O'12o-inch p'QS.Q, 5. Fit vertical stabilizersto horizontalstabilizer'.Verity stabilizerskins' File clearancebetween horizontJl'rtunirirriskin and vertibal verticalstabilizerskin(s)as required' drill a O'144 inch 6. Align horizontalstabilizerattachingho-lgsin C554clips.and Deburr hole and stabilizer. diameter hole through traitini-;ff" bi rroiirontal fasten clips to horizontalstabilizer' per section 1'330 and torque 7. Special torque erglt vertical stabilizerbolts s t r i P eP e r F i g u re2 -1 . wiring and install MS?1919 clamps for tail rotor 8 . Connect tail position light "*a test and verifv

il;;il

ir,ip-o"tJ;i;;

nosilgnlight *i,'ns. lndividuallv

correct tunctton of tail positionlight and TR chip circuits'

9 . Installtail rotor guard per Section4'330' 4.326 F | o a t S h i p ( R 4 4 C | i p p e r ) c o s o S t a b i | i z e r R e m o v a | NAS1351- 4-

ove 1 . R e mo vescre w sfro m D O81- 2block and r em oveblock' Rem and remove block 38p screw tror uii,'fower frolein DO81-4block assembly assemblY.

Tail skid and float stabilizerare unsecuredwhen both NAS1351 stabilizer' Cut sealantaroundedgesof attach bracketsand removefloat fr om Step 1 i n aft l n se rt N A S 1 3 5 1 -4 -3 6 Pscr ew ( note differ ent lenqth inJtutt in vertical stabilizerwith lower hole of DO81-4 block uttttitt'.;g N A d i 1 4 g F o 4 1 6 Pw a sherand M S2104214nut' - NAS1351-4-51P (note differentlglg^!\f1om Step 4 . fnstall DO81-2 block with MS21O42 L4nut' 1 scre w i n u p p e i -tro l e. install nltgOO- + tGLwasher and both NAS1351 Torque taii toioiliaro's sleeve. -and Ensureblocks rrr .iun1ping torque stripe' per Section 1.32O ""i"*t -2 andtorqueto 40 in.-lb. 5 . lnstallNAS1352-3-14pscrewin Dogl block'slower hole

Page 4.2O

T o rq u e N A S 1 3 5 2 -3 -14P( shor t)scr ew last to obtain Proper clampingof tail rotor guard. Change

JUL 2OO8

FIC|BINSICIN

MATNTENANcE MANuAL

MOEIEL]l'44

4.327 FloatShip (R214 ClipperlC050 StabilizerInstalation a) RemoveNASl352-3-14Pscrewfrom DO81-2block'sldwer hole.Remove NAS1351-4-51P screwfrom DO81-2block'supperholeand removeOioir.. RemoveNASl351-4-36Pscrewfrom aft lowdr holein DO81-+UloctLnO ,. removeblock.

,

NOTE Tail skid is unsecuredwhen both NAS1351screws are removed. b) Installfloat stabilizer. cl InstallNASl3Sl-4-38P screw{notedifferentlengthfromstepa} in aft lower holeof DO81-4blockandinstallblockon verticalstabilizerwiin Rrug6o-41 6L washerand MS21042L4nut. dl InstallD081-2btockwith NAS1351-4-S3p (notedifferentlengthfrom step a) screw in upperhole.lnstallAN96O-416L washerand MS2-1O4-2L4 nui. Ensureblocksareclampingtail rotorguard'ssleeve.TorquebothNAS1351 screwsper Section1.320. e) InstallNAS1352-3-14P screwin D081-2block'slowerholeandtorqueto 40 in.-lb. NOTE It is importantto torqueNAS1352-3-14p(short)screwlast to obtainproperclampingof tail rotor guard. 4.330 Tail RotorGuardReplacement

O

a)

Loosentwo screwsthroughDO81-2blockholdingD079-1tail rotor guardto verticalstabilizer.

b)

Removetwo boltsthroughforwardend of guard.

c)

Removetail rotor guard.

dl

Beforeinstallinga new tail rotor guard, that a D081-1 spacer is properly positionedinsideD082-1 tube assembly.

e)

Slide new tail rotor guard under DO81-2block at verticalstabilizerand fasten forward end to D082-1 tube assemblyat tailcone using NAS6603-16 bolts, AN96O-1OLwashersand NAS679A3 nuts. Torque per Section 1.320.

f)

Positionta_ilrotor guardso that D081 blocksare clampingon sleeve.Firsttorque upPer NAS1351-4-51P(-53P if float stabilizeris installed)screw per Section 1 . 3 2 O. T h e nto rq u eN A S 1352- 3- 14P scr ewthr oughlower holein DO81- 2bl oc k to 4O inch pounds. NOTE It is importantto torque NAS 1352-3-14P(shortlscrew last to obtain properclampingof tail rotor guard.

C h a n g e5 : 1 5 J u n 9 8

P a g e4 , 2 1

FlCtEtlNEiClN

MAINTENANeE

MANUAL

MOE EL F'44

4.340 Tail Skid Reolacement

a}RemovethetwoNAS13Slscrewsthroughthe|owerstabi|izerandremove the c470-1 skid. b) Insertthe C47O-3spacerinto the new skid' screwin the upperholeand an c) Installthe skid, usingan NAS1351-4-51P scr-ewin the lowerhole' r.rASr351-4-36P DO81-2block' Then pOsition dl Loosenthe screw in the lower hole of the and-to-riY9-tfp-!wp the block over the sleeve-bi tn" lqrl-ro-tor.guard the NAS1352-3torque Finaliv, pJiSeJtion-i.g2O. NAS1gSl-i r"r"*r 14P screwto 40 inch Pounds'

o

P a g e4 . 2 2

Change4: 1 Jun 97

LANDING GEAR

FIclE|INSclN

MAINTENANCE

MANUAL

MC'E'EL rt,44

SECTION 5 LANDING GEAR 5.OOOLANDINGGEAR 5.001 Introduction 5.002 Description 5.100 LANDING GEARASSEMBLY 5.110 LandingGearRemoval 5.120 LandingGearInstallation 5.2OOCROSSTUBES 5.210 CrossTubeRemoval 5.22O CrossTubeInstallation 5 . 3 O OS K I DT U B E S 5.310 SkidTubeRemoval 5.320 SkidTubeInstallation 5.330 Skid ShoeReplacement 5.340 GroundHandlingWheelReplacement 5.350 Skid ExtensionReplacement 5.4OOSTRUTFAIRINGS 5.410 StrutFairingRemoval 5.42O Strut FairingInstallation 5.5OOUTILITYFLOATLANDING GEAR 5.510 UtilityFloatLandingGearRemoval 5.520 UtilityFloatLandingGearInstallation 5.530 UtilityFloatTubeRemoval 5.540 UtilityFloatTube lnstallation

Cha n g e7 : 0 6 D e c 9 9

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FICIBINEiCIN

MAINTENANcE

MANUAL

MOE,ELF'44

5.610 PoP-outFloat Removal 5.620 PoP-outFloat Installation 5 . 6 3 0 L e a k C h e ck 5.640 EmergencYInflationTest 5.650 Pop-OutFloat PackingProcedure 5.660 PressureCYlinderRemoval 5.665 RechargingPressureCylinder 5.670 PressureCylinderInstallation 5.680 InflationLever Shear-RivetReplacement 5.690 InflationLever Rigging 5.700 MAINTENANCE

P a g e5 . i i

Change7: 06 D ec 99

FICIBINS|C|N

MATNTENANcEMANUAL

Mc,E EL FI44

SECTION 5 LANDING GEAR 5.000 LAND|NG GESR I

5.001 Introduction T^tt t*,,"" removaland installationof the landinggear assembly,cross ""*nskidthg tubes, skid tubes, shoes, ground handlingwheel s,-a-nd strut fairiils. 5.002 Description Standardlanding gear consists of two aluminumskid tubes, four steel struts, two aluminumcrosstubes, and four forgedaluminumelbows. The landinggear connectsto the fuselageat each elbow. Aerodynamicfairingsare clampedto ea6li strut. The right forward connectionis to a pivotingshacklewhich altowsthd forward crosstube to fl6x. The right, aft connectionis to a flexiblesteeltubeframe which allowsthe aft crosstube to flex. Skid shoes, constructedof 4130 steel with a hard wear surface, protect the undersideof the skid tubes during landing. R44 Clippers have permanently inflated utility floats or emergency pop-out floats mounted to skid tubes and incorporateextendeil steel struts and att skid extensionsto the floats. Strut fairingsare not installedwith utility floats. 5 . 1 0 0 L A N D I N GG E A RA S S E M B L Y 5 . 1 1 0 L a n d i n gGe a l R e mo va l 1.

RemoveC388 channelsand C475 cover at forward cross tube.

2.

RemoveDO4Oaft engine cowling and DO41 engine belly cowling.

3.

DisconnectA936 ground wire at aft, right elbow.

4.

Hoist helicopterby main rotor hub per Section 1.22Ountil skids clearground by approximately4 inches.

5.

Remove four NAS66O7 landing gear mounting bolts. Remove forward, left mounting bolt first. Then rotate forward, right shackleto align mounting bolt with access hole in bulkhead before rernoving bolt. Forward bolts can be accessedfrom insideaft baggagecompartments-and throughaccessholesunder carpet at aft outboard cornersof aft floor.

Cha n g e7 : 0 6 D e c 9 9

P a g e5 . 1

FICIBINSiCIN

MAINTENANGE MANUAL

NUMBER

PARTNUMBER

DESCRIPTION

1 2 3 4 5 6 7 8

A21+10 col4-10 c105-1 LJS-1016 col4-5 c141-5 AN960-7161 D310-5 D310-6 8330-21 NAS679A7 AN960-716 c278-1 c241-1 col4-9 c241-2 c141-6 c294-2 c141-4 NAS6607-53 A141-11 NAs6604-17 col4-7 c240-1 NAS1291-4 c247-2 NAs6604-41 AN960-4161 A31007 s14119

Washer strut AssemblY(fwd) Journal Bearing ShackleAssemblY

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Page5.2

MOETEL ]e44

Washer Washer Aft Cowl Bracket,LH (Shown) Aft Cowl Bracket,RH (Not Shown) Palnut Nut Washer Spacer CrossTube (rearl Strut AssemblY(rear) CrossTube {fwd) Washer BearingAssemblY Washer Bolt Washer Bolt AssemblY Elbow Nut RaincaP Bolt Washer Nut Screw

Change3: 5 MaY95

FICIBINEiCIN

MATNTENANcEMANUAL

MOEIEL

F|44

LEFTFORWARD INSTALLATION

INSTALLATION

F IGU R5E 1 LANDING

Change2: 12 Dec 94

INSTALLATION

Page5.3

FloBlNEioN

MAINTENAN'EMANUAL

MoElEL''44

This page intentionallyleft blank.

l s s u e d1: 1 J u n 9 3 P a g e5 . 4

MATNTENANeE MANUAL

FICIBINEiCIN

MOE,ELF,44

5.120 LandingGearlnstallation a) Hoistthe helicopterper Section1. . bl Lift the rightside of the landinggeara1d-installb.othright sidemountingbolts -'pr; Figil; b--f. iorque per Seiiion 1.32O,installpalnuts,and torquestripe. RePeaton left side. cl Connectgroundwire at right aft etbow and attach battery drain tube to aft crosstube. dl Instaltthe C475-2 coverand the C388-1channelsat the forward crosstube. el Installall cowling. 5.200 CROSSTUBES 5.210 CrossTube Removal The aft crosstube must be reptacedif it has yieldedso that the tail skid is less than 30 inchesfrom the ground. NOTE see Section2.550. For hardlandinginspection, al Removelandinggearper Section5.110. b) Disconnectone of the struts from the skid tube. c) Removethe bolts in the elbows at each end of the cross tube and tap the elbowsoff of the crosstube.

l s s u e d1: 1 J u n 9 3

Page5.5

FIGIBINSGDN

MATNTENANcE MANuAL

MOEIEL

FI44

5.22O CrossTube lnstallation al Installcrosstube into the elbowsand insiallbolts per Figure5-1. Torquebolts per Section1.320. bl Connectthe unboltedstrut to the skid tube and torquethe NAS66O6-4bolts per Section1.320. c) Installlandinggearper Section5.120. 5.300 SKIDTUBES 5.31O SkidTube Removal a) Raiseone sideof the helicopterby jackingunderone end of the aft crosstube, one inch inboardof the elbow. bl Removethe 4 bolts at each landinggearstrut. Removethe skid tube. cl Removethe C937 skid extensionby removingthe aft skid shoe. Removethe C719-1wheel. 5.320 Skid Tube Installation al Installthe Cg37 skid extensionand aft skid shoeonto the COl4-11 or -12 skid tube assembly.Installthe c719-1 wheel .and torque.per Section 1.330; the reducedtorque requiredby Section1.330 is requiredto avoiddamagingthe skid tube. bl Placethe skid tube assemblyunderthe fore and aft gearstruts and installthe attach bolts. Torquethe NAS6606-4attachbolts per Section1.32O. cl Seal the slot in the side of the skid extensionwith B27O-9adhesive,if required. 5.33O Skid ShoeReplacement The two A667-8 forward skid shoes and seven A667-7 skid shoes (four on the left skid and three on the right) -andare fastenedwith A142-1 screws. Use new torque to 27 in.-lb. Skid shoes must be shoes ieplaiing screws wnen inchthick at their thinnestpoint. to'O.OSO worn have when thb bott5ms repiaceO a)' To inspector replacethe aft shoeon eachskid,installgroundhandlingwheels tube to tit [ne treticobteror jack up the helicopter. ?1tfte aft landinggearcross replace. and screws and shoes skid woin per ngure S-SB.-nemoJe and'discard wheels,pull installg.rguld.ha.n.dting bl' To inspector replaceall otherskid shoes_, the ttii O-ownarid placewood blocksunderthe skidsto hold the skidsup per Figure5-3A. Replaceany worn shoes.

Pag e5 . 6

Change2: 12 Dec 94

FICIBINSiCIN

MATNTENANeE MANUAL

MOEIEL F'44

5.34O GroundHandlingWheelReolacement al Removethe two mountingbolts and removethe C719-1. bl Installthe usingNAS66O4-47bolts and torquq.pqr Section.1.33O. The reducedidrque of Section1.330 is requiredto avoid damagingthe skid tube. 5.350 Skid ExtensionReplacement al Raiseone sideof the helicopterby iackingunderone end of the aft crosstube, one inch inboardof the elbow. bl Removethe aft skid shoeand removethe four bolts attachingthe aft strut to the skid tube. cl Removethe C937-1or -2 skidtube extensionand replace. dl Attach the strut to the skid tube and torque the four NAS66O6-4bolts per Section1.320. Installthe skid shoe. el Sealthe slot in the side of the skid extensionwith 8270-9 adhesive. 5.400 STRUTFAIRINGS 5.41O Strut FairingRemoval a) Loosenthe clampsthroughthe accessholeon the inboardsideof the fairing. bl Rernoveall screwsalongthe trailingedge. cl Unscrewthe clampsand slidethe fairingoff of the strut.

l s s u e d 1: 1 J u n 9 3

Page5.7

FICIBINSICIN

MATNTENANtrE MANUAL

MOEIELH'4€I

5.42O Strut FairingInstallation al that a 8162-3 clip nut is installedat eachholeat the trailingedggof the fairin-gand that the strtit clampsthrough both of the clips rivetedto the fairing. b) Slidethe fairingonto the strut and looselyfastenthe two clamps. c) Installand tighten all screwsalongthe trailingedge. dl Positionfairingsby placinga long straightedge across-bothforward and aft (Seebelowl.The distancefrom.the straighted-ge fairingsat the-low6r-clamps to th6 centerlineof the tiailinq edge shouldmeasure1.4 inches.Checkfor O.1Oinch clearanceall aroundboth-endsof the fairing.Removefairingto trim and reinstall,if required. adhesiveto both clampthreadsand torqueper Section1.33O. e) Apply B27O-1O 1.4 inch dimensionwith the straightedge. F AIR IN G

(LH) FurD I coaz-3

tnH) Icoez-z STRAIGHT EDGE

FAIRING (LH) AFr{c082-5 (RH) Ic082-4

5.2 FIGURE SKID TUBE

FAIRING

VIEl,l,.A.A''

EDGE STRAIGHT

Pag e5 . 8

Change2: 12 Dec 94

FIGIBINSCIN

MOE'EL

MAINTENANcEMANUAL

F.44

The RobinsonR44 Clipperhelicoptermay be.flownwith float landinggear.orstandard utilityfloat.landing removec.omplete landinfge.i inii.ir"o. Wt,jn chingin'gconfigurqlions, jiO"i*tall completestindardi'aniingge6r.Donot removefloattubesfromlandinggear b"li tor repalrs. skid tubesunlessnecessary CAUTION Float landing gear can only be installed on R44 Clipper helicopters. 5 . 5 1 0 U t i l i tv F l o a tL a n d i n oGe a rRemoval 1.

R e mo vefl o a t l a n d i n gg e ar per Section5.110.

2.

I n s ta l lsta n d a rdl a n d i n gg ear per Section5.120.

3.

RemoveCO50 float stabilizerper Section4.326.

4.

Remove D372-2 air dams aft of static ports. Reinstallattaching screws.

5.

Revise EquipmentList/Weightand Balancedata (located in helicopterPilot's OperatingH'andbook,Section6) using following information: Moment (in.-lb)

Weight

CG Ar m (in.)

co34-2 UtilityFloatLandingGear 1 0 4 . 3 1.1 cos0-2urility FloatStabilizer

95.2

9929

335.4

369

60.9

86.3

5256

Part Number Description

c o 1 4 - 8 StandardLandingGear

(lo1

6.

Performflight check per Section2.22O.

7.

Check and adjust autorotAtion RPM per Section 1O.25O (usually requires lengtheningpitbh links approximately1 full turn at upper rod end).

Ch a n g e7 : 0 6 D e c 9 9

Page5.9

FICIBINEiCIN

MATNTENANeE MANUAL

MOEIEL

F|44

CoVER ENTIRE B0LTHEADIIITH (8 Places) 8270-tSEALANT c944-1 , -2, -3 STRIP (LHor RH) AN960-101t }IASHER (40 Req'd)

AN3-31A BOLT

C949 FLOATTUBE

MS2104213 NUT AN960-10* !.IASHER

GIRT

SKID

GIRT C949-l, -2, -3 STRIP (LHor RH) *BOLTLENGTH MAYBE I.IASHER THICKNESS AND/OR 2-4 THREADS VARIED AS REQUIRED TOMAINTAIN HEADAND SHOI,JING NUTS. SEALUNDER BEYOND GIRTSANDSKID NUTANDAROUND BOLTBETI.'EEN TUBEf'fITH8270-l SEALANT. ASSEMBLY

ATTACHMENT 5-3 UTILITYFLOAT FIGURE FORWARD) (LEFTSIDESHOllN, VIEtltLOOKING

tw)l I

|.t

rFr.r - .

!

TUCKFREEENDSOF CORD AN EYELETTO THROUGH IN FLAILING MINIMIZE FLIGHT

I

c949 FLOAT TUBE LANDING GEAR STRUT

s-4 FIGURE

LACING

squARE KNoT AITACHMENT UTILITY FL0AT-To-STRUT

(vrEl^rL00KING Dot^lN) P a g e5 . 1 O

Change7: 06 D ec 99

FICIEIINSiCIN

MAINTENANcE MANUAL

MIfEIEL

]t44

5.52O Utilitv FloatLandingGearInstnllation 1. Removestandardlandinggearper Section5'1 1O' 2. Installutilityfloat landinggearper Section5'120' 3. InstallCOSOfloat stabilizerper Section4.327 ' 4. Adjust float pressureper helicopter'sPilot'sOperatingHandbook' 5. fnstallD372-2 air dams aft of static ports usingexistingscrews' Pilot's - Revise EquipmentList/Weight and Balance data {located in_h_eljc-opter's 6. 5.51O. provided Section in data 6) using Sectiori OFAing'HbnOUook 7. Shortenboth main rotor pitch links by one full turn of upper rod end. 8. Performflight check per Section2.230. 9. Check and adjust autorotationRPMper Section 10.250. 5.530 Utilitv FloatTube Removal 1. Deflatefloat to loosenlacings. 2. Untie and removelacingsat each landinggear strut' 3. Removehardwareattachingfloat tube to skid tube and skid extension. 4. Removeretainerstrips from girts. Carefullyseparategirt from skid tube and skid extension.

NOTE Sealantbetweengirt and skid tube at each bolt hole also acts as an adhesive. Use cautionto avoid girt damage inq removal. 5.540 Utilitv FtoatTube lnstallation

NOTE removeold sealantfrom skid,float,girts,and Beforeinstallation,

hardware. A soft plasticscrapermay be used-

float are coveredwith a protective 1. SeeFigure5-3. Ensurebolt headsdirectlyb_eneath g,ZlO-l (see additionalsealantas required. Apply t.480). Section sealant t"y"r & 2. See Figure5-3. Positionuninftatedfloat tube over landinggear skid tube and extension. Align holes in C944 retainerstrips, float tube girts, and skid tube. 3. fnstallAN3 attach bolts per Figure5-3. Seal under bolt head and nut with B27O-1 sealant(ref Section1.480). Torquebolts per Section1.32O'

Ch a n g e1 4 : JU L 2 OO8

P a g e5 . 11

FICIBINEIGIN

MATNTENANcE MANUAL

MOEIEL

t,44

5.540 Utilitv FloatTube Installation{cont'd) 4. Inflatefloat with filtered,oil-free,dry air to pressurespecifiedin Pilot'sOperating , Handbook. 5. Installand tighten lacingat each landinggear strut per Figure5-4. POP-OUTFLOATLANDINGGEAR 5.600 EMERGENCY floats are an option tor R44 Clippers-andreplacepermanentlyinflated Emergencypop-out -lncluded are extended struts, skid extensions,uninflatedfloats stowed in utility floats. protectivecovers along skid tubes, a lightweightcompositepressurecylinder.locatedin the compartmentunderthe left-front seat, an inflationmanifold,an inflationlever locatedon the pilot;s collective,and an additionalhorizontalstabilizerat base of lower verticalstabilizer. A valve atop the pressurecylinder incorporatesa pressuregage- a thermal relief valve which releasesiressuie if expos6dto excesiive heat (281 degreesF), a metal s.ealingdisk, and a spring-loidedpin. To inflatethe floats, the red inflationlever on pilot's collectivestick must safety in the READYpositionand then the levermust be.squeezed first liave its sirring-loaded pin shear an aluminumrivet. Squeezingthe levercausesa^spring.-loaded forcefullyenough[o psig helium charge 2O"C} at 4945 the punctirre sealing disk and allows {nominal, metal to the to'inflate both floats via the manifold. The manifold consists of hoses with metal fittings per float (earlier incorporatinga check valve at each float chamber. There are six chambe_rs versibnshavi five chambers).Eachfloat chamberalsohas a toppingvalvefor manualinflation and a pressurereliefvalve which vents excessiveinternalpressure. When inflated,pop-out floats ire identicalto utility floats in size,shape,and internalchamberarrangement. lf installingutility float or standardlandinggearin place of pop-outfloats, removalof pre.ssure pressurecylinder cylinder,iiflation lever(includingbracketJandcabie),and exteriorhoses.(cap. autorotation check h6se and T-fitting in forward crbss tube tunnel)is required. Additionally, RPMper Section-10.250and updateempty weight and balance. WARNING Gylindercontentsare underextremepressure. Installloc-kingpin in piessurecylinder valve (see Figure5-61when working-in fo-rward ieft baggaje compartment, durring cy linder rem_ov_al ^orinstallation. and wfr'dnivorkin! on floats or inflationhoses. REMOVELOCKING PIN WHENWORK IS COMPLETED. 5.610

Pop-outtloat Removal

NOTE To help preventfloat damage,avoidremovingfloats from skid

tubes unlessnecessaryfor

1. Remove heat-shrinkand disconnectflexible line exiting forward strut fairing from T-fitting on float. Cap line and T-fittingto preventcontamination.

P a g e5 . 1 2

Change14: JUL 2OOB

HCIEIINSiCIN

MAINTENANeE MANUAL

MOI]EL

FI44

2.

fastenersalonginboardsectionsof float coverto expose Unfastenhook-and-loop n ot r emove,lacing. b u t d o l a c i n g . L o o se n ,

3.

See Figure 5-5. extension.

4.

See Figure5-5. RemoveC944retainerstrips from girts. Carefullyseparategirts from skid tube and skid extension.

Remove AN3 bolts attaching float to skid tube and skid

NOTE and skid tube at each bolt hole Sealantinstalledbetween girts caution to avoid girt damage Use also acts as an adhesive. during removal. 5.620 Pop-outFloat lnstallation NOTE Before instaltation,remove old sealant from skids, floats, and hardware. A soft plasticscrapermay be used. WARNING Cylindercontentsare underextremepressure.Installlockingpin in'pressure cylinder valve (see Figure 5-6) ryhgn working. in forward left bbggagecompartment,during cylinder removal or installation,and-when w6rking on pop-out floats or inflation hoses. Remove locking pin when work is completed. 1.

See Figure5-5. Ensurestrut bolt headsdirectly beneathfloat are coveredwith a pro$ctive layer of B27O-1 seatant (see Section 1.480). Apply additional sealantas required.

2.

See Figure5-5. Positionuninflatedfloat over landing gear-.skidtube and skid e"t"nrion. Align holes in C944 retainerstrips, float cov-er,floatgirts, and skid.

3.

per Figure5-5. Seal under bolt head, nut, and around InstatlAN3 attach bolts 'skid tl"rbewith B27O-1 sealant (see Section 1.480). bolt between girts and T orq u eb o l ts p e r S e cti o n1.32O.

4.

Inflatefloat with filtered,oil-free,dry air to 3.0 psig via topping valves.

5.

Slide heat-shrinkover flexible line exiting forward strut fairing. Ensureheatshrink is of sufficient length to cover all sharp edges and seal out water after activation. Removeprotectivecaps and connect flexible line to float T-fitting. Orient connectionas requiredto minimizepreload. Torque fitting per Section 1 .330. Positionheat-shrinkover fittingsand shrink with heat gun, usinga shield to protect float from heat.

6.

Pack floats per Section 5.650.

Ch a n g e7: 06 Dec 99

P a g e5 . 13

FICIBINSiC|N

MATNTENANeE MANUAL

MI'DEL]e44

INBoARD .)

I BOLTHEADWITH COVER ENTIRE (8 pl aces) 8270-1SEALANT

TUBE C949FLOAT c950-3LH CoVER, HALF INBOARD (ce50-4RH)

c950-3LHC0VER, HALF OUTBOARD (ces0-4RH) c944-1 , -2, -3 STRIP ( L Ho r R H )

MS2104213 NUT AN960-101* IIASHER AN960-101* ITIASHER

c944-1 , -?, -3 STRIP (LHor RH) SKIDTUBE ASSEMBLY

*BOLT LENGTH I'IAYBE THICKNESS AND/ORWASHER 2-4.THREADS T0 MAINTAIN VARIED AS REQUIRED AND HEAD BEYOND SHO}IING NUTS.'SEALUNDER GIRTSANDSKID BOLTBETWEEN NUTANDAROUND TUBEI{ITH B27O-I SEALANT.

ATTACHMENT FLOAT 5-5 POP-OUT FIGURE (LEF[SIDESH0tlN, F0RI'IARD) VIEt^lL00KING

P a g e5 . 1 4

Change7 : O 6 D e c 9 9

F|CIBINSICIN

MAINTENANcE

MANUAL

MOEIEL

F|44

5 . 6 3 0 L e ak C h e ck WARNING Cvlindercontentsare underextremepressure.Installlockingpin tviinO"r valve (see Figirre.5-6) Yhgn working. in i"';;;;;*" i6til"tO iett Ubggige compartmentl during cy-linderremoval or w6rking on P9p-o-utfloats or inflation installation, "nd"*"hen pin when work is completed' locking ftoies. Remove 1.

'

DisconnectD674-1lineassemblyfrom pressurecylindervalve. lnstallprotective vatvJ titting. Cover D674-1line fiiting to prevent co.ntamination, ;;il;tiind"r n6i'i"J.if ln-"ir+igTlt seal (D674-1 line must be allowed to leak to verifv ili;; check valve function at e-achfloat chamber).

2.

fastenersalonginboardsectionsof float coverto expose Unfastenhook-and-loop remove, lacing. not do lacing. Loosen,but

3.

Unfastenoutboardsectionsof float cover and unroll float to exposevalves.

4.

tnflatefloats with filtered,oil-free,dry air to 2.0 psig via topping valves'

5.

Allow float air temperatureto stabilizefor 5 minutes minimumthen recordOAT and pressurein each float chamber.

6.

One to two hours after initialpressurecheck, again record OAT and pressurein each float chamber. Allowabiechamberpressuredrop from initialmeasurement by O.O.Q ir O.t trig iOjrrt"O for any temperature_-change. .Pressurewill change pressure will chamber float For exdmple, plig pdr O"egrde C temperaturechange. C. 1O degrees 016 psig if temperaturedrops bec-r6ase

7.

ff leaksare detected,repairfloat with suppliedrepairkit and repeatsteps 4,5, &6.

8.

C on n e ctD 6 7 4 -1l i n e a ssemblyto cylindervalve and tor que per Sectio n1.330.

9.

Pack floats per Section 5.650. NOTE Annuallyapply A257-7dry-film lubricant(seeSection 1 .470) to float cover snap mating surfaces.

Ch a n g e7 : 0 6 D e c 9 9

P a g e5 . 1 5

FIclBINSiClN

MAINTENANcE MANUAL

MOEIELF|'44

WARNING Cylindercontentsare underextremepressure.lnstalllockingpin in'pressure cylinder valve (see Figure.5-6) when working.in forward left bbggagecompartment,during cy-linderremovalor installation,ani-when w6rking on pop-out floats or inflation hoses. Remove locking pin when work is completed' 1.

Unsnapoutboardedge of both float covers. Hook-and-loopfasteners{inboard) may remainsecured.

2.

Removelocking pin from valve, move inflationlever safety to READYposition, O and area around floats is clear.

3.

Squeezeinflationlever to inflateflqqts. fppr.oximately20 poundsforce will be i"irir"d Oue io the shear-rivet. Time for floats to attain full shape without wrinkles should be three secondsor less. CAUTION Floats inflate rapidly and with a loud noise. Keep area c.lear Ouringinflationahd ihformall nearbypersonnel.Removeor close OiotJ prior to inflation. Open-doors interfere with float "lf inflationand may be damaged.

4.

Allow float temperaturesto stabilizefor at least five minutesthen record OAT a n d p re rru re i n 'e a chfl o a t chamber . Minimumallowablepr essur esar e: Minimum Pressure Minimum Pressure Minimum Pressure (psig-lin Middle O.A.T lpsigl in Forward lRsig) in Aft Two Cham ber s eham ber ( d eq i e e sC l .T w 6 'C h a mber s

5-9 10-14 15-19 20-24 25-29 30-34 35-39

P a g e5 . 16

1.30 1.60 1.90 2.20 2.50 2.80 3.10

1.OO 1.30 1.60 1.90 2.20 2.50 2.80

o.60 0.90 1.20 1.50 1.80 2.10 2.40

C h a n g e7 : 0 6 D e c9 9

FIG|BINSCIN

5.

6. 7.

MAINTENANcEMANUAL

MOE'ELF44

after DisconnectD674-1hoseassemblyfrom pressurecylindervalveimmediately cnecti.--lnliall prbtective gap 9n bylinder valve fittins. .Cover i-"1i1-.t ;;;;;;; -tObz+-r D674-1hosefitting to preventcontamination,but d'onot installan air tight seal hose musi be allowed to leak to check valve function at each' float chamber). no rips or chafing on floats or covers. pressurein One to two hours after initialpressurecheck, again record OAt qnd nojtLtramuli. Ailowauie chamber pressuie drop from initial measurement by 0.0.6 ""tr, ir O.ZOJii aajuitea for any temperature'change. . Pressurewill.change pressure will chamber float For_exJmple, cfr'ange. psi per degreeC temperatrire C' 1O degrees diops !""i""t" 6.6 psig if temperature

8.

lf leaksare detected,repairfloat with suppliedrepairkit then perfoim leakcheck per Section 5.630 on repairedfloat chamber.

9.

Connect D674-1 hose assembly to vatve fitting. Orient line as requiredto mlint"in minimum0.25 inch clearanceto cylindeiand C390-5 . TorqueBn u t p e r S e cti o n1 .3 3 0 a n d tor que str ipe.

1 0 . Pack floats per Section 5.650. NOTE Annuallyapply A257-7dry-filmlubricant(see section 1.470) to float cover snap mating surfaces. 1 1. RemoveD679 pressurecylinderassemblyper Section5.660 and returnto RHC for servicing. p re ssur ecylinderper Section5.670. 1 2 . I n sta l lse rvi ce a b l e 13. Rig inflationlever per Section 5.690. 14. Replaceinflationlever shear rivet per Section 5.680.

Ch a n g e7 : O 6 D e c 9 9

P a g e5 . 1 7

FIClBINSiclN

MATNTENANeE MANUAL

MOEIEL

]444

5.650 Pop-outFloat PackinoProcedure ,, Deflatefloat. float is properlysecuredto skid and all hosesare properly 1. connectedand coveredwith heat shrink. 2.

Spreaddeflatedfloat to outboardside of skid tube. Using a vacuum, evacuate eich float chamberthrough topping valve to remove as much air as possible.

3.

Using a cloth covered with talcum powder, lightly coat entire float, including i n s i d eo f co ve rs.

4.

Fold front end of float under and back until fold line reachesgirt: \

.t.:> \

b.

P a g e 5 . 18

Fold aft end of float over and forward until fold line reachesgirt:

C h a n g e7 : 0 6 D e c 9 9

.-I

MATNTENANcEMANUAL

F|CIEIINSiCIN

6.

M!]EIEL]f,,44

Securehook-and-loopfastenersat insideof inboardgirt along length of cover:

'.'.itf i*

-.

a INBOARD

7.

A l i g n h o se sa n d va l ve co ver flaps and roll float from outer edge toward skid as t i g h tl y a s p o ssi b l e :

Change 7: 06 Dec 99

P a g e5 . 1 9

---

FICIBINEICIN

9.

MATNTENANcE MANUAL

MOEIELH'44I

Holdfloat on top of skidtube and installcoveraroundfl-oat.Usinga swab or gmJl OiJshr, appty^ZST-7lubricantto matingsurfacesof snaps'.Securehookin"b fastenersalongoutboardgirt (seeFigure5-5). "nO "nA-i*p cordsper float. Onecord securesthe float coveron the Thereare two lacing "The rehrainingcord securesthe float cover to the skid. extension. iLiO in coverusingcrossover("ladder" "tiii.ing corainstalled through-grommets Vi,rity lacing)methodshownbelow:

ialedges.; do not 1 0 . Pu ll l a ci n g a t e a ch se g m ent until tight or until m ater (4 overhand overtighten. Tie lacing ends in douSle square knots knots) to secure.

alternating

fas tener s 1 1 . T u ck i n l o o see n d s o f l a ci ngcor d as shown and secur ehook- and- loop fastener sat end caps: r t o ng i " n g th -o f co ve r. S edur ehook- and- loop

1 2 . Ve r i fY a l l fa ste n e rsa re p r oper lysecur edand floats ar e r olled tightly l u m p so r l o o s ea r e a s . P a g e5 . 2 O

w i th no

C h a n g e7 : O 6 D e c 9 9

-

MATNTENANcE MANUAL

FICIBINSIG|N

M('E'EL

N44

CylinderRemoval(seeFigure5-6A) 5.660 Pressure WARNING Cylindercontentsareunderextremepressure.Installlockingpinin pressurecylindervalve{seeFigures-GA}whenworkingin forward

teft baggagecompartment,during cylinderremovalor installation, and when workino on pop-out floats or inflation hoses.

1. Installlockingpin in valve. 2. DisconnectD674-1 line assemblyat valvefitting. lnstallprotectivecaps on valve and line fittings. 3. RemoveD675-9 cover. 4. On B-125-2connector,cut & removety-rap closestto valve. Disconnectconnector from valve cable. 5. DisconnectD675-10 from valve. Do not kink cable. 6. RemoveD669-3 strap. 7. Carefullyremovepressurecylinder. orderKl-167CylinderValveServiceand Fillkit. 8. lf cylinderhas beendischarged,

NOTE useKl-151 for transportation, lf cylinderrequires depressurization FloatCvlinderBleed-OffKit.

Ch a n g e1 3 : O C T 2 OOo

Page5.21

-

FIGIBINSCIN

MAINTENANeE

-t-tr=-

MANUAL

M|]E'EL

F'44

Cvlinder{SeeFigure5-6) 5.665 FillingPressure WARNING -DoT-E 10915-4945"may be refilled. oNLY cylinderslabeled -DOT-E 10915-4500"must be returnedto Cylinderslabeled RHGfor exchange/upgrade.

and maximumhydro-test Maximumcylinderlife is 1b yearsfrom dateof manufacture is 3 years. intervalis b years. Also,maximumintervalin aircraftbetweeninspections Thereforereturningio r"rui"" cylindersolderthan 12 yearsor havinghydro-testsolder are madeto ensure unlessalternatearrangements than 2 years is nJt recommended limits are not exceeded. life/hydro-test psi minimum O fill equipment (pumps, hoses, fittings, etc') must be ratedfor 600O All working pressureand be in good condition.

andpressuremust be keptwithin safelimits. Monitorpressuregauge Cylindertemperature temperature and use thermocoupfeoi other appropriatetemperatureprobe to monitor SooC exceed to on face of thermaLielieffitting oiliinsitilr. Do not allow temperature stop fill and allow lf limits.are approache.d, 1122"Flor pressureto exceed'SSOO-psig. in a water bath cylinder cylinderto cool und prrsure to drop befo-recontinuing.-Placing keep water bath, water lf using and using slow to moderatefill rates is recommended. level belJw valve assemblyto avoid water contaminationof valve' 1 . R e m o vefi l l -p o rtca p . 2. InstaltMT546-2 AdapterAssemblyper Figure3 (Torque40 in-lb)' 3. Attach fill hose to MT546-2 AdapterAssembly' 4. Fill with 99.98% minimumpurity (industrialgrade)helium per chart below: Ambient T e m p( o C )

Pressure (psig)

-20 -10

4268 4437 4606 4776 4945 5 11 4 5283

o 10 20 30 40

with helium to 5. Allow cylinder and valve to cool to ambienttemperature. Top off for any pressureloss due to cooling' "otpeniate 6. Removefill hose and re-installfill-portcap (Torque40 in-lb)' Page5.22

Change13: OC T 2OOo

FIC|BINSC|N

MATNTENANcE MANUAL

MOE'EL

H44

THERMALRELIEF FITTING {INSTALL THERMOCOUPLE HEREI

ONLYCYLINDERSLABELED "DOT-E10915-4945"MAY BEREFILLED.

Togr

I

l I

w

I

I I

SUBSEOUENTHYDRO.TESTDATE (EXAMPLE:JULY 2OO2l MANDATORYRETESTEVERY5 YEARS TO SERVICE RECOMMENDNOT RETURNING UNLESSTESTEDWITHIN PAST 2 YEARS

\ \

\_e?

FIGURE5.6 FILLINGPRESSURE CYLINDER Cha n g e1 2 : J U L 2 OO5

Page5.23

FICIBINSGIN

MATNTENANeE MANUAL

M.'DEL

F|44

5.Q70 PressureCvlinderlnstallation(seeFigure5-6A) WARNING Cylindercontents are under extremeprelsLlg: Install locking pih in pressurecylindervalve (seeFigure5-6A) when working durins_cylinderremoval #ssise i;'i;;il;Al;ii "ompartmeni p-op-out floats or inflation onwoiking oi intt.il.tion, and"iltien is completed' work pin when locking f,orei. nJmoue 1. Installlockingpin in valve. 2. Ensurecylinder's three forward areasare covered with anti-chafetape' 3. Carefultypositioncytinderinto D669 strap and D669 cradleper Figure5-6A' 4. InstallD675-10 on valve. 5. See Figure5-68. Connectvalve cableto 8125-2 connectorand securewith ty-rap. dimensionshown. 6. InstallD675-9 cover on valve. with 7. Rotate cylinder as requiredto minimizecable bending and ensure clearance strap' surroundingstructure.InstallD669-3 g. connect D674-1 hose assemblyto valve fittin_g.orient line as requiredto maintain per Section minimumO.2Sinch clearanceto cylinderand C3i9O-5.TorqueB-nut 1.330 and torque striPe. 9. Rig inflationlever per Section5.680' 1O.Replaceinflationlevershear rivet per section 5.690. 1 1. RemovelockingPin from valve.

P a g e5 . 2 4

C h a n g e1 2 : J U L 2 O O 5

MATNTENANcE MANUAL

FICIBINSCIN

9,332-42 LOCKWASHER (2 REO'DI

I

7

\r r

NAS1149FN832P WASHER

MS21042108 NUT (2 REO'D}

R\

-4,

r

\\,\ \L \\

j

Ms2Jo42L3

\^^.s

\-s

-oezs-ro / ,/ ,' suppoRr;///

(2 REo'Dl

SCREW 12REO',DI

I

,

\

ti-irro-;--'''"-'( -d'#8f5,=

=\\>, I naszzoggcosoo I I

\

r/ ) - -/' \D676-1 GABLE \-\ . . .,/ ASSEMBLY

(2 REO'D}

4

t,sv

Ms27039C0806 scREW

(2 REO'D}

F7r1:\-

NASl 149F0332P WASHER

o

D67s-e

'-r.a \ ^ FnlrEn COVER

ry) \\

(2 REO'DI

co-PlLor

,h,

,

t2 REO',DI I 1

SCREW {2 REO'D}

SEATBOX

SCREW I2 REO'D)

I

irr+srruaazr /

]f,44

MS27039C1-11

AN735 CLAM (2 REO' WASHER

MS27039CO805

MOEIEL

'/

Jp/'ocK,NG

\

-./'

,.) K ??f, f4> "'/''

8125-2 CONNECTOR

F -'

\.X

(

\

i-/,. kz)

FORWARD

o "r?gx'F (REFI

ztKg\ , ?

-\ \ \ \t t

'-

\

'^#<

\-......

/

D674-1 LINE \- = ASSEMBLY

orrg-,,

CYLINDER D669.1 CRADLE ASSEMBLY t-e c39o-E \

FIGURE 5.6A REMOVAL CYLINDER PRESSURE AND INSTALLATION

C h a n g e1 2 : J U L 2 0 0 5

Page5.25

MC'E'EL

MAINTENANcE MANUAL

RClBINEiclN

F,44

0.00 - 0.20 lNcH D675-10

VALVE CABLE

8125-2 CONNECTOR

D675-9<

t\/

COVER

MS3367-4-9TY-RAP ORIENTAS SHOWN 12PLACESI

PIN LOCKING RECEPTACLE

VIEWA.A FROMFIGURE5.6 (VIEWLOOKING FORWARD}

5-68 FIGURE

Pa g e5 . 2 6

Change 12: JUL 2OO5

FICIBINS|GIN

MATNTENANeE MANUAL

MC]EIEL F44

5.680 InflationLeverRissins WARNING Cylindercontents are under extreme pressure.Install locking pin in pressurecylindervalve {see Figure5-6A) when working in forward left baggagecompartment,during cylinderremoval and when workingon'pop-outfloatsor inflation or installation, hoses. 1 . Installlockingpin in valve. 2 . See Figure 5-7. With inflation lever safety in READYposition, collectivefull up, and no shear-rivetinstalled, 1.3O11.25inch dimensionshown when inflationlever is squeezedto eliminate slack. lf required, reposition cable housing in clamps at inflationleverto obtain 1.30/1.25 inch dimension.

3 . Place inflation lever safety in LOCKEDposition. no preload in cable thru full travel of collective with inflation lever squeezedagainst safety.

4. Replaceinflationlever shearrivet per Section5.690. 5.690 InflationLeverShear-RivetReplacement 1. Beforeinstallingrivet, inflationlever riggingper Section5.680. WARNING Cylinder contents are under extreme pressure. Install locking pin in pressurecylinder valve (see Figure 5-6) when working in forward left baggage compartment, during cylinder removal or installation,and when working on pop-out floats or inflation hoses. Removelockingpin when work is completed.

2 . Installlockingpin in valve. 3 . See Figure5-7. Placeinflationleversafety in LOCKEDposition. 4 . fnsert MS2047OA2-6-5(or MS2O470A2-6.5)rivet per Figure5-7. WARNING Use only MS2O470A2 series annealedrivet in inflation lever assembly;other hardwaremay preventfloat inflation. 5 . Using lockingpliersor similar,flatten shop-headend of rivet per Figure5-8. 6 . Removelockingpin from valve.

C h a n g e1 2 : J U L 2 0 0 5

Page5.27

MAINTENANcE MANUAL

FIClBINSlclN

M|fE

EL R44

l'!! rru*r

'/\

3'!!rucHes

D68O.1 LEVERASSEMBLY INFLATIONLEVERSAFETY (SHOWNIN LOCKEDPOSITION} MS20470A2-6-5 RIVET

rHsrAffien

HEADNEARSIDE MANUFACTURED FLATTENFARENDPERFIGURE5-8

A333-1 STOP

INFLATIONLEVER

SAFETY

0.080- 0.100lNcH

MS20470A2-6-5 RIVET SHOP.HEADEND

Pa g e5 . 2 8

5-8 FIGURE SHEARRIVETIN$TALLATION

C h a n g e1 2 : J U L 2 0 0 5

FICIBINSCIN

MAINTENANtrE MANUAL

M(IEIEL

F.44

5.7O0MAINTENANCE skid, standardand l. Ensuredrainholesin bottomsof skidtubesare not plugged.{twoper just aft of the skid and shoes s-kid forwaid two the pop-outg""l o;iVi, tocaieObetween shoeat the forwardstrut. 2. Touch up skid tubes,crosstubes and strutsto preventcorrosion. See Section1.4O0 for approvedmaterials. or running followingtouch-downautorotations 3. Inspectskidshoesfrequently,especially take-offsor landings. 4. Installlost or looseraincapswith B27O-1or B27O-gadhesive(seeSection1.480). Mix instructions. adhesiveper manufacturer's

lssued:JUL 2005

Pa ge5.29

FICIE|INSCIN

MATNTENANeE MANUAL

MOEIEL

H44

Intentionallyblank

Pag e5 , 3 0

lssued:JUL 2OO5

o 6. POWERPLANT

o

MAINTENANcE

FICIBINSCIN

MANUAL

M3IEIEL

Fl44

6 SECTION SYSTEMS AND RELATED POWERPLANT SYSTEMS AND RELATED 6.000 POWERPLANT 6.001

Introduction

6.002

DescriPtion

6.100 POWERPLANT 6.110

E n g i n eR e mo va l

6.120

Enginelnstallation

6.200 COOLINGSYSTEM 6.210

Fanwheeland ScrollRemoval

6.220

Fanwheeland ScrollInstallation

6.230

(Reservedl

6.240

FanwheelDynamicBalance

SYSTEM 6.300 LUBRICATION 6.310 Oil CoolerRemoval 6.320 Oil CoolerInstallation 6.400 INDUCTIONSYSTEM 6.410

CarburetorRemoval

6.420

CarburetorAir Box Removal

6.430

CarburetorAir Box Installation

6.44O

Carburetorlnstallation

6.450

CarburetorHeat Scoop Removal

6.460

CarburetorHeat Scoop Installation

6.47O

Fuel InjectionAir Box Removal

6.480

Fuel InjectionAir Box Installation

6.490

Fuel Control Removal

6.495

Fuel Control lnstallation

Ch a n g e1 3 : OC T 2 0 0 6

Page6.i

FIOEIINSGIN

MATNTENANcE MANUAL

MoEfEL n,44

6.500 EXHAUSTSYSTEM 6.510

ExhaustSystemRemoval

6.520

ExhaustSystemlnstallation

6.600 TROUBLESHOOTING 6.610 Low-powerChecklist

Page6.ii

Change9: FEB2003

FICIEIINSC|N

MAINTENANcE

MANUAL

MOEIEL

R.I'T

6 SECTION AND RELATEDSYSTEMS 6.000 POWERPLANT 6.001 lntroduction This section includes instructions for the removal and instailation of .engine, induction and exhau:1,^1v.:J:T',i"f:t-^l9.e.n9ine and cooling,system 'maintenance ivliem-,-iuUricaiion system, 'manuiactureri' publications for product specific enqtne componint procedures. maintenance insfection, rdpair,and 6.002 DescriPtion R44 helicopters are powered by one. Textron-Lycoming. O-5{O-F185 six-cylinder, air-cooled,cbrbureted,enginewith a wet sum.p frorizoniilly'opposed, 6verhegQ-_vqive, oit sGt6m'noiriiallyr'atedat 260 horsepowerand28q9-qpmfor..takqof. The engineis OeritJd- to 2OS maximum continuous horsepower (M), with a 5'minute takeoff po*iil"iinq of 225 horsepower,by limiting'manifoldpressure.(seePilot's.Operating indication-theengine is actually turning ta6homete-r RPM. At 1O2o/o ind Ftiirb6ooil 2 7 1 8 R PM . a screenedopeningon the right side of the aircraft R44 inductionair enters through -duct A to the carburetor-mountedair ^b91^3:s_e.m,!Ly. a flexible paiiei through. anO scooii mounted tdthe exhaust manifold esheated air via a duct to the air box. A sliding valve in the air box controlledby the pilo_tallows either cool or -5ii cabld-ooerated to tlow iito the box, through the radial-flow air filt-er and up into the warm iaiUureior. On R44 S/N O2O2 and s-ubsequent,application of carburetor heat is corietaieA with changes in collective setting through a {riction clutch to reduce pilot adds carb heat ald raising collective workload. Lowering-collective mechanical'ly pilot clutch and increaseor decrease friction th-e Ttre may override ieOucei carb heat. carb heat as desired. A latch is providedat the control knob to lock carb heat off when not required. |O-540-AE1A5six-c.ylinder, R44 ll helicoptersare powered by one Textron-Lycoming horizontally 6pposed, bverhead-vilve, air-cooled, wet-sump-oil. system, fuel-injected and 28OO enqine cariabl'e'of3OO horsepowerand normally rated at 260 _l1o_r_sepo-ryer roli for tbkeoff. The enqine is derated to 205 horsepower M, with a S-minute pressure(see Pilot's t'akeoff power rating of 245 horsepowgl,by limiting_m.anifold Operatin'gHandbookland RPM. At'192o/otaihometeiindicationthe engineis actually turning 2118 RPM. R44 ll induction air enters through a screenedopening on the right side of the aircraft and oassesthrouqh a radial-flowJilterwithin an air box. The air then esthrougha the fuel control and into the engine.. A spring-loadeddoor on flexible duct, thr6ugh -automatically opens to supply sheltered engine compartment air top of the air box occur. intake screen blockage or filter should Cooling - is supplied by a direct-drive,centrifugalfanwheel enclosedby a fiberglass scrotl. The sbioll direbts coolins air via flexibl-educts to the muffler, the main rotor qearbox, the hvdraulic reservoii (if installed),the drive belts, and engine-mounted 5heet-metalcooling s. The cooling s also direct.cooling air to the -driv_e belts, and further guille coolingair to the-cylinders,externaloil cooler.{twoon R44,ll}, alternator, magnefos, fuel fld'w divider (fuel injected engines), and battery (when battery is mounted in engine compartment). A sheaveboltedto the propellerflangetransfersengine power to the clutch assembly via four doublev-beltsehgagedby a verticallymountedelectricbelt tensionactuator.

Change9: FEB2003

Pa ge6.1

FICIE|INEiCIN

MC|EIELTl44

MATNTENANeEMANUAL

6.100 POWERPLANT NOTE and inspectionprocedures, For engineand ignitionmaintenance refer t6 the appropriatemanufacturers'maintenancepublications 6.1 1O EnsineRemoval 1. Removetailconecowlingand all enginecowling. 2. Removetailconeper Section4.31 1. 3. Removefanwheeland scrollassemblyper Section6'210' 4.

Removeclutch assembly,belt tensionactuatorand V-beltsper Sections7.21O, 7 . 5 1 Oa n d 7 . 2 8 1 .

5. Disconnectenginebreathertube at engineby removingone clamp from the rubber coupling. Cap exposedconnections. G. Turn fuel on-off valveto off position. Removeair box assemblyand carburetor(if equipped)per Section6.41Oor 6.460, as applicable' 7. Disconnectmanifoldpressurelinefrom the forward left cylinder(0-540) or intake manifold(lO-540)and cap exposedconnections' 8. Disconnectoil pressurehoseand cap exposedconnections. g. 0-540: lf instatled,disconnectprimerline at T-fittingon engineand cap exposedconnections. fuel puqp inlet and disconnect lO-b4O:Diiconnectfuel hosefrom engine-driven fueLreturn hose from fuel con-trolinlet T-fitting. Cap exposed connections. 1O. Disconnectairframeand batterygroundstrapsfrom engineoil sump bolts. 1 1 . Tag for identificationand disconnectalternatorwiring,.starterw.iring,magneto-toairirame *iring. cylinderhead temperaturesenderwire and oil temperature senderwire. 12. Disconnectcabin heaterduct from mufflershroud' 13. engineat bottom of lower sheave. Use a wood blockto preventdamage to sheave. 14. Removeaft engineassemblyby disconnectingall four bolts (seeFigure 6_1). NOTE Do not disconnectthe rod endsfrom assembly. Two dimensionsshown in Figure6-1 are criticaland must be maintained. P a g e6 . 2

Change9: FEB2003

FICIBINEIC|N

MAINTENANeE

MOEIEL F|44

wlANlrAL

6.11O EnsineRemoval(cont'd) 1S. engineat lifting lug usingthe MT548-1tool with a hoist as shown in Figure6'2. bolts (seeFigure6-18). 16. Disconnectand removetwo forwardengine-mounting 17. Removeright, aft verticalstrut weldmentconnectinglower right frame to upper frame. 18. On R44 ll, removeleft, aft verticalstrut weldment connectinglower left frame to upper frame 19. Removeengine. CAUTION To preventdamagewhile removingthe engine,someoneshould assist on each side of the engine.

BETbIEEN ENSURE CLEARANCE TABS RODENDSANDFRAME

1 . 1 5 r0 . 0 3 INCHES

0.80/1.00 llrcH

VIEt,|LOOKING FOR[.|ARD

cl74-l ENGINE ASSEMBLY :

'ni

i...$+./

a

s---|Lt--a

:

6.1 FIGURE

Change9: FEB2003

Page6.3

rvrATNTENANeEMANUAL

FICIBINSCIN

MOE EL FI44I

Y 7 \\ 11

\

IA, \

W

m

23

v->

6

J--a-i,

(<) i t

>,

\J

FORWARD

F I G U R6E. 1 4 ASSEIJIBLY AFT ENGINE NUI4BER PARTNO.

DESCRIPTION

1 2 3

c020-1 NAS6605-9

Upper FrameAssanblY Bolt

AN960-5161

4

NAS679A5

llasher Nut

5

8330-16

Palnut

6

c174-1

7

NAS6604-8

Engine AssY Bolt

8

AN960-4161 NAS679A4

llasher

l0 1l l2

8330-13 8330-l9

Nut P a ln u t Palnut

MS2104216

NuI

13

ANg60-6161

bJasher

14

A14l-23

l.|asher

9

Page6.4

DESCRIPTION

NUMBER PARTNO. l5 16 17 l8 l9 20 2t 22 23 24 25 26

NAS6606-30 NAS6608-20 AN960-8161

c592-2 c653-1 c592-l NASr29r-8 8330-24 1 0173AN316-6R AN316-5R A101-4

Bolt Bolt llasher Link l4ount: EngineMount(Ref.) Nut Palnut Rod End Nut Nut Rod End

Change4: 1 Jun 97

F|C|BINSEIN

MAINTENANcE

M|fEIEL

MANUAL

F|44

FORWARD

w

7

Ii,

a1

:gK

13

l-, '.t ,\\ tI

t

( Left m ountshown;r ight s' ide ENG i I N E M OUNTS 6.18 FORWARD FIGURE p a r t n u m b e ra sre identical.)

DESCRIPTION NUMBER PARTNO. Palnut 8330-24 1. N A S 1 2 9 1 - 8 Nut 2. Washer c 14 1 - 9 3. AN960-8161 Washer 4. A N 9 6 0 - 6 1 6 1 Washer 5. NAS679A6 Nut 6. Palnut 8330-19 7, EngineMount (fwd) 8. c593-1 Mount c653-2 9. Lower FrameAssy (Ref.l c046 10. MS20002C8 Washer 11. NAS6608-39 Bolt 12. Engine( Ref.) 13. Change1: 2 Jul 93

Page6.5

!

I

,.,ii

FICIBINE|CIN

MATNTENANcE MANUAL

MOE EL H44

MT548-1 HOIST

ourrHEAD f rosuPPoRr I

ENGINE LIFTING LUG

HORIZONTAL FIREWALL

OF ENGINE DIRECTION REMOVAL AND REPLACEMENT

F I G U R E6 . 2 E N G I N EH O I S T I N G

Pag e6 . 6

Change12; JUL2005

FICIBINSIEIN

MAINTENANcE

MANUAL

M(fElEL

]l,44

6.12O Enginelnstallation 1. ConnectMT548-1 hoistingtoolto engineliftinglug. Carefullyhoistengineand position it into alignmentwith enginemountingpads (seeFigure6'2l. 2. On R44 ll, installleft, aft verticalstrut weldmentconnectinglower left frameto upper frames. Torquefastenersper Section 1.320 and torque stripe. 3. Installright, aft verticalstrut weldmentconnectinglower right frame to upperframe. 4. Install two forward engine mounting bolts (see Figure 6-18). Torque per Section 1.32Oand torquestripe. 5. weight of engineat bottom of lower sheave. Use a wood block to prevent damageto sheave. Removehoist. 6. Connectaft engineassemblyper Figure6-1A and torquefastenersper Section 1.320. 7. Removefrom lower sheave. 8.

O-54O: Installcarburetorper Section6.44O. lO-54O: Connectthrottle linkage. Connectmixture control cable per Figure6-7A. inch clearanceunder mixture control Adjust cable so therJis O.O3-O.1O knob (springback)when fully depressedand mixture arm is in full rich position.

9. Adjustthrottlecorrelationriggingper Section1O.15O. 1O. Connectcabin heaterduct to muffler shroud. 1 1. Connect airframeand battery groundingstraps to engineoil sump bolts and torque per Section1.330. wiring, cylinder 12. Connect alternatorwiring, starter wiring, both magneto-to-airframe as required. wire. Ty-rap sender oil temperature and headtemperaturesenderwire 13. Connectenginebreathertube. 14.

0-540: lf installed,connectprimerlineto T-fittingon engine. fuel pump inlet and connectfuel return lO-54O: Connectfuel hose to engine-driven hoseto fuel controlinletT-fitting. Torqueper Section1.330.

15. Connectoil pressurehose. 16. Connectmanifoldpressureline. 17. Installfuel injectionair box per Section6.480, if applicable. Ch a n g e1 4 : J UL 2 0 0 8

Page6.7

I

FICIEIINSCIN

MATNTENANeE MANUAL

M('EIEL

H44

.6.120 Enginelnstallation(cont'd) actuator, and clutch assemblyper Sections7 -282, 18. Install V-belts, belt tension '' 7 .52O, and 7 .,22O. 19. lnstallfanwheelper Section6.22O. 20. Installtailconeper Section 4-3122 1 . I n s t a l la l l e n g i n eco w l i n ga n d tailconecowling. 6.200 COOLINGSYSTEM 6.210 Fanwheeland ScrollBe!1oyel NOTE lf same fanwheel witl be reinstalledthen orient starter ring gear timing position-andmark fanwheelat.splitline to magneto "will minimEd need for new balanceweights. See oi'i"ioil; this Figure6-38. 1.

Removeengineaft cowling.

2.

Removecoolinghosesfrom lower and upper halvesof scroll.

3.

Disconnecttail pipe strapsfrom lower scroll. Note shim stack on mountingscrews'

4.

lf installed,disconnectair conditioningcondenserfrom lower scrolland temporarily secureit to a frame.

b.

Removescrollperimeterscrews. Removetwo boltsthat attach scrollto lower actuator bearingblock and removescrolllower half'

6.

Cut safety wire and remove roll pin which securesfanwheel retainingnut. Remove retainingnut.

7,

Use a half-inchopen-endwrench to hold fanwheel hub bolt headsogr-lioyp 6-3A\and remove 6 ot ii nJii and washersper Figure6-38. Replacenuts with MTo92-3 spacers.

g.

Back out MTsg2-1 fanwheel puller's center bolt and attach pullerto the MTO92-3 spacers(seeFigure6-38). CAUTION fan retainingnut has beenremoved.Havesomeone f"" i6 pi"ueni dro"ppingit. Fanwheelmay come off taperedshaft with a loud pop.

g.

ring Securetyattach MTO$1-1starterring gear holdingtool and have sorneonehold gear stationarY{seeFigure6-38).

10.

Tightenfanwheelpuller'slargecenterbolt againstfanshaftuntil fanwheelis unseated'

Removefanwheelpullerand reinstallnuts and washers on fan hub bolts. Special torquenuts per Section1.33O. Change14: JUL 2oo8 Pa g e6 . 8 11.

MAINTENANcE

FIC|BINEiCIN

Mt'E EL F.44

MANUAL

It

\1 \

ll'

["

rl

I

\

Insert screwdriver into bracket notch

tl

I

il

r\ \\

FanwheelPullerBolt Access

\

BearingAssembly/Bracket Realignment

FIGURE6.3A FANWHEELHUB BOLTACCESS

X(,,,

M T O 9 1 - 1E n g i n e Ring Gear Holder

Mark edge of fanwheel adjacentto split line of scroll.

MT592-1

'^'")"ri{i:; Fanwheel

FIGURE6-38 FANWHEELPULLERINSTALLATION Ch a n g e1 4 : J UL 2 0 0 8

Page6.9

i l

" t'- |

FIclBINSIclN

MATNTENANeE MANUAL

MOEIEL

844

6.220 Fanwheeland Scroll Installation 1. Evaluatedrive belts,atternatorbelt, and C181 bearingcondition;replaceas required. Cleantaperedshaft and fanwhee!hub matingsurfaceswith solventand dry. Inspect shaft and hub for damage;replaceas required. 2. Placescroll upper half on fanwheel and installfanwheel on tapered shaft. Secure scrollupper half to enginecoolings. pg(io^n9!!-y of COO7.shaft and clamping 3. Using A257-g anti-seize,coat threade_d'149F2432P washers (use as many as.will surfa-cesof MS2OO02-24washer, NASl washeragainsthub. MS2OOO2'24 with fit), and castellatednut. Installhardware NOTE lf installingoriginalfanwheel, ensurestarter ring-gear is at magnlto t'imingposition and align marks on fanwheel with scroll split line. and holdstationary. ring gearguppo.rt toolto eng_ine 4 . SecureMTO$1-1ring gearholding -Section pin can be installedin 1.330 until.spring Sp""i.l torque CtAZ--l nut per steel wire. stainless diameter ;fi"ft. tnstallspringpin and bafety with 0.041-inch NOTE lf springpin cannot be installedwithin nut's torque range,.then remove-6r add NAS1149F2432P washers under nut. Large pliersmay be used to squeezespringpin into position. b. Mark fanwheeldirectlyoppositeeach end of roll pin (see Figure2-11].. 6. positionlower scrolland insert two AN3-41A bolts through bearingmountingbra.cket, actuator Uearingbloci, and Uearingmounting.bracket nut plates on upper scroll' lf Ur""L"i nutplate-byinsertinga screwdriverinto notch in ipp"irorni i;q;ir;d, "lig" rlgiirE O-SAI.Standardtorque bolts per Section1.320 and torque stripe. bracket(see 7. Installscrews, washers,and nuts aroundscrollperimeter. inch. lf necessary,adjust g. D22g lip-to-fanwheelinlet clearanceis O.O1O-O.O9O lip cl6aranceliy elongatinglip mountingholes' 9. Connecttail pipe to C173 straps.See Section6.520 for shimmingrequirements' 1O. Connect muffler and MRGB cooling hoses to scroll. EnsureMRGB cooling hoses cross and cleJrtail rotor push-pulltube thru full rangeof travel' 1 1. lf applicable,installair conditioningcondenserand condenserheat shieldon lower scroll' 1 2 . B a l a n c efa n w h e e lp e r S e cti o n6.240. CAUTION Fanwheelbalancemust be checkedupon installation;fanwheel i mb a l a n ceca n ca u sed am age' P a g e6 . 1 0

C h a n g e1 4 : J U L 2 O O 8

lfOBlN9C|N -

IUAINTENANeE luANuAL

MoE Elnrra,

6.230 (reserved)

Ch a n g e5 : 1 5 Ju n 9 8

Page6.1 1

; fl

PHOTOCELL (USEDINSTEAD OFSTROBEX) PHOTOCELL BRACKET

MOEIEL

MAINTENANcEMANUAL

FICIBINCiCIN

INSTALLBRACKETS EXISTING USING ALL CABLES SECURE HARDI.IARE. TAPE }IITH IX.ICT c181-3 'r(-" FANSHAFT BEARING ,"t-

lttt

\-:o

t

l-r'

--i

- - - - t \

t'\ l'l ll t, t,

\,

VELOCI}tETER BRACKET

F|44

\---.?

t!

TARGET TAPE

,'-',

ll.

a.-l

i", t-'

ii r

tr .'l

t

LEFTAN3 BOLT

4185-1 BRACKET

STROBEX

BALANCER

(USEDINSTEAD OF PHOTOCELL) 6.4A FIGURE

T}IOACCELEROMETERACCELEROMETER VELOCIHETER BOLTED BRACKETS TOGETHER. VELOCIHETER CABLE

AT B0LT(S) IIIASHERS CHANGE : 00 P OS IT I0 N N E A R E S1 T BOLTS. DONOTREMOVE

= 0.05IPS WASHER AN960-10 = 0.10IPS IIASHER A141-17 = 0.20IPS I,IASHER AN970-3 NUT. WASHERS UNDER U5E FOUR MIX AB0VESIZESAS REQUIRED FORBALANCE. OONOTREMOVE BOLTS. THENAS66O3-6

I I I I I t t,

NOTRTE FANUNTILTARGET TAPEIS AT CLOCK ANGLE N0TED IN 6 .2 4 0 (H ) FIGURE6-48 FANBALANCING P a g e6 . 1 2

Change9: FEB2003

Il

I

MOEIEL

MANUAL

MAINTENANcE

F|CIBINEiCIN

FI44

MUSTBE TI^IOWASHERS INSTALLED

/l

lq '{

716

7

fI

\l

I

I! --|--v

'l-E*" i \

I I t-:l-

17

9io NOTE 1 6 (BOLT),1 0(B 0 L T ),1 ,L ITEMS TORQUE (NUT) 1.330. sEcrIoN PER ANDITEM19

-l 13

FIGURE6-5

FAN INSTALLATION

I{UMBER PARTNUMBER 1 2 3 4

d 7 8 9 10 11 L2 13

DESCRIPTION

EngineFlange EngineRingGear c742-L LowerSheave c493-1 l'lasher AN960-816 Bolt NAS6508-42H -13 Bolt (as required or NAS5605-12 for thread engagment) l,lasher AN960-s161 Cone c187-1 Shaft Assembly c007-s Bolt NAS6603-6 l,lasher AN960-1-0 NASl149F0316P Washer(between coneand fan) Assembly Fanwheel DL74-2

Cha n g e4 : 1 Jun 97

25

".Ffi'

NUMBER PARTNUMBER 14

15 l6 t7 18 19 20 2L 22 23 24 25 26 27

26

DESCRIPTION

l,lasher AN950-10 l,lasher AN970-3 Washer A141-17 (install 4 washersas required for balance) MS2104213 Nut Nut MS21042L5 Washer(install against hub) MS20002-24 NAS1149F2432Pl,lasher(as required to install roll pin)

c182-1 8350-3

Nut Roll Pin 0.041in. dia Safetyt,|ire Scroll (upper) c236-1 MS27039C0806 Screw l,lasher AN960-81 Nut MS21042108 Cover 0229-4 Scroll (lower) c236-2

P a g e6 . 1 3

. l

FIclBINEiClN

MOE'EL

MATNTENANcEMANUAL

1lT44

6.240 Fan DvnamicB?lance NOTE Model 192'or When usingMicro Vib, Chadwick-Helmuth 85OO-seriei, or equivalent equipment consult the specificdperatinginstructions.Thelollowing equipment's Model8350 and initructionspdrtainto Chadwick-Helmuth (Vibrexlequipment. 177-series a)

Removeengineaft cowling.

b)

wire on fanshaftbearingper Figure6-4A. .Accelerometer lnstallaccelerometer JnouiO-6"-pointed down. A suitablebrack-etmay be assembledfrom two bracketsor may be fabricated. acceleromeier

c)

Placea targettapeat edgeof one fan vane(seeFigure6-4A).

d)

Set Strobexmodeto positionB. Set BalanceBox RPMrangeto X1Oscale. Set BalanceBox RPMdialto 270. RPMwith rotor systemengagedand Start engineand run helicopterat 1O2o/o governorON.

e)

WARNING Use extreme care near tail rotor. f)

point Strobexat fanshaft nut and pull trigger. Note clock angle of target tape'

s)

push Tune button on BalanceBox. Note change (if any) in clock angle of target

to bringthetarget,lf,ffl,.1?[11 RP[I-dial i"p": Wtil.e ou;fingfu;a button,,adiust is tunedto fan RP i;-th" cioC[ ingle vTewedin Step"f". BalanceBox ir rioinang" i;iig;t iJpe ctockanglewhenTunebuttonpushedand released.

h)

Note clock angleof targettape when BalanceBox is tuned.

i)

Notevibrationreadingon IPSmeter.

j)

Shutenginedown. CAUTION Ensureignitionswitch is OFFand keys are out of switch wheneveJfanwheelis movedby hand.

P a g e6 . 1 4

C h a n g e5 : 1 5 J u n 9 8

F|CIEIINSC|N

MAINTENANcE

MANIIAL

MIfEIEL]t'44

6.240 Fan DvnamicBalance(cont'd) kl

ll

is over 0.2 lPS,washersmust be exchangedto balance lf balancereading ;ooli;g f.n. ioiate until target !?P!-is ^in positionnoted in Step "h'. undernut nearestto Changi ANg60-1O,A1 41-17,-.orAN97O-3.washers the 1IOOpositionor split requiredweight changeundertwo ,nearestnuts isee Figuie 6-48). Ohe AN96O-10wrasherwill changebarance.reading two AN960-10 i-ppro*imatelyO.O5lPS. One Al 41-17 washer.egyals^ wdshers. On'e erug7}-3 washer equals four AN960-10 washers. Four washersare requiredundereachnut. To accessbolt head,removeD2294 coveron forvriardsideof lowerscrolland rotatefan as required.Do not washersmay be removethe NAS66O3-6bolts or the NAS1149F0316P MS21042L3nut bolt (see and NAS6603-6 Tolque Figure 6-51. dislodged per Section1.330. InstallD229-4 coveron lower scroll. After washershave beeninstalled,check fan balancereading. Exchange washersuntil a readingof lessthan 0.2 IPSis obtained.

and attachingbrackets.Installengineaft cowling. m) Removeaccelerometer

Change4: 1 Jun 97

P a g e6 . 1 5

I I

FICIBINEiCIN

MOE EL F|44

MATNTENANeE MANUAL

SYSTEM 6;3O0 LUBRICATION NOTE SeeSection1 for gradeand quantityof oil required. Refer to the Textion-LycomingOperator'sManual for adjustmentand maintenanceof the lubrication system. 6-310 Oil CoolerRemoval al Removeright engineside and aft enginecowling. bl Disconnectthe oil linesat the cooler. c) Removethe two screwsand nuts holdingthe c636-1 to the cooling shroud(seeFigure&61. dl Disconnectthe four mountingboltsand removethe oil coolerand . 6.320 Oil Coole,rlnstallation al InstallMS2O822-gelbows, if required,usin} 9'270-6sealantand torque to 110 in.-lbsplustorquerequiredto alignthe elbows' to the_enginegqo-Ug.shrojd using b) Installthe oil coolerand C636-1 'bolts per Sect-ion1.320 (see Figure6thd forque UottJ. tf,e ioJi hounting 6). cl Installthe two screwsand nuts that fastenthe to the coolingshroud. Torquethe nutsto 15 in.-lbs.plusnut drag. dl Reconnectthe oil linesand torquethe tubing nuts per Section1.330. el Installcowling.

P a g e6 . 1 6

Change2: 12Dec 94

FIC|BINSICIN

MCIEIELFI44

MAINTENANcEMANUAL

MS20822-8 ELBOI{

MS21042108 T.IUT

I

I

1

A66&1 DOUBLER

tr-=_

I

c649-1 OIL COOLER

II I

I

4658.1DOUELER

A130-49 SPACER

INSTALLATION 6-6 OIL COOLER FIGURE

Change2: 12 Dec 94

Page6.17

- -,.-.i i

FlCtEllNEtON

MAINTENAT\IcE MANUAL

MOEIELH44

SYSTEM 6.400 INDUCTION 6.410 CarburetorRemoval a) Removeright engineside. b) Turn off the fuel valve and disconnectthe fuel line at the carburetor. Cap the fuel line and the carburetorinletport. c) Disconnectthe air intakeand carburetorheat ducts from the air box. dl Disconnect the throttle linkage from the throttle arm, the mixture control cable from the carburetor and the carburetorheat control cable from the air box and slidervalve. e) Disconnect the carburetorair temperatureprobe at the quick-disconnectplug locatedapproximatelyfour inchesfrom the probe. f) Removethe palnuts and nuts securingthe carburetorto the oil sump and remove the carburetorand air box assembly. |

6.420 CarburetorAir Box Removal a) Removethe four long bolts securingthe air filter cover. Open cover and removeair filter. b) Clip the safety wire securingthe four air box-to-carburetorattach bolts and remove the bolts, air box and gasket.

I

6.430 CarburetorAir Box lnstallation a) Installtheair box and gasketto the carburetorwith the four attach bolts. b) Torquethe four attach botts per section 1.330 and safety with 0.032 inch safety wire. c) Reinstaltthe air filter, close cover and securewith the four long bolts. NOTE Tightenthe nuts on the long attachbolts until 2-4 threads pr6trudethroughthe nut ant coveris uniformlysealed' bu"nigntening-ofthe nuts can causedistortionof the cover and leakageof the air box seal.

P a g e6 . 1 8

Change9: FEB2OO3

FICIE|INEiCIN

MAINTENANtrE MANUAL

MIfEIEL

H,44

lnstallation 6.440 Carburetor 1. Installair box per Section6.430.

I

2' y'?iqJiHi8ry[3k.i"T3iif,%o#I3l,?1,3t Tbor'o*l'fo*iLTift "'{"'#TILI'EHll,3fl | palnuts.

'Adjust throttle correlationrigging 3. Connectthrottle linkageto throttle arm. pei Seciion t 0.1 50 ant torque per Section 1.320. 4. Connect mixture control cableto carburetor(9qeFjggF^6-7-l.andcarb heat inch clearance JJntioiio ;ii fti ifoei va-ive. nig eachco4tr<)tfor 0--09-0-.10. arm and mixture of travel full abpress"ea. unddit-nob; wft;iui\i valve. slider heat carburetor b. Connectcarburetorair temperatureprobeand secureconnectorto carburetor with ty-rap. 6. Connectfuel hose to carburetorand torque per Section 1.33O. 7. Connectair intake and carburetorheat hosesto air box. 8. Installenginecowling(s). 9 . Co mp l yw i th S e cti o n2 .2 10, steps15 & 16. 6.450 CarburetorHeat Scoop Removal 1. Removeengineright cowling. 2. Disconnecthose from air box to carb heat scoop. 3. Loosenclamps and removescoop. 6.460 CarburetorHeat Scoop lnstallation 1. Positionscoop on exhaustmanifoldand tighten mountingclamps. 2, Connecthose from air box to scoop. adjust as 3. Inspect scoop for O.1-inchminimum clearancein all diqec-tions; ;;qlira. Toique mountingclamp screws per Section 1.320. 4. Installenginecowling. 6.470 Fuel IniectionAir Box Removal 1. Removeengineright cowling. 2. Removeair intakehose. 3. Coverfuel controlair intake. 4. Removefour screws and largeareawashersatop of , and securingair box to, horizontalfirewall. 5. Removeair box.

Change9: FEB2OO3

P a g e6 . 1 9

r'l

FIG|EIINSCIN

MATNTENANcE MANUAL

MOE EL ]t44

6.480 Fuel IniectionAir Box lnstallation 1. With intake pointing outboard, position alr box below forward,. right side of horizontalfirewafl and secure to firewall with four screws and large area washers. 2. Removefuel control air intakeprotectivecover, if installed,and installair intake hose betweenair box and fuel control. 3. clearancebetween air box, intake hose and adjacentcomponents;adjust componentpositionas requiredfor clearance. 4. Installenginecowling. 6.490 FuelControlRemoval 1. Turn fuel shut-offvalve OFF. 2. Removeright cowling. 3. Removeair intake hose. 4. Disconnectf uetcontrolinlettee f rom f uelcontrolinletreducer.lnstallprotective caps on all open fuel ages.

5 . Disconnectand cap fuel hosefrom fuel control outlet. 6 . Disconnectpush-pulltube from bellcrankattached to fuel control mounting f la n g e . 7 . Disconnectmixturecontrol cablefrom fuel control. 8 . Loosenlower, aft bolt securingfuel controlto intake manifold. Removethree remainingbolis and removefull controlwith attachedlink and bellcrank. 9 . Removeold gasketfrom intake manifoldinlet. Cover inlet if not immediately replacingfuel control. 10. Compare fittings on removed fuet control with replac-ementfuel control. Tranifer f itting; as requiredand torque per Section 1.330. 6.495 FuelControllnstallation fuel control. 1. Compare fittings on removed fuel control with replac^ement 1.330. Tranifer f ittingi as requiredand torque per Section 2. Removetemporaryshippingsafety wire from mixture and throttle arms. 3. correctfull-openthrottle arm angleper Figure6-7B and full-leanmixture arm distanceper Figure6-7C. Adjust as required. 4. Removeprotectivecaps from fuel inlet and outlet. Drain all fluid.

|

b. Usingnew gasketand with fuel inlet pointingaft, install fuel control on intake ma n i T o l d fl # g-e w i th l o ngerbolt thr u bellcr ankin for war d, upperhole. C h a n g e1 3 : O C T 2 0 0 6 ,un" 6 . 1 9 A

FIclBINEiElN

MATNTENANcE MANUAL

MOE EL r|44

6.495 Fuel Control lnstallation{cont'd} 6. Connectfuel intettee to fuel control inlet reducer. Torque per Section 1.330 and torque stripe. 7. Connectthrottle push-pulltube to bellcrankper Figure6-7A. full travel (collectivemust be raisedslightlytn'achievefull-openthrottle). 8 . Referto Figure6-7C. Connectmixturecablehousingto bracketwith housing flush-to-O.25inch extendedbeyond clamps. Connect mixture control cable innerwire to mixturecontrolarm. EnsureA130 spacerlubricatedwith 42570 inch clearanceundermixturecontrol 1 grease. f ull traveland O.O3-0.1 knbb when full rich. Mixture control inner wire should protrude O.1O-0.30 inch beyond A462 fitting securingwire to mixture control arm; trim wire as requirecibut do not bendend. Torquenut on A462 fitting per Section 1.33O anil freedom of rotation between mixture control arm and control wire. lf wire cannot rotate relativeto mixture arm the A130 spaceron fitting may be missingor damaged;replaceas required. 9 . lnstallair intake hose betweenair box and fuel control. 1O.Electricallygroundthe helicopter. 1 1. Placea clean containerbeneathfuel control outlet and connect a ground wire between containerand helicopter. circuit breaker. 12. Pull CLUTCH-START 1 3 . T u rn fu e l sh u t-o ffva l veON. 14. Turn masterswitch ON. Openthrottle. Turn ignitionkey to PRIMEposition and hold until fluid exitingfuel control is the same color as avgas (fuel control is typicallyshippedwith non-flammableoily preservative).Continue flushingfuel control until avgasexitingfuel control no longerexhibitsoily smell and feel. 15. Closethrottle and turn masterswitch OFF. 16. Connectfuel control outlet hose. Torqueper Section 1.33O and torque stripe. 17. Turn masterswitch ON. Turn ignitionkey to PRIMEpositionand hold until AUX FUELPUMPlight extinguishes.Turn ignitionkey OFF. Inspectfuel control and attachedfuel connectionsand no leakage. 1 8 . R e mo veg ro u n d i n gw i re ( s) . 19. Performpreflight,start engine,and run up using R44 POH checklist. 20. Set idle rpm to 58-620/orpm with enginewarm and clutch engaged. 21 . Shut down engineusing R44 POHchecklist. 22. Disconnectfuel control outlet hose, connecttest hose if desired,and measurefuel flow rate at fuel controloutlet with mixture full rich, throttle at i d l e ,a n d e l e ctri cfu e l p um p on ( ignitionkey at PRIM Eposition) . P a g e6 . 1 9 8 C h a n g e1 3 : O C T 2 0 0 6

FICIBINSCIN

MATNTENANeE MANUAL

MOEIEL

F,44

6'495 Fuel control Installation(cont'd) 23. Adjust idle mixtureas requiredto obtain 16-18 pounds/hourfuel flow l170-190 cc/minute). Clockwiserotationof idle mixture adjustmentwheel (viewedfrom aircraftright side)enrichesmixture. Re-checkidle rpm after mixture adjustmentand repeatas requireduntil both rpm and mixtureare within limits. With rpm and mixtureset, smooth accelerationfrom rpm with no enginehesitationor smoke from tailpipe. Also idle to 1O2o/o to idle with no engineroughness smooth needlesplit from 1O2o/o or erraticrpm indicationsand acceptableidle quality. Note that 16-18 pounds/hourfuel flow shouldproduceacceptableidle quality and off-idle throttle performanceundersea-levelstandardconditions. Richermixtures may be requiredfor cold temperatureoperationand leanermixturesmay be requiredfor hot/highaltitudeoperation. Deviatef rom 16-18 pounds/hour as requiredfor acceptableidle quality and off-idlethrottle recommendation and needlesplits)' performance(smoothaccelerations 24. Adjust throttle corretationriggingper Section 10.150' 2 5 . I n sta l lri g h t co w l i n g .

P a g e6 . 1 9 C

C h a n g e1 3 : O C T 2 0 0 6

o

FtClBtNSiClN

MAINTENANeEMANUAL

MotrELp'AA

BLANK INTENTIONALLY

Cha n g e9 : F E B2 0 0 3

P a g e6 . 1 9 D

MAINTENANeE

HCIE|INS|CIN

MCIEIEL F|44I

MANIIAL

,o

SAFETY SPRING ASSEMBLY

ts

I,IIXTURE CONTROL

CABLE BRACKET

FORWARD

(VIEWLOOKING DOWN}

. 0.25 INCH FLUSH

- 0..30

-0.10

MUSTHAVECLEARANCE CABLEHOUSING BETWEEN ANDARMI.IHENARMIS AT POSITION IDLECUT-OFF MIXTURE CONTROL CABLE

CARBURETOR

\ .-.

DoNorBEND

i-'JhMrxruRE I K't coNTRoL \

\\

C0NTR0L ARM

\SZ-oouir,rr,*n

Ki,fiF I ffitlr \h\s\iJY*ilAsHER 6,

)Hr$W-ir,*i'nr,, ?-fl \%'Y: .a..? ,/,/

\zrl

1,1 I'dr)Ei\'6:'^,

( FORWARD

t ' \€ c-o-!\TRoL'MT*TURE ARM-STOP

(sToPMUST gOOV'Rt CARBURETSn r^n

uilcT

enNTrliT

AilD IDLE FULL.RICH cuT-0FFPoSITIoNS)

@

WA

--t

lPALNUT

( LUBRICAI t, WII H

A2s7-tGREASE) }IASHER - sELF-LocKINc NUT

\ \.-\-

N0TE:FUELSCREEN ACCESS

6-7 FIGURE MIXTURECONTROLCABLE R44 CARBURETOR AND SAFETYSPRING Page6 . 2 0

Change9: FEB2OO3

MOEIEL F|44

MATNTENANeE MANUAL

FICIBINSIEIN

3 NAS6603-1 BOLT

NAS1149F0332P-i-\

D731-9 BELLCRANK

WASHERr.rA t

-\NUT MS21O42L3 \\\B33O-7PALNUT

D543-2 SPACERS

NAS6603-1 3 BOLT

NUT MS21O42L4

B33O-13 PALNUT

A341-1 SPACERS

SAFETYWIRE

I

I I

t-/"/

i/

NAS1149FO463P WASHER

I

TUBE A336-6 PUSH-PULL -

t----tt'

RSA-IOAD1 FUELCONTROL

8564-2 LINK

D731-1 BELLCRANK ASSEMBLY

MS2104213 NUT NASl 149F0332P WASHER

NUT MSz1O42L3 8330.7 PALNUT

I,

FORWARD

FTGURE 6.7A THROTTLELINKAGEINSTALLATION

Ch a n g e1 3 : O C T 2 0 0 6

Page6.20A

FICIEIINSCIN

MATNTENANeE MANUAL

MOEIEL

F.44

/\ /\ /\ /\

46.0o+7.s'rRUE ,\tt"

oPENrHRorrLE)

/

THROTTLEARM

RSA.IOAD1FUELCONTROL

ARM ADJUSTMENT 6-78 THROTTLE FIGURE (VIEWLOOKING AFTI

'fuft,i*"

DO NOT BEND

WIRE o . 1 0- 0 . 3 0 INCHBEYOND FITTING

HOUSINGFLUSHTO 0.25 INCH BEYONDCLAMPS

CABLEINSTALLATION 6.7C MIXTURE FIGURE P a g e6 . 2 0 8

Change1 3 : O C T2 0 0 6

FIC|BINSICIN

MAINTENANcE

MANUAL

MOE'EL F,44

SYSTEM 6.500 EXHAUST 6.510 ExhaustSvstemRemoval 1. Removeenginesidesand aft cowling' C173 stra'psfrom tail pipe' 2. Disconnect hosesat mufflershroud' 3. Disconnect 4. lf installed,removecarburetorheat scoop per Section6'450' remove exhaust 5. Disconnect exhaust risers at each engine cylinder, and system.

Ex

lon

clamps 1 . Installexhaust risers with new exhaust gaskets. ts under bead nuts riser torque tape. Special *itt A7O1-10 stainless--steel ;;;'bt*iipp"O p er S e cti o n1 .3 3 0 . bead clamps' 2. Slide muffler section onto exhaust risers and attach with Standardtorque bead cl amp bolts PerSection1.320. CAUTION Ensure bead clamp bolt flanges are oriented.so an-yleakage is Jirected away from ignition componentsand structure. 3 . Installcarburetorheat scoop {O-54Oengine)per Section6'460' 4 . Connectmuffler coolingand heaterhosesto muffler shroud' shim 5 . connect tail pipeto c173 straps.To accommodatethermalgrowth, install O'O2lO'08 washer(s)betweeniailpipeeirs and straps as requiredto breatea inif, tot*ard preloadon btraps at tailpipe attachment. 6 . lnstallheat shields. 7 . Installcowling.

Ch a n g e1 4 : J U L 2 0 0 8

P a g e6 . 2 1

FICIBINSIGIN I

MATNTENANeE MANUAL

MOEIEL

844

6 . 6 0 0 T R O U BL E -S H OOT IN G

I

|

0 . 0 1 0 L o w -P o w e rC h e ckl i st When low enginepower output is suspected,use the following checklistto': 1. Aircraft grossweight is not exceeded.Weighaircraftif it was not weighedat last overhaul. 2. Engineoil pressure,oil temperature,and CHT are within limits. 3. MAP gage indicatesambientpressure(engineoff). 4. Propergradeof fuel per Pilot's OperatingHandbook. 5. Main rotor bladesare clean and smooth (no rough paint). 6. Exhaustis unobstructed. 7. Main rotor bladetrim tabs are not excessivelybent.

I

g. lf equipped, carburetorheat valve closesfully in OFFposition. 9. Inductionsystem is unobstructed. Air filter and both inlet hoses (ambientand carburetorheat) are clean, undamaged,unobstructed,and do not collapse in gasket is correct size. flight. Carburetor-to-engine 10. Fuelinjectornozzlesare unobstructed(lO-540only). Cleannozzlesper Lycoming ServiceInstruction141 4. 1 1. Enginetachometerindicationis correct. with digitaltachometer(such as fouhd in newer dynamic balancingequipment)or similarequipment. 12. Oil screensor filter do not exhibit metallicdebrisconsistentwith internalengine damage. 13. Proper cylinder compression (both leakage and direct) per Lycoming recommendations. 14. Mixture neitherexcessivelylean nor rich. Comparefuel flow. fuel filter cleanliness,check spark plug indications,check carburetorthrottle body-to-float bowl screw securityper LycomingSB 366. 1 5 . P r o pe rsp a rkp l u g typ e a n d condition. timing. engine-left(helicopter-right) 16. Propermagneto-to-engine .magnetois (disconnect position BOTH in is not operatingin retard mode wh-enignition switch retardterminalafter starting engineand comparehover MAP indications;lesser hover MAP with retard terriinaf disconnectedindicatesmagnetowas operating retarded). 17. Properfuet flow and unobstructedcarburetor/fuelcontrol inlet screen. Perform f u e l - fl o wch e ck p e r S e cti o n12. primer PuTp carburetedengine, fuel is not leaking-Pqst 18. - lf primer-equipped past in cylinder fittings not leaking (ensurepriindi pJmp is locked)"and'air is head.

Page6.22

Change14: JUL 2008

FIC|BINSiCIN

MAINTENANeE

MANUAL

MtfE|EL

F,44

6.610 Low-PowerChecklist(cont'd) (collectivemust 1g. Carburetoror fuel control throttle lever s full-throttle stop be raisedslightlY). 20. Carburetoror fuel control mixture arm s stop when mixture control is in full-rich positionand mixture arm does not exhibit springbackat extremesof travel when disconnectedfrom control cable/safetyspring (dueto internalbinding). 21. No induction/MAPsystem leaks. To check MAP system, disconnectMAP line at cylinderhead fitting and apply suction with syringeuntil MAP gage indicates 1O inchesHg. Monitor gage for one minute; indicationshould rise no more than 1 inch Hg. carburetorthrottle shaft bushingsare not worn; check both axial and radialclearances.Intake leakscan also occur due to loose intake pipe connectionsin oil sump and/or cracked sump runner tubes. On fuel-injected engines, intake manifold drain ("sniffle") valve does not leak ambient air into intake manifold. 22. Properexhaustvalve guide clearanceper Lycoming58388 (latestrevision). 23. Properdry-tappetclearanceper LycomingOverhaulManual. 24. With lifters pumped up (valve lash removed),each intake valve should exhibit equal travel during openingwhen measuredwith a dial indicator.Similarly,each exhaustvalve shouldexhibitequaltravel duringopening.Unequaltravel indicates d a ma g e dca m l o b e (s). 25. Propermagnetointernaltiming. 26. Carburetorfloat bowl fuel level correct. 27. Cylinderhead intakeport has radiusededge where inlet airflow turns 90 degrees toward valve. lf no radiusexists, LycomingTechnical. timing: As #1 piston esTDC on compression 28. Propercrankshaft-to-camshaft stroke, the #2 intakevalve shouldopen white the #2 exhaustvalve closes(valve overlapposition). 29. lf engine exhibits low-power immediatelyafter overhaul, correct 8.5:1 compressionratio piston P/N 75089 has been installed (insteadof 7,0:1 low p i sto nP /N 7 5413) . c o mp re ssi o n

Ch a n g e1 4 : J UL 2 0 0 8

P a g e6 . 2 3

MATNTENANeE MANUAL

FICIBINSCIN

MtlE,EL

NAS6603.7BOLT ANg6OPDlOL WASHER (underhead)

8249.7 ARM ASSEMBLY

A142-4 SCREW NAS1149FO332W P ASHER (torqueto 45 in.-lb;includes locking torque) 2 places

F|44

A141-16 WASHER (0.688 in. outsidediameter; 3 required)

8250.8 JOURNAL ( 0 . 1 0 0i n . l o n g )

a R E Nt3???3;l'. 51,'T,o," M S 2 1 O 4 2 L 6N U T (torqueto 28O in.-lb; includesnut self-locking torque) B 3 3 O - 1 9P A L N U T

A141-16 REF

8250-5,-6,-7, -10,or -12 JOURNAL (2 required*)

A647.12 BEARING (2 required)

D333-1 BELLCRANK

D 3 3 3 - 1 0B L O C K D333-11 PLATE 825O JournalLengths(thickness):

8250-5 8250-6 B250-7 8 2 5 0 - 10 8250-12

SPRINGWASHER B1OOO-O35-S {2 required,orientas shown)

O.059 inch long 0.062 inch long

A 1 4 1 . 3 5W A S H E R (2 required)

0.065 inchlong 0.068 inch long O . 0 7 1i n c h l o n g

N A S 1 1 4 9 F O 6 6 3W P ASHER

*fnstall 8250-5, -6, -7, -10, or -12 journalsas requiredto producea rotationalfriction of 1O-i2 inch-pounds.Journaldashnumbersmay be mixed. After adjustment,clamp fong side of D333-11 plate in paddedvise with 8249-7 arm assemblyingvise jawi while providing rotationalclearancefor D333-1 bellcrank;measurerotational torque wrench. friction by rotatingbolt head with dial-indicating

- CARB HEAT ASSISTFRICTIONADJUSTMENT FIGURE6-8 D334 BELLCRANK Page 6.24

C h a n g e1 4 : J U L 2 0 0 8

t 7. DRIVE TRAIN

o

FICIBINSiCIN

MATNTENANcE MANUAL

MOEIEL

1f,,44

SECTION7 DRIVETRAIN 7.OOO DRIVETRAIN 7.OO1 Introduction

:

7.OO2 Description 7. 1 0 0 M A I N ROT ORGE A R B OX 7.11O Main RotorGearboxRemoval 7.12O Main RotorGearboxlnstallation 7.130 LevelingMain RotorGearbox 7.140 C9O8-1Yoke Replacement 7.141 SettingHall Effect SenderGap of Main RotorGearboxPinionSeal 7.150 Replacement 7.155 Main Rotor GearboxSump O-RingReplacementProcedure 7.160 Main Rotor GearboxOvertempInspection 7.17O Main RotorGearboxChip Light lndicator 7.'l8O Lubricationof Main Rotor Gearbox 7.2OO CLUTCHASSEMBLY 7.21O Clutch AssemblyRemoval 7.21'l C184 BearingAssemblyRemoval 7.212 C184 BearingAssemblyInstallation 7.213 ClutchAssemblySealReplacement 7.22O Clutch AssemblyInstallation 7.23O Clutch SheaveAlignment 7.24O ClutchShaft Angle 7.25O LateralClutch Centering 7.260 C9O7Yoke Removaland Installation Change4: 1 Jun 97

Page7.i

FICIBINSiCIN

MATNTENANcE MANUAL

MOETEL F|44

7 . 2 0 O .C L U T C HA S S E MB L Y(co n t'd ) 7 . 2 7 O C 1 9 5 Y o ke R e mo va al n d In s tallation 7 . 2 8 O V- B e l ts 7.281 V-Belt Removal 7.282 V-Belt Installation 7.283 Belt Tension 7.29O COOTFanshaftand BearingAssembly,StarterRing Gear,Lower Sheave.and AlternatorBelt Replacement 7 . 2 9 1 R e mo va l 7.292 Installation 7 . 3 0 0 T A I L R OT ORD R IV ES H A F T 7 . 3 1 0 T a i l Ro to rD ri veS h a ft R e moval 7.32O Tail Rotor Drive Shaft Installation 7.321 Adjustmentof DamperFriction 7.330 IntermediateFlex PlateInstallationand Shimming 7.34O CheckingTail Rotor Drive Shaft Runout 7.350 Two-PieceTail Rotor Drive Shaft 7 . 4 O O T A I L R OT ORGE A R B OX 7.41A Tail Rotor GearboxRemoval 7.42O Tail Rotor GearboxInstallation 7 . 4 3 O T a i l R o to rGe a rb o xC h i p In dicator 7.44O Tail Rotor GearboxOutput Shaft Seal Replacement 7.45O Tail Rotor Gearboxlnput shaft seal Replacement 7 . 5 O O AC T U AT ORA S S E MB L Y 7 . 5 1 O Ac t ua to rR e mo va l 7.52O Actuator Installation |

7.530 Actuator GearmotorReplacement

P a g e7 . i i

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FIIIEIIN€iC|N

MATNTENANeE MANUAL

MoEIEL p,arl

(CONt'dI ASSEMBLY 7.500 ACTUATOR 7.54O Adjustmentof Actuator 7.550 Switchand FePlacement 7.551 SwitchRePlacement 7.552 FePlacement 7.600 ROTORBRAKE 7.610 RotorBrakeRemoval 7.620 RotorBrakeInstallation 7.630 RotorBrakePadRePlacement

C h a n g e5 : 1 5 J u n 9 8

Page7.i i i

FIOBINSCIN

MATNTENANcEMANUAL

MclclELn'4e

This page intentionallyleft blank.

P a g e7 . i i i i

C h a n g e5 : 15 J u n 9 8

FIC|EIINSCIN

MATNTENANcE MANUAL

MOEIEL

FI44

sEcTloN7 DRIVETRAIN

7.000 pRlvErR+lN 7.001 Introduction and This sectioncontainsthe proceduresfor removal,installation,replacement, of the drivetrain components. maintenance (SeeFioure7-11 7.002 Description A V-beltsheaveis bolteddirectlyto the crankshaftof the engine;four doubleVclutch in its hub. beltstransmitpowerto the uppersheave, which has an overrunnin-g The clutch shdft transmits pbiver forward to the main rotor and aft to the tail rotor. Flexiblecouplingsare locatebat the input to the maingearboxand at eachend of the spiral-bevel long tail rot6r diive shaft. The main r6tor gearboxcontainsa single-stage. but bearings Thelong tail rotorshaft has no hanger gea-rset, which is splash-lubricated. a gearbox splashalso contains has a lightly-loadeddamperbearing.The tail rotor lubricateisiirat bevelgearset. Theiail rotor gearboxinput and output shafts are both made of stiinless stedl to preventcorrosion.The other shafts throughoutthe drive systemare madeof alloysteel. 7.100 MAIN ROTORGEARBOX 7.110 Main RotorGearboxRemoval al Removethe C706-1 tailconecowling, both engineside s,and the aft enginecowling. bl Removethe mast fairing per Section4.142. Removethe middleand lower mast fairingribs from the mast tube. c) Removethe mainrotor per Section9.111. dl Disconnectthe rotorbrakecablepulleyson the arm and aux tank. Removethe cablehousingclampon the aux tank channel.

l s s u e d1: 1 J u n 9 3

Page7.1

FIC|BINSiGIN

MOE'EL

MATNTENANeE MANUAL

FI44

VENTHOLE

SHAFT C251.1 I4AINROTOR

cs47.3il

c908-1YoKE

FLEXPLATE ASSETIIBLY

C947-1FLEXPLATEASSEMBLY

c907-10R-2 YoKE c156-1 -_ - CLUTCH

ASSEI{BLY C018.1CLUTCH -2,.-3 , 0R-4 c195-1 .

c02l-l I / TAIL ROTOR / eEmgoxAssEt4BLY

SHAFT

1'

D224-LTAIL R0T0RDRM SHAFri

,:lll-tx'*umt ENGINE

c493-1 SHEAVE A19O-3V.BELT

SYSTEM 7- 1 DRIVE F IGURE

Page 7.2

Change2: 12 Dec 94

MATNTENANcE MANUAL

FICIBINSiC|N

MOEIELF'44

RIBS c261-5,-6 c26l-1 MASTFAIRING ASSEMBLY

crzt-7 PUSH-PULL

rusr(2)

C121-5PUSH.PULL

ruer(r)

PUSH.PULL TUBEGUIDT( 1)

l c?6r-7,-8RIBS .

L== *-/

I 4 K RlIB b ) S1 C 2 6 1 -3- ,-4 \

-

| .\

.4+=

FIGURE7-2

Change3: 5 May 95

REMOVAL GEARBOX MAIN ROTOR

Page7.3

FICIBINSCIN

MATNTENANcE MANUAL

MC|EIELF'44

7.11Q Main RotorGearboxRemoval(cont'dl el Remove the main and auxiliary fuel tanks per Section 12.110. Mark all electricalconnectionsfor reinstallation. f) Disconnectthe iackshaft(C337-11from the forward and aft push-pulltubes and the struts. g) Removethe iackshaftstruts (seeSection8.3OOl. hl Disconnectforward flex plate from gearboxyoke and note the washer stack up on each bolt. il Disconneqtthe chip.detector,Hall Effect sender,overtempsenderleads,and a groundwire. Tag wires for reassembly. nozzle' i) Removethe gearboxleft and right coolinghosesand gearbox kl' Removethe four main rotor gearbox.mountingbolts' .Ca9!1!tVlift-tl9 7-21. Figure remove and {see tubes ijp to cieii-trriloi*iiO dush--pull that the transmissionbe hoistedusing the MT527-1 1l lt is recommended helicoPterlifting fixture. CAUTION Leveling shims may be instatledbetween-the gearbox .ounif anO ine liame mounting pads. These should rerain Jtticned or mark mounlirig pads with shim thicknessfor reinstallation. ll Removethe droopstopsand disconnectthe lower scissorsat the mast. Slide the swashplatea3semblyoff the slidertube' 7.12O MAinRotorGearboxlnstallation CAUTION PriOr to operation of a new, overhauledor repaired oeJrboi, G'ounces ot AZSZ-2gearoil must be iniected Figure7111on the lop ?tt side of int6'inJ'reni noie-tsle 'gearUo'x w1n oil to the level indicated ine riilt tuUe.Fitt The gearboxmust remainvertical ij^ tf,r iigni glais OEcal. duringand after filling.

Page 7.4

Change2: 12 Dec 94

MOEIEL

MATNTENANcE MANUAL

FICIBINSCIN

]l.44

1

K 'ji:';tili

,,N

g. ,!!{,-S-

a

10 11

10 M . R . G E A R B O XC U T AWAY FORCLARITY

"-@

FORWARD

FIGURE7-2A MAIN ROTORGEARBOXINSTALLATION NUMBER DESCRIPTION NUMBER DESCRIPTION Mount 8 Fitting 1 Shim (3 max per pad) 9 Washer 2 10 Washer 3 Brace(hydrauliccontrols) Nut 11 4 Strut Weldment 5 6 7

Ch a n g e1 4 : J U L 2 0 0 8

Spacer Washer

12 13

Spacer Shim (3 max per padl

Mount

Page7.44

r l ' , ' 1 1

FlClBINEiClN

MATNTENANcE MANUAL

MoE EL n'44

Intentionallyblank

Pa g e7 . 4 8

Change14: JU L 2OOB

FIclElINSiclN '-

O

Ml:'ElEL

]f,.44

7.120 Main Rotor GearboxInstallation(cont'd)

'

,

MAINTENANcE MANUAL

1.

LevelMRGBmountingpadsby installingoriginalshims. lf originalshimthickness is unknown, level mountingpads per Section7'130'

2.

two C796-3 spacersare the same thickness and install one C796-3 spaceron each aft mountingpad atop any shim(s).

3.

Removeforeignobjectsand prepareareafor gearboxinstallation.Assistanceis desirableto h6lp positiongearbox.PositionMRGBon mountingpads.

4.

lnstall MRGB mounting hardware per Figure 7-2A. Orient A650 fitting tabs laterallyper Figure8-9, specialtorque per Section 1.330, and torque stripe per F i gu re2 -1 .

b.

Connect forward flex plate, using previouslyrecordedshim washer positions. Standardtorque fastenersper Section 1.320.

6.

Installjackshaftstruts and jackshaft(seeSection8.300).

7.

Connectmain rotor gearboxcoolinghosesand nozzle.

8.

f n sta l lfu e l ta n ks p e r S e ctions12.130 and 12.140.

9.

Connect electricalleads to fuel tanks and main rotor gearbox. Reinstallrotor brake upper pulley and cable and connect pulley to arm. Install rotor brake cable clamp to auxiliarytank channel. Positioncable end fitting on outboard side of pulleyon aux tank.

1O. lnstallmain rotor per Section9.OOO. 1 1. Installmast fairing and connectpitot tube. 1 2 . C h e ckcl u tch sh e a vea l i g nm entper Section7.23O. O

13. Check intermediateflex plate shimmingper Section7.33O. 1 4 . l n sta l la l l co w l i n g . 7 . 1 3 0 L e ve l i n gMa i n R o to rGe a r box Level main rotor gearbox mounting pads laterallyto landinggear aft cross tube and l o n g i t u d i na l layt 3 .8 o + O.2 o a n gleto C046- 6tube ( r ef Figur e4- 2l.Use 4796- 1 s hi m s on forward pads and C796-2 shims on aft pads, maximum3 shims per pad (shimsare 0 . 0 2 0 i n c h th i ck).

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F|44

7 . 1 4 0 C 9 08 -1 Y o ke R e p l a ce me nt Yoke Removal 1. Remove clutch per section 7.210 or remove forward flex plate and let forward I end of clutch shaft rest on firewall per Figure7-8. Placea wood block between horizontalfirewall and yoke flange to preventyoke from rotating. or engagerotor brake. 2. Remove cotter pin, nut, and C1 41-10 washer from main rotor gearbox pinion shaft. 3. Slideyoke off gearboxpinionshaft. Yoke Installation yoke on O 1. Ensureyoke and gearboxsplinesare cleanand undamgged.l1sJ9il-q9o-8-1 castellated AN32O-8 and washer main roior gearbo'xpiniondnatt. InstallC141-10 nut. a _wood block between^yokg. flange and 2. yoke for torquing by placin-gaNS2O-8nut per Section1.330 and installcotter hoiiiontaffirewall. Spdciai-toriu'e pin. Removeblock. CAUTION Check Hall Effect sender-to-yokemagnet gap per Section 7.141 beforerun-upor turningblades. 3. fnstallclutch assemblyandior forward flex plate per Section7 '22O' 7.141 SettingHaltEffectSenderGap lf Hall Effect Sendergap is not O.O30 t O.O1Oinch, loosenjam nuts on senderand iOiuii gtp. Ch""k gads betweenboth yoke magnetsat both senders' of Main RotorGearboxPinionSeal(seeFigure7-2B) 7.1b0 Replacement plate a. Disconnect Ag47-Z intermediateflex plate at tail rotor drive shaft. Mark flex and fastenerswith a greasepencilfor reinstallation. b. DisconnectC947-1 forward flex plate. pinion shaft c. Rest forward end of clutch on firewall. Removethe C9O8-1yoke from per Section7.140. d. Cut safety wire and removerotor brakeassemblyper Section7.61O. e. RemoveHall Effect senderbracketand gearboxovertempsenderbracket. f. Carefullyslidepinionbearingend coveroff pinionshaft.

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F|GIBINSGIN

2

45

SENDER OVERTEMP \

I

L-q-

MC)EIELF|44

\

I

il

l-il

o BRAKE ROTOR ASSEMBLY HALLEFFECT SENDER ASSEMBLY NUMBER

o

1 2 3 4 5 6 7 B 9 10

NO. PART

DESCRIPTION

c2t5-029 c266-l c966-3 c215-156 cl17 cz70-t c908-1 c14r-10 AN32O.B MSz5665-210

''0"-RING SPACER SEAL ,' O' ' - RING SHIM ENDCOVER YOKEASSEMBLY l\lASHER NUT PIN COTTER

FIGURE 7.28 MAINROTOR GEARBOX PINIONSEALREPLACEMENT

Change5: 15 Jun 98

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MlfElELF|44

CAUTION Do not removeshimsunderpinionbearingendcoveras they controlbearingpreloadand gearbacklash' g.

presssealout of bearingend coverand pressin new seal until it seats. NOTE Openface of sealmust pointtoward gearbox'

h.

i. i.

anOO Installbearingendcoverover pinionshaft.PlaceHallEffectsenderbracket per Section assembly rotor brake install and cbver on Uiaitlt overrempseiOei 7.620. Torquescrewsper Section1.330 and safetywith 0.032 inch diametersafety wire. CheckHall Effectsendergap per Section7 '141'

Procedure 7.155 MRGBSumpO-RingReplacement a. RemoveMRGBPerSection7.110. b . Checkandrecordgearbacklashat andtangentialto a geartooth, accessible

via sightgageor fillerPlughole.

and shimstackc . Carefullynoteand recordposition.ofeachfastener,washer (an of

;i iii CZeC-frirp-t*d ZA+-thousingattachpoints equalamount at eachattachpoint).Alsonote "; Jfiirr-ii i*t.lf"O Uetweensumpandhous-ing iocationof grounl *ii"i ano iz+l-t baffldattachpoints.Remove,identify washersand shims' and retainf-asteners,

d. e. f.

Removesumpand o-ring. prelubricatenew c215-279 o-ring with A257-2 0it and installon sump. Ensureo-ringis not twisted in sumpgroove' secure CarefullyassembleSump,baffleand groundwires,to-housing.anq same the in exactly *itn tist"neiC,wasnersan-6shimsinstalled tinger:iigl-,i poiitions recordedin stePc.

positionthose shims usedon NAs1352 series g . Priorto torquingfasteners,'against from prevent € 26!- t housing to i rnt"rnl r-*rt'""fii,igi il;ft int6iteringwith boii threadsand deforming'

h.

Page7.8

shims

1'33O TorqueboltsperSection 1.32O.TorqueNAS1352screwsperSection and safetywire PerMS3354O.

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(cont'dl Procedure 7.155 MRGBSumpO-RingReplacement i)' Checkgearbacklashex-actlyas performedin step bl. Backlashshould be wittiin 0.001 inch of valuerecordedin step bl' il InstallMRGBper Section7.12O 7.160 Main RotorGearboxOvertemplnsoection lf the gearboxovertempwarninglight illuminatesor the orangetemperature be removed the gear.b-ox.must abnormaldperatingtemperatures, OecaiinO'i'cites for inspection facility inOieiurned to an approviORoUiisonHelicopteroverhaul and overhaul. NOTE Light illuminates at 240r 50F.

temperature of

7.170 Main RotorGearboxChio Lightlndicator lf the gearboxchip light illuminates,use the following procedureto drainthe gearboxand inspectthe lubricantand chip detector. a) Removemain rotor gearboxchip detectorby disconnectingthe electrical wire, cutting safety-wire, and' unscrewingthe. chip detector from its housing.(HoIOthe lbrgerhex while unscrewingthe smallerhex.) bl Use MTO53main rotor gearboxdrainfitting to drainth-egearboxoil. The fitting is pushedup into-thechip detectorhousingas.far as ,it will g.o..A smali-wedgeis pla'cedunderthe drainfitting to keepit in place.Drainthe oil into a bban container(it may be strainedat this time-a paint filter works welll for furtherexamination. cl Strain the oil and inspectany particlesfound in the oil or on the chip detector.Examinethe paniclesfor size and performfollowingappropriate correctiveaction: 1 . For tuzz particles: Clean chip detector with compressedair. or

not use magnetland reinstall. Normalwear, especially toothbrush-(do new gearboxes,will producefine tuzz.

2 . For flakeparticlesor sliverslongerthan0.12 inch or wider than O.O2 inch: Clein chipdetector.Drainand flushgearboxper Section1.120.

3 . For largeferrouschipsor chunkyparticles:Removegearboxand return for overhaul.

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7.170 Main RotorGearboxChipLightlndicator(cont'd) d) lf, after performingcorrectiveaction, th_enext 25 hours ggarboxtime-infailure may be s6rvice iroduces more particles, a main -rotor g_e_.arbox possible, include Where re^quired. is gearboi overhaul imminentand a particleswhen refurninggearboxto RHC. e) Flushmainrotor gearboxper Section1.12O. 7.180 Lubricationof Main RotorGearbox See Section1.120 tor Lubrication. 7.2OO CLUTCHASSEMBLY 7.21O ClutchAssemblyRemoval l. FanwheelRemovalMethod a) Removeengineaft cowlingand tailconecowling. b) RemoveC723-Gplatefromto the C723bulkheadby removingfourscrews. flex platefrom C195 yoke. cl DisconnectA947-Zintermediate NOTE Recordshim locationsof forward and intermediateflex plateinstallations for reassembly. dl forwardend of clutch shaft with suitablewooden block. e) DisconnectC9O7yoke from C947-1 flex plate. f)

Mark forward-to-aftorderof drive belts for reinstallation.

g) Removeactuatorper Section7.51O. NOTE The aft end of clutch shaft must be ed. Use a wood blockto preventdamage. h) Removethe drive beltsfrom uppersheaveon clutch. i)

Removeclutch per Figure7-3. lf returningclutch to RHC, removeboth yokes and lateralcenteringstrut to preventdamage.

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MATNTENANcE MANUAL

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CROSSBAR

I AFT ANDUNDER ASSEMBLY MOVECLUTCH FRAME CROSSBAR.UPPER

--_)

--F

I

(\

:::B-/ UP AND F0RI^IARD ASSEMBLY 2 . MOVECLUTCH CROSSBAR. FRAME UPPER OVER

-_) I

- --tr -:)_:-/ { \

w

FROM ASSEMBLY CLUTCH REI1OVE AF BY LOW ERIN GT HELICOPTER OF UPPER REARSECTION THROUGII TAIL BTLOI,J ANDDOWN FRAME CONE.

REMOVAL FIGURE7-3 CLUTCI-I Page7.",O

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MATNTENANcE MANUAL

FIGURE 7-3A ASSEMBLY OF C184.2BEARING REMOVAL ANDI'1T528-1 PRESS USINGHYDRAULIC TOOLS. REMOVAL

ALUMINUM PLATE

cL84-2 BEARING ASSEI4BLY ti{T528-1 BEARING REMOVAL TOOL I'tt529-4 scREbf

MT529-5 PLUG

MT528-2 BEARING REMOVAL TOOL

MT528-4 UPPER PULLER ASSEMBLY

FIGURE 7-38 REMOVAL OF Cl84-2 BEARING hlHENHYDRAULIC ASSEMBLY IS NOTAVAILABLE; PRESS USEMT528-1ANDMT528-2 TOOLS. REMOVAL

Change6: 18 MAR99

c184-2 BEARING ASSEMBLV MT528-1 BEARING REMOVAL TOOL

MT528-11 SPACER (Oneper . cap screw,

Page7.11

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MATNTENANeE MANUAL

MOE ELH'44

RETAINER

srnr_+$ 7.3C FIGURE

ASSEMBLY C184 BEARING

PLUG \

OIL LEVEL ..)

BEARING OIL -/ TRANSFER BEARING

P a g e7 . 1 2

7- 3D FIGURE

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MAINTENANeE MANUAL

7- 3E FIGURE OF C184-2BEARING INSTALLATION PRESSANDMT528-1 USINGHYDRAULIC TOOLS. INSTALLATION

WARNING SHEAVEOR DONOTPRESSACROSS E,ENTIFES WILL BE DAMAGED.

FIGURE

MTsze-4L SCREt.|

ASSEMBLY INSTALL CL84-2BEARING A}IAY bIITHNUTSFACING ONTO SHAFT CLUTCH. FROM

MT529-6TUBEASSEMELY 0 . 3 1 2 "D I Ax 1 . 5 0 " DOWEL PIN (z Req'd)

c184-2 BEARING ASSEMBLY

FIGURE 7-3G

c018-2 CLUTCH ASSEMBLY

INSTALLATION OF C184-2BEARING PRESSIS UNAVAILtdHENHYDRAULIC ABLE;USEI'tT528-1AND Ptt528-2 TOOLS. INSTALLATION

Change4: 1 Jun 97

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MoE ELn'44

nemova Z.ZJlt CtutcnnssemOry ll. TailconeRemovalMethod a) Removetailconeper Section4.311. bl RemoveC723-6platefrom C723 bulkheadby removingfour screws. c) Adjustactuatordown limit stop screwand disengageactuatorso beltsare as looseas possible. dl DisconnectA947-2intermediateflex platefrom Cl95 yoke. NOTE Recordshim locationsof forward and intermediateflex plateinstallations for reassembly. el forward end of clutch shaft with suitablewoodenblock. f)

DisconnectC9O7yoke from C947'1 flex plate'

g) Mark forward-to-aftorderof drive beltsfor reinstallation. h) Disconnectclutch lateratcenteringstrut from upperframe. i)

DisconnectCl84 bearingassemblyfrom actuator.

Beginningwith forward-mostdrive bett, maneuverbelts off uppersheave towards C907 yoke. k) Removeclutch assemblydirectlyaft towardstailconeattach points. O

il

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MATNTENANeE MANUAL

MOE EL ]l'4'4

7.211 Cl84 BearinoAssemblyRemoval a. Removeclutchassemblyper Section7,21O, b. RemoveC195yoke per Section7.270.

,

,

c. RemoveCl91-5 stops. d. Removebearingassemblyas follows: Usinga hydraulicoress: 1. lnstallMT528-1bearingremovaltool per Figure7-3A. 2. MT528-1bearingremovaltool on hydrauliressper Figure73A. platebetweenclutchshaftand pressram per Figure73. Installaluminum protect of shaft. end 3A to 4. Pressuntil Cl8$2 bearingis removedfrom the shaft. CAUTION Hold clutch assemblYto Prevent clutchfrom fallingto the floor. Withouta hvdrauliress: 1. InstallMT528-1and MT528-2bearingremovaltools per Figure7-38. Useonly one MT528-11spacerat eachcap screw. EnsureMT529-4 screwthreadsare coatedwith anti-seize. 2. Removebearingassemblyby holdinghandleand tighteningscrew.

Change6: 18 MAR99

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7 . 2 1 2 C1 8 4 B e a ri n gA sse mb l vlnstallation a. Removeloose paint and clean mating area on clutch shaft. lf reusinga bearing assembly,inspectconditionof sealsand inner races' b. Heat Cl84 bearingassemblyto 20OoF maximum(approximately5 minutes in ZOO;f'oven).Mon-itorbearingtemperaturewith a pyrometeror a telatemp. €p,oxyprimer. c. Coat bearingshoulderon clutch shaft with zinc-chromate.or shaft: clutch on assembly Whit" primei is still wet, installbearing NOTE Be sure to put side of C184 bearingassemblywith nuts facing away from clutch (seeFigure7-3F)' Usi@c|utchassemb|yatforwardendofc|utch ffibeiisemb|yonc|utchshaftperFigure7-3E.Center over inner race of beiring assembly.Pressbearingassemblyuntil . iub" "5"mbly tube asiembly bottoms on en-dof clutch shaft (bearingassemblyshould MTs29-6 be at dimensionshown in Figure7-3D). CAUTION clutch NOT Do assembly at sheave or internal bearingswill be damaged. @UseMT529-6tubeassembly(inc|udedinMT528-1too| seiffietasshowninFigure7-3G.Centertubeassemb|yover innbt race of c184 bearingassembly' Tightennut onto MT529-4 screw (coat nut face and screw with anti-5eize)untii Mt5Z9-6 tube assemblybottoms on end of ciutch shaft (bearingassemblyshouldbe at dimensionshown in Figure7-3D). e. Removebearingpresstooling. f. Check bearingfor smooth rotation. g. Seal bearinginner race-to-shaftjuncturewith primerto minimizecorrosion' h. Torque stripe inner race of bearingto clutch shaft two places,18Ooapart. i . I n s ta l lC 1 9 1 -5 sto p s. T o rq uebolts per Section1.130 and tor questr ipe. j.

I n s ta l ln e w te l a te mpo n C 184 bear inghousingif or iginalwas alter edby heati ng.

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MATNTENANcE

MANUAL

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(reference Figures7-3C& 7-3D) 7.213 ClutchAssemblvSealReplacement NOTE To facilitatefuture spragclutch lubricantservicing,olderclutch assembliesmay be upgradedby replacingearly retainerswith t w o C l 6 8 -5 a n d tw o 8 289- 3 scr ews. 1 . R e m o vecl u tch a sse mb l yp er Section7.2lO. 2 . l f r e p fa ci n ga ft se a l , re move C184 bear ingassemblyper Section 7.21 1. replacingforward seal, removeC9O7yoke.

lt

3 . Removeany loose paint on shaft and thoroughlycleanclutch assembly. 4 . With clutch assembly positionedvertically with appropriateseal up, remove

twelve bolts, nuts, & attendantwasherssecuringC168 retainers. Removetwo socket-headcap screws from retainerand removeretainerand underlyingO-ring. D i s c a rdO-ri n g . CAUTION Clutch assemblieswith internal,tapered roller bearingsutilize bearingpreloadshimsunderretainers;do NOT loseshimswhen removinqretainer{s). NOTE A p p ro xi ma te l y4 fl u i d ounces ( 118 ml) of lubr icantwill dr ain from clutch in following step. Retaindrainedfluid in a suitable, clean container.

5. Positionclutch assemblyhorizontaland rotate clutch shaft so yoke attach holes are vertical. Allow lubricantto drain into container. NOTE Oil transfer holes in clutch sh6ft are parallelwith yoke attach holes. Positioningshaft horizontallywith yoke attach holes verticalallows lubiicantto drainfrom shaft interior. 6. Strain lubricantthru a new paint filter and over a clean magnet. Examinefilter inO magnetfor metallicdebris. lf metallicdebrisis noted,removeclutch assembly

from service. 7 . Presssealout of retainerfrom outsidetowardsinside.Cleanretainerbore. 8 . Pressnew sealflat face down into retaineruntil it seatsagainstretainerlip.

P '!g e7 . 1 6

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MAtNTENAnlcF MANUAL

7.213 Clutch AssemblySeal Replacement(cont'd) 9.

lf replacing aft seal proceed to next step. lf replacing forward seaL lightly lubribaten-ewO-ringand seal inner lip with A257-4lubricant. Install.O-ringin clutch housinggroove and slide retainerover clutch shaft forward end. Ensure any shims are properlypositionedatop bearingouter race. Positionretainer so two smallerholesare aiignedwith tapped holesin spragclutch housing,install both socket-headcap screws, and hand tighten screws sufficient to clamp retainerto O-ring.

1O. Positionclutch assemblyvertical with short end of shaft pointing up. lf not previouslyaccomplished,removetwo socket-headcap sqqw.s from aft retainer bnd lift retainer. Fill sprag and bearingcavity with A257-4 oil until oil level is flush with top of bearingraces per Figure 7-3D. Ensureclutch assembly remainsverticaluntil aft retaineris tightened. NOTE Rotate sheave while filling to ensurecompletefilling of shaft interior. Due to shaft internalplug locationit is necessaryto fill shaft from aft side. 1 1 . ff repfacingaft seal, lightly lubricatenew O-ringand seal inner lip with A257-4 lubricant. Ensureany shims are properlypositionedatop bearingouter race. Install O-ring in clutch housinggrbove and slide retainerover clutch shaft aft end.

1 2 . lf two C168-5 retainersare installed,ensureself-sealingscrewsare on opposite sidesof clutch shaft. Positionaft retainerso two smallerholesare alignedwith tapped holesin sprag clutch housing,installboth socket-headcap screws, and hand tighten screws sufficientto clamp retainerto O-ring.

1 3 . Installtwelve bolts with washersthru retainerswith bolt headstowards short side of clutch shaft. Using a criss-crosspattern, standardtorque bolts per S e cti o n1 .3 2 Oa n d to rq u estr ipeper Figur e2- 1.

14. Fully tighten by hand all socket-headcap screws and torque stripe per Figure 2-1. 1 5 . f f r e mo ve d ,i n sta l lC 1 8 4 bear ingassem blyper Section7.212. 1 6 . Installforward C9O7yoke andlor aft C195 yoke. Standardtorque attach bolts per Section 1 .320, installpalnuts,and torque stripe per Figure2.1. 1 7 . As required,installclutch assemblyper Section7.22O

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MOE EL ]t44

7.220 Clutch Assemblylnstallation A. With fanwheel removed: 1. Be sure actuatoris fully disengaged. 2. Install clutch assemblyinto ship (ref Figure7-3) and pull belts over clutch aft yoke. Reinstallbelts in their properorder on sheave.TemporarilY clutch shaft aft end.

CAUTION Drivebeltsmust be installedboth in properfore-aftorderand in directionof rotation.

to forwardflex plateper Figure7-4. Standardtorquehardware 3. ConnectC9O7^Voke I p e r Se cti o n1 .3 2 0 . 4. fnstall actuator assembly per section 7.52O. Remove clutch shaft temporary . 5 . I n s t a l lfa n w h e e lp e r S e cti o n6.220. 6. Check clutch sheavealignmentper Section7 '23O' 7. Installintermediateflex plate per Section7'330' 8. fnstall C723-6 plate on C723 bulkhead' 9. Installuppertailconecowling and engineaft cowling'

B . With tailconeremoved: belts 1. Ensure actuator is fully disengagedand positionedfar right- Lift drive points' attach tailbone frame upper thru and insert clutch assembly forward Temporarily forward end of clutch'dfrat with suitable non-scratching block or cushion. per 2. Attach c184 bearingassemblyto actuator per Figure 7-14. Torque bolt S e c t i o n1 . 3 2 O . 3. Startingwith aft-mostdrivebelt,maneuverdrivebeltsonto uppersheave,ensuring correct forward-to-aftsequence. per Section 4. Connect clutch lateral centering strut to upper frame. Torque 1.320. Remove 5. ConnectC9O7yoke to forward flex plate and torque per section 1.32O' clutch shaft temPorary. t er Section7 ' 23O' 6 . C h e cksh e a vea l i g n me n p 7. Install C723-6 plate on C723 bulkhead. andshi m m i ng flex plateinstallation g . I n s t a l l ta i l co npee rS e cti o n4.312. lnter m ediate c h e ck p e r S e ci i o n7 .3 3 0 i s r equir ed. P a g e7 . 1 8

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lssued:11 Jun 93

Page7.19

FICIBINSCIN

NUMBER 1 2 3 4 5 6 7 I 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

MATNTENANcE MANUAL

PARTNUMBER 8330-19 MS21042L6 AN960-6161 c908-1 NAS660+4 or -5 (as requiredfor threadengagement) c947-1 NAS6606-5or -6 (as requiredfor threadengagement) NAS6606-31 cl91-1 C907-1or -2

co18-2 c553-1 D224-1 8330-16 AN960-416 c184-2 8330-13 MS21042L4 AN960-4161 C195-1,-2,-3or -4 A947-2 NAS6605-24 AN960-5161 c191-6 MS21042L5 Noneor AN96O-6161 maximum

MOEIEL F,44

DESCRIPTION Palnut Nut Washer Yoke Bolt Flex Plate Bolt Bolt Block Yoke Clutch Assembly Block Tail Rotor DriveShaft Palnut Washer BearingAssembly Palnut Nut Washer Yoke Flex Plate Bolt Washer Block Nut Washer{seeSection7.230)

27

AN960-4161minimumor AN960-416maximum

Washer(seeSection7.3301

28

Noneor AN960-416Lor AN960-416maximum

Washer(seeSection7.330)

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a

(

I

F ORWARD

I

3.90/4.10 INCHES RODEND CENTER.TOCENTER

Change4: 1 Jun 97

t\ -l \

7- 4 FORWARD ANDINTERMEDIATE FIGURE FLEXPLATEINSTALLATION

\ CLUTCH LATERAL CENTERING STRUT

Page7.21

FIClBINSiclN

MATNTENANcE ntuANUAL

MOEIEL F,44

BAR ALIGNM ENT SHEAVE F IGU R7E.5 M T331.4

ASSEMBLY CO1B-2CLUTCH STANDARD UPPER SHEAVE ANODIZED t,'|ITH 0 . 1 3 0i n c h 0 . 0 7 0i n c h and 0.010-0.030 inchlarger t h a nr i g h t s i d eg a p

ASSEMBLY C018.3CLUTCH OPTIONAL SHEAVE UPPER W ITHM ETALIZED 0 . 1 1 0i n c h 0 . 0 5 0i n c h and 0.010-0.030 inch larger than right side gap

0 . 0 9 0i n c h 0 . 0 3 0i n c h

HORIZONTAL INE CENTERL OF UPPERSHEAVE

MEASURE AT HORIZONTAL OF CENTERLINE SHEAVE UPPER

UPPER METALIZED HASROUGH SHEAVE TO FACES SIMILAR LOI.IER SHEAVE

RIGHT VIEWFROM SIDE

Fh,D LOOKING VIEt^J BARPOSITION ALIGNMENT SHEAVE (Determi ne upper sheavetYPe.and i dim ensions) use aPPr oPrate DIMENSIONS ALIGNM ENT SHEAVE F IGU R7.6 E

P a g e7 . 2 2

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MAINTENANcE wtAtuUAL

MCfEIEL n44

7.230 Clutch SheaveAlignment Checkingsheavealignment: 1 . E n g a g ecl u tch . 2. Hold MT391-4 SheaveAlignmentBar again,staft face of lower sheaveextending bar upward to horizontalcenter lind of uppersheave' 3. Measureleft and right gaps per Figure7-6. Both gaps must be within noted limits Adjust lateralclutch inch largerthan right g_ap, and left gap must ULO.OtO/O.O3O centeringper Section7.25O if left gap is not 0.010/0.030 inch largerthan right gap. lf eithergap exceedsmaximumlimitthen uppersheaveis too far forward and must be move? aft by shimmingforward flex plate and/or adjustingC9O7 yoke lenqt_h. Shimming is accomplishedby installinga maximum of one NAS1149FO632P washer bltween C947-1 flex plate and both arms of C9O7 and/or C9O8 yoke; NASl 149F0632Pwashersinstalledon eitheryoke will decreaseright and left gap an amount equalto washerthickness.EachC9O7yoke has two sets of mounting holes which changethe effectiveyoke length by 0.120 inch. The C9O7-2yoke i s e i th e r O.1 2 0 i n ch o r O.2 4Oinch longerthan the long positionof the C 9O7- 1 y o k e. R i g h ta n d l e ft g a p s w i ll both decr easeby O.120 inch with each 0.120 i nc h increasein C9O7yoke length. lf either gap is smallerthan minimum limit then upper sheaveis too far aft and must be hoved forward by removingshims (if installed)at forward flex plate and/or adjustingC9O7 yoke length. RemovingNAS1149fO632P washers from between C947-1flex plateand both armsof C9O7and/orC908 yoke will increase both gaps an amount equalto washerthickness.Each C907 yoke has two sets of mounting hotes which change the effective yoke length by O:120 inch. The C9OT-1yokl is eitherO.120 inChor O.24Oinch shorterthan the short positionof t h e C9 O7 -2yo ke . R i g h ta n d left gaps will both incr easeby 0.120 inch with eac h 0 . 1 2 0 i n ch d e cre a sei n C 9 07 yoke length. 4. Check intermediateflex plate shimmingper Section7.330 if shims were added or removedat C947-1 flex plate or if C907 yoke length was altered. 7.240 Clutch Shaft Angle No check of the clutch shaft angle is required. 7.250 LateralClutch Centering 1 . C l u tcha ctu a to rmu st b e fu lly engaged. t n left and r ight side per Figur e7- 6. 2 . C h e cksh e a vea l i g n me n o

Ch a n g e1 4 : J U L 2 0 0 8

Page7.23

HEIBINE|GIN

MAINTENANcE

MOE EL F,44

MANUAL

7.250 LateralClutch Centering(cont'd) 3 . L e f t s i d e g a p mu st b e 0 .0 1 0 inch to 0.030 inch lar ger thanr ight sidegap. I

4. Cfutch laterat centering strut (see Figure 7-4ll maV be adjusted within limits to improve centering meaiurement. Lengthenthe strut to decreasethe left g.apand increasethe righf gap; shortenstrut tb increaseleft gap anddecrea.seright.gap. Strut limits ard4.iOig.gO inchesrod end center-to-center.Check both rod end witness holes after any strut adjustment' Robinson 5. lf alignmentcannot be adjustedwithin requiredmeasurements, HelicbpterCompanyTechnicalDepartment. 6. Standardtorque attach bolts and jam nuts per Section 1.32O. -lnstall palnuts, standardtorqire per Section 1 .320, and torque stripe per Figure2-1. 7.26O C9O7Yoke Removaland lnstallation To removeyoke: a. Removethe clutch assemblyper Section7.21O. b. Removebolts and clampingbtockssecuringC9O7yoke to clutch shaft. Mark which set of yoke attachmentholes are used. c . R e mo veC 9 O7yo ke : 1. (Preferredmethod).lf press is available,positionclutch assemblyin press per Figure7-7. Ensuie brass or aluminumdrift fits against outer rim of clutch shaft and not againstinner spacer. Pressclutch shaft out of yoke. CAUTION Ensureclutch assemblydoes not fall whe@ tightly secureCgqZ yo[g armsto MT3O3-6handle 'Relerio 2. lt apressis not available, Figure7-7A: Clamp handle.ina vise and botts. ;"irig f..tASOOOO i*iri clutch sfri{ oui of yoke by trlrningupper sheave. Apply penetrating remove oil to yoke-shaftjuncture-asrequired..lf difficulty is enc.ountered, preceding step' handleand arranle to use a pre-ssas describedin CAUTION Avoid bendingloadson clutch shaft when handleis clampedin vi se a s C 9 O7yo ke ca n be dam aged. To installyoke: a . Re mo vel o o seP a i n ta n d cleanm atingar eaon shaft.

P a g e7 . 2 4

Change14: JUL 2008

o

FICIE|INEiCIN

MATNTENANeE MANUAL

MoE!ELH'44

C9O7YOKELENGTH

FIGURE 7-7 REMOVAL C9O7YOKE EDGE RADIUSED

CLUTCH SHAFT

FIGURE 7-74 C9O7YOKEREMOVAL

MT3O3-6HANDLE

Change6: 18 MAR99

Page7.25

FICIBINSCIN

MAIN?ENANeE

MOEIELF'44

MANUAL

7.260 C9O7Yoke Removaland lnstallation(cont'dl b.

Coatinsideof C9O7yokeand matingportionof clutchshaft with zinc-chromate or epoxyprimer. Wtiiteprimeris still wet, installygk-eon clutch shaftand align maricednbns on yoke (ii applicablelwith clutchshaft holes.

c.

an_d_b_olts. to shaftwith clamping^blocks Secureyoke .Torqueboltsper Section 'lnstall and per 1.33O, torquestripe. palnuts,torque Section 1.32O.

7.27O Cl95 YokeRemovaland lnstallation To removeyoke: NOTE Yoke may be removedwithout clutch removal' a.

flexplate. Removeintermediate

b.

Removeboltsand ctampingblockssecuringC195 yoketo clutchshaft'

c.

Twist yoke out of clutch shaft.

To installyoke: a.

Removetoosepaintand cleanmatingareainsideshaft.

b.

or epoxy Coatinsideof clutchshaftandshankof C195yokewith Zinc-chromate holes. and align yoke shaft into clutch primer.-Wt ite primeris stillwet, slide

c.

Installclampingblocksand bolts. Torquebolts.per Section1.32O. Install palnuts,toriudper Section1.330,and torquestripe'

d.

flexplateper Section7.33O. Installintermediate CAUTION Theremustbe oneAN960-416Lor oneAN960-416washer uetweeneacharmof c195 yokeand4947-2flex plate.see Section7.330.

Page7.26

Change6: 18 MAR 99

FIC|BINEiC|N

MATNTENANeE MANUAL

MIJEIELF44

7.28O V-Belts 7.281 V-Belt Removal al Removetailconecgwling. , b) Lower clutch actuatorto its fully disengagedposition. c) Mark the back of each belt with a felt pen. Use numbersor a v-mark to indicatedirectionand orderso they will be in the samepositionsif they are to be reinstalled.Mark the directionof rotation on each belt so that they cannot be reversed. dl Mark and disconnectthe intermediateflex plate from clutch. Disconnect the centeringstrut from clutch to upperframe at frame end. e) Removefan and scroll per Section6.20O. fl

Removeactuatorassemblyper section 7.510.

gl Removebelts from sheave. CAUTION Usedbelts must be reinstalledin properorderdue to individualdifferencesin belt stretch. 7.282 V-Belt Installation WARNING Install V-belts only in matchedsets. Do Not install used V-beltsfrom anotherhelicopter. a) Beforeinstallationof new belts, inspectthe sheavegrooves.Replaceany sheaveshowing corrosion,pitting or flaking of the metalizedor anodized coatings,wear throughthe anodizedcoating,roughness,or sharpridges. CAUTION Roughor corrodedgrooves in the upper or lower sheavecan causeV-beltsto roll, break,or come off. Referalso to Section2.160.

Change2: 12 Dec 94

Page7.27

I

MI]EIEL

MATNTENANeE MANUAL

FIOBINSON

______Jt%%o*

i"'

i I

HORIZONTAL

|

,,FIRtWRtt r.,

F,44

t-

---l \

t

1,,r,""'' t"'-- \ttt:---M P ----

I cosl AcTUATOR

-I -----,"Y'!-

?='=rt 7 t,

/'

OF ROTATION DIRECTION I

BELT0RIENTATI0N

I I

i,

MARKs

\L_,t^-,_ \

.

___r

o

I I

I

-,--

L__

FIGURE7-8

Page7.28

--

D AREMARKE BELTSSHOt^lN FORREINSTALLATION

REMOVAL V-BELTANDACTUATOR

Change2: 12 Dec 94

FIC|EIINEiCIN

MAINTENANcE

MANUAL

MOEIELF'44

7.282 V-Belt Installation(cont'd) b) paint the.groovesin the lower sheavewith a thin coatingof zinc chromateor epoxy primer Per Section 1.400. c) Installbeltson sheaves.lf used beltsare reinstalled,inspectthem for damage p"r-S""tio1,2.15C,;Make sure they arein their proper order with respectto iorelatt position and proper directionof rotation. d) Installthe actuatorassemblyper Section7.52O. e) Connectthe intermediateflex plate to the clutch' f)

Installfan and scroll per Section6.2O0.

g) Check clutch sheavealignmentper SectionT-23O. h) Shim and connect intermediateflex plate per Section 7.330. i) Adjust the actuator'sdown-limitstop screw so when the actuatoris engaged Gi"V of less thbn 5 seconds before rotor starts tuinihg. at start ,p iftiiJi. " NOTE

I

First adjustments of the actuator down limit screw, to with regulatenew belt disengageslack,occur relativ.ely.soon longer periodsbetween later adjustments.Recheck. A delaybetweenclutch switch engagementand the rotor startingto turn of more enginewith than 5 secondsindicatesexcessiveslic[. lf rotor rotateswhen cran-king starter motor, belts may not have enough slack. CAUTION During start up and engagement,belts too tight can damage flex plates anil belts too loose can iump out of grooves. j)

Ground run or hover the helicopterfor at least 20 minuteis.

k) At the end of the ground run, inspect the sheavegrooves for the pattern in the primer.A similar pattern in all eig.htgroovesindicates combinationis compatible. A noticeablydifferent the belt/sheav-e pattern from groove to groove indicatesthe combination is not compatible. l)

lf the belt/sheavecombinationis not compatible,re-checksheavealignment, replacebelts, and repeat installationprocedure. lf belt/sheavecombination is'stillnot compatibld,it may be necessaryto replacethe lower sheave.The wear patternin all eight groovesmust be similarbeforethe aircraftis released fo r fl i g h t.

Ch a n g e7 : O 6 D e c 9 9

P a g e7 . 2 9

I

FICIBINSCIN

MATNTENANcEMANUAL

M(fElELF'44

7.283 Belt Tension No procedurefor checkingbelt tensionon the helicopteris rqQuirecl. 7.290 COOTFanshaftand BearingAssembly.StarterRingGear. Lower Sheaveand AlternatorBelt Replacement. 7.291 Removal al

RemoveV-beltsper Section7.281.

b)

Cut the safety wire and removethe six NAS6608 bolts holdingthe fanshaft.

c)

Temporarily Remove the COOTfanshaft and bearing assem.bly.. securethe lower sheavewith one of the removedbolts if it is not to be removed.

d)

To remove the lower sheave,the use of a soft mallet may be requiredto tap the sheavewhile pullingit off.

el

Removalof the starter ring gear is. requiredto change alternatorbelt or gain accesstb the nosesectionof the engine. 1) Loosenthe alternatorbelt tension. 2) Note the zero mark on the starter ring gear supp-ortat one propellerflangebushing.Markthis bushingto easereinstallation. 3) Removethe starterring gear.

7.292 Installation

Page7.30

a)

lnstall a new alternatorbelt at this time if required. Reinstallthe startet ring gear .Align the zero mark on the ring gear ;rpport witn-tne markeObush'ing.The bushingand matchinghole ard btlgntlylargerthan the five other holes.This makesthe incorrect instaltition of- the starter ring gear difficult but not impossible.

b)

lnstallthe lower sheaveand fanshaftassembly.Checkthat two bolt. AfrfgeO-416washersare installedundereach NAS66O8-42H lower the between for clearance Check bolts. Lightly inug the and starter ring gear 's conical surface. Insert a sh-eav'e feelergauge-af6 placbi betweenthe attachmentbolts. O.OOS-inch the wrong starter ring.gear. is Lack of clearance-indicates Torque installecl. gear installedor that the ring 'staris improper.ly a.circular by pattdrn tqtlgy."q in6-ootG pei seiiion tl3--30in i i."itetn. dalety wire the bolts in pairs with 0.041 inch diameter stainlesssteel safety wire.

Change4: 1 J un 97

MATNTENANeE MANUAL

FICIBINSC|N

)

MOEIEL F,44

CAUTION

Rilinstallingthe bolts with less than two AN960-816 washers liay cause the bolt shank to bottom on the enginepropeilerflangebushing.This conditionwould not cla-mpthe lower sheaveand fanshaftassemblysecurelyto the engineflange.

cl

Tensionthe alternatorbelt at the pulleynut at this time. The slip torque at the pulleynut for a new belt is 11-13 ft-lb; for a usedbelt, the slip torque is 7-9 ft-lb.

dl

ReinstallV-belts per Section7.282.

O ,.r* ,o,' ^oro*o*u,,"ort 7.31O Tail RotorDriveShaft Removal al Removethe tailconeper Section4.311. bl Use a 3-foot socket extensionwith a 3/8-inch socket to disconnectthe two NAS66O3 bolts which hold the drive shaft damper arm to its mounting bracket. the c947-3 aft flex cl using the upper aft tailcone inspectionhole, disco_nnect plate from t-ailrotor gearboxinput shaft flange. the aft end of the drive shaft so it cannbt fall and damagethe drive shaft or tailcone. dl The drive shaft can now be pulledout of the forward end of the tailcone 7.320 Tail RotorDriveShaft lnstallation al Inserttail rotor drive shaft into tailcone. NOTE lf aft flex plate was disconnectedfrom tail rotor gearbox and removed,first connectflex plateto the driveshaft and then insert the drive shaft into tailcone. Torque the NAS6604bolts per Section1.32O. b) drive shaft through upper aft tailcone inspectionhole to prevent damageand for alignmentpurposes. cl Usingthe upperaft tailconeinspectionhole,connectthe C947-3 qft-fl_e1 Plale one AN960-416L to gearboxwitn the bolt headsagainstthe flex plate. U_s_e washerunderthe bolt head. Torqueto per Section1.320.

Change2: 12 Dec 94

Page7.31

MATNTENANcE MANUAL

FICIBINSiCIN

MoEIEL F|44

F O RWA R D

7-9 AFT FLEXPLATEINSTALLATION FIGURE NUMBER. PARTNO.

P a g e7 . 3 2

1 ?

8 3 3 0 ,13 NAS679A4

3 4 5 6 7 I

AN960-4161 c947-3 NAS6604-7 c021-1 NAS6604-4 D224-t

DESCRIPTION PALNUT NUT ldASHER FLEXPLATE(AFT) BOLT GEARBOX TAIL ROTOR BOLT ASSEMBLY DRIVESHAFT TAIL ROTOR

l s s u e d1: 1 J u n 9 3

FICIE|INE|GIN

MATNTENANcE MANUAL

M(JE EL F.44

(cont'dl 7.320 Tail RotorDriveShaftInstallation CAUTION lmproperinstallation of flex platecan damagetail rotor drive shdftand gearbox.

, dl

Throughinspection ho.les on sideof tailcone,determine longitudinal alignment of damper arm with tailcone attachmentbracket. lf clearanceor int-erference between arm and bracket is greaterrthan 0.12 inches, Robinson HelicopterTechnicalDepartment. lf clearance or interference is lessthan damperassembly to tailconecrossmember.Torqueboltsper 9.12 inch,^connect Section1.32O.

el

Installtailconeper Section4.312.

f)

Installand shim intermediate flex plateper Section7.330.

gl

Performtail rotor driveshaft run-outcheckper Section7.340.

I

7.321 Adjustmentof DamperFriction a) Removetail rotordriveshaftfromtailconeper Section7.31O. b) Disassemble damperper Figure7-1O.

c) dl

washers for wornTeflon@ coatins(darkgravfaceland |3;?."rT Sr.lJ;f,[U.

I

Inspect A141-37 washers and C041-3 arm for indicationsof wear or grooving. Replaceas required.

I

e) Reassemble damperper Figure7-1O. Torque pivot bolts per Section1.32O. CAUTION Teflon@(dark gray) face of CO41-5 DU washer must be p l a ce d a g a i n st A 1 4 1 -36 washer or C041- 3 link. Remove plasticor tape coating if installed.

C h a n g e5 : 1 5 J u n 9 8

P a g e7 . 3 3

I

F|CIBINSiCIN

MOETEL]i'44

MAINTENANeEMANUAL

2

il

I

lt

Ftro 14

,dD

\W

o

8

o

1'

ASSEMBLY 7 - 1 0 C O 4 1DAI'/IPER FIGURE

14

NUMBER PARTNUMBER I 2 J

4 6 8

P a g e7 . 3 4

c041-8 6 NAS6604AN96OPD416L A141-37 c041-3 c041-5 c 0 4 11-1 A 1 0 51-2

DESCRIPTION

NUMBER PARTNUMBER

Ann Bolt

9 l0

l,lasher

1tr

12 13 Link 14 Washer Bearing Assemb'lY 1 5

t^Jasher

J o ur n a l

05DU04 c041-6 A141-36 NAS679A4 13 B330A041-10 MSl6562-11

PTION DESCRI B u s hni g S p r i n gW a s h e r l'Jasher Nut P a ln u t DowelPin R o l ' l P in

Change4: 1 J un 97

FIGIBINSCIN

MATNTENANcE MANUAL

%

fr

ls I

? . r 4t o 3 . 5 0 l b s . t o m o v e l i n k (measured at point I'B' bs. to move at point "A" point"B").

MC)E EL FI44

rota t i n g a b o u t p o i n t " C " ) .

FIGURE 7.114 CO41DAMPER ASSEMBLY ADJUSTMENT

CO

VIEt,l LOOKING AFT

DAMPER MOUNT ANGLE c041-8 ARM c041-11 BEARING ASSEMBLY

>-

C041-3 LINK

FIGURE 7.118 CO41DAMPER ORIENTATION

C h a n g e5 : 1 5 J u n 9 8

Page7.35

FICIBINSCIN

MAINTENANeE MANUAL

MC'EIEL H,44

7.g21 Adjustmentof DamperFriction(cont'd)

f l R e f e r t o F i g u r e T - 1 1 A . H o l d c o 4 1 - 3 l i n k a n d a - rtake t a c h2.50 a s p rto i n4.25 g s c alb l-e toP J q e q d weightto 6ne bolt holein co+t-8 arm. lt should CnJc[-uearinfriousingo!v9t frictionwith springscaleor dead move take2.14 to 3.50 lb to movelink' ii iinf.non. tt sho"uld *"ignt"tr.

I I

and bendwasher lf dragis lessthanspgqified,c!qc! -c^ot1-9.spring-washer is correct If spring.washer inbh. o,0Zg oi'o-.oos until it rirJ'Jtblii filight greater neignt,U"t Oragit Ctilitootow,lap.endof .A105-12 iournal'lf dragis tha-nspecified;flattenspringwasherslightly' CAUTION DoNoTADJUSTDAMPERDRAGBYCHANG|NGBoLT TOROUE.

s)

per TorqueMS21O42L4nutpersection1.32Oandrecheckdamperfrictions Stepfi. InstallB33O-13balnutsandtorquestripe'

h)

fnstalltail rotordriveshaftper Section7 '32O'

Measurementstaken with intermediateflex plate removed' a)

Engageclutch actuator.

bl

Rotate drive flangesof tail rotor shaft and c195 yoke horizontal.

c)

d) e)

9 Insert NASl3O4 bolt through tail rotor shaft and c195 aft clutch.yoke.qt position' o,clock position.MeasureanOreiord gap betweenflangesat 3 o'clock Removebolt. position' Insert bolt at 3 o'clock position. Measureand record gqp at 9 o'clock Measurementiin lequdnce C and D are Measurement1. & D' This Remove bolt and rotate tail rotor shaft 180 degrees. Repeat steps c will be Measurement2. NOTE Measurement1 and 2 should be similar. lf measurements ire not similar,one or both yokes are bent'

f)

P a g e7 . 3 6

gap in Measurement1' Determinedifferencebetween3 o'clock and 9 o'clock gab in Measurement2' Determinedifferencebetween3 ;';a;;t ind 9 o'clock

C h a n g e5 : 1 5 J u n 9 8

FICIBINSICIN

MATNTENANeE MANuAL

MOE EL F,44

7.330 IntermediateFlex PlateInstallationand Shimmino(cont'dl gl Use following formula to obtain the calculateddimensionsfor proper shimmingrequiredat the intermediate flex plate. NOTE Use the measurementwith the smaller difference between3 and 9 o'clock readings. 9 o'clockreading+ 3 o'clockreading Divideabovesum by 2 Subtract r CalculatedDimension

=

rAverage thickness of the A947-2 flex plate measuredat the bonded washers. Shimas requiredper Table7-1. h) Reinstallthe flex plate using the shims determinedabove. Torque the attach bolts per Section1.320. Installpalnutand torque stripe. Referto Figure7-4. 7.340 CheckingTail RotorDriveShaft Runout The runout check describedbelow is to preventexcessiverunout on the tail rotor drive shaft which can causea failurein the intermediateflex couplingor damperassembly. a) Removeall the tailconeinspectioncoverson the taitconeright side.Engage the clutch. b) Assemblethe RobinsonTool NumberMT26O-6tool and a suitabledial indicator. NOTE The dial indicator included in the Robinson MT122 bolt stretch gaugeis recommended for this tool.

Change4: 1 Jun 97

Page 7.37

F|GIBINEICIN

MOE'ELre44

MAINTENANGE MANUAL

aft on the right cl Insert the dial indicator through..tlrqipogction hole fa.rthgst the tailcone when presj'ir,-iiiirindic'ator against firmly side of the tailcone. the extensionis riding on the drive shaft' shaft at least three dl Have someonerotate the drive shaft at the c166 clutch revolution so it each with full revolutions.The indicator may vary somewnat will be necessaryto take an average' el Repeatprocedurein steps C & D at the next inspectionhole forward' extensions' f) Removethe extensionfrom the MT26Otool and, using.the.longer holes. inspection two check tnC Orivelnatt at each of tne other not exceed g)The maximumamount of runout a! any-of the locationsmust repairedor be must shaft drive irre 0.025 inch. tf the ,rnori il;;;ssive, replaced. 7.35O Two-PieceTail Rotor Drive Shaft shaft' one Cl95al The two-piecetail rotor drive shaft consistsof one-C196-1 -2 blocksand clamping c191 t*o 5 yoke,6h-J-co+r-fo"-firG{erbti, ' asiociaiedhardware.See Figure7-12Areferto Figures -' The co41-1 damper bearingassemblyis field replaceable; b) criteria. 7-12n and t-{i{tor approfriatedimensional cl The D22+1 drive shaft is producedin one length only.

o

L DRIVESHAFT TAIL ROTOR MT26O INDICATOR RUNOUT

CHECK DRIVESHAFTRUNOUT FIGURE7-12 TAIL ROTOR

Page7.38

Change2: 12 Dec 94

FICJBINSCIN

MATNTENANcEMANUAL

MoE EL n44

TABLE7.1 A947.2 INTERMEDIATE FLEXPLATESHIMTABLE

'

Calculateddimension in inchesfrom Section7.330(gl

Total shims required between the flex plate and the clutch shaft's Cl95 yoke (required 2 placesl.

(0.137 or more calculatedl

The measurementis over the limit and a longer C195 yoke is required.

(0.136) (0.107t

1 each AN960-416 washersubstitutedfor AN960-4161

1 each AN96O-416 washer

(0.1061 to.o77l

1 eachAN96O-416L washer

1 eachAN960-416 washer

(o.o76) (o.o47l

1 eachAN96O-416L washer

1 eachAN96O-4161 washer

(o.046l (0.0171

1 eachAN96O-4161 washer

No washers for shimming

( O . O 1 6ol r less calculated number

ShorterCl95 yoke is required

Total shims required between the flex plate and the TR drive shaft's D224 yoke {required 2 places).

CAUTION: Theremust be an AN960-416Lor AN96O-416washerbetween eacharm of Cl95 yoke and A947-2 flex plate.

Change 3: 5 May 95

Page7.39

MOEIELH44

MAINTENANeE MANUAL

FICIBINSCIN

c196-t TAIL ROTOR DRIVESHAFT

SIDEOFBEARING FLANGED UNWELDED FACES HOUSING SHAFT. ENDOFDRIVE c0 41- 1 DAMPER ASSEMBLY

B0LT NAS6604-28 (2 Req'd) WASHER AN960-4161 NUT NAS679A4 8330.13PALNUT ( 2 p l ' c s .)

@i

l

\

+

o

c191-2 CLAMPING BLOCK (2 Req'd)

c195-5YoKE INSTALLBEARINGONTOSHAFTUSING PRIMER. OREPOXY ZINC-CHROMATE OF DRIVESHAFTAND SEALJUNCTURE BEARINGINNERRACEb|ITH THE SAME PRIMER.

5 1 . 1 3t 0 . 0 3I N C H E S

DRIVESHAFT 7-1?A TAIL ROTOR FIGURE

c041- 1 DAMPER ASSEMBLY D224-7 TAIL ROTOR DRIVESHAFT DIAL iNDICATOR

V.BLOCK

(T0 N0 FoRE0R AFT OF DRIVESHAFT MOVEMENT DAMPER MEASURiNG bIHEN RUN-OUT) BEARING

O.OO5INCHTIR WHEN MAXIMUM HITH DRIVESHAFT ROTATING STATIONARY. BEARINGHOUSING

DIAL INDICATOR

V-BLOCK INSPECTION RUN-OUT BEARING 7-L}B DAMPER FIGURE

Pa g e7 . 4 O

Change3: 5 MaY 95

FICIE|INSiCIN

MATNTENANeE MANITAL

MOEIEL F'44

7.400 TAIL ROTORGEARBOX 7.410 Tail Rotor GearboxRemoval a) Mark the tail rotor hub and bladesand tail rotor pitch links to their respective pitch control arms before disassembly. This will facilitate reinstallationand eliminatere-riggingthe tail rotor if push-pulltube lengths are not altered. b) Removethe tail rotor hub and blades. Leavethe pitch control links attachedto the tail rotor blades. c) Disconnectthe A120 bellcrankfrom the push-pulltube. d) RemoveA12O'3 bellcrankand pitch controlfrom tail rotor gearbox. Disconnect A12O-3bellcrankattach bolt from the gearboxoutput cartridgeand slide pitch control, with the bellcrankattached,off the gearboxoutput shaft. Reassemble bellcrankhardwareto bellcrank.

el Workingthroughupperaft inspectionholeof tailcone,disconnectthe aft flex coupling from gearboxinput shaft flange. CAUTION Drive shaft must be edthrough the upper aft inspection hole to prevent damage to flex plate and drive shaft. Do not leave any loose hardwareinsidethe tailcone. f)

Disconnectchip detector wire at bottom of gearbox.

g) Cut the safety wire and removefour bolts holdingthe tail rotor gearboxto the tailcone. Carefulhandlingof gearboxon removalis requiredto preventdamage to input shaft or the threadson the output shaft. 7.420 Tail Rotor GearboxInstallation a) Install the tail rotor gearbox to the tailcone and torque four cap screws per Section 1.330. Safety wire screws in pairs with O.O32 inch diametersafety wire, b) Connect the chip detector wire at the tail rotor gearbox. c) Connect flex plate to tail rotor gearbox. Torque bolts to per Section 1.32O. d) Tail rotor drive shaft can now be removed.

Ch a n g e7 : 0 6 D e c 9 9

Page7.41

FIC|BINEiCIN

MAINTENANeE MANUAL

MtfEIEL ]e'44

e) check intermediateflex plate shimmingper section 7.330' per Section 8'560 if fl" Installthe tail rotor pitch control and bellcrank.Re-shim 6iidinai ii.-Ji- rbiioioinoingi occurs when assemblvis moved' gl Reconnectcl 21-17 push-pulltube to aft bellcrank. hl Installtail rotor hub and blades' i) Connectpitch links to the pitch control arms' 1'300' i) Ensureall bolts are torquedper Section 7.43O Tail RotorGearboxChio lndicator the lubricantand use the following procedureto drain the gearboxand inspect chip detector for chips. a) use a clean containerto catch tail rotor gearboxoil' wires' Remove bl cut safety wire on chip detectorand disconnectthe electrical chiP deteitor and drainoil' on the chip detector' c) Strainthe oil and inspectany particlesfound in the oil orinch long or O'02 in-ch iarger !O'9.9. for ;#;6ilirtpt;q Examinethe particles ferrous or nonas widel tfiin-fne tizz tnoimii wtiart should bb identified and the next found nurirerou:.Particles.are ferrous by using a tagili.'lf failuremay gearbox more particies,a tail rotor runningof tne gdarboxp-roduces is required' aGiI toioi gearbox'overhaul be impei;id;il gearbox' d) See Section1.130 for flushingand refillingof the a) Removetail rotor and pitch control bearingper Section7'410' NOTE Mark all attachmentsfor properre-assembly' bolts securing the bl cut the safety wire and remove four MS2@7+o+o6 C112-2 caP. 'o'-ring' seal and cl slide c112-2 cap over the output shaft and removethe

Page 7.42

Change2: 12 Dec 94

FIC|BINSCIN

MATNTENANcE MANUAL

MC'E EL F|44

\--'

SHAFTSEALREPLACEMENT FIGURE7 -13 TAIL ROTOR OUTPUT GEARBOX NUMBER

PARTNUMBER

PTION DESCRI

c109-1 c966-2 c215-133 ctLz-2 ANg60-4161 MS20074-04-06

Housi ng Seal 0- Ring cap l^lasher Bolt 0.032in. dia Safety t.Iir e

l s s u e d1: 1 J u n 9 3

Page7.43

FIC|BINSCIN

MATNTENANcE MANUAL

MOE'EL

F,44

(

CAUTION Be careful not to lose or changeshim stack-up between tne cap and the gearbox.Any.changeto the shim stackup wili changefa-ctory-setpreloaddrag. dl Carefullycleanseal seatingsurfaceand O-ringgrooveand dry. el press a new C966-2 seal into the cap bore 0.1.60 inches below the external surfacewith sJallip io-*ai'Aini geaiUox.Lubricatea new C215-133 O-ring with A257-2 gearoil and installin groovein cap' fl Lubricatethe seal seatingareaof the output shaft with A257-2 gear oil' gl Slidethe cap-overqheoytptlt shaft and reinstall.on !19 gea.rbox'TorqueJhe four bottsto 66-in.-ittHd;afeti wire in pairswith 0.032 inch diametersafetv wire. pitch controlbearingand tail rotor per Section8'562' hl Reassemble

It is not necessaryto removepitch control assemblyand tail rotor for this Procedure. al Removegearboxfrom tailconeper Section7'41O' O bl RemoveMS24665-210cotter pin from the nut at the centerof Cl16-1 input yoke. cl Placethe gearboxassem{y gn a bench and put a 2-inchthick wood block betweenone aim oi-tfre Ct t 6-1 yoke and the gearboxhousing' dl Removethe AN32O-8castellatednut and removethe yoke' el Cut the safety wire on and removefour MS20074-O+OObolts' f) Removecl 1 2-1 cap. Be sure not to los-ethe c141-2 washer that is located betweencap and biaring. Removethe O-ring' gl Pressout otd sealand cleanthe sealseatingsurfaceand O-ringgroove'

Pa g e7 . 4

C h a n g e2 : 1 2 D e c 9 4

MATNTENANeE MANUAL

FIG|BINSCIN

t. zltt

'tFr'

MOEIEL

]''44

s

INPUTSHAFTSEALREPLACEMENT GEARBOX 7-13A TAIL ROTOR FIGURE PARTNUMBER

DESCRIPTION

1 2

c110-1 cl4t-2

Input Car tr idge t'lasher(betweencap & input cartridge)

3

A966-3 c215-140 c112-1 MSz4665-210 AN320-8 4141-10 cl 16-1 AN960-4161 MS20074-04-06

Seal 0-Ring

NUMBER

4 5 6 7 I 9 10 11 L? Change2: 12 Dec 94

cap CotterPin Nut l^lasher Yoke l^|asher B o lt 0 . 0 3 2 i n . d i a S a f e t yW i r e

Page7.45

FICIBINSCIN

MATNTENANcE MANUAL

M3fE EL FI44

(eont'dl 7.45O Tail .RotorGparboxInput Shaft SealReolacement h) Pressa new A966-3 seal into cap 0.250-inchfrom externalsurfacewith seal lip toward gearbox. Lubricaiea new C215-140 O-ringwith A257-2 gearoil and installin groovein cap. il'

Install C141-2 washer and cap into Cl10-1 cartridge.Install four bolts with AN960-416Lwashersunderhead.Torqueto MS2OO74-O4-O6 6O in.-lband safety wire in pairswith 0.032-inchdiametersafety wire.

il

Instal C116-1yoke, A141-1Owasher,and AN320-8nut onto gearshaft.

k) Holdthe gearboxand yoke flangewith a 2-inchwoodenblock. l)

Torquethe nut to 290-410 in.-lb and securewith a new MS24665-21O cotter Pin. m) Installgearboxper Section7 '42O.

7.500 ACTUATORASSEMBLY 7.510 ActuatorRemoval a) Removeaft cowlingassemblY. b) Disengageclutch to its fullest disengagedposition. c) Removecoolingfan and scroll per Section6.2O0. d) put a six-inchwooden block under the clutch shaft iust forward of the uppei lneaue on the horizontalfirewall. Tliq keeps the sheave from OioopinglnO-preuentsdamageto the forward flex plate (seeFigure7-8). e) Disconnecttwo wiring connectionsto actuator. f)

Disconnectthe clutch lateralcenteringstrut from the upperframe.

g) Removethe upper NAS66O5and lower NAS66O4 bolts and remove actuator. 7.520 Actuatorlnstallation a) Inspectupperand lower clutch actuatorbearingsper Section2.140.8. b) Positionactuatorfor installation. c) Install lower attach bolt with head faclqg aft: Use one AN96O-416L *asher underbolt headandone AN96O-416washerundernut. Torqueper Section1,32O,installpalnutand torquestripe'

P a g e7 . 4 6

Change4: 1 Jun 97

MATNTENANcE MANUAL

IfClBINSiClN

rliGIEIEL tt44

7.520 Actuator Installation d) Connectactuatorgearmotorhousingto C184 bearingper Figure7-14. Standard torque bolt per Section 1.32O, install & torque palnut, and torque stripe per F i g u r e2 - 1 . e) lf installed,removeblock(s)ingclutch assembly. f) Connectclutch lateralcenteringstrut, standardtorque bolt per Section1.g2O: installpalnut,and torque stripe per Figure2-1. g) Installfanwheeland scroll per Section 6.220. h) Connectgearmotorand switch harnesselectricalleadsand ty-rap as required. i) Balancefanwheelper Section6.240. i ) I n s t al la ft co w l i n g . CAUTION Do not en

e actuatorwithout scroll installed.

7.530 Actuator GearmotorReplacement Actuator gearmotorcan be replacedwith actuatoron helicopter. 1 . D i s co n n e ctg e a rmo to re l e ctr icalleads. 2. Cut safety wire from four gearmotorattach screws. 3. Removescrews, using care not to drop them in V-belt drive. 4. Slowly slide gearmotorassemblyfrom housing.An unscrewingmotion may be necessary. 5 . L i g h tl y l u b ri ca tew o rm g e ar on new gear motorassem blywith 4257- 1 gr eas e beforeinstalling. InstallO-ringonto gearmotornose. 6. Installnew gearmotorinto housingwith wire leads pointingoutboard. no gap exists betweenhousingand motor mountingflange. 7. Install and tighten (4) mounting screws into housing and safety in pairs with O.O32inch diametersafety wire. 8. Connectgearmotorelectricalleads. Engageclutch, listen for binding,and actuatorshuts off after column springsyield (indicatedby "popping"sound). CAUTION lf gearmotorelectricalpins are reversedin connector,gearmotor w i l l o p e ra teb a ckw a rda nddown- lim itswitchandspr ingswitches WILL NOT shut off power; damageto actuatorand drive belts ca n o ccu r. Ch a n g e1 4 : J U L 2 OO8

Pag e7.47

MtfE'EL

MAINTENAIUcE MANUAL

HEIBINSI'CIN

AAJ ,l ,6! l 4

844

5

6

l

6 \tal>

F OR W A R D i:

o

I l.

'.,-\

--E1L--'

o

FIGURE7-14 ACTUATORASSEMBLYINSTALLATION NUMBER 1 2 3 4 5 6 7 I I

P a g e7 . 4 8

P A R TN U MBER

8330-16 MS21042L5 c141-1 ANg60-5161 cA214-8 c105-2 NAS6605-38 cl84-2 c051-1

DESCRIPTION PALNUT NUT W ASHER W ASHER THRUSTW ASHER JOURNAL BOLT UPPERBEARINGASSEMBLY ACTUATORASSEMBLY

C h a n g e4 : 1 J u n 9 7

FIOE|IN$iCIN

MATNTENANcE MANUAL

Mt'E EL 3,g,4

7.540 Actuator Adiustment 1 . En g a g e dL i mi t The actuatorengagedlimit is determinedby column springswhich control drive I belt tension. Columnspringsmay only be adjustedby the factory. 2. Disengaged(Down-Limit)Adjustment

,

'

T h e do w n -l i mi t sw i tch i s activated by the down- lim it stop scr ew, w hi c h c a n be a d j u ste d u si n g l o n g 3i8- inch open- end ( M T357- 6) and %- inch box e n d ( MT 3 5 7 -7 l 'w re n ch e s. Adjust down- limit stop scr ew to m aintain pr oper b e l t d e fl e cti o n p e r S e cti o n 7.282 with actuator fully disengaged.Min i m um c l e a r a n ceb e tw e e n scre w h eads at scissor sis 0.O15 inch per Figur e7- 15. 3. Maximum Extension Maximumengagedextensionis 1.60 inches,measuredas shown in Figure7-15. The extension-limit switch activatesat 1.50/1.6Oinchesextension.DriveV-belts must be replacedwhen maximumextensionis encountered. 7 . 5 5 0 Sw i t ch a n d F u seR e p l a ce ment 7 . 5 5 1 Sw i tch R e p l a ce me n t 1 . R e mo vea ctu a to rp e r S e c tion7.510. NOTE Switches may be replacedas a complete switches & harness a sse mb l y,o r re p l a ce di ndividuallyby installingheat shr inkand solderingwire connections. 2. Removedesiredswitch by removingattachingscrew,nut, washer,and spacing washersbetweenswitch and plate.

NOTE Spacing washers ma y be bondedto new switch(es)to ease reassembly. 3. Replacecompleteswitches and wire harnessassemblyor, if installinga single switch, cut wires from faulty switch as closeto switchesas possible. 4. Slide new heat shrink over each cut wire. Solderwires to switch and install heat shrinkover solderconnection. 5. Reassembleswitch(es)to plate. Two spacingwashersare installedbetween switch and plate at each attach screw and one undernut. Do not over tighten screws or plasticswitch housingmay crack. 6. Reinstallactuatorper Section7.520.

Cha n g e1 4 : J UL 2 0 Oa

Page7.49

FORWARD

M('EIEL

nlrAINTENANtrE MANUAL

FICIBIN$}CIN

U,2

F|44

A481-1 Switch Assembly

Gearmotor (Partiallyremoved for clarity)

\-- ---/ /l

AN525 Screws

O . O 1 5i n c h m i n . (Disengaged)

1 . 6 Oi n c h e s ExtensionLimit (ENGAGED} Extension Limit Switch

:==

Down-Limit Stop Screw Down-Limit (Retraction) Switch

Switches

g.t r'l

rlU t

0 . 0 1 5 i n c hm i n . (Disengagedl t: l^

/ ./

1[" /

DO NOTREMOVE

c 18 5 Brackets

FIGURE Z-tS ncruaron urtnr

Pa g e7 . 5 0

NAS62O-4Washer 2 requiredon each screw betweenA513-2 Plate and springswitches) (VIEWFROMLEFTSIDE}

C h a n g e1 4 : J U L 2 O O B

FICIBINSIC|N

MATNTENANcEMANUAL

MOEIEL F,44

7.551 Switch Replacement {cont'dl dl Slide heat shrink over each cut wire. Solderwires to switch and install heat shrinkover solderconnection. e) Reassembleswitch(esl to plate. Two spacing washcrs are installed between switch and plate at each attach screw and one under nut. Do not overtightenscrewsor plasticswitch housingmay crack. Reinstallactuatoron helicopterper Section7.52O. 7.552 Feplacement An in-linefuse holderis installedin the clutch actuatormotor power circuit. R44 S/N OlOO& prior havethe fuse holderty-rappedin the wire bundleabove the horizontalfirewall in the main rotor gearboxcompartment.On R/$4S/N O1O7 and subsequentthe fuse holderis mountedon the test switch .Replace fuse with 3.0 amp (AGC3.Ol fuse. 7.600 ROTORBRAKE 7.610 RotorBrakeRemoval al Removetailconecowling.Removethe forwardflex plate.Markand recordany shim washersinstalledbetweenthe flex plateand the input yoke to the main rotor gearboxor the yoke on the clutch shaft. b) Removethe cotter pin and the nut securingthe input yoke on the mainrotor gearbox.Removethe yoke. Disconnectthe springfrom the firewallangle. c) Removethe cable pulleyfrom the lever.Disconnectthe wiring to the micro switch at the three-pinconnector. dl Cut and removethe safetywire, then removethe threeboltssecuringthe rotor brake. Record the position of the two small and one long spacersfor reinstallation. Removethe rotor brakeassembly. 7.62O RotorBrakeInstallation a) Placethe rotor brakeassemblyover the splinedinput pinionshaft of the main rotor gearbox. b) Placeone eachof the two small{Cl30-3} spacersin placebetweenthe rotor brake assemblyand the pinion end cover. Installone each AN96O-416L washeron the threeNAS1352-4H3OP bolts.Insertthe first bolt throughthe rotor brakeassemblyand the A130-41 spacer.Insertthe secondbolt through the Hall Effect senderplate, rotor brakeassemblyand the A130-41 spacer. Placeone AN960-416 washerbetweenthe Hall Effect senderplate and the rotor brake bracket,

Change3: 5 May 95

Page7.51

FICIBINSCIN

M('E ELt'44

MAINTENANcEMANUAL

'-/

.r'

)(

181'l

BRAKEINSTALLATION FIGURE7- 16 ROTOR NUMBER

PARTNUMBER

DESCRIPTION Micro Sw'itch

1 2

ouz-r

3 4

D110-1 0123-1

5

NAS428-3-14

6

NAS1291-3 c908-t

7

c141-10

Nut YokeAssemblY tlasher

8

AN320-8

Nut

9

MS24665-210

Cotter Pin

NAS1352-4H30P 6 ANg60-41

Screw tlasher

10 11

Page7.52

Lever ArmAssemblY Arm Assemb'ly B o lt

t2 13 14 15 16 t7 18

PARTNUMBER

DESCRIPTION

0114-1

Eracket Spacer

c130-4 A130-41 cl 30-3 AN210-1A

Spacer S.pacer PulI ey 0 . 0 3 2i n . dia Safety t,lire

E0240-037-3500S Spri ng

Change2: 12 Dec 94

FICIBINEICIN

MATNTENANcE MANUAL

MOE EL F|44

7.620 Rotor Brakelnstallation(cont'd) cl Insert the third bolt through the Hall Effect senderplate and the long Cl30-4 spacer.Fingertigliten the threebolts into the gearbox,then torqu.etfe bolts to 120 in.-lbahd safety with 0.032 inch diametersafety'wire. Attach the spring to the firewall angle. , dl Placethe C9O8-1yoke on the pinionshaft. Installone eachCl41-1O washer and AN32O-8nut on the pinion shaft. Torquethe nut to a minimumof 290 in.-lbs. Align the castellationson the nut with the hole t-hroughthe pinion shaft. Do not exceed41O in.-lbs.Installone MS24665-210cotter pin. gap per section 7.141. el set the Hall Effect sender-to-magnet fl Attach the cablepulleyto the lever.Reconnectthe wiring to the micro switch at the three-pinconnector. gl With the brakeengaged, -andadiust the gap betweenthe NAS428-3-14bolthead inch. Lock the on the D123-1 arm the C130-4 spacerto O.O3O-0.035 adjustmentby tighteningthe MS21O42Lgnut (seeFigure7-16A1. hl With the brakein the releasedposition,measurethe gap betweenthe Dl12shouldbe 0.030 1 leverand the DllGl arm assembly.The gap measurement - 0.170 inch. Adjustthe lengthof the beadchainas requiredto obtainproper gap. il Adjust the micro switch to open and close at a gap of O.2O- O.3Oinch betweenthe Dl12-1 leverand the DllGl arm. il Install the forward flex plate. Checkthe clutch sheavealignmentper Section 7.23O. Checkthe intermediateflex plateinstallationand shimmingper Section 7.330. 7.630 Rotor BrakePad Replacement al Minimumpad thicknessis O.O3Oinch. bl Brakepad replacementis accomplished by replacingthe Dl10-1 and Dl23-l arm assemblies.

Change2: 12 Dec 94

Page7.53

FIClBINEiclN

MATNTENANcE MANUAL

MOE'ELF44

D112-1LEVER

DIIO-I ARMASSEMBLY

BOLT NAS428-3-14 &

BRAKE ENGAGED

NUT NAS1291-3

D123-1 ARMASSEMBLY

0.030- 0.035in. GAPBETI'IEEN BoLTANDC130-4 NAS428-3-14 ENGAGED. I,IITHBRAKE SPACER

F_-.-

.--.r!--

c0420-063-2000s SPRING

T0 SIIITCH I'!ICR0 ADJUST AT A GAP ANDCLOSE OPEN 0F 0.20 - 0.30in. BETI'IEEN ANDD110-1 LEVER D112-1 ARM.

BRAKE RELEASED

O.O1OiN. MIN. CLEARANCE PADSANDYOKE. BETWEEN

7- 164 FIGURE ANDCLEARANCES BRAKEADJUSTMENTS ROTOR

Pag e7 . 5 4

Change2: 12 Dec 94

t 8. FLIGHT CONTROLS

)

MATNTENANeE MANUAL

FIC|BINS|E|N

MOEIEL F'44

8 SECTION FLIGHTCONTROLS 8.OOOFLIGHTCONTROLS 8.001 Introduction 8.002 Description 8.003 HydraulicFlightControls 8.004 HydrauliumpDescription Description 8.OOSHydraulicReservoir 8.006 HydraulicServoDescription

8.100cYcLtccoNTRoLS

l@ 8.1 1 1

Cyclic Assembly Removal

8.112

C ycl i cA sse mb l yInstallation

8 . 1 2 0 C y cl i c Gri p A sse mb l y 8.121

C ycl i cGri p A sse mblyRem oval

8.122

C ycl i cGri p A sse mblyInstallation

8.130 LongitudinalCyclic Trim ElasticCords (electrictrim systems only)

O

8.131

E l a sti cC o rd R e moval

8.132

ElasticCord Installation

(electrictrim systemsonly) 8.140 Lateraland Longitudinat CyclicTrim Assemblies 8.141

LateralCyclicTrim AssemblyRemoval

8.142

LateralCyclicTrim AssemblyInstallation

8.143

Longitudinal CyclicTrim AssemblyRemoval

8.144

Longitudinal CyclicTrimAssemblyInstallation

8.150 CyclicFrictionAssembly 8.151

CyclicFrictionAdjustment

C h a n g e7 : 0 6 D e c 9 9

Page8.i

|

FI(JBINEiCIN 8.160

MATNTENANcE MANUAL

MODEL r?,44

Tube (electrictrim systemsonly) C121-7Push-Pull

Tube Removal 8.161 C121-7Push-Pull

,

Tube Inspection/Repair 8.162 C121-7Push-Pull 8.163

Tube SleeveInstallation C121-7Push-Pull

8.164

TubeSleevelnspection C121-7Push-Pull

Tube Installation 8.165 C121-7Push-Pull 8 . 2 0 0 C O L L EC T IVCEON T R OL 8.210

CollectiveStick AssemblY

8.211 .CollectiveStick Removal 8.212 CollectiveStick lnstallation collectiveFrictionAdjustment 8.213 Pilot-Adjustable 8.214 FixedCollectiveFrictionAdjustment 8.22O

CollectivespringAssembly(manualcontrolsonly)

8.221 CollectiveSpringRemoval& Servicing 8.222 CollectiveSpringInstallation 8.223 CollectiveSpringAdjustment 8.230

RPMGovernorSYstem

8.231 GovernorControllerRemoval 8.232 GovernorControllerInstallation 8.233 GovernorAssemblYRemoval 8.234 GovernorAssemblylnstallation 8.239 GovernorTroubleshooting STRUTS 8.300 JACKSHAFTAND 8.310

J acksh a ft

8 . 3 1 1 Ja cksh a ftR e mo va l 8.312 Jackshaftlnstallation 8.320

Strut Assembly(Jackshaft)

8.321 JackshaftStrut Removal 8.322 JackshaftStrut lnstallation P a g e8 . i i

C h a n g e1 0 : J U L 2 0 0 4

FIGIBINSON

MATNTENANeE MANUAL

Mt'DEL

H44

8.400 SWASHPLATE AND MAINROTOR PITCHLINKS 8.410 Swashplate 8.411 SwashplateRemoval 8.412 SwashplateInstallation 8.413 SwashplateTilting FrictionAdjustment 8.500 TAIL ROTORCONTROLS 8.510 Tail RotorPedals 8.511 Tail RotorPedalRemoval 8.512 Tail Rotor Pedallnstallation 8.520 C317 Bellcranks 8.521 C317-2 Lower ForwardBellcrankRemoval 8.522 C317-2Lower ForwardBellcrankInstallation 8.523 C317-1Lower Aft BellcrankRemoval 8.524 C317-1 Lower Aft BellcrankInstallation 8 . 5 3 0 C 3 1 6 -1U p p e rB e l l cra n k 8.531 BellcrankRemoval 8.532 Bellcranklnstallation 8.540 A331-4 lntermediate Bellcrank 8.541 BellcrankRemoval 8.542 Bellcranklnstallation 8 . 5 5 0 A1 2 O-3A ft B e l l cra n k 8.551 BellcrankRemoval 8.552 BellcrankInstallation 8 . 5 6 0 C O 3 1 -1P i tchC o n tro l 8.561 PitchControlRemoval 8.562 PitchControlInstallation Cha n g e1 3 : O CT 2 0 Oo

Pa ge8.i i i

F|ClElINEiClN

MAINTENANeE

MANUAL

MOEIEL ]r44

8.570 Tail Rotor Pitch Links 8.571 Tail RotorPitchLink Removal 8.572 Tail Rotor Pitch Link Installation 8.600 C2O3YOKEAND A2O5 FORKASSEMBLIES 8.610 BearingRemoval 8.615 C648'2 BearingInstallation 8.620 81 15-1 BearingInstallation 8.700 HYDRAULICFLIGHTCONTROLS 8.710 HydraulicReservoirRemoval 8.720 HydraulicReservoirInstallation 8.730 HydrauliumPRemoval 8.740 HydrauliumpInstallation 8.750 HydraulicServoRemoval 8.760 HydraulicServoInstallation

Pagef .iv

Change13: OC T 2006

FICIE|INSiCIN

MATNTENANcE MANUAL

rtnETETEL.H.44

8 SECTION FLIGHT CONTROLS 8.OOOFLIGHTCONTROLS

8.001 Introduction This sectidn covers removal and installationproceduresfor cyclic controls, collective controls,tail rotor controls,and relatedcomponents. WARNING Assembly of flight controls is critical and requiresinspection by a qualified person. lf a second person is not available, the installer must take a S-minute break prior to inspecting flight control connectionshe has assembled. 8.002 Description(seeFigures8-1 and 8-2) Dual controls, which are removableon the left side, are standardequipment.All primary controls are actuatedthrough push-pulltubes and bellcranks. Bearingsused throughout Teflon@ liners. the control system are eithei sealedball bearingsor have self-lubricated R44 flight controlsoperateconventionally.The cyclic stick appearsdifferent,but the grip moves as in other helicopters.The cyclic grip is free to move verticallyallowingthe pilot to rest his forearmon his knee if he chooses. Electrictrim-equippedaircraftincludestrain gages mountedto the cyclic stick to sensecontrol forces, and electrictrim motors at the base of the stick which automaticallyminimizethese forces. The collectivestick is conventionalwith a twist grip throttle. When the collectivecontrol is raised, the engine throttle is opened automaticallyby an interconnectinglinkage. Additionally,an electronicthrottle governoradjuststhrottle positionto maintainRPM. 8.OO3 HvdraulicFlightControls The optional hydraulicflight control system consists of a pump mounted to the main rotor gearbox,a servo at each of the three push-pullcontrol tubes ingthe main rotor swashplate,a reservoirassembly,interconnectinglines, A257-15 hydraulicfluid (see Section1.4701. An elasticcord replacesthe collectivetrim springand balancesthe weight of the collectivestick. Figure8-1A shows the hydrauliccontrol system. A schematicdiagramof the system is g i v e ni n F i gu re8 -1 B . WARNING Except as instructed in this manual, service on the hydraulic is limited to component removaland CAUTION Cleanlinessof hydraulicfluid is vital to proper system operation. Useonlycleanfluidfromsealedcontainers andavoidcontamination from dirty funnels, tubing, etc, Do not use alcoholto clean auliccomponents. Ch a n g e1 4 : J UL 2 O0 B

Pa ge8.1

FICIEIINEIEIN

MOE EL F44

MAINTENT\NeE MANUAL

8.O04 HvdrauliumPDescriPtion The R44 hydraulic system uses a single stage,.p.ositivedisplacementgear pum.p. rh" pump oriu"'rr,"tt ; ;6ii;;J to i pinionfiear w6ich'is drivenby thp main ;otor-gearboxring The pump drive shaft is designed bear.-ihe purnpgearsare eou,in"edle bearings. prevent crossio shear to pr,ite"ctthe mairi gearbox'if-.pg1npwere to seize. Dual seals also acts as seals contaminationof gl.-iO"i anAfiyOraulicflirids. A vent hole betweenthe a drain to indicatsif either seal has failed. 8.005 HvdraulicReservoirDescription The reservoirassemblyincludesa filter, pressurereliefvalve,PYmpbysolenoid,return Reservoir shut-off valve, 6rd-i;-anJ from'ihe pump ?.n9to and from the servos. provided.along level checks is also pintJ-A-righi giur" i" r.i ";; -allowfor pre-fligrrt.ttuio A 1.25 inch diameterhose directs tluio. 6t "upi"itv adciition *iir, iemovabiefiiler-venito " ii1.from the engine-drivenfanwheelto the reservoircoolingfins. coofing The filter is a disposablecartridgerated at 1O microns(P/NAN6235-1A),to be replaced ouring ioo-norr ihipJction.. Fu"ll-flowfiltrationis providedfor all flow from the pump. pump The pressurerelief valve regulatessystem pressureto 450-500--qsi. Since the excess piouibei"nougl"' flow to meet servo rbquirerirentsduring sfu.u,tgfl!_gll conditions, unJ"r normalflightconditions.The excessfluid flows throughthe pressure how is availabi-e reliefvatvedirectly back into the reservoir.

The pumpbysolenoidallowsth.epilot to shut.offhydraulic.presstrr"^19-:1,"",t:.:I9: which

solenoid, piiotti sripenersiies.the power ls is only onl "v"ri"-"ontrol electrlc Since system.. the the.tv"i9T,: "tiir,lr'vo;;;.i;;.;iir," depressurizes oepressurizes and reservoir tn6iui"iuoii to th; opensa ialve io ;;;;;;;d"; _!i199^ul::itl". "no jo::,::l ?ll:f,"1t)9:?,11l: off, uh 6i""tticalsysteh,,f_?il.{g, to switchir't"-.vrt"lnrequired hydraulics i;:,ffiU "p##" off.

- --;^

ir,"'I.unoii'uul6

--

a:-^^

^l^^+-:^

io

anlrr

ir pr*io"J primarilyto allowpilottrainingwith

The return shut-off valve closesthe return from the actuatorswheneversystem_pressure featureof the actuatorsfunctions oiops ueiow gOpsi. The valveassuresthat the irreversible properlyby preventing-hydriuii"tluiOfrom leavingthe servos if system pressureis lost' The valve includesa thermal relief feature to pr"u"nt-eilessive piessuredue'to thermal O expansionof the fluid. 8.006 HvdraulicServo Description motion The purpose of the servo is to provide output motion equivalentto pilot input at the clevis The without transmitting."in roloiteeooiCt forbesto the pilot's controls. pilot input to move the control valve while also input end has an oier-sizedhole to;lo; prbrioi"g a oirect-mechanicallink if hydrdulir'essureis lost. With hydraulires:urg, clevis i"iuJouiput immediatelymatchr" inpri.'.Absenthydrauliressure,the servo input irreversible An allows O.O4Oinch total travel l"treeFLv") prior to-causingservo gutput. tdr""r with hydrlulics off . A 4o-micronfilter is feature is inctudeJto i"oii. piiot "ohii6t contaminationduring-maintenance. The pressure locatedat the pressureport to prevent and return ports are diffLrentsizesto preventincorrectinstallationof hydrauliclines.

P a g e8 . 1 A

Change7: 06 D ec 99

FIC|BINEICIN

MAt^trENANcE

MANUAL

MC|E EL FI44

cL2r-7

PUSH.PULL TUBEASSIMBLY

c121-3 PUSH-PULL vi TUBEASSEMBL

l-.

-J

\

c069-1 CYCLICSTICK ASSEMELY

c258- i

c258-1

P I T C HL I N K ASSEMBLY

P I T C HL I N K ASSEMBLY

/tl

ASSEMBLY COIi-1 SI.IASHPLATE

c121- 5 PUSH-PULL

TUBEASSEI"IBLY

I

I

I

I

\

I

\-----

c337-1 JACKSHAFT ASSEMBLY

c056-1 SPRING ASSEITIBLY -/-

I 1

--

L_

-/ ASSEI'IBLY C012.2 COLLECTIVE

stoP

c055-6 CYCLICTRI].,I ASSEMBLY (L0NGITUDIilAL)

I

I

_1 \

-

(ilEAR srDE) I$q694-eBoLT 4333-1 Al41-ll wAslER (z nequtneD) COLLECTIVE ils21042t4t{tT

c683-4DAIIIPERASSEMBLY

/ I

\

-/'

(tttttr pitotadJustable frlctlon)

8330-13PALilUT

8247-5 GOVERNOR ASSEI{8LY

cL77-2 P I V OT

c l 2 l- 1 9 PUSH-PULL TUBE ASSEI.'IBLY

FIXED COLLECTIVE FRICTION

C038-5or -6 COLLECTIVE SPRING ASSE}IBLY A2O5-5FORK ASSEMBLY A1OI-4ROD END

\ -

c048-1

_ _ _ c t 7 6 - 2 Y 0 K E_

cYcLIc-

FRICTION ASSEMBLY

c918 ELASTIC CORD

Change7: 06 Dec 99

2 KR E Q ' D ) B E L L C R A(N C121-1 PUSH.PULL TUBEASSEMBLY

c055-2 CYCLIC TRII4 ASSEIIIBLY (LATERAL )

TUBEASSEMBLY C319.3TORQUE

FIGURE 8-I

MAINROTOR FLIGHTCONTROLS (Electric Trim System) P a g e8 . 1 8

MODEL

MAINTENANcEMANUAL

FICIBINSCIN

TUBE C121.31 PUSH.PULL TO SWASHPLATE(3 PLACESI,

FI4'I

NAS1149FN832P WASHER

SCISSORS BETWEEN DIREGTION IOVERLAP NOT CRITICAL)

SEE

FIGURE 8- 1C

D212-1 SERVO {3 placesl

CABIN BULKHEAD

RETURN HOSES ) FORWARD

D203-1

DRIPSHIELD 13placesl

} PRESSURE

.1

HOSES PRESSURE

RETURNHOSE

c121-24 PUSH.PULL TUBE (2 placesl

D211-1(14V1 OR

D211-2l2avl ASSEMBLY RESERVOIR

\G

c343-8 TUBE ADJUST TO 3.9O -t- O.O3 INCHES BETWEEN ROD END CENTERS

-- - cooLlNG BLAST

Y/ [F)-. i-'.]'1DEoo-1

FILTER ACCESS/ --t

-/

-.2/4:/j

u.; \7\--2ijA-l. i2''/' HOSE PRESSURE .z\--/ -/\-/,.--

--

-/

\1- s;ggTRlcAL conxEcro.RFoR PUMP BYSOLENOID

sucTloNHosE FIGURE8-1A HYDRAULICFLIGHTCONTROLSYSTEM Pag e8 . 2

Change9: FEB2OO3

MATNTENANcE MANUAL

FIC|BINSCIN

MOE ELF44

TO MAIN ROTORSWASHPLATE

RESERVOIR ASSEMBLY

COOLING BIAST HOSE

SERVO (3 placesl

PRESSURE..+

-RETURN

-630

sucTtoN+

ON

swtTcHoN cYcltc #

PRESSURE

HYD

2 AMP CIRCUIT BREAKER{TO MAIN BUS)

FIGURE 8.18 SYSTEMSCHEMATIC HYDRAULIC D200-1 CLEVTS

D200-3 WASHER D200-2

scrssoR (Forward servos onlyl

1.40 + O.O3 INCHES

3:i3lXYSllUiiS: 3[i]+oo3'NcH

FIGURE 8-1C

WITHSERVOIN LOWESTPOSITION. SERVORIGGING ADJUST C121-3 ()R C121-24 PUSH- (Typical three placesl PULLTUBELENGTHAS REOUIRED.

(ViewA-A from Figure8-1A) Change9: FEB2003

Page8.3

FIGIBINSCIN

MC'E'EL1t'44

MATNTENANeEMANUAL

ASSEMBLY A755-5 PEDAL

ASSEI.IBLY A331.4 EELLCRANK

A9I8 ELASTIC COROASSEI,IBLY

A120-3 EELLCRAIIK

-'i.r"\

I

i__

-!-'il1

C316.1 INTERI,IEDIATE ASSEMBLY BELLCRANK

\

ASSEIIELY I

>jlt" prrciol'o-rirn* f.l;

A755-4 PEDAL A55E}lBLY

nrss-j

PEDAL A55El{ot

f-;+c334-I REAR ASSEMBLY

r c349-

I

A3l8 BEARII{G BLOCKS

ASSEI.IBLY

cl21-15 PUSH.PULL IUBEASSTMBLY

c3r7-2 LOWERFI,ID BILLCRANK ASSEI'IBLY

CL?T-T7 PUSH.PULL TUEEASSEI.IBLY

TUBEASSEIIBLY C343.I PUSH-PULL

\_--

----J

----c343-5 PUSH-PULL TUBEASSEIIBLY

AFT LotlER C346.I RESTRAINT C3l7-l BELLCRANK

TUBEA5SEHBLY CI21.9 PUSH.PULL

CONTROLS FLTGHT 8.2 TAIL ROTOR FIGURE

Page8 . 3 A

Change7: O6 Dec 99

FIOBINEICIN

MATNTENANcE MANUAL

MODEL

F,44

8 . 1 0 0 C Y C L I CC ON T R OL S

WARNIN Manual control (electric-trim)R44s require 0.O65 inch wall t h ickn e ss C 3 1 9 -3 to rq ue tube assemblieswith C177- 2 pivot R44s with 1 C1 7 7 -4 p i vo t a sse mbly) and C176- 3 yoke. h yd ra u l i cfl i g h t co n tro l srequir e0.049 inch wall thicknessC3195 torque tube assemblieswith C 1 7 7 - 3p i v o ta n d D 6 9 6 y o k e . 8.110 CvclicAssemblv 8 . 1 1 1 Cycl i cA sse mb l yR e mo v al a) Removebelly sand controltunnel covers. b ) Removeroll pin from cyclic friction knob and remove knob. lnstalla pin on shaft

to retainspacers. Removecarburetorheat controlknob on shipsequippedwith carb heat assist.

c) Remove C683-4 damper atop cyclic stick (not applicableto hydraulicflight controls), d ) Removeall screws securingC444-1 cover. Disconnectpost light wire and

securecover at highestpoint of cyclic stick. e) Openupperconsoleand disconnectoutsideair temperaturegaugeand intercom

systemcontrollerwiring. Removeradioface plate.

cyclictrim elasticcords per Section8.131 . f) Removeforwardand aft longitudinal

Change 1 0 : J U L 2 0 0 4

P a g e8 . 3 8

F|CIEIINSiC|N

MAINTENANeE MANUAL

MOE'ELF'44

8.111 CyclicAssemblyRemoval{cont'd}

: gPring retainer^onto.lateraltrim g) c' InstallMT14-zlateraltrir rbringgs^senlgly per-section e.1ai. nemove6SS6-t3 palnrjtandAN316-4Rnut atoplateral to removemotorassemblyfrom cyclic irir rpring sn"t. lt is not necessary assemblY. hl Disconnectelectricalconnectionsat bottom of cyclicstick. tube..Move boltfromforwardendof c1 21-1push-pull RemoveNAS66O4-8 push-pull tube p;;h:euli irUe aft and/ormovecyclic grip aft to disconnect from cyclic stick. Removetwo boltsconnectingforwardend of C319-3torq.uetube asse1bly i;Ci77:2 piuot and movet6rquetube assemblyaft to disconnectit from pivot. CAUTION ProtectC319-3torquetube from scratches' k) Disconnect,but do not remove,two boltsholdingcyclicfrictionassemblyto iaUin. epplv frictionto helpkeeemblytogether' l)

up and Removescrewssecuringcyclicbox to cabin. Lift cyclicassem.bly trim slide.lateral box, cyclic of side left disconnectsiiiin fig."ptu'g on assembly. stick cyclic remove and shafl, arm ott sirihg bss6mb[ aJsemUfy Installnuts ont-otwo trictionassdmblybolts,handtight, to retainboltsand spacers. CAUTION Before removing cyclic, Protect silicone-coveredstrain gages on cyclic stick with soft cloth or foam. straingagesor wiring will D'amaged trim system. electronic disable

m) RemoveAZgl-9 holeplugs -Ooli,in keelin rightaft baggagecompartment' -7 R;il"; ruASOeOS-+e C130-7'spacerand hardwareconnecting C121 push-pulltube lowerrod endsto Cl76'2 yoke' tube boltandhardwareconnectingC121-3push-pull n ) RemoveNAS66O5-16 lower rod end to C958-5bellcrank. ol

Disconnect A2O5-5 fork assembly from C326-7 bellcrank by removing bolt, C130-12 spacei, and relatedhardware. f.fASOOO4-38

p) Remove C319-3 torque tube assembly and attached parts by moving assemblydown and aft through belly'

P a g e8 . 4

Change5: 15 Jun 98

FICIBINEiCIN

MATNTENANeEMANUAL

MOEIEL1e,44

8.112 CyclicAssemblyInstallation a) InstallC319-3torquetubeassembly(with attachedC121-1push-pulltube assembly,C176-2yoke, C958-5bellcranks,and A2O5-5fork assembly) through aft belly of helicopter.Beforeinstallation, center-to-center distancebetween8115-1bearingsand A101-4 rod end in A2O5-5fork is 3.80 + O.O3inchesandiam nut and palnutaretorquedper Section1.320. bl ConnectA2O5-5fork assemblyto C326-7 bellcrankper Figure8-3 and torque. c) Connectlower end of C121-3 push-pulltube to C958-5 bellcranksand torque. d) ConnectC121-7push-pull tubesto Cl76-2 yoke usinga NAS66O5-46 bolt andC130-7spacerandtorque.Installtwo A231-9holeplugsin keel. el Positioncyclicstick betweenkeels.Connectstraingagewire plugto cyclicbox, carefullyslidelateraltrim assemblyarm onto springassembly shaft,andguidecarbheatassistrod (if installed) thru box. Installall screws fasteningcyclicbox to cabin. CAUTION Exercisecare when installinglateraltrim assembly armonto springshaftto avoiddamagingteflonliner in bearingbore. f)

ConnectC319-3torquetubeassemblyto Cl77-2 pivotand torque. CAUTION ProtectC319-3torquetube from scratches.

sl Fastencyclicfrictionassemblyto cabin. h l Connectforwardend of C121-1push-pull tube to cyclicstick and torque. il

Connectall electricalplugsat bottomof cyclic stick. Positionprotective sleevingto covermaximumamountof wiringpossibleand securesleeving endswith lacingtape.

j)

FingertightenAN316-4Rnut on lateraltrim springshaft then installand torqueB33O-13palnut. RemoveMT544-2retainer.

k)

Installlongitudinal cyclictrim elasticcordsper Section8.132,

t ) Movecycliccontrolthroughallpositionsandthat thereareclearances and no binding. Turn masterbatteryand trim switcheson and check clearances with trim motorarmsin differentpositions.Usecircuitbreakers position to control at whicharmsstop.

Change

1 5 J u n9 8

P a g e8 . 5

FICIE|INSC|N

MAINTENANeE MANI.IAL

M(]EIEL

F'44

(cont'dl 8.112 CyclicAssemblyInstallation m)lnstallradiofaceplate,connectOATgage-try-illgicomsystemwiresand ty-rapasrequired.C|oseandsecureupperconso|e. heatassistactuatingrod nl Connectcyclicboxcoverpostlightwire,guidecarb frictionknob, (if installedlthru nolein i;ver, aiid securdcover. lnstallc.yclic with carb heat ships heat control knob on anOroii'iil.- i;stalr-carUuret6r assist. and torque per section o) Installc683-4 damperassemblya19n9V-c-li"^-tjiqk to hydraulicflightcontrolsl. i.s3o [not applicable p) Installall s. tubelength q) RigmainrotorflightcontrolsperSection1O.121it any push-pull was changed. r) Adiusttrim controllerper Section14'710' 8.120 CyclicGrioAssembly Removal 8.121 CYclicGriemblY from withoutremovalofcompletecyclicassembly Thismaybeaccomplished rotorcraft. a) lf installed,removeC683-4damperand disconnectD140-1trim controller from airframewiring. b) RemoveforwardbellY' coverinow1199 c)' Removelacingtape from both endsof protectivesleeving ;i[k iri"*uiv. Usingpin extractor,removefrom housing exitini;;;';i za4, ids, zsa, ?77, 28O,281-,611, 61.2, ;;;i;;; those pins connectect wire 613,'6i'd; dii'; iligg'5 tii i"ttatleot..ltiacn a 3 foot lengthof safetv or wire lacingtapeto one removedpin' where grip d) Removecotter pin, castellatednut, and A141-14 washer assemblyattach6sto stickassembly' el Removegrommetatopcyclicsticka.1Oriemblywiring-att-T::.i:il plvotand removegrrp asseT.btv tap cyclic-grip hammer,'gently a soft-flc"ed safetv wire or .rrrrLii anijittaCn'ei *iilng irom stidk'assemb.ly.Ensure assemblv' stick of tacinginitalled in step ci pr'otiuOejtrom !9P,9q!^"lt3m assemoly' pivot bearingsremainwith stlcK Also,-ensure NOTE Do not damagebearingswhileremoving'

P a g e8 . 6

C h a n g e5 : 15 J u n 9 8

FOE|INSiC|N

MATNTENANeE

MANUAL

MclE EL p.44

left blank. This pageintentionally

l s s u e d1 : 1 Jun93

Page8.7

FICIBINSiCIN

M(lErELF'44

MATNTENANcE MANI.IAL C334 AFT ASSEMBLY

PART NUMBER@

PART NUMBER

DESCRIPTION

1.

MS21042L3

Nut

27.

AN316-4R

Nut

2,

AN960-101

Washer

28.

A127-4

Rod End

3.

D336-1

Plate

29.

NAS6604-8 Bolt

4.

c130-24

Spacer

30.

A141-3

Washer

5.

A130-21

Spacer

31.

A105-3

Journal

6.

c130-25

Spacer

32.

C317-1

BellcrankAssy

7.

81000-050-s

Spring Washer

33.

C121-9

Push-PullTube Assy (Ref)

8.

1 NAS6603-1

Bolt

34.

NAS6604-7 Bolt

9.

8249-6

Arm Assembly

35.

4205-5

Fork Assembly

10.

c315-7

Aft Assy Weldment

36.

C130-12

Spacer

11.

NAS6604-2

Bolt

37.

AN316-6R

Nut

12.

MS21042L4

Nut

38.

D173-1

Rod End

13.

AN960-416

Washer

39.

C121-19

Push-PullTube Assy (Refl

14.

AN960-4161

Washer

40.

A130-47

Spacer

15.

8330-19

Palnut

41.

NAS6604-38 Bolt

16,

MS21042L6

Nut

42.

C326-7

Bellcrank

17.

AN960-616

Washer

43,

8303-1

Bearing

18.

8250-11

Journal

44.

c130-32

Spacer

19.

7 NAS6606-1

Bolt

45.

c958-5

Bellcrank

20.

8330-13

Palnut

46.

AN316-5R

Nut

21.

C038-5or -6

CollectiveSpring Assy (Ref)

47,

8330-16

Palnut

22.

c311-1

Bolt

48.

A101-4

Rod End

23.

A141-11

Washer

24.

NAS6604-11

Bolt

25.

c343-1

Push-PullTube Assy (Ref)

26.

8316-4

Rod End

NUMBER

P a g e8 . 8

I

DESCRIPTION

C h a n g e 7; 06 D ec 99

FIClElINSiClN

MAINTENANcE

MANUAL

M|fElELF|44

8.122 CyclicGriemblyInstallation a) Ensure,rollprnis installedin grip.assemblywith. protruding^ 9l^d_lo^Yt protectivejleevingcoverswirei exitinggrip assemblywith one grommetin griPand one on wire bundle, InstallA141-14washer, in stickassembly. intobearings b) Slidegriembly casteilatednut and cotter Pin. CAUTION Tiohtencastellatednut only untilthereis no axialmovement ind cyctic grip issembly. Overtighteningnut will ;ii;;;i"gs damagebearings. atop c ) Temporarilyattachgriemblywiringto safetywire (or lacing)exiting included ivJr'i[-it'iii1L;;i"ilvbrrr *ires thrucVclicsticli. Installsrgm.met: Routeg.rip ,Jiih gri;;G;bry *ifing,.into cyclicslicf wiringentrancehole.cyclic stick exiting protecting wires ;G;bty wires triru-'eiiiiingsle'eving bottom.'Removesafetywire {or lacing).

Figures d ) Installpinson eachwire into properpositionin housings'Referto 14-2 and 14'4 for Pin Position.

stick bottomto cover -Secure e ) Positionprotectivesleevingon wirinqexiting.cyclic tape. maximum.rorntti*iringlossible.

f)

s)

P a g e8 . 1 0

sleevingendswith lacing

Connectcyclicand airframewiringandty-r.ap.rMole cycliccontrolthrough ind no binbing. Turd masterbattervand ;1 il;iti"rfiinJ uerityclearance with tr:immotor arms in different trim switcheson-inO'cn"cf clearances positions. i'diltio"i. Uie citcuit Ureatersto stop armsin different flightcontrol)or C683-4damperassembly(manual Installendcap (hydraulic fliqht control)at.ip c'Cfi" siick. Torquedamperassemblyattachingscrews pe-rSection6.330.

h)

InstallforwardbellY.

i)

to hydraulicflight Adiusttrim controllerper section 14.710(not applicable controls).

C h a n g e5 : 15 J u n 9 8

FICIBINSCIN

MATNTENANcE MANUAL

M(lElEL13'44

CyclicTrim ElasticCords 8.130 Longitudinal stickforcesduringhoveringand Elasticcordsareusedto zerolongitudinalcyclic and 8-4A. cruiseflight. Referto Figures8-4

I

Oneor two cyclictrim elasticcordsareinstalledin the R44.Oneaft (cruiselcord, motorcable, whichimpartsa forwardcyclicforce,is connectedto the longitudinaltrim (hoverl force, may be an aft cyclic imparts which cord, elastic forward Oneopti6nal replacing any elastic Before assembly. stick bottom of the cyclic connebtedto the range when full operating its is thru motor arm traveling longitudinaltrim ensure cord, position. placed full aft forward and then is in full cyclic stick

l,

lf cyclicgripmovesforwardin hover,a strongerforwardelasticcord is required. lf cyclic grip moves aft in cruise flight, a stronger aft elastic cord is required. Decieasingforward(hover)elasticcord strength_by5 poundshasthe sameeffectas (cruiselelasticcord strengthby 1Opounds. increasing-aft a)

Removeelasticcord per Section8.131 and determinepart numberfrom identification tag. NOTE The R44 IPC lists elastictrim cords by part numberand installedload(force).

b)

Usingaboveinformation,and amountof force requiredto countercyclicforce, elastictrim cordfrom the lPC. lf cord is old, try replacing selectan appropriate it with samepart numbernew cord first.

c)

InstallperSection8.132.

dt

Thecyclictrim must if propercordwas selected. Testfly helicopter to determine (neutralize) KIAS autorotation at C.G. station zero cyclicforcesduringa 1OO 9 9+ .

e)

cyclicforces. Repeatstepsa) thru d) as requiredto balancelongitudinal

C h a n g e5 : 1 5 J u n 9 8

P a g e8 . 1 1

I

FIGIBINSC|N

MIfEIELH44

MATNTENANeE MANUAL

A697-4 BRACKET

C 9 1 8 - 1 1- ,1 2 , o r - 1 3 CORD ELASTIC ( II"IPARTS AFT^ FORCE) CYCLTC

8-4 FIGURE (H0VER) FoRI.IARD TRIMCORD ELASTIC

A697-6 PLATE

RIGTTTKEEL

I I

A697-3 ANCHOR

\/

C918-1thru -7 CORD ELASTIC ( IT4PARTS FORI,IARD FORCE,/ CYCLIC IN CRUISE . T FLTGHT) \.r ELASTICCORD ( IMPARTS A LEFT PEDALFORCE)

/ /

\tt

,

c121-9 PUSH-PULL TUBE (TAIL ROTOR CONTROLS )

.

V.t

37Lli2I CONNECTOR

ELASTIC 8-4A AFr (CRUISE) FrcuRE TRIMCORDS

ROPESECURELY WRAP ANDOVERLEFT AROUND PEDALAMMBLY ,77i"-221 3=::;-'-t=';;;

8-48 FIGURE RELIEF TENSION BRINGROPEOUT CONNECTOR 3711T21 CONNECTOR

P a g e8 . 1 2

ACCESS THROUGH HOLE

C h a n g e5 : 1 5 J u n 9 8

FIC|BINSCIN

MATNTENANcE MANUAL

MOEIEL

FI44

8.131 ElasticCord Removal NOTE See Section 2 for elastic cord inspectioncriteria. 1 . A ft e l a sti cco rd (C 9 1 8- 1thr ough- 9) : a) Removecontrol tunnel covers (referenceFigure2-2, item 3A & 4F). b) Turn masterbattery and trim switches on. Hold cyclic stick firmly against aft stop.to allow longitudinaltrim motor arm to go to upper stop. Turn master battery and trim switches off. c) Move cyclic stick fullforward. Removeblackplastichole plug from right keel just aft of right side tail rotor pedals. dl Referto Figure8-4B. Apply full right pedal. Route one end of an 8 foot lengthof 114inch diameternylon rope through right keel hole iust aft of right side tail rotor pedals, through C918 elastic cord nexi to 3711T21 connectorand back through keel hole. Wrap both ends of rope around left pedal and hold securely,Slowly apply left pedalto take up slack on rope and relieve tension on 371 1T21 connector. Unhookconnectorfrom C918 elasticcord. Let left pedal return slowly tull aft. CAUTION Always remove tension on 371 1T21 connector before unscrewingit. DO NOT allow C918 elasticcord to put tension on an unsecured3711T21 connector. e) Very slowly, easeoff tension on rope until there is no more tensionon elasticcord. fl

Unhook both ends of elastic cord from 4697-3 anchor riveted to right keel . Removeelasticcord.

2 . F o rw a rde l a sti cco rd (C918- 11,- 12, - 13!.t a) Removeforward belly . b) Move the cyclic to full aft position. c) Unhookthe forward trim cord from the A697-5 clip locatedat the bottom of the cyclic stick. d) Removethe trim cord hook from the forward bracket.

C h a n g e5 : 15 J u n 9 8

P a g e8 . 1 3

FICIBINSCIN

MAINTENANeE

MOEIEL

MANUAL

F|44

8.132 ElasticCord lnstallation 1. Aft elastic cord installation

CAUTION C918-8and -9 elasticcordsmay only be usedwith cYclictrim assembly' COSS-tO keel' a) Hookboth endsof trim cord to A697-3anchoron right motor arm in bl Movecyclic to full forwardpositionwith longitudinaltrim uP Position.

8 foot

oneendof an c) Referto Figure8-48.Applyfull rightpedal.R.ou1e. keelholeiust

i;;;ih ;f i7+ inCnbiitEt"i nylgliopd tnrouq[r-ignt ihrougnCglE.elasticcord nextto aft of rightseat'tlii'i6i6i p6Oals, kdelhole'Wrapbothends U5J[inroqOn 9711T2tronn""tJi, ""ii and holdthem securely' of ropearoundleft pedal

pedalto stretchc918 elastic d ) ReferenceFigure8-4A.Slowrv_arpLl"-ft the C918

I

SilltZl connectorbetween cord. fnstattanO-secu6't-n"' Figure8-4A.slowly Reference elasticcordand coss-7 cableassemuty. releasetensionon rope.Removerope'

I

CAUTION DO NOTallow the c918 elasticcord to applytension to an unsecured 3711T21 connector' WARNING Turn on trim system and ensure clearance is mjintaineOUeiwELnihe elasticcord hooks, push.-pull iuUeClnO wiringthroughoutentirecycliccontroland trim sYstemtravel. e) Reinstallall sand the hole plug' f)

P a g e8 . 1 4

E va l u a tetri m co rd per Section8' 130( d) '

C h a n g e5 : 1 5 J u n 9 8

FICIBINSC|N

MATNTENANeE MANuAL

MOE EL F'44

8.132 ElasticCord Installation(cont'd) 2. Forward elastic cord installation

a) Hookforwardend of elasticcord to bracketunderradiorack. bl Pullcyclicto full aft positionand hook aft end of trim cord t.r 4697-5 clip locatedat bottomof cyclicstick. WARNING Turn on trim system and ensure clearanceis maintainedbetween elastic cord hooks, push-pull tubes, and wiring throughoutentire cyclic control and trim systemtravel. cl Installbelly. a

8.140 Lateral& Longitudinal CyclicTrim Assemblies 8.141 LateralCyclicTrim AssemblyRemoval(C055-2or CO55-9) a) Removeforward belly and betweenforwardseats. b) Removeroll pin from cyclicfrictionknob and removeknob. Installpin on shaft to retain spacers. Removecarburetorheat control knob on ships equippedwith carburetorheat assist.

I I

c) Removeall screwssecuringC444-1cover. Disconnectpost light wire and securecoverat highestpointof cyclicstick. d) Openupperconsoleand disconnectthe OAT gageand intercomsystem wiring.Removeradioface plate. e) Turn masterbatteryand trim switcheson. Move and hold cyclic against right stop until lateraltrim arm movesfully left. Thenturn trim and master batteryswitchesoff and movecyclicstick to full left positionto compress trim spring. f)

I

InstallMT544-2lateralspring assemblyretainerand securewith heavy-duty

palnut tospring Remove nut assembly. andAN316-4R :l#o;?,1!*ri3l,?:.t

gl Disconnect lateraltrim motorwiring. h) Removetwo NAS66O3-26 boltswhich connecttrim assemblyto C177-2 pivot. i)

Removegearmotorassembly.

j)

lf necessary, removespringassemblyby disconnecting C591-2blockfrom cabinassembly.

C h a n g e5 : 1 5 J u n 9 8

P a g e8 . 1 5

I

MOEIELll'44

MAINTENANeE MANUAL

F|clEINSclN

(cos5-2or CO55-9) 8.142 Lateralcyclic Trim AssemblyInstallation CAUTION Thereare two trim controllerpart numbers:D'l-40:L31d^D1*O:?; -6 and Co55-2'

with Dffi6-i';ilffiilorreihust 6e-used.9NLY mustbeusedgNtYwith trimlffitroller :'s'J;"1i"'iiihXll.iir,ei. oi+o:z lerandtrim controller Incompatible irlm assemb-lies. co55-9,-10 and-ii COSS-g, failure' .--r

l-^

..^^)

t

"V"fi" in trim system will result is-s"mUiv(s)

block(permanently

installC591-2 was removed, a ) lf CO56-1springassembly attachingscrewheads attachedto springlllemtity nottomiin qqptngtt"ttl bolts downward thru two NAS6603-26 forward. Instaltfi;;;;;lnUiv;i

assemblv C..iituIlv: IIotti im srr ""t3,if Cii i :ib i.1ii!-. n [ilgat*: ff ;5iil C177:?PjYo^t to, it attach and Ueto*, t-rimaslimUtv il;

nuts. Torqueboltsper *aineisand two MS21042108 ANgOO-iOf-

S e cti o n1 .3 2 O.

palnut -Movethen installB33O-13 b ) lnstallAN316-4Rnut fingertight on_spring^shaft, to reftand remove

ii.'o--i"rql"parnliJei becii6nt.320. uis4,+i

cvcric

lat'eralspringassemblyretainer'

outboard of cyclic friction c ) Routetrim motor wiring around.front of andwiring as requiredto prevent assembly.Connecttrim motorwlrlng' Ty-rap interferehcewith flight controls. d) Turn master battery and trim switcheson' of trim motor e) Move cyclic to left stop and right stop and observe movement with no bindingor

of tiauei.lt must.befree arm througnb-ufiiil'-t|ng". furn raJtei batteryandtrim switchesoff. interferenc".

f)

tv-ra0f Installradiofaceplate,connectoAT and intercomsystemwires,and console' iJiequireo. Cloie and secureupper

carbheatassistactuatingrod wig,_quide boxcoverpostlight g) Connectcy-clic jnd secur6cover. Installcyclicfrictionknob (if instatled) thru holein c5uei, heatcontrolknob on shipswith carb heat and roll;il.'inri'rri ".ruuret6r assist. h) Installall s. i)

Adjusttrim controllerper Section14'710'

(C055-6or CO55-1O) Removal CyclicTrimAssembly 8.143 Longitudinat per .Section 8.1 1 1, steps a) thru k). a) Remove cyclic stick assembly^ performstepsa) thru e] a n d g ) o f S e c t i o n8 . 1 1 1 a n d l e a v e Atternat:vely, -assembly installed' cyclicstick b)RemovetwoNASl352.oSscrewsconnecting|ongitudinalcyclictrim asstmUtyto cyclic stick. Removetrim assembly'

P a g e8 . 1 6

C h a n g e5 : 1 5 J u n 9 8

F|CIEIINSCIN

MOE EL F44

MATNTENANeE MANUAL

(CO55-6or CO55-1O) g.1M Longitudinal CyclicTrim AssemblyInstallation CAUTION There are two trim controllerpart numbers:D14O-1and D14O-2. D14O-1trim controllermust be usedONLYwith CO55-2,-6 and -8 cyclic trim assemblies.D14O-2trin: controllermust be usedONLYwith CO55-9,-1O and -11 controllerand trim cyclic trim assemblies.Incompatible will resultin trim systemfailure. assembly(sl a ) Refer to Figure 8-4C. Install trim motor assembty^gl qYc-ficstick with nut in lower washerandMS21O42LO8 screwNAS62O-8L NAS1352-OB-12P NAS1352-08install positionand lightlytighten. Pivotmotor upwardand 32P screw, C{30-11 spacer(maybe securedto motor with ty-rapto ease (chamfer pointingaft),NAS62O-8L washe,r, and C13O-2Ospacer installationl, position C130position. used to Fiemove ty-rap nut in upper MS21O42LO8 1 1 spacer,if installed.Torquenutsto 20-25in.-lbs(includesnut self-locking torquel. per Section8.112 stepse) thru ql. b ) lf removed,installcyclicstickassembly

lf cyclicwas not removed,connecttrim motorwiring and performstepsk) thru q) of Section8.112.

c ) Adjusttrim controllerper Section14.710. MSz104213 NUTl \€r.

v9\

NAs62o-81 >A

\,/-

h

CYCLIC STICK

8-4C FIGURE CYCLIC LONGITUDINAL INSTALLATION TRIM ASSEMBLY

NAS1352-08-12P SCRE}{ WASHER NAS62O-81 MS21O42LO8 NUT

c 1 3 0 - 2 0SPACER

cl30-11SPACER

TEMPORARY TY-RAP NAS1352-08-32P SCREt,l

C h a n g e5 : 1 5 J u n 9 8

FORWARD

P a g e8 . 1 7

MATNTENANcEMANUAL

FIEIBINEiCIN

MOEIEL F44

ROLLPI

ASSEMBLY FRICTION C048.1CYCLIC

OR INSTALLAN96O-416 HERE AN96O-4161WASHER

NOTE FRICTION DONOTREMOVE PLATEBOLTShlHENREMOVASSEMBLY ING FRICTION THEHELICOPTER. FROM

0.310'in.

c130-2 SPACER A130- 18 SPACER

!o*nuo-6 1 6 1 t,|ASHE()

BELLEVILLE WASHERS _

n0 . 0 5 5 / 0 . 0 3i 5

AN960-6161 l,'|ASHER AT WASHERS ADDAN96OPD616L AS REQUIRED NOTEDLOCATION T0 MAINTA0 I N. 0 5 5 / 0 . 0 3 5i n DIM ENSION

ANDADJUSTMENT FIGURE8.4D CYCLICFRICTIONASSEMBI-Y

P a g e8 . 1 8

Change2: 12Dec 94

FICIBINSCIN

MATNTENANeE MANUAL

MOEIEL

F,4ZI

8.150 CyclicFrictionAssemblv The cyclicfrictionassemblyis locatedbelowthe forwardleft cornerof the cyclicbox. Turningfriction knob clockwiseappliesfrictionto both longitudinaland lateralcyclic axes. Adjustmentis requiredif frictioncannotbe applied. ,

8.151 CyclicFrictionAdjustment

until it stops. al Turn frictionknob counter-clockwise bl Removeroll pin connectingknobto shaft. cl

Lift knoboff shaft.

dl InstallAN96O-416or -416Lwasher,as required,per Figure8-4D so knob rotates1/8 to 1 turn beforeaddingfriction. With frictionon, force required at griplwitn to movecyclicin a lateraldirectionshouldbe 7-13lb (measured trim motors in neutral position.

el

Replaceknob and installroll pin.

fl

Move flight controls throughout complete clearanceproblemsexist.

no binding or

8 . 1 6 0 C 1 2 1 - 7 P u s h - P uTl l u b e 8 . 1 6 1 C 1 2 1 -7 P u sh -P u lTl u b e Rem oval a) Removeaft belly . b) Removemast fairing. c)

Removetwo plugs located in aft right baggagecompartment.

d) Remove NAS66O5-46 bolt attaching C121-7push-pulltube rod ends to C176-2 yoke.

e ) Disconnectbolts fasteningCl21-7 push-pulltubes to swashplate. f)

Tape sheet metal edgesto preventpush-pulltube damage.

s)

Positionswashplateand rotor to slide C121-7 push-pulltube up and clear. Mark right and left tubes for reinstallation.

h l Inspect push-pulltubes and sleevesfor damageper Section 8.162. i)

Inspectpush-pulltube guide rollersfor wear. Replaceguide rollersif worn. NOTE lf push-pull tube is replaced,adjust rod ends to obtain same center-to-centerlength or main rotor flight controls will requireriggingper Section 1O.

C h a n g e5 : 1 5 J u n 9 8

P a g e8 . 1 9

MOEIEL]e44

MAINTENANeEMANUAL

FIclBINEiClN

TubeInspection/Repair 8.162 C121-7Push-Pull g1_dno more than a) Nicks,cuts or scratchesin tube which are |ongit,^dllPl inchdeep,may be O.OO5 than more no and inchdeep,or.,"rori t;b; O.O1O out. Polished must be b) Tubes dented or flattenedmore than five percentof diameter replaced. wear wall.afterp^olishing cl Maximumtube wear at guideis o.o1_5inch per. wear beforesleeVeinstallation.Any tube ridges.EpoxyprimerepalTirrtaCes installation' reqiriresnew sleeve tube worn in excessof 0.015 inch after polishing. d) Replace TubeSleeveInstallation 8.163 C121-7Push-Pull NOTE R e p a i ra n y w e a r damageon C121- 7 push- pull.tube p e i S e cti d n8 .1 6 2 pr iorto the push- pulltube sleeve installation.

a ) Cleanpush-pulltube with MEK or acetone' inches b ) Aoolv taDeto restrictadhesiveto a six-inchlong area.beginning30.5 ii6f;'nil"t

end of push-pulltube (not end of rod end)'

of B27O-3adhesiveto one cl Test paint for paint bubbling;aPPlyf -inch band paint applvepoxvprimer

remove enodt ii* incriarei. tt Ginibubblbs,

and

to area beforeaPPlYingadhesive.

WARNING Adhesiveto be aPPliedto comPlete area under Push-Pulltube sleeve' will d) Apply adhesivesuppliedin kit to entire six-inch long.area' {Adhesive large quickty set anOUl;bhe iqlngv. Brushon thin coat of adhesivewithout lumps as raPidlYas Possible). NOTE Sleevemust be installedwithin two minutesafter adhesiveis applied'

e) Slide sleevesonto tube and center on adhesive' f)

Rotatetube and apply heat usingup to 12oo-watt heat gun to evenly shrink sleeveand producea smooth surface' CAUTION DO NOT aPPIYheat continuouslYto sa me a rea.

P a g e8 . 2 O

C h a n g e5 : 15 J u n 9 8

MOEIELH'44

MATNTENANeE MANUAL

FICIBINSCIN

(cont'd) TubeSleeveInstallation 8.163 CI21-7 Push-Pull g) - Allow to cool and apply adhesiveto seal end of sleeve.Do not allow adhesiveat sleeveendsabovesurfaceof sleeveor sleevewill be damaged or will not enterguideduringinstallation. TubeSleeveInspectign. 8.164 C121-7Push-Pull

'

Visuallyinspectsleevefor wrinkles,pin holes,bubbles,gouges,torn areas,etc. Replacesleeveif any damagedor suspectareasare found. TubeInstallation 8.165 C121-7Push-Pull CAUTION Exercise extremecarewheninstallingC121-7pushpulltube into guideto preventdamageto push-pull tube sleeve. tubeand hardwareper Figure8.4F, a) InstallC121-7push-pull b) Attach C121-7push-pulltubesto swashplate. c) Reinstallmastfairing. SeeFigure8-48. NOTE Locateandtightenclampholdinglowerfairingrib to masttube assemblypriorto closing. d) Removeprotectivetape from sheetmetaledgesusedto protectpush-pull tubesduringinstallation and closemastfairing. e) Checkfull travelclearances of flightcontrols. f)

fastenersare torqued.

plugs. g) Installsand baggagecompartment dimensionwas changed,check h) lf push-pulltube rod end center-to-center mainrotor riggingper Section1O.

C h a n g e5 : 1 5 J u n 9 8

P a g e8 . 2 1

MOCIEL]e44

MATNTENANeE MANUAL

FICIBINSiCIN

cL21-7 PUSH-PULL TUBEASSEMBLY

clzl-7 PUSH.PULL. TUBEASSEMBLY

liA

NAS557-284 GROMMET

o:

Ij -::.

ti\

c26t-7 :\\

AN960-101 I,IASHER

RIB

c

\rorr-, G U r D E!; i|

uurr,rL

A S S E M B L YIi Ir

clzr-s

NUT MS21O42L3

p U S H- pULL TUBEASSEMBLY

c43s-7 GUIDE ---."di

i i! ! I tic

|

|

I ' !,_,,O !

i

( *1.

c261-8 RIB

fi;i*

i, i'€i^-,-j;zit, i E:::{/

ASSEMBLY ciu'.*b#,i i I t i--l ill-4 l-

ANDGUIDES TUBES 8.4E PUSH-PULL FIGURE onlY) (Electric Trim SYstem

P a g e8 . 2 2

Change7: 06 D ec 99

FICIBINSCIN

MATNTENANeEMANUAL

MOEIEL

F|44

cI21-7 P U S H -P U L L TUBEASSEMBLY

cL21,-7 PUSH.PULL TUBEASSEMBLY

C 1 5 -1 SP ACER

c130-7

\

SPACER

\

hh

I

cl15-1 SPACER

NAS6605-46 BOLT \\

AN960-516L WASHER

cL76-2 YOKE

-\i

\

I

'@vi \-->.

AN960- s161 WASHER MS2104215 8330-16 NUT PALNUT

INSTALLATION TUBEASSEMBLY F IGU R8E-4 E CI2I-7 PUSH-PULL

Change 2: 1 2 D e c 9 4

Page8.23

FICIBINSCIN

MATNTENANeE MANUAL

MOE EL F44

CONTROL 8.2OO COLLECTIVE 8.21O CollectiveStick Assembly 8.211 CollectiveStick Removal collectiveboot a) Removeforward horizontal,aft vertical , both = left seat back. forward behind 6cated tJr6is, anOtneloliective c6ver bl Installthe MTS44-1springretaineron the collectivespring locatedat the verticattunnel while iolledtive is in full down position. c) Disconnectforward end of C121-19Push-Pulltube from the collectiveby removingNAS6604-9bolt. d l Unplugthe governormotor wiring locatednearleft side of collectivestick. NAS66O3-5 e) Disconnectcollectivestop from the anchor by removing..the. collective' from the spring th'eovertravel UofiinO Oisconneiting

sl

assemblyto Removeone NAS66O/|-17bolt which connectsthe collective. keel right pilot's the on seat the iird'ii.'Iatije ioCitLO-behind the c303-1 at the left end of the -removed Removethe threescrewsholding with the collectiveassembly. toireiiiue. The suJpoti G to Oe

h ) Removecollective. 8 . 2 1 2 CollectiveStick Installation

item a ) AssembleA332-1 frictionleverper Figure8-5. The spring.washers,

i4;th"rld be assembledwith their concavesides together. The two Teflono coated surface -tever 'iviin-ilil itt; ib-,-arl-instatpO wlth lh^e^grey is threadedonto the A33z-1 The 'ai 121. iiriiiiit tr,e A333--i stop iiter the

ilrXdig'Si:iZ+i iCrLfi

the screw starts to protrudefrom

attachmentfitting.

NOTE Seecollectivefrictionadiustmentfor finalizing friction assembly afier completio-n-of Referto Section8.224' Coiltctiveinstallatibn. b) C o n n e c t c 3 o 3 . l s u p p o r t t o c o | | e c t i v e s t i c k , i f r e q u i r e d . | n s t a | | N A s 6 6 0 +

11 bolt and attacnirifinarAware.Torqueper Section1.320.

c) lnstall collectivestick into rotorcraft. d l Connectcollectiveinboardattach bolts.Torqueto per Section1'32O'

Pa g e8 . 2 4

lssued:11 Jun 93

FIClElINSiClN

MAtNTENap6=

MANUAL

MtfElEL

F|44

FORWARD

F IGU R8E-5 COLLECT I VE FRICTIONASSEMBLY

NUMBER I 2 3 4 5 6 7 I 9 l0 11 12

PARTNUMBER

DESCRIPTION

MS27039C0806 Screw A332-1 Lever 4431-r Knob 4N960-81 !lasher MS21042108 Nut NASl352-08-t2PScrew 4959-2 End Cap c348-1 Anchor A601I G r ip c758 C o l ' l e c t i v eA s s y A130-4 Spacer A333I Stop

Ch a n g e1 0 : J U L 2 O O 4

13 l4 15 16 t7 18 l9 20 2t

PARTNUMBER

DESCRIPTION

4141-20

t,lasher

80500-022-s NASl352-4-24P AN960-4161

Bellevi'lle l,Jasher Screw Washer(A/R) washer(A/R)

AN960-10L

l,lasher

NAS6603-5

Bolt

MS2104213

Nut

8330-7

P a ln u t

AN960-415

P a g e8 . 2 5

MAINTENANcE

FIEIBINSiCIN

MANUAL

MffEIEL

F|44

{ShipS/N 1oo01 and subsequentl

(ShiPS/N 0001 thru 99991

INSTALLATION SPRING OVERTRAVEL F IGU R8E-6 U P PER

PARTNUMBER

PTION DESCRI

1

c758

CollectiveAssemblY

2

A486-1

Screw

3

Spacer

4

A341-1 -L A327

0ver tr avel Spr ing Assem blY

5

N A S1I 49F0332P

W asher

6

MS 2 104213

Nut

7

8330-7

Palnut

8

c342-L

Ar mAssem bly

9

A4B6-4 c 3 4 1- 1

Screw

NUMBER

10

P a g e8 . 2 6

Ar mW eldment

C h a n g e1 O :J U L 2 O O 4

FIClElINSiClN

MATNTENANcE MANUAL

MCIEIEL F|44

8.212 CollectiveStick Installation(cont'd) el Connect left held in place by one upper MS37O39C1-OBscrew, AN96O-1OLwasher and MS21O42L3nut. Installtwo lower MS27O39CO8O6 screws,AN96O-8Lwashersand MS21O42LO8nuts. f) Installlower end of A333-1 stop to the C348-1 anchor. When installingA3331 stop onto the A13O-4 spacer,add AN960-416 and 416L washerson either side of stop as requiredto align stop with collectiveand to obtain 0.001 to O.O35inch axial play. Torquenut per Section 1.320. Installpalnut and check for bindingand axialplay. g) Connect C121-19 Push-Pulltube to collective. Torque NAS6604-9 bolt per Section1.320. CAUTION The NAS66O4-9bolt at the forward end of the C121-19 push-pull tube must be installedso the bolt head is toward the left side of the helicooter. Referto Fiqure8-1. h) Connectgovernormotor plug to the connector. i) Removethe MT544-1 springretainerfrom the collectivespringassembly. j) Installthe A327-1 overtravelspringto the collectivearm (seeFigure8-6). NOTE Use specialA486 screw and A341-1 spacer. With screw head against rod end ball, install spacer with large diarreter against collectivearm. Torqueto 28 in.-lbolus nut draq and installpalnut.

WARNING lmproperinstallationcan cause binding,rod end damage or rod end separationwith subsequentloss of ne throttle control. k) For riggingof throttle correlation,see Section 1O.15O. l) all bolts and fastenerstorqued. m) Installall s.

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Page8.27

FI(JBINSiCIN

MODEL F'44

MAINTENANGE MANUAL

collectiveFriction(seeFigure8-5) 8.213 Pilot-Adjustable 1. Loosenscrew (6) on frictionlever' inch aft of full-forward 2. a. Manual controls- Hold friction lever knob 0.3-0.6 (13) be rotated with cannot washers position. Adjust r.r"* ii S) until (6)' iingutt then ti-ghtenfriction lever screw flight controls- Hold friction lever knob futly aft againstcollective -Aaiujt b. Hydraulic screw (15) to producea force of "18-22poundsat collective stick. grip,theniighten frictionleverscrew (6)' g.214 FixedCollectiveFrictionAdjustment(manualcontrolsonly, see Figure8-3) 1. Removeverticalcenterbetweenaft seatbacks. (19) as requiredto eliminate 2. a. Manualcontrols- see FigureB-3. Tightenbolt excessive. feedbick loadthroughc6llectivewithout being b. Hydraulicflight controls- With carburetorheat LOCKEDand.pilot-adjustqb]e to cottectivefriition fulty oft izeio iriction),adjust.NAS66O6 bolt as..required grip collective at force produce 4-5 pounar t.u.tug" of Uottl diiections) within servodeadbands. collectivefrictionper Section8.213' 3. Adjust pilot-adjustable 8-8) 8.220 CotlectivesprinqAssemblv(manualcontrolsonlv, see Fiqure -f6g to balance the collective contro! forces The collective spring assembly is installed spring in the CO38-5 or CO38-6 sprins itiglt by the. main.rotoi. p;;"*J-in after main rotor assemblymay be'ching.d or aujusted-tobalanie t6e collectivecontrol bladechange.

W when collectivespring is compressedand retaining rings.are installed,extreme care must be taken not to remove retalnlng ;;;; ;;f".. ruit"Ut" safety deviceis used to slowly relievetension (seeFigure8-8). 8.221 CollectiveSpringRemoval& Servicing 1. Removeaft verticalcenterbetweenaft seat backs. retaining 2. placethe collectivein the full down position.Install3 MS16633-2018 rotate and nuts locking rings in groout. ott griO" rods. lf necessary,loosen until collective raise springuntil groovesin guide rods are expos6d. Carefully retainingringscap.

Springis undercompresslon.

P a g e8 . 2 8

C h a n g e1 O : J U L 2 0 0 4

FIGIBIIVSCIN

MATNTENANcEMANUAL

M(IEIEL

]t44

VISE

COLLECT IVE SPR IN G ASSEMBLY t^lITHROD ENDS REMOVED

e (LUBRTCATE t,lITH4257-1 SOCKET GREASE) OR SPACER

FIGURE 8-8

--\,,o

METHOD SUGGESTED FORRELIEVING COMPRESSION SPRING

SPRINGASSEMBLY FIGUREB-7 CO38-5AND-6 COLLECTIVE PARTNUMBER

DESCRIPTION

1

NAS6604-7

B o lt

2

4N960-4161

3

BZ92-4

l.lasher Rod End ('left-handthread)

4 5 6

MS2104214 8 3 3 0 1- 3

Nut P a ln u t

NUMBER

7 8 9

MS2104213

Nut AN960-PD1OL hlasher

c426-t c428-2

C h a n g e1 O :J U L 2 OO4

cap Rod

NUMBER 10

PAATNUMBER DESCRIPTION A429-11 4429-t2 A429-13

11 L2 13 L4

Spring (Strong; for C038-5Assy) Spring(Medium; f o r C 0 3 8 - 6A s s y ) Spring(Weak; for C038-7Assy) cap

c426-2 I Nut AN316- 4R I -4 Rod End AL27 M S16633- 3018 R e t a i n i n gR i n g ( u s e d ( or - 2018 for removaland inor - 1018) s t a l l a t i o n o n l y ) P a g e8 . 2 9

FIOBINSiON

MAINTENANcE MANUAL

MOEIEL t,44

8.221 CollectiveSpringRemoval& Servicing(cont'd) 3. Removebottom springattach bolt.

r

4. Disconnectspringassemblyupperattachbolt and removespringassembly. shanks S. Removerod ends from spring assembly_ _a1dinspect. threaded limits' are straightand play is with Section2.120 6. Install spring assembly in vise per Figure 8-8. decompressspring.

Remove retaining rings and

7 . Clean C426-2 tower cap and inspect 0.194 inch diameter-guiderod holes. or greaterthan 0.204 inch diameter nrpl"". cap if holeJar" 6longuted,'tapered, i" !"it"Ut" iize drill bit shank-maybe used as a go/no-gogauge). B . Clean guide rods and inspect visible portions.. Guide rods must be straight, guide'rodsif bent, tapered,worn or rough' ;tlfidril;i, lnO l.oot6. Fieplace 9 . Lubricateguide rods with A257-1 grease(ref. Section 1 .470l' and reassemble springassemblYin reverseorder. 8.222 CollectiveSpringlnstallation

WARNING Installwith nut end of guiderods pointingup (seeFigure8-7).

NING both rod ends must When installingthe CO38 spring ass^embly, end has left-hand rod of turn-s {p,292'4 extend an equ-alnumber protrude equally.can qnd.s rod both if,ru"a). FailJre to ensure and can adjustments during 6T$reads cause either one to run out causebodilyharm. torque 1. Connect B2g2-4 upper rod end to C427 assembly and NAS6604 bolt per Section1.320' per 2. Move collectiveto alignrod end into C326 bellcrank.Installbolt and torque S e cti o n1 .3 2 O. guide 3. After installationof springassembly,removeall three retainingringsfrom r o d s.

Pa g e8 . 3 0

Change1O: JUL 2004

FICIBINSON

MATNTENANeE MANUAL

MOEIEL R44

(cont'd) 8.222 CollectiveSpringInstallation 4. coils are not binding with collective stick full down. Adjust spring assemblyas requiredper Section8.223. WARNING Failureto remove retainingrings or allowingspring coils to bind can limit controltravel. 5. Operatecollectivethroughits full rangeof travel and check for any or binding. 6. Installremoveds. 8.223 CollectiveSpringAdjustment Small force adjustmentsmay be made by extending or contracting overall length.

1 . Securecollectivefully down. 2 . Removebetweenaft seatbacks. 3 . Loosenpalnut and jam nut on A127-4 rod end at bottom of springassembly. 4. Rotatespring assemblyto increaseor decreasecollective-upforce (lower rod

end is right-handthread and upper rod end is left-handthread).Extendingrod force; screwingrod ends in decreasescollective-up ends increasescollective-up force.

5 . T ig h te nj a m n u t p e r S e ction1.320. WARNING Ensurespring coils do not touch with collectivefull down after makingadjustment. Springcoilsthat touch can limit flight control travel. 6 . Whileobservingcollectivespring,move collectivefully up and down and no interference. 7 . lnstallremoveds.

Ch a n g e10 : J UL 2 OO4

P a g e8 . 3 1

FICIBINEiCIN

MOEIEL t.44

MAINTENANeE MANUAL

8.230 RPM GovernorSvstem forces to the The governor system senses engine RPM and applies corrective inPutThrottle inp-t{ts ih;;dl;i *6"n Hpnnis low, governoi in.r"ases thiottle and vice versa.' pilot. .J|t" iriction ctut6h, *t',i.fr can be easilv overridden by.the ;;i"h;ilgh-u off by g o v e r n o ri s a cti ve i ro mT g yo '- 1 i i"i *s' .nJ- neu aho can be switched on or i6! piiot using 6e toggie switct'ron'th" en? of the right seat collective control. RPM in the The governor system is designed to assist the pilot in controlling the ting". lt ma! ng-tPlevqnt over- or under-spegdconditions generated 'd;'il;r;Gfi ;;rr";iop"titind the active range ther.eis a 1olo-widedeadband ffi"n"uu"ir'. Wiirr=in fl''gl-ri 'lO2o/owhere the gov;inoi will not tike action provided the rpm is from 1}1o/o steadY. The governorsystem consistsof the following major components: 1 . The D278 governor controller, a solid-stateanaloq-circuitcontrol unit mounted behindthe left aft seat backrest.f[J controllersensts engine RPM.viatachometer p;ili; in ifre engine right magneto ifreLicopterleft side) and provides a corrective 285ig"ai to trre gori"rnorissemb'iy. Ali goveinor controllersoperate on 14 volts; uo"liif,ips uiifiTea 28- to 14-voit converterto power the controller.

2 . The 14-volt BZ47-5 governorassembly,attachedto the collectivestick assembly governor Ueninathe left front jeat. When activated by the governor controller,the and attached worm geir Urives a friction clutch connected to the ;;;;."i;i throttle.

3 . S i g n a la n d p o w e r w i ri n g . 8.231 GovernorControllerRemoval 1. Removeleft, aft backrestto gain accessto controller.

ARNIN No external adjustment of controlleris available. lf controller fails to operatecorrectly,removeand return it to RHC. 2. Disconnectelectricalconnector. 3. Removefour screws securinggovernorcontrollerto shelf. 8.232 GovernorControllerInstallation CAUTION . R44 helicoPters require the D278-1 controffer helicoptersrequirethe D278-2 controller.

R4411

1 . S e cu reg o ve rn o rco n tro llerto shelf. 2 . Connectelectricalconnector. 3 . l nsta l lb a ckre st. Pa g e8 . 3 2

Change1O: JU L 2OO4

FICIE|INSCIN

MATNTENANcE MANuAL

MOE'EL

F|44

8.233 GovernorAssemblyRemoval The governor assembly is aftached to the collective stick behind the left forward seat. : WARNING No adjustment of the friction clutch is permitted. No replacementof the gear motor is permitted.lf the friction setting is incorrect, or the gear motor operatesincorrectly, removethe completeassemblyand return to RHC. al Removecollectivestick assemblyper Section8.211. bl Removethe NAS66O3-6bolt from the connectingrod. cl Removeone NASl351-+28P screw and NAS1291-4nut. dl Cut safety wire and removetwo AN5O3-8-4screws. el Remove8247-5 governorassembly. 8.234 GovernorAssemblyInstallation al Connectthe connectingarm to the governorassembly. NOTE DO NOT changethe length on the connectingrod. The rod ends center-to-centerdistance should be 2.9O inches- 2.93 inches. bl Installtwo AN96O-10Lwashers,one betweenrod end and governormotor arm and one underthe nut. Torquenut and palnutper Section1.32O. cl Installthe NASl351-+28P screw and torque per Section1.320. dl fnstallthe two AN5O3-8-4screws and torque to 27 in.-lb and safety wire with O.O2Oinch diametersafety wire. el lnstall collectivestick per Section8.212.

Change2: 12 Dec 94

Page8.33

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FICIBINEiC|N

MAINTENANcE MANUAL

MODEL re44

8.239 GovernorTroubleshooting (helicopterleft The majority of governor probtemsare caused by. the engine-right adjustmentor of out being side) magneto's fachomet6r assembly{points) assembly faulty. Refer to'TdM' M"rtli S"i"i." ManJal''for tachom-eter installationand adjustment. rpm. Below When switched on, the governoris active from 8O% to 112o/oengine action. no 80% and above il'Zdt" {ngine rpm the governorwill take maintain engine When operatingin the activg rang-e,the.gqye1norwill attempt to + o.75o/o 1D278-2 6r loii'/. t b.'56t"-llzte-t controller)

;ir ;i:ptr;ii.;i;ti - may - calleda "deadband" controller).ffre'Jag6rotlnit lovernedr.p.m.window level flight as be detected whenl"he helicopte.ris-in siut]t" (no gusts), straight and follows:

(do.not.exceed 1o4vd' ' 1. Gentfy hold throttle and very-slowly increaserpm input (subtlethrottle governor Note and r".oia engine tp*'indi"ation when resistance)is encountered. ( do not go below 99% ) ' 2 . G en tl y h o l d th ro ttl e a n d ver y- slowtydecr easer pm governor input (subtlethrottle Note and *"orO engine rp* inai"uiion when resistance)is encountered. 3. Subtract second readingfrom first reading. Result should be approximately 1 o/ol D 2 7 g -1 )o r l l zY o (D278_21 problem. A deadbandnot centeredon 1o2o/ois indicativeof a governorcontroller of A wider-than-normaldeadband,but still centeredon 1O2o/o,is usuallyindicative u*."rJiuu throttle iinf.ig" friction and/orinsufficientgovernorfriction' rod end Check throttle friction by disconnectingovertravelspring assemblyuPP-el throttle With end. from C341l}34z arm and attaching i"spring scale io the rod note and scale ur11in iafu poiition,-rf"*iy pulLup o"vertrdveliplingassy.with.spring throttle maximum + pounOs-;;;'i"glriciion prior to. tutl,dpen throttle. .Excessive caus"eduy Linling.rod ends, control interference,carburetor iin[Jge friction oi uiniing carbuietoracceleratorpump (typically "un-u" throttle shaft urrrting n l Y ). b i n d si n o n e d i re cti o no"longuiiori, overtravel Check governor friction with cotlective down,- collective friction or, positioned arm spring assy upper rod end disconnu"t"i-trom C341tC342 arm, and scale held horizontally. Attach a spring .tJu 1o trole in the arm and, with and the tangential to armllio*lv'-prir on-rlaie and note both the breakaway moving than moving frictions. Breakawaytriciion iiiypically O-0.5 pound .greater indicate friction. Breakaway*i"iion'l pouna or gieatei.than moving.frictjon-may be damaged or contaminated gou"-oi *i.-iion clutch. Moving friction must be can friction 1ni;i;"u- 8 pounds until arri stopi mouing.. Insufficient moving causedby wear, contamination,or loss of springrate' Proper governor operation requiresa minimum 2:'l ratio of governor friction-tothrottle linkagefriction.

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FICIBINS(JN

MATNTENANcE MANuAL

M(fDEL

F.44

8.239 GovernorTroubleshooting(cont'd) Erratic operation is usually indicative of wiring damage or tachometer point problems. Wiring damagemay be evidencedby crushing,pinching,or abrasion,all of which can result in groundingof one or both center wire conductor(s)to the shielding or to structure. Tachometer point problems may be caused by contamination{due to over-lubricationof magneto cam follower felt), oxidation isuch as from an obstructed vent plug or leaking magneto drive seal), or loose (s),in additionto installationor assemblyerrors. When flying in turbulence,or if the engine is lightly "loaded" (drive train almost freewheeling) fluctuatingMAP indicationis expected. " Any loose connection in throttle linkage (includingworn carburetorthrottle shaft bushings)will result in both RPM & MAP oscillations.

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FIClEl|NSiClN

MOEIEL]3,44

MATNTENANeE MANUAL

Figure8-91 8.31O Jackshaft-(See 8.311 JackshaftRemoval NOTE Riooinocheck is not necessaryif iackshaft strut

;;e";Et lno putn-lulltuberooeriosarenot moved' al Disconnectthe push-pulltubes from the iackshaft'

bl Disconnectthe two iackshaftbolts at the upperrod ends' O c ) Removeiackshaft.

8 . 3 1 2 JackshaftInstallation end requiresa a) Installiackshaftto strut rod ends. Aft .rod andbolthead.

biai-i-;iiery *;sfftei*een

the rodeirdUatl

bt Torquenuts per Section1,32Oand installpalnut' Bottt push-pull c) connect the cl21-3 and -5 push-pulltubesto iackshqft. -3 push-pull tube 21 forryerq-C-l The OJ ioinit,irward tu-d;';G;n uortnd.

the andC115'1 spacerbetween ilHd ;;quites;C14ifi a"f.ry wasfrer a requires end pull-tube rod push rn"-itt Ct21-5 ffi!|a iriO Ubrti"-ab. bolthead. and rod-end the bl4i-f Jitetywisnerbetween

dl Torquenuts per Section1.320 and installpalnut' el no binding or interferencewith control system existsthroughou,O flight control travel. 8.32O Strut Assembly(Jackshaftl 8.321 JackshaftStrut Removal a) Removejackshaftper Section8'311' fittings. Disconnect bl Removethe struts from the mainrotor gearbgxstrut from the aft the aft vertical strut libpJr-ioOend to releaseIhe C345-1 strut weldment.

Page8.34

Change2: 12 Dec 94

FIclBINSiClN

MATNTENANeEMANUAL

MOE'EL

F44

8.322 JackshaftStrut Installation(seeFigure8-91 al Installlowerrod endsto the mainrotorgearboxfittings as shown in Figure 8-9. bl Reinstallthe aft vertical strut upperrod end as shown in Figure8-9. The rod end extensionmust be set to 0.93 t O.O3inch from the end of the strut to the center line of the rod end ball. (The dimensionis the same for all six rod ends.l cl Installjackshaftand push-pulltubes per Section8.312. dl that all bolts and jam nuts are torquedper Section1.320.

Change2: 12 Dec 94

Page8.35

FIClElINEiclN

MAINTENANcE MANUAL

MOEIEL F.44

INSTALLATION JACKSHAFT

1

2 3 4 5 6 7 I 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

P a g e8 . 3 6

JackshaftAssemblY Rod End Washer Nut Palnut Washer Washer Bolt Palnut Nut Bolt Bolt Spacer Washer Tube Weldment Nut Rod End Bolt Washer Nut Palnut Fitting Washer Strut Weldment Spacer Washer (Ref) Push-PullTube Assembly(Ref) Push-PullTube AssemblY(Ref)

Change1O: JUL 2OO4

FICIBINEiCIN

MATNTENANcE MANuAL

MOclEL

F.44

v 8

t

or\ 5

\F-,

\\

Yi'

q.N

15

:'s"L \}-i\

16 5

ii

18\l

"'s$, 17

19

zzr'

17 19-.-

"\F

€*.

23

FORWARD

FIGURE8-9 JACKSHAFTINSTALLATION Cha n g e1 4 : J U L 2 OO8

Page8.37

FIClElINSclN

MAINTENANcE MANUAL

Dl4 8.4oo SWASHPIarE-AN

MOEIEL H.44

ROTORPITCH

8 . 4 1 0 S w a sh P l a te 8.41'l SwashPlateRemoval

Riggingcheck is not requiredif push-pulltube rod end centertolclnier dimensiondoes not ch 9' 121' 1 . Re mo vema i n ro to r b l a d esand hub per Sections9' 111 and 2. Removedroop stops and teeter stops' 3. Disconnectupper C2O4arm at C203 yoke' 4 . Di sco n n e cta n d re mo veC2O3yokesand A210 key' 5. Removeswashplateboot by cutting plasticty-raps' A2O5 fork - Disconnectthree push-pulltubes and rod end of lower forward 6. iti".bly from lower (nbn-rotating)swashplate' 7. Lift swashplatewith attachedfork and pitch links off slidertube' ( seeFigur e8- 10) 8 . 4 1 2 Sw a sh p l a teIn sta l l a ti on WARNING R44||(fue|injectedlhe|icoptersrequiretwoA2o5.Tforks, A6OO-6manifold pressuregage, two cooS-8 main rotor blade & spindle assemblies(two Cbt0-S main rotor blades & two &dl-Z pitch hornsl, CO06-5 main rotor gearbox, COOS-4tail -to. asiembly (two COZS-2 tail rotor bladesl, two CO16-5 main rotor blades, CO17-4swashplate'three C121-31 push-pull tuUes,two C2O3l5 yokes, C2O4-2arm (stainlesssteel, lowerl, C2O4-g arm (stainlsss steet, upperl, C792'4 dual tachometer, D2O1-5 weldment (forward hydraulic servosl, and D2O4-g weldment (aft hydrauli er Scissors' 1 . I n s t a l l s w a s h p l a t eo n t o s l i d e r t u b e a s s e m b l y . C o n n e c t l o wswashpl ate' f o rk to l e ft si d e o f mi d dle of thr ee lugs on lower , non- r otating l ow er on lug C o n n e ct a ft p u .;r-p u fi tube to t!gl!^side. of af1, single palnuts' r*rrftp i .te .- i o rq u 'e p er Section 1.32O and install

2 . swashplatetilting friction per Section8.413; adjust as required' place' 3 . slide swashplateboot over main rotor drive shaft and set in yokes on main 4 . R e f e r t o F i g u r e sB - 1 3 , 8 - 1 3 A a n d B - 1 3 8 . l n s t a l l c 2 o 3 y o k e s t o s h a f t ' r o t o r d r i v e s h a f i u p p l i i l a n g e u s i n g A 2 1 Ok e y t o i n d e x F i n g e rt i g h t e n c l a m P i n gh a r d w a r e

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FICIE|INSiC|N

MATNTENANcE MANUAL

MtIE EL ]l'44

8.41 2 Swashplatelnstallation(cont'd) NOTE Roundedge of A210 key to fit into slot in flangeon C251 drive shaft. 5. Torque yoke clampingbolt securing A21O key first per Section 1.32O and install palnut. 6. lf yoke clampingbolt oppositeA21O key is an NAS66O5 bolt, specialtorque per Section 1.330 and install palnut. lf bolt is an NAS66O4 bolt, torque per Section 1.32O (standardtorque) and install palnut. A slight gap between yokes opposite A21Okey is normal. 7. Installchord arm weights, if any. Torqueper Section 1.320 and installpalnut. 8. ff required,fill remainderof rod end threadedhole in upper 4205 fork with B27O-4 or B27O-13sealant(seeSection1.480). 9. Referto Figures8-13 & 8-13A. Installupper4205 fork and C2O4arm on C203 yoke and torque per Section 1.320. pivot frictions on upper scissorsare iess than 5 inch-poundswith hydrauliccontrois,or lessthan 2.5 inch-poundswith manual controls; as required,replacebearingsper Section 8.600 or change shim thickness. bolt, arm, and clampedhardwarein upper scissor'spivots rotate together. Installpalnuts. 1O. bolt, arm, and clampedhardwarein lower scissor'spivots rotate together. Connectforward push-pulltube rod ends to remaininglower lugs on swashplate. Torqueper Section1.320 and installpalnuts. 1 1 . C o n n e ct u p p e r A 2 O5 fo rk rod end and lower r od end of C258 pitch li nk to interrupter-side swashplateear. Torqueper Section 1.32O and installpalnut. 12. Positionswashplateboot on rotating swashplatewith inner lip ing C2O3 yoke. Securewith ty-raps. 13. Attach two 4255-3 counterweightsand lower rod end of C258 pitch link to swashplate ear opposite interrupter. Torque per Section 1.32O and install p a l n ut. "14. fnstallmain rotor hub and bladesper Sections9.122 and 9.112. 15. safety washersand C115 spacersinstalledon all rod ends per Figure2-1. Torquestripefastenersper Figure2-1. 16. no interferencewith control movementthroughout flight control travel and swashplatemovementcorrespondswith cyclic and collectivemovement. 17. Trackand balancemain rotor per Section10.230. Change14: JUL 2OO8

Pag e8.39

I I

FICIEIINSiCIN

MAINTENANeE

MlfElEL

MANUAL

F|44

SWASHPLATEASSEMBLY NUMBER DESCRIPTION

NUMBERDESCRIPTION

1

Bolt

22

Washer

2

Washer

23

Rod End

3

counterweight ( 1. 1 0 i n c hO . D . )

24

Boot

Counterweight ( 1 . 9 0i n c hO . D . )

25

Pitch Link (incfitems 23,32-34, 36 & 37)

4

Nut

26

Bolt

5

Palnut

27

Ty-rap

6

Bolt

28

Bolt

7

Washer

29

Ty-rap

8

Nut

30

SwashplateAssemblY

9

Palnut

31

Bolt

10

Yoke AssemblY ( 2 Re q 'd )

32

Palnut

11

Washer

33

Nut

12

Washer

34

Fitting

13

Bolt

35

Bolt

14

Washer

36

Link AssemblY

15

Key

37

Nut

16

Bearing

38

Interrupter

17

Spaceror Journal

39

Rivet

18

Arm

40

Arm

19

Bolt

41

CounterWeight ( 0.70 inch O.D.)

20

Fork Assembly

42

Rivet (one per C258-4 Link AssemblY)

21

Spacer

43

Link

P a g e8 . 4 0

Change14: JUL 2008

MATNTENANeE MANUAL

FIElBINEiclN

./ /

/

/

./

./

./

/

a - - - -1111? \ 5 i+ i

'?l{A', tllrRjeD

:

8-13and8-13A SeeFigures

1 -\_

J-(AO-" GrX) /

/

|

\ -.--(.I

\ -.\r

n

./;Y

MOEIELF|44

,,':, iir --:>r _oF *,"2') #" 'lAbr

i J4li<

rl

ffi

i- nq-l

4H

21

,2"-P,

),;;;;;r

J?i' \P ..-

'1'..:....Dtrcrftt.-32

lflLF-

.k"ff .e'.\

\i '\ ASSEi'tBLy FIGURE 8-10 swASHpLATE

\Q\

\

S E TT 0 3 . 7 0t 0 . 0 3 INCHCENTER-TO-CENTER

C h a n g e1 0 : J U L 2 0 0 4

\A\

\^

rc

rry-iS

P a g e8 . 4 1

FIClElINSiClN

MC'E'EL P,44

MATNTENANcE MANUAL qy SCnEw

_)#

0 . 0 2 0 I N .- D i A SAFET'l'RE

wAsHER -.f IN. DIA O.O2O l.llRE SAFETY

I 'f\,,*,,

c200-t

;

C2O6-1RETAINER

:CD \:

s----z

C 2 1 8 - 1S H I E L D

\ NAS62O.BL hIASHER

ASSEMBLY C205.1SLEEVE C197-1THRU-6 SPACERS I MUM ( 0 . 1 5 0i n . MAX sTACK) ,{

& WASHERC218-1 scREw (INNER) SHIELD

1 c201BALL ASSEI'IBLY

& WASHER SCREt^l ci97-1 c200-I c205-1 (ouTER) RETAINER THRU SLEEVE ASSEMBLY .6 SHIMS

Q.i+ii;L. c2L9-2 SPACER SHIELD

c2t9-t SPACER

l^l00DEN BLOCK LOhIER S!,IASHPLATE

ASSET'IBI-Y FIGUREB-11 SI^JASHPI-ATE

P a g e8 . 4 2

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FICIBINSiC|N

MATNTENANtrEMANUAL

MC'E ELr|,4€,

(ssSLIDERTUBE

S---'i

SCALE SPRING

TILTING FORCE F IGU R8E.1 2 MEASURING SWASHPLATE

11 Jun93

Page8.43

FICIBINSiC|N

MAINTENANcE

MANUAL

MctDEL r'.44

8.413 SwashplateTiltingFrictionAdjustment Swasholate tiltinq fricticn is establishedby C197-1 through. C197-6 spacers force of Teflon-linedsleeveson the ball assembly' "l"mpi6g """ii"ii6 (sciss.ors) 1. Mark for reassemblyand disconnectboot, pitch links and drive linkage and both forward push-pulltubes from lower swashplate from upperil;hpl"te swashplatearms with lateral axis of helicopter and center cyclic 2. Align upper ' Using MT359-1 spring scale _(or eq.uivalent)connected to upper sti;k. swishplat" r7r bolt hole p'er Figure 8-1.2,puli down and note scale reading while iwasfrptate-il movind; Ao riot use breakawayreading. Forcerequiredto minimumto 5 poundsmaximum. iiit iwlsf,pl.i" must be frei-without-tooseness 3. To adjust friction, remove outer screws from upPer swashplate and raise and secureretainersto ailow accessto innerscrews. Removeinner screws securing o sleeveto lower swashPlate. 4. Raisesleeveand measurethicknessof C197 spacerstack. Adjust spacerqlgck tilting thicknessas required,but not exceeding0.150. inch, to achieve-proper while friction tilting-. increases thi6kness friction. Oecie-aiing'spacer stack inner screws All friction. tilting inCreasingspacer st6ck'thickness decreases must be instbltedand torquedper Section 1 .330 prior to measuringfriction. 5. Safety wire inner screws with 0.020 inch diameter safety wire. Secure retainersto upp'eiswlshplate with outer screws, torque per Section 1.330, and safety wire. 6. Connectboth forward push-pulltubes to lower swashplate,torque per Section 1.32O,and torquestriPe. (interrupteron 7. Connect both pitch links and drive linkageto upper swa.shplate stripe' torque and 1.32O, per Sebtion samesideas diive linkage),torque 8.500 TAIL ROTORCONTROLS 8.510 Tail RotorPedals l e mo v al 8 . 5 1 1 T a i lR o to rP e d a R 1. Soak both front floor carpets with Prep-soltor 15-20 minutes, then lift calPgt iarefully from the floor ori ootr, riO"r and removefrom the cabin. Caution: This is a flammjbie material. Follow manufacturer'ssafety precautionsto prevent injury. 2. Removethe screws betweenthe pedalsholdingthe accessplatesto the floor and removethe Plates. 3. Lift the consoleand disconnectthe intercomsystem controllerand the outside gaugewiring. air temPerature 4. Removeradios, radio face plate and the radio rack by removingthe screws which secureit to the sidesof the console'

P a g e8 . 4 4

Change10: JUL 2004

.-

FIGIBINSCIN

MAtNTENrlllss MANUAL

MOE EL rl,44

(cont'd) 8.511 TailRotorPedalRemoval tubesby from the C343-3and C343-5push-pull both pedalassemblies 5. Disconnect removingtwo NAS6604-9bolts. CAUTION DO NOTremovethe rod endsor changethe lengthof the pushtubes. 6. Remove six NAS6603-20 bolts (three per side) which hold the A318-1 and -2 bearingblock halvestogether. 7. Removethe lower bearingblock halves. 8. Removethe tail rotor pedalsone at a time by lifting one end and allowingthe other to drop into the chin. They can be removedfrom eitherthe right or the left side.

NOTE On reassembly,the right pedal assemblyis mounted forward in the bearinqblocksand the left is mountedaft. NOTE Pedal blocks (upper and lower) are a machinedmatched set as indicatedby matching letter or number on the upper and lower portion of blocks. DO NOT mix them or alignmentproblemsmay developon installation. 8.512 Tail RotorPedalInstallation 1. Fillthe groovesin the pedalbearingblockswith A257-1 grease. 2. Instatlthe pedal assembliesinto the bearingblocks and torque the bearingblock attach bolts per Section1.320. NOTE lf a force greaterthan 5 lbs is requiredto move pedals,check the bearingblocksto ensurethey are matchedcorrectly. 3. Connectboth pedal assembtiesto the push-pulltubes and torque the NAS6604-9 boltsto per Section1.320 and installpalnuts. 4. Installradioracks,radiosand radioface plate. 5. Move the pedalsthrough the full range of travel to ensurethere is no interference or binding. 6. Secureconsole.Installthe pedal cover plates and carpeting.Use B27O-7or -8 adhesiveto attach carpeting. Ch a n g e1 0 : J U L 2 0 0 4

Page8.45

-

FIC|BINSCIN

MAINTENANeE MANUAL

M(fElEL

t,44

8.520 9317Lryer eelgok 8.521 Cg17-2LowerForwardBellCrankRemoval the upperconsole.Lift up the console -system a) Removetwo screwssecuring controller and outside air and Oisionnect intercom temperaturegaugewiring. b) Removeradios,radio face plate and the radio rack which is securedwith screwsto the side s. tubes and aft forward C343-3 and C343-5 pu.sh-pull -push-pull c) Disconnect all three removing by crank bell the from tube C1Z1-9 NAS6604-9bolts. screws which securethe C349-1 d) Removefour MS27O39CO807 keel' forward assemblyto the e) Removeand bellcrankassemblyfrom the ship. f) RemoveNAS66O4-19bolt which connectsthe bell crank to the .Removebellcrank. 8.522 C317-2LowerForwardBellCrankInstallation This procedurealso coversriggingof. the lower.push-pulltubes and rigging disregard oiiigging is not required, pedat'iirbrOtieJ.tt ie-cnecking sequences. portionsand follow installation one a) Installtwo A105-3 journalsinsideC317-2 beJlcrank. Place journals A105-3 of the ends A141-gwasneragainstthe outside to the . uponassemblY Tighten pivot nut and check for smooth and free operation. to movethe bell Mlximuni springscaledragof 2 lbs is acceptable crank.TorquePerSection1.320. lf a force in excessof 2 lb is requiredto move the bell crank measurethe distancebetween thb 4141-3 washerswith the washeriheldtightly 'aagainstthe iourna.ls.Usingg-ole,inchdiameter lig.htly l9u11qt,. w-itn $.ZSOinch'pilotin 9rye_4105-3 toot ipoliice shaveiho outsideface of eachbearing0.002 inch 0.003 inch at a time. Ass.mUtythe bellcrankon the assembly.lf a force in excessof 2 ld is requiredto movethe bell crank,repeatabove step. b) Installthe assemblyin !p ship and secureit to the keel screws. Adjust the-leng.thof panetswlh idur MS27O3ECO807 to 4.42 inch and center-to-center push-pull ends rod tube bg+g-S inch. that 6.45 to rod ends center-to-center JOirit C543-5 witnessholes the checking by sufficiently engaged rod are ends the wire. piece safety inch of 0.020 with a P a g e8 . 4 6

l s s u e d1: 1 J u n 9 3

MATNTENANeEMANUAL

FICIBINSCIN

MlfE|EL

F'44I

8,522 C317-2LowerForwardBellCrankInstallation(cont'd) Connectall three push-pulltubes to C317-2 bell crank. Do not torque the NAS6604-9bolts yet. The lengthof-C121-9 p.ustl-pult tub6 must be set to 66.0 inch.Ensurethe 121-9 push-pulltube is installedthroughthe centerof the c346-1 restraintat the mid span position. tube which connectsC317-1aft bell The verticalC343-1push-pull crankto C316-1upperbellcrankmust measure13.40 in. rod end center-to-center. Connectfwd end of C121-9push-pulltube to the C317-2fwd bell crankandthe aft endto C317-1bellcrank.Tightenthe boltsbut do tube to not torquethem yet. Connectone end of C343-1_push-pull bell C316-1 upper to other end the the C3i7-1 aft bell crankand yet. them not torque crank.Tightenthe bolts but do fnstalla 3t16 inch diameterpin throughthe riggingholelocatedin the right aft engercargo compartmentand push.it .through hole. With riggingpin installed,adjust C317-1bell ciank'sr-igging lengthsof C121-9and-C343-3push-pulltubesto obtain2.90 in. stop. betweenright pedaland right-hand removethe riggingni-n94aqOlVfull left Afteradjustingpedaltravel, pedal pedal. Witn i-eh at stop, adjust lengthof C343-1 to obtain 0.10 O.20in.frdm C121-15forwardrod end to bulkhead.With to obtain left pedalat stop,adjustlengthof C121-17push-pulltube pitch andface assembly control e03t-1 0.35 + 0.03 inin Oetween push-pull ends tube rod all of the tail rotor gearboxend cap. Check witnessholesfor engagement.

NOTE It is permissiblefor the bell crank arm to foam,as longas touchand deflectacoustical it doesnot interferewith free movementand full travel of the controls. c) Torqueall attachingbolts per Section1.320. Installpalnutsand torquestripefasteners.

l s s u e d1: 1 J u n 9 3

Page 8.47

FICIBINSCIN

MATNTENANcEMANUAL

MOE EL F44

(cont'd) 8.522 Cg17-2LowerForwardBellcrank Installation -' Check for smoothnessand ease of operation.Move pedalsfull d) tiivel. Cnetf for any interferencebetween tubes, wires and structure. e ) lf reouired,checkcomptetetail rotor riggingif changesto C343-1, Ca+3-S,C121,9, C121-15oi C121-17 push-pulltube Cg+3-C,lengthshave beenmade. f) all attachboltsand iam nuts torquedper Section1.300.

sl lnstallradio rack, radioface plate, radiosand all the swhich were removed.

8 . 5 2 3 C317-1LowerAft BellCrankRemoval a) Installcoltectivespringretaineror safety wire the collectivespring per Section8.221. b ) Removecollectivespringper Section8.221. c ) DisconnectC1 21-g and C343-1 push'pulltubes by removing

respectiveNAS66O4bolts from the C317-1bell crank'

d) DisconnectA2OS-3fork assemblyfrom the C326-1 bell crank itiemUly-by removingNAS6604-38bolt. Leavefriction assembly connectedto c315'1 upper. e) RemoveNAS66O4-9bolt and disconnectC121-19collectivepushpull tube from the C326-1bell crank. f) Removefour NAS6604-2bolts which are securingC315-1^rear assemblyto the left and right s. RemoveC334 assembly. g) c317-1 aft bell crank is connectedto rear sup^p€rt..::,e,qql_y_,by C311-1bolt which is commonto C317-1to C326-1bell cranks. Removethe bolt and removeC317'1 aft bellcrank'

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MATNTENANcE MANUAL

F.44

MOEIEL

8 . 5 2 4 C 3 1 7 -1 L o w e r A ft B e l l cr ankInstallation a ) I n s t al l C 3 1 7 -1 a ft b e l l crank on C315- 1 or C315- 7 r ear suppor t ass em bl y w i t h N A S 6 6 O4 -1 0 5b o l t, o ne NAS1149FO432Pwasher under head and tw o NASl 149F0463P washers under nut. Standardtorque bolt per Section 1.320, install& torque palnut, and torque stripe per Figure2-1. , , b) InstallC334 rear assemblyin ship and secureit to side swith four NAS66O4-2bolts. Standardtorque bolts per Section1.320, and torque stripeper F i g u r e2 - 1 . c) ConnectC343-1 and C121-9 push-pulltubes to the C317-1 tail rotor control aft beltcrank.Connectthe C1 21-19 push-pulltube to C326-7, C326-8, or C334-4 bellcrank. A697-6 tab orientedO' to 20" outboardfrom vertical. Standard torque bolt per Section1 .32O,install& torque palnut,and torquestripeper Figure 2-1. distanceto 3.80 inch t 0.03 inch. d) Set upperA2O5-3fork assemblycenter-to-center C326-8, or C334-4 bellcrank. to C326-7, fork assembly ReconnectA2O5-3 to 2.300 rod end link assemblycenter-to-center e) lf applicable,set collective-friction is not adjustable). link assembly inches t O.O1Oinch rc327-1 collective-friction Installbolts and standardtorque per Section1.320. Install& torque palnuts,and torque stripe per Figure2-1. f) lf applicable,connect bottom rod end of collectivespringassemblyto C326-7, or C 3 2 6 -8 su p p o rta sse mb l yper Section8.222. Standar dtor que bolt per Sec ti on 1 . 3 2 O , i n s t a l l & t o r q u e p a l n u t s , a n d t o r q u e s t r i p e p e r F i g u r e2 - 1 . R e m o v e r e t a i n e rfro m sP ri n g . g) Move pedals and check for smoothnessand ease of operation.Move pedals, collective, and cyclic full travel, and no interferencebetween tubes, bellcranks,wires and structure. 8 . 5 3 0 C 3 1 6 - 1U p p e rB e l l c r a n k 8 . 5 3 1 B e l l cra n kR e mo va l a) Removeaft vertical between seat backs and right rear seatback. b) DisconnectC343-1 push-pulltube from the bellcrankassemblyby removingthe NAS66O4-8bolt. c) DisconnectC121-15 push-pulltube from C316-1bellcrankby removingNAS6604-8 bolt. d ) D i s c o n n e cC t 3 1 6 - 1 b e l l crankfr om air cr aftby r em ovingNAS13O4- 17bo l t fr om inboardand N A S 6 6O4- 11bolt fr om outboar dsuppor t. Ch a n g e1 4 : J UL 2 OO8

Page8.49

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F|44

8.532 BellcrankInstallation t) Installbellcrankwith NAS13O4-17bolt throughbearingblockand then through bellcrankand NAS66O4-11bolt connectingbellcrankto outboard . Torquebolts per Section1.320. Installpalnuts,torque per Section1.32O and t o r q u estri p ep e r F i g u re2 - 1. b) Reconnectforward end of C121-15push-pulltube and upperrod end of C343-1 push-pulltube to C316-1 bellcrank.Torque bolts per Section 1 .320. Install palnuts,torque per Section1.320 and torque stripe per Figure2-1. NOTE ff rod ends, of C1 21'15 and C343-1 push-pulltubes, were removed or length of push-pulltubes were altered re-rig tail r o to r b l a d e sp e r S e cti o n1O.14O. B e l l cr ank( SeeFigur e8- 14) 8 . 5 4 0 A 3 3 1 -4 l n te rme d i a te 8 . 5 4 1 B e l l cra n kR e mo va l a ) D i sco n n e ctC 1 2 1 -1 5a n d - 17 push- pulltubes fr om A331- 4 bellcr ank. b) DisconnectNAS66O4-35attach bolt and removebellcrank. 8.542 BellcrankInstallation a ) l n sta l ltw o A 1 O5 -3j o u rnalsinto bellcr ankbear ings. One A1 41- 3 was her i s requiredon each side of beltcrankagainstA1O5-3 journals(lf required,ream A 1 3 9 -1 b e a ri n gw i th O.375/0.376in. dead- shar rpeam erfor jour nal' ss m ooth installation). b) Install bolt and torque per Section 1.32O. Installpalnut, torque per Section 1 .3 2 Oa n d to rq u estri p eper Figur e2- 1. c) Check for smoothnessand ease of operation. d) Connect A121-15 and -17 push-pulltubes. A214-3 safety washer is required u nd e rth e b o l t h e a d w h ich connectsC121- 15push- pullA331- 4 tube to the bellcrankand one MS2OOO2-4washer is requiredbetween the rod end ball a nd th e b e l l cra n k. e) A214-3 safety washer is requiredbetween bolt head and f orward rod end of l be. C 1 2 1 -17 p u sh -P u ltu f ) R e -ri gta i l ro to r p e r S e ction1O.140if push- pulltube lengthswer e altered. P a g e8 . 5 0

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F|44

(cont'dl 8,542 BellCrankInstallation e) Move pedalsfull travel,checkfor any interferencebetweentubes, wire, componentsor structure. 8.550 .A12O-3Aft BellCrank 8.551 BellcrankRemoval tube from 4120-3 aft bellcrank. a) DisconnectCl2l-17push-pull b ) Disconnectbell crank pivot from attach bolt connectedto tail rotor

gearbox.

c) Removenut holdingbell crank to the pitch control. Removebell crankand reinstallnut andshimsfoundbetweenbellcrankand pitch controlfor bell crank installation. 8 . 5 5 2 Bell CrankInstallation {seeSection8.562). SeeCO31-1PitchControlInstallation 8.560 CO31-1 PitchControl 8.561 PitchControlRemoval tail a) Removetail rotor hub and bladeassembly.Mark corresponding rotor bladegrips,tail rotor pitch changeto eachof the pitch control is not required. so re-rigging ears,for later'reinstallation and removeA12O-3aft bellcrankper Section8.551. b) Disconnect c) RemoveC031-1 pitch controlfrom tail rotor output shaft. 8.562 PitchControlInstallation a) SlideC031-1pitch controlassemblyonto outputshaft. b l PositionA120-3 bell crank assemblyon the tail rotor gearboxand installNAS66O+25bolt, one AN960-416Lwasherunderbolt head, washers,one on each side of the bearingand two MS2OOO2-4 MS21042-4nut. Tightenbut don't torqueat this time. c) Measurethe gapexistingbetweenthe A120-3bellcrankearandthe flats on tne Ct25-1 pitChcontrolstud. lnstallsufficientCl17-34, 35 and -36 washersbetweenbellcrankand stud to completelyfill the gap but not applyany axialpreloadon the sphericalbearing^after all the nuts are tightened.The clearancetoleranceis t 0.003". washerand MS21042-5nut on protruding fnstallone AN96O-E16L end of stud. Torquenut to 200 in.-lbplus nut drag while holding stud from rotating,and installpalnut.

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MAINTENANcE MANUAL

F|41I

8.562 PitchControlInstallation{cont'd} palnut. dl Torquenut on A12O-3betlcrankpivot per Section1.320 and install of Cl 21-17 push-pulltube to the A12o-3 bellcrankwith -bott, el Attach aft end arugeO-+i6Ldnder head, and.A214-3safety-.washer flASeeO+lb nut per Section1.320 and installpalnut. undeinut nextto iod enO,-forque fl

Installpitch controllinks per Section8'572'

gl Installtail rotor hub and bladeassembly{seeSection9.2121. h) Ensureall bolts,jam nut and palnutsare torquedper Section1.30O. 8.570 Tail RotorPitch Links 8.571 Tail RotorPitchLink Removal NOTE Toensureproperrigginguponreinsta||atio.n.ofpitch bladegrip linti, marti pitch tiiks io corresponding and Pitchcontrolear. al Disconnectthe two attach boltson both rod endsof the pitch link. bl RemovePitchlink. 8.572 Tail RotorPitchLink Installation WARNING A21+Ssafetywashersaretobeinsta||ednextto eachrod end. CAUTION tail rotorpitch linksmust be usedin sets' One-piece DO NOT use one-piecepitch links with adiustable pitch links. NOTE lf installingsame pitch links, match ni!-cnlink.to proper blade grip- and pitcn control ear. lf installing new, pitch links, measureove.ralllength of oi.dpilcf' iOiusta-Utei iinicwitn niicrometeror caliper.Adiustthe new pitch link obtainddwitnin 112turn of the rod to the measurement end.

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F|44

8.572 Tail Rotor Pitch Link Installation(cont'd) WARNING Both pitch links must be same part number (same type and materiall. Mixing one-piecewith adiustable-lengthpitch links is prohibited. Mixing steel one-piecewith aluminum'one-piecepitch links is R e f e rt o F i gu re9 -1 1 . A. lf installingone-piecepitch link{s}: 1. Connectpitch link to pitch control arm and bladepitch horn. 2. Torqueattach bolts per Section 1.320. Installpalnuts,torque per Sectionl'320, and torque stripe per Figure2-1. Repeatfor oppositeblade. pitch link(s)basedon old pitch link length: B. lf installingnew, adjustable-length 1 . Match pitch link to proper blade pitch horn and pitch control arm and connect pitch link. Torque attach bolts per Section 1.320. Install palnuts,torque per bection 1.32O, and torque stripe per Figure2-1. Repeatfor oppositeblade.

2 . Torque attach bolts per Section 1.320. proper rod end centering and

adjust as required. Installpalnut,torqueper Section 1.32O,and torque stripe per Figure2-1. Repeatfor oppositeblade.

3 . C h e ckta i l ro to r co n tro lri g gingper Section10.140. pitch links (nominallength setting): C. lf installingnew, adjustable-length 1. Assemblemale rod end, with jam nut and palnut installed,into female rod end. Adjust rod ends until a dimensionof 2.620 t O.O1Oinches,measuredbetween rod end bearingcenters. 2. Attach pitch link female rod end to outboardside of pitch control arm. Torque b o l t p e i S e cti o n 1 .3 2 O. Installpalnut,tor que per Section 1.320, and tor que s t r i pep e r F i g u re2 -1 . 3. Connect pitch link male rod end to blade pitch horn. NAS1149FO432P' N A S 11 4 9 F 0 4 6 3 P ,A 2 1 4 -3or A141- 14washer smay be undernut for chor dw i s e b a t a n ce .T o rq u eb o l t p e r S ection1.320. lnstallpalnut,tor queper Section1.32O, a n d to rq u estri p eP e r F i g u r e2- 1. 4 . T o r qu e p i tch l i n k j a m n u t and palnut per Section 1.320 and tor que stri pe per Figure2-1 . Repeatsteps 1 thru 4for oppositeblade. 5 . C h e ckta i l ro to r co n tro lri g gingper Section10.140. Ch a n g e1 3 : O C T 2 0 0 6

Page8.53

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MC'DEL 1n44

8.600 C2O3YOKEAND A2O5 FORKASSEMBLY 8.610 BearingRemoval B1 l5-1 Sphericalbearingsand C648-2 journalbearingsmay be removedwith a press. pressfrom inner side of bearingswhile ingoutboardside of yoke or fork. Use a socket or other suitablepressingtool to applythe force' 8.61S C648-2 BearinsInstallation(0.5625/0.5630 inch diameterbearingbores) 1. Cleanmating surfacesof A2O5 fork or C2O3yoke where C648 bearingis installed. Deburrany sharpedgesthat may damagebearingsduring installation. 2. Coat yoke or fork bearingboreswith zinc chromateor epoxy primer.While primeris O still wet, pressin C648 bearingwhile ingbacksideof fork or yoke. 8.620 B115-1 Bearinglnstallation 1. Pressout old bearings. 2. Cleanyoke or fork assemblybearingboresof old adhesive. 3. Measurebearingbores;maximumallowablediameteris 0.6260 inches. 4. Lightly coat 81 15-1 bearingouter races with 8270-10 adhesiveand install81 15-1 bearingsinto bearingbores.Wipe off excessadhesive.Do not allow adhesiveto enter B115-1 bearingitself. 5. While adhesiveis still wet, assembleyoke or fork assemblyper Section8.412. Wait until adhesivehas beenallowedto cureper manufacturer'sinstructionspriorto checking bearingpivot force.

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FIG|BINS|clN

MAINTENANCE

MOEIEL

MANUAL

F,44

MAIN ROTOR CHORDWEIGHTS

''*'[\'-r#',€;

c2o3-1YoKEASSEMBLY /

l:tt'

WASHER

./\-

^-l

r

$,,

NAS1305 OR NAS6605 BOLT (SPECIALTOROUE PERSECTTON1.3301

A

1

At..o. -U

w\ I

SPHERICAL BEARTNG

ttt)-'-ocKrNcNUr

PALNUT

c204 ABM

ae

A205 FORK ASSEMBLY

BEARING

C2O3-3 YOKE ASSEMBLY I2 REOUIRED) PALNUT

WASHER NAS1304 OR NAS660zt BOLT

WASHER

+SMALLERDIAMETERBOLTSTHAN LATERREVISIONINSTALLATION FIGURE8-13 R44 EARLYREVISIONCHORDARM YOKEINSTALLATIONS R44 II} (DO NOT USE ON FUEL-INJECTED Ch a n g e1 3 : OC T 2 0 0 6

P a g e8 . 5 5

FIGIBINSCIN

MATNTENANcE MANUAL

c203-5 YOKEASSEMBLY (2 Required)

MOETEL F'44

N A S 1 3 O 5B O L T ( T O R O U EF I R S T }

A 2 1 OK E Y (ROUND EDGE INBOARD}

N A S 1 3 O 5B O L T *

WASHER

WASHER

S E L F . L O C K I NNGU T

* C 1 0 5 - 4o r - 5 J O U R N A L *

PALNUT

c648 BEARING

N A S 1 3 O 5B O L T *

C 1 0 5 - 4o r - 5 J O U R N A L** C141WASHER

WASHER

C 1 O 5 - 4o r - 5 J O U R N A L **

S E L F - L O C K I NNGU T WASHER

A2O5-7 FORKASSEMBLY

PALNUT

C648 BEARING C 1 0 5 - 4 o r - 5 J O U R N A L *" C 1 4 1W A S H E R

S E L F . L O C K I NNGU T

*Note targerdiameterbolts than on earlierrevision installations. **Select a combinationof C105-4 or -5 journalsto provide0.001 - O.01Oinch axial play in t. Referto Figure 2-9.

ARMrrq-KElNsIA4ArlgNs B-13A R44ll & R44CHORD FTGURE P a g e8 . 5 6

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FIClBINSiclN

MATNTENANcE MANUAL

c203-5 YOKEASSEMBLY (2 Req'd)

1t44

MOEIEL

PALNUT SELF-LOCKING BOLT (TOTIOUEFIRST)

WASHER WASHER

WASHER NASl305

't\\ WASHER

sELF-LocKrNG \tR*-

'ul >M*

t-:\

pALNUT+Ql

BEARING NASl305 BOLT

c 105-6

WASHER

SHIMS*

C 1 0 5J O U R N A L SELF-LOCKING NUT PALNUT

FORK ASSEMBLY SHIMS" WASHER

PALNUT SELF-LOCKING NUT

*Sefect a combinationof C1 17-67, -68, and/or -69 shims to provide0.001-0.010 inch axial play in t. Referto Figure2-9.

FIGURE8-138 R44 ll & R44 LATE REVISIONCHORDARM YOKE_INSTAL|AIIQNS

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Page8.564

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MAINTENANeEMANUAL

MoE,EL

]f44

blank IntentionallY

P a g e8 . 5 6 8

C h a n g e1 3 : O C T 2 0 0 6

MATNTENANcE MANUAL

FIG|BINSCIN

Mt'EIEL

R44

NAS66O4.1T BOLT A214-3 WASHER WASHER MS2OOO2-4 C 1 2 1 - 1 5P U S H - P U LTLU B EA S S E M B L Y

NASl 149FO432P

WASHER NAS6605.35BOLT

3 8330-1 PALNUT M S 2 10 4 2 1 4 NUT

A105.3JOURNAL

WASHER NASl 149FO432P A 1 4 1 . 3W A S H E R

4 1 4 1 . 3W A S H E R N A S l 1 4 9 F 0 4 3 2 PW A S H E R M S 2 1 O 4 2 LN 4 UT

,A) t2,:l'

A 3 3 1 - 4 B E L LC R A N KA S S E M B L Y ARM INBOARD) {LONGER

tA)

8330.13PALNUT

CO2OFRAMETUBE

>

,"'.1-'

NAS6604-9 BOLT-\_\\

\-wnsHrR c121-17

.*\.-

VIEW LOOKINGAFT

TAILCONE

_A'214-3

PUSH.PULL TUBEASSEMBLY

\unsr

149Fo432P l

WASHER M S 2 1 O 4 2 L 4N U T 8330.13 PALNUT

INSTALLATION FIGURE 8-14 A331.4 BELLCRANK C h a n g e1 3 : O C T2 0 0 6

P a g e8 . 5 7

I

MAINTENANcE

FICIEIINSCIN

#

*E:ll'. )*-- (//

MANUAL

MOEIEL

rl44

,.=_\ ll'[r=il \

\ THROTTLE GOVERNORASSEMBLY

* FWD

-\-

THROTTLEGOVERNORASSEMBLY

\ NOTE: PART OF STICK ASSEMBLY REMOVEDFOR.CLARITY

8-15 THROTTLE FIGURE GqVERNOEINTALLAMN P a g e8 . 5 8

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IICIBINSON

MATNTENANeE MANUAL

MOEIEL

F|,44

Intentionallyblank

Change13: OCT20Oo

Page8.59

FIG|BINSCIN

MAINTENANcE

CORRECT

MOEIEL

MANUAL

1l'44

INCORRECT

Z(

E€ ERlNsrALlArlQ-NloB HYDBASUc-!!N F|GU RE8-16 SEALRETAIN Page 8.60

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1t44

8.700 HYDRAULICFLIGHTCONTROLS 8.710 HydraulicReservoirRemoval(seeFigure8-1A) CAUTION I

Use LPS PreSolveto clean hydrauliarts. Do not use alcohol. 1 . RemoveC706-1tailconecowling. 2 . Placea one-litercontainerbeneathsuctionline fitting on reservoir. Disconnectand cap suctionline at reservoiraft elbow and allow reservoirfluid to drain into container.

3 . Disconnectand cap one return and two pressurelinesfrom reservoirelbows. 4. Disconnectpump bysolenoidelectricalconnector. 5 . Cut safety wire from and remove four drilled-headbolts securing reservoirto upper frame. Removereservoir. (seeFigure8-1A and Figure8-16) 8.720 HydraulicReservoirInstallation CAUTION Use LPSPreSolveto clean hydrauliarts. Do not use alcohol. 1 . Installelbows into reservoirwith palnuts,jam nuts, retainers,and O-rings. 2 . Point forward elbows up. Torquejam nuts and palnuts per Section 1.330. Forward elbows are differentsizesand nuts requiredifferenttorques.

3 . Positionreservoiron upper frame and installfour drilled-headbolts. Torque bolts per Section 1.330 and safety wire. 4 . Connect servo pressureand return lines to forward elbows and torque per Section 1.33O. Torquestripejam nuts, palnuts,and B-nuts. 5 . Connectpump bysolenoidelectricalconnectorand ty-rap wires as required. 6 . Connectpump suction line to aft (suction)elbow. Positionelbow to minimizepreload on suction line. Torquejam nut, palnut, and B-nut per Section 1.33O and torque stripe. 7. Connectpump pressurelineto remainingelbow. Positionelbowto minimizepreloadon pressureline. Torquejam nut, palnut,and B-nutper Section1.330 and torquestripe. C h a n g e1 3 : O C T 2 0 0 6

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R44

8.720 HvdraulicReservoirlnstallation{cont'd) 8. line,andsorvo clearanceto surroundingstructurewhile flight controlsare moved through full rangeof travel. fins. 9. reservoircoolinghose is secureand directedat center of reservoircooling Adjust as required. 10. Fiff reservoirwith 4257-15 (seeSection1'4701fluid' CAUTION Cteanlinessof hydraulicfluid is vital to propersystem operation' Useonlycleanfluidfrom sealedcontainersandavoidcontamination from dirty funnels,tubing,etc. 1 1. SecureC7O6-1tailconecowlingand connectany attachedantenna. 12. Bleedhydraulicsystemper Section1.190' 8.730 HvdrauliumpRemoval(seeFigure8-1A) CAUTION Use LPS PreSolveto clean hydrauliarts, Qg n9llse alcohol. 1. Removeauxiliaryfuel tank per Section12.140. 2. Removereservoirfiller-vent. 3. Coverreservoirfiller-venthotewith fingerto preventfluid loss. Disconnectand cap suction line at hydrauliump forward T-fitting' 4 . Disconnectand cap pressureline at hydrauliump aft T-fitting. nuts and washerssecuringpump to gearbox' 5 . Removefour self-locking 6 . RemovepUffiF,phenolicinsulator(sandwichedbetween pump and metal cartridge)' and O-ring(insideinsulator).Do not removemetalcartridge.

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F44

8.740 Hydrauliumplnstallation(seeFigure8-1A and Figure8-16) CAUTION

'l

Use LPS PreSolveto clean hydrauliarts. Do not use alcohol. 1. Installpalnuts,jam nuts, retainers,and new O-ringson T-fittingsand installT-fittingsin pump. Ensurelower arm of both T-fittingsis capped. CAUTION retainershave been installedper Figure 8-16. lmproper installationwill result in loss of hydraulicfluid.

2 . Lubricatenew O-ringwith A257-2 gearboxoil and installon pump mountingflange. lf C267 cartridgein MRGBhas 0.125 inch thick flangethen also installphenolicinsulator on pump mountingflange. Installpump on gearboxstuds so largerT-fitting is forward. Instatlwashersand self-lockingnuts on studs and specialtorque per Section 1.33O. 3 . Positionpump T-fittings so that outlets are approximately45 degreesfrom vertical. Specialtorque jam nuts and palnuts per Section 1.330. Nuts are different sizes and requiredifferenttorques. 4 . Connectreservoirpressurehose to pump pressure(aft) T-fitting. Specialtorque B-nut per Section1.330. 5. Cover reservoirfiller-venthole with finger to prevent fluid loss. Remove plug from suction hose and connect hose to pump suction (forward) T-fitting. Specialtorque B-nutper Section1.330. 6 . Installauxiliaryfuel tank per Section 12.150 and minimum0.25 inch clearance with hydraulichosesand fittings. Repositionhosesand fittings as required. 7 . Torquestripejam nuts and B-nutsper Figure2-1. 8 . Bleedhydraulicsystemper Section1.190. 9 . Instalfa 11O-4Telatempon easilyvisiblesurfaceof pump.

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I

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MAINTENANcE

MANUAL

Mt)E EL F.44

8.750 HydraulicServoRemoval(seeFigure8-1A) 1. Remove,mastfairingand C706-1tailconecowling' 2. a. lf removingforward right servo,removeauxiliaryfuel tank per Section12-140. b. ff removingforward left servo, removemain fuel tank per Section 12.114. 3. Disconnectc1 21-25 or -31 push-pulltube lower rod end from servo upperclevis. -28 push-pulltube lower rod 4. a. lf removingforward servo, disconnectC121-24 or end from aft end of cyclic torquetube. b. lf removingaft servo, disconnectC343-8 tube's lower rod end from collective jackshaft.

5 . lf removingforward servo, removescrew ingServoscissors' 6 . Disconnectand cap pressureand returnlinesat servo' 7 . Removebolts securingservo cylinderto airframe. CAUTION Servo input rod end is edonly by servo input linkage' Avoid bendingIoadsto input rod end. 8 . Withdraw servo with attached control tube. lf removing more than one servo, identify servosand controltubes for reinstallation. 9 . Rod end at servo input must remain attached to servo. when replacing.servo, removalof control tube from servo input rod end is required. Measureand record bimensionprior to disconnectingcontrol tube controi tube rod end center-to-center f-; iouo input rod end. When attaching co.ntroltube to replacementservo, dimensionas close as possible. miintain originalrod end center-to-center NOTE dimension Failureto maintainoriginalrod end center-to-center will requiremain rotor riggingper Section10.120' be transferredto replacement 1 0 . When replacingservo, D2OO-1upper clevis.mus._t servo. Nominaldimensionfor ufjer clevis installationis shown in Figure8.].C. Fiio.to removal,measureand rec6id actualupperclevisdimension.When installing in rbplacementservo,coat clevisihreadswith B27O-21protectantand ,ppr. "f"uis sli clevisdimensionas close as possibleto originalactual dimension. NOTE Failureto maintainoriginalclevisdimensionwill requiremainrotor ri o o i n oo e r S e cti o n1 0 .120. Pa g e8 . 6 4

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]f,'44

8.760 HvdraulicServoInstallation{seeFigure8-1A and Figure8-16) 1. Positionpalnut, jam nut, retainer,and O-ringon elbow and/or T-fittings and installin servo pressureand return ports. CAUTION retainershave been installedper Figure 8-16. lmproper installationcould result in loss of hydraulicfluid and higherthan normalvibrationsin the fliqht controls.

2 . Installcontroltube onto servo input rod end and adjustcontroltube as closeas possible dimensionrecordedduringservo removal. Rodends to originalrod end center-to-center degrees to each other. Torquejam nuts per Section must remain 90 C343-8 tube in 1.320. WARNING Servo input rod end is ed only by servo input linkage. Avoid bendins loads to input rod end.

3 . Positionservo with attached control tube in helicopterand secure servo cylinderto airframe. Torquefastenersper Section 1.320 and torque stripe. 4 . lf installingforward servo,connectservoscissors(overlapdirectionnot critical). Ensure washeris installedbetweenscissorsand torqueper Section1.330. 5. a, lf installingforward servo, connect C121-24 or -28 push-pulltube lower rod end to aft end of cyclic torque tube, Ensurerod ends are centered;align as required. Torquejam nuts, palnuts,and bolt per Section1.320 and torquestripe. b. lf installingaft servo, connect C343-8 tube's lower rod end to collectivejackshaft. Torquejam nuts, palnuts,and bolt per Section1.320 and torquestripe. 6 . Connect C121-25 or -31 push-pulltube lower rod end to servo upperclevis. 7 . Connect pressureand return lines to servo. Positionservo elbow and/or T-fifiings to minimizeline preloadand ensure clearancewith surroundingstructure. Torque jam nuts, palnuts,and B-nutsper Section 1.330. Pressureand returnfittings are different sizesand requiredifferenttorques. 8. lf removed,installmain fuel tank and/orauxiliaryfuel tank per Sections12.130 and 12.150. 9. InstallC706-1 tailconecowlingand connectany attachedantenna. positionlightwiring (if installed), 10. lnstallmast fairingand connectpitot heat (if installed), and pitot tube. 1 "1 . B l e e dh y d ra u l i csyste mp e r S e ction1.190. Ch a n g e1 3 : O CT 2 0 0 6

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SECTION 9 ROTORSYSTEMS 9.OOOROTORSYSTEMS 9.OO1 Introduction

(

9.002 Description 9 . 1 0 0 M A I N ROT OR 9.110 Main RotorBlades 9.1 1 1 Main Rotor BladeRemoval 9.112 Main RotorBladeInstallation 9.1 13 Boot Removal 9.114 Boot lnstallation 9 . 1 1 5 Fi l l i n gP i tchB e a ri n gH o using 9.116 DrillingMain RotorHub Bolts 9.12O Main RotorHub 9.121 Main RotorHub Removal 9.122 Main RotorHub lnstallation 9.123 Assemblyof the Main Rotor Hub without RHC Static BalanceInformation 9.124 Adjustmentof HingeFriction 9.125 Shiftingthe Main Rotor Hub 9.126 Main RotorHub BearingReplacement 9.130 Inspectionand Repairof Main RotorBlades 9.2OO TAIL ROTOR 9.210 Tail RotorRemoval 9.212 Tail RotorInstallation with SphericalTeeterBearings 9.213 Tail Rotor Installationwith ElastomericTeeter Bearings 9.214 Tail RotorHub SphericalBearingReplacement 9.215 Tail RotorHub Elastomeric BearingReplacement 9.22O Inspectionand Repairof Tail Rotor Blades Change13: OCT 2006

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cooS-2ANDCOOS-4 9.31oToo|sRequiredtoPerformBladeRep|acement 9.320 BladeRemoval TeeterBearing) 9.33O DO62-1Hub Disassembly(Elastomeric 9 . 4 O O T A I L R OT ORH U B IN S P E C T ION 9.41 O GeneralInsPection l sP e cti o n 9 . 4 2 O D i m e n si o n aIn 9.50O COOSTAIL ROTORREASSEMBLY 9 . 5 1 O H u b B e a ri n gl n sta l l a ti o n 9.520 COOS-2Tail Rotor BladeAssembly 9.530 COOS-4Tail Rotor BladeAssembly

9 . 6 1 O C h o rd w i seS ta ti c B a l a n ce 9 . 6 2 0 S p a n w i seS ta ti c B a l a n ce 9 . 6 3 0 F i n a lA sse mb l Y

WARNING (anti' Due to potentialty destructive results, use of blade tape erosiontape) is Prohibited.

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9 SECTION ROTORSYSTEMS WARNING Due to potentially destructive results, use of blade tape {antierosiontapel is prohibited. 9.OOOROTORSYSTEMS 9.O01 Introduction This section contains proceduresand requirementsfor proper maintenanceand servicingof main and tail rotor systems.These systems includemain rotor blades and hub, tail rotor bladesand hub and droop stops. 9.O02 Description The main rotor system consistsof two main rotor bladesand one forged-aluminum hub havingone centerteeterhingeand two coning(blade)hinges. Main rotor blades are constructedwith stainless-steelskins bonded to a D-sectionstainless-steel spar, an aluminumhoneycombcore, and forged-aluminumroot fitting. Bladepitch changeis accomplishedthrough a six-bearingstack attachedto a forged stainlesssteel spindlelocatedwithin the bladeroot fitting. The spindleis the attachmentfor bladeto main rotor hub and also containsan integraltusk for droop stop system. To minimizeteetering,integraltusks drive shaft-mountedaluminumdroop stops when bladesare at rest or turning at low RPM. The tail rotor system consists of an aluminum hub and two blades. The hub containstwo Teflon-linedelastomericbearings,which allow rotor to teeter. Blades are constructedof a wrap-aroundaluminumskin bondedto aluminumhoneycomb and a forged aluminumroot fitting. The root fitting containstwo non-replaceable Teflon-linedsphericalbearings,which enablebladesto changepitch. The bladesare l mountedbetweenhub platesand have a set preconeangle.The tail rotor teetering stop consistsof an output shaft-mountedurethanebumper, which s hub I when teeter limit is reached. 9 . 1 0 0 M AI N R OT OR 9 . 1 1 0 M a i n R o to rB l a d e s 9 . 1 1 1 M a i n R o to rB l a d eR e mo val Fourpeoplewill be requiredto removethe blades.One personmust the bfadeapproximatelV213its length from the root while anothersthe root and removesor installsthe attachedbolt (seeFigure9-1).

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FIGURE9-1 INSTALLATIONOR REMOVALOF MAIN ROTORBLADES

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9 . 1 1 1 Ma i n R o to rB l a d eR e mo val( cont' d) 1. Mark one blade and its correspondinghinge nut & bolt, pitch link and rotor head location with a colored marker, such as a grease pencil and, mark as uxu. Using a different color marker, mark as "O", on the other blade, nut, bolt, pitch link and rotor head location. 2. Disconnectpitch links from each main rotor blade. 3. Removecotter pins and loosen nuts of blade coning hinge bolts so they are just fingertight. 4. Removenut, thrust washer, and shims (if used)from trailing-edgeside of one blade hinge bolt. Cone blade so spindletusk no longer s droop stop. While ingblade at root, carefullyrotate pitch horn down and remove hinge bolt and thrust washer. CAUTION remainingmain rotor blade in a level position during and after removalof oppositeblade. NOTE Installationhardware is matched individuallyto each blade installation;carefullyreinstallall attach hardwareinto rotor hub exactlv as removed. 5. Store rotor bladeson a cushionedsurfaceto preventdamageto bladeskins. 6. RepeatStep 4. to removeremainingblade.

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9 . 1 1 2 Ma i n R o to rB l a d eIn sta llation WARNING Never installCO16-1blade(sl. ReferenceAirworthiness Directive 98-22-16. WARNING R44 ll (fuel iniectedl helicopters require two A205-7 forks, A600-6 manifold pressuregage, two C0O5-8 main rotor blade & spindle assemblies (two c016-5 main rotor blades & two C157-2 pitch hornsl, COO6-5main rotor gearbox, CO08-4 tail rotor assembly (two CO29-2 tail rotor bladesl, two C016-5 main rotor btades,CO17-4swashplate,three C121-31 push-pull tubes, two C2O3-5 yokes, C2O4-2 arm (stainlesssteel, lowerl, C2O4-g arm (staintess steet, upperl, C792-4 dual tachometer, D2O1-5 weldment (forward hydraulic servosl, and weldment (aft hydraulicservo). D204-8 1 . With rotor hub level, insert appropriatejournals into coning hinge bearings. Installthrust washer on coninghinge bolt. in hub until spindlehole alignswith journalbores,coning blade -not"ie 2 . positionblade as iequireO. s id e .

pitcn irorn down ant install hinge bolt at leading-edge

NOTE temporarilyi nsert an old bolt from To assistbolt installation, trailing-edgeside to align spindlewith our nals. CAUTION

To prevent damage, level and installed blade until site bladeis installed.

and, priorto installing 3. Installtrailing-edgeshims {if used)and thrrLs_t_w_asher compound. anti-seize A257-9 with face nut and ittieads nut, coat Uoit

NOTE or hub Do not allow anti-seizecompoundin journal- bearingareas.These areasmust be clean anfu

per 4 . With installedbladelevel and edneartip, installoppositeblade steps 1 thru 3. 5 . Tighten nut on hinge bolt until journalsand thrust washer are firmly seated' fti"n Oacf.nut ott Jntil both thrirst washerscan be freely rotated' 6 . l n sta l fMT l 2 2 -6 ma i n rotor bolt str etchtool on hingebolt per Figur e9- 2- 7er o d i a l i n d i ca to ra n d l o ck i ndicatordial. Rem ovetool' Change14: JUL 2008 Pa g e9 . 4

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FIGURE9-2 MEASURINGBOLTSTRETCH(AS SHOWNON TEETERHINGEBOLT)

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( cont' d) 9 . 1 1 2 Ma i n R o to rB l a d eIn sta l lation 7.

Usingwrencheswith at least600 ft-lb torquecapacity,tighten nut until drilled hole in nut and bolt align. ReinstallMT1 22-6 and measurebolt stretch; the stretch must be between O.O2O'O.O22 inch (0.021 - O.O22inch for new, undrilledbolt). Installa new cotter pin with wet epoxy primer.

NOTE lf drilledholesin nut and boltdo not align,bothnut andbolt must be replaced. WARNING The main rotor blade and hub attach bolts must be stretched from 0.020 - o.o22 inch (0.021 - o.o22 inch for new, undrilled boltl to obtain proper clampingforce. Under-stretchingor overfailure of the bolts. can cause g.

Referto Figure8-10. Connectpitch link to pitch horn. Standardtorque per S e cti o n1 .3 2 O,i n sta l lp a tnut,and tor questr ipeper Figur e2- 1.

9.

Repeatsteps 1 thru 8 for remainingblade.

1 0 . positioncyclic and collectiveat approximatelymid-travelpositionsto minimize wrinklesin boots. 1 1 . Refer to Figure 9-3A. Insert two (2) MT549-1 spacers between hub and boot with gaps at top and bottom. Spacersshouldfit in recessof boot. Hold spacersin placeagainstboot and insertMT549-2 platefrom top between hub and spacers. Push plate down until it s spindle. 12. Removelower plug from pitch horn and allow oil to flow. Placea finger over hole as soon as oii flow decreasesto a drip to preventair from being sucked i n si d eb l a d e . per 1 3 . Remove finger from hole and quickly install drain plug. Specialtorque S e cti o n1 .3 3 0 a n d to rq uestr ipeper Figur e2- 1'

1 4 . Removeplate and sPacers. 1 5 . Re p e a to n se co n db l a d e.

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9 . 1 1 3 B o o t R e mo va l 1 . R e mo vema i n ro to r b l a d esper Section9- 1112. Placea containerunder pitch horn. Removeupperand lower self-sealingbolts pitch horn and drain lubricantfrom pitch bearinghousing. 3. Removeouter boot clamp and hold boot back to expose inner boot clamp. Removeinner clamp and peel boot from spindle. Boot inner portion may be sealedto spindlewith 8270-1 sealant. 9.1 14 Boot Installation 1. As required,use a plasticscraperand vacuum cleanerto removeold B27O-1 sealantfrom spindleareato be coveredby boot innerlip. Avoid contaminating spindlebearingswith old sealant. WARNING Use only plastic scrapels to remove old sealant; chemical removal is prohibited.

2 . Carefullystretch new boot over spindle. temperatures,sealingof boot's inner 3 . lf bladewill be subjectedto sub-freezing

lip to spindle is recommended:Pull boot inner lip back enough to expose j u n cti o no f C 1 4 7 -1 sp a c erand C158- 1 spindle. Solventcleanand dry boot inner lip, spacer,and spindlesurfacesclampedby boot inner lip. Apply an approximately1/16-inchdiameterbead of B27O-1sealantcompletelyaround junction. Whilesealantis stillwet, properlypositionboot innerlip spacer-spindle and installand tighten C165-1 clamp assy. Rotatespindleand adequate clearancebetween clamp assy and pitch horn. Wipe off excesssealantand allow to cure in accordancewith sealantmanufacturerrecommendations. WARNING

Use

B27O-1sealant;silicon sealantis NOTE

When installinginner clamp, ensurethat shoulderof boot inner lip is not wedgedbeneathclampor clampmay loosenin service. Inspectboot interiorand no cuts or punctures. 4. Stretch boot outer lip over pitch horn flange. Rotate spindleand align pitch horn arm bolt hole with spindlebolt hole per Figure9-3. 5 . F i l lp i tch b e a ri n gh o u si ngper Section9.115. Ch a n g e1 4 : J U L 2 0 0 8

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OF A257-4 FLUID3 FEETABOVENEEDLEVALVE CONTAINER

/ FITTING MT147.2 BLEEDER

c 1 6 5 - 2C L A M P BOLTHOLECENTER. SPINDLE LINEAND PITCHHORNBOLT MUSTALIGN. HOLECENTERLINE

VALVE NEEDLE

9-3 FILLINGPITCHBEARINGHQUqNq FTGURE INSERTPLATEFROMTOP

BOLT SELF-SEALING

M A i N R O T O RH U B c157-2 P I T C HH O R N

,

, 'il l ll lll

c157-1 P I T C HH O R N

K\s-

!o

!rl$t \:.

-t I

BOOT I| MT549.2 PLATE

l1

{View from abovel

I

L_-

!: MT549-1sPAcERs (INSERT WITHGAPS AT TOP AND BOTTOM)

c157-2 P I T C HH O R N

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9 . 1 1 5 F i l l i n gP i tchB e a ri n gH o using 1. See Figure9-3. Remove8289-2 self-sealingbolts from pitch horn and install MT147 air-bleedfittings in holes. 2. Position MT147 supply container of A257-4 fluid (ref Section 1.4701 approximately3 feet aboverotor blade. Connecttubing from supplycontainer to lower air-bleedfitting. Connect vent tubing to upper air-bleedfitting and applysuctionuntil tubing from supplycontaineris filled with fluid. Routevent tubing from upperair-bleedfitting to anothercontainer. 3. Allow fluid to siphon from supply containeruntil no air bubblesare visiblein vent line. Carefullymassageboot, rotate spindle back and forth, and raise bladetip up and down to ensureno trappedair remainsinside. 4. When housingis filled, removeupper air-bleedfitting and install8289-2 selfsealingbolt. Roll bladeover. After five minutesinspect boot for leaks. lf no leaks are found, remove air-bleedfitting and install 8289-2 self-sealingbolt. Torque 8289-2 self-sealingbolts per Section 1 .330 and torque stripe. 9 . 1 1 6 D ri l l i n sMa i n R o to rH u b Bolts New bolts and nuts must be installedand bolts stretchedto Section 1.330 limits prior to drilling. Nuts have three blind holes pre-drilledinto every other nut flat use a s d r i l l i n gg u i d e s. U s i n g a si x-i n chl o n g O.1 5 6 -inchdiameterCobalt twist- dr ill,dr ill a hole th r ough nut and bolt using an accessiblepre-drilledhole in nut. lf a shorter length drill is used, protect hub from damage due to chuck by wrapping chuck and/or covering hub edge with severallayers of tape. Preventchips from contaminating other mechanisms. NOTE lf none of the predrilledholesin nut are accessiblefor use as a guide after stretchingbolt, loosen nut and repositionbolt and nut. Restretchbolt per Section1.33O. 9 . 1 2 0 M a i n R o t o rH u b 9 . 1 2 1 M a i n R o t o rH u b R e m o v a l 1 . R e m o v em a i nr o t o rb l a d e sp e r S e c t i o n9 . 1 1 1 . 2. Mark rotor hub using a greasepencilor other soft markeras followsl a. Indicatenut side of teeter bolt. b. Indicatechord arm side of drive shaft.

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9 . 1 2 1 Ma i n R o to rH u b R e mo vq!( cont' d) hub 3 . R e mo veco tte r p i n , n u t, C117 shims, ClQO jour nals,and bolt. Rotate as requiredand'r".ove hub. Do r'tot drop C152 thrust washers or C1O6 journals. 4. Reinstallbolt, thrust washers,shims,journals,and nut in rotor hub exactly as removed. CAUTION Main rotor chordwise batanceis adiusted using ClOG iournals Cf 17 shims. lf assembly stabkup is altered, an out-of"nt balancecondition can occur. 9 . 1 2 2 Ma i n R o to rH u b In sta l l ation 1 . L in eu p ma rk o n h u b w i th chor dar m on r otor shaft' journals exactly as 2. Reinstallteeter hinge bolt, thrust washers, shims, and removed. lf previoiuslyinstalledinformationis unavailable,perform_teeter hingeshim calculationper Section9.1 23.A. Ensurejournalsare clearof droop stops and fully drive shaft. 3. Coat nut face and bolt threadswith A257-9 anti-seizecompound,installand tighten nut, then loosennut until both thrust washerscan be freely rotated. WARNING Do not attow anti-seizecompound to contaminate drive-shaft, iournals, shims, or thrust washer inner faces. Contamination prevents properioint clamp-upand may cause fal 4 . Position Mt122-6 main rotor bolt stretch tool per Figure9-2. Zero tnolcaror by rotatingdial face. Lock dial so it will not move' Removetool.

o

5 . Sp e ci a lto rq u e stre tch bolt per Section 1.330'

Use minimum3/4-inchdrivetools to stretchmain rotor hub bolts' pin; 6. teeter hinge friction per Section 9.124.b betore installingcotter adjust as required' pi n w i th 7 . l f re q u i re dd, ri l lco tte r p i n holeper Section9.116. Coat a new cotter zinc-chromateor epoxy primerand installwet'

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Teeter Hinge Bearing

Width acrossteeter hingebearings Teeter Hinge Bearing

1a'44

Width Dri

Thrust Washer

Shaft

(2 places)

C 1 O 6 - 5o r - 6 Journal

c106-5 Journal c117

c117

Bolt Shims (Head on same side as chord arm)

Shims

Droop Stop

Droop Stop Hub

Teeter Stop Bracket (orientas shown)

Main Rotor Drive Shaft

Chord Arm

FIGURE9-4 TEETERHINGE Width across.coning+; hinge bearings

r-

Coning Hinge Bearing {2 places) Bolt (headon leading-edge side)

Thrust Washer

or C117-A,-9,-10 - 1 1 S h i m s( N u t - s i d e only, requiredwhen t w o C 1 0 6 - 7J o u r n a l s are installed)

journalon Leading-edge both bladeconing hinges to be same length. Spindle

C 1 0 6 - 7J o u r n a(l 2 p l a c e s ) or C 1 0 6 - 1, - 2 , - 3 ,o r - 4 J o u r n a(l2 p l a c e s )

FIGURE9-5 CONINGHINGE{LOOKINGDOWNI Change14: JUL 2OO8

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FRONTVIEW OF MAIN ROTORHUB

T o P v l E Wo F HUB M A | NR O T O R

M A X I M U MG A P ,A T o r A L o F B o r H s I D E S : o . o o 5i n . - U S E D 0 . 0 0 3i n . - N E W

FIGURE 9.6 MEASURING BEARING-TO.WASHERGAP

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9.123 Assemblvof the Main Rotor Hub without RHC Static Balancelnformation A. Teeter Hinge Shim Calculation trefer to Figure 9-41 inches inches inches

1. Measuremain rotor hub width acrossthe teeter hinge bearingfaces: 2. Subtractmeasuredwidth of C251 driveshaftat teeter hingebolt hole: Calculatedempty sp?c€i =

3. Selecta Cl06-5, or C106-6,journaland C117 shimswhich createa combinedlengthof approximately1.835 inches. Use as many differentsizeshims as possible.Placethrust washer, shims, and journalunderteeter bolt head;shims must be placedbetweenthrust washerandjournal. Subtractcombinedmeasuredthicknessof selectedjournaland shims: Difference:=

inches

4. Subtractmeasuredlengthof C106-5 journalto be used on nut'side:-

inches inches

CAUTION Initial teeter hinge hardware stack-up must be adjusted to 0.005/O.OO8inch greaterthan calculatedempty space. A smaller initial stack-up could damagethrust washers and hub bearings duringinstallation. changedue to clampingforce, add: + o.oo5/o'oo8 5. To accommodatedimensional I

inch

oT-ct-t7-snims 6. PrecedingResultis initialcalculatedC117 shim stack between nut-sidejournal and thrust w-asher. Use as many different size shims as possibleto facilitate head shifting during balancing. Deviatefrom initialshim stack as requiredto meet teeter hingeflictionlequiremehts(8-12 poundsis ideal).(Seenext page for ConingfBlade] HingeShim Calculation.)

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BalanceInformation(cont'd)

B. Coning (Blade)Hinge Shim Calculation{refer to Figure9-51 1 . Measureand recordmain rotor hub width acrossthe coning hinge bearingfaces: 2 . Subtract blade's spindlewidth measuredacross faces at coning hinge bolt bore: = Calculatedempty SPoG€l

inches inches inches

CAUTION Initial coning hinge hardware stack-up must be adjusted.to b.OOZiO.O11-inch dreaterthan calculateciempty space. A smaller iniiiif stack-up co-ulddamagethrust washers and hub bearings duringinstallation. inch 3. To accommodatedimensionalchangedue to clampingforce, add: + o.oo7/o'o1t Sum:: _l_inch -4journals whose combinedmeasured sefect a combinationof c106-1 , -2, -3, or thiCSum. Alternatively,us6two Ci 06-7 journalsand shimsdetermined f "quatsteP. "ngthr in following

Leadingedgejournallengthsmust be same on both blades. journalsto 4. Subtractcombinedmeasuredlengthsof both Cl06-7 be installed: Result::

inches I

inch

oTEtTTsnims

journal b. precedingResultis initialcalculatedC117shimstackrequiredbetweentrailing-edge journal as lengrth, and thrust *uJ6"i. Ouuiat" from initial trailing edge shim stack-up,or play.per axial hinge to r""i trttion requirementswhile m?intaining.coning necessary 'C',il;g-'6.-it *rrt be possibleto minually cone.each blade without teeteringthe hub or when bladesur" frufOui off the dioop stopi and lifted at tip. Increasingshim stack-up journallengthdecreaseshingefriction.

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9.123 Assemblvof the Main RotorHub without RHC Static Balancelnformation(cont'd) C1O6 JournalLengths Part No. Length(inches) Location C106-1 C1O6-2 C106-3 C106-4 C106-5 C106-6 C106-7

1 .3 O0 1.3O5 1 .3 1 0 1 .3 1 5 1 .7 7 5 1.8 1 5 1.284

C o ninghinge,no shim s Coninghinge,no shims C o ninghinge,no shim s C o ninghinge,no shim s T e eterhinge T e eterhinge Coninghinge(mustusetwo per hinge),requiresC117 shims

C 11 7 S h i mS i ze s Part No. Thickness(inch) Location(Betweenthrust washer and iournal) C117-8 C117-9 C117-10 C117-11

O.012 O.O15 0.020 0.025

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side Teeterhinge;Coninghingetrailing-edge side Teeterhinge;Coninghingetrailing-edge side Teeterhinge;Coninghingetrailing-edge side Teeterhinge;Coninghingetrailing-edge

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9.124 Adjustmentof HingeFriction

NOTE Adjust teeter

frictionbeforeinstallingblades.

A . Coninghingefriction is adjustablethrough use of variousthicknessC117 shims. The shims, installedbetween thrust washer and trailing-edgejournal, can be four obtainedin four sizes(0.012,O.O15,0.020, and 0.025 inch).Alternatively, differentlengthsof C106 journalsmay be used. See Figure9-5. CAUTION When a shim is replacedwith a shim of a differentsize, it will be necessaryto installa new nut and bolt and drillthem. Drilledholes in originalbolts will not alignat requiredbolt stretch. Installshims e-sideof hinqe. only on traili 1. Removecotter pin, nut, and thrust washer on bladehinge.

2 . Removeshim(s)to be changed.Measureshim thicknessand selectnext size thicker or thinneras required.A thicker shim will decreaseblade'sconing hinge friction. A thinner shim will increaseblade's coning hinge friction and decreaseany gap between blade'sthrust washersand hub bearings.

3 . Installshim with a new bolt. 4 . Installnew nut and stretchbolt per Section9.112, Bladelnstallation. 5 . Check blade hinge friction by lifting blades until spindletusks clear droop stops. Hold one blade level and cone oppositeblade. Rotor hub should not teeter as bladeis coned. Repeatcheck on oppositeblade. 6 . Using a feeler gauge, measuregap between thrust washer and rotor hub bearing. Gap must be measuredon both leadingedge & trailingedge sides of coninghingeand the'totalmust not exceed0'005 inch (o'0o3 inch if new hub bearingsare installed).See Figure9-6. B. Teeterhingefrictionis adjustedby changingC1 17 shimstack in smallincrements. C 1 1 7 -8 ,-9 , -1 0 a n d -1 1 shimsar e O.012,O.O15,0.020, and 0.025 inc hthi c k , respectively.See Figure9-4.

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EL ]|44

MT354-4TEETER MOMENTOOL SPRING SCALE

MEASUREMENT HINGEFRICTION FIGURE9.7 TEETER

P a g e9 . 18

Change14: JUL 2OO8

MATNTENANeEMANUAL

FIC|BINEICIN

MOEIEL F44

9.124 Adjustmentof Hinge Friction(cont'dl NOTE lf shim stack is changed per following instructions, a new bolt and nut must be installedper Section 9.112. 1. Teeter hinge friction must be checked and adjustedwith main rotor blades removedfrom main rotor hub. 2. Removecotter pin and teeter hinge nut. Removethrust washer and C117 shims under nut. 3. Measurethicknessof C117 shims underteeter hinge nut. Changeshims as necessaryto adjustfriction. Reducingshim stack-up by O.OO3- 0.005 inch will increbsefriition. lncreasingshim stack-up will reduceteeter friction. 4. See Figure 9-7. Install MT354 Teeter Moment Tool into main rotor hub coninghingebearings.Usinga springscale,measureforce requiredto_teeter main iotor-hub; use sliding force reading, not breakaway reading.Torque teeter hinge bolt per Section 1.330 and check teeter friction often while stretching-bolt. Do not exceed maximumteeter hinge friction. lf required, increaseshim stack-upper precedingstep so proper bolt stretch is reached prior to maximum friction. Cotter pin holes in nut and bolt will not align. Forcerequiredto teeter main rotor hub must be: Mi n i mu m: N o a xialplay. Maximum: 19 pounds. 5. Removeteeter hinge bolt by pressingit out with an old bolt. Installa new bolt and nut per Section 9.122. Drill and cotter pin new bolt and nut per S e cti o n9 .1 16 . 9.125 Shiftingthe Main Rotor Hub Shiftingthe main rotor hub is used as a coarseadjustmentfor main rotor chordwise b a l a n c e. 1.

Removecotter pin from teeter hingenut. Removenut, washerand any shims from the teeter hinge bolt.

2.

Havetwo peoplecone the main rotor blades. Pushout teeter hingebolt with another bolt.

3.

Move or exchangeexistingshims from one side of hub to other as indicated by main rotor balancechart (see Section 1O).

4.

In sta l lte e te r h i n g e b olt per Section9.122.

Ch a n g e7 : 0 6 D e c 9 9

P a g e9 . 1 9

FICIBINSGIN

M('E,ELH'44

MAINTENANeEMANUAL

9.126 Main RotorHub BearingReplacement 1.

Removemainrotorhub per Section9.121'

2.

with sameblades,measureandrecord lf mainrotorhub is to be reinstalled and iil;;i iengtns,shimthicknesses, locationsin hub' Measureand recordhub width acrosswidestpoint of teeterand coning f,ingebearingfaces(totalof threemeasurements)'

3.

CAUTION To prevent hub damageensureall tool and beaiingsurfacesare smooth. 4.

out of hub.uslng. soc.kethavingan SeeFigure9-7A. Pressold b-e!rring.(s) inchesand an 8-inchextension' outeriiiameterof 1.535-1.555 CAUTION Ensurehub is flat on presstableand socketis centeredon bearingto preventhub damage'

5.

6.

7.

Polishout Inspecthub bearingbore. no scoring_or scratches. (0.005 inch on inch of O.001 to a maximum.depth. i^;ft'r; and sandpaper wet-or-dry "oiroiiSn "nA of Uot"i-rsing32O-grft - dl finer edge -inCf, ilOirs-.t or corrosion fretting if riinimum Uienaridius. Replacehub O.2S cannotbe polishedout withinlimits' bore Ensurenew bearingmatingsurfacesare smooth. Coathub bearing primer {see efo-xy or ttrU U"tting 1n|tingsuifaceswith zinc chromate portion of Teflon "i'tO $".tion i .qqai.' iil n"oiatto* primerto contaminate bearing. s.9 is visible,orientbear-1ng bearing.Te{lon.liner SeeFigure9-7B. lf seam.of. is still Whilg-primer seamis toward top oi nrU (Jsinstitledon helicopter). *;; pi"i. in new bearingusing MT329-6 plug and MT643-1 until bearing iirppSri iJ not ,..4 *fi"niressi"ngin teeterhingebearings) flangeshub. CAUTION Use MT643-1 ' Neverwhen installingconing install coning hinge h i n g e b e a ri n gs. bealings into unedhub.

8.

9.

primer' Seal between bearingflange and hub with zinc chromateor epoxy allow not Do 5-ifirfV sllt Uef*e"eninSoardedge of .bearingand hub. frimer io contaminateTeflon portion of bearing' faces. Compare Measurehub width acrossteeterand coninghinggbearing. wiOtfrswith meairrg;1"nis from Step 3. Any hup width increaserequires cj l cu l a ti n gn e w rfi Ct- up for affectedhinge per Section9.123.

har dwar eas r emovedi n s tep , 1 0 . tf re i n sta l l i n gh u b o n sam ehelicopterinstall 2, subject to PrecedingsteP.

P a g e9 . 2 O

Change7: 06 D ec 99

MATNTENANeEMANUAL

FICIBINSCIN

MC'E EL F|44

PRESS

S INCH SOCKET EXTENSION

:7 O

socKET:oursrDEDTAMETER 1 . 5 3 5- 1 . 5 5 5I N C H E S

FIGURE9-7A MAIN ROTORHUB BEARING REMOVAL

MT643-1

9.78 FIGURE MAIN ROTORHUB

Ch a n g e7 : 0 6 D e c 9 9

Page9.20A

MC'E'ELF'44

MATNTENANcEMANUAL

FIEIBINSiCIN

9.130 Inspectionand Repairof Main Rotor Blades

limits,methodsand materialsusedfor Thisbladerepairprocedureoutlinesthe repa.ir to blendingout scratches,dents,nicks, arelimit'ed Repairs r"priiing ;niin iotoi Ulades.. repairsand limitations removtngcorrot,on,;;d iefinisiringthg blades.Theinspebtions, containedhereinieiei to damages[stainedin service,includingdamageduringshipping by the factor-y)..lnsepa.rately are-treated iTregularities inO tanaling (manufacturing oftentimesfreshlyand or scratches paint scu-ffing exhi-bit *ilig"n"ralli servicedamige questions^as to the are any there lf finish. in the of scratch6s the-form rei.iln "ipoieO p6lJiUilityof a manufacturingirregularity, RobinsonHelicopterCompany TechnicalDePartment. CAUTION A blade may be repairedmore than one time. However, ih no case can more than the maximummaterialbe removedor the maximum dent depth be exceededin any one location. Inspection a)

Scr

corrosionon

ished out

a 0.1

: Scratchesand blen d r adi us

w i th i n th e fo l l o w i n gl i mi ts.:

b)

1)

Ou tb o a rdo f 2 4 i n chesfr om the bladetip, the maximumdepth all ow edi n 0 .0 0 2 i n ch .

2l

In b o a rdo f 2 4 i n ch e sfr om the bladetip, the maximumdepthis 0.0015 i nc h coriosion. For scratchesru-nningin a directionmore than 15o from tor "ny th e sfa n w i se d i re ction,the m aximum depth.lim it is 0.001 inc h. F or scra tch e si u n n i n gl eJsthan 15o of spanwise,the m aximumis 0.0O 15i nc h deep.

Dents on skins (See Fiqure 9-8): Measure dents u.s!n.ga straight edge of amagedareaand a thicknessgaug.e'Always pdrallel with- the leading and trailing edges when [u"p tf,e str"aigl.ttdOge m e a su ri n gd e p th .

P a g e9 . 2 0 8

C h a n g e7 : 0 6 D e c 9 9

FIc|E|INSIclN

MOEIEL

MANUAL

MAINTENANCE

F,44

ANDCoRRoSI0N scRA:rcHES_

: 5

SKINS O.OOI MAX.HAINROTOR DOUBLERS O.OO2 MAX. MAIN ROTOR

sKINS t'lAll'lR0T0R 0.0015 }4AX. DOUELERS O.OO3MAX.MAINROTOR I

I

-t

ti-:: -:.-Z - O.O3O DENT (FILLONLY)

-;:'t'j:-=

0 .s 0 TYP.

- O.O9ODENT (FILLONLY)

i7:j

7't--,

1.5 TIP CAP

DENTS ANDOTHER DEFORMATION

- 0 . 1 2 5D E N T (FILLONLY)

'f':jj - O.OO2DENT

-'r-=j--z

(FrLLor,rLY)

-#:;

- 0 . 0 1 5D E F 0 R T T A T I O N

#= -r----

- 0.060 DEFORMATION ANoFILL) {STRATGHTEN

:ittu, 7:a=

- O.O1O DEEP ( B L E NO DNLY)

.:----

-7--

't':"---

-:;-j_

_ O . 0 6 0D E E P (BLENo 0NLY)

1---

- O.O2O DEEP ( B L E NO DN L Y ) L0 . 3 5 (O.OO2 MAXMATERIAL IN THIS AREA) REMOVAL AREEXPRESSED NOTE:ALL I+IEASUREHENTS IN INCHES (o-RtllcGRooVE)

LII'IITATI0NS DAI4AGE FIGURE 9-8 MAINR0T0RBLADE Ch a n g e6 : 1 8 MA R 9 9

P a g e9 . 2 1

FIGIBINSCIN

c160 SPAR

MATNTENANeE MANUAL

M(IEIEL

Fl44

INTERNAL ALUMINUM TIP CAP

crca4 SKIN

3.0

(TYP 15

places ) 0.20

cL62 t,lRAP. AROUND DOUBLER 0.30 (TYPICAL) 0.50 (TYPICAL) TRAILINGEDGE ENDS DOUBLER (c016-20NLY) THIRDDOUBLER REVY& SUBSEQUENT BLADES c934 UPPER& LOt.lER DOUBLERS SURFACES

c93s DOUBLERS

ICAL - CRIT AREA BOND

0.50 (TYPICAL) TRIM TAB

- SEMI-CRIT ICAL ARTA EONO - NONCRITICAL AREA BOND

0.30

- NOBOND IN THISAREA

c161

r$orott*n-q SPLICE& HONEYCOMB ENDOF ONETRAILING DOUBLER EDGE

FIGURE9-9 MAIN ROTORBLADEADHESIVEBONDEDAREAS GiiO" shown foreshortened,all dimensionsin inches)

P a g e9 . 2 2

Change14: JU L 2OO8

MOE'EL F|44

MATNTENANcE MANUAL

FICIBINSICIN

BLADE C

CHORD LINE

rnarurue { EDGE L

REPAIRS EDGEALLOWABTE 9-9A MAIN ROTORBLADETRAITING FIGURE O F R . S .1 2 2 1 . O | N C HB O N DC O 1 6 - 2& C O 1 6 - 5I N B O A R D 124 R . S . O F O U T B O A R D I N C H B O N D 1. 5 CO16-5 0 . 2 I N C HS P A C E

1 . S 5* l

7 . oI N C H EBSo N D - + l *

i HONEYCOMB I

I . 15 I N C H E S

0 . 5 I N C HB O N D

o.2 r NcH SPACE

I

IN NO DENTSPERMITTED T H I S0 . 7 I N C H - W I D A EREA O F R . S .1 2 2 9 . 9 I N C H E SM I N I M U MC H O R DC 0 1 6 - 2 ,a n d C 0 1 6 - 5I N B O A R D O F R . S .1 2 4 l O . 4 I N C H E SM I N I M U MC H O R DC O 1 6 . 5O U T B O A R D

FIGURE9.9B MINIMUMCHORDLENGTH

*l

C934 DOUBLER (Top and Bottom of Blade)

I

l--,

. TNcHES

MAXIMUM ALLOWABLE D E B O N D E AREA D

LIMITS DEBOND FIGURE 9-9C DOUBTER Ch a n g e1 4 : J U L 2 OO8

Page9.22A

FICIBINEiC|N

MOE EL F.44

MATNTENANeE MANUAL

c016-2

BLADETIP MAIN ROTOR LEADINGEDGE { PERMISSIBLETO REMOVE UP TO NOTED AREA VIA HAND FILINGPAR. ALLEL TO SPAN AND CHORD. REMOVEALL FILE MARKS WITH 220 GRIT OR FINER ALUMINUM OXIDE ABRASIVE PAPER. TRAILING EDGE TO MUST REMAIN PERPENDICULAR 9-9A. CHORDLINE;REFERTO FIGURE SEAL EXPOSEDTRAILINGEDGEBOND T. TRACKAND BALANCEMAIN ROTORPERSECTION1O.

EDGE TRAILING

DRAIN MINIMUM O.75 inch RADIUS

O.75 inch

rl

l*l

l+4.0

/

1 . O Oi n c h inches-)>

FIGURE9.9D C016.2 MAIN ROTORBLADETIP REPAIRLIMITS LEADINGEDGE

PERMISSIBLETO REMOVE UP TO NOTEDAREA VIA HAND FILINGPAR. ALLEL TO SPAN AND CHORD. REMOVEALL FILEMARKS WITH 220 GRIT OR FINER ALUMINUM OXIDE ABRASIVE PAPER. TRAILING EDGE TO MUST REMATNPERPENDICULAR CHORDLINE;REFERTO FIGURE9-9A. SEAL EXPOSEDTRAILINGEDGEBOND T. TRACKAND BALANCEMAIN 'IO. ROTORPERSECTION

EDGE TRAILING

l* l--

v

co16-5 N ROTORBLADETIP

MINIMUM 0.75 inch RADIUS 0.75 inch

1 . O Oi n c h

4.0 inches

9-9E C016.5 MAIN ROTORBLADETIP REPAIRLIMITS FTGURE Page9.22B,

Change13: OCT 20Oo

MATNTENANcE MANUAL

FICIBINSiCIN

MI'EIEL

]t.44

NOTE

h|HENEVER MEASURING DENT, NICK, ORSCRATCH DEPTH ALI,IAYSKEEPSTRAIGHT EDGE I'JITHBLADE PARALLEL LEAD. IffiND-TRAILING EDGE.

FORDAMAGE I,|HENCHECKING TO BLADESINSTALLEDONA HELICOP ER, ALI'IAYS TAKE .INTO THE NATURAL BY DROOP BOt,lCAUSED OF THEBLADE.

TRAILING EDGE BLADEDAMAGE DEPTHMEASUREMENT

}JHITE

YELLOW IIHITE

BLACK SEMI.GLOSS

IEADI116EDGT

T M I T I N GE O G E

TRAItI116EDGE

SIDE BOTTOM OF BLADE

BLACK SEMI-GLOSS

CO16-1MAIN ROTORBLADEPAINTSCHEME

FIGURE9.10 MAINROTORBLADEREPAIR Ch a n g e1 4 : J UL 2 0 0 8

Pa ge9.23

FICIBINSiCIN

MC]EIEL F'44

MATNTENANcE MANUAL

Semi-GlossBlack

LEADINGEDGE

CO16-2MAIN ROTORBLADEPAINTSCHEME

LEADINGEDGE

CO16-5MAIN ROTORBLADEPAINTSCHEME

FIGURE9-1OA MAIN ROTORBLADEPAINT

P a g e9 . 2 3 A

Change14: JU L 2OOB

FIIJB|NSiCIN

MATNTENANcE MANUAL

MclEtEL p'44

Intentionallyblank

Change14: JUL 2OO8

Pag e9.23B

FICIBINSCIN

MATNTENANcE MANUAL

MI'EIEL

1f,.44

9.130 Inspectionand Repairof Main Rotor Blades(cont'd) When checkingfor damageto bladesinstalledon helicopter,use the shortest straightedgepossibleto spandamagedareas.Usinga straightedgeof excessive length will cause a false readingdue to natural bow caused by droop of the blade.Smoothroundbottom dents which have a O.O6-inchminimumradiusand occur in honeycornband unedareasof the bladeare acceptablewithin the limits shown below. Tap test dented areasin honeycomb.lf any voids are found associatedwith dents, CustomerService. 1) Outboardof 35.1O inches from the blade tip, dents cannot exceed 0.125 inch deep. NoTE: Inspect opposite side of the blade for a bulge. Scrapany blade with a bulge oppositea dent when the bulge i s g re a te rth a n O.O1 Oinch. 2 ) B e tw e e n3 5 .1 O a n d 103.50 inchesfr om the bladetip, dents canno t e xce e d0 .0 9 i n ch d e ep.

3 ) B e tw e e n1 O3 .5 Oa n d 179.90 inchesfr om the bladetip, dents canno t e xce e d0 .0 3 0 i n ch d eep.

4l For dents at the spar or trailingedge bond ts, the repairlimit is the same as for scratches. CAUTION Do not repair any dent that has a sharp cut or break in the skin. lf necessary,locallypenetrantinspect, keepingpenetrant materialsaway from bond tsc ) Nicks and notchesin trailingedge: Blendout all nicks and notchesin the up to a maximum of 0.040 inch from the edge' *t*.ttt"ili"g must extend for 1.0 inch minimumon each side of the The blendedarea"dge nick or notch with a minimumradiusof 12.a inches.The minimumchord width after a repairis calledout in Figure9-9B' d)

P a g e9 . 2 4

Nicks and notchesin Trim Tab: Nicks and notchesin the trim tab trailing @nintromtheedgemaybee|iminatedbyremoving materialfrom the trim tabs. Maximumtrailingedge materialremovalfrom trim tabs is 0.050 inch, keepingthe edge parallelwith the bladetrailing e dg e .

Change14: JUL 2OOB

MATNTENANcE MANUAL

FICIEIINSCIN

MOETEL F|44

and Repairof MainRotorBlades(cont'd) 9.130 Inspection All.spardamagemustbe oq sp?r(SggFigure__9-8): e) Dents,dingsandscratqhes blendedout with a minimum1.Oanchblendradlusas Tollows:

1) 103.5 inchesfrom bladetip and outboard:maximumdepth is O.O2Oinch. 21 103.50 to 136.00 inchesfrom 'bladetip: maximumdepth is O.O1Oinch. 3) 136.00 inchesfrom bladetip and inboard:maximumdepth is 0.030 inch. f) Erosionon spar leadingedge:Replaceblade.if erosionhas reducedthickness .o40inch.Rep|aceanyb|adeshowingripp|esor deformationof leadingedge due to erosion.

s)

and corrosionon

must

f

usrnga

All damage

radiusas

follows: 1) Outsidediameterof flange:maximumdepth is O.O4Oinch. 2l Root areaO.35 inch outboardof flange:maximumdepth is O.OO2inch. 3) All other exposedareasof root fitting: maximumdepth is O.O60inch. h) Voids and debonds(SeeFiqure9-9 and 9-9C): Bladesmust be tap tested using a ondition. Maximum limits for voids and debondsare as follows: 1) For root fittings, tip caps, sparsand trailingedges,907o^ofthe area must be securelybondeilwith no singlevoidslargerthan O.1Osquareinch.Voids separatedby lessthan O.25 inch shallbe consideredcontinuous. 2) Voids or debondsin doublersare not field repairable.lf any voirls or debonds are detectedin doublers,beyondlimits in Figure9-9C, Robinson HelicopterCompanyTechnical.

Change13: OCT 2006

Page9.25

FIClElINSlClN

MATNTENANeE MANUAL

MtfE,EL

F,44

andRepairof MainRotorBlades(cont'd) 9.130 Inspection i) ReworkProcess: file may be usedto 1) Referto Figures9-9A, 9-98,9-9Dand9-9E. A fine-toothed trim bladetiP withinlimits. 2) Polishout all scratches,dentsand corrosionusing 22O grit.orfiner wet-or-dry aluminumoxideor siliconcarbideabrasivepaper,and finish with 32O grit or the spar finer wet-or-dryabrasivepaper.A fine-toothedfile may_be.used-.along grit wet-or-dry or finer andtrailingedie, provideithe areais finishedwith 32O in the spanwise abrasivepiperl Mbte sureall sandingor filing is accomplished direction. CAUTION DO NOT USE power tools or chemicalpaint s.triqqejgto remove material.The maximum surfacetemperatureis 175oF. Remove only the minimumamountof materialneededto get to the bottom of ihe damageand blendin the reworkedarea. 3) Visuallyinspectall reworkedareasto see that the scratches,corrosionor other damagehas been removed. j) Measuringthe MaterialRemoved: For locally-reworkedareas,the foltowing two methods of checkingthe amount of materialremovedare suggested: 1) Use calipers or micrometers and compare measurementsbefore and after blending. (2) inches I 2l Forareasin the skinsand sparwhere reworkedareasare lessthan two 9-1O' Figure See used. gauge be may it*igh,i eOg- uncithickness acr;*

Page9.26

Change13: OCT 20Oo

FIClBINElclN

MAINTENANeE MANUAL

MtfElEL

1t44

air of Main Rotor Blades(cont' Sealing,Fillingand Fairing: a ) C l e a n a l l a re a s n e e ding sealing or filling and fair ing with 1,1,1 Trichloroethylene. ,. , b) Apply Scotch-Weld 2216 B/A structural adhesiveto all bond ts that show any pin holes or other openings.Mix per the manufacturer'sinstructions. Allow a minimumof 24 hours cure time. c) Sand sealed areas in a spanwise direction to smooth aerodynamicfinish maintainingthe same shapeas the bladeairfoil. Use 240 or finer grit wet-ordry aluminumoxide or siliconcarbideabrasivepaper. DO .NOTREMOVEany metal while sanding. d) Sand the remainingpaintedsurfacesuntil about 75o/ois down to the original paint primeror to metal. Keepthe amount of bare metal to a minimum. P a i n t i n g(S e eF i g u re9 -1 O) and wipe lint- fr eewith a tack r ag. a ) Cl e a nw i th 1 ,1 ,1 , T ri chlor oethylene b) Apply a 2 to 3-inch wide strip of epoxy primeralong all exposedbond ts. c) Apply two full coats of epoxy primerto all exteriorsurfaces.Allow first coat to dry to touch before applyingsecondcoat. lf 8 hours is exceededbetween primercoats,scuff with 320 grit or very fine Scotch-Brite,lacquerthinnerwipe and mist primer before applyingnext coat. NOTE: Best results are achieved wheneversecondcoat of primeris allowedto air dry for 12 hours beforetop coats are applied. d ) Spray white finish coat; first paint on both sides. e ) Mask off white paint on top and scuff white paint along the bottom surface

then paint bottom semi-glossblack. f ) Spraytrim stripesand center strip on top. Paint root fitting dark gray.

l s s u e d :1 1 J u n 9 3

Page9.27

FICIBINSiCIN

MAINTENANcE

MANUAL

MOEIEL

F,44

9.130 Inspectionand Repairof Main Rotor Blades(cont'd) ApprovedMaterialsList:

MATERIAL

MANUFACTURER

1. Alumiprep33 Stock No. DX533

HenkelCorporation Parker& Amchem ProductsCo. 300 Brookside Ambler,PA 19002 Tel: 215-628-1OOO

2. Alodine 1201 Stock No. DX5O3

HenkelCorporation Parker& Amchem ProductsCo'

3. Scotch-Weld StructuralAdhesive # 2 2 16 B /A

3M ComPanY 3M Center St. Paul,M N 55144- 1000 T e l :6 1 2 - 7 3 3 - 1 O 0

4. Acryl-GreenSpot Putty P / N0 5 1 1 4 4 -0 5 9 6 0

3M Company

5. EpoxyPrimer see Section1.450

DuPont Los Angeles,CA

6. FIat Black lmron Polyurethane Dupont E n a me l3 7 3 -P -2 9 9 5 O 7. Dark Gray lmron Polyurethane Dupont EnamelDSO2OHK 8. White lmron Polyurethane E n a me lK O7 7 4 H K

Dupont

9. Yellow lmron Polyurethane E n a me K l O6 S OH K

Dupont

U.S. Chem ical& Plastics 1 0 . Ea s yWh i te B o d y F i l l e r 2OO-92ProductCode 1OO1O 1446 W. TuscarawasSt' Canton,OH 44702 1 Tel: 12161455- 431

Pa g e9 . 2 8

Change14: JU L 20OB

Mt'ElEL

MAINTENANcE MANUAL

F|GIEINSC|N

]?.44

(VIEWLOOKING FORWARD} I!

FOURALUMINUMSPANWISE BALANCEWASHERSON HEAVIERBLADE

C137.2 SPACER (LARGER,OUTBOARD) NAS66O4-17{to -22} BOLT (as required) A1 41 -14, A214-3, NASl 149FO463P OR NASl149FO432PWASHERS(AS FORBALANCE) REOU]RED

8345 PITCHLINK (TWO PLACES;MUST BE SAME TYPEAND MATERIAL}

WASHER NAS1149FO432P 41 15.1SPACER (8 Req'd) A214.3 WASHER (O.688inch diameter) {2 Req'd) TAIL ROTORGEARBOX OUTPUTSHAFT {palnutnot required)

A14'1.14WASHER {0.750 inch diameter) C119-2 BUMPER

C 1 3 8 - 1B U S H I N G {2 Req'd) ( 6 Req'd) c137-1 SPACER

c137-2 SPACER

(LARGERSPACER OUTBOARD)

FOURSPANWISEBALANCEWASHERS (PLACELARGESTWASHERSCLOSEST TO HUB ASSEMBLYI

FIGURE9-11 COOS-4TAIL ROTORASSEMBLYINSTALLATION Ch a n g e1 3 : OC T 2 0 0 6

Pa ge9.29

FIG|BINSictN

M(]DEL

MANUAL

MAINTENANCE

F|44

LOOKING INBOARD

c134-1, -2 SPANWISE BALANCE WEIGHTS

co29- 1 BLADE ASSEMBLY

, I

I

,

I

, NAS6605-32 BOLT (4 places)

---+-i

I I t t t

I

cl29-2 HUB PLATE

c129-1 HUB PLATE

co30-1 HUB ASSEMBLY

t I I

I

/l ll

\

I

'J-.!-2 . O O Ol N .

cI28-1 HUB NOTE CI27-1 WASHER UNDERBOLT HEAD ICHAMFERTOWARDS BOLT H E A D )W H E N U S I N GN A S 6 6 O 6 . 5 4 BOLT (NO WASHER IS USED WITH NAS6606-53).

c130-1 SPACER

TAIL ROTORASSEM BLYINSTALLATION F IGU R E9 -1 2 C OOS -2 Pa g e9 . 3 0

Change13: ocT 2006

FICIBINEiCIN

MAINTENANcEMANUAL

MtfE ELF'44

9.200 TAILROTOR 9 . 2 1 0 T a i l R o to r R e mo va l 1.

Disconnectpitch link from each tail rotor blade.Tag each pitch link with blade , serialnumber for re-installation. CAUTION Tail rotor pitch-link-to-bladeattach bolts may have different under nut. Theseare used for balancing washer stabksanstalled and must be reinstalledto the same blade (see Figure9-1 1).

Z.

Removepalnut,nut, and A141-14 washersecuringbumper(urethaneteeterstop) to output shaft.

3.

Removethe palnut, nut, and hub attach bolt. Carefully slide hub off shaft. Bumperand spacerswill come off with hub.

Ch a n g e7 : 0 6 D e c 9 9

P a g e9 . 3 1

FICIBINSiCIN

MATNTENANcE MANUAL

MI)EIEL

F'44

NAS6604-31 BOLT

| NAS66'4-31-q\ BoLr \-

MS2104214 NUT

*="s>,

8330- 13 PALNUT

WASHER AN96O-4161

AN960-4161

TAIL ROTOR HUBPLATES TAIL ROTOR HUB

MS2104214 NUT

FORBEARINGREPLACEMENT HUBREMOVAL FIGURE9-13 TAIL ROTOR

P a g e9 . 3 2

Change2: 12 Dec 94

FIC|EIINSiCIN

MATNTENANcE MANUAL

MoE EL F44

ORAN6 NAS66O6 LONG,ISCRAP" BOLT. GRINDOFFBOLTHEAD TO ANDPAINTYELLOI.I CORNERS INDICATE "TOOL"STATUS.

TAPONBOLTHEADTO BEARING. OPPOSITE REMOVE

A N 3 105RA N 3 I 6N U r .' G R I N D SOMAXDIAMETER OFFCORNERS OF NUTIS LESSTHANMINIMUM HUB OFTAIL ROTOR DIAMETER BORE.

BEARING SPHERICAL

HUB TAIL ROTOR \ PORTION ENSURE THREADED THROUGH OFBOLTPROTRUDES NUTTOACTAS A MODIFIED BoLT "PILoT"(T0 CENTER IN BEARING BALLANDPREVENT HUBBoREDAMAGE). BEARING SPHERICAL

PRESSING I[T252BEARING FIXTURE

9-134 TAIL ROTOR FIGURE HUB BEARING REMOVAL SPHERICAL

BEARING HUB TAIL ROTOR

HUB FIGURE9-138 TAIL ROTOR

REPLACEMENT BEARING SPHERICAL

Chan g e7 : 06 Dec

Page9.33

FIG|E|INSICIN

MtfEIEL

MAINTENANcEMANUAL

F44

9.212 Tail Rotor Installationwith sphericalTeeter Bearings isee Section-g.213if tail rotbr has elastomericteeter bearings) 1.

Beforeinstallation,inspectfollowing: a . C 1 3 O-1S p a ce r s: Faceswor n or deep indentationsfr om bear i ngbal l are cause for rePlacement. .spaceror bolt hole b. TRGBOutput Shaft: Shaft worn at flats for_Cl3_O-1 .ldng.i"d-areiause for repairof CO21-1TR Gearboxby RHC. c. pivot bearingsin hub: lf inner balltight, move ball in bearingto workin and reduce stiffness.

2.

Align tail rotor bladeswith same pitch change link from which removed.I

3.

on tailrotor rotorassembly placeC130-1spacers insidehubandinstalltail of direction geirUor ortpul-sf,itt-per Figure.?-12... clockwise iotation(whbnviewedfrom left sideof aircraft)' WARNING Ensurebladesare installedin properdirectionof rotation, and large C137-2 spacers installed p ro p e rl yP e r F i gur e9- 11.

4.

Installtail rotor teeter (delta)hinge bolt and nut. Torque nut per Section 1 .3 2 0 a n d i n sta l lPalnut. NOTE No washersare installedunderteeterhinge nut' No washer is used under head of NAS66O6-53 bolt. A C127'1 washer (chamfertoward bolt fteiOt is installedunderbolt headon NAS66065 4 b o l ts. WARNING Failureto check tail rotor bearing for proper initilt"tion per step 5 can result in failure of teeter hinge bolt and loss of tail rotor'

b.

Check tail rotor hub bearingsafter torquing teeter bolt as follows: pen or a. placea line on exposedportionof each bearingball usinga felt g re a seP e n ci l . b. Teetertail rotor while observingmarkedline in relationto output shaft.

P a g e9 . 3 4

C h a n g e7 : 0 6 D e c 9 9

MAINTENANcE

F|clBINSiClN

MANUAL

MOETEL T,44

g.212 Tail Rotor Installationwith SphericalTeeter Bearings(cont'd) (see Section 9.213 if tail rotbr has elastomericteeter bearings) c.

Bolt, nut, bearings' inner balls, and spacers must remain riqid to output shaft when tail rotor teeters.

'd. Teeter bearing outer race is press fit in hub and should not move i n si d eto h u b . NOTE lf bearingball, bolthead,and/ornut move when teetering tail rotor, insufficient clamp-up is indicated.Possiblecausesand correctiveaction for insufficientclamp-upare: 1.

Wo rn C l 3 O- 1 spacer s- r eplacespacer s

2.

Hub teeter bearingstiff - manuallywork-in bearingby moving ball.

3.

Output shaft flat at pivot bolt hole worn - returngearboxto RHC fo r re p a i r.

4.

Bearingouter race has metal at bottom of tail rotor hub bore preventing bearingseating - remove bearings,clean bore and reinstallbearings.

6.

In sta l t u re th a n e b umper , A141- 14 washer , and nut on output s haft. T o rq u en u t p e r S e c tion1,32O. Installpalnut,tor que per Section1.320, a n d to rq u e stri p e .

7.

Connect pitch links to tail rotor blade. Torque nuts and palnuts per Section 1.32O and torque stripe.

8.

Dynamicallybalancetail rotor per Section 10.240.

9 . 2 1 3T a i lRotor lnstallationwith ElastomericTeeter Bearings {seeSection 9.212 if tail rotor has sphericalteeter bearings) 1.

Align tail rotor bladeswith same pitch link from which removed. Install tail rotor on tail rotor gearboxoutput shaft, and clockwisedirection of rotation (when viewed from left side of aircraft).

2.

See Figure9-1 1. bladescone toward tail rotor gearbox.

3.

Installtail rotor teeter hinge bolt, washers, and nut. Tighten nut until elastomericbearingmetal spacers output shaft.

4.

Connect pitch links to bladesand torque fastenersper Section 1.32O.

5.

See Figure 10-7. With tail rotor horizontal,tape a tracking stick to tailcone at blade tip.

Cha n g e7 : 0 6 D e c 9 9

P a g e9 . 3 5

FICIBINSiCIN

MAINTENANcE

MOE EL F|44

MANUAL

g.213 Tail Rotor Installationwith ElastomericTeeter Bearings(cont'd) (sie section 9.212it tail rotor has sphericalteeter bearings) NOTE A tracking stick can be made from sheet metal a p p ro xi ma te l y1 inch wide x 12 inches long wiitr a 90o bbnd 2 inchesfrom one end. 6.

Rotatedrivetrain at ctutchshaft. Mark trackingstick where forward drain hole of each blade tiP es.

7.

Reposition(teeter)tail rotor on outp'lt :ltqtl until both blade tips the sa me p o i n t o n th e tr ackingstick + 0.125 inch'

8.

Torqueteeter hingebolt per Section1 .330. Rechecktrack per step 6 and adjust per step 7, if required.

g.

per When track is satisfactory,instatlpalnut on teeter hinge bolt, torque Section 1.32O, and torque striPe.

10. Removetracking stick. 1 1 . Teeter tail rotor back and forth. teeter hinge bolt, bearingmetal und nuts remainstaiionarywhen tail rotor is teetered. spacers,*"ihlri WARNING Movement of teeter hinge bolt, washer(s), spacer(s),or nut(s)indicateinsufficientclampu'p, which can result in loss of tail rotor.

bumper,washer,an{ 1yt. Torquenut perSection1.32O'O 12. Installurethane Installpalnui,torqudper Section1.32O,and torquestripe. 13. Dynamicallybalancetail rotor per Section 1O.24O. 9 . 2 1 4 T a i l R o to r H u b S p h e ri calBear ingReplacem ent

P a g e9 . 3 6

1.

R e mo veta i t ro to r per Section9' 21O'

2.

M a r k h u b P e r F i g u r e9 - 1 3 .

3.

Loosenfour blade retainingbolts. Removetwo center bolts securinghub between hub Platesand remove hub'

4.

R e mo vew o rn b e a r ingsper Figur e9- 13A'

b.

Clean hub bore, removing old primer and metal shavings which might preventbearingsfromseatingatbottomofbores.

Change7: O6 D ec 99

HCIEIINEiCIN

MATNTENANcE MANUAL

MOEIEL

F|44

9.214Tail Rotor Hub SphericalBearingReplacement(cont'd) CAUTION Bearinqsare a sliqht press fit in hub bores. Inspect bores for frelting. lf frettin-g is found, tail rotor hub assembly is UNAIRWORTHY. 6. See Figure9-138. Usingspecialtool MT252-1,installbearingsinto hub as follows: NOTE Hub may be heatedto 17OoFmaximumto easebearinginstallation installation and help Apply Section 1.45O-approvedprimer to originalprimed bore. Bearingis to be instalfedto bottont of hub bore. Apply primeror A257-7 lubricantto remainingbore and installbearingflush with top of hub. lf bearingis installedtoo far, spacersand hub will not fit over gearboxoutput shaft. NOTE lnstall tail rotor without delay if using primer in both bearing bores. 7. Reinstallhub betweenhub plates,per referencemark (seeFigure9-13). Torque two center hub attach bolts per Section1.320 and installpalnuts. 8. Installtail rotor per Section9.212. 9.215 Tail Rotor Hub ElastomericBearingReplacement 1 . R e mo veta i l ro to r p e r S e ction9.21O. 2. Removefour blade retainingbolts and removeblades. 3 . S e e F i g u re9 -1 3 C . U si ngspecialtool MT556, pr essout wor n bear ing . 4. Clean hub bore, removingold primeror metal shavingswhich might prevent bearingfrom seating at bottom of bore. CAUTION Bearingsare a slight press fit in hub bores. Inspect bores for fretting. lf fretting is found, tail rotor hub assembly is U N A IR WOR T H Y . Coat bottom of bearing bore with Section 1.45O-approvedprimer. While p r i me ri s sti l l w e t, p re ssbear ingfully into hub using specialtool M T5 56- 11 p e r F i g u r e9 - 1 3 D . Repeatsteps 1 thru 5 to replaceoppositebearing,if required.

Ch a n g e1 3 : OC T 2 0 Oo

Page9.37

FICIBINEiCIN

MATNTENANcE MANUAL

MCfEIEL H,44

9.215 Tail Rotor Hub ElastomericBearingReplacement(cont'd) 7. Seal between circumferenceof each bearingand h',rbwith primeras required in two places. 8. Assemblebladesto hub. clockwisedirectionof rotation. correct orientation of bolts and correct location/orientationof C137-1 & C137'2 spacersper Figure9-1 1. Standardtorque bolts per Section 1.32O, install & torque palnuts,and torque stripe per Figure2-1' 9 . I n sta l lta i l ro to r p e r S e ction9.213.

P a g e9 . 3 7 A

C h a n g e1 4 : J U L 2 O O 8

MATNTENANcE MANUAL

FIC|BINSCIN

MOEIEL

F|.44

9.215 Tail Rotor Hub ElastomericBearingReplacement(cont'd)

BEARING PRESSTO REMOVEOPPOSITE

r

v AN6.34ABOLT (Supplied with tool)

DO62-1 HUB ASSEMBLY

M T S 5 6 - 1 6C A p ( B e v e l e ds i d ef a c i n g bolt and concave side againstbearing to be removed)

MTs56-15

BEARINGREMOVAL FIGURE9-13C ELASTOMERIC Cha n g e1 3 : O CT 2 0 0 6

Page9.37B

FIclBINEiClN

MATNTENANeE MANUAL

MOE'EL

F.44

(cont'd)

9.215 Tail Rotor Hub ElastomericBear

PRESSTO INSTALLBEARING

+

MT556-12MANDREL

8 3 6 1 - 2B E A R I N G

HUBASSEMBLY

MT556-15

l-

' '-l

e-13D ELASTOMERI@TIqN FTGURE P a g e9 . 3 7 C

Change13: OCT 2006

MATNTENANcE MANUAL

FlElBINEiClN

MOEIEL

F|44

I'IAXDEPTH 0 . 0 0 5i n .

r1.00tr---+l

MAXDEPTH

i15'

IIAXDEPTH 0 . 0 0 8l n .

SCRATCHES

15'

I

0.030 in. llAXDEPTII FIBER ROOT FITTING,CARBOII AREAS:0.008 ln. l|AXDEPTH B0llDED

DENTS

AREA: TIP CAPBONDED 0.008 in. l4AXDEPTH

BLACK hJHITE

r/

*l L

2.75" TY?. PAINT OF TAIL ROTORBLADES 9 -1 4 IN S P E CTION/REPAIR F IGU R E

Pa g e9 . 3 8

Change13: OCT 2OOG

FIC|BINSiGIN

MATNTENANeE MANUAL

MOEIEL

F,44

9.220 Inspectionand Repairof Tail Rotor Blades This procedureoutlinesthe inspectionand repairlimits for tail rotor blades. Repairsare limited to blendingout mechanicalscratches,nicks, removingcorrosion,filling dents and refinishingthe blades. WARNING Any damagedtail rotor blade that cannot be repairedwithin the limits of this section must be removedfrom service immediately and marked as "scrap." Inspection: A) Scratchesand Corrosion(SeeFigure9-14): Bladeskins may be polishedout with a 0.10 inch blend radiuswithin the following limits: 1) Outboardof 1 1 inchesfrom the bladetip. The maximumdepthallowedis O.OOB inch. 2) Inboardof 11 inchesfrom the bladetip. The maximumdepth is 0.O05 inch for any corrosionor scratchesrunning in a direction more than 150 from the spanwisedirection.The maximumdepthlessthan 15o is O.OO8inch. B) Dentson Skins(SeeFigure9-14): Smooth, round-bottomeddents which have a 0.06 inch minimumradiusand occur from the leadingedgeto a point O.75 inch aft of the leadingedge and are limitedto O.O1Oinch.Aft of O.75 inchfrom the leadingedgedentsare acceptablewithin the following limits: 1. Outboardof 8 inchesfrom the bladetip, dentscannotexceedO.O9inch depth. 2. Inboardof 8 inchesfrom the bladetip dentscannotexceed0.03 inch depth. 3. Dents within O.4Oinch of the trailingedge cannot exceedO.O3 inch depth. Dentswithin O.50 inch from tip cap cannotexceed0.OO8inch depth. bond t cannot exceed0.008 inch depth. 4. Dents over the skin-to-root-fitting CAUTION Do not repairany dent that has a sharpcut or breakin the skin. lf necessary,locally penetrantinspect keepingpenetrantmaterials away from bond ts. Ch a n g e1 4 : J UL 2 0 0 8

Pag e9.39

FICIBINSiCIN

MAINTENANeE MANUAL

MOEIEL

444

9.220 Inspectionand Repairof Tail Rotgr Blades(cont'd) C. Nicks and Notches in TrailingEdgg: Blend all nicks and notches in the extreme trailing edge up to a maxifnumof O.05 inch. The blend must extend for 1.0 inch each side of the nick or notch. D. Erosionof the LeadingEdge:Replaceany bladewhereerosionhascauseddeformation or ripplesin the leadingedge. E. Dents, Scratches,and Corrosionon the Root Fitting: Damageon root fittings must be blendedout using0.10 inch radiuswithin the followinglimits: 1. No repairs allowed within 1.5 inch diameter-circlefrom the center of each bearing. 2. Maximumdepth of O.O4Oinch all other areas. F. Lework Processand Measurementof Material Removed: See Main Rotor Blade Repair,Section9.130. G. Painting(SeeFigure9-14): 1. Cleanwith OSOL22Oand wipe lint-freewith a tack rag' 2. Apply a 2to 3-inch wide strip of epoxy primeralong all exposedbond ts. 3. Apply two full coats of epoxy primerto all exteriorsurfaces.Time limits are 1O minutes minimum, 8 hours maximum between coats. lf 8 hours is exceeded, scuff with 600 grit wet-or-dryaluminumoxide or siliconcarbideabrasivepaper in a spanwisedirection,Q,SOL22O wipe and mist primer before applyingnext O coat. 4. Spray white all over and allow to dry beforemaskingfor trim stripes.See Figure 9-14. 5. Sprayfinish coat semi-glossblack stripesand root fitting. 6. Removeall maskingmaterials.

Page 9.4O

Change13: OCT 2006

FIGIE|INEiC|N

MATNTENANcE MANUAL

M(tElEL

1t44

9.300 COO8.2AND COOS-4TAIL ROTORASSEMBLYBLADEREPLACEMENT This section containsproceduresnecessaryfor C008-4 (CO29-2tail rotor bladereplacement) overhaul. CAUTION CO29-1bladesmust be scrappedat 22OOHours. CO29-2blades must be a matched set from RHC. lf only one blade is being replaced,then the usable blade must be sent back to RHCfor matchins. 9.31O Tools Requiredto PerformBladeReplacement Part No.

QuantitY

Description

MT179-3 Static BalancingWheels- T.R. MT179-4 Static BalancingBar - T.R. MT556-11 Tools - ElastomericT.R. BearingRemovaland Installation

1 1 1

9 . 3 2 0 B l a d eR e mo va l 1. Removefour NAS66O5-31bolts attachingCO29-1 blade assembliesto CO3O-1 hub and carefullyremovebladesfrom assemblyor; 2. Removetwo NAS66O4-31and two -35 bolts attachingCO29-1or CO29-2blade assembliesto D062-1 Elastomericteeter bearing hub assembly and carefully removebladesfrom assembly. WARNING Scrap C030-1 tail rotor hub assemblies. The D062-1 tail rotor hub, C029-1 ot -2 tail rotor bladesare li limited components. Gonsult RHC MM Section 3 for life limits. TeeterBear ing) 9 . 3 3 0 D O 6 2 -1H u b D i sa sse mb l (yElastomer ic P r e s s o u t 8 3 6 l - 2 E l a s t o m e r i c b e a r i n g u s i n g s p et coioallM T 5 5 6 - 1 1 p e r S e c t i o n 9 . 2 1 5 .

Ch a n g e1 4 : J UL 2 0 0 8

P a g e9 . 4 1

FICIBINS|CIN

MATNTENANcE MANUAL

MOE'EL

F'44

9.400 TAILROTORHUBINSPECTION InsPection, 9.410 General

''

1. lf one or bothtail rotorbladesareto be reused,inspectper Section9.220. 2. CleanDO62-2hub with solvent. 3. Removedata plate and retain for reinstallation. Strip paint from D062-2 hub. Removecorrosionif necessarywithin limits found in Section9.320. 4. fnspectDO62-2hub usingeitherdye penetrantor fluorescentpenetrantinspection procedures. 5. Visually inspect for indicationsof damage, wear, nicks, dings and corrosion. Dimensionallyinspect any suspect areas to ensure they are within the limits the part outlinedbelow. lf a part fails to meet any of the followingspecifications, (see 9-1). Figure must be scrappedor sent back to RHCfor further inspection 9.42O DimensionalInspection DO62-2 Hub (Elastomeric) 1 . C h e ck 1 .3 4 3 5 t1 .3 4 3 0d i a meterBear ingbor esfor over sizeconditionor gal l i ng - 1 . 3 4 4 5m a x . 2. Check bolt holesfor elongation,no elongationfrom distortionallowed (referenceFigure9-1).

3 . C h e cka rmsa re fl a t w i th i n O.010 inch bow end to end' n o tto exceedO.O1Oinch max as shown in Figur e9- 1. 4 . C h e cka rm stra i g h tn e ss

5 . No corrosionallowedon clamp-upsurfaces. Blendto 0.002 inch max in clamp, p a r e a s,o th e r a re a sma y be blendedto o.o1o inch max depth.

REASSEMB-LY 9.500 COOsTAILROTOR lnstallation 9.510 Hub Bearing into DO62-2hub per Section9.215. bearings Install8361-2Elastomeric

Page9.42

Change14: JUL 2OO8

FICIBINEiCIN

MATNTENANcE MANUAL

1f,.44

M(IEIEL

1 . 3 4 3 5 / 1 . 3 4 3 0- 1 . 3 4 4 M A X (TWO PLACES}

o . 0 1 0T I R (TWOPLACES)

0 . 3 1 7 / 0 . 3 1D 5 IAMETER PLACES TWO THRU

o . o 1 0T I R

RE A RS I D E 0 . 3 1 5 / 0 . 3 ' I 4D I A M E T EN I A M E T EFRA RS I D E O , 4 3 7 8 1 O . 4 3D 75 (TWOPLACES)

F IGU R E9 .1 5 T A IL R OTORHUB DIMENSIONALINSPECTION Change1 4 : J U L 2 0 0 8

Page9.43

FIClBINElclN

MATNTENANcE MANUAL

MOE'EL

F|44

9.520 CO08-2TailRotorBladeAssemblv 1. Paintheadsof NAS66O5blademountboltsblack. 2 . t n s t a l f(1 ) C 1 3 8 -1 b u sh i n gi nto each0.43781O.4375inch diameterinboardhol es

of hub arm until it is flush with insideface of arm per Section 1.45O - approved wet primer.

3 . Refer to Figure 9-3. Hold DO62-1 hub horizontalwith bushingsfacing down.

Installfirst CO29-1or -2 tail rotor bladewith pitch horn pointingaway and blade tip to left. Position C137-1 and -2 spacers,align holes, install NAS66O5-31 bolts and attachinghardwarewith bolt heads facing up, but DO NOT TOROUE (seeFigure9-2). CAUTION C 1 3 7 -2sp a ce ri s l o n g erthan C137' 1 spacerand gives blades a preconeangle. Ensurethey are installedin correct position.

4. Installsecondtail rotor blade with pitch horn pointing in the oppositedirection. Positionspacers,alignholesand installNAS6605-31boltsand attachinghardware with bolt headsfacing uP. 5 . B a l an cep e r S e cti o n9 .5 0 0 . 6 . V e r i fy p re co n ea n g l e(ti p sa ngletowar d C138- 1 bushings) . 7 . Torqueall MS21O42L5nuts per Section1.320. Installpalnuts,torque per Section 1 . 3 2 O,a n d to rq u estri p ep e r Figur e2- 1. 9.53O COOS-4Tail Rotor BladeAssemblv 1. Paintheadsof NAS6605 blademount bolts black. 2 . Pr e pa reD 0 6 2 -1 h u b a s i n 9.42O Step 2' 3. Refer to Figure9-3. Hold DO62-1 hub horizontalwith bushingsfacing down. Installfirst CO29-2tail rotor bladewith pitch horn pointingaway and bladetip to - 35 l e f t . P o si ti o nC 1 3 7 -1a n d - 2 spacer s,alignholes,installNAS6605- 31and bolts and attachinghardwarewith bolt headsfacing up, but DO NOT TOROUE. 4. Installsecondtail rotor blade with pitch horn pointing in the oppositedirection. Positionspacers,alignholesand installNAS66O5-31and -35 bolts and attaching hardwarewith bolt headsfacing up. 5 . B a l an cep e r S e cti o n9 .5 0 0 . 6 . V e r ify p re co n ea n g l e(ti p s angletowar d c138- 1 bushings) . 7 . T o r q u ea l l n u ts p e r S e cti o n1.320. Installpalnuts,and tor queper Section1.32O. T o r q u estri p ep e r F i g u re2 -1. Change14: JUL 2008 Pa g e9 . 4 4

FICIBINSiC|N

MATNTENANcE MANUAL

M()trEL n44

>2

o

o FIGURE9 - 1 6 COOS-4TAIL ROTORASSEMBLY I T EMN O . DE S C R IP T ION 1 Bolt 2 Wa sh e r Spacer 3 Pitch link 4 Pa l n u t 5 6 Nut C h a n g e1 4 : J U L 2 0 0 8

ITEMNO. DESCRIPTION 7 Elastomericbearing 8 BalanceWashers I Hub 10 Tail RotorBlade 11 Bushing 12 Bumper Pa ge9.45

FIClBINSiclN

MODEL ]r44

MAINTENANcE MANUAL

FOURALUMINUMSPANWISE BALANCEWASHERSON HEAVIERBLADE

Cl37.2 SPACER

OUTBOARD) {LARGER, (to -22) BOLT NAS66O4-17 (as required)

A 1 4 1 - 14 , A 2 1 4 - 3 ,N A S 1 1 4 9 F O 4 6 3 P OR NASl149FO432PWASHERS(AS FOR BALANCE) REOUIRED

8345 PITCHLINK (TWO PLACES;MUST BE SAME TYPEAND MATERIAL)

WASHER NAS1149FO432P A1 15-1 SPACER (8 Req'd) A214-3 WASHER (O.688inch diameter) (2 Req'd) TAIL ROTORGEARBOX OUTPUTSHAFT (palnutnot required)

A 1 4 1 . 1 4W A S H E R (O.750 inch diameter) C 1 1 9 . 2B U M P E R

C 1 3 8 - 1B U S H I N G( 2 R e q ' d ) C 1 3 7 - 1S P A C E R( 6 R e q ' d )

c137-2 SPACER

(LARGER SPACER OUTBOARD)

FOURSPANWISEBALANCEWASHERS (PLACELARGESTWASHERSCLOSEST TO HUB ASSEMBLY}

FIGURE9-17 TAIL ROTORINSTALLATION P a g e9 . 4 6

Change1 4 : J U L 2 O O 8

MATNTENANcE lrnANUAL

FICIEIINEIC|N

MOE,EL

F|44

9.600 STATICBALANCINGCOOS-2and -4 ASSEMBLIES 9.610 ChordwiseStatic Balance 1 . I n s t al lMT 1 7 9 -4 b a l a n ceb ar into tail r otor assem blywith ( 1) NAS66O6-53bol t a n d (1) MS 2 1O4 2 L On u t a s shown in Figur e9- 18. Tor queto 350 in.- lb. 2. PlaceCOOS-4assemblywith MT179-4 balancingbar installedon Anderson2O or equivalentbalancingstand, and determinewhich CO29-2blade is heavieras s h o wn i n F i g u re9 -1 9 .

NAS66O6-53BOLT

ffi

m .\ /

MT179-4 BALANCING BAR

,P

MS21042L6 NUT

TAIL ROTORFORBALANCING FIGURE9-18 PREPARING

C h a n g e1 4 : J U L 2 0 O B

Page9.47

FIC|BINEICIN

MOE'EL

MATNTENANcE MANUAL

F,44

FALLSLEADINGEDGEFIRST THIS IS HEAVIERBLADE.

FALLSTRAILINGEDGEFIRST

ISTHE LIGHTEA-? THIS

COOS-4TAIL ROTORASSEMBLYSHOWN

l$i

MT179.4 BALANCEBAR

N./

2O (Or Equivalent) ANDERSON STAND BALANCING

.a'

HEAVIESTBLADE FIGURE9-19 DETERMINING

P a g e9 . 4 8

C h a n g e1 4 : J U L 2 0 0 8

MATNTENANcE MANUAL

FICIBINEiCIN

MCIEIEL FI44

9.610 ChordwiseStatic Balance(Cont'd) 3. Prepare{2) NAS66O4-17bolts as shown in Figure9-20.

B 11 5 - 1 B E A R I N G

NAS6604.17BOLT

A214-3 WASHER

4115.1SPA

BALANCE BOLT FORCHORDWISE FIGURE9.20 PREPARING 4 . P l a c e o n e p r e p a r e db o l t ( 1 ) N A S l 1 4 9 F 0 4 6 3 P w a s h e r , ( 1 ) M S 2 1 0 4 2 L 4 n u t a n d (1 ) B 3 3 O-1 3 p a l n u t o n the heavy blade as shown in Figur e 9- 7. U s e ( 1 ) NA S 6 6 O4 -1 7 th ru -2 2 bolt, and NAS1149FO432P,NAS1149F 0463P, o r A 1 4 1 - 14 washer sand ( 1) 8330- 13 palnuton lighttai l r otor N A S 11 4 9 F O4 3 2 P bfadeto bring chordwisebalance(see Figure9-21l'. NOTE Bolt length may vary from NAS6604- 17to NAS6604-22 tor balancing:requirementsand also to ensure proper locking of the fastener after washers are added (see R44 MM Section 1.320).

C h a n g e1 4 : J U L 2 0 0 8

P a g e9 . 4 9

FIclElINEiClN

MOE,EL

MAINTENANcE MANUAL

1'.44

8330-13 PALNUT / I NAS1149Fo432P f ,/ wASHER

HEAVYBLADE

9,/ @' I

i ,.111 7 BoLr xl /'-l-r'rRso604-1 if llI ;l l. I aztq'swASHER

(2Req'dl ilfll|v'|ltlllfliftlf'AcER wASHER 149Fo432P

NAS66O4-17THRU.22 BOLT

\^e

+l, \il $f 'lllli @ \

A214-3wesHen\H

\tJ A11s-1sencen

Yt

\b

*-

BEARING_+$

A115-1 "rOrr

- l + 4, , l . 49FO432P, fitrv'+Jzr, IA214-3, \ z l + - . t , lNASl \lAol 1 A141-1

R s -1 5 3 PS H E{n o R N AS 1 1 4 eF o 4 6WA

I B33o-13PALNUT

1ilN\rDEN'FYNUrsrDE

\ al\) 3i'J1"'il3fl,''I'fl1+FELTTIP MARKER

fl

/{l+f

+l

lrunst l tvtszto42L4NUr

a

l a'ilr) K

requiredfor chordwise balancel

LIGHTBLADE

M S 2 1 O 4 2 L 4N U T

8330.13PALNUT

COOB. TAIL ROTORASSEMBLYSHOWN

STATIC BALANCE F IGU R E9 -2 1 CHORDW ISE

P a g e9 . 5 0

Change1 4 : J U L 2 0 0 8

FICIBINSiCIN

MATNTENANcE MANUAL

MOEIEL

F44

9.62O SpanwiseStatic Balance COO8-4Tail Rotor Assemblv 1. I n sta l lN A S 11 4 9 F O4 6 3 P,NAS1149D0432K,NAS1149D0463K,or A1 4114 washers as requiredonto outboardtail rotor mount bolts {minimumof four NAS1149DO463Kwasherson the heavy blade)to bring in spanwise balanceas shown in Figure9-94). 2. Recheckspan and chordwisebalance. Chordadjustmentscan be achieved or NAS1149FO463P b y e xch a n g i n gA 1 4 1 -1 4, A214- 3,NAS1149FO432P, washers.

WARNING There must be at least four washers under each nut at outboard mount bolts

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LIGHTBLADE , ASl149D0563K, N A S l 1 4 9 D 0 5 3 2 KN c008-4 , N 9 7 0 - 5 ,O B A 1 4 1 - 2 0 N A S l 1 4 9 F O 5 6 3 PA TAILROTORASSEMBLY W A S H E R SA S R E O U I R E T DO B R I N GI N SPANWISEBALANCE,

7-'., I t"' I I

I

- -/ -/l 0A N D E R S O2N t BALANCING ./,-\ t\) I--I

L

F l I I l

l I

r I I

I \!/

)

STAND

H E A V YB L A D E I N S T A L LA M I N I M U M O F { 4 } N A S l 14 9 D O 5 6 3 KW A S H E R S .

t

ee;

t

F,44

\ \ \ \ \ \ \ I

I I \ - -

- - - l

r\l \ iz \

===:=r=-l\, -1

It

\

\i rl ll !

I '

FIGUREg-22 COOS-4SPANWISESTATICBALANCE

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o

MC'E EL H,44

I.D. PLATE

COOS-4TAIL ROTORASSEMBLY

I.D.PLATE

I.D.PLATE

o

PLATEPLACEMENT FIGURE9-23 IDENTIFICATION

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Pa ge9.53

FICIBINSiCIN

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MOE EL ]t44

9.63O FinalAssemblv 1 . R e r n o veMT 1 7 9 -4 b a l a n ci ngbar fr om tail r otor assem bly. 2. ReinstallNAS66O4-53bolt and MS21O42L4nut into tail rotor assembly. 3. Installidentificationplate on DO62-1tail rotor hub as shown in Figure9-9, and ensurethat both CO29tail rotor bladeshave identificationplateson them. 4. Final inspect C0O8 tail rotor assembly checking for precone angle and that NAS66O4bolt headsare paintedblack.

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o 10.

o

RIGGING, TRACK AND BALANCE

MATNTENANcE MANUAL

FICIBINEICIN

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1O SECTION TRACK,AND BALANCE RIGGING, TFACK..qNDBALANCE 1O.O0ORIGGING. 10.001 Introduction 10.002 Rod EndAdjustmentProcedures 10.100 RIGGING 10.110 Main RotorFlightControls 10.111 CyclicControls 1O.112 Swashplate 10.113

CollectiveControl

10.120 MainRotor 10.121 CyclicTravelRigging TravelRigging 10.122 Collective 10.130 Tail RotorFlightControls 1 0 . 13 1

Pedals

10.132 C316 BellCrank 1 0 . 1 3 3 A 1 2 0 - 3B e l lC r a n k 10.134 Tail RotorPitchLinks 10.140 Tail RotorRigging Rigging 10.150 ThrottleCorrelation 10.160 ActuatorRigging 1O.2OOTRACKAND BALANCE Requirements 10.210 Equipment Installation 1O.22O Equipment Installation 10.221 Main RotorEquipment

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1O.2OOTRACKAND BALANCE(cont'dl 10.222 Tail RotorEquipmentInstallation 10.230 Main RotorTrackand BalanceProcedure 10.231 Main RotorBalanceAdiustments 10.232 Main RotorPitchLink Adiustment 10.233 Main RotorBladeTrim Tab Adjustment 10.294 Main RotorTrack and BalanceTrouble-Shooting 1O.24O Tail RotorBalanceProcedure RPMAdjustment 10.250 Autorotational

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1O SECTION RIGGING, TRACK,AND BALANCE TRACK,AND BALANCE 1O.OOO RIGGING, 1O.OO1Introduction This section contains proceduresnecessaryto rig the main rotor flight controls, tail rotor flight controls and throttle correlation. The track and balanceproceduresin this section are to be used in conjunction with Chadwick-Helmuthbalancingequipment instructions. WARNING A rotor which is smooth after balancing but then goes out of balance again within a few flights is suspect and must be examined by a RHc-authorized component overhaul facility before further fliqht. 1O.OO2Rod End AdiustmentProcedures The following procedureis standardfor adjustmentof rod ends: 1. Loosenpalnut and jam nut on rod end shank. 2. Screw rod end in or out of push-pulltube or pitch link as requiredto obtainproper riggingadjustment. 3. After any rod end adjustment, rod end threadedshank blocks ageof O.O2Oinch diameterwire thru the witness hole in the push-pulltube or pitch link as shown in Figure2-1. When no witness hole is provided,referto Figure2-1 for maximumrod end extension. 4. Positionrod endsto allow as much push-pulltube or pitch link rotationas possible without binding.Referto Figure2-1A. 5. C258-1 main rotor pitch links may requireadjustmentduringriggingor tracking. For collectiveadjustments,both pitch links must be adjustedexactlythe same. Eachmain rotor pitch link has coarse,medium,and fine length adjustments: section of a. Coarselength adjustmentsare made by rotating coarse-threaded pitch link. Disconnectupper rod end from bladeand loosenjam nut in middle of pitch link only. lncreaseblade angle by unscrewingC258-2 fitting from lower pitch link. Decreaseangleby screwingfitting into lower pitch link. One f u l l tu rn ch a n g e sb l a d eangleby appr oximately O.88 degr ees.

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(cont'd) 1O.OO2Rod End AdiustmentProceduresfor Rigging b. Mediumlengthadjustmentsaremadeby rotatingupperlodend olly'Disconnect by rod ends from blade ano looien rod bnd jam-nuts..lncreaseblade.angle. e.nd^in19 screwing-rod by. angle pitlh link. Decreise unscredini-ioo iurn changesblade ingle-by approximately0.48 full rod pitch tint."One ""i]-r "r|o degrees.

'ff adius11",:f^?:'^T:3:P;'o,t:ll3-o,:'J c. Fine.rensth =t3ru3;3JJl51e;jjt;"e ja.m.nuts at upper-.rot to*6t rod'endsremainconnected.Loosen by screwing fitti an-qle bv.screwiry in rha rnirldla ^f piti,f, nitch iin[.-lnCt"a"e link- lncrease blade blade angle "na riOOi"ot in irt" I']lilg

9u.19f

pltcr link' pjtch into-lower fitting i*o"l:Y:r scre*iry.I1$ bv screwing utto"-tnsleby . d;;;;"* decreaseblade.angle pit"r,iint iinri. i;il; i;;; pit"f, degrees' O'40 O;;iJlilrrn ot tltiingihang"s bladearigleapproximatelv

per Figu r e2- 1' b . T o r q u ej a m n u ts a n d p a l n u tsper Section1.92Oandtor questr ipe 10.100 RIGGING 1 0 . 1 1 0 M a i n R o to rF l i g h tC o n tro ls 19-.11 1 Cvclic Controls The cyclic control travel is non-adjustableand is controlledby the attacliedto cyclic box assemblY'

A211-2 stop plate

NOTE The following push-pulltube assembliesand fork assembly UetweLntfre [.eblsare to be adjustedto the noted centerto-centerdimensions:

C121'1 c121-3 c121-'19 A2O5-5

= : : =

51.O3+ 32.54 + 31.38 + 03.80 +

O . O 3i n c h e s O.03 inches O . O 3i n c h e s O.O3inches

position'.Cyclicneutr al a ) R e fe rto F i g u re1 O-1 . Placecyclic contr olin neutr al at mid-point of total and travel biiiii"" irTo in"rrel io-in._right of full-left control full collective Place fore and aft travel or use MTs59-1 iigging blocks. down. b ) Apply full cyclic and collectivefriction'

NOTE Care must be taken not to move cyclic control from neutral

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MOEIELF|44

VIEhlLOOKING Fl,lD

T'---: L]

CYCLICCONTROL LATERAL NEUTRAL POSITION

FULL LEFT

TOTALTMVEL MID POINTOF TOTALTRAVEL CONTROL CYCLIC LONGITUDINAL NEUTRAL POSITION FULLFORl,l

POSITION STICK NEUTRAL F IGU R1E0 .1 CYCLICCONTROL

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10.112 SwashPlate 1o'111' with the cyclic and collectivecontrolslockedin positionper sectionclearance

a constant aoilsi'ir,'d-ciiit;f,d ql2\i puln-prttigb^ep^tg'obtain 1o-2}. MT146-2 Fisure r.beg {see oi ?iiti'if, '6d fromthe franse6r ine czgr-r u-sedas a spacerto set the 1.o69 inch iri'd}ib'r"t6-iigsiig6i6"rc r.i dimension.

10.113 CollectiveControl this check is.t9 ensurefull since the coltectivesliderstop is non-adiustable,. coniib-rl,ivliis 6uiiineo ind-oobs nof inter'ferewith the swashplatetravel. al Lift the swashplateboot so the uniballand slidertube may be observed' o with the top bl pull the coilectivecontrol f,u!l.up, The uniballmust be flush the upper turn not occur, does lf this inbhes. ot tni-lriOiiiu6e wiiniii-O.O3 to equallv out in or push-pull tubes Cizt-7 roo e-noioi ine-crzi:b6d raiseor lower the swashplate. 1O.120 Main Rotor Bladea,ngle The main rotor is riggedby determiningthe av€rageblade-angle. (or in from inches 49.5 rotor main o]zs-raoiusoithe ;iiil measurem"nrcaiJiir; the bladetipl.

[%'J]qJ$yl".T ,YJ,?i'* .0sererrll,3,Tiltil3"?i"J.1,3lBi?1,'##T,1t3ffi1'?;lf tne followingpr6cedureto set up for rigging: are.setto the-properlength a) that the A2O5-5forks at the swashpla.te the lower fork assemblv lines, centdr (see Figure 1O-3). rvrga_i,;iinltb oof should be 3.85 assembly forli upper shoutdffi 3.tb-; ij.oiiriin-eJ and the * O.O3inches. bl Levetthe rotorcraftper Section1,22O(Method2, Main Rotor Hubl' cl Placea trackingstick at the end of one rotor bladeand markthe heightof the

btadetip. notrir-ih. ;i;'iab;

theheish!911!-.:PL9tlt"bladetip' Jnornart<

Teeter the main rotor as necessJryto obtain a m-ainrotor track of * 1 inch' zero the propellerprotractorto the main rotor hub at the location marked dl -' ;feuei'ffeie;.-ffre drotractormusi be placedparallelto ths teeter hinge bolt'

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MATNTENANcE MANUAL

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F'44

TOP OF BALL FLUSHWITH TUBEWITHINO.O3OINCHAT FULL.UPCOLLECTIVE

LOWER,NON-ROTATING SWASHPLATE

M T 1 4 6 - 2 ( u s ew i t h C O 1 7 - 2S w a s h p l a t e 1) . 0 6 9 I N C H E Sh i g h MT'|46-3 (usewith CO17-4Swashplate)0.969 INCHhigh

FIGURE1O-2 LOWERSWASHPLATECLEARANCE

0.03 INCHES- UPPER(Rotating) 0.03 ]NCHES- LOWER(Non-Rotating)

FOR F IGU R E1 O-3 A 2O5.5FORKDIM ENSIONS SCISSORS SWASHPLATE

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]r44

PROTRACTOR PROPELLER

\

0 MT525-1 MAIN ROTOR R I G G I N GF I X T U R E

tlt--h' s.Q:;, MAIN ROTORBLADE

4 9 . 5 I N . F R O ME N DO F MAIN ROTORBLADE

T A P ES T R I P (HANG FROM O N L YO N E BLADETIP)

OF PROTRACTOR FIGURE1O-4 PLACEMENT

Page1O.6

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1 0 . 1 2 0 M a i n R o to r(co n t'd ) NOTE When zeroingthe protractor,the face or dial should remain facing one of the rotor blades. Mark this bladewith a pieceof tape. When makingbladeanglereadings,the face or dial of the protractormust always face the markedblade. e) Measurein from the tip of each main rotor blade 49.5 inchesand place a piece of 1-inchmaskingtape chordwiseacrosseach blade with the center of the tape over the mark. WARNING Do not mark the rotor blades with a ball point pen or other sharp instrument. Use a grease pencil or soft marker. Sharp instruments can scratch the blades skins, causing cracks and fatique failure of the blade. f) Mark each rotor bladewith a differentcolor designationsuch as red or blue. This will be used in recordingbladeangles. 1 O . 1 2 1 C vcl i cT ra ve lR i g g i n g NOTE Adjust collective travel rigging before cyclic travel rigging. Hydraulicflight controlsmust be pressurizedpriorto measuring bladeanqles.

a) Place the collectivecontrol full down. Place the cyclic control in the neutral positionlaterally(7.O inchesto the right of full left travel) and hold againstthe forward stop. NOTE Sand bags may be used to securecyclic stick againststops to e n su rei t w i l l n o t mo ve . b) Rotatethe bladesso the pitch links are alignedwith the longitudinalaxis of the helicopter. Placethe tracking stick at one of the blade tips for referencewhen rotatingthe rotor.

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MATNTENANcE MANUAL

1O.121 CyclicTravelRigging{cont'd) c) ForwardlongitudinalcYclic: 1) Measurethe bladeanglesand record below. Rotate the rotor 18Oo and recordthe bladeanglesbelow. BlueBladePosition Pitch horn aft Pitch horn forward

Cyclic Full Forward o nose up -o nosedown + o . o: a- -

-

o

114.25| 13.50degreesrequired) Red BladePosition Pitch horn aft Pitch horn forward

CyclicFullForward

o nose up o nose down o +2=

o

tl +.ZSt I g.SOOegreesrequireO) : 2l Adjust the aft swashplatepush-pulltube as required_{onefull turn 0 .4 4 o ) to o b ta i n b l ade anjle aver agesbetween 13.500 and 14.250. Additionafc-oarseadiustmen-tis availible by simultaneo.uslyadjusting the two forwarOpusfr-pulltubes but they both must be adjustedexactly the sa mea mo u n t. d) Aft longitudinalcYclic: 1) placethe cyclic control in the neutralpositionlaterallyand hold againstthe aft stop. 2l

Measurethe blade anglesand record below. Rotate the rotor 180o and recordthe bladeanglesbelow. Blue BladePosition Pitch horn aft Pitch horn forward

Cvclic FullAft o nose down o nose up + o :2:-o

(14.25113.50 degreesrequired) Red BladePosition Pitch horn aft Pitch horn forward

Cvclic Full Aft nose down --o o nose up + o +2

=-o

114.25113.50 degreesrequired)

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1 0 . 1 2 1 C ycl i cT ra ve lR i g g i n g(co nt' d) 3) Adjust the aft swashplatepush-pulltube as required(one full turn : 0.440) to obtain blade angle averagesbetween 13.50o and 14.250. Additionalcoarse adjustmentis availableby simultaneouslyadjustingthe two forward push-pull tubes, but they both rnust be adjustedexactly the same amount.

NOTE to obtainaft cycliccontrolbladeangles, lf adjustment is required the forward cvclic must be rechecked. e) Left LateralCyclic: 1) Placethe cyclic control in the neutralpositionlongitudinally(mid travel)and hold the cyclic againstthe left stop. 2) Rotate the rotor until the pitch links are aligned with the lateral axis of the helicopter. Placethe trackingstick at the end of one bladefor reference. 3) Measurethe blade anglesand record below. Rotatethe rotor 180o and record the bladeanglesbelow: Blue BladePositio! Cvclic Full Left Pitch horn right + Pitch horn left

o

Red Blade Posilioq Cvclic Full Left Pitch horn right Pitch horn left +

nose up nose down o Average -2= ( 8.5i7.5 degr eesr equir ed)

nose up nose down o Average +2= ( 8.5/7.5degr eesr equir e d)

4) Adjust eitherof the two forward push-pulltubes as required(onefull turn = 0.6 d e g r e e )to o b ta i nb l a d ea n gleaver agesbetween7.5o and 8.5o. f) Right lateralcyclic: 1) Placethe cyclic control in the neutralpositionlongitudinally(mid travel)and hold the cyclic againstthe right stop.

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1 0 . 1 2 1 C v c l i cT ra ve lR i g g i n g(co nt' d) 2) Measurethe blade anglesand record beiow' Rotate the rotor 18Oo and record the blade anglesbelow: Blue BladePosition CvclicFullRisht Pitch horn right + Pitch horn left

Red Blade Position Cvclic Full Risht Pitch horn right + Pitch horn left

nosedown noseup o Average +2= (7.0/6.0degreesrequired)

nosedown noseup +2=

o Average

(7.Ol6.O degreesrequired) (onefull turn = 0.6 3) Adjust eitherof the two forward push-pulltubes as required degree)to obtain bladeangteaveragesbetween 6.0o and 7.oo.

NOTE lf adjustmentis requiredto obtainright cyclic control blade angles,the left cyclic must be rechecked' 1 0 . 1 2 2 C o l l e cti veT ra ve lR i sg i n g

Placethe I a) Place the cyclic controt in the neutral position (see Figure 1O-1). collectivecontrolfull down. Apply futl cyclic and collectivefriction. b) Rotatethe main rotorto alignpitchlinkswith the longitudinalaxisof the helicopter' Placethe trackingstick at the end of one bladefor reference' propeller c) Measure the blade angles using the MT525-1 rigging fixture and protractor.

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10.122 CollectiveTravelRigging(cont'd) NOTE The MT525-1 fixture is placedon top of the bladeat 49.5 inches from bladetip. The fixture must be heldtightly againstthe leading edoe to ensure accurate readings. readinqs. All measurementsmust be edge taken with protractorfacing markedblade. Recordbladeangles,then rotate rotor 180o and againrecordangles. Adjust the pitch link of each bladeuntilthe two bladeanglesare within 0.2 degreesof each other when the bladepitch horn is in the forward position. Checkthe bladeangleswith each blade pitch horn aft. Averageof these anglesmust be within O.2 degreesalso.

FULLDOWN COLLECTIVE Red Blade

Blue Blade Pitch horn forward + _o Pitch horn aft

o nose up nose up o +2:

o

+ _o

o noseup nose up o

o +2=

(1.Ol2.Odegreesrequired) d) Raisecollectivecontrol to the full up position. Apply full collectivefriction. Measurethe bladeanglesper Step c) above and recordaveragesbelow. BlueBlade Pitch horn forward + _o Pitch horn aft

o nose up nose up o -2:

Red Blade o noseup o

+ -o

nose up o +2:

o

(Average12.5o113.5odegreesabove collective-down requiredfor rigging; final angle) will determine autorotationrpm adjustment e) Trackand balancemain rotor per Section10.2001 0 . 1 3 0T a i ln o to r H i sh t C o n

(SeeFigure1o-5) 1o.rcl Pedqlg as follows: Pedalriggingis accomplished a) Insert a 3116-inchdiameter rigging pin through the hole in the right-handkeel and the riggingpin holesin the C317-1 bellcrank. b) Adjust the C121-9 push-pulltubes as requiredto obtain a dimensionof 2.9O t O.O3inchesfrom the pedal to the right hand stop locatedon the side of the forward console(doesnot apply to heliIopterswith6ut stop on lower console). C h a n g e1 4 : J U L 2 O O B

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10.132 C 3 1 6 B e l l cra n k{S e eF igur e1O- 5)

R e m o v e r i g g i n g p i n a n d p | a c e l e f t . p e d a | a g q l g t ^ i t : S t o p . . A d j u . s(O.3 .t9.q €-1pulh-qu - 0.5 tubeto obtaino.1O- O.20inchesf,eiw"en"c316-1rod-endano butkhead ibif,"ti"opterswithoutpedalstopon lowerconsole). 1O.133 A12O-3 Bellcrank to With left pedalat stop, adjustthe C121-17 push-pulltube length as.required the and assembly obtainO.35 t O.O3inch betweeni*o tac"i of fitctr control housing.(SeeFigure10-71.

10.134 Tail RotorPitch!=i!rlq r od end Adjust the pitch links to a dimensionof 2.620 + O.O1Oinchesbetween centers(see Section8.570). 1 O . t+ 0 f a i t n o to r n l 1)

Setup: a) Levelthe rotorcraftper section 1.22O (Method 2, Main Rotor Hub). b) Rotatethe tail rotor until the bladesare parallelto the tailcone. c) Tape a trackingstick to the tailconeat the tip of the fwd blade'

NOTE A tra cki n gsti ck ca n b e madeusinga 1" x 12" str ipof aluminum with a 9d-"bend 2 inchesfrom one end. stick d ) Visuallyalignthe tail rotor to a zeroteeter positionand mark the tracking where the tip of the tail rotor bladees.

e ) Rotatethe tail rotor 180o, using the forward flex couplingso.teeterangl-eis not disturbed,uniil tf,e oppoiitdbtade tip is alignedwith trackingstick. Mark the stick. the f) Teeter the tail rotor to positionthe blade tip 19 the mid point between

marks. Rotatethe iail io[or anOcheck that th'ebladestrack. Repeatthe above procedureas necessaryto track the tail rotor'

its stop. Mark the trackingstick .whergthe bladetip s) Placethe left pedalagainst againstits stop and mark the tracking tfrl right p..rii'the stick.

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stick. Ff#"

bedal

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tt44

CONTROLS TAIL ROTOR

c317-1 BELL CRANK

RIGGING PIN HOL E

0 . 1 0- 0 . 2 0 i n . (t-ett pedalagain stop) PEDAL STOP

c121-9 PUSH-PULL TUBE

CONTROL FIGURI1O- 5 TAIL ROTOR RIGGING PEDAL

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cL?t-r7 PUSH-PULL TUBE

4120-3 BELLCRANK

0 . 3 5i n . ( L e f t p e d a l a t s t o p )

c031-1 PITCHCONTROL ASSEMBLY

RIGGING F IGU R1E0 -6 A12O- 3BELLCRANK

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H44

AFT MACHINED FACE c 1 4 8 - 1TAILCONE BULKHEAD CLOSURE

A12O-3BELLCRANK

TUBE c121-17PUSH-PULL

' . _ _(9J ::\y ;- re_

-i (t ASSEMBLY TA|LROTOR I I \ .-l L

Mrs2s-2

tvr I ozo-z

RIGGING FIXTURE \

INCHES DISTANCEFROMTIP OF TAIL ROTORBLADE

o'tto*tt

'*

F R O MT I P O F TAIL ROTOR BLADE

MT525-2 RIGGING FIXTURE

\\:#;t

,\4 I

FIGURE 1O.7 TAIL ROTORRIGGING

Ch a n g e1 3 : O C T 2 OOG

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A44

1 O . 1 4 0T a i l R o to rR i g g i n g(co n t'd ) '

2l Measurethe tail rotor blade anglesas follows: blue. a) Using a soft markeror greasepencilmark each bladeas red or maskingtape b) Measurein from each blade tip 7.25 inchesand place 3/4 inch chordwiseon each blade at this point' pedal c) Have someone hold one blade tip at left pedal track mark with left againstits stoP. d) Place MT525-2 riggingfixture on aft bladeinboardside.

NOTE MT525-2fixturemuststraddlemas tail e) using a propellerprotractormeasurebladeangleand recordbelow. Rotate rotoi 18o degreesand recordoppositebladeangle' PedalsFull Left o nose right

Blue Blade Red Blade

+

o nose right o +2:

(18.5119.Odegreesrequired) CAUTION For acceptabletrack, differencesbetween Blue and Red blade angles must not exceed 0.4 degree.lf blade angles cannot be adpsteo to within 0.4 degree of each other using adjustable pitch links then removetail rotor assemblyand rotate it one-half ievolution,reinstalland repeatabove procedure. lf blade angles still cannot be adjustedto within 0.4 degreeof each other then replaceblade(s).Co NOTE Adjustablepitch link jam nuts must be tight to ensureaccurate bladeanglemeasurements.

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F'44

1 0 . 1 4 0 T a i l R o to rR i g g i n g(co n t'd) WARNING Both pitch links must be same part number {same type and material). Mixing one-piecewith adiustable-len$hpitch links is prohibited. Mixing steelone-piecewith aluminunione-piecepitch links is prohibited. Ad j u stme n to f b l a d e a nglesis m ade using r od ends of C121- 17 pu s h- pul l tube. One full turn of rod end will changebladeanglesO.33 degrees. Adjust rod end as necessaryto obtain 18.5 to 19.0 degrees. g . Place right pedal against its stop. Measureblade angles and record below

using right pedaltrack mark. PedalsFull Right o nose left

BlueBlade Red Blade

+

o nose left o -2:

(15.5/16.5 degreesrequired) h. Adjust C121-17 push-pulltube as necessaryto obtain bladeanglesof 15.5 to 16.5degrees.

NOTE lf adjustmentis requiredto obtainrightpedalbladeangles,left pedalanglesmust be rechecked. i. lf bladeanglerange,for left and right pedalsettings,cannot be obtainedusing above procedure,this indicatespedaltravel is either too great or too small. Use following procedureto check and adjust pedaltravel: 1) Add right and left pedal anglestogether. lf total is less than 34.0o pedal total travel is too small. lf total is greaterthan 35.5o total travel is too great. 2) lf total travel is too small, first increaseright pedal travel by increasing l e n g th o f C 1 2 1 -9 p ush- pulltube. To incr easeleft pedaltr avel, de c r eas e length of C343-3 push-pulltube.

C h a n g e1 4 : J U L 2 0 O g

P a g e1 0 . 1 7

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MAINTENANeE MANUAL

FlclBINBClN

H44

COLLECTIVE

/'\ /t \\ /\

------.-\ a\

J\

7t PUSH.PULL

\

c336

/ TUBE

PUSH-PULL TUBE

/t

ts

OVERTRAVEL SPRING ASSEMBLY

FORWARD

I

,l

i\ .,

\_---COLLECTIVEAND THROTTLE F U L L YC L O S E D I D L ER P M ADJUSTMENT TOROUE NUT 20-60 SCREW INCHPOUNDS

\ \ \

PIN COTTER MS24665-132

\ \ \

THROTTLE STOP

(X.BURETOR c336 PUSH-PULL TUBE

o . 0 1 0- 0 . 0 3 0l N c H

q

T H R O T T L EL E V E RP O S I T I O N C A R BF U L LO P E N 27,50!7.50

\

la

9.o*t RIGGING FIGURE10.8 THROTTLECORRELATION (CARBURETED SHIPS} P a g e1 0 . 1 8

Change1 4 : J U L 2 0 0 8

FIclElINSiclN

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MANUAL

MOEIEL

F.44

COLLECTIVE

i\

FORWARD

ll

/\

JI

3l

FUELCONTROL

PUSH.PULL

,/'1"'

A336 PUSH-PULL TUBE

OVERTRAVEL SPRING ASSEMBLY

A

r

3.OOINCHESWITH FULL-UP COLLECTIVE AND THROTTLE FULLYCLOSED

F U E LC O N T R O L

-V

0 . 0 1 0- 0 . 0 3 0 IDLERPM

r ADJUSTM ENT VIEW ' ' 4"

\

)

ull

(VIEWLOOKINGAFT}

RIGGING FIGURE1O-8A THROTTLECORRELATION (F U ELINJECTED SHIPSI C h a n g e1 4 : J U L 2 O O 8

P a g e1 0 . 1 8 A

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MOETEL F|44

blank IntentionallY

P a g e1 0 . 1 8 8

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10.140 Tail RotorRigging(cont'd) 3) To decreasethe total travel,shortenthe C121-9 push-pulltube for right pedal travel and increasethe length of C343-3 or C343-9 push-pulltube for left I pedaltravel. 4) Recheckthe tail rotor bladeanglesper steps e) through h) above. j) Ensureall rod ends are installedproperlyby checkingthe push-pulltubewitness holes.Tightenall rod end palnutsand jam nuts. Torquestripe all nuts. k) Balancetail rotor per Section10.240. 10.150 ThrottleCorrelation Rigging(seeFigure10-8) For in-servicecheck and adjustment: 1. idlerpm is correctwith enginewarm, clutchfully engaged,and throttle closed. Adjust 0-540 idle to 53-57o/oand lO-540 idle to 58-620/o. 2. Shut down helicopter. 3. Rotatetwist-grip throttle fully closedthrough overtravelspring pressureto positive stop. Holdingthrottle tight against stop, raise collectivefull up while observing throttle arm on carburetoror fuel control,as applicable.Throttle arm should move 0.O10-0.030inch off of idle stop screw when collectiveup-stopis reached. 4. lf necessary,adjustlengthof throttle push-pulltube at carburetoror fuel control,as applicable. 5. Standardtorque jam nut(s) per Section 1.32O, check witness holes, and torque stripeper Figure2-1. 10.160 ActuatorRigging belt tensionis permitted. Adjust actuator'sdownNo field adjustmentof actuator-engaged limit stop screw so there is a delayof lessthan 5 secondsbeforerotor starts turning when actuatoris engagedat start up. 1O.2OOTRACKAND BALANCE The Chadwick-HelmuthVibrex system, the TEC ACES system, the Dynamic Solutions Systems' MicroVib system, or equivalentequipmentis requiredto perform dynamic rotor balancingand in-flighttrackingchecks.

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10.210 EquipmentRequirements for track and balance: The following list of equipmentmay be used on the R44 a) Balancers Chadwick-Helmuth 1 7 7 M 0 5 177M-6 ModelNumber 177M-6A 177M-7 177M-7A 8350 series M192 ser ies or equivalentequiPment b) Strobex Chadwick-Helmuth ModelNumber

135M-10* 135M-10A*B , * a n dC * 1 3 5 M - 11 or equivalentequiPment

* When trackingthe main rotor usingthe 135M-10 seriesStrobexa double interruptermust be used. pickups,and targetsH c) cables, accelerometers/velocimeters, D'C' AdapterCable Chadwick+"rmuir' 3140 Masnetic PickuP 3o3o Model N;;b;; Magnetiickupc abl e 1080825 33tg- t or Accelerometer 4177 AccelerometerCable 4296-1 and -2 Patches Target 33OO Patches Target 4270 Velocimeter 7310 VelocimeterCable 112i}-2ot-5o d) Brackets** R o b i n s oM n T 1 2 1 - 1MagnetiickuPBracket e) Charts*" Robinson

Main Rotor Chart Tail RotorChart

** As requiredby the balancingequipmentbeingused. 10.220 EquiPmentlnstallation 10.221 Main RotorEquipmentlnstallation(seeFigure1O-9A) .balancing Refer to specific manufacturer'sinstallationinstructions when using equipmentas Lquip..,.'"nrbiri"itnin oraowic[-uelmuth, InstallChadwick-Helmuth f o l l o w s: underthe upperconsoleleft-sideattachment a) Installthe accelerometer/velocimeter screw with cableconnectorpointingoutboard'

P a g e1 0 . 2 0

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FICIE|INSCIN

M(IE'ELF'44

WIDTH TARGET IJ.J

a/,

= z o-

tt'l

4270 ttl.R. TARGET

F IGU R1E0 .9 MAINROTOR TARGET PATCHLOCATION

Change2: 12 Dec 94

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M3fElELF,44

TAPE DUCT

3030 MGNETIC PICKUP

4777 ACCELEROMETER

BALANCING 10.9A MAINROTOR FIGURE INSTALLATION PMENT EQUI

Pag e 1 0 . 2 2

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10.221 Main RotorEquipmentInstallation{cont'dl b) Install MT121-1 Bracket onto the lower right-handside of the swashplate.

I

WABNING Ensureattachmentbolts are torquedto 200 in.-lb plus nut drag.The MT121-1Bracket will remain installedfor in-flight track and balance. c) Installthe 3030 magnetiickupontothe MT121-1Bracket.Set the interrupterpickupgap to 0.030" t O.O1O". dl Attachthe cableto the magnetiickup.Pullcollectivestick full up and cyclic stick full left. Securethe cableto the mast fairing with duct tape. Routethe cableto the lowerfront of the left door frame. Securethe cableevery 12 incheswith duct tape. CAUTION Security of the cable is essentialas the helicopterwill be flown at Vne. mountedon the e) Attach the cableto the accelerometer/velocimeter with duct tape. Secure forward hold screw the console. left down of CAUTION Ensurethe cable cannot becomeentangled with tail rotor pedals. f) Attach the cablesto the balancerand secureexcesscableto the bracketin front of the left seat. g) Appfy the 427Otargettapesto the main rotor bladesper Figure10-9.

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MAINTENANcE MANUAL

(seeFigures10-9C and 1O-gD) 10.222 Tail RotorEquipmentInstallation

are clean and Prior to installingbalancingequipment, b]ad.e.s

smooth,no debriiJnoer-tip'c6vers..isqu?l9,Ip and elastomeric limits, !l:9"t^l'^j3^LlLl ;;-$h;ii."f

U"lr'ri- pttv .are withiri

bracket under upper forward tail rotor gearbox lnstall accelerometer/velocimeter of Connector end bolt." .tt."n."nt seal it;ff;; output must point up' accelerometer/velocimeter photocell, install photocell bracket 2 . lf using a Vibrex 2ooo-seriesbalancerwith bs 1O-gC' between velocimeleianOvelocimeterbracket shown in Figure a, tl1get. tape. sp.anwisefacing 3 . lf using Strobex to obtain clock angle,.-installphotocell to obtain clock angle,

iotor ftuU". lf using outboard on one ;;;i;fu tail rotor hub' install a target ttp" ib"n*it" i"cing inboardonbhe arm of and.photocell (if used)' Route connect cable(s)to accelerometer/velocimeter securewith duct

;66F1 f"fi;;d ;;d ffit

.iouno taitconeseveraltimes.

tape.

Ensurecable(s)cannot a position located 5. lf using Strobex to obtain clock angle, route cable to (or similarl on cable approximat"rviij f;"t t"-Gft ot iait rot-or..Placesandbags ph.otocellto obtain clock angle, cables 1n*"rn"nt. tt-riing 6-d;;;"t "iUI" into cabin and seclured with duct tape to prevent cable may be ,orteJ movement. 6. Connectcable(s)to balancer.

Pag e1 0 . 2 4

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MATNTENANeEMANuAL

MC'EIEL

H44

TAPE (S) cABLE

BALANCERSTROBEX

OPTIONAL CABLEROUTING }{HEN USINGPHOTOCELL

CABLE

ACCELERoMETER/V ELoCr METER PHOTOCELL IF USED)

oc)o

_5..J

TARGET TAPE (TNSTALL AS SH0l^lN USINGSTROl^lHEN BEX. INSTALL ON INBOARD SIDEPER FIGURE 10.9D}IHEN usr NGPH0T0CEL L.)

FIGURE1O-gC TAIL ROTORBALANCINGEOUIPMENTINSTALLATION

Ch a n g e9 : F E B2 OO3

P a g e1 O . 2 5

FICIE|INEICIN

MAINTEIUANcE

wIANUAL

MCIE'EL

F|dIA

ENSURETARGET TAPEIS IN PATH

reauT oFPHorocELL I

PHOTOCELL

o

I

o (vrEw LooKlNGFORWARDI

FIGURE1O-9D INSTALLATION TAIL ROTORPHOTOCELL

P a g e1 0 . 2 6

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10.230 Main RotorTrack and BalanceProcedure NOTE Priorto installingbalancingequipment, bladesare cleanand smooth, rod ends and sphericalbearingsplay are within limits, corrept swas;tplatetilting friction, and correct teeter and coning hingefrictions. In-flight track and balance is accomplishedusing the following testing and adjustment sequence: 1. Check main rotor track in a hover. When using Vibrex 177- or 8350-series equipment,place Functionknob in track position,RPM (flashrate) on Strobexto 326. Adjusttrack by shorteninghigh bladepitch link per Section 10.232 to bring track within 0.25 inch: 2. Check main rotor balancein a hover. For Vibrex 177- or 8350-seriesequipment, place Functionknob in "A" position, RPM on Phazorto 408. Adjust balanceas indicatedby main rotor balancechart (maximum0.2 IPS). 3 . F l y t h e h e l i c o p t eart 5 0 , 6 0 , 7 0 , 8 0 , 9 0 , 1 0 0 , 1 1 0 , 1 2 0 , a n d 1 3 0 k n o t s . C h e c k track at each airspeedand record.

WARNING Do not exceed Vne of helicopterwhen

track.

4. Make slight tab adjustmentto correct for a climbing blade by bendingtrim tab down per Section10.233. WARNING Bladeswith two tfm tabs are obsoleteand must be removedfrom service. 5. RepeatSteps 3 & 4 as requireduntil track will remainon at all airspeedswithin 3i8 inch. 6. Readjustmain rotor balancein a hover (maximumO.2 IPS). 7. Check autorotationalRPM per Section 10.250. Adjust as required. aircraftonly). 8. Evaluatecollectivetrim and adjust as required(non-hydraulic 9. Checkmain rotor balancein a hover. Adjustas required.

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(cont'd) 10.230 Main Rotor Track and BalanceProcedure 10.231 Main Rotor BalanceAdiustments weight as indicated Spanwisebalanceadjustmentsare madeby addingor subtracting tip coverand changing by the balancechart. weight is changedby removingthe blade or - 1OLwas her s c 2 9 8 t i p w e i g h ts. F i n ea d j u stmentsm aybe made with AN960- 10 and also bY trimming washers. rotor hub (see Coarseadjustmentof chordwisebalanceis accomplishedby shifting chordwisebalance Sectiong.1241as indicatedon balancechart. Fineadjustmentof -2 chord weights or AN97O-4 is accomplishedby adding or subtractingA255-1 or weights (four washers as indicatedby balancechart. A maximum of four A255-2 A255-2 weights equaltwelve A255-1 weights)may be installed' ThreeA255-1 Weights = One A255-2 Weight EightAN97O-4Washers = A255-1 Weight 10.232 Main Rotor Pitch Link Adiustment coarseadjustment Two lengthadjustmentscan be madeon the main rotor pitch link' from blade is made by looseningupper rod end jam nut, disconnectingrod end track changes pitch horn and turning rod end up or down (one-halfturn of rod end a p p r o xi ma te l0y .2 5 i n ch ). Fine adjustmentis made by leavingrod end connectedto pitch horn and loosening One rod end jam nut, looseningbarreljam nut, and then screwingbarrelup or down' can barrel of turns barrelrevolutionis equivalentto one-halfturn of rod end. Partial be made by countingnumberof hex flats rotated (see Figure10-11)' CAUTION After adjustingpitch tink, o.o2o inch diametersafety wire cannot through witness holes.

Pa g e1 0 . 2 8

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FICIBINSC|N

MATNTENANcE MANuAL I|AIN ROTOR

SHIPS/N

Page

MC'EIEL FI44 M1vra,,...

,#T;,

TRACKAND BALANCEC]|ART rro*tt;y rEou

of Page

"fflx'?r .o30

l'louNTAccqLERoMETE;r 0NLEFT SIDEOF CONSOLE POII'ITED LEFT

FOR}|ARD BLADE

t| oN ./ rnrrnnuPTER

INSIDELEADARM OF SWASHPLATE

MAGPICK-UP

SPANWISE NEIGHTS = (1)AN960-10 (2)AN960-101 WASHER WASHERS CHORD ARMI.IEIGHTS = (1)C298-2WEIGHT (5)Ar,1950-10 WASHERS = (1)A25s-1IIEIGHT = (1)c298-3 |.lEIGHT (B)AN970-4 WASHERS (11)AN960-10 IIASHERS = (1)A255-2l,tEIcHT (3)A255-1l.lEIGHTS (4)c298-3 wElcHTS= (1)c298-4 hIEIGHT

TRACK( KNoTS)

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CIIANGE MDE:

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MAINTENANeE

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MANIIAL

FI44

RODEND UPPER

HOLES I,IITNESS

PITCHLINK 10-11 MAINROTOR

I'11526-1TABBENDER

BENDDOI.|N NOTEDIFFERENCE

10.12 MAINROTOR FIGURE TRIMTABADJUSTMENT BENDUP

P a g e1 0 . 3 0

C h a n g e5 : 1 5 J u n 9 8

FIGIBINSIGIN

MATNTENANcE MANUAL

MOEIEL r|.44

DIAL INDICATORSPINDLE

MT352-1 TRIMTAB GAGE

MT352-1 TRIMTAB GAGE TAB Too! bottom edge must trim tab trailingedge.

MEASUREHERE

3 MEASURING

\

EOUALLY SPACED

\

't

) -/ ,/

FIGURE10.13 MAIN ROTORTRIMTAB MEASUREMENT

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10.233 Main Rotor BladeTrim Tab Adiustment MTs26-1 .tab benderand Main rotor bladetrim tab adjustmentsare made using the a felt marker,draw a'line the MT352-1 trim tab gage. Referto Figure1O-13.Using Mark line with three equally acrosstop of trim tab arignedwith bladetrairingedge. uppersurfaceof blade spacedmeasuringpoints.Placetrim tab gagechordwiseacross on a marked measuring and trim tab trailingedge with dial indtaior stylus resting measuring point. Set dial indiiator scale to zero. Similarlymeasureboth remaining pointsandtheyarewithin0.oo5inchoffirst. CAUTION MT352-lgagemusttrimtabtrailingedge.Space between eJge of gage and trailing edge of trim tab indicates trim tab bent beYondlimit. benderover trim To bend trim tab, loosenbolt on MT526-1 tab benderand slidetab side of tool single-rib tab trailingedge as far toward leadingedge as possible.Ensure bolt to bend s blade bottom surfaceto bend tab down and vice-versa'Tighten use tool like a lever' tab. clamping action of tool is sufficientto bend tab; do not tab' Do not bend Referto Figure 1o-12.Make very slight bendsdownward on trim can increase trim tab upward unlessabsolutelynecessary;bendingtrim tab upward 0.o15 inch will movetip o f m ai n c y c l i cs ti ck sh a ke .A tri m ta b b endof appr oxim ately trim tab with MT352-1 gage' Adjust rotor bladeapproximately0.2 inch. Remeasure inch' bend in trim tab as requiredto keep three measuringpoints within 0'OO5 CAUTION Do not use mainrotor bladetrim tab bendingtools manufactured by other helicopter manufacturers.Use of these tools will damaqemain rotor blade.

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10.234 Main Rotor Track and BalanceTroubleshooting The following are some of the symptoms and correctionswhich occur in the Track and Balanceoperationsof the helicopter.Decideon the variouscausesof a given trouble and then eliminatecausesone by one, beginningwith the most probable. Sy$pl"t 1.

ProbableCause

ExcessiveCyclic Main RotorOut of Track or Stick Shake

Correction Track and Balancewith ChadwickHelmuthBalancingEquipment

Roughor Binding42055 Fork Assy (Upper Swashplate)

Replaceor referto Section8.6 of MaintenanceManual

BrinelledSpindleBearing (roughmovement)

ServiceCenteror RHC replacementof SpindleBearings

Bladesurfacerough {chipped}paint

Featherin rough edgesor repaint

I I

Roughor BindingPitch links Replacepitch link rod ends for smooth operation M.R. BladeBoot Misaligned Replaceboot or realign.Boot should

g,?"1 "j[ili:?,1',i'..3 lj!fr11',,"., ::fr arc or travel

M.R. Hub Teeteror Coning ReplaceBearingsper Section9.126 or rework for smooth operation HingeBinding

2.

ExcessiveShip Vibration

M.R. BladeTrim Tabs Bent Upward

BendTrim Tabs down evenly

BladeMatch

RHC replacementof blade(s)

Main Rotorout of Track and Track and Balancewith ChadwickHelmuthBalancingEquipment Balance M.R. Hub Teeteror Coning Referto Section9.123 of MaintenanceManual HingeFrictionlmproperly Adjusted Sticky Coning - HingeBearing Replacebearingper Section9' 126 or referto Section9.123 in M.R. Hub BrinelledSpindleBearings {roughmovement)

ServiceCenteror RHCreplacementof SpindleBearing

Worn TeeterBearingin M.R. ReplaceM.R. Hub bearingsper Section9.126 Hub

Change12: JUL2005

Page10.33

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MOEIEL

MAINTENANeE MANUAL

FI44

(cont'd) 10.234 Main Rotor Track and BalanceTroubleshooting Correction Probable ause Symptom -C, Centeror RHC ExcessiveCyclic BrinelledSpindleBearings(rough Service of SPindleBearings replacement movement) StickForces

lntermittentBlade M.R. Hub Teeteror ConingHinge Referto Section9.123 Friction lmproPerlY Adjusted TrackPicture

In Bearinss Hinse glieky.coning $:fl?"3ff?:1ffS::rtff'!l?rt M.R.Hub Teeter Hinge not Broken-in

Adjust track to minimizeerror

BrinelledSpindleBearings(rough ServiceCenteror RHC replacementof SPindleBearings movement) 5.

RadicalChanges Worn Teeter HingeBearingsin M.R. Hub to CyclicTrirfr'

ReplaceM.R. Hub BearingsPer Sebtion9.126

BrinelledSpindleBearings(rough ServiceCenteror RHC replacementof SpindleBearings movement)

6.

Lateral triil-rmittent

dueto Enginemisfiring il;]i,.;;iiiil in "spaltplugs,

Referto Textron;Lyc.oming Instructions Maintenance

*"snetoorensrne Vibration Aircraft i%l'i?i,lSfi1;: 10.240 Tail Rotor BalanceProcedure

Referto specificmanufacturer'sinstallationinstructionswhen using balancingequipment other than Chadwick-HelmuthVibrex system. tnstalfChadwick-Helmuthequipmentper Section 10.222. Set FunctionKnob on Balancer i;-;pprpiiite cf,"nnei. Set'b"lanc"r heM nange knob to X1O and set RPMto 231. With 6lriJopi,irrrnning *iin go,r"rnorON, view taillolor assemblywith Strobex. Tune Balancer and IPS *nile viewing taigei iaffand adjusiing RPlvldial on Balancer. Recordcl^oc_!.1qsle lPS. 0.2 than is less on tail rotor Salinte ch'irt. Adju3t as rlquired until balance Spanwisebalanceadjustmentsfor CO29-1square-tipbladesmade.byadding,subtracting, oi-"ic6.nging weigfrfi-rnAerthe removable'tipcover. Use C134-1 or:? tip weightsor AN96O-B5r -Et-*i"1.t"r.. -8L washersmay bd trimmed as a very fine adjustment. differenldiameter arq mad.eby er<.changing Spanwisebalancefor CO29-2round-tip.blades sufficientlength has washersunder nut .""uilng bt"Oe'soritboardretainingbolt. The bolt past nut after protruding changes; 2-4 threads to allow n""".r"iy ;p;;i;t*"igf't torquingper Section1.320. o.rexchang.ing.41.41L4,AN96OChordwisebalanceis adjustedby adding, s.ubJrgcting, pitch link attaching.bolt. Cf."ngg pitch 41Gor -416L washers under nut'securin-gblade's lint, attacrringooii l"ngih as requiredfor-properthread engagement(see Section 1.300, referto IPCfor allowablelengths)'

P a g e1 0 . 3 4

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COO8.2TAIL ROTOR TIP COVERSI IREMOVABI."E TRACKAIID BALAI{CECHART

SHIPS/N of Page

Page

MANuAL

TARGET BLADE REFLECTIVE TARGET TARGET REFLECTIVE ITOUIITEO OPPOSITE ANYCHORD }'EIGHT INSTALLED PREVIOUSLY

BLANK BLADE

IiOUNTACCELEROI,IETER I.IITHcONONGEARBOx POIIITED IIECTOR UP.

.^ . A -e8 ^ E

CHORDI.IISE t,,EIGHTS

SPANI{ISE I.'EIGHTI = (1)AN960-8}IASHER (2)AN960-81I'IASHERS = (t)C134-1 l.lEtGHT (14)AN960-81 I{ASHERS

RUN

CLOCK

IP S

= (1)AN960-416 (2)AN960-4161 HASHER WASHERS = (1)A141-14|{ASHER (5)AN960-4161 I,TASHERS

CHANGE MADEBEFORE NEXTRUN

NOTE CLOCKANGLESPROGRESS WHENUSINGVIBREX2OOOWITH PHOTOCELL, (11 1 o'CLOCK, o'CLOCKBECOMES FROM12 o'CLOCK ANT|-CIOCKWISE TO VIBREX2OOOMAN. 2 O'CLOCK,ETCI. REFER 10 O'CLOCKBECOMES INSTRUCTIONS. UFACTURER'S

Change9: FEB2OO3

Page10.35

TARGET BLADE REFLECTIVE TARGET TARGET REFLECTIVE OPPOSITE I,IOUNTED }IEIGHT ANYCHORD II{STALLED PREVIOUSLY

+

EL F|44

COO84TAIL BOTOR (ROUND.TIP BLADESI CHART' BALANCF TRACKAND

SHI PS / N of Page Page-

r.

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MAN

MAINTENANcE

FICIBINEICIN

i-=-"1 Et- rl e . @

'.?6 , 1 6 - A

2'

:qa

og? ,

BLANK BLADE

$w;!*

Ga

ot

vv? ,i! z

'-.r3--Z '

I.OUNTACCELEROI4ETER I.,ITH CONONGEARBOX UP. POINTED I{ECTOR

P4,

'aEJ-,

?Ei 'rll€.'

I.IEIGHTS SPANWISE

co-=' -rag z

}|EIGHTS CHORD}'|ISE

= (r)AN960-416 I{ASHER WASHERS = (l)C141-20I',ASHER (2)AN960-4161 (5)NAS1149F0563P t'lASHEp5 = (1)A214-3hfAsHER = (1)At{970-5 }lAsHER (3.s)AN960-4r61ulASHEs5 (13)NASll49F0s63P }IASHERS = (1)Ar4l-14 I{ASHER }fASHERS (5) At{960-4161

RUN

CLOCK

TPS

NEXTRUN BEFORE I.,IADE CHANGE

NOTE CLOCKANGLESPROGRESS WHENUSINGVIBREX2OOOWITHPHOTOCELL, 1 o'CLOCK' (1',l o'cLocK BECOMES FROM12 o'CLOCK ANTI-CLOCKWISE TO VIBREX2OOOMAN' 2 O'CLOCK,ETCI. REFER 1OO'CLOCKBECOMES INSTRUCTIONS. UFACTURER'S P a g e1 0 . 3 5 A

Change9: FEB2OO3

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INTENTIONALLY BLANK

Change9: FEB2OO3

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FICIBINEiC|N

Usethefo||owingprocedureforcheckingandadjustingautorotationa|RPM: WARNING Failureto properlyadiust autorotationalRPM-(RPM tne rotorcraftfrom achieving ioo lowl maV-preirent gross weights' P.Per RPMbi low

I I

I I

lb gross weight' a) perform autorotation RPM check at less than 19OO the time on Record Catcutatetn" t"GJtt d.ir welght of the helicopter. the hour meter. Take-Offgrossweight Take-Offhourmeterreading performingthe bl set the altimeterto 29.92".Hg (101.3.2.millibars).prior.to. held againstthe firmly Autoiotate-wittrini cottectivecontrol autorotataon. Ooi"n iiop with an airspeedof 5O KIAS' WABNING Do not allow the rotor to overs-peedwhen pettotmlng autorotation. checks' Progress!.v-ely iedgitG;fottrmainrotor pitch link rod ends until full oofin collective can be obtained without overspeedingthe rotor.

I

Take at least 3 RpM readingsat 5OOto l OOOfoot altitude intervals.

I

Recordthe following in-flightdata: Test #

Hourmeter CJg OAT

Pressure Altitude

Test o6RPM

1

2 3 4 5

Page10.36

Change3: 5 May 95

FIOBINSiON

MATNTENANcE MANuAL

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C h a n g e1 O :J U L 2 O O 4

HEATING AND VENTILATION

FICIBINSiCIN

MATNTENANeE MANuAL

MOEIEL

F|44

SECTION 11 HEATING, VENTILATION ANDAIRCONDITIONING 11.OOOHEATING AND VENTILATION 11.001 Introduction 11.OO2Description 11.1OOCABINHEATER 1 1 .1 1O ControlCableand Valve Replacement 11.120 Muffler ShroudReplacement 1 1 .2OO VENTILATION 1 1 . 2 1 O C a b i nA i r V e n t C a b l eR e moval 11.22O CabinAir Vent CableInstallation 11.23O Door Vent 11 . 3 0 0 A t RC O N D I i l O N I N G 11.301 Introduction 1 1. 3 O 2 D e scri p ti o n 1 1 .310 SystemTroubleshooting 11.32O Refrigerant 11.321 RefrigerantRecovery 1 1. 3 2 2 R e fri g e ra nCt h a rg e 11.323 Leak Detection 1 1 . 3 3 0 C o mp re sso r r e l t R e p lacement 1 1 . 3 3 1 C o mp re ssoB r e mo va l 1 1. 3 3 2 C o mp re ssoR r sta l l a tion 1 1 . 3 3 3 C o mp re ssoIn C h a n g e1 4 : J U L 2 0 0 8

Page 1 f .i

FTclElINSClN

MATNTENANeE MANUAL

MOE EL F'44

1 1.34O EvaporatorAssemblY 11.941 EvaporatorAssemblyRemoval "l1.342 EvaporatorAssemblyInstallation 1 1 . 3 4 3 E va P o ra toDr ra i nS ystem 1 1.350 Full ThrottleCut-Out Switch Rigging

CARTEIpGE 11.400 DRIVE 1 1 . 4 1 0 D r i veC a rtri d g eS e a l R e moval 11.42O Drive CartridgeSeal Installation

Page 1 f .ii

C h a n g e1 4 : J U L 2 0 0 8

FIC|BINSCIN

MATNTENANGE MANuAL

MCIE'EL

F'44

SECTION 11 ANDVENTILATION HEATING 11.OOO ANDVENTILATION HEATING 11.001Introduction of the heaterand This sectioncontainsthe proceduresnecessaryfor replacement ventilationsystemscomponents. 11.OO2Description The cabinheatersystemconsistsof a heatshroudoverthe muffler,a controlvalveon the forwardsideof the firewall,an outletgrillforwardof the pilot'stail rotorpedals,and ducts betweencomponents.Air is suppliedby the enginecooling the interconnecting push-pull heatcontrolis locatedon the face of the lowerconsole.The heat fan. The controlactuatesthe controlvalvewhich directsthe air eitherinto the cabinor out an of the cabin. discharge on the underside overboard A push-pull Freshair ventsare locatedin eachdoorand in the noseof the helicopter. controlfor the nosevent is locatedon the faceof the lowerconsole. (SeeFigure11-11 11.10OCABINHEATER NOTE The cabin heateris requiredto be installedin the R44 helicopter. Air flow through the muffler shroudcoolsthe muffler and engine compartment. 1 1.1 1O Control Cableand Valve Replacement a) Removethe aft tunnel belly and enginebellycowling. b) Remove the three screws holding the C753-1 cover and remove the cover and insulation. c) Removefour screws holdingthe C625-1 box and removethe box. d) Remove the control wire by straighteningthe end (if applicable)and looseningthe A462-1 fitting clampingthe wire.

Change12: JUL 2OO5

P a g e1 1 . 1

I I

FICIBINSG|N

MAINTENANcE MANUAL

MOE EL ]|.44

(cont'd) 11.11OControlCableandValveReplacement 4623-1 inlet,removethe two hosesand e) To removethe AO19-3valveass.embly.and four screwsthroughthe firewall' the remaining the cableiam nut f) To removethe controlcablecasing,oPqlqqpgr console'Remove to the chin. casing holding.the clamp behindthe towerconsotetac" aiJ'inJhr.rz+z'-3 of the Outboard blamp' the remove Insidethe right forwardbaggagecompartment, casing' cable the to. the top from 99ce9.s right aft ttoor,'iemou"tt'," 5ItU'ottO "itp"toutboardgf th.9right aft seat. Removethe Removethe two fla.pi unoo iri" p.ndt ;iilp r,oioing'ii" ;;i'.6 to-irr" u"rticatfirewall and pull the casingout throughthe lowerconsoleface. grommetis g ) To installthecontrolcablecasing,that an MS35489-4or AN931-3-5 grommet is installed6 NAS557-3A tii t|,revatveandan in the tunn"i*ill instalted place through place ";ii hoi"r ir,.ubn *rti.r',irri caiing.pa?sq:.(each ,except,one ;i;;;i" forward the right front of the at a verticalfirewallstiffenerand thro;gf,if,e bulkhead. baooaoecomoart;"ntl.lnJi.U the iZsing throughthe tower consoleface and cable irii",IJir-in" stitieneron the sid-eof th-econsole,through..tt9right.forward irifi"ri,it, 'Uaggagd comp6rt."nt, ouiUoq$ of the right aft.flooL,throughth9 lght aft bagglge trrroulii't*o-lqi1"n"rr on tFe verticalfirewall,and into the tunnel.set "oit"p.?ir*t, .pproiimately0.8 inchel into the tunnel,Fastencasingwith AN742-3 bi "nO five places. clamps".sing h ) To installthe valveand inlet,cleanoff the old sealantand resealwith B27O-4sealant.

lnstallvalveandinletandfastenwith screwsin four places.

the A462-1fitting and adiustto.give approximately i ) fnstaffcontrolcablewire through -when Vgfy_ controloperates the valve is fully cJose{.r O.b6bipringUactit tlre knob the fittlng. O.O1inchor lessfrom wire approximately freely.Cut e-xcess fnstailthe c625-1 box and sealwith B27O-1sealant. the valve and box are to the inlet. Check andapplyinglow air press-ure i"lf"O UVtrp,ngthe bellynoteCtosed stick. ioileits'insiOeif,elunnfi by usinga pieceof yarnat the end of a overthe C625-1box and installtheC753k) tnstallone inchthick MicroliteAA insulation 1 cover.

Installheaterhoses.Installbellycowling.beltycover,andcloseupperconsole.

Pa g e1 1 . 2

Change12: JUL 2005

FICIB|NSICIN

MATNTENANeE MANUAL

MOCIELF|44

14

,l\

G;?'

,/

11-1 CABINHEATER FIGURE (srNGLE oUTLET)

OESCRIPTION l. 2. 3. 4. 5. 6. 7. 8. o

10. 11 T2 13 14 15 -16 t7 '18 19

Change4: 1 Jun 97

c522-5 As22-8 8164-1 4785-15 Rlll A701-1 A701-2 0230-1, c631-2 c63r--1 016+1 c630-1 A785-14 A019-3 c625-1 A753-l A758-13 ct69-2 4785-12 c236

C a b i nA i r C o n t r o '(lR e f . ) CabinHeaterContro'l HeaterOut'let Hose I nsu'lati on Foi'l Tape(Foruardof item 7) Foi'l Tape(Aft of item 7) B u l k h e a(dR e f . ) C'lip C]ip Duct I nsu'lation Hose ValveAssembly Box Cover Hose ShroudAssemb'ly Hose C o oifn g S c r o l I ( R e f . )

P a g e1 1 . 3

FIGIBINEiCIN

MOEIELFl44

MAINTENANcE MANr.rAL

t"/'" --.:::i It

11-1A CABINHEATER FIGURE (MULTIPLE OUTLET)

2 3 4 5 6 7 I 9 10 11 t2 13 14 15 16 17 18 19

P a g e1 1 . 4

NUMBER PART

DESCRIPTTON

c522-5 A522-8

CabinAir Control(Ref) CabinHeaterControl HeaterOutlet Hose outlet (LH) Hose I nsulati on Foi'l Tape(Fonrardof ite+ 9) Bulkhead(Ref) Foil Tape(Aft of item e) Duct Hose Cover Box Va'lveAssembly ShroudAssembly Hose C o o l i n gS c r o l l Hose

D164-l A785-24 0166-1 A785-23 Rl11 4701-1 0230-1 A70r-2 Dt64-2 A785-14 c753-1 c625-l A019-1 c169-2 A7B5.L2 c236 A785-13

Change4: 1 J un 97

FICIBINS|CIN

MATNTENANeE MANuAL

MOEIEL

F,44

11.120 MufflerShroudReplacement al Removethe D040-1 aft enginecowling. bl Removethe tail pipe from the exhausthangerat the enginecoolingscroll. c) Disconnectthe two heaterhosesfrom the shroud. dl Removethe screwsat the top of the shroudand removethe shroudover the tail pipe. el To installthe shroud,reversesteps a throughd. 11.2O0 yENT|LAT|ON 11.210 CabinAir Vent CableRemoval {SeeFigure11-2} al Openupperconsole. bl Removecotter pin and clevispin at the forwardcabinvent. cl Removeattachingclamps. d) Removecablejam nut at lower consoleface and removecable. (SeeFigure11-21 11.220 CabinAir Vent CableInstallation a) Installor replacethe MS3548-4grommetin the vent box, if required. bl Insertthe A5225-5 cablethroughthe holein the lowerconsoleandtightenthe jam nut. cl Securethe controlwire to the vent door usingone MS2O392-2C13clevispin and one MS24665-73cotter pin. d) Install the cable clamps.Adjust cable casing for proper operationof vent. Then tighten clampssecurelyto insurecasingdoes not slide when operating the vent control knob. e) Closeand secureupperconsole. 11.230 DoorVent (SeeFigure11-31 The door vent hinge is rivetedin placeand can be replaced,if damaged,by drillingout the rivetsand replacingthe vent door and/orhingeas required. The A226-3seal aroundthe vent door can be replacedif damagedusingB27O4 or B27O-13adhesive. The frictioncan be adjustedon the doorvent by tighteningthe NASl291-08 nut holdingthe knobon the centerpivot of the doublearm linkage. Change4: 1 Jun 97

P a g e1 1 . 5

F|C|E|INEICIN

t47039?I S ?ttt*t!CLEV

\rtr

MAINTENANeE

M('EIEL

MANUAL

F|41t

MSz4665-73 PIN COTTER AN742-3CLAMP scREl'l MS27039C1-06 NUT NAS679A3

C522-5CABINAIR VENTCONTROL

CLAMP AN742-3 SCREW MS27039C0806 hIASHER AN96O-81

NUT NAsozgnoa r ffi

l^IASHER AND JMNUT CABINAIR VENTINSTALLATION

I

/ -sz6o-g SEAL

l'1s204704D3 c285-1KNoB

FIGURE VENT DOOR

P a g e1 1 . 6

Change4: 1 Jun 97

FICIE|INSiCIN

MATNTENANeE MANuAL

MOE'EL

F,44

11.300 ArRCONDtTtONtNc 1 1.301 lntroduction Thissectioncoversmaintenance procedures andtroubleshooting for the optionalcabin ' air conditioning system. , NOTE Air conditioningservice proceduresand required equipment are generally similar to those for standard R134a automotive systems. In the United States, only personnel with EPA certificationunder Section 609 of the CleanAir Act may charge the system with refrigerantor work on the refrigerant system once it has been charged. Differentrequirementsmay apply in countries other than the United States. 1 1 . 3 0 2 D escri p ti o n The optionalcabin air conditioningsystem is shown schematicallyin Figure11-4. The system is similar to conventionalautomotive and light aircraft systems and consists of a compressoraccessiblethrough the left engine cowl door, a condensermountedon the left side of the enginecoolingfan scroll,an evaporatorand fan assemblymounted to the aft cabinwall, an overheadoutlet duct, and interconnectinglinesand hoses. The system uses R134a refrigerant. The compressoris belt-drivenfrom an engine accessorydrive cartridge and equipped with an electromagneticclutch. When the system is off, the compressorclutch is disengaged,allowingthe compressorpulleyto freewheel. The evaporatorfan draws warm cabinair thoughthe evaporatorinletgrilland evaporator where it is cooled. Cooledair is drawn throughthe fan and blown throughthe overhead duct. The system is controlledby a toggle switch on the overheadduct which allowsselection of off , low, and highfan settings. The compressoris automaticallyengagedby switching the fan on. A temperature{freeze)switch disengagesthe compressorwhen evaporator switchesdisengagethe compressor temperaturedropsbelow freezing.Safety (pressure) if excessiverefrigerantleakageoccursor if refrigerantpressureis excessive.A full-throttle switch disengagesthe compressorwhen the engine is near full throttle to ensurethat aircraftperformanceis not affected. The compressorclutch and fan circuitsare protected by the A/C circuit breaker.

Change13: OCT 2006

Page11.7

FIclBINEiClN

LOW PRESSURE CUT.OUTSWITCH OPENSAT 4.6 PSI & closEs AT 32-34 PSI

MOEIEL

MAINTENANcE MANUAL

FI44

HIGH PRESSURE CUT.OUT SWITCH oPENS AT 340-37 CLOSESAT 240.2

\ \

J._.._

iT* ---+J _

COOLEDCABIN AIN THERMALEXPANSIONVAL

TEMPERATURE

TEMPERATURE

=tJ FULLTHROTTLE CUT.OUTSWITCH

C O O L I N GA I R F R O M E N G I N ES C R O L L

j

AMBIENTCABIN AIR

+ 28 VDC

FREEZESWITCH OPENSAT 34OF & C L O S E SA T 3 8 O F

ENGINECOMPARTMENT FIREWALL

SYSTEM FIGURE11-4 AIR COIUOITIONING

P a g e1 1 . 8

Change13: OCT 2006

FIG|BINEICIN

MATNTENANcE MANuAL

MOEIEL

F|44

1 1 . 3 1 0 S yste mT ro u b l e sh o o ti n g Two likely system difficulties are: 1. Failureto cool the air flowing throughthe evaporatorand overheadduct. 2. Excessive conddnsate (water) in the evaporator box area when the system is operating. Failureto cool is most likelycausedby eitherrefrigerantlossor interruptionof the compressor clutch power supply (by one of the in-lineswitches or a wiring fault, see Figure 1 1-4 schematic). Excessivecondensate is most often caused by an improperly assembledor blockedevaporatordrainsystem. Both difficultiescan usuallybe correctedwith minimum effort and expenseif carefultroubleshootingis donepriorto majorcomponentmaintenance. A troubleshootingchart follows.

Cha n g e1 3 : O C T 2 0 0 6

P a g e1 1 . 9

FICIB|NSICIN

MANUAL

MAINTENANcE

MOEIEL

FI44

1 1.310 System Troubleshooting(cont'd) ACTION rnouelesHo oT/GoRRECTVE

R"c".rtr t"f"gerantper.Section11'321' ?y:tgp u' /c shouldoperaienormallyon approxlmately Low RefrigerantCharge/ to 1.25 lb refrigerant. ir"r"s ihun o:i5lb refrigerantis.recovered'leak RefrigerantLeak i;;ip*5t"iiqn tt.szi repairleaksif anv,and reehbroe oerSection11.322 !Vitl',ait"r"ft not running,turn on Masterswitch duct {loWor high on ove-rhead ;;'Alft*iictr to andobserve listen observer Hau" rLttii'tl cowl door' lefl "tt. throush Jlutch ;;;;r%;;"t (click against and.snap engage ci;i;h-ahould pulley)wheneverA/C is switchedon' D798-1 6;;'( ;iii"t ai treezeswitch (behind press-ure Problem Wiring or low Switch evaporatorassembly),high and fullInterruptingComPressor;;iI"h;Jiuerrina lefi'reai seatback),.and (in Clutch Power controltunnel)' Fgpgi' ihrottlecuioutswitch connectors' wiring'or ;;y'eilPged -Section Air is not cold Check 1 1'350' per correct rlgglng each switch. All switches -de with a properlv tharsed "olitinritv"irrrdugh itosEd ;il;id rest on grouncl'Heplace aircraftat system_and FailedComPressorBelt

Inspectbelt.

aLLU"ltper Section11.331as required'

installation(left side of fan -Veirv l".p""t .ondenser no blockage and all seals in ;;;6lli.-

lnsufficient Condenser Airflow and/orrepairsealsto ensure R',Li,?;"blockage airflow through core. Extremetemperatureand hum.iditymay res.ultin ExtremeEnvironmental effeit lessthan a typical automobile' Conditions "ootinq No coirectiveaction available. Voifv tvttem is drainingnormally.After several Blockedor Kinked conditions yi1[11 run.inh-umid 'i';;;;;ier ;fiui#siound EvaporatorDrain Line srroulobe seen drainingfrom the tube. -water drain drainage is not -ob^served,inspect tt drain line (see S-ection1 1.343). Correct any damaqedor kinked lines. Cleansediment.trap is ieduireO. proper function of check

Excessive condensate around DamagedInsulation evaporator assemblyand overheadduct ExtremeHumiditY

P a g e1 1 . 1 0

Verltv evaporatorassemblyald duct insulation ire iri.tattddcorrectlyand undamaged(seeR44 PartsCatalog). Correctany insulationdeficiencies. Some condensationis unavoidablein extreme hum idity. itt frestrair vents closed. Lirnitopening il;"* ana ltosing cabin doors as much as practicalto limit humiiiity enteringcabtn. Changet3: OCT 20Oo

FIGIBINSC|N

MATNTENANeE MANUAL

MOEIEL tr'44

11.320REFRIGERANT 1 1.321 RefrigerantRecovery lf a leak or other service problem is encountered after system is charged with refrigerant,refrigerantmust be recoveredbefore work on system can proceed. AutomotiVe-styleair conditioningserviceequipmentis requiredto recoverrefrigerant. This equipmentis availablefrom many manufacturersin varying levelsof automation and complexity. Minimum componentsincludea vacuum pump, storagecontainer, pressure/vacuumgauge, and appropriate lines and fittings. Ensure equipment is compatiblewith R134a refrigerantand technicianis appropriatelyqualifiedbefore attempting refrigerantrecovery. Automotive-stylehigh and low side system serviceports are located on the vertical firewall insidethe left-handenginecowl door. Connect service equipment to system service ports and recover refrigerant per equipmentmanufacturer'sinstructions. 1 1.322 RefrigerantCharge Automotive-style air conditioning service equipment is required to charge system with refrigerant. This equipment is availablefrom many manufacturersin varying levels of automation and complexity. Minimum components include a vacuum FUffip, pressure FUmp, refrigerant supply, scale to measure refrigerant charge, pressure/vacuumgauge, and appropriatelines and fittings. Servicesystem only with qualifiedbeforeattempting R134a refrigerant,and ensuretechnicianis appropriately refrigerantcharge. CAUTION Properlubricationis requiredto minimizecompressorwear. compressoroil levelper Section1 1.333.5 beforebeginningcharge procedure. The R44 air conditioningsystem is not equippedwith a traditional receiver-dryer.Ensuresystem is under full vacuum to eliminate all moisture before c Automotive-stylehigh and low side system service ports are located on the vertical firewall insidethe left-handenginecowl door. Connectserviceequipmentto system serviceports, vacuum system, and chargewith R134arefrigerantper equipmentmanufacturer'sinstructions.Correctchargeis 1.25 lb (1 lb 4 oz, or 0.567 kg) refrigerant. CAUTION Do not overchargesystem. lf a slow leak is suspected,find and correct per Section 1 1.323 first, then use correct charge.

Change13: OCT 2OOo

P a g e1 1 . 11

FICIBINACIN

MAINTENANeE MANUAL

M('EIEL

F|44

1 1.323 Leak Detection eeui3mentavailable' Leaksmay be detected using severaltechniques,depending.on running' In addition Leakdetection should not be attempted with the aircraft/system with the varying pressuresand to safety hazards,leaks are more ditficult to detect temperaturesof an operatingsystem vacuum at sea level)with An empty system should hold full vacuum |.27to 29 in Hg lf a vacuumedsystem no assistancefrom the vacuum pump ior 2Q minutesor more. should be thoroughly creeps up in pressure,a leak may be present.. Technician and not in vacuum familiarwith vacuum equipmentto ensureleak is in aircraft system equipmentor connections. and water solution I Leaks in a charged system may be detected using a mild soap (bubbles indicate leaks) or applied to lines and fittings in suspected leak areas detector using commercially available electronic refrigerant detectors' Follow if area is quiet or manufacturer,sinsiructions. Largeleaksmay be detectedaudibly by formation of frost in area of leak. NOTE indicatea teak.Normalsystemoperation Frostdoesnot necessarity and/or charging procedurescan cause frost to accumulateon some componenrs.

NOTE System pressureis not a reliableindicatorof chargestate or the pi"."n"" of leaks. Beca134a is a liquid/vapormixture with the system at rest, pressurewill remainconstant as more liquid is lost. ch maioritvof charge vaporizesuntil majority Very small leaks can be detected by chargingthe system with helium gas' Helium moleculesare smallerthan R134a moleculesand will leakmore quickly. Chargesystem soap to 2OOpsi maximum. Use commerciallyavailableelectronichelium detector or and water solutionto locate leaks. Leaksare most likelyto occur at fittings and crimpedtransitionsbetween hard line and flexiblehose. Concentrateinitialleak detectionefforts in these areas.

P a g e1 1. 1 2

Change13: OC T 2OOo

FIC|BINSiC|N

MATNTENANcE MANuAL

M('EIEL

F'44

1 1 . 3 3 0 C OMP R E S S OR 1 1.331 CompressorBelt Replacement Compressorbelt replacementis basedon belt condition. Replaceany belt exhibiting frayed edges,excessivecracking,heat damage,or rubberdeterioration. To replacebelt, loosen NAS66O4 bolt through D782-3 adjustingarm slot, and loosen all three NAS66OGboltsthroughcompressorlugs. Rotatecompressorup and inboard as requiredto disengagebelt from either compressoror drive pulley, and remove belt. CAUTION Do not rotate compressor further than necessary to avoid damageto refrigerantlinesand fittings. Do not use refr ant linesor fittings for leverage;handlecompressorbody or s, Slip new belt over both pulleys,and rotatecompressordown and outboardto tension belt. Tensionbelt such that a 4.5 to 5.5 lb force appliedmid-spanproduces0.14 inch belt deflection. Tightencompressormount and adjustmenthardware. 1 1 . 3 3 2 C o mp re ssoR r e mo va l 1 . R e m ovee n g i n el e ft co w l i n g. 2. Disconnectand remove battery as requiredfor compressoraccess. 3. Recoverrefrigerantper Section 11.321. 4. Disconnectcompressorclutch wiring from airframeharness. 5. Disconnectrefrigerantlinesfrom compressor. Protectall open linesand fittings from contamination. 6 . R e m o veb e l t fro m co mp re ssordr ive pulleyper Section1 1.331. 7. Removethree compressorlug bolts loosenedin step 6, and removecompressor.

Cha n g e1 3 : O C T 2 0 0 6

P a g e1 1 . 13

FIC|EIINSCIN

MOE EL F.44

MAINTENANcE MANUAL

1 1.333 ComPressorInstallation mount lugs and NAS6604 bolt 1. Installcompressorusing three NAS66OObolts at PartsCatalogfor hardware at D782-3 adjustingarm slot. Referto R44 lllustratei compressor' stack up. Leaveall hardwarelooseenoughto rotate 1 1'331' and tighten mount and 2. Installcompressordrive belt, tensionper Section adjustinghardware. (large)fitting to 3. connect refrigerantrines to compressor. Torque row-pregsure (small)fitting Io 210 in'-lb' 3OOin.-lb. Torquehigh-pressure 4. Connectcompressorclutchwiringtoairframeharness. 5 . Check and adjust compressoroil quantityas follows:

Recoverrefrigerantprior to checki outboardsurface a. Removecompressoroil fill cap (blackhex-headcap on upper of compressorbody behindclutch and pulley)' is positioned b. Turn compressorshaft clockwiseuntil clutch platecounterweight p e r F i g u r e1 1 - 5 . 11- 5, and tak e oi l c . l n se rtA i rp roP /N 9 0 -3 0 28 or equivalentdipstickper Figur e l e ve lre a d i n g . 10 notche'' o d. Add A25 7-2O oilas requiredto bring dipstick readingto B to empty Approximately 2 to 3 ounces total oil is required for completely with compressors. Compressorsare typically shippedat least partiallyfilled oil. e . R e i n sta lfil l l ca p . T o rq ueto 156 in' - lb' 6 . P e r fo rmva cu u mo r h e l i u mleakcheckper section 11.323. 7. Chargesystem with refrigerantper Section 11'322' 8. lnstalland connect battery (if removed)' 9 . l n s t al le n g i n el e ft co w l i n g '

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MATNTENANcE MANuAL

DIPSTICK- INSERTINTOOIL FILLER HOLEUNTILSTOP IS FLUSHAGAINST CASE COMPRESSOR

MOEIEL

F'44

COUNTERWEIGHT POSITION APPROX AT 2:30 O'CLOCK

COUNTERWEIGHT

OIL FILL F IGU R E1 1 .5 COM PRESSOR

Ch a n g e1 3 : O C T 2 0 Oo

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MAINTENANeE

MANUAL

M('E

EL F,44

1 1 .340 EVAPORATORASSEMBLY 1 1.341 EvaporatorAssemblvRemoval

,

1. Recoverrefrigerantper Section 11'321' 2. Removeoverheadduct as follows: a. Removescrew aft of rotor brake knob' box and b. Slide duct forward and down to disengagetabs from evaporator windshieldframe. c. Pushrotor brake knob throughslot in duct' d. Disconnectelectricalconnector. e. Removeduct. 3.Removescrews|4eachside)securingheadsetjackboxestoevaporator assembly. NOTE Two differentlength screws and two differentlength spacersare used to mate headsetjack boxes to evaporator. Use caution to retainspacersduringdilassemblyand note hardwarearrangement

for re-assemblv. NOTE coveris securedto the evaporator The entiredecorative(headliner) box via hook and loop fasteningmaterialand may be removedif desired. lt is necessaryto removethe headsethangersin order to removethe cover. ilefer to R44 ltlustratedParts Catalogfor details. 4. Removetrim securingheadlinerbetween seats, and removeleft rear seat back' b. Removeand discardsafety wire, and removedraintube from drain fitting at base of evaporatorbox {right side). 6. Disconnectrefrigerantlines at vertical connectionnuts near upper inboardseat back corner. 7. push back headlineras required,and remove 6 screws securingevaporatorbox flangesto aft cabin bulkhead. Tilt top of evaporatorbox forward and lift up and out. c h a n g e1 3 : O C T2 0 0 6 P a g e1 1 . 1 6

FIclBINEiClN

MATNTENANcE MANUAL

MI'EIEL

]l.44

1 1.342 EvaporatorAssemblyInstallation 1. Secure evaporator box to aft cabin bulkhead using 6 screws through box flanges. ,.

2. O-ringsare cleanand undamaged,and connectrefrigerantline connection lineto 150 in.- lb . n u t s . T o rq u ei n su l a te dl i n eto 210 in.- lband uninsulated 3. Connect drain tube to evaporatorbox drain fitting and secure using 0.032 in diameter safety wire. 4 Secure headset jack boxes to evaporatorassembly. Use screw and spacer arrangementretainedfrom Section11.341or referto R44 lllustratedPartsCatalog for hardwaredetails. 5. lnstalloverheadduct as follows: a. Position duct approximately,feed rotor brake knob through slot in duct, and connect electricalconnector. b. Slide duct up and aft such that tabs engage evaporatorbox fan opening and windshieldframe. c. Installscrew aft of rotor brake knob. 6 . Ve r i fy n o l e a ks{re fe rto S e ction11.323 as r equir ed) .Char gesystemper S ec ti on 11.322. 7. Installleft rear seat back, and secureheadlinerbetweenseat backs usingtrim.

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MAINTENANcE rtnANUAL

Mt'E EL H44

r ra i nS vstem 1 1 . 3 4 3 E va p o ra toD to The evaporatordrain system, shown schematic:llyin Figure 1 1-6, is designed prevent condensatefrom backing up in the evaporatorbox and leaking into the t engercompartment.All componentsarenecessaryfor properdrainage'Blockage near the or kinkingof a drain line may result in water damageto the cabin interior evaporatorbox. The flexibletube drainscondensateto the tee located behindthe right rear seat back. At tee, a sediment-tubeextends severalinches down to a plug. The sediment-tube is designedto allow contaminationto settle out without clogging the main drain system-. Inspect tube periodically. Removeplug and clean out tube if sediment build-upnearstee fitting. Just above tee fitting is a ball retainedin upperflex tube. Normallya small amount of water is retainedin tft" loop formed by draintube and tee fitting. lf the system is dry, the ball seats againstthe tee and preventsthe evaporatorfan from draWingair up through the drain system until water fills this area' The hard drain tube runs along the aft, inboard corner of right-rear baggage compartmentand out the belly. Normalsystemoperationin humid conditionsshould resultin condensationdrippingfrom the tube. In extremelydry conditionsthere may inspectevaporatordrain assemblyto be little or no condensation.Periodically it has not been damagedor dislodged.

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FICIBINSCIN

MOEIEL

R44

EVAPORATOR

DRAINTUBE EVAPORATOR

VERTICAL FIREWALL I FORWARD) TUBE DRAINTUBE

DRAINSYSTEM FIGURE11-6 EVAPORATOR

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FICIBINSGIN

Mt'E'EL

MANUAL

F44

11.35O FullThrottleCut-Out Switch Riggins clutch A full-throttle cut-out switch is designed to disengage the compressor approximately1 inch MAp below {ull throttle. This guaranteesthat air conditioning is operation does not affect aircraft performancea_taltitude. Full throttle cut-out of controlledvia a microswitchlocated near the bellcrankassemblyat the aft end closed the throttle push-pulltube in the main controltunnel. The switch is normally (allows current flow to the compressor)when its button is not depressed. A cam full on the bellcrankassemblydepressesthe button and opens the switch near throttle. Adjust switch so button is depressedby cam when throttle arm at fuel control is 0.15 to O.2Oinch away from full-openthrottle stop'

D731-'tBellCrankAssembly Cam D731-11 PlateAssemblY

MS35206-219 Screw

V3-1 Switch* Screws and Lockwashers suppliedwith Switch

JV-5 Actuatot

C 0 5 9 - 1 8 2W 3 ire

C059-1B22Wire

*Adjust positionof V3-1 switch so that switch opens when fuel controlthrottle arm is o.15 -0.20 off full throttle stop,

CUTOFFSWITCH FIGURE11.7 AIR CONDITIONING {View lookingoutboardfrom centerlinel P a g e11 . 2 O

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FIclBINSiClN

MATNTENANeE MANUAL

MOEIEL

F.44

11.400 DRIVECARTRIDGE 1 1 . 4 1 0 D ri veC a rtri d g eS e a lR emoval 1. Removeengineleft cowling. 2. Disconnectand removebattery as requiredfor access. 3. Loosenbelt tensionand removebelt from pulley. 4 . Re fe rto F i g u re1 1 -7 . R em oveB33O- 19palnutand M S21O42L6nut. 5. Removepulleyfrom shaft to exposeA966-5 seal and woodruff key. 6. Removeseal usingappropriatetool beingcarefulnot to damagehousing. Do not removeshims underseal. 1 1.420 DriveCartridgeSeal Instgllation 1. Ensureseal recessareais cleanand free of debris. 2. Ensureshims are in place,and installA966-5 sealflush with the 3. Installwoodruff key and pulleyon shaft. 4. InstallMS21O42L6nut and specialtorque per Section1.33O. InstallB33O-19 pafnut and standardtorque per Section 1.32O. Apply B27O-22protectorant to exposedsurfacesof shaft. 5 . I n sta l l co mp re sso rd ri ve belt, tension per Section 11.331, and ad j us ti ng hardware.

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MAINTENANCE

MANUAL

Mt:ElEL

H44

PULLEY

ffi DRIVE ASSEMBLY. COMPRESSOR FIGURE11.7 CARTRIDGE

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o 12.

o

FUEL SYSTEM

FICIBINEiCIN

MAINTENANeE MANUAL

M('EIEL

F|44

blank IntentionallY

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FICIBINSCIN

MAINTENANcE MANuAL

M(fEIEL

F|4'T

SECTION12 FUELSYSTEM 12.OOOFUELSYSTEM

:

12.001 lntroduction The fuel system components covered in this section consist of the fuel tanks, fuel on/off valve, gascolator,fuel gages, and low-fuel warning senders.Maintenanceproceduresfor the carburetormay be found in the LycomingOperator'sManual. 12.002 Description The R44 fuel system is itlustratedin Figure 12-'lA. illustratedin Figure12-1B.

The R44 1l fuel system is

The main fuel tank capacity is 31.6 gallons,30.6 gallonsof which are usable. The auxiliaryfuel tank capacity is 18.5 gallons,of which 18.3 gallons are usable. Fuel tank air vents are located insidethe mast fairing,and fuel tank expansionspacesare interconnectedfor redundancy in the event one vent becomes clogged. A coarse finger screen strainer is located at the outlet of each fuel tank. Aux tank fuel feeds into the main tank. Fuel flows from the main tank outlet through an on-off valve located on the forward side of the vertical firewall, then through the firewall to a gascolator(combinationsediment bowl, water trap, and fine strainer). The on-off valve is controlled by a knob located between the forward seats. One electric fuel sender in each tank is connectedto dedicatedfuel quantity gages in the instrument cluster. A LOW FUEL warning light on the upper instrument is actuated by a float switch in the main fuel tank. For the R44, a flexible fire-sleevedhose routes fuel directly from the gascolatorto the carburetorfuel inlet, which includesa fine finger screenstrainer. For the R44 ll, the gascotator incorporatesa pressure switch, which activates the FUELFILTERwarning light if the strainerbecomescontaminated.Fueltravelsfrom the fuel pump, then to the gascolatorto the electricfuel pump, then to the engine-driven fuel control, then to the flow divideratop the enginevia flexiblefire-sleevedhoses. A pressureswitch abovethe electricfuel pump illuminatesthe AUX FUELPUMPwarning light if the electriump output pressurefalls below 23 psi. The electricfuel pump is pump and is capable of supplying more fuel than a- 3o-gph positive-displacement engine demand under all operatingconditions. A return hose from the fuel control inlet to the aux fuel tank allows this excessfuel to recirculateprovidingcoolingof fuel system componentsupstreamof the fuel control. Under low enginedemandsuch as idle. almost all of the electric pump output is being recirculatedprovidingsignificant cooling and improved hot idle performance. Recirculationflow is controlled by a pressurerelief valve mounted above the horizontalfirewall. The relief valve maintains return line and thus fuel control inlet pressureat 28 psi. The engine-drivenpump is also capableof supplyingmore fuel than enginedemandunderall operatingconditions, but has an output pressure of only approximately22 psi. Therefore, if the electric pump is inoperative,the engine will run normally,but the 28 psi relief valve will not open and no fuel recirculationwill occur.

Change9: FEB2003

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MANUAL

MOEIEL]r'44

(cont'd) 12.OO2Desc-riPtion for engine-glgltilg(priming)'but runs necessary "'ftreThe R44 ll electricfuel pump is only in*oh. switcF PRIME(momentarv)position in flight to provide reoirnain"y. After start' the operatesthe elecirlctuel puryb toi'bilffing prior to engine.start' and CLUTCH oil.pressure t:: eng'11e Ioiig;;itie etectriump runs continuously fuel pumps or both either with ". norm-ally switch is ENGAdio. itt" engine*itt oferate pump tunctioiris indicatedby.normal engine functioning. prop"i and before shutdown while "ngin"-Oiiuin-iu.l operationafter enginesJartprior'to-ciuichbngagement, by pullingthe aux fuel conducted 5e tiV afs6 clutch is disenga;;1f. A-utiO "n".rc for troubleshooting' er'if necessary p*p Ut6"-t "it"rii 12.100 FUELTANK 12.11O MainFuelTankRemoval a) Removemast fairing,tailconecowling and left enginecowling. b) Drain all fuel from aircraft. electrical c) Disconnect the fuel quantity sender and low fuel warning light sender leads. upper cross d ) Disconnectboth fuet lines going to fuet tank and plug both ends and feed vent line. engine e) Remove the two forward tank mounting screws, accessiblefrom the left on the forward lefiside of the horizontalfirewall.

f)

"orp"rtr"nt.located Removethe two rear mountingbolts connectedto the upper frame'

s) Removethe three rear screws connectingthe fuel tank to the center bulkhead. h) Removeall forward and lower left sidemountingscrews. Removefuel tank.

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MATNTENANcE MANUAL

FIC|E|INEIGIN

MCIE EL r|44

C 7 3 I . 1 V E N TL I N E S

4729-t7 INTERCONNECTING VENTLINE A689-6FILLERCAP

C028.1MAINFUELTANK FUELQUANTITY SENDER

\T

c550-1 FUELQUANT SENDER

"rl

8254-1 FUEL STRAINER\

8254_1 FUELSTRAINER

(:

A761-1

\

DRAINVALVE

c726-7 t AUX-TO-MAIN,, As21- 1 F U E LL I N E I LOl^lFUEL : l ->J_I St,lITCH

c726-2 I \ \ \

HORIZONTAL FI REWALL B2B3-3 FUELHOSE

C670-1a FUELON/OFF -

V A L V E c7 4 1 _ 1 FUELLINE

CARBURETOR A666-1 GASCOLATOR

FIGURE12.1 FUELSYSTEM(0.540)

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MOE EL F|44

MAINTENANcE MANUAL

FIClEIINEiclN

VENTLINES

AUXFUELTANK

INTERCONNECTING VENTTUBE F I L L E RC A P

FILLERCAP MAINFUELTANK-

FUELQUANTITY SENDER

\t \

)

I

/ FUELQUANTITY SENDER

N AUX-TO-l.,|AI F U E LL I N E

,/,,,. \ STRATNER \'\v r\t t\t FUELDRAIN- l, \ VALVE ----=/FUEL SHUT-OFF tl. illOg

FUEL STRAINER

Ff-1 lt\ .1

t

\

1

st---_ >Yal I \ - l

t

-'

il\-,

LOt,lFUEL St^llTCH \-

FUEL DRAINVALVE FUELRETURN L IN E HORIZONTAL FI REWALL

I

_-:>,Jffirru** __:__=:_S FIREWALL

\

FUELPRESSURE St,lITCH

\ FUEL SHUT-OFF VALVE

\

HOSE(TO FUEL FLOWDIVIDER)

ENGINE.DRIVEN FUELPUMP

FUEL / GASCOLATOR ELECTRIC CONTROL FUEL PUMP FUELFILTER INSULATIoN pur,ip PRESSURE PUMP INTAKEMANIFOLD DIAPHRAGM St,lITCH LEAK-CHECK F U E LD R A I N LEAK-CHECK DRAIN ("SNIFFLE") DRAIN VALVE FUELLINE

F OR W A R D

FIGURE12.14 FUELSYSTEM(IO.54O}

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MATNTENANcE MANuAL

MOE EL 1l,44

12.120 Inspectionand Repairof the FuelTank The interiorof the fuel tank shouldbe inspectedfor signsof peelingof the slosh sealer.lf any indicationsare found,the tank shouldbe re-sloshedwith B27O-3sealant per the manufacturer'sinstructions.Pressurecheckthe tank by pluggingall vents and to 1 psi. Checkfor leakswith a ,:nildsoap and water solution fittings and pressurizing re-sloshing, After ensurethet the vent line is open. Reinstallthe all seams. appliedto low fuel warningswitch. Reinstallthe tank and performa fuel flow check. 12.130 Main FuelTank Installation al Fit the fuel tank in place and installall the forward and left side mounting screws. bl Reinstallthe threerearmountingscrewsconnectingthe fuel tank to the center bulkhead. cl Connectthe two rear mountingbolts and torque per Section1.320. d) Installthe two screwsthroughthe horizontalfirewall,accessiblefrom the left sideof the enginecompartment. e) Connectboth fuel linesand uppercrossfeed vent line. Connectall electrical leads. f) Add two gallonsof fuel to the tank and checkfor leaksaroundthe fuel tank outlets. g) Installmastfairing,uppertailconecoverand left enginecowling. 12.140 AuxiliaryFuelTank Removal a) Drainall fuel from aircraft. b) Removetailconecowling.Openmastfairingfrom right side only. the vent line and fuel quantitysenderwires at the connector. c)Disconnect dl Disconnectthe fuel line at the Aux tank and plug both sides. e) Disconnectforward clamp, holdingrotor brake cable housingto Aux tank channeland removeupperpulleyfrom Aux tank channel. f) Removetwo screwsunderthe Aux tank at the cabinbulkhead. g) Removeall forward mountingscrews.

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Page12.3

FIC|BINSON

MATNTENANeE MANUAL

MC'EIELF,4/I

to CO20-1upper hl Removethe NAS66O4bolt connectingAux fuel tank channel to center cowling frame. Removethe two ttie*s ionilecting the Aux tank bulkhead. i) RemoveAux fuel tank. 12,150 AuxitiaryFuelTank Installation al PositionAux tank in Place. the two under the Aux tank b) lnstall all forward mountingscfew.s.including which connectit to the forwardbulkheacl' torque cl Gonnectthe NAS66O4bolt connectingthe Aux tank to upperframe' per Section1.320. d) Installthe two screwsconnectingAux tank cowl to cabin bulkhead' el Connectthe forward clampwhich holdscable housingto Aux tank channel' Reinstallupperrotor brakepulley. quantity f) Re-connectfuel line going to Aux tank, upper vent line and fuel senderconnector. gl Closemastfairingand installtailconecowling' h) Add a smallamountof fuei to Aux tank and check for any leaksat the fuel tank outlet. 12.160 SumpDrainValveRemoval using 112" deepsocket,removethe valve body from the sump housing 12.170 SumoDrainValve"O" RinoReolacement a) Holdvalvebodyfirmlyand pressin on valvestem' b) Remove"O' ring and rePlace. 12.180 SumpDrainValveReolacement a) Coatthe threadedportionof the valvebody with Bakersealor a suitablefuelresistantthreadsealingcompound' b) Installthe valvein the housingandtorqueto 6O in.-lbs.

Page 12.4

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FIclBINSlclN

o

MATNTENANeE MANuAL

MC'E EL F|44

1

/

FIGURE 12.2 FUELVALVEINSTALLATION

Nul,tsrir

o

7 8 9

NUMBER PARTNO.

DESCRIPTION

PARTNO.

DESCRIPTION

MSl6562-5 c499-1 c 7 91 - 3 c348-1 c79-t-2

R OL LP IN KNOB

10 11

c670- 1 c741.-L

SHAFT ANCHOR

t2

SCREt^J MSz7039C0806 BRACKET c798- 1 F IR EVERTIC AL W A L L( R e f . )

13 14

TUBE 0 . 0 3 2i n . S A F E T Y 15 t,JIRE 16 M S 1 6 5 6 2 - 1 6R OL LP IN t7 c79L-4 SPACER 18 F U E LL INEASSY c726-2

lssued:1 1 J u n 9 3

AN500A4-3 NAS620-4 AN960-8 NAS679A08

FUELVALVE FUELLINE

SCREt^J I/,IASHER WASHER NUT

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FICIBINEICIN

MAINTENANcEMANUAL

MOE ELFd4,

12.200 FUELOUANTITYSYSTEM 12.210 FuelOuantitySenderRemoval hole' a) Drainthe fuel tank untilthe levelis belowthe sendermounting WARNING The masterbattery switch must be off' and remove -' Removethe 5 fastenerssecuring.thesenderunit to the fuel tank b) the senderunit from the fuel tank' fuel al lnstallthe gasketon the senderunit and insertit thru the mount in the tank. b) Installfive boltsand torqueto 27 in'-lb' c) CheckFuelOuantitySenderCalibration' 12.230 FuelOuantitySenderCalibration a) Disconnectthe fuel line from the fuel strainerat the carburetorend and completelYdrainthe fuel tanks. b) Closethe fuel valve. 'one (55 lbs] of clean fuel into main tank ttnis includes c) -' pour g.ZS ga[ons drained .ppio*ir?.iy fiiffon-ui,nicncross feeds into Aux tank plu-s feed. five minutesfon fuel to cross unusableiu;li. Allofr approximately lhe. gage dl Turn on the masterbatteryswitch and readthe fuel qu-antity.gag9, shoutdreiO one-naHneediJ*iOtnto one and one-halfneedlewidths below one-quarterfutl (seeFigure12'4l'.

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MATNTENANeE MANuAL

M(,E EL F|I44

NOTE C a l i b r a t i o ni s r e q u i r e dw h e ni n s t a l l i n g a newsenderor a n e wi n stru mentcluster .

FIGURE12-3

ANDLOl'l FUELSENDER FUELQUANTITYSENDER NUMBER PARTNUMBER DESCRIPTION

4058-9 MS29512-s 5D AN9248289-1 7740-15-423 c550-1 A550I

l s s u e d :1 1 J u n 9 3

Low Fuel Switch Gasket Nut Bo' lt Gasket S e n d e r( M a i nT a n k ) Sender( Aux Tank)

Page12.7

F|clElINSiclN

MOE EL H44

MAINTENANcE MANUAL

\ il 1ao

READING MINIMUM

MAXIMUM READING

CALIBRATION GAUGE F IGU R1E2 -4 FUELQUANTITY

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MATNTENANeE MANuAL

MOEIEL

]l,44

12.230 Fuel,,Ouantity SenderCalibrationfcont'd) e) lf the gage does not give an indicationas describedin Step d), use the followingprocedureto adjustthe fuel quantitysender{float). 1l Removetne tu6l quantitysender. 2l Bendfloat arm up for a gagethat readstoo high. Bendarm down for a gagethat readstoo low. Makeslight bendsand reinstallto checkgage. 3) When the gaugeis calibrated,completethe final installation.Torqueall fastenersto 27 in.-lbs.plus nut drag. 12.240 Low FuelWarningSenderRemoval(SeeFigure12-31 a) Removethe fuel tank per Section12.110. b) Removethe nut securingthe senderto the bottom of the fuel tank, remove the senderwires from the pin connector,and removethe senderthroughthe filler neck in the top of the fuel tank. (SeeFigure12-31 12.250 Low FuelWarningSenderInstallation a) lnstallthe new O-Ringon the senderunit over the threadedportion. b) Tapethe senderleadsto a 3O-inchlengthof safety wire and threadthe wire throughthe fillerneckand sendermounthole. c) With the tank upsidedown, carefullypullthe senderinto place. d) Coatthe threadsof the senderunit with B27O-1.Installthe retainingnut and torqueto 150 in.-lb. e) Installthe maintank per Section12.130.

O

12.260 FuelFlowCheck Fuelflow may be reducedby an obstructionin eitherthe fuel linesor in the vent lines. Whencheckingfor properfuel flow, the fuel tank vents shouldalso be checked. To checkthe vents,openthe mast fairingand attach a hoseto one of the vent lines. With the fuel capson, blow into the hose and feel for air blowingout the other vent tube {Do not use compressed air; the pressuremay damagethe tanks). lf flow is for restricted,check obstructionsin the vent linesor fuel tanks. A fuel flow checkmay be performedwith eitherfull fuel or minimumfuel. Fora 2 gallonsto any emptymaintank.Checkfor checkat minimumfuel,addapproximately properfuel flow as follows:

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. I

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MAINTENANcE

M(fE'ELF,44

MANUAL

al Obtaina containerof known volume: 1 U.S.Gallon 1 lmperialGallon 4 Liters Also havea secondcontaineravailable' b) Turn the fuel valve off and disconnectthe fuel line at the carburetor. to removeair from -' Turn fuel valve on and atlow fuel to draina few seconds c) ini'iyri61n. in"h- nii containerand recordthe time to fill. dl Checkdraintime againstthe chart below: MaximumTime Ouantitv

FullFuel

MinimumFuel

1 U.S.Gallon 1 lmperialGallon 4 Liters

1 min 12 sec 1 min 24 sec 1 min 16 sec

1 min 30 sec 1 min 48 sec 1 min 35 sec

lines, e) lf fuel flow is insufficient,checkfor obstructionsin the gascolator,fuel fuel valve,or fuel tank strainer' 12.27O Low FuelSenderCheck float The low fuel warning light shouldilluminatewhen the low fuel sender the draining on and either drops.ttrt inl i6i,oii 6v tulniiglhe master.battery-switch. fuel the fuet untittn. ir,rii oropJbr by liniiv oepiessingthe float with a stick through the dut doesilluminatewhen depressing filler neck. lf ;;;ingiight odeEnot'ilturirinate test button, replaceihdsender per Section12'240' 12.300 GASCOLATOR tllg Gascolator 12.310 Cleaning a) Removeright enginecowling. b) Turn fuel valve off. bowl clip c) Cut the safetywire that securesthe thumb screw to.the gascolator bowl' the remove an-d side to the clip Uowt tne and loosenthe;;;;.-6;ing d) Cleanthe bowl of any sedimentor deposits'

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MATNTENANeE MANuAL

MCIEIEL F|44

VERTICAL FIREWALL -".

NAS12g1-4, 'NUT \ AN960-416 \ l,lASHER MS20816-6D N IP P L E

G'.,./ :.....,"fu -''1'-'it\-

./

,/

,'

NAs679Ao8

-lg+--

tluo"uroi*t

-\

6P;

A454-1

- MszTo3ecosob SCREt,l

4741-1 FUELLINE ASSEMBLY

A455-1 PLUG

@----t'fr?Bll;uo

A 6 66 -1 GASCOLATOR 8283.3 HOSE ASSEMBLY

A729-8 TUBE 4728-2 STIFFENER

---/

0 . 0 3 2i n . SAFETYHIRE

(2 P L ' c s . ) BELLY

NAS557-8A GROMMET

12-5 GASCOLATOR INSTALLATION FIGURE

lssued:1 1 J u n 9 3

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MAINTENANeE MANUAL

MOE,ELF44

e) Rembvethe gascolatorfilter screenlocatedin the cap and clean' f) Reinstallfilter screenand bowl. Swing bowl clip underthe bowl and tighten the thumb screw. gl safety wire the thumb screw to the bowl clip using0.032 inch wire' h) Turn fuel valveon and checkfor leaks' i) Installcowling. Connectair intakehose' Removal(SeeFigure12-5) 12.320 Gascolator a) Removeright enginecowling. b) Turn the fuel valveoff. c) Drainthe gascolator. dl Disconnectthe fuel linesfrom the gascolatorand plug the open end. e) Removethe gascolatormountingstud nut and remove. (SeeFigure12-5) Installation 12.330 Gascolator a) Installthe gascolatormountingstud throughthe firewallmount,Installthe nut and torqueto 70 in.-lbs. b) uncapthe fuel linesand connectto the gascolator. c) lf necessary,aligndrainwith hole in bellyby rotatingthe sedimentbowl. dl Turn the fuel selectorvalveon and checkfor leaks' e) Installthe rightenginecowling. Connectair intakehose.

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13 SECTION INSTRUMENTS 13.OOOINSTRUMENTS 13.001

Introduction

13.002

Description

13.100 PITOT. STATICSYSTEM 13.200 FLIGHTINSTRUMENTS 13.210

Airspeedlndicator

13.220

Altimeter

13.230

VerticalSpeedIndicator

13.24O

OutsideAir Temperature

13.250

Com

INSTRUMENTS 13.300 DRIVETRAINAND POWERPLANT 13.310

Engine- RotorTachometer

13.320

ManifoldPressureGauge

13.330

CarburetorAir Temperature

13.340

EngineInstrumentsCluster

13.341 Oil Pressure Gauge 13.342 Oil Temperature Gauge 13.343 CylinderHeadTemperature Gauge 13.344 FuelOuantityGauge 13.345 Ammeter 13.400 TROUBLE-SHOOTTNG GUtpE

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SECTION13 INSTRUMENTS 1 3 . O O OI N S T R U ME N T S 1 3 . O O 1 l n tro d u cti o n

t This section containsa basicdescriptionof instrumentationinstalledin R44 Helicopters, procedures. generalmaintenanceproceduresand trouble-shooting 1 3 . 0 0 2 De scri p ti o n Standard flight instruments include an airspeed indicator, dual (engine and .rotor) tachometer,-sensitivealtimeter, manifold pressure gauge, vertical speed indicator and magnetic com. Engine cluster gauges include an ammeter, oil pressure, oil temp-erature,cylinder head temperature and fuel quantities. Also provided are a carburetorair temperaturegauge (for carburetedengines),a clock and a digitaloutside air temperature gauge. An hourmeter actuated by engine oil pressure (and collective switch on Raven)is locatedto right of pilot's seat. SYSTEM 13.1OO PITOT-STATIC The pitot-static system supplies air pressureto operate airspeedindicator, altimeter, and vertiial speed indicator. The pitot tube is located on front of mast fairing above cabin. Dual static ports are locatedaft of rear engerdoors;one on each side of cabin. Water can be drainedfrom pitot-staticlines by removingplasticdrain plugs which are accessible through removabteinspectionon undersideof cabin. Drainingthese linesshouldonly be requiredif operatiohof airspeedor altimetersystems appearerratic. Openingsof both pitot and static sourcesshouldbe inspectedfrequentlyfor bugs or other obstructions. 1 3 . 2 0 0 F L I GH TIN S T R U ME N T S Referto Section2 of R44 Pilot'sOperatingHandbookfor specific instrumentmarkings. 1 3 . 2 1 0 Ai rsp e e dIn d i ca to r The airspeedindicatordisplaysairspeedin knots and miles per hour. Airspeedindicator will be operativein forward flight only. Backwardor lateralflightwill not indicatecorrect airspeed.The airspeedindicatorwill indicateforward airspeedsup to a maximumof 130 knots (RedLine).

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.STATIC VERTICAL PRESSURE SPEED AIRSPEED PORT INDICATOR INDICATOR \

e

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H44

B240-2 B L I N DE N C O D E R

I

)tL

) TRANSPONDER

\ ALTIMETER

l

TO PITOTTUBE

(VIEWLOOKINGAFT) PITOTTUBE

TRANSPONDER

B.240-2 B L I N DE N C O D E R

STATIRESSURE PORTS (LH & RH FUSELAGE S}

DRAINPLUGS

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13.211Pitotlineleaktest CAUTION Do not applysuctionto pitot systemor pressureto static system 1 . Method 1: Usinghand pump a. Seal pitot tube drain hole with pressure sensitive tape. Attach flexible tubing and hand pump unit (60 ml syringelto pitot tube with pump plungerat top of cylinder. b. SLOWLYapply pressureto pitot line by depressingpump plungeruntil airspeed indicatorreads 80 mph (7O knots). Pump plungerwill remain in place without needto pinch off flexibletubing. c. Gently tap airspeedindicatorglass to remove friction effects. d. lf indicator pointer drops more than 10 mph (8-9 knots) in one minute, an unacceptabteleak is indicated.After leak has been repaired,retest per sections (a)thru (d). e. Removetape from pitot tube drain hole and airspeedindicatorgoes to zelo. f. Remove test apparatus from pitot tube after acceptable test results are obtained.

2 . Method 2 : Usingflexibletubing a. Seal pitot tube drain hole with pressuresensitivetape. Attach flexibletubing to pitot tube. b. SLOWLYapply pressureto pitot line by rollingflexibletubing around rolleruntil airspeedindicatorreads80 mph {70 knots). Pinchoff pressuresupplyat flexible tube. c. Gentlytap airspeedindicatorglassto removefriction effects. d. lf indicator pointer drops more than 10 mph (8-9 knots) in one minute, an unacceptableleak is indicated.After the leak has been repaired, retest per sections(a) thru (d). e. Removetape from pitot tube drain hole and airspeedindicatorgoes to zefo. f. Remove test apparatus from pitot tube after acceptable test results are obtained. 13.22O Altimeter The altimeterprovidesaltitudeinformationrelativeto sea levelwhen barometriressure correctionscale is properlyset. Check altimetercalibrationby setting correctionscale to presentaltimeteisettind and checkingaltimeterreadingagainstfield elevation.They must agreewithin 70 feet. Cha n g e1 2 : J U L 2 0 0 5

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13.221Staticlineleaktest CAUTION altimeterand vertical When applyingsuction to static line,-airspeed,. is appliedor removed if suition 5p,e;Ainiid"tjrs miv Ue damaged rapidly. 1. Method 1: Usinghand PumP a . Set altimeterto field elevation. b . Seal static openingwith pressuresensitivetape. Attach flexibletubing and hand pump unit to static line at drain with pump plungerdepressed. SLOWLYapply suction to static line with hand pump until altimeterreaches5OO ft. greateriti"n ti"tO elevation. Pumpplungerwill remainin that position. d . Gently tap glass on altimeteruntil rate-of-climbindicatorhas stabilized. After

stabilizationlahimeter should be adjustedto the next higher 1OOfoot mark and then timed for one minute. Change of less than 100 feet in elevationin one minute is acceptable.

e . SLOWLY remove suction from static line' f . After leak has been repaired,retest per sectionsa thru e. g. Removetest equiPment.

2 . Method 2: Usingflexibletubing a. Set altimeterto field elevation. b. Seal static opening with pressuresensitivetape. Prerollflexible tubing around roller so that suction may be produced by unrolling.Attach flexible tubing to static line at drain. SLOWLYapply suctionto static line with hand pump until altimeterreaches5OO ft. greaterihan field elevation.Pump plungerwill remainin that position. d . Gently tap glass on altimeter until rate-of-climbindicatorhas stabilized.After stabilizationlahimetershouldbe adjustedto next higher 100 foot mark and then timed for one minute. Changeof leis than 100 feet in elevationin one minute is acceptable. e . SLOWLYremovesuction from static line f . After leak has been repaired,retest per sectionsa thru e. g . Removetest equiPment.

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13.230 VerticalSpeedIndicator The vertical speed indicator provides rate of ascent or descent. Check vertical speed indicatorfor a zero rate needleindicationwhen rotorcraft is stationary. 13.240 OutsideAir Temperature(OAT) The outsideair temperatureindicatorhas a stainlesssteel probe protrudingfrom chin of rotorcraftand is connectedto gaugeby a calibratedlength of cable. NOTE No cutting or splicingof OAT probe wires is permitted.

INSTRUMENTS 13.300 DRIVETRAINAND POWERPLANT 1 3 . 3 1 0 E n g i n e- R o to rT a ch o me ter The R44 is equippedwith one electronicdual (engine and rotor) tachometer. The sensorfor enginetachometeris breakerpoints in engineright magneto.Sensorfor rotor tachometeris an electronicHall Effect device which sensesageof two magnets attached to main rotor gearbox input yoke assembly.Each tachometer circuit has a separatecircuit breakerand is completelyindependentfrom the other. They can be powered by either alternator or battery even if "MASTER BAT" switch is turned off. With alternator,battery and electricalcircuits functioning normallytachometerpower will be interrupted only if "MASTER BAT" and "ALT" switches are turned off and "CLUTCHENGAGE"switch is disengaged.

CAUTION can affect accuracyand reliability of electricaldevices Installation of electronictachometers. Therefore,no electricalequipment may be installedin the R44 helicopterunless installationis RPMof engine,engine specificallyapprovedby RHC. At l OOo/o and rotor tachometer needles must indicate lOoo/o + 1o/o. For adjustmentof rotor tachometer,see Section 14.1OODual TachometerAdiustment.

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1 3 . 3 2 0 M a n i fo l dP re ssu reGa u g e pressure-inengine The manifold pressuregauge providesan indicationof absoluteair intake manifold. neO tiile dn gauge indicatesmaximum manifold pressurefor which ioiorcraft is type."rtiti".t"d at-1odw rotor RPM.Manifoldpressuregaugeshouldindicate within 0.3 incher Hajoi;.bient barometriressurewhen engineis not running. 13.330 CarburetorAir Temperature A carburetorair temperaturegaugeon is used to determinewhen carburetorheat Applv i. ;;q"f"d durinj p"iriUiJ cirbu-retor-'icingcondition_s,such as high humidity. gauge air temperature Carburetor y_elpw band. of neai ii requireOio keep needle out sfroufdread approximatblythe same as QAt gaugewhen engineis cold' t l u ster 1 3 . 3 4 0 E n q i n el n stru me n C 1 3 . 3 4 1 Oi l P re ssu reGa u g e The oil pressuregauge indicatesengine oil pressureand receivesits signal from a variable-r"ririoi-ivi" iJnOer loca-ted in ieft-hand forward corner of engine compartmentnext to hourmeterpressureswitch. Ga u ge 1 3 . 3 4 2 Oi l T e mp e ra tu re The oit temperaturegaugeindicatesengineoil temperatureand receivesits electrical piob." -"orntea in engine oil pressurescreen housing or oil filter iig"Jf t-"i " adapter. Gauge 1 3 . 3 4 3 C yl i n d e rH e a dT e mp e r atur e of cylinder#2 (0-540), The cylinderhead temperaturegaugeindicatestem_perature probe installedin bottom a from signal its cyfindbi #1 or-iS tlo-b o) and-rec'eives of cylinderhead. 1 3 . 3 4 4 F u e l9 u a n ti ty Ga u se The fuel quantity gauge indicatesfuel level and receivesits signalfrom a variableresistor-tybeftodt indi6ator(see Section 12.000 for adjustment).

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13.340EngineInstrument Cluster(cont'd) 13.345Ammeter The ammeterindicatesloadsin electricalsystem.The systemloadsare measuredat shuntlocatedon lowerright-hand in the enginecompartment. sideof verticalfirewall 13.4O0TROUBLE.SHOOTING GUIDE Trouble-Shooting Chart lnstrument

Problem

ProbableCause

1. Blockageof pitot tube. pitot tube. 2. Disconnected No Indication

3. Kinks(bends)in pitot lineunder upperconsole. 4. Defectiveindicator.

Airspeed lndicator

Loose pitot or static line connection. Erraticlndication

2. Brokenpitot line. 3. Water in pitot-staticsystem. 4. Defectiveinstrument. 1 . Blockagein static line.

Altimeter

No lndication Erraticlndication Climb indicationwith no returnto zero in levelflight.

VerticalSpeed lndicator

2 . Defective instrument. 1. Water in static line. 1. Blockagein the static line.

1 . Waterin static system. Erraticlndication No Indication

2 . Defectiveindicator. 1. Defectiveindicator.

NOTE For trouble-shooting procedures for instruments,see Section 14.000.

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ELECTRICAL & AVIONICS

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SECTION 14 ELECTRICAL AND AVIONICS SYSTEMS 14.OOOELECTRICAL ANDAVIONICS SYSTEMS 14.OO1Introduction 14.OO2Description 14.100 DUALTACHOMETER ADJUSTMENT 14.2OO LOW RPMWARNINGUNITADJUSTMENT 14.300 CHARGING SYSTEMVOLTAGECHECK

14.400 TROUBLE-SHOOTING 14.405 A569 Low Rotor RPM WarningUnit 14.41O ElectricalTrouble-Shooting 14.420 InstrumentTrouble-Shooting 14.430 ClutchActuator ElectricalTrouble-Shooting 14.440 ElectricallyPoweredInstrumentsAccuracyCheck 14.500 COMPONENT LOADS 14.600 ELECTRICAL SYSTEMSSCHEMATICS 14.7OOELECTRIC TRIM SYSTEM 14.710 Trim ControllerAdjustment 14.720 Trim System ElectricalTroubleshooting 14.800 ANTENNALOCATIONS 14.9OOAVIONICSSCHEMATICS

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F|44

SECTION 14 ELECTRICAL ANDAVIONICS SYSTEM 14.OOOELECTRICAL ANDAVIONICS SYSTEMS 14.0O1 lntroduction This section containsinformationfor correctingdifficultiesthat may arise in the electrical system. lt includesa generaldescriptionand some test and adjustmentprocedures. 14.002 Description 14-volt electricalsystems includea 14-volt, 7o-amperecapacity alternator(limitedto 50 amps continuous),battery relay,alternatorcontrol unit and 12-volt battery. 28-volt electricalsystems include a 28-volt, 7O-amperecapacity (limited to 64 amps continuous) alternator, battery relay, alternatorcontrol unit, and 24-volt battery. A 130amp capacityalternator,limitedto 85 amps continuous,is standardon the Policeversion. The bafiery is in a fiberglasscontainerlocatedon the lower left steel tube frame, in the nose underthe upperconsole,or in the left-frontbaggagecompartment. Policeand E.N.G. versionshave the battery suspendedfrom the tailcone. Circuit breakersare located on the ledge just forward of the left-front seat. The breakers are markedto indicatetheir function and amperageand are of the push-to-resettype. The master battery switch, located on the console, controls the battery relay, which disconnectsthe battery from all circuits except the tachometer and the clock. The tachometerand the clock also receivepower directlyfrom the battery via a Clutch switch terminal. The alternatorcontrolunit (ACU)sensessystemvoltageat the ammetershunt via a remote sensewire. The 14-voltACU has three f unctions: it regulatesalternatoroutput voltageto maintaina battery voltageof 13.7-13.9 volts, it warns of low-voltageby illuminatingthe ALT warning light if voltagedecreasesto 12.55-12.95 volts, and it protectsagaingtov_e_rfield if voltage increasesto 15.75-16.25 volts. The 28voltage by shutting off alt-ernator volt ACU alsohas three functions: it warns of low-voltageby illuminatingthe ALT warning volts, it protects against over-voltageby shutting light if voltage decreasesto 24.OO-26.OO off alternatorfield if voltage increasesto 32.00-33.4O volts, and it regulatesalternator output voltage by modulatingfield current within a 0.25-1.00 volt window centeredat 28.25-28.75 volts. This allows alternatoroutput to more closely follow electricalload demandsand reducesvoltagefluctuations. In additionto a circuitbreaker,the clutch actuatorcircuit incorporatesa low-amperagefuse to preventa motor overloadfrom trippingthe circuit breakerand turning off the CLUTCH light prematurely,and to preventmotor burnoutdue to prolongedmotor overload.This also resultsin drive belt overtensioningprotection. A time delay is also includedin the circuit to prolongactuatorspringswitch life, and to preventovertensioningdue to springswitch flutter resultingfrom excessivevibration. The time delay affects gearmotoroperationonly during Engagecycle; the time delaydoes not affect CLUTCHlight operationand does not functionduringDisengagecycle. The time delayallows gearmotoroperation0.25 seconds after circuit completion(indicatedby CLUTCHlight illumination). Any circuit interruption (indicatedby CLUTCHlight extinguishing)instantlyresetsthe time delay. Ch a n g e1 0 : JU L 2 0 0 4

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{cont'd) 14.002 DescriPtion light,navigationlights,two landinglights, ' The lightingsysteminctudesthe anti-collision map light' Landinglightsare post and internallightsfor.instrumenisino an-overhead didengaged'Postandinternal wiredthroughtne ciutifr switch,triiinJ n"lignt" off when rheostalon early 14-v.olt.ships, it ia]r.iJtubrJvia a irvire-w_ound instrumentlight brig#; dimmer The electronic or via an electronicdimmeron lateii+-uoit and all 28-voltships.will is short when reset will shut down lt'"""i,.inl"ring a irro'rt-t;:g;Jundcircuiudimnier cleared. pressure,low fuel' main Waminglightson the instrumentincludeclutch,low oil iighit, tiin totor gearboxover-temp,enginefire.{sensor rotor and tail rotor ;;;d;;oF), "f'rip low .'otoi-npMtiglrl,lovivoltage(ALT),rotor brake,andstarter --wi1 275 + 1O activatesat

ffi;!"!-.

rr.

warning lights.

in"iroJtueititier,auxfuil pump,andcarbonmonoxide "Joiti6hJrv

cylinder head I The gage cluster includes an ammeter, oil .pressure,oil temperature.'circuit are the on.this irriduintiii"t. temperatureand riin ina-u*iti.ry '"ny) {ts9 nro_vra.ea air terirperature.outside and fhe.f9p. light is on carburetor.ir t".p"iutui" to:S4O lightingsystem the same breatcer?l u Uu"i.-upln itre'event of a short and failure of the circuit. The sensorfor the The tachometer is an electronicengine and rotor dual tachometer. (helicopter magneto engine-right in the points) Jr uiJemurv tFr*t enginetach is . rtteli sensorfoi, and receivingpower from, the rotor tachometersenses r"iiria"i. A Hall"onti"i

fromthesesensors Sisnals input.voke. -Each th".;4" rotot.se"rSox b;;*dbrt*o rnl;;;i;; circuit tachometer ""oriJ.ijte iachometer. dual the circuiilinlia6 uv areconditioned They can be independentof the other. Ur*ier and i" has a separate "o-pretely ieceive current from two redundant a.nd "il"uii the alternator oi1h" ubtt"ry po*"rro-uv the masterbattery and alternator only.when powerto "itrrrr the tachometeris interrupted sources. operateon 14 volts; rul tachometers ai;"ng"gub. -"hin switchesare off and the clutch swiic'trii 14 volts requiredby the to ge volts 28 to zii-""riinlpi Jtitir" two voltag" r"tuiutoir both tachometers. CAUTION ?nq of electricaldevicescan affect-the accur?cy .jf The installation qefre, no eleitrical

r.j ihe o iii' ia;'iiomet-e ii"biiiw ili i'e Htr;'ri;iiad unlessthat ii4+. hbticopt6r"; Ll6l".ini'miv-d;fi bt I n lly .lhJ ry. f acto ihe by approved a iribCrtic ii: ;;ft6ri;i' ini'iiilaiidn' CAUTION are When installinqupper console,ensuremulti-p-inconnectors have

1 connector of numb.er' -C;osiin #;i;i.r;i;;;;;%iif.'-bdih'I';ffei I' i^i[iiilsir-,p'e.!' iiinheltions wilI result in damage to

electricalsv'stem.

right-sidecircuitbreaker9l ll" E.N.G.and policeversionseachhavean additional, for the optionalE.N.G' breakers ledgejust forwaroof t!9 nilot;sseai-contuini"g-uit'"irEuit to a 28-voltbus. or policeequipmeni.tr,Jt"rward ro* of circ-uitbreakersis connected whileon versions the aft row of circuitbreakersis conneciedto a 14-voltbus on E.N.G.is connectedto a aft row of circuitbreakers irr" ouiui"ra section-'of-the iifi* 28-to 14-voltconverter'A gepapteMaster a "*rion" bV -volt powered is bus. The i+--uoirUus 1 pan"lcontrolspowerto all E.N.G.or police switchon the left sideof the "ir"uii'nreulier equipment. Page 14.2

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14.100 DUALTACHOMETER ADJUSTMENT The C792 DualTachometeris pre-setat the factory. Slightvariationsbetweenrotorcraftmay requirereadjustmentof the rotor side of the tachometer. To adjust: 1. Removescrews securinginstrument,faceto upper consoleand carfullypull face aft. 2. Groundrun the helicopterat'lO2o/oenginetachometerindication.Adjust screw on back of tachometerso rotor tachometerindicates1O2%. Turn adjustmentscrew clockwise to increaseand counter-clockwiseto decreaserotor tachometer indication(O.4 turn 17ochange). equalsapproximately 3. Installface. 4. lf tachometercannot be adjusted,replaceor returnto RHCfor repair. 14.2OO LOW ROTORRPM WARNINGUNIT ADJUSTMENT When the collectiveis raised0.2 to O.4 inches (measuredat grip) above fully down, the low-rotor RPM warning unit must activatethe low-rpm warning horn and low-rpm light at 97o/oto 96% rotor RPM; horn and light mustturn off above g60/oto 97o/orotor RPM. The low rotor RPM warning unit is insidethe upper console mounted on the left vertical . Adjustmentsare made by turningan exposedscrew on warning unit, accessibleby removinga black-plastilug from a 3/8-inchdiameterhole on the left vertical.The A569 wbrningunit's adjustmentscrew sensitivityis approximately2 turns per 1% change. lf warning unit cannot be adjustedto rangestated above, it must be replaced. 14.300 (RESERVED) 14 . 4 0 0 T R O U B L E -S H OOT IN G Followingare some troublesand corrections.When investigatingtrouble eliminatecauses one by one, beginningwith the most probable. 14.405 4569 Low Rotor RFM WarningUnit Performfollowingtests prior to replacingA569 low rotor-rpmwarning unit: 1. : a. Low RPM light bulb is functional. b. Master switch off. c. Full-downcollective. d . H o r n ci rcu i tb re a ke ri n . 2. Accessand disconnectboth horn and A569 low rotor-rpmwarningunit from airframe electricalwiring. 3. Turn Masterswitch on and Horn Start circuit breakerremainsin. lf Horn Start circuit breakerpops then -70 wire is shorted to ground; repair as required. Turn Master switch off. C h a n g e1 3 : O C T 2 0 0 6

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( cont' d) 1 4 . 4 0 5 A 5 69 L o w R o to rR P MWar ningUnit a jumper between wires 4. On the warning unit's airframeelectricalconnector,install - 7 0 & - 7 5. breaker remainsin. lf Horn b. Turn Master switch on and Horn start circuit -75 wire and/orcollectivestart circuit oiu.["ipops then a ihort-to-groundexists in activatedV3-1 switch; repairas required' remainsin and Low RPM 6. Fully raise collectiveand Horn Start circuit breaker exists in light illuminates. lf Horn Start circuit breakerpops I!9n- a short-to-ground as required' repair V3-1 switch; -76 wire and/or-78 wire and/orcoliective-activated V3-1 switch is faulty collective-activated then lf Low neU tilfrt Ooesnot illuminaie -76 wires' an open exists in -70, -75, or or misadjusted'and/or manipulating 7. Slowlyraiseand lower collectivefully severaltimeswhile simultaneously RPM light remains throttle. Vurity Ho. Start circuit'breakerremainsin and Low Start circuit breakerpops then illuminatedwhenevercollectiveis raised.. lf Horn -70, -75, or -76 wires and/or collectivea short-to-groundconditionis tccurring in wiring pinched/rubbing activatedV3-1 switch due to collectivemovement. Checkfor and repairas required. 8. Turn Master switch off. Connecthorn to airframewiring. g. Turn Masterswitch on. Raisecollectiveand horn activatesand has consistent -78 wire is shorted tone. lf Horn Start circuit breakerpops then horn is faulty and/or -79 wire is open or horn to ground; repairas required. ff hbrn fails to activatethen andlor poor is faulty; ,"p"i, as required. lf tone is inconsistentthen horn is faulty connectionsexist; repairas required. 1 0 . C h e c k4 9 9 9 ma ste rra d i ore l a ycur r entdr aw: a. Master switch off and belt tension actuatorfully disengaged. place an ammeter in b. DisconnectA569 low-rpm warning unit's connector and of s e r i e s (p o si ti vel e a d o n p i n 10) between pins 10 and 11 on air fr amesi de connector. off, c. Master switch on, Horn start and clutch start circuit breakersin, avionics rotor brake released,mixture at idle cut-off' and-crankengine' Note d. Select key switch to Start (Both on Ravenlls) position_ switch to and recordcurrentdraw at ammeterwhile crankingengine.Selectkey O f f p o si ti o n . (do not let e. Disconnectb82 wire at tab on starter solenoidand isolateconnector draw at it groundi. Select key switch to Start position.Note and recordcurrent buz z i ng a and a m m e te r;fo r 1 4 -vo l tsystemscur r entshouldbe 94- 156 m illiamps current sound should be heard from the starter vibrator (for 28-volt systems key Select noise). no make should shouldbe 40-70 milliampsand startervibrator switch to Off Position. C h a n g e1 3 : O C T 2 0 0 6

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14.405 4569 Low Rotor RPMWarnins Unit (cont'd) 1 1. Checkstartercircuit: a. Master switch off and belt tension actuatorfully disengaged. b . D i s co n n e ct4 5 6 9 l o w -i p m war ningunit' s connectorand jum p pins 1Oand 11 on airframeside of connector. c. Master switch on, Horn Start and Clutch Start circuit breakersin, rotor brake released,mixture at idle cut-off. d. Select key switch to Start positionand crank engine. lf engine does not crank there is a problemin the startercircuit. lf enginecranksthen there is a problem in eitherthe A569 unit or the sensecircuit. 1 2 . C h e c kA 5 6 9 se n seci rcu i t: a. Master Switch on. b. Momentarilyengage clutch and Clutch light illuminatesthen disengage clutch completely(switch to remaindisengagedthroughoutthis sequence). c. Masterswitch off. d. DisconnectD6O2time delay connector.Groundairframe-sideplug's pin 1 thru a suitablevoltage (post-lighttype) lamp.

CAUTION Failureto ground p i n 1 thru a suitablevoltage lamp (such as direct grounding) result in wirinq d e. lessthan 2OOohms (20 ohm nominalfor 14-volt system;70 ohm nominalfor 28-volt system)to groundat pin 4 and at pin 5 on ship side of A569 connector. f. Master switch on. g. With A569-5 unit connectedto airframeharness, voltagedoes not exceed O.5V from pin 4 to groundand from pin 5 to ground. h. Master switch on, Horn Start and Clutch Start circuit breakersin, rotor brake released,mixture at idle cut-off. i. Select key switch to Start positionand crank engine. Failureof engineto crank indicatesproblemin A569 unit. 13. Upon completionof precedingtests, a faulty A569 low rotor-rpmwarning unit may be replacedand adjustedper Section 14.2OO. C h a n g e1 3 : O C T 2 0 0 6

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14.41 0 ElectricalTrouble-Shooting TROUBLE

PROBABLECAUSE

CORRECTION

1. No electrical power

Batteryterminalscorroded

Cleanter m inals

Bad or no ground

Cleanground Path

Trippedcircuit breaker

Check circuit, if circuit checks ok, reset circuit breaker

Low batterY voltage

Check battery. Rechargeif necessary

wiring, Low or no alternatoroutput Check alternatorbelt tension, and alternatorcontrol unit

2 . E n q i n ec r a nks slo-wly,but will not start

Bad wire or terminal Low battery voltage

Replace

lnsufficient drive belt deflection

Adjust actuatordown-limitscrew

Serviceor rePlacebatterY

Corrodedor dirtY batterYor Cleanterminals starterterminals ReplacedefectiveParts Bad starter relay, wires or terminals 3 . E n g i n ec r an ks, Key switch in OFFPosition Placeswitch in BOTH Postition (ro-540) but will not start Replaceswitch Bad ignitionswitch'

4 . Starterfails to operate

Page 14.4

Bad startingvibrator

Repairor replacevibrator

Incorrectretardtiming Rotor brake engaged

Adjust retardmagnetointernaltiming Releaserotor brake

Low battery charge

Check and rechargeif necessarY

CircuitbreakerstriPPed

Resetboth HORNSTARTand CLUTCH STARTcircuit breakers

Actuator not fullY disengaged

EngageactuatormomentarilY,then fully disengage

Looseconnections

Check all wiring (referto wiring diagr am) .

Defectivewiring

Checkall wir ing ( r eferto wir ing diagr am) .

Startermotor - burned w i n d i n go r b a d br ushes'

Repairor replacestarter.

F a u l tyA 5 6 9 l ow- RPM w a rn rn gu n l t

Check unit per Section 14.405 C h a n g e1 3 : O C T 2 O O o

FICIBINEiCIN

MATNTENANcE MANUAL

MI'EIEL

N,44

(cont'd 14.410 ElectricalTrouble-Shooting TROUBLE 5)

I

Discharged

,

PROBABLE CAUSE

CORRECTION

Batteryworn out

Replacebattery

Chargingrate not set correctly

Checkalternatorcontrol unit output. Replaceif below 13.4 volts

Standingtoo long

Removeand rechargebattery if left in unusedhelicopterfor four or more weeks.

6)

Starter- tow crankingspeed

Sameelectricalcauses as listed under "starter fails to operate"

Sameremedieslistedfor those troubles.

7l

Batterylife is short

lmpuritiesin electrolyte

Replacebattery.

Low chargingrate

CheckACU output. lf below 13.4 volts replacethe unit.

Electrolyteruns out of battery

Too much water added to battery.

Drainand keep batteryat proper fluid leveland specificgravity.

Chargingrate too

Checkthe ACU output voltage.Replaceif necessary.

8)

high.

9)

Excessive electrolyteinside container

Ch a n g e1 4 : J UL 2 0 0 8

Spillagefrom overfilling Use care in addingwater.

Vent linesleakingor clogged

Repairor clean.

Chargingratetoo high

CheckACU output voltage. Replaceif necessary.

Page14.5

tt

FICIBINEiCIN

MAINTENANeE MANUAL

MOE EL R44

(cont'd 14.410 ElectricalTrouble-Shooting TROUBLE 1O) Batteryconsumes excessivewater

CAUSE PROBABLE

CoRRECTIOI_{

,

Chargingrate too high (if in CheckACU outPut voltage.RePlaceif all cells) necessary.

ACU failureOPenfield 1 1 ) Alternatorfails to circuit wiring supply charging current with engine operating.

CheckACU outPut voltage.RePlaceif necessary.RePairor replacewiring to field circuit.

Retardbreaker in 12t, Starter kicks back the engineleft magneto while cranking (may cause broken pushedout or no connectionbetweenthe starter or starter lead and the magneto ring gear)

Measurethe retard breakerlead connection. Connectorlead must be 0.609 in. + 0.1O.Ther e must be a small amount of springbackwhen the connectoris Placedinto the magneto.

Incorrectignitionvibrator wiring

Trace ignitionvibrator wiringfrom ignition switch to magneto. Correctas required.

Bad ignitionswitch

Replaceignitionswitch.

Bad ignitionvibrator

Replacevibrator

Incorrectinternalmagneto Correctas required ConsultTCM Aircraft retard breakertiming. Productsliterature. Engineleft magneto Opencircuitin ignition vibrator wiring circuit

P a g e1 4 . 6

Repairor rePlacewiring for ignitionvibrator

Change14: JUL 2O0B

FIClBINsiClN

MATNTENANcE MANuAL

MOE EL F|44

(cont'd) 14.430 Clutch Actuator ElectricalTrouble-Shooting

TROUBLE

PROBABLE CAUSE

Actuator diserigaged will not engage WARNING(yellow)

Lighton X X X X

Lisht off

X X X X

Change1 4 : J U L 2 0 0 8

1) 2l 3) 4l 5) 6) 7l 8)

M otor seized. Motor fuse blown {3-amp). Open circuit in motor wiring. Overtravelswitch assy tripped. No voltageat circuit breaker. Circuitbreakertripped. Up limit switch stuck (Normallyclosed). -88 wire not grounded.

Page 14.7

FIElElINEiClN

MAINTENANcE

MANUAL

MOEIEL

FI44

CAUSE PROBABLE

TROUBLE Actuator disengaged will not engage W AR N I N G(ye l l o w )

Lighton X X X X

Lisht off

X X X X

P a g e1 4 . 8

1) 2l 3) 4l 5) 6) 7l 8)

seized. M otor assemblY Motor fuse blown (3-amp). Open circuit in motor wiring' Overtravelswitch assy tripped' No voltageat circuit breaker. Circuit breakertripped. Down limit switch stuck (Normallyclosed)' -88 wire not grounded.

Change14: JUL 2008

F|C!BINEiC!N

MATNTENANeEMANuAL

MC]DELF44

14.420 InstrumentTrouble-shooting

1)

TROUBLE

PROBABLE CAUSE

CORRECTION

Enginegauge(sl not reading

Trippedcircuitbreaker

Checkcircuit.lf circuit checksok resetcirCuitoreafter.

No poweror ground

Checkpower and groundwires.

Bad senderor wire

Checkwith new one, replacesender or wire if necessary.

Bad gauge

Checkwith new gauge.Replaceif necessary.

2l

Erraticor intermittent reading

Loosepower,groundor sender wire. Loosebatteryconnection

Checkall three. Tachometerwill be erraticwhen alternatorswitch turned off if there is a bad battery connection.

3t

Excessivelyhigh or low gauge readings

Badgauge

Checkwith new gauge.

Crossedor shortedwire

Checkcircuit

l s s u e d 1: 1 Jun 93

Page 14.9

FIOBINSiGIN

MAINTENANcE

MANUAL

MoE ELe,44

left blank' This pageintentionally

P a g e1 4 . 1 O

l s s u e d 1: 1 J u n 9 3

FICIBINS|CIN

MATNTENANcE MANUAL

M('EIEL

F44

14.430 Clutch Actuator ElectricalTrouble-Shooting (cont'd) TROUBLE

PiOBABLECAUSE

!n flight Actuator engaged warning (yellow) Flickers

Comes on for 1-6 seconds

Comeson for over 6 seconds

1) 2l 3) 4l

Actuator leaf springimproperlyadjusted. C190 drive belts not matchedproperly. Open circuitin motor wiring C184-1or C0O7-3bearingrunningrough. Normaloperationof actuatoras it re-tensions drive belts.

1) Drivebelts stretchedbeyondlimit of actuator overtravelswitch. Beltsmust be replaced. 2l Actuator overtravelswitch activatedby outside force.

Comeson for over 1O seconds 1) Checksheavesand belts for excessivewear. 2l Checkcolumnspringsfor operation. 3) fanwheelbalance. 4l Checkor changeout time delay. 5) Removeactuatorand send to RHCfor evaluation.

Cha n g e1 4 : J U L 2 0 0 8

P a g e1 4 . 11

FICIEIINSCIN

MOE'EL

MATNTENANeE MANUAL

F|44

Accuracvcheck Poweredlnstruments 14.440 Electricallv (or similar)capabreof dispraying+ 1 rpm using Vibrex 2OOObarancing.equipment accuracy.pe-r.{ollowing resorutionand caribratedwithin o#'v;ut,'Jerity^tachometer Manuar(MM)sections vtuintenance in accoid"ari**iiti nzz tabres.connectequipment aircraftat insiealof strobel perFigure6-44)_.operate 10.221and6.240 (usephotocerr Tachometer specified' as rpms and.i"i',tylngineinarotor indications notedtachometer needlesare 1olowide. C792-xDuqlleghometer Tachometerindication 960/o l OOo/o 1O2o/o

EngineRPM 2556-2561 2662-2667 2715-2721

ROtOrRPM 383-384 399-400 529-530

14.1o0. No other adjustments The rotortachometermay be adjustedper MM section then it must be replaced are permitted. iil;;frometer does not meet a""ututy tolerance or ri:turnedto RHCfor rePair. AO58-10 Carb. Air TemP. Probe O d e g r e e s : 8 9 . 6 8 / 9 1 . O 8o h m s l5 d e g r e e s : 9 5 .6 7 1 9 8 .0 7o h ms 1 6 d e g r e e s = 9 6 .1 0 /9 8 .5 0o h ms 1 7 d e g r e e s : 9 6 . 5 4 / 9 8 . 9 4o h m s 1 8 d e g r e e s : 9 6 . 9 7 / 9 9 . 3 7o h m s 1 g d e g r e e s = g 7 .4 )l g g .8 o o h ms 2 0 d e g r e e s = 9 7 .8 3 1 1 0 0 .2 3o h ms 9 8 .2 7 1 1 0 0 .6 7o h ms 21 degrees : g 8 . 7 O t 1 O 1 . 1oOh m s 22 degrees : 2 3 d e g r e e s : 9 9 . 1 3 / 1 0 1. 5 3 o h m s 2 4 d e g r e e s = 9 9 ' 5 6 / 1 0 1 . 9 6o h m s 2 5 d e g r e e s = 1 0 0 .0 0 /1O2 .4 Oo h ms

degr eesc 77 .4Oohms = - 3Ot 2 8 1 . 7 3 o h m s = - 2 O + 1 . 7 5 d e g r e e sc 8 6 . 0 5 o h m s : - 1 0 * 1 ' 5 d e g r e e sc degr eesc ot1 90.38 ohms = g4.71 ohms = 10 + 1 ' 5 degr eesc 99.03 ohm s = 2Ox' 1' 75 degr eesc d e g r e e sc 1 0 3 . 3 6o h m s = 3 0 + 2

a !. to 1-watt 1OO-ohm Example:Replacingthe carburetorair temperatureprobe^witl'r c (measureexact 21 resistor should result in a indiclii;; ;i ap.proximately .degrees full of crushedice Stytofoam'cup resistorvalue & referto above)'"4-iton"-iibptO in p.er " above table. Probeinstallation iesisiance ;[;; and water should indicate so.ie' pr obewill r esultin damage' o ver - tor quing i o t q u "l J g to 4 i n c6 -p o u n d s;

Pa g e1 4 . 1 2

Change14: JUL 2008

FICIB|NSiC|N

MATNTENANeE MANUAL

]vl('DEL

H'44

14.440 ElectricallvPoweredlnstrumentsAccuracvcheck (cont'd) Following instrument cluster gages are calibratedat 20 to 25 degree angle from horizontal. Fuel level sendersshould have 90 + 2 ohms resistancewhen fully up (full fuel) and O to O.5 ohm when fully down (no fuel). Performfuel sendercalibrationper MM section 12.230 whenever senderis replaced,or if factory-setfuel gage potentiometershave been disturbed. on backsideof each fuel gage are "Nult" and "Gain" potentiometer screws, covered with aluminum tape pressedagainst the screw heads to prevent rotation. "Null" potentiometeris adjustedso gage indicatesempty at O.7 ohm sender circuit resistance;"Gain" is adjustedso gage indicateshalf at 42 ohms sendercircuit resistance. Calibrationvaluesare:

FuelOuantityGages 6246-00473(14V1& 6246-00716(28V) O.7Oohm : E (empty)-1,+O pointerwidth 114tull + 112 tull + 3i4 full + F (full) +

2 1 . 2 Oo h m s 42 .OOo h ms 67.50 ohms 9O.OOohms

- 1 O 4m V -5 2 mV OmV +52 mV + 104 mV

pointerwidth pointerwidth pointerwidth pointerwidth

Ammeter 6246-00468 {14V & 28V} -70 amps a 1 pointerwidth -35 amps + 1 pointerwidth O amps t 7+ pointerwidth pointerwidth + 35 amps + 1 pointerwidth + 70 amps + 1

CHT Probe 3080-38 (14V & 28Vl 2OOdegreesF = 745 ohms 4 7 5 d e g r e e sF : 3 8 o h ms 5OOdegreesF = 32 ohms Oil PressureSendingUnit B 3 O 8 - 1(1 4 V & 2 8 V l O psi : 5-13ohms : psi 29 48-57 ohms : 58 psi 84-94 ohms = 87 psi 119131 ohms : 115 psi 1 4 5 - 1 6 1o h m s Cha n g e1 4 : J U L 2 OO8

1 1 1 1

GHT Gages 6246-00088 (14V1& 6246-00718 (28V1 745 ohms = 2OOdegreesF + 1 pointer width 1 10 ohm s = 350 degr eesF + 1 pointerwidth 34 ohms = 500 degreesF t y2 pointerwidth 1 15-psi redlineOil PressureGages 6246-00647 (14V) & 6246-00715 (28V1 9ohms: 0psi + l pointerwidth 46 ohm s = 25 psi + 1 pointerwidth 84 ohms = 55 psi + 1 pointerwidth 131 ohms : 95 psi + 1 pointerwidth 152 ohms : 1 15 psi + 1 pointerwidth P a g e1 4 . 1 3

I fl

FIClEttNgiClN 14.440 Electrical

W

MOEIEL

MAINTENANeE MANUAL ed Ins

1 O Od e g r e e sF : 4 9 7 o h ms 1 5 0 d e g r e e sF = 1 7 9 o h m s 7 2 o h ms 2 O Od e g r e e sF : 250 degreesF = 34 ohms

F.44

k (cont'd

75 degreesF + 1 pointerwidth 903.5ohms 1OOohms 180 degr eesF + 1 pointerwidth 36 ohms 245 degreesF t 1 pointer width

o

Pa g e1 4 . 1 4

Change 1 4 : J U L 2 0 0 8

FICIB|NSGIN

MATNTENANeEMANuAL

MOEIEL

F|44

14.500 COMPONENT LOADS DUTY CYCLE CONTINOUR INTERMTTTENT EOUIPMENT (amps)

x X X X

X X X X X X

X X

l s s u e d :1 1 J u n 9 3

BatteryRelay StarterRelay StarterMotor Belt TensionActuator WarningLights(engineoil pressure,alternator-off actuator-on,low fuel, main rotor gearboxchip, main rotor gearboxovertemp,tail rotor gearboxchip) PositionLights Anti-Collision Light LandingLight InstrumentLights DigitalO.A.T.Gauge EngineGaugeCluster Com Transmit Com Receive Low RPMHornand Relay Map Light

LOADS 0.75 4.50 150.00 1.20 O.O8each

2.20 3.20 8.30 each O.O8each 0.13 0.50 3.66 0.70 o.35 0.58

Page14.15

F|OBINSGIN

MAINTENANeEMANUAL

_-

MclE ELn,44,

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Change13: OCT 2006

FICIBINSiCIN

MATNTENANcE MANUAL

MOEIEL

F|44

FORWARD BATTER

CONSOLE ELECTRICAL

c0r{NEcT0Rs lr

RIGHT MAGI{ETO

ii

A661tcl{ITrot{ST.IITCH

ENG I NE HOUR METER

cft

COLLECTIVE SI,IITCH

T OO I L PRESSURE S}lITCH

CYCLICSTICK

1.0 AMP FUSE

TO CLUTCH S}IITCH 661 BREA(ER CIRCUIT "GAGES'

I'

-l

c0NsoLE' CAL ELECTRI CONNECTORS A999 MASTER RADIORELAY

1540 LIGHT nrre* HARNING 1539 l-ruEl I T E S TS H ] T C H

FIGURE14.1E R/T4II {IO-54O}STARTINGAND FUELPUMPSCHEMATIC Ch a n g e1 4 : J U L 2 0 0 8

P a g e1 4 . 1 8 C

FIclBINEiclN

MOEIEL

MANUAL

MAINTENANCE

F,44

(Cont'd) SYSTEMSSCHEMATICS 14.600 ELECTRICAL

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Change 1O: JUL 2OO4

MAINTENAIIcE

FICIBINEiCIN

MANUAL

MOE'EL

F|44

(CONt,d) SYSTEMSSCHEMATICS 14.600 ELECTRICAL

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P a g e1 4 . 1 9

I

MAINTENANeE MANUAL

FIClElINSclN

r

M(fEIEL 'r44

(8191-1INslL.) HoRIzoN ATTTTuDE

I I I I

DCGROUND DC POWER INT. LIGHT

I LIGHT COMMON

L

c059-513 PTO6A8-4S CONNECTOR

c059-514

TURNCOORDINATOR ( B 1 9 i - 5 I l , i s T ' 1).

I

INT. LIGHT

L __ GYRO DIRECTIONAL ( 8 1 9 1 - 2r N S T ' 1).

MS3i16F-8-4S CONNECTOR

Pa g e 1 4 . 2 O

14-3 FIGURE 8 1 9 1- 3ATTITUDEHORIZON( J . E . T . E L E C T R 0 N I C s ) GYROi,:.r.r. ELEcrRoNi cs) 8 1 9 1 - 4DIRECTIONAL C0RP. (ELEC.GYR0 ) 8 3 29- 1TURNCOORDINATOR

l s s u e d :1 1 J u n 9 3

FlClBlNsioN

MATNTENATvcEMANUAL

MorlEL n44

14.600ELECTRICAL (Cont,d) SYSTEMS SCHEMATICS

TOOPPOSITE SEATINSTALLATION

RED L492 D

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Cha n g e1 0 : J UL 2 0 0 4

Page1 4.198

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Change6: 1 8 M A R 9 9

FICIBINSCIN

MATNTENANeE MANUAL

MOE'ELt'44

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FICIEIINSC|N

MATNTENANcE MANI.IAL

MOEIELF'4/I

TR|MSYSTEM 14JOO ELECTRTC The R44is equippedwith an automaticelectrictrim system.The systemincludescyclic stick-mountedstrain gages,a trim controllerin the left front baggagecompartmentand lateraland longitudinal electrictrim actuatorsat the baseof the cyclicstick.Thestraingages sensecyclicstick forcesappliedby the pilot.The trim controllerprocessesthe straingage signalsand sendscompensatingtrim force commandsto the trim actuators.A thr,rmbactivatedtrim controlswitchon the right handcyclicgripallowsfine adiustmentof the trim controller. The automatictrim controllerconsistsof two independent motorcontrollershousedin the samebox. Eachsectionhas inputsfor power,straingagesignal,and offsetcontrolas well as outputs for motor and regulatedstraingagespower. A singleon-off switch on the cyclic centerstick deactivatesthe trim actuatoroutputs while signalprocessingcircuits remainon and stabilized. lf a problemis evident,then checkandadjusttrim controllerper Section14.710. Refer to Section14.720if problemsareencountered whenadjustingtrim controller.RHC Technicalif trim controlleradjustmentandtroubleshootingdo not corrector identify problem. 14.710 Trim Controller Adjustment CAUTION partnumbers: Therearetwo trimcontroller D14O-1andD14O-2.Dl40-1 trim controllermustbe usedONLYwith the CO55-2,-6 and-8 cyclictrim assemblies. D140-ztrimcontrollermustbe usedONLYwith the CO55-9, -10 and -11 cyclic trim assemblies.Incompatible controllerand trim ' assembly(s) will resultin trim systemfailure. 1)

Preparehelicopter: a) Shipon levelground. b) Cyclicstick must haveC683-4damperfirmly attached. c) Removable co-pilotgrip or C683-6damperinstalled. d) Cyclicboot installedand secured. e) Cyclicstickvertical. f)

Cyclicfrictionfully on.

g) Trim switch "OFF". h) Trim box connectedto airframeharness(but not mounted). i)

Attachtest cord from MT547-1set-upbox to trim controller.Removecover nuts from longitudinaland lateralbalancepotentiometers.

Change5: 15 Jun 98

Page14.21

FIEIBINSC|N

MOE EL]r44

MAINTENANeE MANUAL

warning.lights,.trim (28V aincraft.gnly) i. Pull all circuit breakersexcept trim(14vaircraftontvl. bnryt,and'rati'rar

i"iibiir'oi*iilin..iilf;irc'at

k. Turn on masterbatterYswitch.

2. 3.

minutesto stabilize Note: Systemmust be on (circuitbreakersin) for 1Oand checkoutcan be (coarse adiustments i,;f.;* fi#i;oirriii"iiriie'maol doneduringwarm uP). (redto { + ), blackto ConnectMT547-1set-upbox test leadsto the.VDCiacks (such as Fluke75' muttimeter Oigitat (-l) of a sensitivescalahign impedlnce fiute 8O1OA,Fluke8O5OA,etc). balancepotentiott"' O andadiustlong.itrldinal Switchon set-upboxto LONG-TP1 to adiust screwdriver

ioi'i'ieiii";

o?b.ti;v

;-5.O ;v.

Lisesmin brade

do not looseniam nut' potentiometer;

5.

Switch set-upbox to LONGTP2. Readingshouldbe O.OmV + O'2 mV' mV Recordreading: pressand hold trim controlthumb switch in forward direction.Meterlqqding

* 325mV vr qPr'' l ' r o l r r r r , " r r r r9l9p^ptot'"19y.911!19[ Lu o q1ni1in.,' 5ffi"rjfdill;'iiil; oiiiiiionto (for controller)' Dl4O-2trim +gz mv should go In poslrlve olrecrloll

Ii;; Dl TO-tfrim lbntrolt"'i; Recordreading:

6.

Metertttd'f?)tJr"-gt Pressandholdtrim controlthumbswitchin aft direction' -72 (D14( ir|in neqitiueOitictlo-n'i;;;;iimum of approximatelv mY

;lv'iDiAo-ii.n."oidreaoins:

7.

8.

9.

mV

mV

Thetime requiredto travelfrom full t + ).to.fqJlJ:) lgt viceversa)is approximately (D1 40-21' iiinei 6 secbnos(Dl4o-11or 4 seconds reading,O Note: Somemetersmay take up to 1 secondto stabilizeat the new acceptable. be inlrLtoie a 1 secondlongerreaciingcould turn.master"oFF" then back "oN"' For 28V For 14V aircraft,momentarily then reconnect lo-pin. power connector iirtratt. ro-r"ni"iiiy JisConhect giit trim controller.Meterreadingshouldreturnto 6 ano or (containing i,u-ilei-or O.OmV * O.2 mV. mV Recordreading: -

boxto LoNGT|Q.n1el 1om!nutes--ry.1tlY-p-1.19j*t.l^"ryi*9 Switchset-up rappo1

;r it.o'V * s.o.my, ;;i#;1"r";?"'Ji'Jr"6 Y'1!I1!:!F'-19.1.:19':^ until asrequired Readiust tefision. ffi6'ffihi;iilr""i;iii".p"6itg:T&"'-initti reinstalilongitudinalbalancepotentiometer readingstays *,ttiin li;i6. Then cover nut. Recordreading:

mV

result 1t? lb forwardforceappliedto middleof stickshould 1O. An approximately ? applied force aft 112lb 2 in a readingif -1bo iiV to -r s'omV nn .aooroximately 1oo mV to to middleof stick shouldt"rji in a similai'butpositivereadingof + + 1 5 Om V . Note: Do not actuallYmovestick' Page14.22

Change6: 18 MAR 99

FIC|BINSCIN

MATNTENANeE MANIIAL

MOE ELF|,44

14.71O Trim ControllerAdiustment(cont'dl 11. No force on stick shouldresultin samereadingas in step 9, * 2.5 mV. mV Recordreading:-

12. Switchset-uppoxto LATTP1andadjustlateralbalancefor a readingof O.OmV * 5.O,mv.

1 3 . Switch set-upbox to LAT TP2. Readingshouldbe eitherO.OmV * 0.2 mV (Dl4O-1lor +2O.OmV * 0.2 mV (Dl4O-2). mV Recordreading: Meterreading reaolngsnoulo in len left orreclron, should switch In direction,Meler holdtrim tramcontrolthumb control tnumD swrtcn 1 4 . Press Pressand and hold go in positive direction to a maximum of approximately +92 mV (D14O-11or

+75mV (D14O-21.Recordreading:

mV

1 5 . Pressand holdtrim controlthumbswitchin rightdirection.Meterreadingshould

-92 mV (Dl40-11or go in the negativedirectionto maximumof approximately mv 35 mV (D140-21.Recordreading:-

7 1 6 . The time requiredto travelfrom full ( + I to (-l (or vice versalis approximately or 6 secondslD14O-21. seconds(D14O-11 Note: Somemetersmay take up to 1 secondto stabilizeat the new reading, thereforea 1 secondlongerreadingcouldbe acceptable. 1 7 . For 14V aircraft, momentarilyturn master "OFF" then back "ON". For 28V

aircraft, momentarilydisconnectthen reconnect lo-pin power connector (containing wires616 and 619) at trim controller.Meterreadingshouldreturn 2O.OmV * 0.2 mV (Dl40-21. to O.OmV * 0.2 mV (D14O-1)or mV Record reading: a. For systemswith D14o-2 trim controllerONLY: Momentarilypresstrim controlswitch until a stablereadingof O.OmV + 0.2 mV is obtained.

Note:Voltageat LAT TP2 must remainat O.OmV * 0.2 mV thru step 20. The voltagewill be correctprovidedtrim controllerpoweris not interruptedandthe trim controlswitch is not moved. 18. Switch set-upbox to LAT TP3. After 1Ominutewarm up adjustlateralbalance for a readingof O.OmV * 5.O mV. Tap box with knucklesto relieveO-ring tension,readjustas requireduntil readingstays within limits. Reinstalllateral cover nut. balancepotentiometer mV Recordreading: 1 9 . An approximately 2 112lb left forceappliedto middleof stick shouldresultin a

2112lb rightforceapplied readingof -1OOmV to -15OmV. An approximately to middleof stick shouldresultin a similarbut positivereadingof + 1OOmV to + 150 mV. Note:Do not actuallymovestick.

20. No forceon the stickshouldresultin the samereadingsin step 18, * 2.5 mV. Recordreading:

Change6: 18 MAR 99

mV

Page14.22A

FICIBINSCIN

MAINTENANcE

MANUAL

MOE'ELt44

14.710 Trim ControllerAdiustment(cont'd) oN and 21. With thumb switch, adjustLAT TP3 to +1O0mV. Turn trim switch '{urn trim !lpJtof'. observetrim actuatorresponle;it shouldIgllTootryYJo -100mV.' switch Turn trim TP3 to switchoFF. with thumb.*ii"r,,'iojutt LAT it shouldrunslgglhly to the stop' Turn ONandobservetrim actuatoi-re.'ponie; 1OOmV. Turn trim switchOFF.-Wt6 tf,umUJ*ittr,, againadjustLAT TP3to +sm-oothly to the run it should respohse; trim switch ONandobservetrim actuato-r master and switch Turn trim ;6p: nepiaceactuitorlt it doesnot run smoothly. switch OFF. switch' 22. TurnmasterswitchON. Switchset-upbox to LONGTP3. With thumbactuator trim observe and oN ;iil;f Ioirtb TFs to--t oomV. Turn tiim switch -i''ibo sJgp. Turn trim switch OFF. With thumb response;rt shouldrun smooi6ry-to mV.' Turntrim switch oN and observetrim ;*ii;h;i'ojuri lotrtc rp3 to actuatorif it does actuatorr"Jpon*; iisnoulO,un'rmoothlyto the stop. Replace not run smoothly. Turntrim switch OFF' mV t O'2 mV' 23. Switchset-upboxto LONGTP2andadjustthumbswitchfor o.omV + 0.2 mV' for 0.0 Switchseti;6;; i; rni-ri2 tnO aajustthumbswitch cap.(makesureit locksin meterandtest cableand installreceptacle 24. Disconnect politionf.- Turntrim systemJ*itcn "ON". Motbrsshouldnot be running. causelongitudinal 25. A lightfingerpushto stick in forwardor aft direction.should pushstops' when motorto run down or up, respectively.Motor shouldstop Motor shouldrun smoothlyfrom stop to stop' Note: Motor runsfasterwith strongerpush' motor 26. A lightfingerpushto stickin the left or rightdirectionshouldcauselateral run should . to run left oirigr,t.- Motor .nouio stop-whenpush stops. Motor from stoPto stoP. smoothly 'Motor runsfastei with strongerpush' Note: motorto run and viceversa' 27. Lateralpushshouldnot causelongitudinal function-s 2g. pull LONGTRIMcircuitbreakerand only lateraltrim actuator LONG Reset stick. cy-clic to are'_6pplidd forces when laterali-io l""gituainil to 28 volt aircraft.) TRIMcircuiibieaker.-(Not appticable trim actuatorfunctions 29. pullLATTRIMcircuitbreakerandonlylongitudinal ResetLAT TRIM stick. cyclic iq .pritieo f";;d;;;6 when tateratand - tonsitudinai to 28 volt aircraft.) circuitbreaker. (Noi applicable -lf cyclic grip and moveit in all directions' 30. Partiallyreleasecyclic friction. Hold backand resistsmotion(or Motorsshouldmovewith m6i'lon. m6torp"ushes movessidewaysto force),thereis a wiringerror' of stickand motorarmpositions' for all combinations adequateclearance cyclicstick wires' and for motorwires Verity;a"q";i; "l-"i13n." 'OFF". Resetallcircuit 31. Centermotorsandturntrim systemandmasterswitches breakers. harnessout and routeD161-1trim controller 32. lnstalland securetrim controller, (sheet screws' metal' fromany sharpedges .nJ compartment of baggage "*"y etc). Page 14.228

C h a n g e7 : 0 6 D e c 9 9

FICIBINEICIN

MATNTENANeE MANuAL

MOEIEL

F,44

14.72O Trim SvstemElectricalTroubleshooting PerformTrim ControllerAdjustmentper section 14.710 whenevera problem is suspectedin trim system. . ff.LONGor LAT TPl is in excessof t2.OO volts and will not adjust,theremay be a brokenctraingagesignalwire. Referto Figure14-4AutomaticTrimControlschematic. Lateralcircuitsignalis pin S & pin R. Longitudinal circuitsignalis pin T & pin U. lf LONGTPl & TP3 (or LAT TPl & TP3l adjustsatisfactorily(balancelbut it is not possibfeto obtain t 1OO-15OmV readingwhenpushingcyclicstick (refSection14.710 slepg10 & !9), theremay be a brokenstraingagepowerwire. Lateralcircuitpower is pin A & pin P. Longitudinalcircuitpower is pin-V& pin N. Checkfollowingif straingagewiring faultsare suspected. 1.

StrainGageBridgeResistance Readings:Disconnect19-pinsignalconnectorat trim controllerandmeasureresistance betweenfollowingharnessconnectorpins. lf infiniteresistanceis found betweenany 3 combinations in one circuitthen an ope! circuitexists. A damagedstraingageis indicatedif resistancereadingsdo not follow chart. LateralGircuit Pin to Plg = A P S R A S A R P S R P

2.

Resistance 35O*3ohms 350*3ohms 262*,3 ohms 262*,3 ohms 262*,3 ohms 262*.3 ohms

Longitudinal Gircuit

elo to PlO = Resistance V T V V N N

N U T U T U

350*3 ohms 350*3 ohms 262*.3 ohms 262x.3 ohms 262*.3 ohms 262+3 ohms

StrainGageBridgeInsulationResistance:Disconnect19-pinsignalconnectorat trim controllerand measureat harnessconnector;resistancemust be in excess of 20 megohmsfor eachof the following: LateralGages Pin A to ship ground

Longitudinal Gages Pin V to ship ground

LateralGages-toLongitudinalGages Pin A to Pin V

LateralGagesto-shield Pin A to Pin G

LongitudinalGagesto-Shield Pin V to Pin G

Shield Pin G to ShipGround

Change6: 1 8 M A R9 9

Page14.22C

FICIBINSGIN

MAINTENANeE MANUAL

MOEIEL

FI4CT

This page intentionallyleft blank'

Page 14.22D

C h a n g e5 : 1 5 J u n 9 8

FIC|BINSiCIN

MATNTENANeE MANuAL

MOE EL F|44

0140-1 or -Z AUTOMATIC TRIMCONTROLLER

{{JE

E

ti': @ F

-=

FINE TRIMADJUST S}IITCH

SYSTEM CONTROL sr.lITcH

l ,o ,r*ru* BREATER' |

(14-V0LT$|lPS)

TOCIRCUIT BREAKERS (28-V0LT SHIPS)

Change5: 15 Jun 98

FIGURE 14-4 AUTOMATIC TRIM CONTROI. SCHEMATIC

Page 14.23

FICIBINSiCIN

MAINTENANcE

MANUAL

MoE'ELn44

This pageintentionallyleft blank'

Page14,24

l s s u e d 1: 1 J u n 9 3

FIC|BINSiCIN

MATNTENANcE MANUAL

MOE EL F'44

14.800 ANTENNALOCATIONS

,o, -\_P

I

5**

LOCATIONS 14-5 ANTENNA FIGURE

N o . ANTENNA

1 2 3 4 5 6 7 I

ELT GP S {GA R MIN) COM, GPS, OR LORAN co M'r, GP S ,OR LORAN NAV** ADF MA R K E RB EACON

T R A N S P ONDER *COM Antenna at this positionif ELT is installed * * Use this NAV antennawith RAVENll

Changet2: JUL 2OO5

Page14.25

FICIBINSCIN

MAINTENANcE

MANUAL

MtfE'EL

F|44

IntentionallYblank

Page 14.26

l s s u e d1 : 1 Jun 93

FICIEfINSC|N

MATNTENANeE MANUAL

MODELF,44

14.900 AVIONICSSCHEMATICS include wiringcommonto all the Com.radioconfigurations The basiccommunications Pilot and provides intercom and Co-Pilot voice-activated a a N.A.T. IntercomSystemthat cyclic stick switches. In addition,an intercomswitch at eachof the 2 rearseatscan also 'activatethe intercom. and a The pilot's and co-pilotsindividualheadphone iacks are mountedto the ceiling. enger are contained in headphone llttle behindtheir respectiveheads. The rear iacks pilot portion The use can the of the cabinceiling. a com box centeredat the rear most Pilot "lsolate" switch which will remove him from the Intercom bus; he can then communicateover the com radiowithout disturbances.

l s s u e d 1: 1 J u n 9 3

Page14.27

Page 1 4 . 2 8

l s s u e d1: 1 J u n 9 3

FICIBINSiCIN

MATNTENANeE MANUAL

MCIE'ELF'44

14.90O AVIONICSSCHEMATICS(Cont'd)

KY197A COM TRANSCEIVE R

-t

272 (ADF*AUDr0)

PHONES

656 (or 706**) ORANGE)

il

SHIELD GND

657 (or 707**)

I4IKEAUDIO

I

I I I I

INTERCOM AUDIO 655 (or 705**)

I4IKEKEY SHIELD GND

Lightlng powerfrrrn consolellghts termInal block (or Audio Control**)

TO optional radlos INTERCOMTo requiring I.IIRING poh,erfor variable lighting.

25.rlst,l RISISTOR

LIGHTING HI

200 (or 703**) POt,lER Sl.l POI,IER

*If installed. **For secondaryKY197Ai n s t a l l a t i o n o n l y . ***14-volt ships only.

7 I

I

267

I

I

I

I

sl'l PoHER 201 (or 704**)

,62 267

POLARIZ.ING KEY

POI.IER GROUND

I

II

I

AECDEFH.'XLIINPRS

POI^|ER GROUND t 2 3 4 5 5 7 8 9101112t314Is KINGKY 197ACOM TRANSCEIVER FRoNT Vt EX-CoNI'IECroR (LOOKING IN FROI.| FRONT OF RACK)

LIGHTING LO REIOTE TRANSFER 2L2 or l2l4

FI G U R1E4 . 6 BENDIX/KING KX197ACOM TRANSCEIVER NOTE: DOES THIS SCHEMATIC NOTAPPLY TO ENGSHIPS

COMP.NTENNA

!{ITHGENEVA AUDIOSYSTEM.

Cha n g e5 : 1 5 J u n 9 8

Page14.29

FIclBINEiclN

MC'OEL],'44

MAINTENANeE MANUAL --T ?oLARlalrc

(Cont'd) 14.9O9 AVIONICSSCHEMATICS

rl^lr PLArE 9 wEwrvn cof{tEcron xgan nEAR

v,eweo Fno[

r I

I I I I I

!

TO COM ANTENNA

COMANT.

PLUG) P4o1(B0TToM

I I

FnoNT OF UiltT

t

fL

K X1 55 V H F , - NAV/COMM TRANSCEIVER

I I I

-t:

AU D IOH I ADF*AUDIO)

NAVA U D IOH I AUDIOLO COT4

656 (oRANGE)

NAVAUDIOLO

1i657

COMMIC AUDIO

I I

I

655 (I^IHITE)

INTERCOM MIC

l I

P O WEIN R AVIONICS BUSBAR

PO WEIN R

I

I

A/C GRoUND

l I I

A/C GROUND

I I I I I I

I

I I

L

TO INTERCOM I.IIRING

OUT ShIPOI.IER IN Sl,lPOWER IN Sl^|POWER OUT SI.JPOWER

I L S E N E R GIZ E OUT VOR/LOC

267 267 267

lIro

I V O RI N S T ' 1 . W IR IN G

z'L 240

NAVANT.

F T GU R1E4 -7 P a g e1 4 . 3 0

,| TO NAV ANTENNA

*IF INSTALLED

TRANSCEIVER M KX 155 VHFNAV/CoM B E N D IX/KING

l s s u e d1: 1 J u n 9 3

FICIBINEiCIN

MAINTENANeEMANUAL

MtfE'ELF,44

(Cont'd) 14.900 AVIO\||CSSCHEMATICS

TO NAVRECEIVER

ILS ENERGIZE COMPOSITE GROUND + 14 VDC

O

F IGU R1E4 -8

l s s u e d 1: 1 J u n 9 3

B ENDIX/KING KI 203 VORINDICATOR

Page 14.31

Mt'DELF44

MATNTENANcEMANUAL

FICIBINSCIN

J441 P441 \

14.900 AVIONICSSCHEMATICSlCont'd) J871 ,p871 RF INPUT oor ** tt

[

(

P872

i-T--

i

I 6

9

(cREEN) i LooPEN1qLE

ffisr;1tD1er-ue)

15

(CABLE

2 3

|

ouT , t L UCos J\ DC

B

r + 4 . 5 VC O M .

ronlE

20-4 E

))

M P

\

n

\

F

+L )_

ABCOEFHJ

KLMNPRS

I

l_ KI 2 oo'lr c II ADF INDrcAr0Rl t

q \

D

i' DIMMER 28V V DIMMER 14V

H

GROUND

F

FROM JUMPER RADIoRACK

I wrne#z7zcomHooK-uP* |

lbl

|_n

L_

272*

><

tl

J2271

J

GHI

GROUND

7

(s;-ffi

AVIONICS BUSBAR )

:llrr 10

)

A

270

^,r*| 1 3 14VDC POWER

HIGH AUDiO

? 4

?67

AN T .P O S I T BOTTOM

9

I I

254 257

D

28V DIMMER 14V DIMMER

I

2s3

illI 't

t

DRAINt^tIRE) tiTj *lilEfi'PnrH" pzzT

I

D CS I N O U T

I

\ -/

7

r

D

r t r

i

uz

Tt

3 I

./

\

powEn(RED) ANTENNA

/ \

\2

'l

I

\#

RECEIVER

KA44BANTENNA

?67 257 267. 267

lrr*

t

fIffi[Il?l^i,r'*'r I I

K

f' L M N P

R

_-J

255

27rr ?=

AIRFRAME GROUND

VIE}I FROi.I CONNECTOR OF KR87 FROIIT

t o * o 1 to -a -o

-r,1 PR[ili';?-'Illi^i8r @aa I o oooa= OU

a-.4

14- 9 FIGURE

KR87 BENDIX/KING ADFRECEIVER

rasls67891ol!2!41,

Page 1 4 . 3 2

l s s u e d1: 1 J u n 9 3

FIC|E|INSiCIN

MtfElEL

MAINTENANcEMANUAL

TI44

14.90O AVIONICSSCHEMATICS(CONt,d} KT76A TRANSPONDER

AVION IC S BUSBAR

26L

TO LIGHTS AVIONICS BLOCK TERM.

204

260 KY 197A COMTRANSCEIVER

KA 60 ANTENNA

*FOR DMEINSTALLATION TO PIN ONLY.CONNECT I'KIIOF KN 63 DME.

KT 76ATRANSPONDER F IGU R1E4 -1 0 BENDIX/KING

l s s u e d 1: 1 J u n 9 3

Page14.33

FICIBINSiCIN

MATNTENANeE MANuAL

MOEIELF,44,

14.900 AVIONICSSCHEMATICS {Cont,dI 8241-3 I.IIRE KT76A TRANSPONDER HARNESS 8240-1 BLIND ENCODER

AVIO N IC S BUSBAR

TO AVIONICS LIGHTS TERM. BLOCK

KY 197A COl'|TRANSCEIVER

M 60 ANTENNA

*FORDMEINSTALLATION ONLY.CONNECT TO P IN I'KII

OF KN 53 DME.

F I GU R1E4 -1 1 B E N D IX /K ING KT 76ATRANSPONDER BLINDENCODER W ITI.I Page 1 4 . 3 4

l s s u e d1: 1 J u n 9 3

FIEIBINSiON

MATNTENANeE MANUAL

MOEIELF,44

14.9O0 AVIONICSSCHEMATICS(Cont,dl

M-1A RECEIVER

I

PHR

I I I

P}JR

I I

BLOWER MOTOR

I

I I

I I I I

I

GND

I

GND

AN 1OO ANTENNA

ANTE COUPLER

M-1A LORANC RECEIVER FIGURE14-T2 NORTHSTAR

l s s u e d1 : 1 Jun93

Page14.35

MAINTENANcE

FICIBINSIC|N

MANUAL

MOE'ELF,44

(Cont'dl 14.9O0 AVIONICSSCHEMATICS

KLN 88 RECEIVER BLO}'lER MOTOR Ph,R GND L T . GN D L T . POWE R

204 To CONSOLE LIGHTS BLOCK TERMINAL

KA83 ANTENNA

FIGURE14-13BENDIx/KINGKLNSBLoRANcRECEIVER

P a g e1 4 . 3 6

Change2: 12 Dec 94

FIC|ElINSiclN

MATNTENANeE MANuAL

MtfE'ELF.44

GROUND

12 VDOWER

ANTENNA APOLLO820 - A-31 ANTENNA APOLLO8OO. A-16 ANTENNA APOLLOII 618 . A- 16 ANTEN N A 7531

RECEIVER

EEE EEEH EEE EEEE 14

12.

10

I

VIE!'lCONNICTOR FRONT

( L O O K I NFG ROR ME A R or unlr) F IGURE 14-74 APOLLO 820 FLYBUDDY GPSRECEIVER APOLLO 8OOFLYBUDDY PLUSLORAN C RECEIVER A P OL L6O1 8 TCALORAN C RECEIVER

l s s u e d1: 1 J u n 9 3

Page14.37

FIC|BINSGIN

MtfE

MAINTENANeEMANUAL

EL F'44

(Cont'dl 14.900 AVIONICSSCHEMATICS

GARMIN 1OOAVD GPSRECEIVER

2 BUSBAR

1OOAVDGPSRECEIVER F IGU R1E4 .1 5 GARMIN

P a g e1 4 . 3 8

l s s u e d :1 1 J u n 9 3

MOE'ELH,44

MAINTENANcEMANUAL

FlC|EllNEtClN

KLN89 RECEIVER P891 (25PIN) TOI,|IRE#204 JUMPER

LT 14V LT 28V/ L0

A/C GROUND

A/C GROUND 11-33 VDoWER MONITOR POWER

468

BLOl,lER MOTOR

cI-4510-7C vHF/S ANTENNA

KLN89 GPSRECEIVER 14-16 BENDIX/KING FIGURE

Change4: 1 Jun 97

Page14.39

FICIBINEiCIN

MATNTENANeE MANuAL

M3)E!ELF|44

(Cont'd) 14.90O AVIONICSSCHEMATICS

K L N9 0 R E C E IV E R

R . D .R C V ' A . D .R C V I B R

429XMITB 429XMITA

GN D L T . GN D LT. POWER

TO CONSOLE LIGHTS TERMINAL BLOCK

RS-232 IN BUSBAR

cI -4510-7C VHF/GPS ANTENNA KLN90 GPSRECEIVER F IGU R 1 E4 -L 7 BENDIX/KING

Page14.40

Change4: 1 Jun 97

GARMIN 4@t420t430 (1ST INST'L)

D 0

GARMIN 400t420t430 (2ND INST'L)

g

SHIEI.OGND

z

SHIELDGROUND

(o o

GPS RS 232 tN 3

5

b o

,

-

|

GPS RS 232 OUT 3

o

Kr525A

r

GPS RS 232 OUT 3

/-

Gt 106A

rr,; I I Tl

GPS RS 232 rN 3 +LtsFI +FIGHT

NAVIGATION INDICATOF

+TO

+FROM

+FROM

LATERAL + FLAG

+VOR/LOC FLAG

LATERAL.FLAG

.VOR/LOCFLAG

VLOC ANNUNCIATE

VLOC ANNUNCIATOR

+UP

AUP

+DOWN

+DOWN

VERTICAL + FLAG

+G.S. FLAG

VERTICAL.FLAG

.G,S. FLAG

GPS ANNUNCIATE

GPS ANNUNCIATOR

OBS ROTORH

ROTORH

o8sRoroRc

ROTORC

OBS STATOF D

STATOR O

OBS STATORE

STATORE

OBS STATOF F

STATOB F

OBS STATORG

z 3

+RIGHT

+TO

o l z-{

m

z z

o m 3 D

z

c

D |.

STATOR G ANNUN. POWER

T o c

POWER

ANNUN. POWER

POWER

LIGHTINGiPWR

GROUND

28V DIM,/14VLO

GROUNO

14V OtM.

LIGHTINGHI

€

LIGHTINGLO

r

JUMPERTO CO59.204 WIRE AVIONICSFAN CIRCU|TSNEAKER

:E

m

I $

CONNECTOR

s

s N KT7O, KT76A, OR KT76CXPDR

ALT. D4

n = z A

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ALT. A 1

A1

ALT. A2

A2

ALT, A4 ALT. 81

B1

ALT, 82

a2

ALT. 84

84

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c1

ALT. C2

c2

ALT. C4 ALT. COMMON

330 XPDR

GTX327 XPDR

GPS RS 232 tN 1

BS232 oUT 1 TO BLINOENCODES

GROUNO

ARINC 429 OUT A

U

ARINC429 IN 1 A

ARINC 429 OUT B

ARTNC 429 rN 1 I

ARINC 429 IN 1 A

AFTNC 429 out 2 A AFINC429 OUT2 B

AR|NC 429 tN 1 I ANNUNCIATEE

TISCONNECT SELECT GPS ANT.

COM ANT.

GPS/COMANTENNA OIPLEXER

ONLY}

VOR/LOCANT. NAV ANTENNA IGNS43OONLY)

GLIDESCOPE ANT,

GROUND GBOUNO 14/28 VDC

= q)

-201 {COM 1).

AAr2S-O05 {t4Vt AA't25-002{28V)

-200(coM 1),-703{R44COM2t

AA83 1oO

14t2A VOC

AUDiO CONTROL

MIC KEY

COM 1 KEY

MIC HI

coM 1 Mtc Hl

AUDIO HI

coM 1 AUO|O Hr

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COM 1 AUDIO LO

AUDIO LO

COM 2 KEY

COM REMOTEX'FER

COM 2 MIC HI coM 2 AUDTOHl COM 2 AUDIO LO

I N

VOLNLSAUDIO LO

o o,

GROUND

VOL/ILSAUDIO HI

VLOC REMOTEX'FER

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-138'l {GNS430J

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8261.2 SPUCE

E zo

TOC8:12 BOSE HEADSETS POWER POWER GND TIGHTII{G POWER TIGHT GND MUSIC RIGHT HI MUSIC ITFIHI MUSTC t0

0

z 3 ! |

c059.1791

EXT AUDIO INPUT

z D z o m

Ptt0T tcstGY PITOT TXIGY PIIOT MIC HI Pil.oT MtC r0 PITOT HISRIGHT HI PII.OT H/SLEFT HI Hr0TH/St0

3 D

z c

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:! 6)

c m

I (o

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coPttoT tcstGY COPITOT TXKEY coPll.oT MlcHl coPtr0T Mrct0 COPITOT H/SRIGHT HI c0Pil.oT H/sEFrHl coPtLoT H/st0

coPfl.oT tcs|(EY COPILOT XMIT KEY

PAX #1ICSKEY PAX f1 MIC HI PAX t0 #1MtC PAX #1H/SRIGHT HI PAX #1H/SLEFT HI PAX #1H/St 0

RRPAXICSKEY

Hts c0P[0T

a o ('t

c

l.

n

rt-

RRPAXH/S

PAX #2rCS r(EY PAX #2MIC HI PAX #2MtC t0 PAX #2H/SRIGHT HI PAX f2 HiSLEFT HI PAX #2H/St0

m

MIC SHIETD GND H/S&MUSIC IIISHIETD GND COMM 3 KEY COMM 3MIC HI COMM 3 BCVR HI coMM3 RCVR r0

xcvRs oPTroNAt

COMM 2IGY COMM 2MIC HI 2 RCVR COMM HI coMM2 RCVR r0 COMM 1 KEY COMM 1MIC HI COMM 1RCVR HI COMM I RCVR LO

n

(o

t

A

o

NAVRCVR HI NAVRCVR LO AOT RCVR HI ADFRCVR tO MKR RCVR HI DME RCVR HI DME/MKR RCVR I.O PAKEY PAlilCHl PAMICtO

T

s A

I

o

3

o o m

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N

I z

-l [l

KY197A XCVR COMM OR KX155 NAV/COMM XCVR

RCVRS OPIIONAL

PACONTROL ACS€36 HEAD (0m0NAU

GARMIN 4@t4201430 {1ST|NST'L)

0t

l

GARMIN 400t420t430 {2NOINST'L) SHIELD GND

o g

GPSRS232rN3 A F @

zo

SHIELDGROUND

GPS8S 232 oUT 3

rKt /

|

GPS RS 232 OUT 3

5254 -

/-

Gt 106A

rr,s "1 |

GPSRS 232 rN 3 +LEFT

Tl

NAVIGATION INDICATOR + LEFT

TRIGHT

+RIGHT

+TO

+TO

+ FROM

+FBOM

3

LATERAL + FLAG

+VOR/LOC FLAG

LATERAL.FLAG

.VOR/LOCFLAG

VLOC ANNUNCIATE

VLOC ANNUNCIATOR

+UP

+UP

+ DOWN

+OOWN

VERTICAL + FLAG

+ G.S. FLAG

VERTICAL.FLAG GPS ANNUNCIATE

o z

GPS ANNUNCIATOR

OBS ROTORH

ROTORH

OBS ROTORC

ROTOF C

OBS STATOF D

STATORD

O8S STATOR E

STATORE

OBS STATOR F

STATOR F

OBS STATORG

STATORG

POWER

ANNUN. POWER

POWER

LIGHTING/AT/R

GROUND

28V DtM./14VLO

GROUND

14V DIM.

P z{ m 2 D

zo

m 3 D

z c |.

ANNUN. POWER

3

G)

€

LIGHTINGHI LIGHTINGLO

s

CONNECTOR

$

5 N)

o o

KT7O, KT76A, OR KT78CXPDN

ALT. 04 ALT. A1 ALT. 42

= z F

o o F N)

o

A CD

A2

ALT. A4 ALT. B,I

B1

ALT. 82

82

ALT. 84

84

ALT. C 1 c2

ALT. C2 ALT. C4

o

ALT. COMMON

6)

GPSRS 232 tN 1

GTX327 XPOR

TX 330 XPDF RS 232 oUT 1 TO BLINOENCODER

GROUND ARINC 429 OUT A

AFINC 429 IN 1 A

ABINC 429 OUT B

ARINC 429 IN 1 B

ARINC 429 IN 1 A

ARINC 429 OUT 2 A

ABINC 429 IN 1 B

ARINC 429 OUT 2 B

ANNUNCIATEE

TIS CONNECTSEiiE

GPS ANT.

COM ANT.

VOR/LOCANT.

-2't 3 {GNS 430 NAV ANTENNA IGNS43OONLY]

ANT ANT. GLIDESCOPE

GLIOE

704tcoM 2)

GROUND GROUND 1 4t28 VDC

AA12S{05 t14V) aa12s-002 t28v)

-200(coM r), -703{R44coM 2t

AA89100 AUDIO CONTROI-

14t2g VDC

o

-E56 tWHrTEr|COM1)

MIC (EY

COM 1 KEY

MIC HI

coM 1 Mtc Hl

=

AUDIOHI

coM 1 AUOIO Hl

o

MIC LO

COM 1 AUDIO LO

AUDIO LO

COM 2 KEY

0,

COM REMOTEX'FER

coM 2 Mrc Hl

o

COM 2 AUDIOHI

-t N

o o o)

o o m t!

JUMPERTO C059.204 WISE AVIONICSFAN CIRCUITEREAKEB

7 m

3

coM 2 AUOTOLO VOL/ILSAUOIO LO VOL,IILSAUDIO HI

NAV RCVRHI

GNOUND VLOC REMOIE X'FEF

NAV RCVRLO -1 3E1 (GNS 430) TO CYCLICGRIP

' 1 @ch r€qulrgdwhen Mo Ga.nin 400/420/4306 are installed, " Omlt -1,168 wirc on 28-volt Ins.llarions. rrilffc@t**

c) A'

o ol

r o g z u o z

=8

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or L

5.9 T

(o

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l3 D

3 a

z {

€ J

= -{ rn r m

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m

z D z

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m = -i

3 o o m

|! A A

T o) o

I

A

?f"f,.*3#q19.1?5Ff€.31?!?.:F'a:!:i?r4{4i--l4fJ''i1r"{.s{wff.

*Blr!?'i$:'*'i

'

t t

tr ul

o o :

J

f

z E

ut U

z ztu

F

z

6:. =-

=ai

=:

:

z

6

o a

zo

o c

o -) rJ)

a =

F F

e=F 8=

ro

{,

o) (o

()

o 15.

o

FT}RNISHINC

FIclElINETC|N

MAINTENANCE

MANUAL

MOEIEL F'44

15 SECTION FURNISHINGS 15.OOOFURNI 15.001

Introduction

15.002

DescriPtion

15.1OOSEATBELT 15.11O

SeatBelt Removal

15.120

SeatBeltInstallation

Or s.zoo sEAT ASSEMBLY 15.210

Seat BottomAssemblyRemovaland Installation

15.220

Seat BackAssembtyRemovaland Installation

15.300 CARPET 15.310

CarPetRemoval

15.320

CarPetInstallation

15.400 FOAMINSTALLATION 15.41O

FoamRemoval

15,42O

FoamInstallation

15.51O

Removal Map MaPHolderRemoval

15.520

MaPHolderInstallation

15.600 FIREEXTINGUISHER 15.610

HolderRemoval FireExtinguisher

15.620

HolderInstallation FireExtinguisher

HOLDER 15..700_LICENSE 15.710

LicenseHolderRemoval

15.720

LicenseHolderInstallation

l s s u e d1: 1 J u n 9 3

P a g e1 5 . i

FIOBINEiCIN

MAINTENANeE MANUAL

MoEIEL tt44

15.800 OPERATOR'S MANUALSTFAP 15.810

StrapRemoval

15.820

StrapInstallation

P a g e1 5 . i i

l s s u e d1: 1 J u n 9 3

FIClBINEiclN

MATNTENANcE MANuAL

MODEL

]t,44

SECTION 15 FURNISHINGS 15.OOOFURNISHINGS

,

.,

15.001 Introduction This section contains the proceduresnecessaryfor removal, instattation, replacement, and maintenance of interiorfurnishings. 15.O02 Description A baggagespaceis locatedundereachseat,and the seat bottom hingesup and forward for access.Eachseat is equippedwith a combinedseat belt and inertiareel shoulderstrap.

@ 15.110 SeatBeltRemoval inertiareelis held by four screws.thru the verticalcabin al The aft engers' permanently to attachednutplates.The forwardinertiareelsare held bulkhead four screws nuts. Eachbelt has a guide which is securedto the by and airframeby a bolt. b) Removethe bolt holdingeachend of the lap portionof the seat belt. (SeeFigure15-11 15.120 SeatBeltInstallation The connectorassemblies are identifiedas follows: C628-1 C628-2 C628-3 C628-4

Left Forward Right Forward Aft Both Sides BuckleAssembly(all)

Secureinertiareel with four screws and the guideto the airframe.TorqueNAS6604 bolts per Section1.320. The end fittings must be installedon the inboardsides of the bracketsusing the requiredspacerwith a washeron eachside of the spacer. a) The bolt headis to be installedinboard;torquenut to 100 in.-lbplus locking torque.

l s s u e d1: 1 J u n 9 3

P a g e1 5 . 1

FIclBINSiClN

MAINTENANcE MANUAL

MOE ELt44

attaching is installedon the inboardsideof the anchor b) The buckleassem.bly. must head bolt The side' each on i washer tugusingtn" r"iriii[tni..i*iin at slot in buckle Foiceto toi.tE dela.a guckleassembly be pointingino-oird. bv decreased maybe spacer shaube 1.5 to 2.5 lbs. Lengih';ietaO-S! force). ishorterspdcerincreases rl"li"g it required CAUTION No sharpedgesor burrsareallowedon the roundknurled lockingbar or the latchingPlate, 15.200 SEATASSEMBLY

To removethe seat bottom: a) Removethe sevenattachingnuts and screwsat the hinge' bl Removethe seat bottomfrom the helicopter and tighten To installthe seat bottom,set seat in placeand positionthe hinge.Install the attachingscrews.

To remove the aft seat back: back. a) Removethe MS27O39CO8screws aroundthe perimeterof the seat b) Removethe seat back. To install the seat back, install the right and.left aft seat backs usino MS27O39CO8 Ms27o39co8

attaching scre*i. inslatt tne ceniei"Jeriical intJettion pJnei usingattachingscrews. Shouldthe seat backcushionneedto be replaced,a new back can be installed onto the seat back. 1) Removethe aft seat backsfrom the helicopter' , 2) Carefuily,drillout the eightrivetsholdingthe cushionto the seat back so as not to elongateor enlargethe hole'

P a g e1 5 . 2

l s s u e d1: 1 J u n 9 3

FIC|BINSCIN

MATNTENANeE MANUAL

MC'E'ELF,44

15.22O SeatBackAssemblvRemovaland Installation {cont'd} 3l Positionthe replacementcushion againstthe seat back . Using the existing#30 holesin the seatback,markand drillthe eightholesin the to match the seat back . , crLslrion 4) UsingAVDELrivets(1693-0414rivet,I each)installthe cushionto the . 5) Reinstallseat back assembly. Shouldthe front seat back cushionsneedto be replaced,follow thesesteps: llDrill out the twelve rivetsholdingthe cushionto the seat back. 2l Positionthe replacement cushionon the seatbackand centerit from the sides. 3) Usingthe existing#3O holesin the seatback,markand drillthe twelve holesin the cushionto matchthe seat back. 4) UsingAVDELrivets(1693-0414rivet,twelveeach)installthe cushion to the . 5) Bondthe top part of the cushionaroundthe front seat backcrosstube using B27O-7,-8, or -14 adhesive. 15.300 CARPET 15.310 CaroetRemoval CAUTION Carpetis installedusingadhesive.Cautionmust be usedin removingcarpetif it is to be reinstalled. to loosenthe carpetglueand then slowlypullcarpetback.A putty knife Use Prep-Sol may be usefulto facilitatebreakingthe bond.

l s s u e d1: 1 J u n 9 3

P a g e1 5 . 3

FICIBINSG|N

MOE EL F|44

MAINTENANeEMANUAL

15.320 CarpetInstallation

, NOTE

Use B27O-7,-9, or -14 adhesiveto securethe structure' carpetto the underlying a}Checkcarpetforproperfitandtrimifrequired. side of the carpet and b) Apply the adhesiveto the structureand the bottom areas' on caretltivlniiiii so as hot to teaveexcessadhesive adioining beforethe c) Ensuresmooth wrinkle-freesurfaceimmediatelyupon installation adhesivesets. 15.409 FOAM INSTALLATION 15.41O FoamRemoval NOTE Foamisinsta|ledusingadhesive.Remova|offoam Do not damage for later reuseis not recommended' operation' removal in structure underlying a)Pee|the|argestportionsofthefoamoffbyhand. b) carefullyremoveremainingfoam pieceswith a putty knife' 15.420 Foamlnstallation NOTE to securethe foam UseB27O-7,'8, or -14adhesive, structure. to the underlYing a) Checkfoam for properfit and trim if required' Apply the adhesiveto the structureand the bottom side of the foam and b) -'car'etuly instail-iois not to leaveexcessadhesiveon adingareas. upon installationbeforethe surfaceimmediately c) Ensuresmoothwrinkle-free adhesivesets.

P a g e1 5 . 4

l s s u e d 1: 1 J u n 9 3

FIC|EltNSiclN

MATNTENANcE MANUAL

MC'EIEL TI44

15.500 MAP HOLDERPOCKET 15.510 Map HolderRemoval right seat. b) Removethe map holderand the two retainingstrips. 15.520 MaBHolderInstallation al Foldthe edgeof the map holdermaterialaroundthe long strip and positionat its matchingholesin seatfront.UsingthreeAVDELrivets(1693-04141, install with the rivet headon the insideof the baggagecompartmentand placinga AN960-6 washeronto the rivet next to the materialon the outside,rivet in place. b) Pullthe materialtaut, fold the materialaroundthe smallstrip and positionover its matchingholes.Cut off excessmaterialat this time. Using two AVDEL rivets,followingthe procedureabove,rivet the smallerstrip and materialin place. (ootional) 15.600 FIREEXTINGUISHER 15.610 FireExtinguisher HolderRemoval al Drillout the rivetsholdingthe strap.Do not elongateor enlargethe holes. b) Removethe rivetsholdingthe trim strip at the keel. 15.620 FireExtinouisher HolderInstallation a) Locatethe pocketassemblyoverthe holesin the keel.Alignthe holes in the edgestripsover the holesin the keelwith a pointertool. b) Rivetthe pocketto the keel with AVDEL1693-0414 rivets usingan AN96O-6Lwasherunderthe headand againstthe pocket. Rivetfrom the outsideof the keel. c) The straemblyis installedin the samemanneras the pocketassembly. 15.700 LTCENSE HOLDEB 15.710 LicenseHolderRemoval Drillout the two rivetsholdingthe bottomof licenseholder,do not elongateor enlargeholes.

l s s u e d1 : 1 Jun93

P a g e1 5 . 5

FICIBINSfC|N

MAINTENANcE

MANUAL

MOEIELF'44

'' , seat' Drill the two #3O al Positionthe licenseholderon the front of the left 1696-0414 rivets AVDEL two lnstatl the (.128) holes, if necessdiy,--"nJ compartmentand baggage the in"-noio"r witn {t'rijtiuet headoutiide -Afijgoo-G through washerunderthe rivet head' in hold the top of the licenseholderto b) Installthe velcro strip with adhesive-to -9, oi -14 adhesiveto attachthe strip. the front of the teft seat.'usi e270-7.

15.720 LicenseHolderlnstallation

MANUALSTRAP 15.800 OPERATOR'S 15.81O StrapRemoval Dritlout the four rivetsholdingthe strapto the structure' CAUTION Do not elongateor enlargethe holes' 15.92O Strao lnstallation a) Positionstrap and install using existingholes' b) Installthe strap using four AVDEL 1693-0414 rivets.

P a g e1 5 . 6

l s s u e d 1: 1 J u n 9 3

F|CIEIINEiCIN 784041 COVER --

MATNTENANcE MANUAL

MOEIELF|44

AN970-4

ilszI04zL4 HASHER 4130-44 SPACER NAS6504-21 BOLT

.

c628-1

I connecron

(-

I ASSEI'IBLY I (Fl,tD,LH) c628-2 CONNECTOR ASSEMBLY (Ft'f0,RH)

o

A141-14 . WASHER

c628-4 BUCKLE ASSEMBLY ASSEMBLY (F}tD AFT F}ID& AFT, LHor RH) ANg60-416L ,',"{ bIASHER :

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FIGURE 15-1 SEATBELTINSTALLATION (C0NNECT0R ANDBUCKLE ASSEMBLTES) Change4: 1 Jun 97

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c628-2 CONNECTOR ASSEMBLY (Fl,lD,RH)

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FIGURE 15-18 SEAT BELTINSTALLATION ( c0NNECT0R ASSEMBLIES) Change4: 1 Jun 97

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SPECIALTOOLS

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SECTION16 SPECIAL TOOLS 16.000 SPECIAL TOOLS 16.001

lntroduction

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MATNTENANeE MANuAL

MclE EL n44

SECTION16 SPECIALTOOLS 1 6 . 0 0 0 S P E C IA LT OOL S 1 6 . O O 1 I n tro d u cti o n The following sectioncontainsa list of specialtools availablefrom RobinsonHelicopter for use with the proceduresin this manuatto properlymaintainthe R44 helicopter. 16 . 1 0 0 T O O L L |S T 1) 2l 3) 4l 5)

O

MT548-1 MT525-1 Mf525-2 MT122-6 MTO53-1

E n g i n eH o i st Main Rotor RiggingFixture Tail Rotor RiggingFixture Main Rotor Hub Bolt stretch MeasuringTool Main Rotor GearboxDrain Valve Tool (for old-style47260 chip detector) 6) MTO54-1 Main Rotor GearboxDrainValve Tool (for 87260 "quick release" chip detector) 7l MT526-1 Main Rotor BladeTrim Tab Bender 8 ) M T O 9 1 -1 E n g i n eR i n gGearHotder 9 ) M T 5 9 2 -1 F a n P u l l e r(i n ctitem 10) 10) MT092-3 S p a ce r 1 1 ) M T 1 2 1 -1 B ra cke t- Ma gnetiickup 121 MT146-2 B l o cks- S w ashplateRigging( set of 2 btocks;use with C19B- 1 sw a sh p l a teuse , M T146- 3 with Cl98- 2 swashplate) 1 3 ) 6 0 2 9 7 - 10 E n g i n eOp e rator ' sM anual( Lycomingpar t no.) 141 MT173-5 Torque Wrench ExtensionTool Set - Fan Nut (R22 and R44; i n cl u d e si te m s 15 thr u 19) 15) MT173-6 TorqueWrench WeldedAssembly 16) 9HT4441* ExtensionBar 1.314" drive, 8-in. length) 1 7 1 M T 1 7 3 -7 S o cke tl 3 l 4 'dr ive, 1- 112"12pt. 9- 47782*l 18) MT173-4 S o cke t(3 1 4 "dr ive, 1- 11116"12 pt. 9- 47784"1 1 9 ) M T 1 7 3 -8 S o cke t(3 1 +"dr ive,2" 12pt. 9- 47788*l 2Ol MT147-1 Air BleedTools - Main Rotor Spindle 211 MT252-1 BearingPressingTool - Tail Rotor Hub 221 MT549-2 Flat Plate 23) MT549-1 Spacer- SpindleBoot Adjustment 241 MT527-1 HelicopterLifting Fixture 251 MT527-5 Bushing *SearslCraftsmanpart no. C h a n g e1 4 : J U L 2 O O 8

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26|MS16633.2ol8RetainingRing(3requiredforremovalorinsta||ationofC038 collectivesPringassemblY) S p ri n gR e ta i n er ' Tr im 271 MT544-2 Main Rotor BladeTrim Tab Gage 281 MT352-1 Cyclic Trim Set-uPBox 291 MT547-1 Hex Driver(Snap-onpart no' FABLB) 30) MT357-4 NippleChuck 31) MT357-8 TorqueAdapter (Snap-onpart no' FRDHlOl) 321 MT357-5 Wre n ch- Op en End ( 3/8" & 7 t16' ; 44475*) 33) MT357-6 Wrench - Box End l7132' & 114"; XDHT8A* ") 34) MT357-7 Valve SpringComPressorTool 35) MT516-1 cyclic stick in Blocks- Main Rotor Rigging(set of 2 blocks; holds 36) MT559-1 neutral position) Tool (For use with Clutch Bearing (C184) Removal/lnstallation 371 MT528-1 hydrauliress) Tool (For use when clutch Bearing{c184) Removalilnstallation 38) MT528-2 hydrauliressis not available) TeeterMoment Tool 39) MT354-4 0 .1 5 6 i n . d i a . CobaltSteelDr ill Bit 40) MT357-3 0 . 3 7 5 i n . d i a .R e a m e r 411 MT357-2 Tail Rotor Drive Shaft RunoutIndicatorKit 421 MT260-6 SheaveAlignmentBar 4 3 ) M T 3 3 1- 4 Plug (hub bearinginstallation) 44!- MT329-6 (hub bearinginstallation) 45) MT643-1 SpringScale 46) MT359-1 Tool Tail Rotor ElastomericBearingRemoval/lnstallation 47!' MTs56-11 (includesitems 46 thru 49) 481 MT556-15 ca p 49) MT556-16 MandrelAssemblY 50) MT556-12 Bolt 51) AN6-34A ParallelValve Tool AssemblY 521 MT133-1 (0-320, 0-360, & 0-540 engines;not shown) Angle Valve Tool Assembly(l0-540 engines;not shown) 53) MT133-5 Adapter (for measuringvalve wiggle; not shown) 54) MT133-9 and H yd ra u l i ump Assem bly ( 115V, 6OHz for USA' Cana da 55) MT384-1 Mexico; not shown) Hydrauliumemblyl22OV,SOHzfor outsideNorth America; 5 6 ) M T 3 4 8-2 not shown) *Sears/CraftsmanPart no' * * S n a P - o nP a r tn o . P a g e1 6 . 2

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REVISIONLOG 17.OOO R E V I S ION L OG Upon re_ceiving a change-packagqto this manual,insert revised pages. Destroy superseded pages.Retainin Section 17 only the most currentrevisionlog. Explanationof ChangeSymbols: Changes,except.asnoted below, which includenew materiaton added pages, are indicated by a vertical line in outer margin indicatingentire area of material affecteb. bniv moit recent change is indicated on each-page. Changesymbols are not utilized to indiiate tottowing changes: 1. Tabulardate or indexeswhere changescannot be identified. O

2. Blankspace resultingfrom deletionof text, a table or an illustration. 3. Correctionof minor inaccuracies, such as spelling,punctuationor retocationof material, unlesschangealters meaningof instructiveinfoimationand/or procedures.

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C H A N GEN O. 1 4

The following is a list of all revisedpagesand pagesaddedto R44 MaintenanceManual and Instructionsfor ContinuedAirworthinessissued 11 JUN 93. The most current revisiondate is given for each page. Previouschangescan be ordered,for a fee, from RHC Publications Department.Manualsmissingany precedingchangesmust be replaced. Page Revision Page Revision Page Revision Number Date Number Date Number Date JUL 2OO8 JUL 2OO8

1.13 1.14

JUL 2OO5 5 May 95

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1.15 1. 1 6

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1.17 1.18

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f .i f.ii 1.1 1.2 1.3

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ocT 2006 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL2OO8 JUL 2OO8 JUL2OO8 JUL 2OO8 ocT 2006 ocT 2006 JUL2OOB JUL 2OO8 JUL2OO8 JUL2OO8 JUL2OOB ocT 2006 JUL2OO8 JUL2OO8 JUL 2OO8 JUL2OOB JUL2OO8 ocT 2006 ocT 2006 ocr 2006 JUL2OOB ocT 2006 JUL2OO8 ocT 2006 ocT 2006 ocT 2006 ocr 2006 ocr 2006

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1.3A 1.38 1.3C 1.3D 1.4 1.5 1.6 1.7 1.8 1.8A 1.88 1.8C 1.8D 1.9 1.10 1.10A 1.10B 1.',t1 1.12

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1.21 1.22 't.23 1.24 1.25 1-26 1.27 1.28 1.29 1.30 1.31 1.31A 1.318 't.32 1.33 1.34 1.35 1.36 1.37 1.38 1.39 "t.40 1.41 1.42 2.i 2.ii

JUL 2OO8 JUL 2OO8

2.1 2.2 2.3 2.4 2,5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29 2.30 2.31 2.32 2.33 2.34 2.35 2.36 2.37

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LOG (cont'd) CHANGENO' 14 RE-V|S|ON Paoe Revision Page Nr-ilnber Date Number 2.38 2.39 2.40 2.41 2.42 2.43 2.44 2.45 2.46 2.47 2.48 2.49 2.50 2.51 2.52 2.53 2.54 2.55 2.56 2.57 2.58 ' 2.59 2.60 2.61 2.62

ocT 2006 JUL2008 JUL2008 ocr 2006 ocT 2006 ocT 2006 ocr 2006 JUL2008 ocr 2006 ocT 2006 ocr 2006 ocr 2006 ocT 2006 ocT 2 0 0 6 ocr 2006 ocT 2006 ocT 2006 ocT 2006 ocT 2006 ocT 2006 ocr 2006 ocT 2006 JUL2008 ocr 2006 ocr 2006

1 Jun 97 3.i 11Jun93 3.ii JUL 2OOB 3.1 ocT 2006 3.2 JUL 2OO8 3.3 JUL 2OO8 3.4 JUL 2OO8 3.5 JUL 2OO8 3.6 JUL 2OOB 3.7 JUL 2OO8 3.8 Airworthiness Limitations JUL 2OO8 3.9 FEB2OO3 3.10

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4.1 4.2

JUL 2OO8 JUL 2OO8 JUL 2OO8 JAN 2OO5

4.3 4.4

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JUL 2OO8 JUL 2OO8 1 Jun 97

5.15 5.16 5.17 5.18 5 . 19 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30

4.i 4.ii

4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4 . 15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 5.i 5.ii 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.',l1

1 Jun 97 15 Jun98 11 Jun93 12 Dec94 12 Dec94 12 Dec94 12 Dec94 2 Jul 93 1 Jun 97 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OOB 15 Jun98 1 Jun 97 06 Dec 99 06 Dec 99 O6 Dec 99 5 M a Y9 5 12 Dec94 11 Jun93 11Jun93 12 Dec 94 11 Jun93 12 Dec94 06 Dec 99 OGDec 99

6.i 6.ii 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6 , 13 6.14 6 . 15 6.16 6.17 6.18

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JUL 2OO8 JUL 2OO8 06 Dec 99

6.19 6.19A 6 . 19 B

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6 . 19 C

Revision Date 06 Dec 99 06 Dec 99 O6 Dec 99 O6 Dec 99 06 Dec 99 06 Dec 99

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ocr 2006 FEB2OO3 FEB2OO3 FEB2OO3 FEB2OO3 1 Jun 97 2 Jul 93 JUL 2OO5 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 15Jun 98 FEB2OO3 1 Jun 97 15 Jun98 1 Jun 97 12 Dec94 12 Dec94 FEB2OO3 FEB2OO3

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7.a 7.ii 7.iai I .lltl

7.1 7.2 7.3 7,4 7.4A 7.48 7.5 7.6 7.7 7.8 7.8A 7.88 7.9 7.10 7.'t1 7.12 7.13 7.14 7.14A 7.148 7.15 7.16 7.17 7.18

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1 2 D e c9 4

8.6 8.7 8.8 8.9 8.10 8 . 11 8.12

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O6 Dec 99 1 Jun 97 15Jun 98 15 Jun 98 15Jun98 15Jun 98 15 Jun 98 15Jun98 15Jun 98 15Jun 98 12 Dec94 15Jun 98 15Jun 98 15 Jun98 06 Dec 99 12 Dec94 11 Jun93 JUL 2OO4

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JUL 2OO4 11 Jun93 JUL 2OO4 JUL 2OO4

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9.45 9.46 9.47 9.48

8.43 8.44 8.45 8.46 8.47 8.48 8.49 8.50 8.51 8.52 8.53 8.54 8.55 8.56 8.564 8.568 8.57 8.58 8.59 8.60 8.61 8.62 8.63 8.64 8.65 8.66 f.i 9.li 9,1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 Page 17.4

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JUL 2OO8 JUL 2OO8

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JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUr- 2008

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10.23 10.24 10.25 10.26 10.27 10.28 10.29 10.30 10.31 10.32 10.33 10.34 10.35 10.35A 10.358 10.36 10.37 10.38

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JUL 2OO8 JUL 2OO8 18 MAR99 15 Jun 98 JUL 2OO8 JUL 2OO8 JUL 2OO5 JUL 2OO5 FEB2OO3 FEB2OO3 FEB2OO3 5 May 95 JUL 2OO4 JUL 2OO4 JUL2008 JUL2008 JUL2005 JUL 2005 1 Jung7 1 Jun97

12.1A 12.18 12.2 12.3 12.4 12.5

JUL 2OO8 JUL 2OOB 11Jun93 11Jun93 11Jun93 11Jun93 11Jun93 11Jun93 11Jun93

12.6 12.7 12.8 12.9 12.10 12."t1 12.12

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13.i 13.ii

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13.1 13.2 13.3 13.4

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14.38 14.4

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14.26 14.27

14.22D 14.23 14,24 14.25

JUL 2OO8 JUL 2OO4 JUL 2OO4 JUL 2OO4 11Jun93 18 MAR 99 15 Jun 98 18 MAR99 15 Jun98 JUL 2OO4 18 MAR99 JUL 2OO4 JUL 2OO4 15 Jun 98 18 MAR 99 18 MAR 99 06 Dec 99 . 18 MAR 99 15Jun 98 15 Jun 98 11 Jun93 JUL 2OOB 11Jun93 11Jun93

P a g e1 7 . 5

FIclBINSclN

MAINTENANCE

LOG (cont'd) CHANGENO' 14 REVISION Page Revision Paqe Nuhber Date Nr-ilnber 14.28 14.29 14.30 14.31 14.32 14.33 14.34 14.35 14.36 14.37 14.38 14.39 14.40 14.40A 14.408 14.41 14.42 14.43 14.44 15.i 15.ii 15.'l 15.2 15.3

11 Jun93 15Jun98 11Jun93 11 Jun93 11Jun93 11Jun93 11Jun93 11 Jun93 1 2 D e c9 4 11 Jun93

ocr 2006 ocr 2006 JUL 2OO8 JUL 2OO8 JUL 2OOB JUL 2OO8 JUL 2OO8 JUL 2OOB

ocr 2006 ocr 2006 11 Jun93 11 Jun93 11 Jun93 11 Jun 93

11Jun93 1 Jun 97

P a g e1 7 . 6

Revision Date

15 Jun98 1 Jun 97

15,6 15.7

16.3 16.4 16.5 16.6

Date

Paqe Nr-imber

EL F|44

ocr 2006 ocT 2006

15.4 15.5

16.i 16.ii 16.1 16.2

17.4i 17.1 17.2 17.3 17.4 17.5 17.6

Revision

M('E

11 Jun93 1 Jun 97 1 Jun 97

11Jun93 11 Jun93 11 Jun93

15.8 15.9 15 . 1 0

17.i

MANUAL

1 Jun 97 1 Jun 97 11Jun93 11 Jun93 11Jun93 JUL 2OOB JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8

Change14: JUL 2008