ROBINSON F\44

MAINTENANCtr MANI.]AL
AND INSTRUCTIONS FORCONTINUED AIRWORTHINESS

ROBINSON HELICOPTER COMPANY, TORRANCE. CALIFORNIA

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ClassS Revision Serviceform ComponentReturn/Authorization form Recommended ChangeReportform Limited Warranties 1.000 2.000 3.000 Ge n e ra l Inspection Life-Limited Componentsand OverhaulSchedules AirworthinessLimitations 4.000 5.000 6.0O0 7.000 8.000 9.000 10.000 1 1.000 12.00O 13.0O0 14.000 15.000 16.000 17.000 Airframe Landing ar Ge Powerplant DriveTrain FlightControls Rotor Systems Ri g g i n g T ra ck a n d B a l ance , Heating,Ventilation,and Air Conditioning Fuel System I nstru me n ts Electrical and Avionics Systems Furnishings S p e ci a T o o l s l Re vi si o n o g L

13: Change OCT2006

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ClassS Revision Service

MODEL

F|44

ClassS revision to is this manual service required ensure remains current. ClassS subscribers will receivefuture issuesof the followingfor a periodof one year:

Safety Notices to Revisions R44 Pilot'sOperating Handbook R44 ServiceBulletins R44 Service Letters Revisions R44 Maintenance to Manual& lllustrated PartsCatalog 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 1 5 , 1 UNITED STATES

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

JtL

m8

lf you own an R44 helicopter, pleaseindicateship seriarnumber

Change 7r O6iDec 99

Robinson Helicopter tRHCI Go. 2901 Airport Drive T o r r a n c e ,A 9 0 5 0 5 - 6 1 1 5 , S A C U

Phone: 539-0508 {31O} F a x :( 3 1 0 ) 3 9 - 5 1 9 8 5 FAA CRS YV3RO1 2M

COMPONENT RETURN/AUTHORIZATION
A copy of this form must accompanyANY parts or componentsreturned to RobinsonHelicopterGompany. A.O.G. to I acceptthe expediting charge($50.00 U.S., $60.00 Foreign), insurethat work is commenced within (1) work day.

SUBMITTED BY: Name: Company

Telephone: Email: COMPONENT DATA: Component Part No: or SerialNo: Hours in Service: Date of last repair: Reason return: for

ContactName: Fax No:

ROTORCRAFT DATA: Rotorcraft S/N: Total Hours: Registration No: Registered Owner:

R22

R44

WORKREOUESTED:
None (seewarrantyclaim section) Overhaulin accordance with RHC price list Core credit. Core chargedon RHCinvoiceno. WARRANTYCLAIM: work requested replaceunderwarranty or _Perform part purchased RHCinvoiceno. credit. Replacement on _lssue THE ABOVE WARRANTYIS BASEDON: Rotorcraftlistedabove is under warranty w C o m p o n e np u rch a se d i th i n one ( 1) yearon RHCinvoiceno. t INFORMATION: SHIPPING Address: Carrier: URGENT SHIPNEXTDAY AIR URGENT SHIP2ND DAY AIR Repairestimateonly Repairas necessary, cost not to exceed $

I certifv that the above componentand rotorcraft data is correct in accordancewith FAR 91.417 and hereby materials. the above work to'be comoletedincludinq of RHC authorize orocurement and installation necessarv employeesmay operatethe compondntat my risk foi tne purposeof testing, adjusting,inspeclion, delivery. or RHC is not responsible loss or damageto the componentin case of theft, fire, accident,or any other causes for beyond the control of RHC. A mechanic'slien on the componentto securethe amount of repairsand storage and charges herebygranted.Any component is left at RHCbeyondsix monthswill be considered abandoned will be disposed . I agreeto pay the full amount in cash upon deliveryof the component.RHC will retainall scrapped of parts.The abovecost estimatemay not be exceeded or replaced without my approval.

PRINT NAME: SIGNATURE:

Change13r OCT 2006 RSF 205 REV F

DATE:

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R E C OMMENDED CHANGE REPORT Periodicrevisionsof this manual will be made to incorporate the latest information.lf, in the opinion of the reader,any informationhas been omitted or requiresclarification or correction,pleasedirect your comments to RHC using this form {or a duplicate}.Such informationwill be includedin future revisions. Send recommendations to: Technical Support Robinson Helicopter Company 2901 Airport Drive T o rra n ceCalifor nia , 15 90505- 61 STATES UNITED 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 o d e l : r Ser ial Num 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 terms 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 terms 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. 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.
ROBINSON HELICOPTER COMPANY. INC. 29Ol Airport Drive Torrance, California 90505 U.S.A.

Effective 1 February 2OO3

Change9: FEB2OO3

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COMPANY'INC. HELICOPTER ROBINSON WARRANTY PARTS LIMITED

RHq warrants each new helicopter RobinsonHelicopter company, lnc. (hereafter referred to as one year from the .within part to be free from defects in material and workmanship appearing(l O)q hours of operation' thousand date of detivery from the RHC factory i, Jirirg the firs.tone proviAeJ, iie p"art has been subiecte-dto normal use and service' whichever event occurs first; as basis-, selected bY BHC' of This warranty is limited to repair or replacement on an exchange defective when the part left nV-hii it de.e.1t9d have been any part, which upon .to for "*u.in'ation period'is not established parts reppcgd under the terms of this the factory. A new warranty parts,r" iurrunted only for'the remainder of the originalwarrantY Warranty. Suchreplacement reinstallation of parts under for period. RHC is not responsible th.tecost of removing, shipping, or which has been repaired This warranty shattno-t ipply'io the terms of this wiiiritv. "hy.partaffected the perfarmance in RHC's iudgment, has or altered outside ln" fu"tory, anA iiici, i'nail not appty {o any part which has been subiect to or retiabirity of the part. This warranlyparts.normally replace! !u1ing- routine corrosion, misuse, negligence or accident, nor to any rod eid or spherical bearings, light bulbs, etc' ikid uii ai, c,teaners, 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 it teft the factory, RHC will pro-rate the cost 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.

oF ANy ANDALLorHER wARRiiiifes-nno REPRESENTATIONS' LtMtrATtoN wt.THour 'rnEnciaNTABiLITy, oR srATUToRy, qHETHERwRiiiEi oc oa,a, N0LU_D\NG FtrNE-lsoi FoR A PART,,ULAR ANy tMpLtEDwARRANTtEs 9HALLBELtMtrEDTo or rHE BUYER (tsAGE,rnE'tiEuEoiies puRposE nRADE oR BE pRovtDED HEREIN. w'aii-Ev-Eni wttt THE MANUFACTURER LIABLE THosE COLLATERAL' oF THEHELI0OPTER' FoR LossEsaEsuLTtNGFRIM'ioss- o'r usE cosrs' oR coNsEaUENnAI-oi ipecnL DAMAGES, ANY oTHER
by RHC will be ma Warranty adjustments with respect to anY helicopter or parts manufactured onty upon compliance with the following procedure: (1) Claim' must be The defective part or assembly, together wilh a written Warranty (3O) days after discovery of the defect nor returned to RHC not later than thirty period' more than thirty (3O) days after expiration of the Warranty part was defective RHC will, after inspection, determine whether the material or Finat determination of a when it teft the factory ana iitt respond accordingly. Warranty adiustmenf resfs with RHC'

AND ACCEPTED IN LIEU THE FORGOING WARRANTY IS EXCLUSIVE AA!? IS GIVEN IMPLIED' ExPREss'

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Ol June 06

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

xil

Change13: OCT 2006

1. GENERAL

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MATNTENANeE MANUAL SECTION 1 GENERAL

MOE EL 1l'44

1.OOO INTRODUCTION
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 Maintenance Authorization 1.004 OverhaulAuthorization 1.O05 CustomerSupport 1 . 0 0 6 Ex t ern aD i me n si o n s l 1.OO7 VersionDescription 1 .1O OH E L I C OP T ES E R V IC IN G R O 1 . 1 0 1 S c h e d u l e d i n te n a n ce n d Inspections Ma a 1. 1 0 5 C a l i b ra ti o n f T o o l s o 1 . 11 O L u b ri ca ti o n Ge n e ra l 1.1 15 Chip DetectorCleaning 1 . 1 2 O M a i n R o to rGe a rb o x ra i nand Flush D 1. 1 3 0 T a i l Ro to rGe a rb o x ra i na nd Flush D 1 . 1 4 0 C l u tch -A ctu a toL o w e r B e ar ing r Lubr 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 HydraulicReservoir FilterReplacement 1. 1 8 0 D r a in i n g n d F l u sh i n g yd r aulic a H System 1 . 1 9 0 B l e ed i n g yd ra u l i c yste m H S 1 . 2 0 0 H A N D L | N G , J A C K | N G ,O t S T t N G , E V E L T NA N D W E | G H | N G H L 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 g e e l sl nstallation Standar d Wh Landing Gear 1 . 2 1 2 G r o u n dH a n d l i n g e e l sInstallation FloatShip Landing Wh Gear 1 . 2 1 3 M o vi n gth e H e l i co p teo n Gr oundHandling heels r W 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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JACK 1.200 HANDLING,

(CONt,d) AND WEIGHING LEVELING, HOISTING,

'1.22OJacking, Hoisting,and Leveling a 1 . 2 3 O W e i g h i n g n d C G C a l cu l a ti on WeighingProcedures 1.231 Helicopter 1.24O BallastInstallation R T 1 . 3 O 0 F AS T EN E R OR OU E E OU IR EM ENTS 1.31O General 1.32O StandardTorques l 1 . 3 3 O S p e ci a T o rq u e s LIST MATERIALS 1.4OO APPROVED 1. 4 1 O Pa i n tS tri P P e rs a 1 . 4 2 O S o l v e n ts n d C l e a n e rs a 1 . 4 3 O F i l l e rs 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 a 1 . 4 8 O Ad h e si ve s 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 R T R G, FO 1 . 7 O O I N S T R U C T I O N S RU N C R A T I N G ,E A S S E M B L I NA N D F L I G H T E S T I N G 4 4 H S E R I E S E L IC OP T E R S ( DATA)PLATES IDENTIFICATION C R E P L AC E ME N TOMP ON E NT

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14: JUL 2008 Change

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SECTION 1 GENERAL

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1.OOO INTRODUCTION
This manualcontainsreferencematerialnecessary the properservicing,maintenance. for and handlingof the R44-series helicopter.This manual is to be used in conjunctionwith the R44 and R44 ll Pilot'sOperatingHandbooks(POH),R44 lllustrated PartsCatalog(lPC), R44 ServiceBulletins,R44 ServiceLetters,Lycoming0-5401 lO-540 Operator'sManuals publications, and enginemaintenance by and applicable technicaldata supplied 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 available the internetat on RecentLycomingServiceBulletins available www.lycoming. at www.robinsonheli.com. are textron.com and recent Teledyne Continental Motors (TCM) ignition systems Service Bulletins at are available www.tcmlink.com. O Always read instructions completelybefore beginning task. a 1.001 ManualNotations The following notationswill be found throughoutthe manual: WARNING Personal injury or death can result if a WARNING is not followed. CAUTION Equipment damagecan result if a CAUTIONis not followed.

NOTE
explanation. A NOTEprovidesemphasisor supplementary 1.002 ManualRevisions Beforeusing this manual, be sure it includesall current revisions.A list of all applicable be in revisions contained Section17.OOO. a new manualis purchased, sureto complete is lf found in the front of the manual;this will insure and mail the revisionserviceapplication publication that you receiverevisionsfor a one-yearperiod.A list of all current Robinson revisions can be accessed the internetat www.robinsonheli.com. on Authorization 1.003 Maintenance completeda factoryOnly appropriately certificatedmechanicsthat have successfully sponsoredmaintenancecourse, or are under direcr!supervisionof such mechanic, may perform maintenance, in repairs,or inspectionEiescribed this manual. The daily preflightmay be accomplished the above-stated mechanicsor pilot/ownerafter careful by study of the appropriatesections of the Pilot's OperatingHandbook,Some preventive maintenancemay be performed by the pilot after receivingappropriateinstructionsin Regulations. with the Pilot'sOperating FederalAviation accordance Handbook applicable and C h a n g e1 4 : JU L 2 OO8 P a g e1 . 1

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1.004 OverhaulAuthorization that have completedspecialRHC factory certificatedmechanics Only appropriately and and possessspecia.ltools technical coursesfor overhluringipecific components or repair major o"ti-i"ppii"o uv CnCuj" authorizebto disassembleand overhaul componentsas requiredby Section3. 1.005 CustomerSuPPort .

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: TechnicalSuPPort: E-mail:

E sio xten n'

customerservicb@robinsonheli'com 208

Po?'" ro b s h I m ltr1o l"iil#J.9ifl: [H"J$"ii"3iri, roin on ei.co

Chris Sennett,ts3@robinsonhe.li'com

Includethe following informationwhen contactingTechnicalSupport: model Helicopter H e l i co p tese ri a ln u mb e r r total time (TT) Helicopter time since overhaul(TSOH) Helicoirter Componentname ComponentPart number time since repairor sinceoverhaul Comironent Parts Ordering: - par -[l-isp a re s@ro b insonheli.com tsilndacc- epsor yor der ing E - ma i l : (habla'espafiol), cs2@robinsonheli.com Catry Obando Extension, 216 Lea 6ass, cs3@robinsonheli.com cs4@r obinsonheli.com 2 2 2 Ja cki eGaspar o, cs5@r obinsonheli.com 2 O7 Je a n n eShaw, 245 SandraAure, cs6@robinsonheli.com 2O4 Sandy Nuffez,cs7@robinsonheli.com ReturnedParts: All parts returned to Robinson HelicopterCompany must have.an attached 205) to avoid delaysin processing. form ('RSF ComponentReturnAuthorization in the front of this manual. Return parts to: A copy of the form is included Attn: RepairStation Com pany HelicoPter Robinson 2901 Airport Drive 1 Torrance,California 9 0 5 0 5 - 6 1 5 UNITEDSTATES Subscriptionsand Factory MaintenanceTraining Courses: ad1@robinsonheli.com E-mail: Kohler Ex te n si o n : 2 0 9 Ma l l o rY P a g e1 . 2 1 Change 4: JUL 2008

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1.OOO EXTERNAL DIIIENSIONS

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

(30 INCHES t'tINIMUM TAIL SKID HEIGHT I'IEASURED FROM LEVEL GROUND UP)

353 lN. 459 IN. OVERALL

29 lN, I

Fla4 & Fl44 II I

EXTERNAL IMENSIONS D

.Y

I I

I I

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

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MODEL1f,'44

DlllENsloNs (conr'o) r.006 EXTERNAL

353 lN. 459 IN. OVERALL

Fl44&rro
t(44 Clq',r- II
(shown with fixed utilitYfloats) D EXTERNAL IMENSIONS

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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 groundadjustable collective trim). Grossweight 24OO pounds.14-volt electrical systemstandard; 28-volt optional.optionalhydraulic cyclic & collectivecontrolb. Based "Astro". Fixedor pop-outfloat landing on gear.Additional corrosionprotection.Auxiliaryhorizontalstabilizer installedat 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-side pedals.Serialnumber0761 and higher. 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 support 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-injected engine 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.

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

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

R 4 4 l l , " C l i p p e r l " : S i mi l a r R44 "Clipper ", l to but basedon "Ravenll" InstrumentTrainer: R44 or R44 ll configurationwith 1O-holeinstrument panel. VMC operations only. 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 electrical system.Includes searchlight,police radio package, and nose-mountedgyrostabilized infrared-capablecamera with tailcone-mounted battery. Optionalmicrowavecapability. Change 4: JUL 2008 1 P a g e1 . 3 B

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

to listed Publications aresubject revision. 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: oil, oil fi l ter , AD S l 1 O8 OCa n d ( as r equir ed) 2008- 06- 51. Change , 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 ( Sl1 s8366, Sl1O8OB, 1298, andSB342E l O- 540 Manual, o p e ra to r,s only). As required,inspect and serviceTCM ignitioncomponents p e r T C M 5 8 6 438. f hydr au l i ci l ter per C Every30O hours: L u b ri ca te 181- 3 bear ing Section1.14O.Replace v al v e p e r S e cti o n1 .170. Inspectvalvesand check engineexhaus t per LycomingSB3O1B,SB388C, and Ope r ator 's g u i d e cl e a ra nce Manual. per Sections1 .120 & 1.130. C l ean Every5OOhours: D ra i n a n d fl u sh gear boxes per Section 1.115. Verify magneto drive gearbox chip detectors iushion pliability. Service collective spring assembly (manual inspectand service controfsonly) per Section8.221. As required, TCM ignitioncomponentsper TCM 58658 and 586634' per Section2-7OO. Every22OOhours: Overhaulhelicopter (in Calendar 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 locatortransmitter(ELT)per 14 CFRPart 1 .1 15. Inspectemergency 91.2O7.Inspectoptionalpop-outfloats per Section5.630. per Every24 months: T e st a n d i n specttr ansponder 14 CFRPar t91' 413' per Section1.140. Inspectoptio nalpopC L u b ri ca te 1 81- 3 bear ing Every3 years: cylinder' test pressure out floats per Section5.640. Hydrostatic OverhaulTCM magnetosper TCM 586438. Verify magnetodrive Every4 years: cu sh i o np l i a bility. and limitedoverhaulper Section2.600, Perform 12-yearinspection E v e r y1 2 y e a r s : l o r o ve rh a u per Section2.7OO.

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1.105 Calibration Tools of The dimensionsand tolerancesgiven in this maintenancemanual are critical. RHC recommendsmeasuringtools be calibratedat least once a year. This includestorque and balancing wrenches,micrometers, calipers, dial indicators, springscales,protractors 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-lubricated and do not require periodic lubrication; bearings with specificlubrication intervals noted in Section1.101 . Engine are lubricationrequirementsare contained in the Pilot's OperatingHandbook, Lycoming Operator'sManual and LycomingServiceInstructionNo. 1O14 (currentrevision).Main and tail rotor gearboxesrequireadditional when indicatedby sight plug reading. oil WARNING The only approved lubricant for use in the main rotor and tail rotor qearboxesis Robinson A257-2lubricant. When a new or overhauled gearboxis installed, must be drainedand flushedafter the it first 4 hours of flight or first chip light, whicheveroccurs first, and again at the next 1OO-hour inspectionafter installation. Thereafter, drain and flush gearboxes intervals at per Section 1.101. Additionally, changegearboxoil and cleansight plug glasswhenever oil becomesso dirty that its level cannot be determined.

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

P a g e1 . 3 D

FIGIBINEION

MAINTENANeE MANUAL

MIfEIEL

H44

1 .1 15 Chip DetectorCleaninq on film of varnishcan accumulate a Duringnormalgearboxoperation,an insulating chip dltector,s magneticprobe and preventgearboxchip warning light illumination. CleanchiP detectorbY: securingchip detector. Disconnecr 1. Removeand discardsafety wire (if applicable) 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 air drying with compressed or a lint-freecloth' wiring, 3. Check chip detector circuit function by connectingchip detectorelectrical magnetic probe to turning MASTERswitch on, and groundingdetector's central gearboxchip warning light illuminates.Turn MASttb airframe. Verify appropriate switch off . chip detector per Section 1.330 and 4. Installchip detector. Torque threaded-type wiring as required. safety wire. Ty-rap chip detectorelectrical by grounding b. Turn on MASTER switch. Check chip detector circuit function warning light detector,s center terminal and verifying appropriategearbox chip illuminates.Turn MASTERswitch off' | DrainAnd Flush 1.120 Main RotorGearbox To drain and flush main rotor gearbox: RPMto warm main rotor gearbox two to five minutesat 60-700/o 1. Groundrun helicopter oil.

located approximately1o inches 2. Disconnectchip detector wiring at quick-disconnect gearboxsump from chip detector. Cut safety *ir" r"ruring chip detectorto main rotor chip detectors). to attach bolt (not applicable 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 installmain rotor occurs,immediately lf must be replaced. leakage 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 helicopter approximately minutesat 60-700/o for five RPM. 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 residual oil. 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. Compressed or maskingtape may also be used to removedebris but scrubbing air with solventis mandatory removeany varnishaccumulation. not use a magnet to Do to removedebris.Cleanand visuallyinspectchip detectorhousing.

1 2 . Verify chip detectorfunction by connectingelectricalleads,turning Master switch

on, and touchingdetector'scentralmagneticprobeto horizontal firewall. MR CHIP warning light should illuminate. Disconnect wires. electrical

1 3 . Installchip detector housinginto main rotor gearbox.Torque per Section 1.330.

and safety wire. 14. Installchip detectorinto chip detectorhousing.Torquethreaded-type chip detector per Section1.330 and safetywire. Connectchip detectorelectrical wires and ty-rap. 15. As required, removesight gage and cleanwith solvent. Reinstall sight 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

FlclBINEiON

MATNTENANcE MANUAL

MOEIEL

H44

I I

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

\
87260 CHIP DETECTOR

DETECTOR HOUSING

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

r\+
\'\

FOR87260 ASSEMBLY MTO54.1DRAIN CHIPDETECTOR "OUtCK-RELEASE" OR WEDGE GEARBOX MTO53-1MAIN ROTOR FORA7260 DRAINASSEMBLY CHIPDETECTOR THREADED

G G F I G U R 1 - 2 D R A I N I NM A I NR O T O R E A R B O X E

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 helicopter approximately for five minutesat 60-7o0/o RPMto warm tail rotor gearboxoil. located approximately11 2. Disconnect chip detector wiring at quick-disconnect . inchesfrom chip detector. 3. Removeand discardsafety wire securingchip detectorto sight gage. 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 l n g i n eo i l . e 7. Installfiller plug, tighten, but do not safety wire. five minutes. 8. Groundrun helicopter 60-7Oo/o at RPMfor approximately 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 g e te cto r'sce n te rter minal; CHIPwar ninglight shouldillum i nate. d TR Turn off Master switch and disconnectchip detectorwiring. 12. Indtall chip detector, torque per Section 1.330, and safety wire. Connect chip as detector wiring and securewith Ty-raps@ required. sight g?g,torque 13. As required, removesight gage and cleanwith solvent. Reinstall p e r S e c ti o n1 .3 3 O,a n d sa fe ty wir e. 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 RobinsonA257-2lubricant levelindicatedby sight glass decal. I to I l n s t a l lf i l l e r-ve n p l u g ,to rq u ep er Section1,330, and safety wir e. t Tur 1 5 . T u r n o n Ma ste rsw i tch . C h e ckchip detectoroper ation. n off Masterswitc h. I I I

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

P a g e1 . 7

FICIEIINSCIN

MAINTENANcE

MANUAL

MOE EL ]t44

;ee (c_ommerciaily avpirabre, section with 4-b gramsof A2b7-12grease 1 . Fiilsyringe a inside syringe i""f''iiS mm)lonbspice tillt of Note:b grams grease . rlO 1.47O1. diameter' (16 mm) inner rilov,iiitt i o.os inch may sc.r.eyv be covered housing. screw from left side of c181-3 bearing screw' lt is not necessary 2 . Remove to by Telatemp;,e.ove Telate.p .f itquiied to adcess easebearing access' to Telatemp.-;.t;t"';ii cowfingriiay be removed replace 3 . Using syringe,inject greasethrough screw hole'
set screw and screw, or,Ihorltughly,glean. lnstall 8289-3 self-sealingcross-head B27o-2o :9119nt, wet epoxy screw hote threa"d;;"d i"n"n lnrtull set screw q!!n.g set screw only until screw primer, or wet tin?-.iiio."aie'primei on tfrreaOs'Tig6ten h i s f l u s h w i th b e a ri n g o u si n g '

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

l-

cavity. Tightening Set screw hote is throughto bearing.housing can result in set further thai flush-with-housing ;;i r;;* damaging internal bearing assemblY tii"t i'ib-nta"iing and RPM for two minutes,shut down, inspect bearing' a 5 . G r o u n dru n h e l i co p te r t 1 0 2olo grease' and clean off anY escaPed 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' flexiblefuel line at car bur etor ' 1 . T u r n f u e l va l ve o ff a n d d i sconnect r containerGr oundcontaine' toher icopteand tur n . 2 . p r a c ee n d o f fu e r ri n ei n a su itabr e f u e l v al ve o n . to repeat as necessary 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
1. 1 6 0 St o r a se

MATNTENANeE MANuAL

MOEIEL

F|44

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-dryingcorrosionpreventative compound 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) inspectaircraftfor corrosionand correct as required. 8. Periodically R r 1 . 1 7 0 H v dra u l i c e se rvo iF i l te rReplacem ent CAUTION of Cleanliness hydraulic fluid is vital to propersystem operation. Use only clean f luid from sealed containers and avoid contamination from 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 filter again Ferrousdebrismay indicatepump damage.Replace after one flight hour. lf more ferrous debris is found, replace hydraulicpump 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 . Install 4 . Lubricate O-ringin new filter with A257-15fluid and installfilter in reservoir. per Section 1.330, and safety wire. filter cap, torque 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 e 3 : O C T2 0 0 6 1

P a g e1 . 8 A

FICIBINSICIN

MAINTENANtrE

MANUAL
(seeFigure 8-1A)

MOE'EL

F|44

of Cleanliness hydraulicfluid is vital to propersystem operation' and ti1iialior r.it"O containers avoidcontamination Ur" ";iy;f"un funnels,tubing, etc. from dirty

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

filler-vent. reservoir 1. Remove pump at hydlaqlic D5O0-1 fluid for container contaminated beneath 2. placea one-liter T-fittings'-Allow suctionandpressure itot..puTq mainrotor gearbox. Remove of smallamount clean Pour "u-pJ tine 'tri" in ,"r"-oiito orjin ir.riorgh"Su"iion intocontainer. fluid line line. Pressure wittj purge suction S"Jti"n i.i7Ot inio r"i"ruoirto nzSj-15ftuid ariin in followingstepwhenfiltercap is removed'
filter per Section 1'17O' ace 3 . Repf hydraulicreservoir test pump to T.2 e 4. See Figur 1-2A. ConnectMT384 (or similar)O.S-1 gpm hydraulic. connection' iitti,.tb;;; p"rj. OSOO-1 fittittgt ai" Ait"t"nt sizesto ensurecorrect fluid. Fill reservoirwith A257-15 fluid' hydraulic 5 . Disposeof drained,contaminated forwardelbow and placeend in empty container returnline servo'hydr;;ii; at reservoir 6 . Disconnect (usecap from pump for contaminated T-fitting). assembly flrio. Cap elbow on reservoir

7 . Activate hydraulictest pump and inspecthydraulicsystem for leakage'

fully and move-cyc_l'1c forward. Then simultaneglsly fully raisecotlective 8 . Simultaneously fluid level and fill as coliectiveand move cyciic iutty gft: . Monitor reservoir friiliil;i until i"qlitiO. Repeat-pioceOurJ ieturn linefluid into containeris clean. WARNING Stay clear of moving flight controls. Hydraulicforces can cause fully g. Simultaneously 'Monitor aft then simgltaneously-{ully fuily raisecollectiveand move cycLic fluid level and fill as reservoir tor*ard.. inl moue .y"li" iuliv lower cottectirie fluid into containeris clean. i'"ifrir"O. nepelipio"eduru irntil retdrnline forward elbow. Torque B-nut per Section 1 '33O 10. Connectservo return tineto reservoir and torque striPe. systemper Section1.190. 1 1. Bleedhydraulic procedure. lf filter 12. Removeand inspectfilter. lf debrisis found, repeat drain and flush & 5' per is clean,reinstali 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 (seeFigure1-2Al Hydraulic System

1. Disconnect cap on Db00-1 hydrau.licpump pressure (aft) T-fitting and connect pressure tine from MT3g4 hfdrautic te.st'ptimp (or iimiiar o.e_i.z gpm-unit). Pressure and suctionfittings are-different sizesto assurecorrectconnection]' 2. Remove reservoir filler-vent and cover hole with finger to prevent fluid toss. Disconnectcap on. hydraulicpump suction (forward)f-i''i:ting-ani nyOrauft test pump suction line. Fillreservoir required. "onnr"t as

3 . Activatehydraulic pumpandinspect leakage. test for 4. s.imu.ltaneous.ly - I-rlly raise collective and move cyclic fullv forward then simultaneously lowercollective movecyclicfully aft. Rep'eat fully and procedure ten times. WAR
stay clear of moving flight contrors. Hydraulicforces can cause Inturv. 5 . Simultaneously fully raise collective and move gvclic futly aft then simultaneously fully lower collectiveand move cyclic futly forward.' Repeatprocedure times. ten 6 . shut off hydraulic test pump. verify 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.nnect hydraulictest qump pressureline from D5OO-1pump aft T-fitting and installcap. Torquecap per Seciion 1.330 and torque stripe. 9 . 49jy"^tre_se_rvoir level as required. tnstallfitler-ventand torque per Section fluid_ 1.330. Safety wire is not required.

C h a n g e 0 : JU L 2 0 0 4 1

P a g e1 . 8 C

F|E|BINSiEIN

MAINTENANcE

MANUAL

MOEIELF44

!:

=ll

:t ll

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

' ..ti

l
?r.rrr

I I I

I I

r'',/

I I -Z(\.

'":.7=

jrii " I
D500-1 HYDRAULIC PUMP PRESSURE

1-2A FIGURE

P a g e1 . 8 D

7: Change 06 Dec99

FIGIBINSCIN

MAINTENANeE MANUAL

MtlOELH'44

AND WEIGHING LEVELING, HOISTING. JACKING, 1.200 HANDLING, Handling 1.210 Ground WheelsInstallation 1.211 GroundHandling pin locking andsliding the by the a) Extend handle depressing handle out the handle untilthe pin snapsintothe outerhole.Holdhandle in spindle its lowestposition. Insert andwheelwith the protruding on into supportmounted skid {seeFigure1-3}. Spindle NOTE the spindles has not settledon its skidscompletely, lf helicopter may not go in all the way. In this case,pull down on the tail cone to the to spread gearenough allowinstallation.

spindleis all the way in with the bl Make sure that the protruding pastthe insideof the support(seeFigure widenedend completely 1-34).

and lock wheel in c) Pull handleover centerto raise helicopter (seeFigure position 1-4).

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

NOTE pressure. 70 psi maximum inflation tire

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

P a g e1 . 9

FICIBINSiCIN

MATNTENANeE MANUAL

MOEIEL'|'44

F I G U R1 - 3 E

F I GU R1 -3 A E

SPINDLE SUPPORT

1FIGURE 4

P a g e1 . 1 O

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

FIGIBINSC|N

MAINTENANci

MANUAL

MO6ELF44

(cont'dl 1.210 GroundHandling Gear wheels- Floatship Landing Handling 1.212 Ground INSTALLATION: , Align aft blocks adiacentto mark on skid tube and position forward blocks to removecord slack.
SKIDS

a)

Pulltail down. lnseft forward blocks at their lower height underboth skids. Pushtail uP. lnsert rear blocks at their lower heightunderboth skids at marks. Pulltail down. Move forward blocksinward to their upper heightundei skid tubes. 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 to required pull down. tail e) Pulltail down and remove forward blocks.
Hl

/\
l.-! t, _. f I

\,/ FBOTT
BLOCK POSTTIONS

bl

c)

:l

/>
SKIDS FRONT ELOCK POSITIoNS

\/

d)

INSTALLATION WHEELS HANDLING SHIPqROUND F IGU R 1 -3 8 FLOAT E

Change4: 1 Jun 97

P a g e1 . 1 0 A

FIClEIINSlclN

MATNTENANcE MANUAL

M('EIEL1f,,44

Gear{cont'd} Wheels FloatShipLanding 1.212 GroundHandling REMOVAL: a) Pulltail down. Insert forward blocksat their upperheightat forward marks underskids.

c,, >
SKIDS

\/

FBOUT BLOCK PO$T|ol|S

b)

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.

FROlIT BLOCK POSITIONS

d)

Pushtail up. Removerear blocks.

e)

Pulltail down. Removefront blocks.

WHEELS REMOVAL SHIPGROUND 1-3C FLOAT FIGURE

P a g e1 . 1 0 8

Change 1 Jun 97 4:

FICIBINEiCIN

MATNTENANeE MANUAL

MC'EIEL

F'44

1 . 2 1 3 M o vi n gth e H e l i co p teo n Gr oundHandling heels r W 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 horizontal stabilizer, rotor, or tail rotor controls. tail 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 Operating Handbookfor parkingprocedures. 1.216 Trailering Trailering R44 is not normally the Mosttrailers largeenoughto accomodate recommended. the helicopterare designedfor much heavier loads; the trailer's springs and shock will not function properlywhen lightly-loaded.lf traileringis unavoidable the absorbers should be observed: following precautions 1. Loadtrailerwith ballastuntil it is at the averageweight it is designedto carry. 2. Supporttailcone,taking care to preventchafing or abrasionat the support point. 3. Removemain rotor blades. lf not practical remove,supportthe main rotor blades to so they will not bear on droop stops. Locate supports about 5 feet in from blade tips. Supportsmust be cushioned preventblade damage. to 4. Restrain rotor to preventteetering. tail

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

P a g e1 . 11

FIC|BINSiEIN

MAINTENANeE

MANUAL

MODEL

]I44

. THE DETAIL TIE AROUND ABOVETHE BRACKET

CAUTION OvertighteningTie'Down straps can blades.

TAIL CONEIN FRONT WRAPAROUND TO TAIL CONE AROUND OF LIGHT, THENWRAPAROUND BACKOF LIGHT; BASETO ATTACHVELCRO.

1-5 MAIN ROTORBLADETIE-DOWW FIGURE

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

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

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, holesin main or by passingone-inchdiametersoft nylon rope throughthe lightening 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) Verify aft cross tube is not bent. Place a bubble level in center of aft cross tube. 4) Levelhelicopterlaterallyby placingshims under landinggear skid tubes. levelper steps 1) and 2) above. Repeatsteps 1) through 5) Rechecklongitudinal 4) as required.

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

1 Change 2: JUL 2005

P a g e1 . 1 3

FICIBINSGIN -L vr[527
HELICOPTER LIFTING FIXTURE

MAINTENANcE MANUAL

MODEL

F|44

1.6A HELICOPTER FIGURE

HOISTING

lj

TAIL ROTOR
BOX TAILCONE
\

\t
1.68 HELICOPTER FIGURE HOISTIN G ;URE RE

-\..

f-\-

/o
)

rfr:;

ffi 1
o
1FIGURE 7

VERTICAL FIREWALL

AFT INSERT TUBEINTO HOLE FiREI.IALL OF VERTICAL

AT IN WATER TUBE BELLY CABiN

C.G. HELICOPTER DETERMINATION

P a g e1 . 1 4

Change3: 5 MaY 95

FICIB|NSiCIN

MATNTENANcE MANuAL
{cont'd}

MIIEIEL

F44

b. Levelingat the main rotor hub: 1. Rotatemain rotor until teeter hinge bolt is alignedwith longitudinal axis of helicopter. Placea bubbleleverat locationmarked ,,level here',.

NOTE
hinqe bolt.

Levelmust be on top of mainrotor hub and parallel teeter to

2 . Levelhelicopterlongitudinally placingshims under landinggear skid by

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. Rechecklongitudinal level 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

MAINTENANcE MANUAL

MlfElEL

F44

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

Data form in the Pilot's and Balance ListAtreight The Equipment continuous Operaiing Handbookmust be used to maintain a weight and bqlanc recordof the helicopter's

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

r 1 . 2 3 1 H e l i co p teWe i g h i n gP rocedur e and both fuel tank sumps' g 1 . D r a i na l l fu e l , i n cl u d i n g a s colator to and gear boxes full m ar ks' fl 2 . F i l len g i n eo i l , h yd ra u l i c uid { if applicable) , 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 i n s ta l l e dn 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

w of helicopter 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' fore and aft, raiseboth blad", ofl 8. With main rotor bladesorientedapproximately droop stops to allow hub to freely teeter' measuredifference L With aircraft hangingfreely and steadily,use a water level and cabin belly at vertical in verticalheight between centerlineof tail rotor gearboxand firewall. Referto Figure1-7. Recordheight differenceto nearesttenth of inch: inches(no ballast)

P a g e1 . 16

Change1 4 : J U L 2 O O B

FIclBINSiclN

MATNTENANcE MANuAL

MOEIEL

'''44

1.231 Helicopter (cont'd) WeighingProcedure 1O. Determineuncorrected longitudinal centerof gravity: 114.34 - t0.32 x (difference height,from Step g)l = in 't1. inches

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

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. Determineuncorrected empty weight: Right Scaleindication plus Left Scaleindication + minus Tare (such as lifting fixture, if installed) Uncorrected EmptyWeight = 14. Determine with f ull fuel and 150 lb pilot: CG [(CGfrom Step tO) x (emptyweight from Step 13)] + 3gg4o (emptyweight from Step 13) + 451.2

tb
tb

tb

inches

15. lf CG f rom Step 14 is greater than 102.5 inches, determine required nose 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 nearest 0.2b lb and install nose ballast per Section 1.240. Record actual noseballast installed:
tb

Repeat steps 7 thru 15 and revisemeasurements calculations. and

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

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FICIBINSCIN

MAINTENANeE

MANUAL

M('EIEL

F44

(cont'd) Procedure fuel: unusable 16. Adjust weight and balanceto correctfor drained

ITEM Shipas weighed

WEIGHT (tb) X
(from Step 13)

CG (inchesfrom datum)

MOMENT (in.-lb)

(fromStep 1O) 96.0

fuel Add unusable basic empty Helicopter and CG (includes weight fuel and full oil) unusable

+7.2

+691

*_

*cG location(arm)is determined dividingtotal moment by total weight' by 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 centerof gravityusingstep 13 data: lateral 17. Determine (RightScale- Left Scale) L a t e r aC G A r m = l (RightScale + Left Scale) x 41.2O = inch

P a g e1 . 1 8

1 Change 4: JUL 2008

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, installappropriate batlastjrer Figure 1-8, 1-8A, or 1 - 8 8 , a s a p p l i ca b l e .

NOTE Maximum allowable ballast 1 0 is s.

4. Torqueboltsper section1.32o andtorquestripeper Figure 2-1.

5 . Closeand secureupper console. landinglights and retainer. Functioncheck landinglights. 6 . Reinstall

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

'li,(.".,,' -A\.,'i '', eT:i-fjl'..^',)

i_--l:;-... t. .

MS21o42L3
/-\

'{Rrs\

(4 ptaces)

*oo

rq \./ i"r \\

\ NASl't49F0332P WASHER (4 places)

.-'

r\
\l \l

Grl ll \\ \)

il

A941-2 BALLAST PLATE

( 0.25 b) r

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

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

FIGURE FIXED 1-8 BALLAST INSTALLATION (with -holeballasr platesl C h a n g e 4 : J U L2 O O 8 1

P a g e1 . 19

FIclEtINSCIN

MAINTENANCE

MANUAL

MOE'EL

1t44

(cont'd) 1.240 Fixed BallastInstallation

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

.(.---,)-'.-I t

';
f,MS21 '\NUT
\

o42Lg
(4 Places)

t )

-s\\ 'l-'

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

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

,/0,,,
' \ \

\ NASl 149F0332P WASHER (8 Places)

Sf

\l'

'.-

"-.. l:

b'\ 'tl
''-r

Q)-,. G,

t-

\
\

tl
..--l

\
A941-2 BALLASTPLATE (0.25lb)
'.

li

tt.

---

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

'j.'-o)-'

or NAS6603*
BOLT (4 places)

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

NASl 149FO332P WASHER

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

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

1.8A FIXEDBALLASTINSTALLATION FIGURE (with 6-hole ballast Plates)

P a g e1 . 1 9 A

1 Change 4: JUL 2OOB

FIclBINSiClN

MATNTENANcE MANUAL

MOEIEL

F,44

(cont'd) L240 Filqd Ballast_lnstallation

c 3 6 1 PANEL

7
A941-6

/,1

FORWARD

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

FIGURE 1-8B FIXED BALLAST INSTALLATION (with 2-holeballastplates,required wirh 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 FASTENER 1.3OO

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 u s e c a applicablelr hardware.n d (where | i b r a t e d w e n c h e s a undamaged, proplii/ -fuUricated_. climp-only bare metal Ensureall clampingsurfacesare clean' and

nloq -iq'lll : I gi*v* p or wet- rimedt uftil" J' r".' in'los,ot-ctamp-up, 1 :,:.l,ii:t"^1 or hardware i.,"v ,"ruii ;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 shail be torquedto standarddry.va.rues Fasteners to torque value by 10o/o account 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 5 N A S 1 3 O 5b o l t (5 i n d i ca te s /1 6 i nch size)dr y 24 in .- l b bolt head Add 1O% becaut"-i"tqJi must be appliedat 264lnLE Torque wrench setting B33o stampednuts on at criticalfasteners. -r.'i"ir'inismq A secondaryrockingmechanismis required and heticopter, are

on in ''ost areas thespecific (parnuts) ur"JX"oriiuoi^r9."i.i"e serve fasteners' for ;;;;;J;;tlo.t ingmechanisms tpc per torqued TabteT.-in" tists
a inspgction.by Assembly of flight controls is criticaland requires. the insta||er is -;;f. qua|ifiedpe]son. lr '""ond pers.on not avai|ab|e, " 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. jointsin Thisincludes ;;";;;ai;; tii" oplruiionot trt" heficopter. structural joints in the primarycontio"l';;;i;;' "lq l"li?il:{" ear, and drive sYStqlL , th e b i rfra me l a n d i
in after palnut installation a stripe Torque seal (paint)is appliedto all criticalfasteners boih nuts. ontothe component tro,i'ir,'" irii"n"r,, q;'io;i-t'iit^"udracrosr extending ot bolt can be detected (referenceFigure 2-1). An_y,rbd.qu"nt rotatio;-;-th;-nut 1.460. given in section visually.npprou"olour"" tbr t-qud seal is must appreciably has deteriorated Any nut damageddue to handlingor whose nut drag b e r e p l a ce d . 1 Change 4: JUL 2008 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 insufficientjoint clamping. Torquingrequirements: 1. Bolt and nut are to be cleanand dry exceptwhen assemblyprocedure specifies antiseizeor thread-locking compound.

2 . lf chatteringor jerking occurs,disassemble re-torquefastener. and 3 . lf specialadapterswhich changeeffective length of torque wrench are used, final
torque value must be calculated usingformulabelow. threadengagement requires 4. Proper 2-4 threadsbeyondprimaryself-locking (palnuts nut excepted). 5. Torque wrenchesmust be calibrated annually, when dropped,or when a calibration error is suspected.
WHENUSING TOROUE A WRENCH ADAFTER WHICH CHANGES THEDISTANCE FROM THETOROUE WRENCH TO DRIVE THEADAPTER DRIVE, APPLY THEFOLLOWING TO THECORRECTED FORMULAS MAINTAIN TOROUE HEADING: T. Y. L. E. TOROUE ACTUAL. {DESIRED} (INDICATED} APPARENT TOROUE EFFECTIVE LENGTH LEVER EFFECT1VE LENGTH EXTENSION OF

<J-TOROUE WRENCH

))

\u/

SHORT OPEN-END ADAPTER

TOROUE WRENCH ADAPTER DRIVE CENTERLINE

OPEN{NDWRENCH ADAFTER

/n U
serscREw
ADAPTER

WBENCH DRIVE CENTERLINE

Al---/A

e---v)

*l .
F o R M U T A I. ' ! L+E -v FoRMULA,ftL L+E =v 'E'AS PLUS EXAMPLE: DIMENSION) WITH 1 3 5 x 1 0 - l - 9 , ! , 9= . trz.gg l0 + 1.5 11.5 Y= 1171b-in. (WITH'E" AS MINUSDIMENSION) EXAMPLE:

FLARE.NUT WRENCH ADAPTER

)a &/./
I tLY HOSECLAMP ADAPTER

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

,'6a

T = l3srb-in. Y = UNKNOWN L - loin. E = 1 . 6i n .

t-

T=135lb-in, Y = UNKNoWN L - 10.0in. E = 1 . 5i n .

.T = - = - = x c1 0. 8 2 1 3 5 0 , 1 3 5r 6 8.5 10 + 1.5 Y - 1 5 9| b - i n .

F IGU R E .9 C A L C U LATING TOROUE 1 ADJUSTMENT EXTENSION FOR C h a n g e 3 : OC T 2 0 Oo 1 P a g e1 . 2 1

FICIBINSCIN

MAINTENANeE MANUAL

MOE EL H.44

Torques 1.320 Standard TOROUES WRENCHING STANDARD SERIES FASTENER

slzE
10-32 1t4-28 5t16-24 3t8-24 7t16-20 1t2-20

EXAMPLE FASTENER
NAS6603
NAS6604 NAS6605 NAS6606

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

5O, 120 240 350 665 995 37 90 280
795 6to15

N/A
N/A

Bolts NAS 13OO NAS 660OBolts NAS600 THRU606 Screws NAS623 Screws NAS 1351 Screws NAS 1352 Screws AN3 Bolts AN4 Bolts AN6 Bolts AN8 Bolts AN5O2Screws AN5O3Screws Screws ANSO9 AN525Screws MS24694Screws MS27039Screws

N/A N/A N/A

N/A N/A

NAS6607
NAS6608 AN3 AN4 AN6 AN8

10-32 1t4-28 3t8-24 1t2-20 10-32 1t4-28

N/A N/A
N/A N/A N/A

51-7) 8330-7(MS271

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

STAMPEDNUTS (PALNUTS)

5t't6-24 3t8-24

2Oto 40

N/A
N/A N/A N/A N/A N/A N/A

M B 3 3 O - 1(9 S 2 7 1 5 1 - 1 9 ) 2 9 t o 6 O I (MS27151-241 5 4 t o 1 1 O B33O-24 60 NiA

N/A N/A NIA N/A

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

1t2-20 1t8-27 1t4-28 PIPE TAPERED THREADS 3/8-18
112-14

85 110 160 230 15 40 80 110

N/A N/A N/A

N/A N/A N/A

3t4-14 10-32
RODENDJAM NUTS ( A N 3 1 5a n d A N 3 1 6 )

AN315-3
AN316-4 AN316-5 AN316-6

1t4-28 5tI6-24 3t8-24

Notes: torque 1, Valuesincludenut self-locking values 1O% if torqued at bolt head 2. lncrease value, then tighten to desiredposition 3. For elbow and tee fittings which requir" iiinrn"na, torque to indicated range is specified 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 o rq u e s l Thesetorques are non-standard and supersede those in Section 1.320.

AREA

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

TOROUE
150 90 90 300
150 wet wl A257-2O

D799-2highpressure cutoutswitch
D799-3 low pressurecutout switch MS21O42L6nut, compressor drive pulleyretaining nut, D792-2 line assy-to-evaporator AIR nut, D794-1 hose assy-to-D793-2line assy CONDITIONING nut, D793-2 line assy-to-evaporator

210 wet wt A257-20 210

3OOwet wl A257-2O 210 wet wl A257-2Q

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

nut, D81O-1hose assy-to-D777-1 compressor assy nut, D810-1 hose assy-to-D783-1 condenser nut, D811-1 hoseassy-to-D783-1 condenser nut, D811-1 hoseassy-to-D793-2 assy line (41valve cores (on servicingand cutout switches fittings)

150 wet wl A257-20

150 wet wl A257-20 150

1 (21NAS135l-6H2OP bolts securing 8253-2 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 assemblies with smallernuts are obsolete SYSTEM (6) NAS6608-42H bolts, lower sheave 900 EMPENNAGE {8) NAS6604-5 bolts, verticalstabilizer attach 170 C182-1 nut - see DRIVE SYSTEM(above) CABIN FANWHEEL (16) NAS66O3-6 bolts, cone-to-fanwheel ( 8 ) N A S 6 6 0 5 - 1 2 r - 1 3 b o l t s ,h u b o (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 - 1 0 2 230-260 110-130

Values in inch-pounds unlessotherwisespecified. Valuesincludenut self-locking torque. Increase values 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.

Change 4: JUL 2008 1

P a g e1 . 2 3

FIClEIINEiclN

MAINTENANcE MANUAL

MIIEIEL

H.44

(cont'd) Torques J.330 Special 1'320' thosein Section and torquesare non-standard supersede These

lines {0-540) nuts,fuelprimer It OtnNgOS

clamp,electricfuel PumP(lO'540) fuel controlinlet reducer(lO-54O) (2)fue|hosenuts,engine.drivenfuelpump.to-fuelcontro|in|ettee 100, wet with adhesive B27O-1O

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

13 5 - 15 0

110-130 110-130

FUEL SYSTEM

valve-to iziru"tline nuts,relief "@

(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 engine-driven pump (lO-540) inlet adapter, (0-540) (4) bolts, airbox-to-carburetor gascolatordrain valve on next Page
Notes: unlessotherwisespecified' 1. Values in inch-pounds torque. 2. Values includenut self-locking if values 1Oo/o torqued at bolt head 3. Increase 4. Wet indicatesthreadslubricatedwith A257-9 Anti-Seize value,then tighten to desiredposition torque to indicated s. For elbow and tee fittings which requirealignment, 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

1 Change 4: JUL 2OO8

FIClBINSiclN

MATNTENANcE MANUAL

MOEIEL

F|44

1.330 SpecialTorques(cont'd) those in Section 1.320. and supersede Thesetorques are non-standard

AREA

FASTENER
(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 suction (2) 8330-25 palnuts,pump suctionT-fitting & reservoir elbow (if installed) T-fitting cap, pump pressure cap, pump suction T-fitting

TOROUE
30 45
45

75 60 120 60 90 90
150 13 5 - 15 0 9 5 -10 5

(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) & (41 D452-4 jam nuts, return elbows (if installed) T-fittings el D452-O iam nuts, pump suctionT-fitting & reservoirsuction (if installed) elbow pressure hose (2) nuts, pump-to-reservoir (6) nuts, pressurehosesto servos(exceptpump) (2) nuts, reservoir-to-pump suctionhose (61nuts, return hosesfrom servos mounting nuts (see MAIN ROTOR HYDRAULIC Hydraulicpump-to-gearbox GEARBOX} PUMP (41attach bolts, reservoir-to-f rame filler-vent HYDRAULIC RESERVOIR filter cap sight gage scissors HYDRAULIC MS27039CO806screw attachingD2OO-2 SERVOS 8330-6 palnut on above screw LANDlNG GEAR (8) clamps,strut fairings (4) NAS6604 bolts,groundhandling wheelsupports nuedon next p a g e

190-210
135-150

60 100
150 150

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

70

Notes: unlessotherwisespecified. 1. Valuesin inch-pounds torgue. 2. Values includenut self-locking it values 11o/o torqued at bolt head 3. Increase with A257-9 Anti-Seize 4. Wet indicatesthreadslubricated torque to indicatedvalue,then tighten to desiredposition 5. For elbow and tee fittings which requirealignment, 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

FICIBINEiCIN

MAINTENANcE MANUAL

Mt)E EL F,44

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

AREA
MAIN ROTOR BLADE

FASTENER
l2l 8.289-2bolts, self-sealing l2l C722-3 screws, tip balanceweight fittings, gearboxmountingor t+t AGSO-+ l 4 l N A S 1 2 9 1 - 1 Ou t s n AN32O-Bnut, gearboxpinion {retainsC908 yoke) chip detector housing chip detector (threadedtYPe) fillerplug (or (4) NASl 291-4 nuts, hydraulicpump-to'gearbox cover) (6) NASl 352-4 screws, end cover (6) NASl 352-4H16P screws, sump-to-housing sight gage (1) NAS634-105bolt, teeterhinge

TOROUE
60-80 55
90 ft-lb, dry, torqued from bolt head or nut 35-45 ft-lb Approximately15O Approximately75

MAIN ROTOR GEARBOX

150 40 120
12O at head 150 New bolt: O.O21-O.O22 inch elongation,wet Used bolt: 0.O20-O.022 wet, and inch elongation, cotter pin holes must align

MAIN ROTOR HUB

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

PITCHLINKS

300
25 to 30

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

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

POWERPLANT

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

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

25-35

Notes: unlessotherwisespecified. 1. Valuesin inch-pounds torque. 2, Valuesincludenut self-locking values 10% if torqued at bolt head 3. lncrease 4. Wet indicatesthreadslubricatedwith A257-9 Anti-Seize to desiredposition b. For elbow and tee fittings which requirealignment,torque to indicatedvalue,then tighten rangeis specified 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 o rq u e s(co n t'd ) l Thesetorques are non-standard and supersede those in Section 1.320.

AREA

FASTENER

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

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 7 u t n (18l AN503-8-8fillister-head screws (26) NASl 352-O8HBP socket-head screws SWASHPLATE (1) NAS6605-8bolt clampingC2O3-1yoke TAIL ROTOR NAS66O6-53 bolt, elastomeric teeter (delta)hinge (4) bolts, input cap (8) bolts, input housingand output cap chip detector filler-vent plug input yoke retaining nut TAIL ROTOR GEARBOX MS21O42L5nut, pitch controlhousingstud (4) NAS1352-5H12Pdrilled-head bolts, gearbox-totailconeattaching (4) NAS1352-5-12P bolts (undrilled), gearbox-totailconeattaching sight gage

30 190 (opposite clamping bolt must be torqued first) 380 60

I l

100
100 100 35-45 ft-tb

240 200

240
150

Notes: 1. Valuesin inch-pounds unlessotherwisespecified. 2. Valubsincludenut self-locking torque. 3. Increase values 10o/o torquedat bolt head if 4. Wet indicatesthreadslubricated with 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.

Change 4: JUL 2008 1

P a g e1 . 2 7

FICIBINSiCIN

MAINTENANcE

MANUAL

MOE'EL

FI44

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

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

Stripper Cee-Bee A-292

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

PlasticMedia BlastingSystem

Metal parts excePt blades and sheet metal less than unsupported inch thick O.O4O

P a g e1 . 2 8

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

FIGIBINSCIN

MATNTENANcE MANUAL

M(IEIEL

]f,,44

1.42O Solventsand Cleaners

PRODUCT MANUFACTURER/SUPPLIER APPLICATION

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

Safety-Kleen Systems,Inc. General use for cleaning TX and prior to applyingprimer, Plano, adhesive "t ",:.:"t Any Any Acrylic plasticcleaneronly and degr easing, Cleaning, removingsandingdust prior to primingor top coat Clean hydrauliccomponents only. Vapor degreaser cleaning lmersion/ultrasonic

Any Lacoline (AliphaticHydrocarbon) Dupont Lacquer& 3 En a m e C l e a n e r 9 3 9 5 l o r K w i k C l e a n3 9 4 9 5 * Presolve Tetrachloroethylene (Perchloroethylene) 815 GD Dupont Los Angeles,CA LPS Federal Spec

o-T-236

BrulinCorporation lN In d i a napolis,

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

PRODUCT MANUFACTURER/SUPPLIER APPLICATION

229OSPutty 22915 (Hardener) 0 5 1 1 4 4 - 0 5 9 6 0A c r y l Green Spot Putty

Dupont Los Angeles,CA 3M St Paul,MN

Minor surfaceimperfections

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

PRODUCT MANUFACTURER/SUPPLIER APPLICATION

F-9OOWhite

Products Co. Organic P.O.Box428 TX lrving, 75060

Torque Seal-White

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

P a g e1 . 2 9

FIEIBINEICIN 1.450 Primers

PRODUCT

MAINTENANcE

MANUAL

MC?E'EL F'44

MANUFACTURER/SUPPLIER

APPLICATION

GrayepoxyCA 75O1with Desoto AerosPaceCoatings, Unlimited Int., Inc. PRC-Desoto C A 7 5 0 1 B a cti va to r CA Gl e n dale, I AluminumPartsand Gray epoxy 44-GY-79 Deft, Inc. and fiberglass assemblies, with 44-GY-79 activator l rvi n e,CA components Aviation Primer,Green, A9O2* (Aerosol) * shelf life two years 1.455 PowderCoat (steelparts only) ValsparCorporation Me d i na,OH Limitedor touch-upuse only.

n'li?:ffi ffi ffiil*i{;"33:'ilfl1,'J3i8;ar,";'S:#1;:l':*s'erectrostatica MANUFACTURER

PRODUCT

Gre y 1 3 - 7 0 0 4 C o ve lZ i n c-R i ch Epoxy Powder GreY 81-2158 VitralonZinc-Rich Epoxy Powder

Morton International PA Reading, 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 CA RanchoCucamonga, Powder. WeatherResistant Polyester 39-80040 Semi GlossBlack Polyester WeatherResistantPowder Tiger Drylac USA

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

P a g e1 . 3 0

1 Change 4: JUL 2OO8

FICIBINSICIN
1.460 Paints

MATNTENANcE MANUAL

M('E,EL

F'44

Paintcode numbersfor specifichelicopterserialnumbersare listedon the insidecover of factory gupplied maintenance record (log book). Use fisheyeeliminator, accelerator, or other additivesper manufacturers recommendations.
MATERIAL MANUFACTURER

A Flat Black lmron 373-P-29950 Polyurethane enamel Dupont with 193S or 89OgSactivatorand 86855 reducer Los Angeles,CA Semi-gloss Black3900-05-1GK with 39-SG CardinalIndustrial Finishes catalyst and water reducer(landing gear only) El Monte, CA B Dark gray lmron DSO2OHK Polyurethane enamelwith Dupont 193S or 89095 activatorand 86855 reducer c Lycoming engine gray (high temperature)#76448* Textron Lycoming (engine caseand cylinders) Williamsport, PA Lycoming engine gray E-8948 (cooling panels and Randolph ProductsCo. carburetorheat shroud) Carlstadt,NJ Lycomingenginegray enamel#A,219 Tempo Products (aerosol can, for touch up)* Cleveland, OH D WhitelmronK0774HKPolyurethane enamelwith193S Dupont or 89095 activator and 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 (11-parts) H Cfearlmron24005 (1-part) and RK-P-19478 with 193S or 89095 activator(4-parts) J White #23OOlatex flat exterioracrylic Vista PaintCo. (for landinggear floats) Long Beach,CA (shelflife 3 years) K White Cat-L-lnk #50-1OOR Ethone,Inc. A2O Catalyst* tfor silk screenletters) West Haven,CT (shelflife 3 years) Yellow Cat-L-lnk#5O-2O2BR A2O Catalyst* (for silk screenletters) L Red lmron K0759HKPolyurethane enamelwith 193S or 89095 activatorand 86855 reducer N Kryfon 1311* # Matte clear (aerosol can; for silk screenletters) For limitedtouch-upof interiorand landinggearonly: A Krylon#1613 Flat Back(aerosol can)* NYBC#14 FlatBack (aerosol can)* "Shelf life two years Change 4: JUL 2008 1 P a g e1 . 3 1 Dupont KrylonDiv. of Borden Columbus, OH KrylonDiv. of Borden New York Bronze PowderCo. Scranton,PA

FIclBINSiClN

MAINTENANcE MANUAL

MoEIEL H44

PAINTING SURFACE E X T E RNAL list See approvedmaterials 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. CODELOCATIONS 1 F IGU R E -1 1 A PAINTFINISH 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

I I
/.___ ,
I

EXTERIOR SURFACE FUELTANK OF FACING GEARBOX COMPARTMENT

i
I I
t
I
l
I

C - (CARBHEAT SCOOPON EXHAUST COLLECTOR SIDEOF AIRCRAFT) RH

F IGU R E -1 1 8 PAINTFINISH 1 CODELOCATIONS

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

P a g e1 . 3 1 8

FICIBINSiCIN
1.470Lubricants

MATNTENANeE MANUAL

MOE'EL

F|44

A257-1

Mo l y Gre a se1 O1

Southwestern Petroleum Corp. Fort Worth, TX SouthwesternPetroleum Corp. ShellOil ComPanY Houston,TX State Pennzoil-Quaker Divisionof ShellOil Co. Houston,TX Inc. Sta- Lube, Compton,CA Lubrimatic BuffaloGrove,lL Inc. FleetSupplies OH Cleveland, Div. of United-Erie lnterstateChemicalCo. Erie,PA

A257-2 A257-3 A257-4

Ge a rL u b e2 0 1 gear oil Aero Shell 14 MIL-G-25537 Dexronll or Dexronll/Merconor Dexronlll/Mercon fluid automatictransmission Sta-Lube3120 grease water-resistant 1 1 4O2 water-resistantgrease grease f Fuelube uel-resistant

A257 -5 A257-5 A257 -6 A257 -6

A257 -7 A257 -8 A257 -9 A257 -10 A257 -10 A257-12

TYPeA 1040 CR drY film Lubri-Kote lubricant P-8O,rubberlubricant 767 Anti-seize 2612, spark plug thread lubricant T-556 2 Mo b i l g re a se 8 g rease

Mealey Lubricants OH Cleveland, Products lnternational Trenton,NJ Loctite CorP. Newington,CT SPar kPlug Champion Toledo,OH Union Industries FL Jacksonville, CorP. Exxon-Mobil VA Fair fax,

P a g e1 . 3 2

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

IICIBINSGIN

MATNTENANeE MANuAL

M('E

EL F|44

L4ZQ lubricants(cont'd)
RHC PART NO. MFR. PART NO.

MANUFACTURER

4257-15 4257 -16

Mil-H-s606 hydraulicfluid

Any
t

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

Phillips Co. 66 Pasadena, TX ExxonMobil Corp. Fairfax,VA Dow CorningCorp. Midland,MlDow CorningCorp. Midland,M l SandenCorp. Wylie,TX PanefCorp. Milwaukee,Wl

A257-16 Aviation Oil 2OW-50,

S A EJ 19 6 6 , 4257 -18

55 lube O-ring 111 Valvelube& Sealant

SP.15 PAG OiI P-16 PetrolatumLube

A257-19 A.25720 A257 2 1

Ch a n g e1 3 : OC T 2 OOo

Pa ge1.33

FIGIEIINSE|N

MAINTENANeE MANUAL

MOEIEL

'f,,44

1.480 Adhesivesand Sealants

ide, B.270-1 Sealant-PolYsulf

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

Gray Gray Silver

B-2 FS-8907 AC-35082 2084

PPGAerospace CA Glendale, Advanced ChemistrY & TechnologyInc., GardenGrove,CA 3M St. Paul,MN GeneralElectric Waterford, NY 3M RadiatorSpec. Co. Charlotte,NC 3M StabondCorP. CA Gar dena, 3M

ide, B.270-1 Sealant-polvsulf

( B'270-2 Sealant-metal 1-Part) ( 1 -p a rt)

rubber Translucentscs 1201 B.270-4 Sealant-silicon

B.270-5 Sealant-synthetic
thread (1-part)

rubberputty (1-Part)

Black Cream Amber Brown Gray

04-2805 94-031 55 Titeseal 74 c 160 2216 BlA

B.270-6 Sealant& lubricant& B.270-7 Adhesive-foam fabric (aerosol) nitrile/solvent {1 -p a rt)

B27A-8 Adhesive-rubber, B,270-9 Adhesive,epoxy,

structural,flexible (2-part)
Red

B.270-10Adhesive/sealantthread-locking {tight-fits) ( 1-part)

Loctite CorP. Newington,CT Loctite Corp.

B.270-11Adhesive/sealant

Red

thread-locking (loose- its) (1-Part) f Tan potting (2-part) CorP. Flamemaster Chem Seal Division Sun Valley,CA Dow Cor ningC or P. Midland,Ml

B,270-12Sealant-electrical B,270-13Sealant-silicone,
electronicuse (1-part)

Translucent 3 14 5

8,270-14Adhesive-foam,

neoprene/water (1-part) fo r vi n yl (1 -p a rt)

100 Neutr al 3 M White Lavender lOO Lavender Clear 2262 3M

B.270-15Adhesive-Plastic,

P a g e1 . 3 4

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

FICIE|INSiCIN

MATNTENANeE MANUAL

MOEIEL

H'44

1.480 Adhesivesand Sealants(cont'd)

RHC PART NO. DESCRIPTION COLOR MFR. PARTNO. MANUFACTURER

8270-17 Adhesive-

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

Clear

SuperBonder Loctite Corp. 495 Newington,CT 05113508008 1838 B/A 3M 3M

8270-18 Adhesive- Weather-strip

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

Black Green Purple

8,270-19 Adhesive- Epoxy,

222 or 222M5 Loctite Corp. LPSLaboratories, Inc. Tucker,GA

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)

Lt. Amber LPS3 Amber Brown Brown

LPS Hardcoat LPS GM3D JV66B P . O . B .I,n c . , Cincinnati, OH DanaCor p. Chur ubusco, lN (Victor ReinzBrand) Loctite

B270-23 Sealant- gasket,

(1-part) 8270-24 Activator/Primer AnaerobicAdhesive (1-part)

Translucent7649 Green Clear

B.270-25 Clear Coat - Automotive

Touch-up,brushin bottle (1-part)

ClearCoat Automotive- Touch Touch up bottle up

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

Page1.35

FICIBINSiCIN
1.49O StorageLimits

MAINTENANeE

MANUAL

MOEIEL

F44

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 first' n ice|ifeis,,o whichever hOurs, with a maximumof 12 yearsor 22OO condition,,, cord servicelife is "on cords have a sherf storagerife of 5 years. Erastic 2. Erastic 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 motors' arc welding' ionizing sunlight,and ozonesources(electric contaminants, are precedingrecommendations 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 has markedcontainerwith manufacture the manufacturer date as start date). manufacture life of 20 quarters (5 5 . Rubbero-rings, seals, and gaskets have a shelf storage with a m aximumol 12 year s' Usecur e date l y e a r s). S e rvi cei fe i s " o n condition" on packageas start date. ( 1.5OO RESERVED}

P a g e1 . 3 6

1 C h a n g e 3 : O C T2 O O o

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 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 OO u t n AN 9 3 1 g r o m me t AN936 lockwasher AN96O-8L asher w AN 9 6 0 - 8 w a sh e r AN 9 6 O - 1 O L a sh e r w AN96O-1O asher w AN96O-416Lwasher AN 9 6 0 - 4 1 6 w a sh e r AN96O-516L asher w AN96O-516 asher w AN 9 6 O - 6 1 6 L a sh e r w AN96O-616 asher w AV D EL 1 6 9 3 ri ve t MS2O604ML4W1rivet MS2191gDG lamp c 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 with Interchangeable MS35649 nut per NASM35649 except brass nut M S35650 nut per NASM 35650 n MS21O83 ut perNASM21083 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 scr M S27O39C 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 w N A S 11 4 9 F N 8 1 6 P a s h e r NAS1149FN832P washer NAS1149F0332P washer w N A S 11 4 9 F 0 3 6 3 P a s h e r NAS1149FO432P washer NAS1149F0463P washer N A S 11 4 9 F 0 5 3 2 P a s h e r w NAS1149F0563washer P NAS1149F0632P washer NAS1149F0663washer P AVDEL 1691 r ivet rivet per NASM2O6O4 MS2O6O4M4W1 A S 2 1 9 1 9c l a m p MS21O42 nut per NASM21042 NAS6603thr u NAS6620 bolt* MS33737 Instrumentnut per NASM33737 NAS1291-_ ut n N A S 1 g 1 C - _ Mn u t 2 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 1 0 4 - 2 8 ,- 3 5 ,- 3 7 , & - 3 8 , a n d N A S 1 3 0 5 - 3 5 3 C h a n g e1 4 : J U L 2 0 0 8 P a g e1 . 3 7

FIElBINSiclN

MAINTENANeE

MANUAL

MOE,EL 1r'44

R44 TESTING SERIES AND lNSTtuerlo.NSFORREASSEMBLTNG FLIGHT 1.700SPEC|AL

MECHANIC BY TO REASSEMBLY: BE PERFORMED A CERTIFICATED I

"A" by removinglag bolts 1. Removetop of cabin assemblycrate. Removewall marked remainingwalls' Removeall assembly' Remove paintedblack. Remove "tp"|nug" baie. open main rotor blade and tailcone tr"i" parts, "r"t" crate. """"ii'"rnin "ri".tiiv, 2. main rotor hub per Section 9'122' Reinstall

gearper Section5'320' landing 3. Assemble

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 position'lift with horizontal time taking up slack in hoist. when r',"ri"opt"tq",,t is in a screws and carriagebolts hoist until cabin is supportedby hoiit alone. Removelag cabinto crate' Removecrate' attachinghelicopter CAUTION lift helicopterand attached crate using box and frames could to main rotor landing points and install assembled 5. Removesupportsfrom tandinggear attachme.nt front crosstube cover gearper sectionl.l2o or seclio'ns (ttoutlandinggear).lnstall to utilitv float inrt"tt ,trrt f.;;"d t"; Sectioi 6.qZO (not applicable panel. tt Oesir-ed, gear). landing 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 drive shaft could damageto tail rotor tailconebeforeinstallation; assemblyper Section4'322' 7 . lnstallempennage 4.330. 8 . Filltail rotor gearboxwith A257-2 oil to full level. markingson bladeswith 9 . lnstalltail rotor per Section9-212. Match color coded links. 6.22O' 1 0 . lnstallf a n a n d scro l lP e rS e cti on pitch Installtail rotor guard Per Section

Page1 . 3 8

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

FIG|E|INEiC|N

MATNTENANcE MANUAL

MOEIEL

F|44

INSTRUCTIONS REASSEMBLING FLIGHT FOR TESTING SERIES R44 1.700SPECIAL AND (cont'd) AFTER HELICOPTERS CRATING EXPORT FOR
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. main rotor gearboxwith A257-2 oil to full level as required. 14. Fall 15. Fuelhelicopterand drain a smallamountof fuel throughgascolator. 16. lf ship is equipped with attitude horizon,directionalgyro, turn coordinator,and/or verticalcard magneticcompass,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) securingwith hardwareprovided. by CAUTION gyro mount screws must not exceed 1 inch in length Directional unit will be damaged. or Connect existing straight connector(s) directionalgyro and/or turn coordinator. to Connect angle connectorto attitude horizon,ensuringstrain relief points down. Ensureconnectorslock in place. Ty-rap excess wiring. Reinstall8197-1 face to (lO-54Oonly), AUX FUEL PUMP (lO-54O console. Reinstallamber FUELFILTER only), ALT, & GOV OFFlights and red ENGFIRE& OIL warning lights. VerticalCard MagneticCompass: Removeverticalcard compassfrom foam-protected box. Installa 2-inch length of 8158-3 heat-shrink tubing over eachcompasswiring pin. Locateexistingwires from windshieldcenter bow. Connectpins from compassto existingsockets (polarityis not critical),cover connectionwith heat-shrink, then apply heat. Securecompassin mount with four screws and hide and securewiring atop compass.

13: Change OCT20Oo

Page .39 1

rl

FIEIE|INSCIN

MATNTENANcE MANUAL

MOE'EL

]',44

R44 TESTING SERIES AND FOR INSTRUCTIONS REASSEMB.LING FLIGHT 1.700 SPECIAL (cont'd)
groundsystem)' 17. Installbattery (negative plugsfrom each cylinder'supper spark plug hole' 1g. Removeplasticdehydrator install' provideduppersparkplugswith A257-1O spark plug thread lubricant' 19. Lubricate and torque PerSection1.330. spark plug accesscovers' 20. Connectignitionleadsto upperspark plugs and install lower spark ignitionleadsfrom lower sparkplugs and remove 21. Disconnect 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 oil preservation 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' is 25. After oil pressure 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

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

FICIBINEiCIN

MATNTENANEE MANuAL

MOEIEL

F|44

1.700 SPECIAL INSTRUCTIONS REASSEMBLING FLIGHT FOR AND TESTING SERIES R44 (cont'd) HELICOPTERS AFTER CRATING EXPORT FOR NOTE fO-540engines shouldidle at 58-620/o vrdth rpm enginewarm,
clutch enqaqed. IO-54O IDLEADJUSTMENT 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 required obtain16-18 pounds/hour flow {170-190 cc/minute). to fuel Clockwiserotationof idle mixture adjustmentwheel (viewedfrom aircraft right side)enriches mixture. Re-check rpm after mixtureadjustmentand repeatas idle requireduntil both rpm and mixtureare within limits. With rpm and mixtureset, verify smooth acceleration from idle to 1O2o/o rpm with no enginehesitationor smoke from tailpipe. Also verify smooth needlesplit from 1O2o/o idle with no to engineroughness erraticrpm indications acceptable quality. Notethat or and idle 16-18 pounds/hour fuel flow shouldproduce acceptable qualityand off-idle idle throttle performanceunder sea-level standardconditions. Richermixtures may be requiredfor cold temperature operationand leanermixturesmay be required for hot/high altitude operation. Deviatefrom 16-18 lb/hr recommendation as requiredfor acceptableidle quality and off-idle throttle performance(smooth accelerations and needlesplits).

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

Page1.41

FICIBINSCIN

MATNTENANeE MANUAL

MOEIEL

F|44

TESTINGR44 SERIES AND.FLIGHT FOR.REA-SSEMBLING INSTRUCTIONS 1.700 SPECIAL (cont'd)

MECHANIC ptLor ANDA cERTtFtcATED To TEST: BEDoNEBy A ouALFED FLTGHT Handbook' operating per inspection the Pilot's preflight 1. Perform
fanwheel per Section6'240' 2. Balance tail 3. Balance 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 R P M p e r S e c t i during 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 higher altitudeso n 1 0 . 2 5 0 . Avoid rotor overrfiJt checks. autorotation by avoidinghigher gross weights (MCP),60 KIAS' and governoron: 7 . while climbingat MaximumcontinuousPower and controllability' roughness a. Evaluate directionalcontrol' b. Perform3O degreeleft yaw to checkfor adequate and terrain)' feet density altitude(deviateas requiredfor weather 8 . Levelflight at 2OOO gou"tnor on, evaluatethe following: MCP, ",id and lateralcyclic controlforces' a. Longitudinal eontrolforces. b. Collective at roughness MCP and 130 straightand level flight' 9 . Evaluate gauges,and avionicsfor properoperation' 1 0 . check all instruments, perform a 30 degree right yaw to 1 1 . During autorotationat 50 KIAS and 9o% RPM, control' directional check-foradequate (DATA)PLATES IDENTIFICATION COMPONENT 1.8OOREPLACEMENT plate- field installation'RHC for componentidentifjcation ln order to issue a replacement lf old identification ftut" in regibrecondition.. must first receive the ord identiil;i;; or (photocopies faxes letter plate is rost o|. a"riroyed, then RHC must have an original identification from customer's civir Aviation Authority authorizing are Nor acceptabre) serialnumberfor each AND statingcomponentname,part number' and plate replacement is plate.-There a chargefor each plate issued' i"qr"rtLO identificaiion Pa g e1 . 4 2 Change13: OCT 2006

2. INSPECTION

FIGIBINSCIN

MATNTENANcE MANUAL
2 SECTION INSPECTION

MI,E'EL

F,44

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-Pull Tubes, Rod Ends,and Spherical Bearings ll 2 . 1 2 1 P u sh -P u T u b e s 2 . 1 2 2 R o d E n d sa n d S p h e ri cal Bear ings 2.125 Elastomeric Bearings 2.130 TelatempIndicators 2 . 2 0 0 G R O U N pA N D F L T GH T H F CKFOR1OO- HOUR/ANNUAL C 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 ME R E P A R A T IONOR 1OO- HOUR/ANNUAL P F INSPECTION 2 . 4 O O 1O O . H OU R /A N N U A L F R AM E A IR INSPECTION 2.41O InspectionProcedures and Checklist 2 . 5 0 O S P E C IA L S P E C T ION S IN 2.541 Clutch Actuator Upperand Lower Bearings Inspection 2 . 5 0 2 C 1 8 1 L o w e r B e a ri n g Inspection 2 . 5 0 3 C 1 8 4 U p p e rB e a ri n g Inspection 2.507 V-Belt Inspection Ch a n g e1 4 : J UL 2 OO8 Page2.i

FICIEIINSGIN

MAINTENANeE MANUAL

MOE EL F|44

IN S 2 . 5 0 0 SP E C I A L S P E C T ION(co n t'd) 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 I
I

of 2.560 penetrantInspection co2o Upper steel Tube Frame on 2.561 Corrosion CO20 Upper SteelTube Frame 2.57O {Reserved} InsPection 2.580 Windshield

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

neoutnenn ) z.too 22oo-Houn avrnHnul

a

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

Pa g e2 . i i

Change14: JUL 2008

FICIBINSCIN

MATNTENANcE rraANUAL
SECTION 2 INSPECTION

MCIDEL

1l.44

2.000 TNTROpUCT|ON The R44 helicopter periodically verify it is in airworthycondition. Required must be inspected to inspection intervalsare maximum 1OO hourstime-in-service 12 calendar or months (annually), whichever occurs first; the inspectioninterval may be extended up to 10 hours, without accumulation,if allowed by local regulations. Preventive maintenance requiredbetween is 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 procedures performingthe requiredperiodicairframeinspections. for

z.1oo GENERAL PROCEDURES

When required,magneticparticleinspectionmay be performedin accordance with ASTM E 1444 and MIL-STD-19O7. penetrantinspection Fluorescent may be performedin accordance with ASTM E 1417 and MIL-STD-1907.Unlessotherwisespecified, the followinggeneral procedures apply to R44 inspection. 2.110 Balland RollerBearings The first indication bearing of failureis usuallyan increase bearing in noise.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 Telatemps detect failingbearings temperature to as 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 retensioning flight (on for 1-8 secondsthen off). Flight should not be in resumeduntil causeof the flickeringclutch light has beendetermined.

Change 4: JUL 2008 1

Pa ge2.1

FIC|BINSiCIN

MAINTENANcE

MANUAL

M(fE EL F44

Tubes,Rod Ends,and sphericalBearings 2.120 Push-Pull ll 2 . 1 2 1 P u sh -P u T u b e s and not more 1. Nicks, cuts, or scratchesin tube not more than O'O1Oinch deep directionusing out in lengthwise may be polished than 1/4 of tube circumference paper and 1-inch minimum blend radius' 32O-gritor finer wet-or-dry abrasive tube if depth exceedsthese limits' Replace it must be 2. lf tube is dented or flattened more than 5 percent of its diameter, replaced. ( l 2 . 1 2 2 Ro d E n d sa n d sp h e ri ca Bear ings seeFigur e2- 1l' inch 1 . M a x i mu ma xi a lP l a Y : O.O2 O inch M a x i mu mra d i a lP l a Y :O.O1 O permitted' between bearingouter race and rod end housingis not 2. Looseness inch diameterwire 3. Rod ends not riveted in place must block passageof o.o2o through witness hole. 1.32O and torque 4 . Rod end jam nuts and palnuts must be torqued Pgt section pre-flight inspection' ;'ir'|ffi,-fi"i eigrt" 2-1', at the moit-uisiUlti position for tube and push-pull Torque stripe must extend acrossn,1. tJboth'rod end shank are subject to (or pitch link barrel, yoke, support, itrut, etc-)-Torque stripes renewed' and Oetdrioration musi be periodically allow as 5 . Refer to Figure 2-1A. Rod ends must be centered,or.positio.ned'.to without binding' possible tuue or link rotationalmovementas much push-pull

Teflon-lined bearings must not be lubricated or solvent

Page2.2

Change13: OC T 2006

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MATNTENANcE MANUAL

MOEIEL

]i44

( 2 . 1 2 2 R o d E n d sa n d S p h e ri cal Bear ingscont' d)

NOTE
HOUSING

RODEND !r."

RACE

A in. FOR MAXIMUM ROD EXTENSION 1 0 1 - 4 :i'.10 WHEN WITNESS NO HOLE IS Dl63-1 1.40n. i PROVIDED: D173-1 1.30n. i
TOROUE STRIPE*

MAXIMUM RADIAL PLAY O.O1O INCH

A PIECE O.O2O INCHDIAMETER OF SAFETYWIRE MUSTNOTPASS THROUGH WITNESS THE HOLE.

AN316JAMNUT B33O PALNUT

EXPOSED THREADS TOROUE STRIPE* BOL

MAXIMUM AXIAL PLAYO.O2O INCH WASHER *Typicaltorquestripelocationshown. Adlust locationas required maximum for visibility duringpreflight inspection.

A 1 1 5 -0 RC 1 1 5 -S P A C E R 1 1 (SMALL DIAMETER SPACER OF TOCONTACT END ROD BALL)

FIGURE 2.1 ROD END AND SPHERICAL BEARING PLAY LIMITS AND TOROUESTRIPE APPLICATION

Positionrod ends for maximum rotation

FIGURE 2-1A ROD END CENTERING Ch a n g e1 3 : OC T 2 0 0 6 Page2.3

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MAINTENANeE MANUAL

n{tfEIEL F,44

Bearings 2.1 25 Elastomeric bearingsare used in the D062-1 tail rotor hub. Fatigue,oil contamination, Etastomeric or overloadcan degradethe elastomer. dust or "erasercrumbs" (seeFigure Smallsurfacecracks(fatiguecracks)and elastomer 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. of o.1o inch) cracks are presentover more than 25o/o 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 weakenedby This can occur when normalloads are appliedto a bearing is exceeded. from and large is fatigue or oil contamination. Overtoad indicatedby large extrusions as clean cracks in elastomer shown in Figure2-2C' from metal bushings.lf separationoccurs over may also separate(debond) Etastomer more than 25o/oof bonded area,replacebearing'

Page2.4

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MATNTENANcE MANUAL

MclE EL n'44

(cont'd) Bearings 2.1 25 Elastomeric

Figure2-2A - Elastomer Fatigue

Figure2-28 - Elastomer Contaminat_ion Qil

o
\

Figure2-2C - ElastomerOvedqad

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FICIBINEiCIN

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MOE'EL

H44

2 . 1 3 0 T e l a te mpl n d i ca to rs of temperatures bearings, in recordincreases operating indicators Telatemp self-adhesive the highesttemperature line draw a reference between etc. To useTelatemp, gearboxes, square' Jqrrru which has darkenedduring normaloperationand the next undarkened block has e See Figur 2-3. During every check thereafter,determineif an additional cannot be accountedfor by a change increase lf blackened. an indicatedtemperature subjectcomponentshouldbe carefullyexaminedbeforefurther conditions, in operating flight.

"fi il nn
116

RECOROER telatemp TEMPERATURE ',127

121

1320C 2700F

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

250

line Reference

Telatemp 110-4 o 1 1 O - 2 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 HydraulicPump (if installed)

Ranges: TelatempP/Ns & Temperature F C/190 degr ees F C 6 O d e g re e s /1 4 0 d e gr ees - 88 degr ees 110-2 - 1 1OdegreesC/23OdegreesF F C 8 2 d e g re e s /l 8 0 d e gr ees 11 0 - 3 es 104 degre Cl22O degreesF - 132 degreesCl27O degreesF 110-4

P a g e2 . 6

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FIG|BINSiCIN

MATNTENANeE MANUAL

MCICIEL F44

INSPECTION AND FLIGHT CHECKFORlOO.HOUR/ANNUAL 2.200 GROUND Completefollowing checklistsin conjunctionwith a 1OO-hour annualinspection. Note or 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. Release throttle and ensureit returnsto normal idle position.

3 . Mixture Control:Check for smoothnessof operationwith no binding.

Check press-to-unlock button for properfunction. Verify O.O3to 0.10 inch spring-back full rich position. at

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

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

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

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

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MAINTENANcE

MANUAL

MOE'EL

844

2.205 GroundCheck(cont'd) 10. Lightingand Instruments: (MasterSwitch on) a.cARBoNMoNoXIDEwarning|ightflashestwice(ifinsta||ed}. b.CarbAirTempapproximatelysameasoutsideAirTemp. c. d. e. f. g. h. i. j. k. l. m. ALT warninglight on' warninglight on' OIL Pressure only)' AUX FUELPUMPwarninglight on (lO-54O Fuelquantitygages- indicationof fuel level' and panellights - check function' Navigation Strobelight- checkfunction' Landinqlights- check function (clutchswitch must be engaged lights)' to chedki-anding MaP light - check function' Ammeter- shows discharge' gage - slight needledeflectionwith enginecold' oil temperature with engine cylinderheadtemp gage- slightneedledeflection c ol d .

n.MRTEMP|ight-onwhensendershortedortestswitch depressed. o.MRcH|P|ight-onwhensendershortedortestswitch depressed p.ENG|NEF|RElight-onwhensendershortedortestswitch 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 rodw f u e | .lo with'clean, non-sparking or send"i in lunt is depreJieO when test switch di:Pressed' (lo-54O light - on when test switch depressed s. FUELFILTER o n l y). (referto 1 1. Verify aircraftchecklistlaminatedcard is currentrevision S e c t i o n1 .OO2 )'

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1 Change 3: OCT2OOo

FlClE|INSiClN
2 . 2 1 0 R u nU p 1. 2. 3.

MATNTENANcE MANUAL

MOE EL ]t44

PerformPOHSection4 'Preflight" checklist. Perform"BeforeStartingEngine"checklist. lO-54O engine: Verify AUX fdel PUMP light extinguishesduring prime and illuminatesafter priming. Verify fuel drains from sniffle valve.

NOTE
valve. Wait for valve to stop draining before starting engine. Enginewill be hard starting/flooded while valve is draining. 4. O 5. 6. 7. 8. 9. Perform "Starting Engine and Run-Up" checklist. lf less than 15 minuteshas elapsed since Step 3, use minimumor no prime. Checkclutchengagement time - maximum70 seconds. Ammeter indicates charge,ALT light off. Both magnetosground (off momentarily) 600/o at RPM. Tachometer operateswith alternatorand battery switches off. No unusualbearingnoisewhen varying RPMthrough operatingrange (mechanic listen near V-belt drive). Referto Section2.110 and to 2 . 5 0 1 th ru 2 .5 0 3 .

primemay be required Significant beforefuel drainsfrom sniffle

10. Set RPM at 75o/o,governor on. Increaseto 85o/o,releasethrottle, and verify governorincreasesRPM to 101 to 1O2o/o.IncreaseRPM release to 1O4o/o, throttle, and verify governordecreases RPMto 101 t o 1 O2 o /o . 1 1. Engine and rotor tach needles of within 1o/o each other at 1O2olo RPM. 12. Verify alternatorvoltageas follows: 13.4 to 13.9 vdc for A942-3 alternatorcontrol unit 27.75 to 29.25 vdc for A942.4 alternator control unit properly. 13. Heateroperates 14. Tachometer needles not jump more than 2o/o do when transmittingon 1 1 8 .OO, 2 5 .0 0 , a n d 1 3 6 .975MHz with gover nor 1 on. 15. Raisecollectivecontrol O.5 inch at grip and slowly decrease RPM. g7o/o 96% Verify low-rotor-RPM warning horn and light activateat to RPMand remainon as RPMis decreased idle. to 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 17. throttle closed' ldle mixture with enginewarm, clutch engaged, pulledslowly to to o-54O engine: 2o/o 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 operation. using cyclic-mounted system (if installed) 1 8 . check hydraulic cyclic OFF. Usingsmalllongitudinal switch, turn hydraulics hydraulics one-halfinch of freeplaybefore inputs,there shouldbe approximately stiffness and feedback.Turn hydraulicsON' Controls encountering motion("motoring")' shouldbe freewith no feedbackor uncommanded on' Completeflight check with hydraulics Verify system blows cold air on both low and high 1 9 . Air Conditioning: and systems' After settings.Verify no fUtiRfi with other instruments draintube in on, a flight with air conditioning verify water drainsfrom ship;s belly (may be little or no water in very dry conditions)'

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1 Change 3: OCT2OOo

FIEIBINSCIN
2.220 FlightCheck 1. Hover:
a. b. c. d. 2.

MATNTENANcE MANUAL

MOEIEL

F|44

All gagesgreen. Controllability lett,andright pedalturns. in Cyclic electrictrim (or hydraulics) zeroscyclic stick forces. Vibration levels satisfactory.

Levelflight Typicalcruisealtitude(if possible, deviateas requiredfor weather and regulations), maximumcontinuouspower, governoron. a. b. c. Vibrationlevelssatisfactory. Cyclic electrictrim {or hydraulics} zeroscyclic stick forces. Collective trim spring (electric trim system only) zeroscollective forces. For hydrauliccontrols: Verify no feedback and collectiveis balanced. Fixedcollectivefriction adequate prevent "bounce" but not to excessive(electric trim system only). Tail rotor pedalpositionwhen yaw string is centered: 0.25 to pedals,within 0.25 inch of neutral 0.75 inch right for adjustable pedals. for non-adjustable Tail rotor elastictrim cord zerospedalforces (cord appliesleft pedalforce). For hydrauliccontrols: Turn hydraulics OFFand verify no excessive feedbackforces.

d. e.

f. g. 3.

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

2.230 Shutdown 1. 2. Verify rotor brakefunctions and ROTORBRAKElight illuminates. Completeshutdown per POHchecklist.

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MAINTENANeE

MANUAL

MoEIEL n'44

blank Intentionally

2 Page .12

13: Change OCT2006

HCIE|INSC|N .

MATNTENANtrE MANuAL

MOE EL 1|'44

2.300 AIRFRAME PREPARATION l OOHR/ANNUAL FOR INSPECTION Thoroughly priorto inspection.Wipedown mainand tail rotorblades, cleanairframe hubs, andairframe exterior with 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 parentheses indicate location illustrated Figures as in 2-4 and 2-44. CAUTION lf pop-outfloats are installed, ensuresafety on pilot's red inflation positionwhen working on helicopter. lever is in LOCKED 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, Inflauon noses. Remove ano wnen worKrng and when workin-gon floats or inflation hoses. . Hemove tocKtng (> 200 pin when work is completed. Avoid excessive heat lq"Lilg degreesF) as thermal relief valve will activate. Perform1OOhour or Annual inspectionper Section2.410. 2.410 InspectionProcedures and Checklist R44 SerialNo.: Registration No.: Hourmeterlndication: Aircraft Total Time: 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 inspection light and mirrorto inspectbearingblocks. Inspect play is 0.080 inch and loosenes5 play. Maximumallowable for condition or axiallyand 0.030 inch radially. Inspectall weld areasin pedalcontrols. Change13: OCT 2006 P a g e . 13 2 Technician name: Technician Certificate number:

FIGIBINEiC|N

MAINTENANeE

MANUAL

MOEIEL

FI44

./

,ffi
co-PILOT'S SEAT 10
..48
\ 4H
il

3E

co-PlLoTs
SEAT

4I (ENGONLY)

,,$
ARD FORW

PANELS AND INSPECTION 2.4 ACCESS FIGURE

P a g e2 . 1 4

Change1 3 : O C T2 0 0 6

FICIBINSiCIN

MATNTENANeE MANUAL

MOE'EL

N44

-*--.Ho--"
/

BATTERY TAILCONE (POLICE ENG and versions only)

l=m
6B

:J

PANELS FIGURE2-4A ACCESSAND INSPECTION

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) 1 co03-1 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 4G 4H 4H

c444-1 c398-1 c794-1 c680-1 c461-1 c464-1 c463-1 co54-1 c474-2 c474-1 c794-2 c794-3 c794-2 c794-3

Cover CoverAssy Panel Cover Assy Cover Tray Cover Cover Assy Cover Cover Panel(without scoop) PanelAssy (with scoop) Panel(without scoop) PanelAssy (with scoop)

6D 7A

DO40-1 DA42-4 DO42-4

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

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

78 8A 88 I 10

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MIfEIEL

F|44

and Checklist(cont'd) 2.410 InspectionProcedures 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 pinchingor kinking. check all-connections security. Flightand EngineGages: Checkall gaugesfor security' Inspectwiring and connectionson all gages. RadioTray(sl: Checkconditionand security. for portionsof TR pedal assemblies Tail Rotor Controls:Check accessible defects. Verify operatingclearance. (3Cl' Sto.p.Go.ver -' 3. RemoveForward Tunnel Covers (3A & 3Bl, -Gyclic (3D1,and ForwardBdllyPanel(3El Cover inUoirAColtective NOTE on lf radio antennasare installed removedpanels,disconnect lead and any groundwire. Pullrespecliveradio circuit Removed"' "nt"tnt andtaq ciicuit-Ureaker "Antenna with Ur"ili". 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

strainq.?9.9s,.9r coatingprotecting Do not disturbclearsilicone or wiringwill disable stra-in-gages to .ti."f't"a *iiing. Any damage trim system.
Cyclic Trim (manualcontrolsl: Turn masterand cyclic trim switches on. stop tP :!9l uld_check stop to stop and longitudinally Mbve cyclic iateratty Cr'ecirtrim moiors, springsand elastic cords for rbtliri ljp"iiti.i" oi tiirn 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 cyclic stick to left stop to compresssprlng' stops then turn trim off . Moverod il;p;"i expoieO ponion of st'tuttfor wear and.galling.Do not glga.sq on bearingis seH-lubricating. springassemblies, neu H una'subse{ueniCOSO-t Checksecurityof attachmentto inipi,ti CtbO-t S'uiuthanespacbr{s--topl. cyclic pivot. C.130-13 controls): Insp.ect Cyclic LongitudinalTrim Actuator (man-ual cyclic stick' u*thin" rfacer trioii. bfteit<tecrrity of attachmentto P a g e2 . 16 Change13: OCT 2006

FICIBINEiCIN

MATNTENANcE MANUAL

MCICIEL ]|44

and Checklist(cont'd) 2.410 InspectionProcedures 3. RemoveForward Tunnel Covers (3A & 3Bl, Cyclic Stop Cover (3C1, InboardCollectiveCover {3D} and Forward Belly Panel(3El (cont'd) Cyclic Friction: Check for excessiveplay or loosenessin links and rod flaringat eitherend of ends connectedto cyclic stick. Verify no excessive C13O-2spacer. Tube and TorqueTube: InspectC319 torquetube paying Cyclic Push-Pull specialattentionto area around blocksand end of torque tube for cracks. Inspect C121-1 push-pulltube rod end palnut and jam nut for tightness. for tubes. Checkrod ends and bearings Check witness holeson push-pull portionsof cyclic pushexcessive play and looseness. Check accessible pull tube and torque tube for defects, includingscratches. Pay particular below C348-1 anchorassembly. attentionto top of torquetube immediately Inspectall nuts and bolts in cyclic controlsfor rotationand looseness. portionsof C121-9 tail rotor Tube: Inspectaccessible Tail Rotor Push-Pull push-pulltube. Look for defects such as cracks, bends, scratches,or play and looseness. chafing. Checkrod ends for excessive GollectiveFrictionand Stop: Inspectcollectivestop condition;no nicks, cuts or scratchesare allowed. Check collectivefriction lever for security and operation. Move collective up and down and verify no bending or bindingof stop. Verify 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. from controls. Wiring Harness: Inspectfor chafingand clearance 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. areasand chafing. HeaterHose: Check heaterhose for collapsed Fasteners and Torque Stripes:Inspectconditionand verify securityof all fasteners. Renewdeteriorated torque stripesper Figure2-1 Remove Outboard Collective Cover (4A), Collective Torque Tube Cover (481,Tray (4C1,Mid Tunnel Covers (4D & 4El, Aft Tunnel Covers (4F & 4Gl, Aft BellyCover Panel(4H), and RearConsole(41,ENGshipsonlyl NOTE antenna lf radioantennais installed removedpanel,disconnect on groundwire. Pull respective radio circuit lead and corresponding breakerand tag circuit breakerwith "antennaremoved". Change 4: JUL 2008 1 P a g e2 . 1 7

'

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MAINTENANeE

MANUAL

MOE'EL

1f,'44

and Checklist(cont'd) 2.410 InspectionProcedures TorqueTube Cover (4Bl' Cover (4A1,Collective 4. RemoveOutboardColtective (4F & 4G)' Aft Tray l4C), Mid Tunnel Covers (4D & 4E), Aft Tunnel Covers (cont'd) Belly Gover Panel(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: Verify no corrosionpitting. Apply a corrosionpreventativecompound such as LPS 2, ACF-50, or Corrosion-Xto any governor area while avoidingcontaminating unpainted,phosphate-coated interiorof openworks well). Ensure friction clutch (a foam-typeapplicator ,,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 torque and yoke, payingspecialattentionto areaaroundblocksand end of -crreck per Section2.12Q.Inspect bearings playin bellcrank tube for cracks. yoke' swaged bearingfor movementin and Tube 1C121-1) Lower Endsof Vertical PushAft End of Cyclic push-Pull Pu||Tubes|C121-7|:|nspectpush-pulltubesforcracks.Checkrodend jam nuts and palnuts for tightnessand rod ends for play' Check rod end -bearings for looseness. Inspectfork assemblyareas' Check bearingsfor looseness. Check between bearingsand swage for evidenceof fretting. Check and Aft End of (C121-1gl Tait Rotor Push-PullTube Lower Bearing: welds on for bearing play. Inspectall witnesshole. Checklower bellcrank sheet metal and inspectsurrounding support assemblyfor lower bellcrank area for cracks. Tube (Cl21-19): Check for bindingor nicks' Check CollectivePush-Pull for play' witness holes.check jam nuts and palnutfor tightnessand rod end for tightness CollectiveFriction Assembly: Check jam nuts and palnuts and supportassembly and rod endsfor play. Inspectall welds on bellcrank sheet metal for cracksand corrosion. inspect surrounding up CollectiveSpring Assembly (ManualControlsOnly): Move collective not touch and down and verify no bindingor cracking. spring coils must Verify when collectiveis full down. Verify jam nut and palnut tightness' lf requiredby rod ends play within limits. Verify guide rods are greased' per Section1.101, serviceassembly Section8'221' fittings for FuelValve and FuelLine: Inspectfuel linefor damageand valve on fuel is leakage(leakage indicatedby a blue or greenresidue,depending used,or odor of fuel). Verify no chafingof fuel lines. TorqueTube: lnspectcondition.Verify attachingsecurity' FuelValve-to-Knob P a g e2 . 1 8 1 Change 4: JUL 2OO8

FlClBINSlClN

MATNTENANcE MANUAL

MC'EIEL

F.44

and Checklist(cont'd) 2.410 InspectionProcedures 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: Verify security and no damage. Verifytubesareunobstructed. EvaporatorDrainTubesandValve(ifinstalledl: protruding from bottom of tee-fitting Placea containerundersediment-tube plug from sediment tube into right-aft baggagecompartment. Remove and allow any accumulatedmoisture and debristo drain. Reinstallplug. squeezedrain tube and sedimenttube near tee-fittingand Simultaneously ball moves up momentarily. verify check-valve StrobePowerSupply&AlternatorControlUnit:Inspectstrobepower supply and alternatorcontrol unit wiring. Inspectmountingpanelsfor cracks. Blind Encoder& GovernorController: Inspectblind encoderand governor controllerwiring. lnspectmountingpanelsfor cracks. and TorqueStripes:Inspectconditionand verify securityof all Fasteners fasteners. Renewdeteriorated torque stripesper Figure2-1. 6. Remove EngineAft (6D1,Belly {6G1,and both side (6A & 68l Cowlings Vertical Firewall: Inspect vertical firewall condition, especially around structuralattachmentpoints,verify no cracks,bucklingor wrinkles. (if Verify security Fuse{slandFuseHolder(sl installed verticalfirewall}: on -66 wire requiresAGC-3 fuse, and no corrosion. Verify correct fuses: -1601 l-1602 wires requireAGC-Sfuse. lf installed -1226 wire requires , AGC-3 fuse. Wiring: Verify security,properinstallation, and no deterioration. Electric Fuel Pump (lO-54O onlyl: Verify security, proper installation, unobstructed drain tube, and no leakage. FuelLine & Hoselsl: Inspectcondition. Verify security,properinstallation, on no leakage, (lO-54O & of only) good condition spirapinsulation fuel line betweenfirewall & gascolator. Lower SteelTubeFrames: Thoroughly inspectlower steeltubestructurefor framesare not chafedby corrosionand inspectall welds for cracks. Ensure wires, hoses,clamps,etc. Engine Cooling Panels: Inspect cooling panels for cracks and missing fasteners. Oil Gooler(s): Inspectoil cooler(s) fittingsfor damage,leaks,cleanliness, and and security. Checkoil coolermountingarea(s) cracks. for 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

and Checklist(cont'd) 2.410 InspectionProcedures (6A & 68l Cowlings 6. Remove Engine Aft (6D), Belly {6G}, and both side (cont'd) Oil Lines: Inspectentirelengthof all oil tinesand verify no cracks,abrasion, wires, ty-raps,and structuremust not or broken clamps. Verify clearance; contact lines. Gascolator: With fuel valve OFF, remove and clean gascolatorbowl and bowl is secured of filter screen. Verify no deterioration gasket. lf gascolator grease. by threadedcollarand ring,lightlylubethreadsand ring with A257-6 and turn fuel valve ON. Safety wire after ensuringno leaks Reassemble occur. Verify drain valve is secureand torque-striped' Mixture Gontrol:Verify mixture control moves mixture control arm stop to stop. Inspectconditionand verify securityof mixture control cable clamps to on bracket;push and pullcablehousing ensureit doesnot slip in clamps. security of mixture control cable inner wire Inspect condition and verify attachment to mixture controt arm. Ensurefreedom of rotation between mixture control arm and innerwire retentionfitting {bolt)when arm moves. (so spring force Verify 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 (lubricating lOair movesfully from stop to stop. Replace filter applicabte) sealing). b4O air filter rubber with A2s7-B rubberlubricantwill facilitate alternate Check air box for conditionand security. Verify spring-loaded air door opens without bindingand closescompletely. rips' & EngineAir Inlet Hose: Verify correct iristallation security' Verify no hose is not chafingframe. areas. Ensure holes,or collapsed 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 instructions battery. As required,performcapacitytest per manufacturer's in drain tube' or replacebattery. Verify securityand no obstructions (9) 7. Open Cowling Doors t7A), RemoveTailconecowling {7Bl & Mast Fairing Cowling Door: Inspecthingesand latchesfor conditionand security' rivets' Tailconecowling: Verify no cracks,air inlet obstructions'or loose and no Electricaland Antenna wires: Inspect condition. Verify 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. Verify 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 InspectionProcedures and Checklist(cont'd) 7. Open Cowling Doors {7A1,RemoveTailconeCowling (78} & Mast Fairing(91 (cont'd) Forward Flex Plate: Inspectcondition, particularlyedges. Verify security. Verify bonded washers are securely bonded to both sides of each flex plate arm. Verify 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. Verify no cracks,corrosion, or fretting. Verify securityand operatingclearance. Rotor Brake: Inspectcondition,includingactivatingcable & pulleysand microswitch. Verify integrityof brakepads and 0.030 inch minimumpad thickness.Verify brake pad clearanceto input yoke when brake is off. Verify securityand operatingclearance. Jackshaft: Inspect entire welded assemblyfor cracks and corrosion. jackshaftsupporting Inspect strut 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). Verify securityand operating clearances. Main Rotor Push-PullTube Rollers & Bushings: (manual controls orllyl' Inspect condition. Verify 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

and Checklist(cont'd) 2.410 InspectionProcedures (91 7. Open GowlingDoors {7A1,RemoveTailconeCowling {78} & Mast Faidng (cont'd) Tube and upper Bellcrank: lnspect c121-15 pushTail Rotor Push-Pull pull tube, especiallyat ends, for cracks. Check iam nut for tightness and mountingfor cracks or and rod end for looseness.lnspectbellcrank 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 for cracks' Verify gearboxmounts, cap mounting lugs, and mast tube and no detertration of rubbermounts. Verify security no contamination of Hall Effect senders. check Telatempfor overtempindications. oil Main Rotor GearboxOil: With ship on level ground, verify correct 1' 101, u l e v e l a n d cl e a n ti n e ss si n g si ght gage. lf r equir edby Section 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 r e rS e c t i o n1 . 1 1 5 . P to inspect Upper Steel Tube Frame: Use an inspectionlight and mirror each weld, verify no cracksor corrosion'

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

FICIBINSCIN

MATNTENANeE MANUAL

MC,EIEL F'44

2.410 InspectionProcedures and Checklist(cont'd) 7. Open Gowling Doors (7A1, RemoveTailconeGowling (7Bl & Mast Fairing(91 (cont'dl Fuel Caps: Inspect condition, to include gasket. Verify security when closed. Verify 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) corrosion, for looserivets, deformationand cracks. Clutch Assembly: Inspectends of drive shaft and sealson sheavefor oil junctures. leakage.Inspect shaft for corrosion,especially shaft-to-seal at junctures,and apply a Removeany light surfacecorrosionat shaft-to-seal suitablecoriosion-inhibitor. Upper Sheave: Inspect sheave grooves. Replaceany sheave showing corrosionpitting or flakingof metalized anodized or coatings,wear through anodizedcoatings,roughness, sharpridges. or Ddve V-Behs (see Section 2.5071: Inspect V-belts. Verify no breakage, deterioration rubber,cuts, fraying,oil, grease,or foreignobjects. of Actuator Fuses& Holders: Inspectcondition. Verify no corrosion. Verify correct fuses (14-voltsystemsrequireAGC-3fuses while 28-volt systems requireAGC-1% fuses). Verify 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 increased without corresponding increase ambienttemperature. in 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 bearingbrackets looseness wear. lnspectbearingper Section for or 2.502 if discrepancies found are 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

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]l44

and Checklist(cont'd) Procedures 2.410 Inspection

Belt TensionActuator Test Plug

VIEW LOOKING INBOARD

1_...
Aft Cowl Door

2.6 MT558.1 TOOL INSTALLATION FIGURE

2-6A ACTUATORSWITCHTEST FIGURE P a g e2 . 2 4 1 Change 4: JUL 2008

FICIBINS|CIN

MATNTENANcE MANUAL

MOEIEL

R44

Procedures and Checklist(cont'd) 2.41O Inspection 7. Open Cowling Doors (7A1,RemoveTailconeCowling tTBl & Mast Faidng(9) (cont'd) Actuator (CO51l: Verify clearance structure and drive train when fully to Turn masterswitch on and engage disengaged. clutchswitch. Whileactuator depress is engaging, extensionlimit switch lever {seeFigure7-15) and verify gearmotorstops; release leverand verify gearmotorresumesrunning. Verify integrity of activatingcable for extensionlimit switch. Use an inspection mirror to observe column springs at end of belt-tensioning cycle; springs should snap outward simultaneously.Verify maximum engagedextension limit per Figure7-15 is not exceeded.Verify clearance structureand drive to train when fully engaged. Verify down-limitstop screw jam nut is tight. Check actuatorfor failed-closed spring switch using either of the following two methods: Method 1 - (actuatorelectrical harnessmust be equippedwith "Test" plug per Figure2-6) a. With MASTERswitch on and actuatorfully engagd, connect one end of MT558-1 tool to actuatortest plug and verify gearmotorremainsoff. CAUTION lf gearmotoractivateswhen installing MTs58-1 toolthen a sprin switch has failedin closedposition;immediately removeMTs58to preventactuatordamage. b . DisconnectMT558-1 tool, connect oppositeend to actuator test plug, and verify gearmotorremainsoff . Disengage clutch and turn MASTERswitch off. d. MT558-1 pins 1-2 jumpertests wire 98 springswitch; pins 2-3 jumper testswire 91 springswitch (seeFigure 14-1D). Replace malfunctioning any switch per Section7.551 beforefurther flight. Method 2 - (actuatorelectrical harnesswithout "Test" plug) a. Referto Figure 2-6A. With MASTER switch on and actuatorfully engaged, depresscolumn springson one side of actuatoruntil springssnap inward (uselargescrewdriver similar or tool with several layersto tape over end to protect actuator). Hold springsinward for at leastone second. Actuator motor shouldnot run. lf motor starts, allow motor to run approximately pressure columnsprings. Depress two seconds, then release on and 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-functioning switch 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

and Checklist(cont'd) Procedures 2.410 Inspection Fairing(91 7. Open Cowling Doors (7A), RemoveTailconeCowling t7B) & Mast {cont'd) any sheaveshowing Lower Drive Sheave: Inspectlower sheave. Replace coating, wear grooves' roughness' corrosionpitting ot it.t inb of metalized or sharpridges. Adjust as SheaveAlignment: Verify sheave alignmentper Section 7 '23O' required. no Hydraulic Reservoir: Inspect condition. Verify security^and. significant per Section1'1.7O' filter by teakage.lt requireO Section1.101, replace per Seciion 1.180 if oil has turned dark or Drainand flush hydraulicsystem emits bad odor. Add fluid as required' CAUTION of cleanliness hydraulicfluid is vital_toproper system operation' arid containers avoidcontamination Cl".n tfiiO tiom seated Ur" ""iV funnels, etc. from dirtv is secure HydraulicReservoirCooling Hose: lnspect condition' Verify hose coolingfins' anOi. directedat centerof reservoir shouldnot indication Pump: Inspectcondition. Pumptemperature Hydraulic significant exceed gearboxtu,iipttuture indication' Verify security and no leakage. Servos: Inspectcondition. Inspectrod ends per Section ForwardHydraulic rod servo--input 2.120. Verify ,."rtity and no significantleakage. Verify solvent non-alcoholic end/clevisareais clean;cleanseaiea with no-residue, inch total freeplayat servo valve as iequireO. Verity apiroximately O.O4O structurewhile flight controls to input. Verify valve ciearance surrounding security are movedthroughfull rangeof travel. lnspectconditionand verify of scissorsat upperclevis of servos.

parts' Oo not to UseLPSPresolve cleannydrautic

servo: Inspectcondition. Inspectrod ends per section Aft Hydraulic input 2.120. Verify r""uiit' ind no significantleakage.. Verify servo non-alcoholic -Verify area is clean;cleanseareawith no-residue, rod end/clevis 0.040 inch total freeplayat approximately ,oiu"nt as required. structurewhile to input.-Verify valve clearance surrounding servo valve flight controlsare moved through full rangeof travel. Aft Hydraulicservo: Inspectrod ends per section.?'120. Inspect attachmentto Sheetmetal, verify no cracks. Verify security' to HydraulicLines& Fittings:Inspectcondition. Verify valve clearance range structur" *iil" flight controlsare moved throughfull surrounding 0.25 inch of travel. Verify security and io leakage. Verify.minimum betweenpump hosesand aux fuel tank' clearance securityof all and TorqueStripes:Inspectconditionand verif,y Fasteners toique stripesper Figure2-1. fasteners.Renewdeterioiated 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

Criteria(cont'd) 2.410 Inspection 8. RemoveTailconePlugs{8Al & Aft PlasticCover (8Bl NOTE Aft plastic cover (88) is secured with two MS27039C0806 tailcones. On Rev K and prior screws on Rev L and subsequent plasticcover are short enough ensurescrewssecuring tailcones 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 contact 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 immediate replacement tail rotor drive shaft. of Damper: Inspecttail rotor drive shaft damper{C041-1}. lnspectbearing and housingfor cracks,corrosion,wear (see Figure 2-81,and bearingseal cracks, bendsand for deterioration.Inspectarms and bearings cleanliness, shaft torque stripe. corrosion. Inspectbearing'sinner race-to-drive TailconeExterior: Inspecttailconeexteriorfor nicks, scratches,corrosion, fretting between skin joints, 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 verify clearhalf of lensfaces aft. lensis installed, security. lf split red/clear Antennas: Inspectall antennasfor conditionand security. battery condition TailconeBattery {if installedl: Inspecttailcone-mounted and security. Verify 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:Inspectentireempennage and attachmentpoints for damage, cracks, and loose fasteners. Check tail skid for evidenceof tail strike. lf evidenceof tail strike is found, refer to specialinspectionsection. (if Float Stabilizer installed): Inspectconditionand security. Aft Flex Plate(SeeFigure2-51: Inspectflex plate for cracks, fretting, and distortion. lf fretting is detected,contact RHC TechnicalSupport. Inspect securityof flex plate fasteners. Tail Rotor Drive Shaft Aft Yoke: Using inspectionhole, check yoke for cracks,fretting, and corrosion. TailRotorGuard:Inspect security.Checkforwardmountfor cracksaround for welded area. Inspectareaaroundaft mount for crackingand fretting.

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

Page 2.27

FIC|BINSiCIN

MATNTENANeE MANUAL

M|lE

EL ]?'44

(cont'd) Criteria 2.41O Inspection

FWD

WEA MAXIMUM ALLOWABLE 0.040 inch

A V IE W L OOK IN G F T

INSPECTION 2-8 TAIL ROTORDRIVESHAFT DAMPERBEARING FIGURE

Page 2.28

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

FIGIBINSC|N

MATNTENANtrE MANUAL

MOE'EL

F'44

Criteria(cont'd) 2.41O lnspection 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 cleanliness throughsight gage and adjust or flush as required. Check gearbox-to-tailcone mounting security. Inspect output shaft for nicks, gearboxbolts. scratchesand corrosion. Check safety wire on applicable CheckTelatemp. NOTE At 500 hourstime-in-service annually.whicheveroccurs first, or removechip detectorand cleanvarnishfrom detector'smagnetic probe and adjacent metal body (a toothbrush dampened with solventworks well). Also, drain and flush gearboxes intervals at (ref not to exceed500 hourstime-in-service Section 1.101). Pitch ControlAssemblyand G121-17 Push-Pull Tube: Check pitch control assemblyfor free movementthroughoutits entire rangeand for looseness on output shaft (0.25 inch maximumrotationalplay measured pitch link at attach bolt). Inspectbellcrank cracks and ensurefree movement. Pay for specialattentionto sphericalbearingatop stud protrudingfrom underside of pitch control;it is permissible have a singleradialcrack in the spherical to bearingball. Inspectaft end of C121-17 push-pull tube for cracks and (Ref R44 SB 43A). check rod end for excessivelooseness PitchLinks: Checkrod endsfor excessive looseness.lf equipped with onepiecepitch links,disconnect and rotate inboardend outboardas required to obtainmaximumservice life. 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,requiringreplacement blade. CO29-1bladesonly: remove of tip covers,inspectfor debrisand corrosion,& reinstallcovers. Hub Plates and Hub: Inspect for cracks and corrosion, paying special attentionto areasaroundbladeand hub mountingbolts. Ensure teeterhinge bearingouter racesmove with hub and bearinginnerballsand retainingnut and bolt remainstationarywhen hub is teetered. Hub should move freely on bearings without stiffnessor jerkiness. Checkteeter hinge bearings for play. For elastomeric excessive bearings inspectper Section2.125. Fasteners and TorqueStripes:Inspectconditionand verify securityof all fasteners.Renewdeteriorated torquestripesper Figure 2-1. 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

and Checklist(cont'd) 2.41O InspectionProcedures 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. at rollersand guide' tude sleeves manualcontiols, i;tp""t pusir-pult tube rod ends per section 2.120. Rod Ends: check push-pull and Plastic Rollers and Guide {manual controlsl: Inspect plastic rollers deterioration' security,and grid" fot cleanliness, attentionto connecting PitotTube: Inspectpitot lineandtube, givingspecial pitot tube elbow drain hole area,tor n"nii[g, Liatr.ingandkinkind. verify is unobstructed. tube Fuel Tank Vents: Inspect conditionand security of fuel tank,vent tube Check clamps. Ensuie-pitofiine is noi chafing fuel vint tubes' pinched, and connectionr.-V"?ity tubes are unobstruc-ted are not kinked, 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. ends and Swashplate Upper Scissors: lqsqq"^tcondition. Inspect rod per Figure play 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.nd operating and arm rotate'toglther ut uu"h rcirsor linkagepivot. verify c l e a r a n ce . condition.Verify no cracks at rivet holes SwashplateSliderTube: In-spect anodized to, on or corrosior, urle. Veritv no durnage or wear through, tube surface. swashplate' Remove swashplate Boot Lower Ty-rap: Lift boot from drive shaft main rotor lnspeit .i"u'U"t*een Using insp"cfion-16irror, "n of slidertube. Veriiy no corrosionand no debris. Verify no and inside boot damage. radialplay swashplate: Inspectcondition.Verify 0.920 inch maximum

and have ball SwashplateShimming:Observeswashplat^e from below swashplate someonemove collectivesticl-siowty up & down. Verify reverses swasfrptatewhen swash.plate ball immeOiai"fy1.11ou6t-witfr without.attendantball movement of direction. fVfou6ment swashplate shim swashplateper indicatesu*il'i pr"v ultw#n-uJtl ana swashplate; 8 Section .416. position and Install Swashplate Boot Lower Ty-rap: Verify 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

and rotorby hand verifv ,*uri.,-ilriduirri"o riiori tr'uu.Rotate between or il;;;tilg-clearanceandno rough dry bearings'

FICIBINS|CIN

MATNTENANcE MANUAL

M(lElEL n44

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

i FeelerGauge /';" ,'

fI\
HoldingTool

-----4

S-_

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

For scissors with 8115 spherical bearinqs:

PLAY ROTATIONAL FIGURE 2-9 MEASURING SWASHPLATE UPPER (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

and Checklist(cont'd) 2.410 InspectionProcedures 12. Main Rotor Blades(Referto Section9.130 for damageand repairlimits) CAUTION care when working Main rotor bladeskinscan be dented;exercise on or aroundblades. Inspectvisibleportion.Verify no corrosion. apd n9 .oil leakage..Verify Boots: Inspect condition.Verify security. betweenboots and main rotor hub at full-up and full-down clearance collectiveat cyclic travel extremes. Nicks, Scratches,Buckling,and Dents: Verify no nicks, scratches,or buckling.Verify any dents are within limits. 9-9 & 9-9B: Usinga 1965Areas: Referto Figures Adhesive-Bonded critical bond areas and or-i"i"t U.S. qratter-dollarcoin, taf-test..all. bond areas and u"iity no dull'or hollow sounds. Visually^inspect for void limits. verify no separation,Referto section9.13O.h. visuallyinspect magnification, bond line: Using5x--1Ox Skin-to-spar -Verify-no. separation and no cracks in 'Refinish Jf.in-to-"par bonded ireas. any exposed {bare metal) bond [n"-. pii"iit"hg skin-to-spar 'bond with R44 ServiceLetter SL-32. line in accordance or Remove tip covers: Verify no_corrosion foreign material in blade U'S' a Refelto Figure9-9. Using. 1965-or-later iipJ o. o.t iip and "ou"it.tap-test skin]to-tipcap b-ond.areas verify no qliti"t-Ooiiir-coin, inspect ciullor hollow sounds. Using 5x-1Ox magnification,_visually bondid areas {see Figure9-9} and verify no eJge-of siin+o+ip cap bn.y and p_aint, exposedbare Telgl -Ensure s"iar"tion. epoxy prir", or p.rime tip cover and bladetip tip cover. *f,icf, may conta6t'inJtaited drain holesare unobstructed. WARNING Structuraldamagemay occur if compressedair is appliedto blade drain holes.
THESEAREAS FOR SIGNS INSPECT SUCH AS BLISTERS OF SEPARATION

AND BULGES.

HONEYCOMB

\ SPAR

P a g e2 . 3 2

INSPECTION SKIN.TO-SPAR BI-ADE 2.1O MAIN ROTOR FIGURE c h a n g e1 4 : J U L 2 O O B

FICIBINEiCIN

MATNTENANcE MANUAL

MOEIEL

H,44

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

all fasteners. Renewdeteriorated torque stripesper Figure2-1 13. ScrollArea Fanwheel Assembly: Cleanand inspectfanwheelassembly cracks for and corrosion. Checkleadingedge of vanesfor damage. Verify spring pin andfanwheelalignment marksarealigned(seeFigure2-11l';remove fanwheel and inspect mating surfacesfor darnageif misalignment is evident. Fiberglass Scroll: Inspectfiberglass scrollfor cracksand contact marks from fanwheel. Inspectflexibleseal aroundscroll inlet for any rips or damage.Inspectvane assemblyin right upperscrollfor damage.Verify drainhole is unobstructed. ScrollMetalInletLips&Gap: Verify0.030 / O.O9O inchgap 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 publications 1OOenginecomponentmanufacturer's maintenance for hour or annualinspectionand serviceprocedure. Engine Cooling Panels:Inspect condition. Pay particularattention to panel(s)mounting oil cooler(s)and panel attachedto alternator cooling hose. Verify no cracks or missingor loose fasteners.Verify security. Alternator & Pulley: Inspect condition. Verify steel pulley (use magnet); aluminum pulley is not approved.Verify security. Verify wiring security. electrical Alternator Belt:Inspectcondition.Replace belt if thereareany cracks, missingteeth, or delamination.Checktensionper LycomingService Instruction1129 (latestrevision). Verify properbelt alignment. EmergencySpare Alternator Belt: Removeif installed. AlternatorCoolingHose:Inspectcondition.Verify no obstructions or holes.Verify security. Air Gonditioning Refrigerant Lines (if installedl: Verify security, no damage,and clearance adjacentstructure. Verify dust caps to installedon servicingfittings at verticalfirewall. (if Air Conditioning Compressor installedli Verify security. Air Conditioning Gompressor Drive Belt (if installedl: Inspect condition. Verify 4.5/5.5 pounds force appliedat mid-span belt of c au se s0 .1 1 /0 .1 7 i n ch b elt deflection; adjustas r equir ed. Muffler Elbow & Tailpipe Shields: Verify no cracks in shieldsand shieldattachingbrackets.Verify clamp security. C h a n g e1 4 : J U L 2 0 O B P a g e2 . 3 3

Installtip covers: Verify security. & Fa{iteners TorqueStripes:Inspectcondition and verify securityof

FICIEIINSCIN

MAINTENANeE

MANUAL

MOE EL F|44

2.410 InspectionCriteria(cont'd)

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

P SPRING IN

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

NUT CASTELLATED

MARKS ALIGNMENT 2-11 FANWHEEL FIGURE

Page2.34

1 Change 3: OCT2OOo

FIGIEIINSCIN

MATNTENANeE MANUAL

MODEL

Fl44

2.410 InspectionProcedures and 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, supports, riser. flangesand gaskets.Pressurize muffler 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. Verify drain holes are open (not applicable float landinggear). to Struts and Elbows (open fairings if installedl: lnspect for cracks and corrosion,especiallyat elbow joints. Inspect weld area at bottom of strut for cracks. Landing Gear Fairings (if installed): Inspect for cracks and loose rivets. Verify security. Grosstubes:Inspect,especially elbow joints, for cracks and corrosion. at 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. Verify security. Verify pressure gageindicates for correctpressure ambient temperature; refer to placardon cylinderfor limits. Pop-outFloats (if installedl Inflation Manifold: Inspect condition. Verify no chafingor pinchingof hoses,especially where hosespassthru structure. Pop-out Floats (if installedl: Inspect condition of stowed floats. Verify no holes, cuts, tears, abrasionthru, or unravelingof, float covers. lf cover damage is found, inflate and inspect floats. Verify all float cover snaps and hook-and-loop fasteners are properly secured. Verify 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

MAINTENANeE MANUAL

M.fDEL

F|,44

and Checklist(cont'd) 2.410 InspectionProcedures 17. Cabin Verify no looseequipmentthat might foul controls' floats are Static ports: Inspect static ports for obstructions. lf fixed utility aft verify air dam installed of both static ports' installed, RearSeat-Bottomsuspensionstraps: Inspectcondition and security' Inspectforfraying and brokenstitching. SeatBeltsand ShoulderHarnesses: quicklyto verify by Checkinertiareelsfor properoperation 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 an a. one nick, not more than o.o1o inch deep and occupying 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' faults in smallareasof windshieldnear edges' d. Minor polarization by for skin: Inspectskinfor damage.Inspect looserivets,indicated cracked paint and/or black residuearoundheads' for Doors: lnspect for cracks around hinges and latches' Check vents tightness with cotter pins' check hingepins are secured operation.Ensure of hinge mounting .Jr"*r. Verify proper operationof door latching and lockingmechanisms. Chin Drains (R44 Clipper):Verify no obstructions' 18. Special Equipment(if installedl by Peak Beam searchlight: check for proper operation. Align beams a wall at and shiningagainst spot possible focusingboth lightsto smaltest same point within one foot' least 1OOfeet u*ty. Verify both spots hit units Nose Gimbal and Monitors: Turn power on and verify infrared time' complete cool down sequence in manufacturer'srecommended focus Verify gimbal steers smoothly in azimuth and elevation' check Verify and zoom of infrared/video.check for clear imageson monitors' monitor retractswithout interference. retractable Pa g e2 . 3 6 Change13: OC T 2006

FIclElINEiClN

MATNTENANcE MANUAL

MOEIEL

F|44

(cont'd) Procedures Chec.klist 2.410 Inspection and (if 18. Special Equipment installedl
SpectrolabSearchlight: Verify light starts and cooling fan operates. Verify searchlight steerssmoothlyin azimuthand elevation. For slavedunits,turn on slavingand verify light follows nose gimbalapproximately. FM Radios: Verify radiostransmit and receiveproperlyand control head programsradiosproperly. VideoTape Recorder:Verify all videotape recorder modesoperateproperly and remote control correctlycontrolsmodes. OverheadLight: Verify overheadlight on/off. TransmitandIntercomSwitches: Verifyproperoperation specialtransmit of and intercomswitches. Talent Light: Verify talent light on/off, acceptable friction. Micro Cameras:Verify all micro cameras selectable are from videoswitcher producefocused,uprightimageson monitors. and (videoclear on monitors, TV Tuner: Verify TV tuner receivesbroadcasts audio clear in headset). MicrowaveAntenna: Verify omnidirectional microwaveantennaextends/ retractsproperly. Verify up/down indicatorlights function properly. Electromagnetic and Radio Frequency Interference: With all special equipment turned or, check for EMI/RFIwith tach, COM, intercom, compass,or other systems. 19. Life-limitedParts, Airworthiness Directives,& Service Bulletins Life-LimitedParts: Verify S/Ns of installedparts correspondwith those listed in maintenance recordsand all installedparts have adequateservice lives remaining. AirworthinessDirectives:Check status of applicableairframe, engine, and accessoryAirworthinessDirectives,includingcompliancemethod. Some aircraftmay have Airworthiness Directives which requirerecurring inspections at less than 1OO-hour annual intervals. Recent U.S. or AirworthinessDirectives on may be accessed the internetat: http: //www 1.f aa.gov/certification/aircraft/ Service Bulletins: Check status of applicableairframe, engine, and accessory ServiceBulletins, compliance including method. Some aircraft may have ServiceBulletins,which requirerecurringinspectionsat less than 1OO-hour annualintervals. RecentRHCServiceBulletinscan be or via accessed the internetat: www. robinsonheli.com/support. htm 2O. RequiredDocuments and Placards Documents:Check that requireddocuments(Airworthiness Certificate, Registration, applicable Radio Station License, Pilot's Operating Handbook,Equipment List/Weight Balance & Data)are on board,legible, and current. Placards: lnsureallrequired placards installed, are legible, andcurrent;refer to Section 2 of Pilot'sOperatingHandbook placardrequirements. for Ch a n g e1 3 : OC T 2 OOo Page2.37

FIElBINEiclN

MAINTENANcE MANUAL

MOEIEL

F|'44

(cont'd) and Procedures Checklist 2.410 . Inspection and 2O. Inspection AccessCovers Verify all tools'.lggt" hardware, rags, and ForeignObiectsRemoved: from aircratt" otherioreiin objectsare removed covers and all coversclosedand secure:Instatl/close inspection access accesscovers' steps.Verifysecurityof all t"rJ""a in pieceding with is air clipper I Airbox sealed:Ensure box cover perimeter sealed only)' I tape {Clipper models aluminum Records 21. Maintenance records are current and Records:EnsuremaintenanCe Maintenance oil adjustments' (sucii'i; i;n' replacement, '.nO correct.Entermaintenanc" Datamust includea inip'"ction'data. O""tinJlrbti""tionf change, date,aircrafttotal timeto, of description , or reference worti performed-, return righiiri";;;d ;.dificate humberof personapproving in-service, 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 L S P E C T ION S IN 2.501 Upper and Lower ClutchActuator Bearings Inspection 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 retensioning time of up to 8 seconds,then off). Flight should not be resumeduntil causeof abnormalclutch light illumination has 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 g sp ection In 1 . R e m o vescro l la n d fa n w h e e lp er Section6.210. 2. Support clutch drive shaft aft of sheave. Disconnectlower end of belt tension actuatorfrom bearinghousing. scrapingor excessive 3. Rotate bearinghousingwith finger tips. Verify no roughness, (O.O1 On ch ma xi mum axial play) . Ver ify no seal dam ageand no heat l o o s e n e ss i p d a m a g e . L u b ri ca te e a ri n g er Section1.140. b 4. Carefully inspect inner race bearingson fanshaft. Forward bearing inner race is torque-striped fanshaft two places 18O degreesapart; crackedor brokentorque to stripes indicatemovement.No movementor fretting is allowed between inner race and fanshaft. Verify no distortion due to bearingouter races rotating in housing. Replace fanshaft & bearingassemblyif indications movementare noted. of 5. Reinstall fanwheelper 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

Inspection 2.503 C184 UpperBearing housing' 1. Disconnectlateralcenteringstrut from left side of bearing positionby to housingfrom actuator.Runa-ctuator its furl disengage bearing 2. Disconnect Do not allow upper 7-15. adjustingu.tuiior-oown-tiirit,"ir* ,p*"rd. Referto Figure screw headsto contact each other' ittaching and lower scissors; of any roughness'scraping' or 3. Rotate bearinghousing and check for sound or feel Vbrify no suatdamage,loss of lubricantor heat damage' excessivetooJeneJs-. raceis torqueon inspectinnerracesof bearings clutchshaft. Aft bearinginner torque stripes 4. Carefully or broken stripedto clutl-hr6uii two-placeiiab-u"gr"es apart; cracked and races shaft.Verifvno inner n"ifi""q b6aring *ou"i.,"if. V";iit 'io trliting indicate and Removebearings rotatingin beariig hou.sing. distortiondue to bearingouter r"""irT of inOications movementare noted' ;;;f,tiiit inri"dfUetid down-limit b. Connect centeringstrut and actuator to bearinghousing. Adjust.actuator and secbndsbeiween clutch engagement stop screw ir,"ltuir-i oetay "o rotor turning duringstart-up. "il"ii-tin-5

Pa g e2 . 4 4

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

FIClBINEiclN

MATNTENANeE MANUAL

MOEIEL

F|44

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 gradualhardening of undercord.

REMEDY

Returnactuatorto RHC for servicing.

2. Top of tie bandfrayedor damaged.

CAUSE

REMEDY

structure Surrounding with normal interfering of operation belt.

\N

Foreignmaterial contactingbelt.

affected Reposition sheavefor proper clearance and align per Section sheaves 7.230. Removeforeign material

3. Top of tie band blisteredor perforated.

CAUSE

REMEDY

material Foreign between accumulating belts.

Checkfor and remove foreignmaterial.

FIGURE 2-12 V-BELT DISCREPANCIES

Ch a n g e1 3 : OC T 2 OOo

Page2.41

FIClElINEiclN

MATNTENANeE MANUAL

M('EIEL

]I44

(cont'd) 2.507 V-BeltInspection CUTON BOTTOM 4. BELT

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

GROOVE SHEAVE OUTSIDE 5. BELTRIDING 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 from One belt separated tie band Remedv Both belts separated from tie band

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

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

DISCREPANCIES 2-12A V-BELT FTGURE

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

Page2.42

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.

DRIVE BELTS

/\

WEARPATTERN RATIO GROOVES IN N OTMORE THAN3:1

r,4

FIGURE 2-13 LOWER SHEAVE V-BELT PATTERN WEAR

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 with bendingor breaking tail skid and/orbucklingof lower of tail skid. Part B is concerned 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 contact. lf tail rotor damage is found, inspect tail rotor per Section 2.520. for 2 . Visuallyinspectverticalstabilizer evidenceof buckling,cracksor loose stabilizer rivets at tail skid and lower verticalto horizontal attach 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. perforrn B. For skid bendingor breakage, bucklingof lower verticalstabilizer, or in the following inspections additionto those listedin Step A. 1 . Inspecttail rotor drive shaft run-outper Section7.340. 2 . Removetailconeand dye check CO2O uppersteeltube structureat tailcone attach points per Section2.560. 3 Visually inspect tailcone attachment points for elongatedholes (0.454 maximum. inch-diameter ) 4. Remove the stabilizerassembly and dye penetrant inspect the tailcone casting. a) Removepaint from tailconecastingin areasshown iri Figures2-14 and per paint remover Section1.410. 2-14A usinga suitable providedby manufacturer b) Dye penetrantinspect using instructions of dye penetrantinspectionkit.

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

Page2.45

FIG|BINSIG|N

MAINTENANcE

MANI.IAL

M('E'EL

],'44

t; | |

ta

I ttl I tl I
l|l

1l

,,\

I lt r
:t t I ltl

I
I
\ I

I i\! \l

i,!

t I t
I

r -4t

I :,i=

l,^

DYE

F|GURE2.14TA|LCoNEcAsT|NGToPAFTV|EW AREASAFTERPAINTREMOVAL DESIGNATED INSPECT PENETRANT

Page2.46

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

FICIBINSIC|N

MATNTENANeE MANUAL

MOE EL N44

FIGURE 2.14A TAILCONE CASTINGBOTTOMFWD VIEW DYE PENETRANT INSPECT AREASAFTERPAINT REMOVAL DESIGNATED

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

Page2.47

FIclBINEiclN

MATNTENANeE MANUAL

MI:'EIEL

F|44

(cont'd) 2.510TailSkidStrike as stabilizer follows: horizontal 5. tnspect attach pointsfor elongated stabilizer a) Visuallyinspecthorizontal looserivetsor buckling. maximum) diameter 6oiJJtb.Sg6-inch and from horizontal visually lowerverticalstabilizer b) Disassemble for stabilizers inrp""i ittach points on verticaland horizontal cracks buckling, maximum), diameter ;ffig;td-hol"r iO.ZOO-inch of ofio"oi" rivets. bJcklingand cracksare causefor replacement out be rivetsm-ay drilled and replaced' tn" *ii. Loose tail rotor guard. Removepaint from forward and aft Remove utti"f,*"ni points 5nd dye penetrantinspect using instructions kit' inspection Remove dye piouiO"O manufacturer'of penetrantby by rdmovinsfour 10-32 screws and tiorn t"itione 6;;;J;;"hf inspectsameas abovestep' dye penetrant
2.52O Tail Rotor Strike is Tail rotor strike inspection listedin two parts,{.and B. PartA concernsdamagereceived obiect UV a tiif roto, blaile due to contact with a small stone, tall grass, or some small rotor B is concerned with sudden stopp?ge of tail iotor Uf"O"ln ir"" air. Part "6ni."iing solid object contact causingbendingor shearingof a tail rotor blade or Ar" to gr6unO-or blades. A. tnspectper Section9.220 and completepart B item 1' -' B. lf one or both tait rotor bladescontact ground or a solid obiect causing a UtaOes tail rolor sudden stoppage inspection U"nAingoi she;ilg;i per following procedure: performedl Inspect must b"e 1 ) Check tail rotor drive shaft run-out per Section 7.34O' lf run-out or exceeds 0.025 inch at any location'the shaft must be -replaced 2 inchesfrom welds at forward end Strip p;fif U""L ai least ;A;;;J. b.y. oi-Oiivesfritf inO dye check per instructions.su-pplied manufacturer of cracks is found, drive shaft must [it. ff'ity evidence OV" "ft"tL"i replaced. be 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 of replacement 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 of int[tu"iioni supplied6y manufacturer dye check kit' 4l Removetait rotor and tail rotor gearbox and return them to an RHC apJio"eOoverhaulfacility for overhauland/orrepair' flex platesafter tail strike' 5 ) Always replaceaft and intermediate for 6) Visually inspecttailcone and empennage evidenceof a tail rotor bladestrike. 7l Visuallyinspectmain rotor system. Change13: OC T 2006

Page2.48

FICIBINEiCIN

MATNTENANcE MANUAL

MOEIEL

H44

2.530 MainRotorStrike is contactof The mainrotor strikeinspection listedin two partsA and B. PartA concerns rotorblades with objectin freeair suchas smallstones, smallbirds, etc. Part main brush, stoppage mainrotordueto ground solidobjectcontact. B is concerned of or with sudden has a brush, A. lf mainrotorblade contacted smallobjectin freeair suchas smallstones,
small birds, etc the main rotor bladesshouldbe inspectedas follows: shouldbe inspected evidence nicks,scratches, for 1. Main rotor blades of 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 to considered havesuddenstoppage sudden and stoppage inspection must be used to inspect the entire rotorcraft B. lf main rotor blade or bladeshave contactedground or a solid object, they must be inspected suddenstoppage. Suddenstoppageis evidentwhen bucklingor bending for 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. Remove followingcomponents the and returnto a Robinson Helicopter Companyapprovedoverhaulfacility for inspection and/orrepair. Main RotorSystem COOS Main RotorGearbox COOO 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

MAINTENANeE MANUAL

MOE'EL

F|'44

OversPeed 2.540 Rotor/Engine 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. inspections' with engineoverspeed at overspeeds or above 114o/o.Part C is concerned between 108 and 114o/o: A. For rotor overspeeds

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

CAUTION
on per Part B.

rotor dynamicbalancegreater than 0.3 iPs

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

occurs' Referto Part C if a power-onoverspeed 1. PerforminsPection PartA. Per anY bent bolts. of 2, Checkconinghingeboltsfor evidence bending' Replace insPected' 3. Coning hinge bolts, washers,and journalsmust be magnetic Particle or any crackedbolts,journals washers' Replace Pa g e2 . 5 0 Change13: OC T 2006

FIGIBINSCIN

MATNTENANeE MANUAL

MOE EL Fr44

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

bladesand check balance. lf a changein balanceis evident,rotor system 5. Reinstall should be returned to an approved RHC overhaul facility for inspectionand/or repair. percentengineoverspeed C. Determine from enginetachometerindication usingfollowing formula:

percentengineoverspeed=

Engine tachometerindication 2665 x 1O0 28OO

NOTE 1O2o/a enginetach indication equals 2718 actual engine RPM. The ensine is rated at 2800 RPM Referto LycomingServiceBulletin revision) engineoverspeed for 369 (current inspection requirements.

2.550 Hard Landing The hard landing inspectionis listed in two parts: A and B. Part A concernsyielding (bending) the cross tubes due to hard landingsuch as hoveringautorotations run-on of or landings that do not applyside loadsto the landing gear. Part B is concerned with 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

MAINTENANcIE MANUAL

MODEL

F|44

2.550 Hard Landins(cont'd) A. Yieldingof cross tube due to hard landingwith no side loads:, 1. Checktail rotor drive shaft run-outper section 7.340. See Section for 2. Visuallyinspectmain rotor btades oil canningof skins and buckling. blades. g.i ao ior irispection and repairof main rotor limit. Placerotorcraft serviceable 3. Checklandinggearcrosstubesfor yieldingb.gVond to ground. lf lessthan 30 inches, 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 verify 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. and cracks. Pay particularattention 2. Visuallyinspect steel tube framesfor yielding. to att ,iertiiaiittrt membersof lower steeltube structure' :l

is No frameyielding allqwed'
3. Visually inspect fusetage,landinggear attach points, and firewalls cracks. for bucklingor

Vertical firewall attach points for to susceotible cracksdue to hard lan

4. Dye check upper steeltube structureand all welded

joints'

5 . Visuallyinspecttailconefor bucklingor looserivets.

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

;i"fiild;i

of parts and assemblies' by Major defects *"y-u" factory-repaired replacement Change13: OCT 2OOo

or"lling'il;L;i

are or irur stiJctui'e tailcone cause

Page2.52

FICIBINSC|N

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 beforeapplication dye penetrant. of 4. Carefully checkfor cracksin and aroundeachweld beadand alongeachsteelsupporting tube for at leasttwo inchesaway from weld beads.Replace any frame exhibitingcrack indications. materials from steel tubing. 5. lf no cracks are found, clean all inspection 6. Prime with good quality zinc chromate or epoxy primer and allow adequatedrying time. 7. Refinishareawith gray epoxy top coat or equivalent. on 2.561 Corrosion C02O UpperSteelTube Frame 1. Polishout corrosionon steelframe tube members. a. Polishout light surface corrosionon frame membersusing Scotchbriteor 40O grit wet-or-drysandpaper subjectto dimensional limitationsshown in Figure216. b. Polishout corrosionpitting using320-grit wet-or-drysandpaper subjectto limitationsshown in Figure2-16. dimensional NOTE For large areasof corrosion,it may be necessary removeentire to paintto adequately upperframefrom aircraftand strip off determine 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

Change OCT2006 13;

Page2.53

FICIBINSiCIN

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MANUAL

MOE EL F|44

FORCRACKS INSPECT AT THIS LOCATION (TYPICAL BOTH SIDES)

THIS AREA FORCRACKS CHECK (TYPICAL BOTH SIDES)

/I-E/

z'rN
\

l./

,/-

CHECKEACHWELDBEAD 2 FORCRACKS IN. AREA FROM DIRECTION EACH T H EJ O I N T .

INSPECTION FRAM E 2 F IGU R E .1 5 UPPER

Page2.54

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

FICIE|INS|GIN

MATNTENANcE MANUAL

MOE'EL

F|44

CORROSION: LIGHTSURFACE 0.002 in. MAX. DEPTHAFTERREWORK

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

O.5Oin. MlN. SEPARAT AREASOF PITTING BETWEEN

LIMITATIONS FIGURE REMOVAL 2-16 UPPER FRAME CORROSION

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

P a g e2 . 5 5

FICIBINEiCIN

MAINTENANeEMANUAL

MtfElEL

H44

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

CENTER RETAINER

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 TO BE MORETHAN 1 IN. IN CRACK LENGTH.

STIFFENER

AREABETWEEN cLEAR r itrt.tvtttt.

OF PATCHES CRAZING

LOWER RETAINER LEFT

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

\y

INSPECTION 2 F IGU R E -1 7 W INDSHIELD 2 Page .56 13: OCT 2006 Change

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MATNTENANcE MANUAL

MOEIEL

H44

OVERHAUL REOUIREMENTS INSPECTION LIMITED AND 2.600 12-YEAR sincehelicopter but ff lessthan 2200 hourstime-in-service, 12 yearsor morehaveelapsed proceed follows: as was new or lastoverhauled,
NOTE This Section does not supersede 2200-hour inspection and containedin Section 3. Section 3 must overhaul requirements of be compliedwith basedon componentservicelives regardless was completed. when a 12-veari 2.61O InspectionProcedures 2.205 and 2.210. 1. Groundcheckand run up aircraftper Sections component overhaul 2. Removefollowing componentsand return to an RHC-authorized per & facility for disassembly inspection 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 assembly Swashplate Clutch assembly Tail rotor gearboxassembly Belt tensionactuatorassembly Tachometer Fanwheel assembly HydraulicReservoir Hydraulicservo actuators Governorcontrollerassembly

following parts with new or overhaulexchangeparts: 3. Replace

4120-3 A190-3 4785-x 8173-x 8283-x c o 11 - 2 c031-1 1 c041-1 c480-1 c653-1 c653-2 C792-x D756-x

Tail rotor bellcrank V-belts dash numbers) Hoses,air ducts (various Alternator belt dash numbers) Hoseassemblies {various Arm assembly Tail rotor pitch control assembly Bearing Swashplateboot Mount Mount DualTachometer assembly Bellcrank

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 publications and servicebulletins. Ch a n g e1 3 : OC T 2 0 0 6 Page2.57

FICIEIINSON

MATNTENANcE MAr\luAL

M(fE

EL F|44

(cont'd) Procedures 2.61O Inspection Visuellyinspect.Verify no cracks,corrosion, and verticalstabilizers. b. Removehorizontal loose rivets, dents, or deformation. Dye penetrantinspect suspect areas' telbows to remain attached to struts), 6. Remove landing gear assembly,disassemble Magnetic or removepaint, andvisuallyinspect.Verifyno cracks,corrosion, deformation. prime,and paint usingsection 1'4OOpenetrantinspect.clean, particleand fluorescent approvedmaterials. and visuallyinspect. paintfrom framesnot replaced, steeltubeframes.Remove 7. Remove prime, and paint using Verify no cracks or corrosion.Magneticparticleinspect.clean, materials. Section 1.4OO-approved or g. Inspectairframewiring condition.Verify no corrosion,insulationdeterioration, other damage. test fuel tanks per section 12.120. 9. lnspectand pressure Limitations. parts as requiredper Airworthiness additional 1O.Replace 1 1. Assembleaircraft.Rig flight controlsand rotor systems per Section 1O'1OO' reviseEquipment C.G. per Section1.231. As required, and calculate 12. Weighhelicopter Listryeight & Balancedata in Section 6 of helicopter'sPilot's OperatingHandbook. 13. Inspectaircraftper Section2.4OO. 2.2O5 and 2'210' 14. Groundcheck and run up aircraftper Sections

NOTE
with new pistonrings may prevent low-poweroperation Extended properpiston ring seating. fanwheelper Section6.240. 15. Balance tail 16. Balance rotor per Section1O-24O. main rotor per Section1O'20O' 17. Trackand balance 18. Flightcheck aircraftper Section2-220. 1.120 and 1.130. s f 1 9 . D r a i n , l u sh ,a n d fi l l g e a rb o xeper Sections per system(if equipped) Section1' 190' 20. Filland bleedhydraulic 2.620 (Reserved) P a g e2 . 5 8 Change13: OCT 2006

FICIBINSiCIN

MATNTENANcE MANUAL

MC'E'EL

H'44

2.63O ComponentInspectionProcedures An RHC-authorized componentoverhaulfacility shallperformnoted procedure.

PART NUMBER DESCRIPTION

COO5-x

NOTES

Removebearings.Visually inspect hub. Verify no fretting, corrosion,or obvious damage.Fluorescent Main rotor hub assembly penetrant inspect hub. Magnetic particle inspect journalsand thrust washers. Main rotor blade& spindleassembly of dueto possibility internalcorrosion blades Replace and adhesive deterioration. Replace pitch horn screws, boots, and O-rings. Pitch horn, spindles, and other hardwaremay be reusedafter inspection and verifyingno damage. pinionsealand all O-rings(mast tube base, Replace input shaft, end cover, sump, chip detector, chip sealed ball andsightgage).Replace detectorhousing, rubbermounts. bearingatop mast tube. Replace with factorynew assembly C181-3bearing Replace part. Inspectfanshaft. or overhaulexchange of due to possibility internalcorrosion blades Replace and adhesivedeterioration.Remove teeter hinge bearings.lnspect hub and hub plates; verify no penetrantinspect fretting or corrosion.Fluorescent plates.Replace teeter hinge bearings hub and hub and bladeattach bolts. clean, inspect, regrease,or replace {as required) duplexbearings. swashplate all clean,and inspect.Replace seals, Disassemble, Replace C184-2 bearing O-rings, and lubricant. assemblywith factory new or overhaul exchange part. Return to factory for lubrication and calibration check. clean, inspect. Verify no cracks or Disassemble, corrosion.

COO5-x

COO6-x

Main rotor gearboxand mast assembly Fanshaftand bearing assembly

cooT-5

COO8-x

Tail rotor assembly

CO17-x

assembly Swashplate

CO18-x

Clutch assembly

CO51-x
D174-2

Belt tensionactuator assembly Fanwheelassembly

Change13: OCT 2OOo

FICIEIINEiCIN

MATNTENANcE MANUAL

MC'EIEL t44

REOUIREMENTS OVERHAUL 2.700 22OO.HOUR proceed follows: as hourstime-in-service, 22OO has Whenhelicopter accumulated
NOTE for Kit R7543 containsthe majority of parls required. a 22OOfor check www.robihsonheli.com/public current f,out overhaul; componen-tsmay kit contents. Previously replaced airworthy 'accirmulating 22OO hours or 12 years ;;-.;il l; service until ocCurs first, since new or slnce whichever 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' exchangeparts: following parts with new or overhauled 2. Replace

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 D17 4-2 D211-1 D212-1 D268-x 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 Page .60 2

Main rotor blade and spindleassembly. dnd mast assembly Main rotor qearboxes Fanshaftani bearingassemblY Tail rotor assemblY assemblY Swashplate Clutch assembly Tail rotor gearboxassemblY Tailcone(RevM&Prior) Tail rotor pitch control Actuator assemblY Sorinqassemblv +lpoitt Harness& Buckleassemblies & Harness Buckleassemblies DualTachometer FanwheelassemblY reservoir Hydraulic servo actuators Hydraulic GovernorController

3. On all aircraft,replacefollowing parts with new parts: Tail rotor bellcrank V-Belts dash num ber s) Oi l l i n e s(va ri o us Batterycables Hoses,air ducts (variousdash numbers) Flex plate assemblY Alternator belt (variousdash numbers) Hoseassemblies tube assembly Tail rotor push-pull Muffler with risers Main rotor pitch link assemblies Swashplateboot trim system only) Etjstic'trim cord {electric 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 co E n g i n e o l i n gpanels( consultIPC)

1 Change 4: JUL 2OO8

FICIBINE|CIN

MATNTENANcE MANUAL

MOE EL F|44

Procedure 2.71O Inspection {cont'd} 4. Removeengineand overhaulor inspectas requiredby Lycoming.Flush and pressure test oil cooler. Overhaulor inspect,as required,magnetos,alternator,and carburetor publications maintenance manufacturers' or fuel injectioncomponentsper appropriate bulletins. and service Visuallyinspect.Verify no cracks,corrosion, and verticalstabilizers. 5. Removehorizontal Dye penetrantinspectsuspectareas. looserivets, dents, or deformation. removepaint, and visuallyinspect.Verify disassemble, 6. Removelandinggear assembly, no cracks, corrosion, or deformation. Magnetic particle and fluorescent penetrant inspect.Clean,prime, and paint usingSection1.400 approvedmaterials. paintfrom framesnot replaced, and visuallyinspect. steeltubeframes.Remove 7. Remove Verify no cracks or corrosion.Magneticparticleinspect.Clean,prime, and paint using materials. Section 1.4OO-approved

or insulation deterioration, other Verifyno corrosion, wiringcondition. airframe 8. Inspect

damage. test fuel tanks per Section 12.120. 9. Inspectand pressure per parts as required AirworthinessLimitations. additional 10. Replace aircraft. 1 1. Assemble 12. Rigflight controlsand rotor systemsper Section1O.1OO. 13. lnspectaircraftper Section2.4OQ. 14. Pertormweight and balanceper Section1.23O. 2.205 and2.2"10. 15. Groundcheckand run up aircraftper Sections NOTE with new piston ringsmay prevent low-poweroperation Extended r piston ri 16. Balance fanwheelper Section6.240 17. Baf ancetail rotor per Section"1O.24O. main rotor per Section1O.2O0. 18. Trackand balance 19. Flightcheckaircraftper Section2.220. per 20. Drain,flush, and f ill gearboxes Sections1.120 and 1.130. per system(if equipped) Section1.190. 21 . F.lland bleedhydraulic Change13: OCT 2006

Page2.61

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MAINTENANeE

MANUAL

MoEIEL pt44

blank Intentionally

Page2.62

Change13: OC T2006

o
3. LIFE LIMITBD COMPONENTS

FIOBINSICIN

MATNTENANcEMANUAL

MoEtEL p.arr

sEcTtoN 3
LIFE.LIMITED COMPONENTS 3.OOOLIFE.LIMITED COMPONENTS 3.OOl 3.002 3.003 tntroduction Time-ln-ServiceRecords FatigueLife-Limited Parts

3.100 OVERHAUL REOUIREMENTS 3.110 3.120 Powerplant Requirements Overhaul Aircraft Overhaul Requirements

TYPECERTIFICATE DATA SHEET SECTION AIRWORTHINESS LIMITATIONS

4: Change 1 Jun 97

Page3.i

FIOBINEiEIN

MAINTENANeEMANUAL

MoEIELn,4

left This pageintentionally blank.

Pag e3 . i i

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

FIclBINEiClN

MATNTENANeE MANuAL
SECTION 3 LIFE-LIMITED COMPONENTS

rv|(,EIEL ]l'44

3.OOO LIFE-LIMITED COMPONENTS

3.O01 lntroduction parts and specified This section lists fatigue life-limited for overhaulrequirements the R44 helicopter. Records 3.OO2 Time-ln-Service records for the It is the operator's responsibility maintainaccuratetime-in-service to airframe,engine, and life-limitedcomponents. An hourmeteractivated by engine oil pressureis standardequipmenton earlierR44 helicopters and is an acceptablemeans time in service. Laterhelicopters equipped are with an hourmeteractivated of recording the hourmeterwill recordtime only by a combinationof oil pressureand up collective; oil pressure exists and the collective raised. is when engine When installing a life-limitedpart, record in the helicoptermaintenancerecords the installationdate, part number, part name, serialnumber,helicoptertotal time, and all of previous time-in-service usedlifetime-in-service accumulated the part. All previous by retirementrequirements. limited parts must be includedin orderto safelydetermine recordsthe When installingan overhauledpart, record in the helicoptermaintenance installationdate, part number, part name, serialnumber,helicoptertotal time, and all previoustime-in-service accumulated the part sincelast overhaul. All previoustimeby next overhaul must be includedin orderto safelydetermine sincelast overhaul in-service requirement. WARNING Components with mandatory overhaul or retirement intervals whose time-in-serviceis not reliably documented cannot be consideredairworthv and must be removedfrom service. Parts 3.OO3 FatigueLife-Limited schedule replacement liststhe mandatory Section Limitations Thef ollowingAirworthiness 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 P a g e3 . 1

-*i

FICIBINSCIN

MAINTENANcE

MANUAL

MOEIEL ]''44

R 3 . 1 O 0 O V E R H A U L E OU IR E ME N T S OverhaulRequirements 3.1 1O Powerplant overhaul with the enginemanufacturer's in The enginemust be overhauled accordance to latest reiision of rextron Lycoming Refer recommendationsand proci;;;;No. 1OO9' Instructions Service 3.1 2O Aircraft OverhaulRequirements control system' and The complete airframe, including-rotor s.ystems,drive sylle.T' Companywhen Robinson'Heticopter ir-inrtru"t'eo uy fuselage,.nu.rn" oveirrauted any of the following occur: hours since new or since last for 22OO has been operated a) When the helicopter o v e r ha u l . corrosionin indicatesextensivesubsurface of b) When an inspection the helicopter system' the primarystructure,drive system or control so conditionhas deteriorated the helicoptercan no longer c) when the helicopter specificationsgiven in the Pilot's or safety meet the perfor;;;";;;;itori"uiriiv Handbook. Operating years since new or since last d ) when the aircrafthas been in servicefor twelve of overhaul,regardless the hoursflown'

WARNING

in aircraftare not to be reinstalled from damaged Partsremoved RHC,rogjther with to tii n"en returned ;t;ir;;;itunr".r-p"rt and history,-foiinspection is found by RHCto be 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 ADM INISTRATION

HIINM Revision 5 Robinson Rt4 R44 tl February 23,2007

TYPE CERTIFICATE DATA SHEETNO. HIINM This datasheet, which is a parl of Type Certificate No. Hl lNM, prescribes condirions linitations underwhich the product and for which the type certificate wasissued meets airworthiness the requirements theFederal of AviationRegulations. Type Certificate Holder: Robinson Helicopter Conrpany 2901AirportDrivc Tonunce. Califomia 90505

I. Modcl R44 (Normal CategoryRotorcraft), Approved December10, 1992 Engine Fuel OneLyconringO-540-FIB5, TypeCtertificate nurnber E-295 grade gasoline 100LL minimum aviation 100/130 gasoline milinrumgrade aviation Maximum continuous: (5 Takeoff minute): 205hp ar2718rpnr(102o/o) 225hpat 2718rprn(102o/A

Engine Limits

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

RotorSpeed Limits

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

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

Airspeed Limits

VyB (never exceed speed) sealevelis 130KIAS (120KIAS rvithfixedfloats;lqt at takcoffgross weights 2200lb. or less.Vpg at sealevelis 120KIAS (l l0 KIAS with of fixed floats)for takeoffgross weights over2200lb. Porver Off (Autorotation) Vyg at sealevelis 100KIAS. For reduction Vyg with altitudeandtemperaturc, R44 Rotorcraft see Flight Manual of (RTR46r). Airspeed linritat powersettings above Maximurn Clontinuous Poweris 100KIAS. pop-out Airspeed limit witlr intlated floatsis 80 KIAS. Airspeed limit for anycombinalion Doors is 100KIAS. of Off

Pase No.
Rev. No.

I 5

., 5

3 5

4 5

5 5

6 5

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

P a g e3 . 3

HI INM

2 Page of6

(qq!qg) 10, Dccember 1992,

C.G.@ggLonsitudinal Gross Aft Forward Weight (in.) (in.) 0b.) LateralC.G.\q1g9Long.

Centerof Graviry (C.G.)Range

c.c.
(in.)

Left (in.)

Right (in.)

I 550 2000 2200 2400

92.0 92.0 92.0 93.0

Note: ffi;

102.s
102.5 r00.25

92.0

rm.0
102.5

-3.0 -3.0
-1.5

+3.0 +3.0
+1.5

98.0 pointsshown' trnetartationbetween

C.C' Range WeiSht Erupty MaximunlWeight MininrunrCrew Numberof Seats

or beSTA102'5 forward' full lb. C.G. Calculated with150 pilotand fuelrnust lb. 2400
I pilot in forward right seat. 4 (3 for Police and ENG Version) at Pilot and Forward Passenger STA 49'5 Seat Locations: at Aft Passengers STA 79'5 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. CapacitY (sal.)

MaximuurBaggage

FuelCapacity

Tank Main Auxiliary

Us$le (eal.)

Location (STA)

31.6 18.5

30.6
18.3

| 06.0 102.0

Oil Capacity

MaximumOperatiou Altitude

ft' AltitudeLimit 14.000 Density gloundlevelis 9000ft' to allow landingwithin 5 altitudeabove Maxinrunr of irr minutes case fire. ll40 excePt thru 0002.0004 9999. |4cFRPart27,datedFebruaryl,1965,irrc|udingArnendments2T.|throughz7-z4' and and2?' 1305(q)' to No. Exemption 54?3oatediuli 2, 199J, 827'?5^5-(aX7) to $27'695' 17, October 1997 ei"tption No. 6692dated 36-2014CFRPart36 Anrendment Findine: Safety Eouivalent TD Nurnber I 0352LA-R/S-1 Light Svstem Anticollision 14CFRPart 27.1401(d).

SerialNttmbers Manufacturer's Basis Certification

P a g e3 . 4

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

HI INM

Page of6 3

l. lVlodelR44 (Normal Equipment

Deccmber10,1992,(cont'd) The basicrequired equipment prcscribed the applicable as in airworthiness regulations (see Certification Basis) nrustbe installed theaircraflfor certifi-cation.In addition, in thefollowingFAA-approved Rotorcraft Flight Manualis required: R44Rotorcraft Flight Manual(RTR461)dalcdDeccnrber 1992, laterrevision 10, or ( S e e N O T E4 , 5 , & 6 ) . S

ll. Model R44 ll (Normal CategoryRotorcraft), Approved Ocrober9,2002 The R44 Il helicopter includes fuel injected a engine with a 245 hp takeoffratinganda maxiumweightof 2500lb. Engine Fuel OneLycominglO-540-AElA5, TypeCertilicate numberlE4 100LL minimumgrade aviationgasoline 100/l30 grade mininrum gnsoline aviation Maximum continuous: Takeoff(5 minute): 205hp ar2718rpm (102o/o) 245hp at 27l8 rpm (l02Yo)

Engine Linrits

See RzMII Rotorcraft Flight Manual(RTR462),dated October 3.2002 or laterFAA approved revision. nraximum for corrc'sponding horsepower manifoldpressure to rating. RotorSpeed Limits Porver OIT(RotorTach) (108%l Maximum:432rom Minimunr: rnm (907o) 360 PowerOn (RotorTach) Maximum: mm ( l02o/o\ 408 Minimum:404 (l0l%) rpm

Airspeed Limits

Vyg (never for exceed speed) sealevelis 130KIAS ( 120KIAS with fixedfloats) at takeoffgross weights 22Q0lb. less.VpB at sealevelis 120KIAS (l l0 KIAS with of or fixed floats)for takeoffgross weights over2200lb. Porver Vyg at sealevelis | 00 KIAS. OfT(Autorotation) For reduction Vpg with altitudeandtenrperature, R44 II Rotorcraft see FlightManual of (RTR462)dated revision. 3,2002,orlaterFAA approved October Airspeed Power 100KIAS. is limit at powel'settings above Maxinrurn Continuous pop-out Airspeed limit with inflated floatsis 80 KIAS. Airspeed limit for any conrbination DoorsOff is 100KIAS. of

Center Gravity(C.G-)Range of

Iinal C.G. .ange

l-ateral C.G. Range Long.

I

Gross Weight ilb.)

Forward (in.)

Aft (in.l

c. c.

Left
(in.)

r600
2t00 2300 2500

92.0
92.0 92.0

t02.5
102.5 t00.25 98.0

(in.) 92.0

I
|

Right (in.)

r00.0
102.5

-3.0 -3.0
-1.5

+3.0 +3.0
+1.5

93.0

Notc: Straightline varialion betweenpoints shown

EmptyWeightC.G.Range

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

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

Page .5 3

r . , I I l -

_ "

_ " _ _ j

- '

"ft)' Weight Maximum (lrew Minimunt of Nunrber $wts

Ottobut 3' 2002'(tont'd) Apptonud

2500lb. floats' rvithfixedor pop-out landings water 2400lb. for inrentional l pilot in for*'ardrightwt. 4 (3 for PoliceandENG Versions) at Passenger STA 49'5 SeatLocations: PilotandForward al Aft PassengersSTA 79'5 F'or compartnrent'. any in equipnrent any baggage and of 50 pounds baggage installed and loact, baggage. installed of theseat combineo'weight the location, nraximum seat is equiprnent 300 Pounds' Tank
Main Capacity (sal.) Usable (nal.1 Location (STA)

Baggage Maximum

FuelCapacity

3r.6
r8.5

Auxiliarv
Oil Capacity F-npirre

30.6 18.3
Capacity (qt.)

r06.0
t02.0
Location (STA)

ComDonent

Transnrission Miin Rotor

Tail Rotor Transmission Hvdraulic Reservoir

9 2
0 . 1I

I t0.0
t00.0 327.O I t7.o

0.65

MaxirnutnOperatton Altitude

f1. AltitudeLinrit' 14.000 Dcnsity within5 tcvclis 9000ft' to allowlanding ground above altitude Maximum of in rninutcs case fire. arrd I 140,10001 subsequent 7-21'and 27-l Amendmcnts through including l. t4 CFR Part2l datedFebruary 1965. l'1 October ,1991to $2?'695' dated No. Exenrption 6692, 36-24' 14CFRPart 36 Amendment SatbtvFintlinq,: Equivalent I TD Nurnber I 035ZLA-R/SLightSystent Anticollision l4 CFRPart 2?.1401(d),

Manufacturer's Serial Nuntbcrs CertificationBasis

Equipment

regulations airworthiness in as equipment prescribed the.applicable required Thebasic lbr aircraft certifi-catio''In addition' in Saiisi mustbelnstalled the lseeCerrificarion is FlightManual required: Rotorcraft ilrefotlo*iug FAA-approvetl (See october3, 2002'or laterrevision (RTR462)dated FlightMantral R44|| Rotorcraft 7 NOTES & 8).

TO DATA PERTINENT ALL MODELS Datunr Mcans L,eveling

| 00 in. forward of main rolor centerline' for Manual antl Instructions continued Airworthiness Rcfer to the R44 N,laintenance (RTR 460).

P a g e3 . 6

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HI INM

Page of6 5

RotorBladeand ControlMovenrents

Main Rotorblatleangles ?5%radius: at +l Collective Pitch: 12.5o .0ototaltravel Note: Collectivelow pitchto be established accordance the Maintenance in with ManualandInstructions Continued for (RTR 460)procedures obtain Airworthiness to properautorotation RPM. CyclicPitch: Forward Aft Left Right I3.50o 14.25o to 13.500 14.250 to 7.5o to 8.5" 6.(F to 7:()"

Tail Rotorbladeangles 75%o at radius: Colleotive Pitch: Thrust left to Thrust right to 15.5" 16.5o to | 8.5o 19.0o to

Production Basis

Production Certificate 424WE,dated No. February l. 1993. I

.ENERALN.TES
NOTE l. . A current weightandbalance report, including list of equipment in a included thecertificated onpty weight, and loadingirrstructions rvhennecessary, nrustbe providcdfor eachaircraftat thetime of original air-rvorthiness certification at all tinresthcreafter, and exceptin thecase operators lravingan approved of weightcontrolsystem. Tlrcfollowingplacard mustbe installed clear in viewof thepilot: APPROVEDFOR DAY ANIDNICHT VFR OPERATIONS" "THIS ROTORC'RAFT Foradditional placards, theRotorcraft see FlightManual.All placards required theFAA-approved in Rotorcraft Flight Manualmustbe installed theappropriate in lcrcations. NOTE 3. Information to essential the propermaiutenance thehelicopter. tine of critical of includingretirement components. contained theRobinson is in R44 Maintenancre For MamralandInstructions Continued (RTR 460). Retirement Airworthiness timesarelistedin theFAA-approved "AIRWORTHINESS LIMITATIONS" section.The values retirement servicclife and inspection intervals cannot changed of or be withoutFAA Engineering approval. R44 Rotorcraft Flight ManualSupplement datcdJuly | 7, 1996. laterFA.A-approved revisionis requircd 5 or whenfloatlanding gearis installed. R44 Rotoroafl Flight N{anual l0 June10, 1999, laterFAA-approved or revision is Supplement dated required whenenrergency (pop-out)floatsareinstalled. R44Rotorcraft Flight Manualv,'ithFAA-approved November 1999, laterFAArevisions through 5, or approved revisionis required rvhenhydraulically-boostecl rotorflight controls installed. nrain are R44 ll RotorcraliFlight ManualFixedFloatsSupplement October dated 3,2002,or laterFAA-approved gearis installed. revision required is whentixed-float landing R44 Il Rotorcratt Flight ManualPop-Out FloatsSupplenrent datedOctober 3,2002,or laterFAA-approved revision required is whenpop-out floats installed. are

NOTE2.

NOTE 4.

NOTE 5.

NOTE 6.

NOTE 7.

NOTE 8.

Change 4: JUL 2008 1

Page3.7

HIINM

6 Page of6

NOTE 9.

(TC)' type of an anrended certificate by of to Any clranges the typedesign this helicopter means airworthiness for Sig'requiring instructions continued type supplemental certiRcalifiicj, ".**to{ office (ACo) for reviewandacceptance tirlgi tii" ptoj".t l*.oll certification (lCA,s)musrbe subnrirted offrce (FSDo) prior to Group(FTW-AEC)Flight standards,District by the Fort worth -Aircranrvat-uation aircraftfor oi*-otthin"tt certificate theaffected thefirst standard of theaircraltdelivery,or uponissuance or (majorrepairs changes later* pt"r.tiU.a UyTitle t4 CFR21.50. Type design occurs whichever ICA'snrusthavethoseICA's reviewed that of by means a iAn form 132(field approval) iequire 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

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

TheAirworthiness Limitations section f44 lrpproved specifies ': and inspections other and g-i.+oe,;;b';; 14 cFn

55 43.16-;J

iiternatiuet's;;;

FATIGUE LIFE-LIMITED PARTS

Maximum Service Life 2000 Hours

c023-1
-5, C01S2, and-7 C020-1and-2 C029-1 -2 and

TailconeAssembly, M andprior Rev

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

MainRotor Blade 2200 Hours 12years* or Upper Frame 2200 Hours TailRotor Blade 2200 Hours 12years* or TailRotor HubAssembly 2200 Hours Gear Set,MainRotor Gearbox 2200 Hours MainRotor Hub 2200 Hours MainRotor Spindle 2200 Hours TailRotor Drive Shaft 2200 Hours Sump, MainRotor Gearbox 2200 Hours Housing, Rotor Main Gearbox 2200 Hours Gear Set,TailRotor Gearbox 2200 Hours Bearing in C017-6 Set SwashplateAssembly Hours 2200 TailRotor Hub 2200 Hours TailRotor Guard 2200 Hours

A7s6-6 Cyclic Grip 4400 Hours c023-1 TailconeAssembly, N andSubsequent 4400 Rev Hours -3,4, C023-2, -14, -15 Tailcone and Assembly 4400 Hours c044-1 Horizontal Stabilizer 4400 Hours C198-1 -2 and Lower Swashplate 4400 Hours c251-1 MainRotor Shaft 4400 Hours c319-3 Cyclic Torque Tube 4400 Hours c320-1 Cyclic Stick 4400 Hours c337-1 Jackshaft 4400 Hours D196-1 TailRotor Drive Shaft 4400 Hours * Wfrichever occurs limit first.
Approved By: Manager, Federal Administration /' flTiffi Aircraft L? Office LosAngeles !, Aviation 5'"i?l3J'1"# Certification A1'Til3lifl'j"^

' /O ' a' Date Approvat: of FAAApproved:Thispage constitutes Ainruorthiness the t-iritrti*, S..tionin itsentirety, considered is segregated the restof the document, setsforththe FM-approved from and mandatory replacement times thefatigue for life-limited listed parls above. Te m p o r a r R e vi si o n :1 MA R 2 0 1 1 y 0
l_l

Page3.9

FIclBINSiClN

MATNTENANcE MANUAL SECTION 4 AIRFRAME

MIfEIEL

]''44

4.OOO AIRFRAME
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 d sse mb l y A 4 . 1 2 ' , Wi n d sh i e l d e mo va l R 4 . 1 2 2 W i n d sh i e l d e p l a ce ment R 4.123 Windshield Installation 4 . 1 3 0 D o or R e mo vaa n d In sta l l ation l 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 ection , Panels 4.141 Engine owling C 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 n a n e ls P 4 . 2 O O W E L DE D T E E L U B EF R A MEASSEM BLIES S T 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 |

MAINTENANeE

MANUAL

MC'E'EL

F.44

(cont'd) ASSEMBLIES TUBEFRAME STEEL 4.200 WELDED

+.ZzO UPPerFrameAssemblY 4.231 FrameRemoval 4.232 FrameInstallation and Installation 4.240 Strut AssemblyRemoval

I
|

AND EMPENNAGE 4.300 TAILCONE

4.310 Tailcone R 4.311 Tailcone emoval 4.312 TailconeInstallation R 4 . 3 1 3 T ai l co n e e P a i r AssemblY 4.32O EmPennage Removal 4.321 EmPennage Installation 4.322 EmPennage Replacement 4,323 UpperStabilizer Replacement 4.324 Lower Stabilizer Replacement Stabilizer 4.325 Horizontal Removal Stabilizer 4.326 Float Ship (R44 Clipper)COSO Installation 4.327 Float Ship (R44 Clipper)COsOStabilizer 4.330 Tail RotorGuardReplacement 4.340 Tail Skid RePlacement

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FICIE|INS|CIN

MATNTENANcE MANuAL
SECTION 4 AIRFRAME

MOEIEL

]t44

4.OOO AIRFRAME
4.001 Introduction This section contains procedures removaland installation cabin components,steet for of tube structures,tailconeand empennage. 4.OO2Description The R44 is a four-place, single-main-rotor, single-engine helicopter constructedprimarilyof metal and equippedwith skid-typelandinggear. Primarystructure of fuselageis welded steel tubing and rivetedaluminum. The tailcone is a semi-monocoque structurein which aluminumskins carry most of the primaryloads. Fiberglass and thermosetplasticsare used in the secondary structureof 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 additional accessto controls panelsbetweenseat cushionsand seat backs, and other components, there are removable 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 replacement must 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 l a t e r i a li s 0 . 0 1 6 - i n c ht h i c k , type 301, one- quar ter d m har corrosion-resistant steel. {CRES} 2. Keelpanelreplacement must be performedat the factory in a jig. Keelpanelrepairs 43.13-18. may be accomplished accordance in with U.S. FAA AdvisoryCircular Keelpanelmaterial O.O25-inch is sheet. thick, 2O24-T3 clad aluminum 3. To preserve repairsto seat structureare limitedto replacement crashworthiness, of damagedcomponentsonly.

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

P a g e4 . 1

FIGIEIINSclN

MAINTENANCE

MANUAL
tt t

M(fE EL r|'44

I
t t .II ilt ,,

_){r
12

t>=

o
Screw Retainer Washer Nut Tape

INSTALLATION 4-1 WINDSHIELD FIGURE

(1.H.) Windshield Retainer (R.H.) Windshield AN526832R7 c367-5 AN960-81 NAS1291-08 c367-11

1 2 3 4 5 6 7 I I 10 11

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

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

Page 4.2

1 Change 1: JA N 2005

FIclB|NEiClN

MATNTENANeE MANUAL

MC'E'EL

F|44

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

1. Remove forwarddoor 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. Reinstall hingesand doors for cabin structuresupportwith 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 retainers they are to be reused. if 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 according contourof to frame and windshield. 5. Mark windshieldfor trim using non-permanent marker,such as greasepencilor masking tape. 6. Trim to mark. A band saw is recommended.Bandsaw bladeshouldcontainat least 24 teeth per inch.

Ch a n g e 3 : O C T 2 0 0 6 1

Page4.3

FIclBINEiClN

MAINTENANGE MANUAL

MOEIEL

FI44

(cont'd) 4.1 22 WindshieldReplacement

of Tape cardboard to band saw table to prevent scratching of saw blade and 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 Installation' 9. See Section4.123 Windshield

4.123 Windshield hqlallqilg!

and windshield' a) Removeall old sealantfrom cabin,retainers wide white polyvinyl with A7o1 -4314-inch b) Tapebottom and aft edgesof windshield taPe (3M #47U. chloride c) Installwindshieldand cleco retainerstrips' tape' This will d) Mask windshieldalong edge of retainerstrips with 1/2" masking strips. of on catch siliconerubbersqueeze-out installation 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) j) strips are secure'removedoor and hinges When center,upperand lower retaining for side striP installation. lnstallside retainerstriP.

all hingesand door. Ensure fastenersare tight. k) Reinstall f) Fiffany gap betweenretainerand window with B27O-4sealant'

Page4.4

Change13: OCT 2006

FIclBINEiClN

MATNTENANeE MANUAL

MCIE'EL

]l.44

4.123 WindshieldInstallation {cont'd) m) n) Removemasking tape next to retainers. Be careful not to smear wet sealant. Cleanany sealantoff windshield after 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. 2. 3. 4. Disconnect door(s)gas.spring holdingdoor full open and lifting up firmly aft by on gas spring'sinner attach point. Removecotter pins and/or cotter rings from both hinge pins. Removedoor by openinglatch and lifting door to disengage hinges. lf required, door hingesmay be removedby removingmountingscrews.

4 . 1 3 2 D o o r In sta l l a ti o n 1. 2. 3. I n s ta l ld o o r h i n g e si f re moved. I n s ta l ld o o r b y a l i g n i n g i ngepins and slidedoor down to engagehinges . h 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. Reconnect door's gas spring. aft

4 . 1 4 0 F a i ri n g C o w l i n ga n d In sp ection , Panels MS27O39COB screws are used for fastening all removablecowlings and inspection panels. 4 . 1 4 1 En g i n e o w l i n g C Enginecowling includesleft-handand right-hand belly cowling cowling assemblies, assembly,and the aft cowling assembly. The lower edge of both engine cowling assemblies are supported by removable channels. The air intake hose is attachedto right engineside panelassembly, which may be removedor connectedthrough door in panel. 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

for must be installed 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. throughgrommetsin lower rib and attach to middle The fuel tank vents are installed is push- pulltube 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 tube' preloadon push-pull to to center rib. lt shouldbe adjusted 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 panelsaroundmast 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 CabinInspection Panels CAUTION panelsmust be instalted riight.All tnspection for panelsmay be left off for run-up.All must be installed flight. for

panelsincludethe following: The cabin inspection 1. 2. 3. 4. 5. 6. C794-1forwardbellypanelandC794-3aft bellypanelassembly. C465-1and C465-2att seat back panels. C474-1 panel between the aft seat backs and C474-2 panel betweenthe aft seats. C463-1 cover underthe C464-1 tray. C445-1 and C445-3 covers between the forward seats and CM4-1 cyclic box cover. C461-1 collective crosstube cover behindthe left forward seat.

Change 1 Jun 97 4:

Page4.7

F|CIE|INEiCIN

MAINTENANeE MANUAL

MOEIEL

F'44T

WARNING All welded steel tube frames used in the R44 are stress outside Robinson are iJii"ueO.ruo-weiO-iepairs permissible ComPanY. HelicoPter on The followingsteeltube framesare required the R44z C02O-1 UpperFrameAssemblY L.H. AssemblY, CO46-1 LowerFrame R.H. CO46-2 LowerFrameAssemblY, CO46-3 Strut AssemblY C237-1 FrameAssemblY L.H. Assembly, 4.210 LowerFrame Removal 4.211 Frame all a) Remove cowling. b) Removemain rotor gearbox,includingboth fuel tanks, per Section 7.110. per and tailcone clutchassembly, SectionO powerplant, including c) Remove 6.110. d) Removebatteryand batterybox. Panel. e) Removeleft aft seatback tligur" a-?Lt DetailsD, rhe f) Disconnect threeforwardmounting_.pointq (Figure 4-28, DetailH). point E, anOF) and tne at mounting gearmountingbolt' g) Disconnect left aft NAS1307landing the 604-2bolt and the C722-2 capscrew connectingJhg the h) Remove NASO 4-2, DetailsA & frameto'ine foweifettlrime aisemOly(Figure upper B).

P a g e4 . 8

Change4: 1 J un 97

FICIE|INEiCIN

MATNTENANeE MANUAL

MC'EIEL ]''44

NAS6604-2 BoLT (2 AN960-4161 WASHERREQ'0.) NUT NAS679A4 (2 PL'CS. ) c020-1 UPPER FRME c046-2 LOt,IER FMME

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

c046-6 TUBE

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

NAS6605.21 BOLT

c722-z scREbr +l Mszooozclo *rT-/

BoLT NAS6605-4 (2 I'IASHER R E Q ' D ) 4N960-5161 NAS679A5 NUT (4 PL'CS. )

.\

LO!\lER FRME

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

FRAME INSTALLATION TUBE 4-2 STEEL FIGURE

Change : 15 Jun98 5

Page4,9

FIC|BINSiCIN

MAINTENANcE
B0LT NAS6604-2 (2 ttAsHER REQ'D-) Ang6o-qrot

MANUAL

MOEIEL ]r44

c632-1
ANGLE

NUT NAS679A4 (2 PL',C) . S

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

(z pr-'cs. )

BoLT NAS6604-2 (2 !',ASHERREq'D.) Anioo-qtot

NUT NAS679A4 (2 PL'CS.)

c046-1 L0l,lER FRAME

BoLT NAS6604-3 (2 WASHERREQ'D.) AN960-4161 NUT NAS679A4 (2 PL',CS.) BoLT NAS6604-3 E R A N 9 5 0 - 4 1W1 S H ( 2R E Q ' D . ) 6A
NUT NAS679A4 (4 PL'CS. )

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

I

NUT NAS579A4

(z PL'cs.)

B0LT NAs6605-24
NUT NAS679A5 (2 PL'CS. )

(2 D. [ijei[:iroi t^tnsHrnREQ')

BoLT NAS6605-23 E A N 9 6 0 - 5 1W1 S H ( 2RR E Q ' D . ) 6A NUT NAS679A5

INSTALLATION FRAME TUBE 4-2A STEEL FIGURE

P a g e4 . 1 O

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

FIClEIINsic|N
c046-3 STRUT

MAINTENANGE

MANUAL

MOEIEL H,44

@'
c046-2 LO!||ER FRA}IE ltAs6605-4BoLT (2 NASg5O-5161 WASHER R E q ' 0 . ) . . . NAS679A5 NUT a B33O-16 PALNUT

Y\

BENT TUBE c237-l FRAME

tii t' t \ \ \

c020-1
UPPER FMME

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

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

UPPER FRAME NAS679A7 NUT 8330.21PALNUT (4 PL'CS. )

BoLT NAS6607-24

-r c237
BOLT NAS66O5.4 c046-1 WASHER AN96O-5161 LOl,|ER NUT NAS679A5 FRAME 8330.16 PALNUT (2 PL'CS. ) VIEI,I LOOKING FORI.IARD ( 1 . H) .
FRAME

o
/

c023-1 TAIL CONE ASSEMBLY

INSTALLATION FRAME TAIL CONE AND T FIGURE-28 STEEL UBE 4

2: Change 12 Dec 94

Pa ge4.11

FIGIEIINSiC|N

MAINTENANeE MANUAL

MOE EL F'44

(cont'dl 4,211 FrameRemoval il I I | 'il the left frame assemblY' Remove

RemovetheCOl4-7landinggearsupportandD31O-5cowlingbracketfrom the left frame assemblY'

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

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 othe3 2 0 ' T g firewallP C 7 ? 2 - 2 C a p n l ' c385-1 l q g " : h doubler screw per secii6n-i.$o-lrio-tateii wire to wire. with 0.b41 inchdiameter
mountingbolt per Figure5-1, DetailB, and landin_g-gear d) InstallNAS66O7 torqueper Section1.320. per el Installpowerplant Section6.120' fl fnstalltailconeper Section4,312, gl Installmain rotor gearboxper Section7 '12O' per hl fnstallclutch assembly Section7'22O' il il InstallbatterYbox and battery. is Verify all mountinghardware torquedand instatlleft aft seat back panel'

kl lnstallall cowling.

4 Page .12

2: Change 12Dec 94

FICIBINSCIN

MATNTENANeEMANuAL

MOEIEL F44

4.22O Lower FrameAssemblv. R.H. 4.221 FrameRemoval a) Removeall cowlipg. bl Remove mainrotor gearbox, including both fuel tanks,per Section7.110. pow_erplqnt, cl Remove including tailcone,CO46-3strut, and clutch assembly, per Section 6.110. dl Removeright rear seatback. el Disconnectthe aft NAS66O7landinggear nxrunting bolt from the right landinggearsupport. fl Disconnect tv\roforward mountingpoints (Figure+2A, DetailsC and the 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 Rernove right frame assembly. the il gearsupportandthe D310-6bracketfrom the Remove C014-7landing the right frame assembly.

4.222 FrameInstallation al Installthe CO14-7landinggearsupportand 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.

Change 12 Dec 94 2:

Page 4,13

FICIBINSCIN

MAINTENANcEMANUAL

MtfEIELF,44

(cont'd) 4,222 FrameInstallation

, bolt per Figure5-1 and torqueper landinggearrK)unting dl InstallNAS66O7 Section1.320. per e) Installpowerplant Section6'120' fl Installtailconeper Section 4'312' gl fnstall main rotor gearboxper Section7 '12O' per hl lnstallclutch assembly SectionT'22O'

is hardware torquedand installright aft seat back o i) Verify all mounting

Panel. il Installall cowling.

4.23O UpnerFrameAssembly 4.231 FrameRemoval powerplantmust and Beforethe upperframe is disconnected removed,the be either removedor supported' CAUTION Extensivedamageto the firewall and lower frame isiembties *itidccui ii powerplantis not supported is or if suPPort dislodged. all al Remove cowling. b) Removeclutch assemblyper Section7 '21O' both fuel tanks, per section7'110' including mainrotor gearbox, cl Remove tailconeper Section4.311' dl Remove or e) Supportpowerplant removeper Section6'11O'

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2: Change 12 Dec 94

FICIBINEIC|N

MATNTENANeE MANUAL

MOtrlEL H'44

(cont'dl 4.231 FrameRemoval f) Remove right and left aft seat backsand panelbetweenseatbacks. the

g) Remove per C316-1uftperbellcrank Section 8.531 and remove C121the 15 push-pull tube. h) Removethe C723 bulkhead assemblies the aft end of the horizontal at firewall. i) it Remove NAS6605-4boltsat the aft outboard the corners the horizontal of firewall(Figure 4-2B., DetailsH). Remove NAS6600 bolts and the C722-2cap screwsshown in Figure all 4-2, DetailsA and B.

k) Remove upperframe. l) assembly Remove and 4331-4 bellcrank C329-1bearing blockassembly from upperframe.

4.232 FrameInstallation pointsof all sealant, grease oil. Install and frameand mounting a) Clean upper screws,AN960-8L using AN5O9-8R11 C329-1 bearingblock assembly washers, nuts, 3 places. Install and NAS1291-08 per A331-4 bellcrank assembly Section8.542. lnstall all hardwareper Figure4-2, b) Positionupperframe for installation. before DetailsA and B and Figure+2B, DetailH. Installall hardware torquing. c) Torqueall NAS66OO bolts per Section 1.320. Torque the C722-2 cap screwsper Section1.330 and safety wire to the C385-1 firewalldoubler with 0.041 inch diameter wire. a fuel seepage. to sealant prevent d) Sealfirewalts using B27O-1 assemblies. e) Install the C723 bulkhead per the 8.532andinstall C121bellcrank Section f) Install C316-1upper the 15 push-pull tube. per g) fnstallpowerplant, removed, Sections 6.120. if per h) fnstall 4.312. tailcone Section

1 Change : 2 Jul93

Page .15 4

F|ClBINSiclN

MAINTENANeE MANUAL

MOEIELFI44

(cont'dl 4.292 Framelnstallation j2O' il lnstallmain rotor gearboxper section7 per i) Installclutchassembly SectionT'22O' aft seat back and k) Verify all mountinghardwareis torquedand install centerPanels. ll Installall cowling. and lnstallation 4.24O- Strut AssemblvRemoval To removethe C046-3 strut: a)Removerightenginesidepane|andaftenginecow|ing. lower frames' b) Supportenginefrom below to reducethe load on the c}Removeupperand|owermountingbo|tsandremovestrut. To installthe strut: G and as a) Installstrut and hardware shown in Figure4'2F.,Details bl Torquebolts PerSection1'320' enginesuPPorts' c) Remove d) Installcowling. AND EMPENNAGE 4.300 TAILCONE 4.31O Tailcone Removal 4.311 Tailcone a) Removec7o6-1 tailconecowlingand DO4O-1 cowlingassemblies' .tft light,and chipdetector) strobe,tail position wiring (antenna, b) Disconnect to tailcone. c) Mark tail rotor drive shaft and A947-2 flex plate for reinstallation. H'

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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 e e mo va (co n t' d) R l d) Disconnecttail rotor drive shaft at intermediateflex plate. Use a rag or foam rubber to support and protect forward end of drive shaft in taitcone. e) Disconnect forward end of C121-17 push-pull tube. 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 e sta l l a ti o n ' In 1. Verify C237-1 frame assembly installed upperframe with bent tube down is in and tabs to right per Figure 4-28. Verify 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.Standard torque bolts per Section1.320. Installiralnuts, standardtorque per Section 1.320, and torque stripe per Figure2-1. shown in Figure8-14. Standard torque bolt per Section1.320. Installpalnut, standardtorque per Section 1.32O,and torque stripe per Figure2-1.

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

4 . Installand shim intermediate flex plate per Section7.330. 5 . Checktail rotor drive shaft runout per Section7.34O. 6 . PullStrobecircuitbreaker. for Connectelectrical tail connections strobe,antenna,
positionlight, and TR chip detector.Individually test and verify correct function of tail positionlight and TR chip light circuits.Turn NAV LTS switch off. strobe light. 8 . Ty-rap wiring as required. 9 . InstallC7O6tailconecowling and D04O aft cowling assemblies.

7 . Push Strobe circuit breakerin. Individually test and verify correctfunction of

Ch a n g e1 4 : JUL 2OO8

Page .17 4

FICIBINBCIN

MAINTENANcE

MANUAL

MOE EL F44

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

D E N T SIN T A T L C ON E : inch deep, Dent minimumbottom radius:O'125 No dents greaterthan O.O3O 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'

to iiJv-onoir1r""li-iti reprui"t"il"on. or return RHcfor

0 . 0 1 Oi n c h d e e P (Lessthan 15o from tailconecenterline)

Q Tailcone

inch deep O.OO5 ( M o r et h a n 1 5 o f r o m tailconecenterline)

L S T AI L C ON E C R A T C H IMITS: are to relative tailconecenterline orientation Allowablescratchdepthsconsidering of of RHcreplacemert thatsection scratche" asshown. radi us ' O.1Oinch blend oui; mu st Oe' UTenOed ,"e r ninim um t a i l co n e . S cra tch e s "*"""iiili;iir;q;i* A 4 . 3 2 O E m p e n n a g e sse mb l Y e 4 . 3 2 1 E mP e n n a g R e mo va l a ) Re mo veD O7 9 -1ta i l ro tor guar d' ta b ) Di sco n n e ct 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

1 Change 4: JUL 2OO8

FIC|ElINSiclN

MATNTENANcE MANUAL

MIfEIEL

F44

4.322 Empennage Installation 1. Installempennage assemblyonto 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 verify correct function of tail position light and TR chip light circuits. 4. Installtail rotor guard per Section4.330. 4.323 VerticalStabilizer Replacement 1. RemoveDO79tail rotor guard if replacing lower 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 required a 0.030-to-0.120inch gap for to horizontal stabilizer. 5. Installverticalstabilizer.Attach C554 clip to horizontal stabilizer.Match drill clip to vertical stabilizerwith #30 drill and rivet using MS2047OAD4rivets; N A S 1 9 1 9 B 0 4 S l i n d ri vet is optional for war dhole. b in 6. Specialtorque verticalstabilizer attach bolts per Section 1.330 and torque stri p ep e r F i g u re -1 . 2 7. lf removed,installtail rotor guard per Section4.330.

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

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MAINTENANcE MANUAL

MOE EL ]''44

Replacement Stabilizer 4.325 Horizontal lower vertical.stabilizers' 1. RemoveDO79-1tail rotor guard and upperand remove N1S21919clamps from 2. Disconnect tail position light wiring and horizontalstabilizer. stabilizer' 3. Removehorizontal usingNASl 149F0663Pwashersundereach nut stabilizer 4. Installnew horizontal EqiqnA nut' Torquebolts per Section1'32O' as requireAiii i:qthreads per Figure2-1' """pot"O Installpatnuts,torque p"t S"5i''J;l:420, ;nd torque stripe to p'QS.Q, O'12o-inch 5. Fit vertical stabilizersto horizontalstabilizer'.Verity stabilizerskins' File clearancebetween horizontJl'rtunirirriskin and vertibal skin(s)as required' verticalstabilizer inch in attachingho-lgs C554clips.anddrill a O'144 6. Align horizontalstabilizer stabilizer. Deburr hole and diameter hole through traitini-;ff" bi rroiirontal stabilizer' fasten clips to horizontal 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 . clamps for tail rotor 8 . Connect tail position light wiring and install MS?1919 "*a test and verifv

il;;il

correct tunctton of tail positionlight and TR chip circuits'

ir,ip-o"tJ;i;;

nosilgnlight *i,'ns. lndividuallv

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 | 1 . R e mo vescre w sfro m D O81- 2block and r em oveblock' Rem ove and remove block
38p screw tror uii,'fower frolein DO81-4block assembly assemblY. NAS1351- 4-

when both NAS1351 are Tail skid and float stabilizer unsecured 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 w N A d i 1 4 g F o 4 1 6 P a sherand M S2104214nut' -4-51P (note differentlglg^!\f1om Step 4 . fnstall DO81-2 block with NAS1351 MS21O42 L4nut' 1 scre w i n u p p e i -tro l e. install nltgOO- + tGLwasher and both NAS1351 Torque taii -and toioiliaro's sleeve. Ensureblocks rrr .iun1ping torque stripe' per Section 1.32O ""i"*t screwin Dogl -2 block'slower holeandtorqueto 40 in.-lb. 5 . lnstallNAS1352-3-14p

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 of clamping tail rotor guard. Change

JUL 2OO8

FIC|BINSICIN

MATNTENANcE MANuAL

MOEIEL]l'44

4.327 FloatShip (R214 ClipperlC050 Stabilizer Instalation a) Remove NASl352-3-14P screwfrom DO81-2 block'sldwer hole.Remove NAS1351-4-51P screwfrom DO81-2 block'supperholeand remove Oioir.. Remove NASl351-4-36P screwfrom aft lowdr holein DO81-+ UloctLnO ,. removeblock. NOTE Tail skid is unsecured when both NAS1351screws are removed. b) Installfloat stabilizer. cl InstallNASl3Sl-4-38P screw{note length different fromstepa} in aft lower holeof DO81-4 blockandinstall blockon vertical stabilizer wiin Rrug6o-41 6L washerand MS21042L4 nut. dl Install D081-2btockwith NAS1351-4-S3p (notedifferent lengthfrom step a) screw in upperhole.lnstallAN96O-416L washerand MS2-1O4-2L4 nui. Ensure blocks clamping rotorguard's are tail sleeve.Torque bothNAS1351 screwsper Section1.320. e) Install NAS1352-3-14P screwin D081-2 lowerholeandtorque 40 block's to in.-lb. NOTE It is important torqueNAS1352-3-14p (short) to screwlast to obtainproperclamping tail rotor guard. of 4.330 Tail RotorGuardReplacement a) b) O c)
dl e)

Loosen two screwsthroughDO81-2 blockholdingD079-1tail rotor guardto verticalstabilizer. Remove two boltsthroughforwardend of guard. Remove rotor guard. tail
Beforeinstallinga new tail rotor guard,verify that a D081-1 spacer is properly positionedinsideD082-1 tube assembly. Slide new tail rotor guard under DO81-2block at verticalstabilizerand fasten forward end to D082-1 tube assemblyat tailcone using NAS6603-16 bolts, AN96O-1OL washersand NAS679A3 nuts. Torque per Section 1.320. Positionta_il rotor 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 ewthr oughlower holein DO81- 2bl oc k scr to 4O inch pounds. NOTE It is importantto torque NAS 1352-3-14P(shortlscrew last to obtain properclampingof tail rotor guard.

f)

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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 the skid, usingan NAS1351-4-51P c) Install in scr-ew the lowerhole' r.rASr351-4-36P Then pOsition dl Loosenthe screw in the lower hole of the DO81-2block' 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'

P a g e4 . 2 2

4: Change 1 Jun 97

LANDING GEAR

FIclE|INSclN

MAINTENANCE

MANUAL

MC'E'EL rt,44

SECTION 5 LANDING GEAR 5.OOO LANDING GEAR 5.001 Introduction 5.002 Description 5.100 LANDING GEAR ASSEMBLY 5.110 Landing GearRemoval 5.120 Landing GearInstallation 5.2OOCROSS TUBES 5.210 CrossTubeRemoval 5.22O CrossTubeInstallation 5 . 3 O OS K I D U B E S T 5.310 SkidTubeRemoval 5.320 SkidTubeInstallation 5.330 Skid ShoeReplacement 5.340 Ground Handling WheelSupportReplacement 5.350 Skid Extension Replacement 5.4OOSTRUT FAIRINGS 5.410 StrutFairing Removal 5.42O Strut Fairing Installation 5.5OOUTILITY FLOAT LANDING GEAR 5.510 UtilityFloatLanding GearRemoval 5.520 UtilityFloatLanding GearInstallation 5.530 UtilityFloatTubeRemoval 5.540 UtilityFloatTube lnstallation

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

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5.610 PoP-outFloat Removal 5.620 PoP-outFloat Installation 5 . 6 3 0 L e a k C h e ck InflationTest 5.640 EmergencY 5.650 Pop-OutFloat PackingProcedure CYlinderRemoval 5.660 Pressure PressureCylinder 5.665 Recharging CylinderInstallation 5.670 Pressure Replacement 5.680 InflationLever Shear-Rivet 5.690 InflationLever Rigging 5.700 MAINTENANCE

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FICIBINS|C|N

MATNTENANcEMANUAL

Mc,E EL FI44

SECTION 5 LANDING GEAR 5.000 LAND|NG GESR

I

5.001 Introduction T^tt t*,,"" of thg removaland installation the landinggear assembly,cross ""*n tubes, skid tubes, skid shoes, ground handlingwheel supports,-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 support the floats. Strut fairingsare not installedwith utility floats. 5 . 1 0 0 L A N D I N G E A RA S S E M B L Y G 5 . 1 1 0 L a n d i n gGe a l R e mo va l 1. 2. 3. 4. 5. RemoveC388 channelsand C475 cover at forward cross tube. RemoveDO4Oaft engine cowling and DO41 engine belly cowling. DisconnectA936 ground wire at aft, right elbow. Hoist helicopterby main rotor hub per Section 1.22Ountil skids clearground by approximately inches. 4 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 accessed from insideaft baggage compartments-and throughaccessholesunder carpet at aft outboard cornersof aft floor.

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

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MAINTENANGE MANUAL

MOETEL ]e44

NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

PARTNUMBER 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

DESCRIPTION Washer (fwd) strut AssemblY Journal Bearing AssemblY Shackle Washer Washer Aft Cowl Bracket,LH (Shown) Aft Cowl Bracket,RH (Not Shown) Palnut Nut Washer Spacer CrossTube (rearl (rear) Strut AssemblY CrossTube {fwd) Washer AssemblY Bearing Washer Bolt Washer Bolt SupportAssemblY Elbow Nut RaincaP Bolt Washer Nut Screw

Page5.2

3: Change 5 MaY95

FICIBINEiCIN

MATNTENANcEMANUAL

MOEIEL

F|44

LEFTFORWARD INSTALLATION

INSTALLATION

F IGU R5- 1 LANDING E

INSTALLATION

Change 12 Dec 94 2:

Page5.3

FloBlNEioN

MAINTENAN'EMANUAL

MoElEL''44

This page intentionallyleft blank.

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MATNTENANeE MANUAL

MOE,ELF,44

Gearlnstallation 5.120 Landing per a) Hoistthe helicopter Section1. . bl Lift the rightside of the landing right sidemountingbolts geara1d-'pr; installb.oth and torquestripe. per Seiiion 1.32O,installpalnuts, . Figil; b--f iorque on RePeat left side. cl Connectgroundwire at right aft etbow and attach battery drain tube to aft crosstube. at dl Instaltthe C475-2 coverand the C388-1channels the forward crosstube. el Installall cowling. TUBES 5.200 CROSS 5.210 CrossTube Removal if The aft crosstube must be reptaced it has yieldedso that the tail skid is less than 30 inchesfrom the ground. NOTE see inspection, Section2.550. For hardlanding gearper Section 5.110. landing al Remove one of the struts from the skid tube. b) Disconnect 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 :

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FIGIBINSGDN

MATNTENANcE MANuAL

MOEIEL

FI44

5.22O CrossTube lnstallation al Installcrosstube into the elbowsand insiallbolts per Figure5-1. Torquebolts per Section1.320. strut to the skid tube and torquethe bl Connectthe unbolted NAS66O6-4 bolts per Section1.320. gearper Section 5.120. c) Installlanding 5.300 SKIDTUBES 5.31O SkidTube Removal by one sideof the helicopter jackingunderone end of the aft crosstube, a) Raise one inch inboardof the elbow. the skid tube. bl Remove 4 bolts at each landinggearstrut. Remove the cl Removethe C937 skid extensionby removingthe aft skid shoe. Removethe C719-1wheelsupport. 5.320 Skid Tube Installation and aft skid shoeonto the COl4-11 or al Installthe Cg37 skid extension -12 skid tube assembly.Installthe c719-1 wheel .supportand torque.per to by torque required Section1.330 is required Section 1.330; the reduced the damaging skid tube. avoid underthe fore and aft gearstruts and installthe bl Placethe skid tube assembly attachbolts per Section1.32O. attach bolts. Torquethe NAS6606-4 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) are fastenedwith A142-1 screws. Use new -and torque to 27 in.-lb. Skid shoes must be screws wnen ieplaiing shoes inch when thb bott5mshaveworn to'O.OSO thick at their thinnestpoint. repiaceO wheels the a) To inspector replace aft shoeon eachskid,installgroundhandling ' jack up the helicopter. tfte aft landinggearcrosstube or to tit [ne treticobter ?1 woin skid shoesand screwsand replace. per ngure S-SB.-nemoJe and'discard wheels,pull installg.rguld.ha.n.dting all bl To inspector replace otherskid shoes_, ' arid the ttii O-own placewood blocksunderthe skidsto hold the skidsup per any worn shoes. Figure5-3A. Replace

Pag e5 . 6

2: Change 12 Dec 94

FICIBINSiCIN

MATNTENANeE MANUAL

MOEIEL F'44

Reolacement WheelSupport Handling 5.34O Ground the al Remove two mountingbolts and removethe C719-1support. bolts and torquq.pqr Section bl Installthe supportusingNAS66O4-47 .1.33O. the skid to reduced idrque of Section1.330 is required avoid damaging The tube. Replacement 5.350 Skid Extension by one sideof the helicopter iackingunderone end of the aft crosstube, al Raise of the elbow. one inch inboard the the bl Remove aft skid shoeand remove four bolts attachingthe aft strut to the skid tube. and the cl Remove C937-1or -2 skidtube extension replace. bolts per dl Attach the strut to the skid tube and torque the four NAS66O6-4 shoe. the Section1.320. Install skid with 8270-9 adhesive. el Sealthe slot in the side of the skid extension FAIRINGS 5.400 STRUT Removal 5.41O Strut Fairing sideof the fairing. holeon the inboard the through access the a) Loosen clamps all bl Rernove screwsalongthe trailingedge. cl Unscrewthe clampsand slidethe fairingoff of the strut.

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MATNTENANtrE MANUAL

MOEIELH'4I

5.42O Strut FairingInstallation at al Verifythat a 8162-3 clip nut is installed eachholeat the trailingedggof the passthrough both of the clips rivetedto the fairin-g and that the strtit clamps fairing. b) Slidethe fairingonto the strut and looselyfastenthe two clamps. c) Installand tighten all screwsalongthe trailingedge. forward and aft fairingsby placinga long straightedge across-both dl Position (Seebelowl.The distance from.the straighted-ge fairingsat the-low6r-clamps of to th6 centerline the tiailinq edge shouldmeasure1.4 inches.Checkfor fairingto trim of both-ends the fairing.Remove all O.1Oinch clearance around if and reinstall, required. to adhesive both clampthreadsand torqueper Section1.33O. e) Apply B27O-1O with the straightedge. Verify 1.4 inch dimension
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

2: Change 12 Dec 94

FIGIBINSCIN

MAINTENANcEMANUAL

MOE'EL

F.44

gear.or standard with float landing may be.flown helicopter R44 Clipper The Robinson utilityfloat.landing c.omplete remove configurqlions, landinfge.i inii.ir"o. Wt,jn chingin'g gear floattubesfromlanding jiO"i*tall complete ge6r.Donot remove stindardi'aniing b"li tor skid tubesunlessnecessary repalrs.
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. 2. 3. 4. 5. R e mo vefl o a t l a n d i n gg e ar per Section5.110. I n s ta l lsta n d a rdl a n d i n gg ear per Section5.120. per Section4.326. RemoveCO50 float stabilizer attaching screws. Remove D372-2 air dams aft of static ports. Reinstall Revise EquipmentList/Weightand Balancedata (located in helicopterPilot's Section6) using following information: OperatingH'andbook, Weight CG Ar m (in.) Moment (in.-lb)

Part Number Description

(lo1

Gear 1 0 4 . 3 co34-2 UtilityFloatLanding 1.1 cos0-2urility FloatStabilizer Gear Landing c o 1 4 - 8 Standard 60.9

95.2 335.4 86.3

9929 369 5256

6. 7.

Performflight check per Section2.22O. Check and adjust autorotAtion RPM per Section 1O.25O (usually requires 1 lengtheningpitbh links approximately full turn at upper rod end).

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Page5.9

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MATNTENANeE MANUAL
IIITH CoVER ENTIRE B0LTHEAD (8 8270-tSEALANTPlaces) c944-1-2, -3 STRIP , (LHor RH)

MOEIEL

F|44

AN960-101t }IASHER (40 Req'd)

TUBE C949 FLOAT

MS2104213 NUT
GIRT

AN3-31A BOLT

AN960-10* !.IASHER

GIRT C949-l, -2, -3 STRIP (LHor RH) *BOLT MAY I.IASHER THICKNESS BE LENGTH AND/OR 2-4 VARIED REQUIRED MAINTAIN THREADS AS TO AND HEAD UNDER SHOI,JING NUTS. SEAL BEYOND ANDSKID GIRTS NUT AND AROUND BETI.'EEN BOLT TUBE f'fITH8270-l SEALANT. ASSEMBLY

SKID

ATTACHMENT FLOAT 5-3 FIGURE UTILITY FORWARD) (LEFT VIEtlt SIDE SHOllN, LOOKING

tw)l
I
|.t

rFr.r - .

!
I

OF TUCKFREEENDS CORD TO AN THROUGH EYELET IN F M I N I M I Z EL A I L I N G FLIGHT

c949
FLOAT TUBE LANDING GEAR STRUT LACING

squARE KNoT AITACHMENT UTILITY FL0AT-To-STRUT

s-4 FIGURE
P a g e5 . 1 O

(vrEl^r Dot^lN) L00KING

Change7: 06 D ec 99

FICIEIINSiCIN

MAINTENANcE MANUAL

MIfEIEL

]t44

5.52O Utilitv FloatLandingGearInstnllation gearper Section5'1 1O' landing standard 1. Remove gearper Section5'120' 2. Installutilityfloat landing per float stabilizer Section4.327 ' 3. InstallCOSO Pilot'sOperatingHandbook' per 4. Adjust float pressure helicopter's 5. fnstallD372-2 air dams aft of static ports usingexistingscrews' Pilot's 6. Revise EquipmentList/Weight and Balance data {located in_h_eljc-opter's Sectiori6) usingdata providedin Section5.51O. OFAing'HbnOUook 7. Shortenboth main rotor pitch links by one full turn of upper rod end. 8. Performflight check per Section2.230. RPMper Section 10.250. 9. Check and adjust autorotation 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
hardware. A soft plasticscrapermay be used-

from skid,float,girts,and old remove sealant installation, Before

float bolt headsdirectlyb_eneath are coveredwith a protective 1. SeeFigure5-3. Ensure g,ZlO-l sealant(seeSectiont.480). Apply additional sealantas required. t"y"r & float tube over landinggear skid tube and 2. See Figure5-3. Positionuninftated 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. GEAR FLOATLANDING POP-OUT 5.600 EMERGENCY replacepermanentlyinflated Emergencypop-out floats are an option tor R44 Clippers-and -lncluded are extended struts, skid extensions,uninflatedfloats stowed in utility floats. in protectivecovers along skid tubes, a lightweightcompositepressurecylinder.located the inflationlever locatedon the compartmentunderthe left-front seat, an inflationmanifold,an at stabilizer base of lower verticalstabilizer. A pilot;s collective,and an additionalhorizontal pressuregage- a thermal relief valve which a valve atop the pressurecylinder incorporates disk, and a releasesiressuie if expos6dto excesiive heat (281 degreesF), a metal s.ealing pin. To inflatethe floats, the red inflationlever on pilot's collectivestick must spring-loided safety in the READYpositionand then the levermust be.squeezed first liave its sirring-loaded pin the shearan aluminumrivet. Squeezing levercausesa^spring.-loaded forcefullyenough[o punctirrethe metal sealingdisk and allowsthe 4945 psig {nominal,at 2O"C}heliumcharge to to'inflate both floats via the manifold. The manifold consists of hoses with metal fittings per a incorporating check valve at each float chamber. There are six chambe_rs float (earlier 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 installing utility float or standardlandinggearin place of pop-outfloats, removalof pre.ssure pressure cylinder bracketJandcabie),and exteriorhoses.(cap. cylinder,iiflation lever(including check autorotation h6se and T-fitting in forward crbss tube tunnel)is required. Additionally, and updateempty weight and balance. RPMper Section-10.250 WARNING pin Gylindercontentsare underextremepressure. Installloc-king in (see Figure5-61when working-in fo-rward piessurecylinder valve g ieft baggaje compartment, durrin cy linder rem_ov_al installation. ^or LOCKING and wfr'dnivorkin! on floats or inflationhoses. REMOVE PIN WHENWORK IS COMPLETED. 5.610 Pop-out tloat Removal

NOTE
for tubes unlessnecessary

floats from skid avoidremoving To help preventfloat damage,

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

14: JUL 2OOB Change

HCIEIINSiCIN

MAINTENANeE MANUAL

MOI]EL

FI44

2. 3. 4.

alonginboardsectionsof float coverto expose fasteners Unfastenhook-and-loop b u t d o n ot r emove,lacing. l a c i n g . L o o se n , See Figure 5-5. extension. Remove AN3 bolts attaching float to skid tube and skid

girts separate strips from girts. Carefully See Figure5-5. RemoveC944retainer from skid tube and skid extension. NOTE Sealantinstalledbetween girts and skid tube at each bolt hole also acts as an adhesive. Use caution to avoid girt damage during removal.

5.620 Pop-outFloat lnstallation NOTE remove old sealant from skids, floats, and Before instaltation, hardware. A soft plasticscrapermay be used. WARNING contentsare underextremepressure.Installlockingpin Cylinder 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. tube and skid See Figure5-5. Positionuninflatedfloat over landing gear-.skid floatgirts, and skid. e"t"nrion. Align holes in C944 retainerstrips, float cov-er, InstatlAN3 attach bolts per Figure5-5. Seal under bolt head, nut, and around '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. Inflatefloat with filtered,oil-free,dry air to 3.0 psig via topping valves. 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 over fittingsand shrink with heat gun, usinga shield 1 .330. Positionheat-shrink to protect float from heat. Pack floats per Section 5.650.

2. 3.

4. 5.

6.

Ch a n g e7: 06 Dec 99

5 P a g e . 13

FICIBINSiC|N

MATNTENANeE MANUAL

MI'DEL]e44

I
HEAD WITH BOLT COVER ENTIRE (8 8270-1 SEALANTpl aces)

INBoARD .)

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

c950-3 C0VER, LH HALF OUTBOARD (ces0-4 RH) 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'IAY THICKNESS BE WASHER AND/OR 2-4.THREADS T0 VARIED REQUIRED MAINTAIN AS AND HEAD UNDER BEYOND SHO}IING NUTS.'SEAL GIRTSANDSKID BOLTBETWEEN NUTANDAROUND I{ITH B27O-I SEALANT. TUBE

ATTACHMENT FLOAT 5-5 POP-OUT FIGURE (LEF[SIDESH0tlN, F0RI'IARD) L00KING VIEt^l

P a g e5 . 1 4

Change7 : O 6 D e c 9 9

F|CIBINSICIN
5 . 6 3 0 L e ak C h e ck

MAINTENANcE

MANUAL

MOEIEL

F|44

WARNING contentsare underextremepressure.Installlockingpin Cvlinder tviinO"r valve (see Figirre.5-6) Yhgn working. in i"';;;;;*" i6til"tO iett Ubggige compartmentl during cy-linderremoval or floats or inflation w6rking on P9p-o-ut installation, "nd"*"hen pin when work is completed' locking ftoies. Remove 1.

'

cylindervalve. lnstallprotective from pressure D674-1lineassembly Disconnect 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;; float chamber). check valve function at e-ach alonginboardsectionsof float coverto expose fasteners Unfastenhook-and-loop do not remove, lacing. lacing. Loosen,but Unfastenoutboardsectionsof float cover and unroll float to exposevalves. tnflatefloats with filtered,oil-free,dry air to 2.0 psig via topping valves' for to Allow float air temperature stabilize 5 minutes minimumthen recordOAT and pressurein each float chamber. One to two hours after initialpressurecheck, again record OAT and pressurein each float chamber. Allowabiechamberpressuredrop from initialmeasurement will changeby O.O.Q ir O.t trig iOjrrt"O for any temperature_-change. .Pressure will For exdmple,float chamberpressure change. plig pdr O"egrde temperature C 1O degreesC. 016 bec-r6ase psig if temperaturedrops ff leaksare detected,repairfloat with suppliedrepairkit and repeatsteps 4,5, &6. to C on n e ctD 6 7 4 -1l i n e a ssembly cylindervalve and tor que per Sectio n1.330. Pack floats per Section 5.650. NOTE Annuallyapply A257-7dry-film lubricant(seeSection 1 .470) to float cover snap mating surfaces.

2.
3. 4. 5.
6.

7. 8. 9.

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

5 Page .15

FIclBINSiClN

MAINTENANcE MANUAL

MOEIELF|'44

WARNING contentsare underextremepressure.lnstalllockingpin Cylinder in'pressure cylinder valve (see Figure.5-6) when working.in removalor forward left bbggagecompartment,during cy-linder pop-out floats or inflation installation,ani-when w6rking on hoses. Remove locking pin when work is completed' 1. 2. fasteners{inboard) Unsnapoutboardedge of both float covers. Hook-and-loop may remainsecured. Removelocking pin from valve, move inflationlever safety to READYposition, O and verify area around floats is clear. inflationlever to inflateflqqts. fppr.oximately20 poundsforce will be Squeeze 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 or inflationahd ihformall nearbypersonnel.Remove close Ouring with float OiotJ prior to inflation. Open-doors interfere "lf inflationand may be damaged. 4. for to Allow float temperatures stabilize at least five minutesthen record OAT pr ar a n d p re rru re i n 'e a chfl o a t chamber . Minimumallowable essur es e: Minimum Pressure Minimum Pressure Minimum Pressure (psig-l Middle in 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

3.

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

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

P a g e5 . 16

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

FIG|BINSCIN

MAINTENANcEMANUAL

MOE'ELF44

5.

after cylindervalveimmediately from pressure D674-1hoseassembly Disconnect cnecti.--lnliall prbtective gap 9n bylinder valve fittins. .Cover i-"1i1-.t ;;;;;;; but -tObz+-r D674-1hosefitting to preventcontamination, d'onot installan air tight seal be allowed to leak to verify check valve function at each' hose musi float chamber). Verify no rips or chafing on floats or covers. pressure in One to two hours after initialpressurecheck, again record OAt qnd nojtLtramuli. Ailowauie chamber pressuie drop from initial measurement will.changeby 0.0.6 ""tr, ir O.ZOJii aajuitea for any temperature'change. . Pressure will float chamberpressure cfr'ange.For_exJmple, psi per degreeC temperatrire diops 1O degreesC' !""i""t" 6.6 psig if temperature lf leaksare detected,repairfloat with suppliedrepairkit then perfoim leakcheck per Section 5.630 on repairedfloat chamber. Connect D674-1 hose assembly to vatve fitting. Orient line as requiredto to mlint"in minimum0.25 inch clearance cylindeiand C390-5 panel. TorqueBn u t p e r S e cti o n1 .3 3 0 a n d tor que str ipe.

6. 7.

8.
9.

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 cylinderper Section5.670. 1 2 . I n sta l lse rvi ce a b l e re ssur 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. Verify float is properlysecuredto skid and all hosesare properly 1. connectedand coveredwith heat shrink. 2. 3. 4. Spreaddeflatedfloat to outboardside of skid tube. Using a vacuum, evacuate eich float chamberthrough topping valve to remove as much air as possible. Using a cloth covered with talcum powder, lightly coat entire float, including i n s i d eo f co ve rs. Fold front end of float under and back until fold line reachesgirt:
\

.t.:>
\

b.

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

P a g e 5 . 18

7 Change : 06 Dec99

.-I

F|CIEIINSiCIN

MATNTENANcEMANUAL

M!]EIEL]f,,44

6.

fastenersat insideof inboardgirt along length of cover: Securehook-and-loop

'.'.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

MATNTENANcE MANUAL

MOEIELH'44I

9.

Holdfloat on top of skidtube and installcoveraroundfl-oat.Usinga swab or hookSecure of to gmJl OiJshr, appty^ZST-7lubricant matingsurfaces snaps'. girt (seeFigure 5-5). alongoutboard in"b fasteners "nA-i*p "nO the Thereare two lacingcordsper float. Onecord secures float coveron the "The rehraining the float cover to the skid. secures cord extension. iLiO ("ladder" in "ti through-grommetscoverusingcrossover Vi,rityii.ing corainstalled lacing)methodshownbelow:

1 0 . Pu ll l a ci n g a t e a ch se g m ent until tight or until m ater ialedges.join; do not (4 overhand

overtighten. Tie lacing ends in douSle square knots knots) to secure. alternating fas 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 tener s at fastener s 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

FICIBINSIG|N

MATNTENANcE MANUAL

M('E'EL

N44

(seeFigure Removal 5-6A) Cylinder 5.660 Pressure WARNING pin pressure. Install locking in contents underextreme are Cylinder pressure whenworkingin forward Figure s-GA} cylinder valve{see

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. connector connector,cut & removety-rap closestto valve. Disconnect 4. On B-125-2 from valve cable. 5. DisconnectD675-10 supportfrom valve. Do not kink cable. 6. RemoveD669-3 strap. cylinder. 7. Carefullyremovepressure ValveServiceand Fillkit. orderKl-167Cylinder 8. lf cylinderhas beendischarged,

NOTE use for lf cylinder requires depressurization transportation, Kl-151

FloatCvlinderBleed-Off Kit.

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

Page5.21

-t-tr=-

FIGIBINSCIN

MAINTENANeE

MANUAL

M|]E'EL

F'44

5-6) Cvlinder {SeeFigure Pressure 5.665 Filling WARNING -DoT-E 10915-4945"may be refilled. labeled oNLY cylinders -DOT-E10915-4500"must be returned to labeled Cylinders
RHGfor exchange/upgrade.

hydro-test and life cylinder is 1b yearsfrom dateof manufacture maximum Maximum is 3 years. betweeninspections in interval aircraft is interval b years. Also,maximum older olderthan 12 yearsor havinghydro-tests io returning r"rui"" cylinders Therefore are arrangements madeto ensure unlessalternate 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.

gauge must be keptwithin safelimits. Monitorpressure and Cylindertemperature pressure probe to monitor temperature and use thermocoupfeoi other appropriatetemperature SooC on face of thermaLielieffitting oiliinsitilr. Do not allow temperatureto exceed stop fill and allow are approache.d, lf to 1122"Flor pressure exceed'SSOO-psig. limits. cylinderin a water bath continuing.-Placing cylinderto cool und prrsure to drop befo-re slow to moderatefill rates is recommended.lf using water bath, keep water and using of level belJw valve assemblyto avoid water contamination valve' fi 1 . R e m o ve l l -p o rtca p . 2. InstaltMT546-2 AdapterAssemblyper Figure3 (Torque40 in-lb)' 3. Attach fill hose to MT546-2 AdapterAssembly' grade)helium per chart below: 4. Fill with 99.98% minimumpurity (industrial Ambient T e m p( o C )

Pressure (psig)
4268 4437 4606 4776 4945 5 11 4 5283

-20 -10

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 fill-portcap (Torque40 in-lb)' 6. Removefill hose and re-install Page5.22 13: OC T 2OOo Change

FIC|BINSC|N

MATNTENANcE MANUAL

MOE'EL

H44

THERMALRELIEF FITTING {INSTALL THERMOCOUPLE HEREI

LABELED ONLYCYLINDERS MAY 10915-4945" "DOT-E BEREFILLED.

Togr

l I

w
\ \
\_e?

I I

DATE SUBSEOUENT HYDRO.TEST (EXAMPLE:JULY 2OO2l MANDATORYRETESTEVERY5 YEARS NOT RETURNING SERVICE TO RECOMMEND UNLESSTESTEDWITHIN PAST 2 YEARS

FIGURE PRESSURE 5.6 FILLING CYLINDER Cha n g e1 2 : J U L 2 OO5 Page5.23

FICIBINSGIN

MATNTENANeE MANUAL

M.'DEL

F|44

(seeFigure 5-6A) lnstallation Cvlinder 5.Q70 Pressure WARNING Cylindercontents are under extremeprelsLlg: Install locking valve (seeFigure5-6A) when working pih in pressure cylinder removal durins_cylinder #ssise i;'i;;il;Al;ii "ompartmeni floats or inflation woiking on-p-op-out oi intt.il.tion, and"iltien f,orei. nJmouelockingpin when work is completed'
1. Installlockingpin in valve. 2. Ensurecylinder's three forward contact areasare covered with anti-chafetape' positioncytinderinto D669 strap and D669 cradleper Figure5-6A' 3. Carefulty 4. InstallD675-10 supporton valve. 5. See Figure5-68. Connectvalve cableto 8125-2 connectorand securewith ty-rap. Verify dimensionshown. 6. InstallD675-9 cover on valve. with 7. Rotate cylinder as requiredto minimizecable bending and ensure clearance strap' structure.InstallD669-3 surrounding orient line as requiredto maintain g. connect D674-1 hose assemblyto valve fittin_g. panel.TorqueB-nutper Section and C3i9O-5 to minimumO.2Sinch clearance cylinder 1.330 and torque striPe. 9. Rig inflationlever per Section5.680' inflationlevershear rivet per section 5.690. 1O.Replace 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

FICIBINSCIN

MATNTENANcE MANUAL

MOEIEL

]f,44

9,332-42 LOCKWASHER (2 REO'DI MS27039CO805

SCREW {2 REO'D} NAS1149FN832P WASHER

AN735 CLAM (2 REO'

MS27039C1-11
SCREW I2 REO'D)

irr+srruaazr /
WASHER I

t2 REO',DI I 1

,h,
7 t,sv

'-r.a F n l r E n \ ^ COVER
\ ,

D67s-e

(2 REO'DI

MS21042108 NUT (2 REO'D} SEATBOX

ry)
\\
F7r1:\-

\ r r

\\,\ \L \\

\-s

\^^.s
\

Ms27039C0806 scREW

(2 REO'D}

co-PlLor

NASl 149F0332P WASHER

-4,

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

(2 REO'D}

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

'/

4
R\
I I

Ms2Jo42L3
(2 REo'Dl

=\\>, I naszzoggcosoo
I
SCREW 12REO',DI

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

\

Jp/'ocK,NG

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

-./'

F -'

8125-2 CONNECTOR

\.X
ztKg \
, ?
-\ \
\ \t t
'-

o "r?gx'F (REFI

i-/,. kz)
orrg-,,

\ \-......

D674-1 LINE \- = ASSEMBLY

'^#<

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

\

FIGURE 5.6A REMOVAL CYLINDER PRESSURE AND INSTALLATION

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

Page5.25

RClBINEiclN

MAINTENANcE MANUAL

MC'E'EL

F,44

0.00 - 0.20 lNcH

D675-10 SUPPORT

VALVE CABLE

8125-2 CONNECTOR

D675-9 <
COVER

t\/
TY-RAP MS3367-4-9 AS ORIENT SHOWN 12PLACESI

PIN LOCKING RECEPTACLE

5.6 VIEWA.A FROMFIGURE (VIEWLOOKING FORWARD}

5-68 FIGURE

Pa g e5 . 2 6

Change 12: JUL 2OO5

FICIBINS|GIN

MATNTENANeE MANUAL

MC]EIEL F44

LeverRissins 5.680 Inflation WARNING Cylindercontents are under extreme pressure.Install locking pin in pressure cylindervalve {see Figure5-6A) when working during cylinderremoval compartment, in forward left baggage floatsor inflation and or installation, when workingon'pop-out hoses.
1 . Installlockingpin in valve. 2 . See Figure 5-7. With inflation lever safety in READYposition, collectivefull up, and inch dimensionshown when inflationlever installed, verify 1.3O11.25 no shear-rivet 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. Verify no preload in cable thru full
travel of collective with inflation lever squeezedagainst safety. inflationlever shearrivet per Section5.690. 4. Replace Replacement 5.690 InflationLeverShear-Rivet 1. Beforeinstallingrivet, verify 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 and when working on pop-out floats or inflation or installation, hoses. Removelockingpin when work is completed.

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

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

Page5.27

FIClBINSlclN

MAINTENANcE MANUAL

M|fE

EL R44

l'!! rru*r

'/\

3'!!rucHes

D68O.1 LEVERASSEMBLY INFLATIONLEVERSAFETY (SHOWNIN LOCKEDPOSITION}

rHsrAffien

MS20470A2-6-5 RIVET

HEADNEARSIDE MANUFACTURED 5-8 FLATTENFARENDPERFIGURE

A333-1
STOP

INFLATIONLEVER

SAFETY

0.080- 0.100lNcH

MS20470A2-6-5 RIVET END SHOP.HEAD

5-8 FIGURE IN$TALLATION RIVET SHEAR

Pa g e5 . 2 8

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

FICIBINSCIN
5.7O0MAINTENANCE

MAINTENANtrE MANUAL

M(IEIEL

F.44

per skid, and drainholesin bottomsof skidtubesare not plugged.{two just standard l. Ensure aft of the skid shoesand the two forwaid s-kid between pop-outg""l o;iVi, tocaieO shoeat the forwardstrut. 2. Touch up skid tubes,crosstubes and strutsto preventcorrosion. See Section1.4O0 materials. for approved or autorotations running touch-down following especially frequently, skidshoes 3. Inspect or take-offs landings. (seeSection 1.480). Mix adhesive or with B27O-1 B27O-g lost or looseraincaps 4. Install instructions. per adhesive manufacturer's

lssued: JUL 2005

Pa ge5.29

FICIE|INSCIN

MATNTENANeE MANUAL

MOEIEL

H44

blank Intentionally

Pag e5 , 3 0

lssued: JUL 2OO5

o
6. POWERPLANT

FICIBINSCIN

MAINTENANcE

MANUAL

M3IEIEL

Fl44

6 SECTION SYSTEMS AND POWERPLANT RELATED SYSTEMS AND 6.000 POWERPLANT RELATED 6.001 6.002 Introduction DescriPtion

6.100 POWERPLANT
6.110 6.120 R E n g i n e e mo va l Enginelnstallation

SYSTEM 6.200 COOLING 6.210 6.220 6.230 6.240 and ScrollRemoval Fanwheel Fanwheeland ScrollInstallation (Reservedl FanwheelDynamicBalance

SYSTEM 6.300 LUBRICATION 6.310 Oil CoolerRemoval 6.320 Oil CoolerInstallation SYSTEM 6.400 INDUCTION 6.410 6.420 6.430 6.44O 6.450 6.460 6.47O 6.480 6.490 6.495 CarburetorRemoval Air Carburetor Box Removal Air Carburetor Box Installation Carburetorlnstallation Heat Scoop Removal Carburetor Heat Scoop Installation Carburetor Fuel InjectionAir Box Removal Fuel InjectionAir Box Installation Fuel Control Removal Fuel Control lnstallation Page6.i

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

FIOEIINSGIN

MATNTENANcE MANUAL

MoEfEL n,44

SYSTEM 6.500 EXHAUST 6.510 6.520 SystemRemoval Exhaust Systemlnstallation Exhaust

6.600 TROUBLESHOOTING
6.610 Low-powerChecklist

Page6.ii

Change9: FEB2003

FICIEIINSC|N

MAINTENANcE

MANUAL

MOEIEL

R.I'T

6 SECTION SYSTEMS AND RELATED 6.000 POWERPLANT 6.001 lntroduction This section includes instructions for the removal and instailation of .engine, induction and ivliem-,-iuUricaiion system, cooling,system and exhau:1,^1v.:J:T' 'manuiactureri' 'maintenance ic publications ,i"f:t-^l9.e.n9ine for product specif 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, 28q9-qpmfor..takqof. The engineis oit sGt6m'noiriiallyr'atedat 260 horsepowerand OeritJd- to 2OS maximum continuous horsepower (MCP), with a 5'minute takeoff pressure po*iil"iinq of 225 horsepower,by limiting'manifold .(seePilot's.Operating engine is actually turning indication-the ta6homete-r ind RPM. At 1O2o/o Ftiirb6ooil 2 7 1 8 R PM . openingon the right side of the aircraft R44 inductionair enters through a screened -duct A air to the carburetor-mounted ^b91^3:s_e.m,!Ly. paiiei through.a flexible anO scooii mounted tdthe exhaust manifold passesheated air via a duct to the air box. A allows either cool or sliding valve in the air box controlledby the pilo_t -5ii cabld-ooerated iito the box, through the radial-flow air filt-er and up into the to tlow warm application of carburetor heat is iaiUureior. On R44 S/N O2O2 and s-ubsequent, corietaieA with changes in collective setting through a {riction clutch to reduce pilot adds carb heat ald raising collective collective mechanical'ly workload. LoweringTtre pilot may overrideth-efriction clutch and increaseor decrease 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, are powered by one Textron-Lycoming R44 ll helicopters 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 MCP, with a S-minute pressure(see Pilot's t'akeoff power rating of 245 horsepowgl,by limiting_m.anifold taihometeiindicationthe engineis actually Handbookland RPM. At'192o/o Operatin'g turning 2118 RPM. R44 ll induction air enters through a screenedopening on the right side of the aircraft within an air box. The air then passesthrougha and oassesthrouqh a radial-flowJilter door on flexible duct, thr6ugh the fuel control and into the engine.. A spring-loaded -automatically opens to supply sheltered engine compartment air top of the air box occur. shouldfilter or intake screenblockage centrifugalfanwheel enclosedby a fiberglass Cooling is supplied by a direct-drive, ducts to the muffler, the main rotor scrotl. The sbioll direbts coolins air via flexibl-e qearbox, the hvdraulic reservoii (if installed),the drive belts, and engine-mounted cooling panels. The cooling panels also direct.cooling air to the -driv_e 5heet-metal externaloil cooler.{twoon R44,ll}, belts, and further guille coolingair to the-cylinders, alternator, magnefos, fuel fld'w divider (fuel injected engines), and battery (when battery is mounted in engine compartment). flangetransfersengine power to the clutch assembly A sheaveboltedto the propeller mountedelectricbelt tensionactuator. via four doublev-beltsehgagedby a vertically

2003 9: Change FEB

Pa ge6.1

FICIE|INEiCIN
6.100 POWERPLANT

MATNTENANeEMANUAL

MC|EIELTl44

NOTE
procedures, and For engineand ignitionmaintenance inspection publications maintenance manufacturers' refer t6 the appropriate Removal 6.1 1O Ensine 1. Remove tailconecowlingand all enginecowling. tailconeper Section4.31 1. 2. Remove per fanwheeland scrollassembly Section6'210' 3. Remove 4. belt tensionactuatorand V-beltsper Sections7.21O, Removeclutch assembly, 7 . 5 1 Oa n d 7 . 2 8 1 .

tube at engineby removingone clamp from the rubber enginebreather 5. Disconnect connections. coupling. Cap exposed G. Turn fuel on-off valveto off position. Removeair box assemblyand carburetor(if per equipped) Section6.41Oor 6.460, as applicable' line manifoldpressure from the forward left cylinder(0-540) or intake 7. Disconnect connections' manifold(lO-540)and cap exposed hoseand cap exposedconnections. oil 8. Disconnect pressure g. 0-540: lf instatled, primerline at T-fittingon engineand cap disconnect exposedconnections. fuel lO-b4O:Diiconnectfuel hosefrom engine-driven puqp inlet and disconnect inlet T-fitting. Cap exposed fueLreturn hose from fuel con-trol connections. and batterygroundstrapsfrom engineoil sump bolts. airframe 1O. Disconnect wiring,.starterw.iring,magneto-toalternator and 1 1 . Tag for identification disconnect airirame *iring. cylinderhead temperaturesenderwire and oil temperature senderwire. cabin heaterduct from mufflershroud' 12. Disconnect 13. Supportengineat bottom of lower sheave. Use a wood blockto preventdamage to sheave. all by 14. Removeaft enginesupportassembly disconnecting four bolts (seeFigure 6_1). NOTE the Do not disconnect rod endsfrom supportassembly. Two shown in Figure6-1 are criticaland must be dimensions maintained.
P a g e6 . 2

9: Change FEB2003

FICIBINEIC|N

MAINTENANeE

wlANlrAL

MOEIEL F|44

(cont'd) Removal 6.11O Ensine 1S. Supportengineat lifting lug usingthe MT548-1tool with a hoist as shown in Figure6'2. bolts (seeFigure6-18). and removetwo forwardengine-mounting 16. Disconnect lower right frame to upper 17. Removeright, aft verticalstrut weldmentconnecting frame. 18. On R44 ll, removeleft, aft verticalstrut weldment connectinglower left frame to upper frame engine. 19. Remove CAUTION the To preventdamagewhile removing engine,someoneshould assist on each side of the engine.

BETbIEEN ENSURE CLEARANCE TABS ANDFRAME ROD ENDS

1 . 1 5 r0 . 0 3 INCHES

0.80/1.00 llrcH

LOOKING VIEt,| FOR[.|ARD

cl74-l ENGINE SUPPORT ASSEMBLY

a

'ni
a

i...$+./

s---|Lt---

6.1 FIGURE

9: Change FEB2003

Page 6.3

FICIBINSCIN

MANUAL rvrATNTENANeE

MOE EL FI44I

Y
7 \\
11

\
\

IA,
J--a-i,

23

v->

m
\J

(<)
i
t

>,

FORWARD

F I G U R6 . 1 4 E ASSEIJIBLY SUPPORT AFT ENGINE

NO. NUI4BER PART 1 2 3 4 5 6 7 8 9 l0 1l l2 13 14 c020-1 NAS6605-9 AN960-5161 NAS679A5 8330-16 c174-1 NAS6604-8 AN960-4161 NAS679A4 8330-13 l9 8330MS2104216 ANg60-6161 A14l-23 DESCRIPTION AssanblY Upper Frame Bolt llasher Nut Palnut AssY Engine SuPPort Bolt llasher Nut P a ln u t Palnut NuI bJasher l.|asher NO. NUMBER PART DESCRIPTION Bolt Bolt llasher Link l4ount: EngineMount(Ref.) Nut Palnut Rod End Nut Nut Rod End

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 01 A1 -4

Page6.4

Change4: 1 Jun 97

F|C|BINSEIN

MAINTENANcE

MANUAL

M|fEIEL

F|44

FORWARD
7

:gK

a1
l-,
'.t
,\\ tt

Ii,

w
13

( Left m ountshown;r ight s' ide ENG i 6.18 FORWARDI N E M OUNTS FIGURE p a r t n u m b e ra r e i d e n t i c a l . ) s

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

6.5 Page

,.,ii

FICIBINE|CIN

MATNTENANcE MANUAL

MOE EL H44

MT548-1
HOIST

ourrHEAD f rosuPPoRr I

ENGINE LIFTING LUG

HORIZONTAL FIREWALL

OF DIRECTION ENGINE REMOVAL AND REPLACEMENT

H FIGURE .2 ENGINE OISTING 6

Pag e6 . 6

12; Change JUL2005

FICIBINSIEIN

MAINTENANcE

MANUAL

M(fElEL

]l,44

lnstallation 6.12O Engine hoistengineand position 1. ConnectMT548-1 hoistingtoolto engineliftinglug. Carefully pads (seeFigure6'2l. it into alignmentwith enginemounting 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. Support weight of engineat bottom of lower sheave. Use a wood block to prevent damageto sheave. Removehoist. per per 6. Connectaft enginesupportassembly Figure6-1A and torquefasteners Section 1.320. 7. Removesupportfrom lower sheave. 8. O-54O: Installcarburetorper Section6.44O. lO-54O: Connectthrottle linkage. Connectmixture control cable per Figure6-7A. under mixture control inch clearance Adjust cable so therJis O.O3-O.1O when fully depressedand mixture arm is in full rich knob (springback) position. riggingper Section1O.15O. 9. Adjustthrottlecorrelation 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 senderwire. Ty-rapas required. and oil temperature senderwire headtemperature tube. 13. Connectenginebreather 14. connectprimerlineto T-fittingon engine. 0-540: lf installed, fuel lO-54O: Connectfuel hose to engine-driven pump inlet and connectfuel return hoseto fuel controlinletT-fitting. Torqueper Section1.330. hose. 15. Connectoil pressure pressure line. 16. Connectmanifold 17. Installfuel injection box per Section6.480, if applicable. air 1 Ch a n g e 4 : J UL 2 0 0 8 Page6.7 I

FICIEIINSCIN

MATNTENANeE MANUAL

M('EIEL

H44

(cont'd) lnstallation .6.120 Engine 18. Install V-belts, belt tension actuator, and clutch assemblyper Sections7 -282, '' 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. SYSTEM 6.200 COOLING 6.210 Fanwheeland ScrollBe!1oyel NOTE then orient starter ring gear lf same fanwheel witl be reinstalled mark fanwheelat.splitline supportto magnetotiming position-and "will minimEd need for new balanceweights. See oi'i"ioil; this Figure6-38. 1. 2. 3. 4. b. 6. 7, g. engineaft cowling. Remove Removecoolinghosesfrom lower and upper halvesof scroll. tail Disconnect pipe strapsfrom lower scroll. Note shim stack on mountingscrews' from lower scrolland temporarily condenser air disconnect conditioning lf installed, secureit to a frame. two boltsthat attach scrollto lower actuator screws. Remove scrollperimeter Remove bearingblock and removescrolllower half' Cut safety wire and remove roll pin which securesfanwheel retainingnut. Remove retainingnut. Use a half-inchopen-endwrench to hold fanwheel hub bolt headsogr-lioyp 6-3A\and nuts with MTo92-3 spacers. remove 6 ot ii nJii and washersper Figure6-38. Replace Back out MTsg2-1 fanwheel puller's center bolt and attach pullerto the MTO92-3 (seeFigure 6-38). spacers CAUTION nut Verify fan retaining has beenremoved.Havesomeonesupport it. f"" i6 pi"ueni dro"pping Fanwheelmay come off taperedshaft with a loud pop. g. 10. 11. hold ring attach MTO$1-1starterring gear holdingtool and have sorneone Securety gear stationarY {seeFigure6-38). Tightenfanwheelpuller'slargecenterbolt againstfanshaftuntil fanwheelis unseated'

Removefanwheelpullerand reinstallnuts and washers on fan hub bolts. Special torquenuts per Section1.33O. 14: Change JUL 2oo8 Pa g e6 . 8

FIC|BINEiCIN

MAINTENANcE

MANUAL

Mt'E EL F.44

["

I
tl
I

ll'
rl

It

\1
\
\

Insert screwdriver into bracket notch

il
PullerBolt Access Fanwheel

r\ \\

BearingAssembly/Bracket Realignment

HUB BOLTACCESS 6.3A FANWHEEL FIGURE

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

X(,,,

Mark edge of fanwheel adjacentto split line of scroll.

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

MT592-1

INSTALLATION PULLER 6-38 FANWHEEL FIGURE 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 belt, and C181 bearingcondition;replaceas required. drive belts,atternator 1. Evaluate 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 enginecoolingpanels. shaft and clamping pg(io^n9!!-y of COO7. 3. Using A257-g anti-seize,coat threade_d '149F2432Pwashers (use as many as.will surfa-ces MS2OO02-24washer, NASl of washeragainsthub. nut. Installhardwarewith MS2OOO2'24 fit), and castellated NOTE gear support lf installingoriginalfanwheel, ensurestarter ringmarks on fanwheel with is at magnlto t'imingposition and align scroll split line. and ring toolto eng_ine gearguppo.rt holdstationary. 4 . SecureMTO$1-1ring gearholding -Section pin can be installedin 1.330 until.spring Sp""i.l torque CtAZ--l nut per steel wire. ;fi"ft. tnstallspringpin and bafety with 0.041-inch diameterstainless NOTE then within nut's torque range,. lf springpin cannot be installed nut. Large 6r remove- add NAS1149F2432P washers under springpin into position. pliersmay be used to squeeze b. Mark fanwheeldirectlyoppositeeach end of roll pin (see Figure2-11].. 6. positionlower scrolland insert two AN3-41A bolts through bearingmountingbra.cket, bracket nut plates on upper scroll' lf actuator Uearingbloci, and Uearingmounting. Ur""L"i nutplate-byinsertinga screwdriverinto notch in ipp"irorni i;q;ir;d, "lig" torque bolts per Section1.320 and torque stripe. bracket(seerlgiirE O-SAI.Standard 7. Installscrews, washers,and nuts aroundscrollperimeter. adjust inch. lf necessary, is g. Verify D22g lip-to-fanwheel inlet clearance O.O1O-O.O9O lip liy lip cl6arance elongating mountingholes' 9. Connecttail pipe to C173 straps.See Section6.520 for shimmingrequirements' 1O. Connect muffler and MRGB cooling hoses to scroll. EnsureMRGB cooling hoses tube thru full rangeof travel' cross and cleJrtail rotor push-pull heat shieldon lower scroll' and condenser condenser installair conditioning 1 1. lf applicable, fa 1 2 . B a l a n c e n w h e e lp e r S e cti o n6.240. CAUTION fanwheel Fanwheelbalancemust be checkedupon installation; ca i mb a l a n ce n ca u sed am age' P a g e6 . 1 0 1 Change 4: JUL2OO8

lfOBlN9C|N
6.230 (reserved)

IUAINTENANeE luANuAL

MoE Elnrra,

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

Page6.1 1

;
fl

FICIBINCiCIN

MAINTENANcEMANUAL BRACKETS INSTALL EXISTING USING ALL SECURE CABLES HARDI.IARE. TAPE }IITH IX.ICT c181-3 'r(-" FANSHAFT BEARING
lttt

MOEIEL

F|44

PHOTOCELL (USED INSTEAD OFSTROBEX) PHOTOCELL BRACKET BRACKET

\-:o
TARGET TAPE
t!

l-r'
- - - - t \

,"t-

--i

VELOCI}tETER

t'\ l'l ll t, t,

\,

\---.?

ll.
t

,'-',
a.-l

i",
t-'

tr
.'l

ii r
4185-1 BRACKET

LEFTAN3 BOLT

BALANCER

(USED INSTEAD OF PHOTOCELL) 6.4A FIGURE

STROBEX

ACCELEROMETER T}IOACCELEROMETER VELOCIHETER BOLTED BRACKETS TOGETHER.

VELOCIHETER CABLE

AT IIIASHERS B0LT(S) CHANGE 1: N E A R E S T00 P OS IT I0 N BOLTS. DONOT REMOVE

= 0.05IPS WASHER AN960-10 = 0.10IPS IIASHER A141-17 = 0.20IPS I,IASHER AN970-3

NUT. WASHERS UNDER U5E FOUR AS SIZES REQUIRED MIX AB0VE REMOVE FORBALANCE. NOT OO BOLTS. THENAS66O3-6 NOTRTE UNTILTARGET FAN TAPEIS AT CLOCK ANGLE N 0 T E D 6 .2 4 0 (H ) IN 6-48 FANBALANCING FIGURE P a g e6 . 1 2 9: Change FEB2003
I I I I I t t,

F|CIBINEiCIN

MAINTENANcE

MANUAL

MOEIEL

FI44

Il
/l

MUST BE WASHERS TI^IO INSTALLED

lq '{

fI

I
17

716

I! --|--v
\

\l

I I t-:l25

'l-E*" i

9io NOTE 1 1 ITEMS TORQUE 6 (BOLT), 0(B 0 L T ),1 ,L (NUT) 1.330. sEcrIoN PER 19 ITEM AND

-l
13

6-5 FIGURE

FAN INSTALLATION DESCRIPTION

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

26

NUMBER I{UMBER PART 1 2 3 4

NUMBER NUMBER PART 14

d
7 8 9 10 11 L2 13

Engine Flange RingGear Engine 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 (between NASl149F0316P Washer coneand fan) Assembly Fanwheel DL74-2

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

c182-1 8350-3

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

Cha n g e4 : 1 Jun 97

6 Page .13

. l

FIclBINEiClN

MATNTENANcEMANUAL

MOE'EL

1lT44

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

engineaft cowling. Remove wire lnstallaccelerometer on fanshaftbearingper Figure6-4A. .Accelerometer from two may be assembled pointed down. A suitablebrack-et JnouiO-6"fabricated. or brackets may be acceleromeier 6-4A). Place targettapeat edgeof one fan vane(seeFigure a Box RPMrangeto X1Oscale. Set B. Set Strobexmodeto position Set Balance to 270. Box RPMdial Balance RPMwith rotor systemengagedand at Start engineand run helicopter 1O2o/o governor ON.
WARNING Use extreme care near tail rotor.

c) d) e)

f)

point Strobexat fanshaft nut and pull trigger. Note clock angle of target tape' push Tune button on BalanceBox. Note change (if any) in clock angle of target

s)
h) i) j)

the to RP[I-dialbring target,lf,ffl,.1?[11 i"p": Wtil.e ingfu;a button,,adiust ou;f is tunedto fan RP
Box in i;-th" cioC[ ingle vTewed Step"f". Balance whenTunebuttonpushedand released. ir rioinang" i;iig;t iJpe ctockangle Box is tuned. Note clock angleof targettape when Balance on reading IPSmeter. Notevibration down. Shutengine CAUTION ignitionswitch is OFFand keys are out of switch Ensure is fanwheel movedby hand. wheneveJ

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

(cont'd) Balance 6.240 Fan Dvnamic kl to readingis over 0.2 lPS,washersmust be exchanged balance lf balance positionnoted in Step "h'. ;ooli;g f.n. ioiate until target !?P!-is ^in to undernut nearest AN97O-3.washers Changi ANg60-1O,A1 41-17,-.or nuts weight changeundertwo ,nearest the 1IOOpositionor split required will changebarance.reading Figuie 6-48). Ohe AN96O-10wrasher isee two O.O5lPS. One Al 41-17 washer.egyals^ AN960-10 i-ppro*imately wdshers. On'e erug7}-3 washer equals four AN960-10 washers. Four undereachnut. To accessbolt head,removeD229washersare required sideof lowerscrolland rotatefan as required.Do not 4 coveron forvriard washersmay be bolts or the NAS1149F0316P removethe NAS66O3-6 (seeFigure6-51. Tolque NAS6603-6bolt and MS21042L3nut dislodged per Section1.330. InstallD229-4 coveron lower scroll. check fan balancereading. Exchange After washershave beeninstalled, washersuntil a readingof lessthan 0.2 IPSis obtained.

ll

I I

and accelerometer attachingbrackets.Installengineaft cowling. m) Remove

4: Change 1 Jun 97

Page .15 6

FICIBINEiCIN

MATNTENANeE MANUAL

MOE EL F|44

SYSTEM 6;3O0 LUBRICATION NOTE SeeSection1 for gradeand quantityof oil required. Operator'sManual Refer to the Textion-Lycoming of and maintenance the lubrication for adjustment system. 6-310 Oil CoolerRemoval al Removeright engineside paneland aft enginecowling. the bl Disconnect oil linesat the cooler. the c) Remove two screwsand nuts holdingthe c636-1 supportto the cooling shroud(seeFigure&61. the dl Disconnect four mountingboltsand removethe oil coolerand support. lnstallation 6.320 Oil Coole,r usin} 9'270-6sealantand torque to elbows, if required, al InstallMS2O822-g plustorquerequired alignthe elbows' to 110 in.-lbs shrojd using enginegqo-Ug. b) Installthe oil coolerand C636-1 Supportto the_ 'bolts per Sect-ion 1.320 (see Figure6UottJ.forque thd tf,e ioJi hounting 6). cl Installthe two screwsand nuts that fastenthe supportto the coolingshroud. plusnut drag. Torquethe nutsto 15 in.-lbs. the dl Reconnect oil linesand torquethe tubing nuts per Section1.330. el Installcowling.

P a g e6 . 1 6

Change2: 12Dec 94

FIC|BINSICIN

MAINTENANcEMANUAL

MCIEIELFI44

MS20822-8 ELBOI{

MS21042108 T.IUT

I
I I
I

1 SUPPORT

tr-=_
I

1 A66& DOUBLER
I

c649-1 OIL COOLER

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 Removal 6.410 Carburetor a) Removeright enginesidePanel. b) Turn off the fuel valve and disconnectthe fuel line at the carburetor. Cap the fuel inletport. line and the carburetor heat ducts from the air box. c) Disconnectthe air intakeand carburetor 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. plug e) Disconnect the carburetorair temperatureprobe at the quick-disconnect the probe. four inchesfrom locatedapproximately f) Removethe palnuts and nuts securingthe carburetorto the oil sump and remove the carburetorand air box assembly. | Air 6.420 Carburetor Box Removal the a) Removethe four long bolts securing air filter cover. Open cover and removeair filter. attach bolts and remove b) Clip the safety wire securingthe four air box-to-carburetor gasket. the bolts, air box and I 6.430 Carburetor Box lnstallation Air with the four attach bolts. a) Installtheair box and gasketto the carburetor b) Torquethe four attach botts per section 1.330 and safety with 0.032 inch safety wire. the c) Reinstalt air filter, close cover and securewith the four long bolts. NOTE Tightenthe nuts on the long attachbolts until 2-4 threads pr6trude throughthe nut ant coveris uniformlysealed' the nuts can causedistortionof the cover and bu"nigntening-of air box seal. of leakage the

6 Page .18

9: Change FEB2OO3

FICIE|INEiCIN

MAINTENANtrE MANUAL

MIfEIEL

H,44

lnstallation 6.440 Carburetor 6.430. air 1. Install box per Section

palnuts.

2' y'?iqJiHi8ry[3k.i"T3iif,%o#I3l,?1,3t Tbor'o*l'fo*iLTift "'{"'#TILI'EHll,3fl |

'Adjust throttle correlationrigging 3. Connectthrottle linkageto throttle arm. pei Seciion t 0.1 50 ant torque per Section 1.320. .andcarb heat 4. Connect mixture control cableto carburetor(9qeFjggF^6-7-l inch for JJntioiio ;ii fti ifoei va-ive. nig eachco4tr<)t 0--09-0-.10. clearance Verify full travel of mixture arm and abpress"ea. unddit-nob; wft;iui\i carburetorheat slidervalve. probeand secureconnectorto carburetor air b. Connectcarburetor temperature with ty-rap. and torque per Section 1.33O. 6. Connectfuel hose to carburetor heat hosesto air box. 7. Connectair intake and carburetor 8. Installenginecowling(s). 2 9 . Co mp l yw i th S e cti o n .2 10, steps15 & 16. Heat Scoop Removal 6.450 Carburetor engineright cowling. 1. Remove 2. Disconnecthose from air box to carb heat scoop. 3. Loosenclamps and removescoop. Heat Scoop lnstallation 6.460 Carburetor 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 engineright cowling. 1. Remove air 2. Remove intakehose. 3. Coverfuel controlair intake. 4. Removefour screws and largeareawashersatop of , and securingair box to, firewall. horizontal air 5. Remove box.

Change9: FEB2OO3

Page .19 6

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. Verify clearancebetween air box, intake hose and adjacentcomponents;adjust for componentpositionas required clearance. 4. Installenginecowling. 6.490 FuelControlRemoval 1. Turn fuel shut-offvalve OFF. 2. Removeright cowling. 3. Removeair intake hose. f 4. Disconnectuetcontrolinlettee f rom f uelcontrolinletreducer.lnstallprotective caps on all open fuel passages. and cap fuel hose from fuel control outlet. 5 . Disconnect

6 . Disconnectpush-pulltube from bellcrankattached to fuel control mounting

f la n g e . mixturecontrol cablefrom fuel control. 7 . Disconnect 8 . Loosenlower, aft bolt securingfuel controlto intake manifold. Removethree bolis and removefull controlwith attachedlink and bellcrank. remaining 9 . Removeold gasketfrom intake manifoldinlet. Cover inlet if not immediately fuel control. replacing fuel control. 10. Compare fittings on removed fuet control with replac-ement 1.330. Tranifer f itting; as requiredand torque per Section 6.495 FuelControllnstallation fuel control. 1. Compare fittings on removed fuel control with replac^ement 1.330. and torque per Section Tranifer f ittingi as required 2. Removetemporaryshippingsafety wire from mixture and throttle arms. throttle arm angleper Figure6-7B and full-leanmixture 3. Verify correctfull-open 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 in ma n i T o l d # g-e w i th l o ngerbolt thr u bellcr ank for war d, upperhole. fl 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. per Figure6-7A. Verify full tube to bellcrank 7. Connectthrottle push-pull (collective tn'achievefull-openthrottle). must be raisedslightly travel 8 . Referto Figure6-7C. Connectmixturecablehousingto bracketwith housing inch extendedbeyond clamps. Connect mixture control cable flush-to-O.25 with 4257A130 spacerlubricated innerwire to mixturecontrolarm. Ensure undermixturecontrol 0 1 grease.Verify f ull traveland O.O3-0.1 inch clearance 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 but requireci do not bendend. Torquenut on A462 fitting per Section 1.33O anil verify 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. groundthe helicopter. 1O.Electrically 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. position 14. Turn masterswitch ON. Openthrottle. Turn ignitionkey to PRIME and hold until fluid exitingfuel control is the same color as avgas (fuel oily control is typicallyshippedwith non-flammable 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 and verify no leakage. control and attachedfuel connections g w 1 8 . R e mo ve ro u n d i n g i re ( s) . 19. Performpreflight,start engine,and run up using R44 POH checklist. rpm with enginewarm and clutch engaged. 20. Set idle rpm to 58-620/o 21 . Shut down engineusing R44 POHchecklist. fuel control outlet hose, connecttest hose if desired,and 22. Disconnect measurefuel flow rate at fuel controloutlet with mixture full rich, throttle at position) . key at PRIM E i d l e ,a n d e l e ctri c e l p um p on ( ignition fu Page .198 6 C h a n g e 3 : O C T2 0 0 6 1

FICIBINSCIN

MATNTENANeE MANUAL

MOEIEL

F,44

(cont'd) 6'495 Fuel control Installation fuel flow to 23. Adjust idle mixtureas required obtain 16-18 pounds/hour l170-190 cc/minute). Clockwiserotationof idle mixture adjustmentwheel (viewedfrom aircraftright side)enrichesmixture. Re-checkidle rpm after and repeatas requireduntil both rpm and mixtureare mixture adjustment from within limits. With rpm and mixtureset, verify smooth acceleration rpm with no enginehesitationor smoke from tailpipe. Also idle to 1O2o/o to verify smooth needlesplit from 1O2o/o idle with no engineroughness idle quality. Note that 16-18 and acceptable or erraticrpm indications pounds/hour fuel flow shouldproduceacceptableidle quality and off-idle standardconditions. Richermixtures undersea-level throttle performance operationand leanermixturesmay be for may be required cold temperature for required hot/highaltitudeoperation. Deviatef rom 16-18 pounds/hour idle quality and off-idlethrottle for as recommendation required acceptable and (smoothaccelerations needlesplits)' performance riggingper Section 10.150' 24. Adjust throttle corretation 2 5 . I n sta l lri g h t co w l i n g .

6 Page .19C

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

FtClBtNSiClN

MAINTENANeEMANUAL

MotrELp'AA

BLANK INTENTIONALLY

Cha n g e : F E B2 0 0 3 9

Page .19D 6

HCIE|INS|CIN

MAINTENANeE

MANIIAL

MCIEIEL F|44I

ts

SAFETY SPRING ASSEMBLY CABLE BRACKET

FORWARD

I,IIXTURE CONTROL

(VIEWLOOKING DOWN}

. FLUSH 0.25 INCH

,o
-0.10 - 0..30

CLEARANCE MUST HAVE HOUSING CABLE BETWEEN ARMIS AT I.IHEN ANDARM POSITION IDLECUT-OFF MIXTURE CONTROL CABLE CARBURETOR

\ .-.

DoNorBEND

i-'JhMrxruRE I K't coNTRoL

\

Ki,fiF I ffitlr \h\s\iJY*ilAsHER 6,

.a..? ,/,/

\\

C0NTR0L ARM

\SZ-oouir,rr,*n

)Hr$W-ir,*i'nr,, ?-fl \%'Y:

\zrl

( FORWARD

t ' \ c-o-!\TRoL'MT*TURE
ARM-STOP
uilcT enNTrliT

@
---

1,1 I'dr)Ei\'6:'^,

A2s7-tGREASE) }IASHER - sELF-LocKINc NUT

( LUBRICA t, WII H I

WA
t

\
\.-\- -

(sToPMUST CoNTACT gOOV'Rt CARBURETSn

r^n

lPALNUT

FUEL SCREEN N0TE:

ACCESS

AilD FULL.RICH IDLE PoSITIoNS) cuT-0FF

6-7 FIGURE CABLE CONTROL MIXTURE R44 CARBURETOR SPRING AND SAFETY
Page6 . 2 0

9: Change FEB2OO3

FICIBINSIEIN

MATNTENANeE MANUAL

MOEIEL F|44

3 NAS6603-1 BOLT

-i-\ NAS1149F0332P -\NUT MS21O42L3 \\\PALNUT B33O-7 D543-2 SPACERS NUT MS21O42L4

WASHER r.rA t

D731-9 BELLCRANK

NAS6603-1 3 BOLT A341-1 SPACERS

I I

B33O-1 PALNUT 3
WIRE SAFETY

I
t-/"/

i/
I
t----tt'

NAS1149FO463P WASHER TUBE A336-6 PUSH-PULL 8564-2 LINK

RSA-IOAD1 FUEL CONTROL

MS2104213 NUT NASl 149F0332P WASHER

D731-1 BELLCRANK ASSEMBLY

NUT MSz1O42L3
8330.7 PALNUT

FORWARD

I,

LINKAGEINSTALLATION FTGURE 6.7A THROTTLE

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

Page6.20A

FICIEIINSCIN

MATNTENANeE MANUAL
/\ /\ /\ /\ / 46.0o+7.s'rRUE ,\tt"

MOEIEL

F.44

oPENrHRorrLE)

ARM THROTTLE

FUEL CONTROL RSA.IOAD1

ARM ADJUSTMENT 6-78 THROTTLE FIGURE (VIEW AFTI LOOKING

'fuft,i*"

DO NOT BEND

WIRE o . 1 0- 0 . 3 0 INCHBEYOND FITTING

TO FLUSH 0.25 INCH HOUSING CLAMPS BEYOND

INSTALLATION CABLE 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 SvstemRemoval 6.510 Exhaust and aft cowling' sidepanels engine 1. Remove from tail pipe' C173 stra'ps 2. Disconnect at hoses mufflershroud' 3. Disconnect
removecarburetorheat scoop per Section6'450' 4. lf installed, remove exhaust 5. Disconnect exhaust risers at each engine cylinder, and system.

Ex

lon

clamps 1 . Installexhaust risers with new exhaust gaskets. Joints under bead nuts torque riser tape. Special *itt A7O1-10 stainless--steel ;;;'bt*iipp"O 1 .3 3 0 . p er S e cti o n 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. heat scoop {O-54Oengine)per Section6'460' 3 . Installcarburetor 4 . Connectmuffler coolingand heaterhosesto muffler shroud' thermalgrowth, installshim 5 . connect tail pipeto c173 straps.To accommodate to washer(s)betweeniailpipeeirs and straps as required breatea O'O2lO'08 preloadon btraps at tailpipe attachment. inif, tot*ard 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
I

MATNTENANeE MANUAL

MOEIEL

844

6 . 6 0 0 T R O U BL E -S H OOT IN G 0 . 0 1 0 L o w -P o w e r h e ckl i st C use the following checklistto'verify: When low enginepower output is suspected, 1. Aircraft grossweight is not exceeded.Weighaircraftif it was not weighedat last overhaul. and CHT are within limits. 2. Engineoil pressure, temperature, oil 3. MAP gage indicatesambientpressure(engineoff). Handbook. 4. Propergradeof fuel per Pilot's Operating 5. Main rotor bladesare clean and smooth (no rough paint). 6. Exhaustis unobstructed. bent. 7. Main rotor bladetrim tabs are not excessively g. lf equipped, verify 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 per Lycoming (lO-540only). Cleannozzles 10. Fuelinjectornozzles unobstructed are ServiceInstruction141 4. 1 1. Enginetachometerindicationis correct. Verify with digitaltachometer(such as or equipment) similarequipment. fouhd in newer dynamic balancing 12. Oil screensor filter do not exhibit metallicdebrisconsistentwith internalengine damage. 13. Proper cylinder compression (both leakage and direct) per Lycoming recommendations. lean nor rich. Comparefuel flow. Verify fuel filter 14. Mixture neitherexcessively throttle body-to-float plug indications, check carburetor check spark cleanliness, per LycomingSB 366. bowl screw security 1 5 . P r o pe r a rkp l u g typ e a n d condition. sp is timing. Verify engine-left(helicopter-right) 16. Propermagneto-to-engine .magneto is in BOTHposition (disconnect not operatingin retard mode wh-enignition switch lesser retardterminalafter starting engineand comparehover MAP indications; indicatesmagnetowas operating hover MAP with retard terriinaf disconnected retarded). control inlet screen. Perform 17. Properfuet flow and unobstructedcarburetor/fuel f u e l - fl o wch e ck p e r S e cti o n12. primer PuTp engine,verify fuel is not leaking-Pqst carbureted 18. lf primer-equipped not leaking past fittings in cylinder (ensurepriindi pJmp is locked)"and' is air head. 14: JUL 2008 Change

Page6.22

FIC|BINSiCIN

MAINTENANeE

MANUAL

MtfE|EL

F,44

6.610 Low-PowerChecklist(cont'd) (collectivemust 1g. Carburetoror fuel control throttle lever contacts full-throttle stop be raisedslightlY). 20. Carburetoror fuel control mixture arm contacts stop when mixture control is in full-rich positionand mixture arm does not exhibit springbackat extremesof travel spring (dueto internalbinding). from control cable/safety when disconnected 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. Verify 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,verify intake manifold drain ("sniffle") valve does not leak ambient air into intake manifold. per Lycoming58388 (latestrevision). 22. Properexhaustvalve guide clearance per LycomingOverhaulManual. 23. Properdry-tappetclearance 24. With lifters pumped up (valve lash removed),each intake valve should exhibit each with a dial indicator.Similarly, equal travel during openingwhen measured travel indicates exhaustvalve shouldexhibitequaltravel duringopening.Unequal ca d a ma g e d m l o b e (s). 25. Propermagnetointernaltiming. float bowl fuel level correct. 26. Carburetor edge where inlet airflow turns 90 degrees 27. Cylinderhead intakeport has radiused toward valve. lf no radiusexists, contact LycomingTechnicalSupport. timing: As #1 piston passesTDC 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, verify correct 8.5:1 compressionratio piston P/N 75089 has been installed (insteadof 7,0:1 low p c o mp re ssi o n i sto nP /N 7 5413) .

1 Ch a n g e 4 : J UL 2 0 0 8

P a g e6 . 2 3

FICIBINSCIN

MATNTENANeE MANUAL

MtlE,EL

F|44

8249.7 ARM ASSEMBLY

BOLT NAS6603.7 ANg6OPDlOL WASHER (under head)

A142-4 SCREW NAS1149FO332WASHER P (torqueto 45 in.-lb;includes locking torque) 2 places

A141-16 WASHER (0.688 in. outsidediameter; 3 required)

8250.8 JOURNAL ( 0 . 1 0 0i n . l o n g )

R Nt3???3;l'. E a 51,'T,o," N MS21O42L6 UT

A141-16 REF (torqueto 28O in.-lb; includesnut self-locking torque) P B33O-19 ALNUT

A647.12 BEARING (2 required)

8250-5,-6,-7, -10,or -12 JOURNAL (2 required*)

B D333-10 LOCK 1 D333-1 PLATE

825O JournalLengths(thickness):

D333-1 BELLCRANK

WASHER SPRING B1OOO-O35-S orientas shown) {2 required, A 1 4 1 . 3 5W A S H E R (2 required) N A S 1 1 4 9 F O 6 6 3W A S H E R P

8250-5 8250-6 B250-7 0 8250-1 8250-12

O.059 inch long 0.062 inch long 0.065 inchlong 0.068 inch long O . 0 7 1i n c h l o n g

*fnstall 8250-5, -6, -7, -10, or -12 journalsas required producea rotational friction to clamp may be mixed. After adjustment, of 1O-i2 inch-pounds.Journaldashnumbers contactingvise 8249-7 arm assembly fong side of D333-11 plate in paddedvise with jawi while providing rotationalclearancefor D333-1 bellcrank;measurerotational torque wrench. friction by rotatingbolt head with dial-indicating

ADJUSTMENT FIGURE 6-8 D334 BELLCRANK CARB HEAT ASSISTFRICTION

Page 6.24

1 Change 4: JUL 2008

t
7. DRIVE TRAIN

FICIBINSiCIN

MATNTENANcE MANUAL
7 SECTION TRAIN DRIVE

MOEIEL

1f,,44

TRAIN 7.OOO DRIVE 7.OO1 Introduction 7.OO2 Description GE 7. 1 0 0 M A I N ROT OR A R B OX 7.11O Main RotorGearboxRemoval 7.12O Main RotorGearboxlnstallation Main RotorGearbox 7.130 Leveling Yoke Replacement 7.140 C9O8-1 7.141 SettingHall Effect SenderGap PinionSeal of 7.150 Replacement Main RotorGearbox Procedure 7.155 Main Rotor GearboxSump O-RingReplacement 7.160 Main Rotor GearboxOvertempInspection Chip Light lndicator 7.17O Main RotorGearbox of 7.'l8O Lubrication Main Rotor Gearbox ASSEMBLY 7.2OO CLUTCH 7.21O Clutch AssemblyRemoval AssemblyRemoval 7.21'l C184 Bearing AssemblyInstallation 7.212 C184 Bearing SealReplacement 7.213 ClutchAssembly 7.22O Clutch AssemblyInstallation 7.23O Clutch SheaveAlignment 7.24O ClutchShaft Angle 7.25O LateralClutch Centering and Installation 7.260 C9O7Yoke Removal Change 1 Jun 97 4: Page7.i :

FICIBINSiCIN

MATNTENANcE MANUAL

MOETEL F|44

(co A 7 . 2 0 O .C L U T C H S S E MB L Y n t'd ) l 7 . 2 7 O C 1 9 5 Y o ke R e mo va a 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 Assembly,StarterRing GearSupport,Lower 7.29O COOTFanshaftand Bearing Sheave.and AlternatorBelt Replacement 7 . 2 9 1 R e mo va l 7.292 Installation D 7 . 3 0 0 T A I L R OT OR 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 and Shimming Flex PlateInstallation 7.330 Intermediate 7.34O CheckingTail Rotor Drive Shaft Runout 7.350 Two-PieceTail Rotor Drive Shaft GE 7 . 4 O O T A I L R OT OR A R B OX 7.41A Tail Rotor GearboxRemoval 7.42O Tail Rotor GearboxInstallation C 7 . 4 3 O T a i l R o to rGe a rb o x h i p In dicator 7.44O Tail Rotor GearboxOutput Shaft Seal Replacement 7.45O Tail Rotor Gearboxlnput shaft seal Replacement A 7 . 5 O O AC T U AT OR 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

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

FIIIEIINiC|N

MATNTENANeE MANUAL

MoEIEL p,arl

(CONt'dI ASSEMBLY 7.500 ACTUATOR of 7.54O Adjustment Actuator 7.550 Switchand FuseRePlacement 7.551 SwitchRePlacement 7.552 FuseRePlacement BRAKE 7.600 ROTOR Removal 7.610 RotorBrake 7.620 RotorBrakeInstallation 7.630 RotorBrakePadRePlacement

Change : 15 Jun98 5

Page7.i i i

FIOBINSCIN

MATNTENANcEMANUAL

MclclELn'4e

left blank. This page intentionally

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

7 sEcTloN
TRAIN DRIVE

rR+lN 7.000 pRlvE

7.001 Introduction and replacement, installation, for This sectioncontainsthe procedures removal, of maintenance the drivetrain components. (SeeFioure 7-11 7.002 Description four doubleVof A V-beltsheaveis bolteddirectlyto the crankshaft the engine; clutch 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. and at eachend of the are couplings locatebat the input to the maingearbox Flexible spiral-bevel containsa single-stage. long tail rot6r diive shaft. The main r6tor gearbox but bearings The gea-r which is splash-lubricated. long tail rotorshaft has no hanger set, gearboxalso containsa splashdamperbearing.The tail rotor has a lightly-loaded input and output shafts are both lubricateisiirat bevelgearset. Theiail rotor gearbox The other shafts throughoutthe drive made of stiinless stedl to preventcorrosion. systemare madeof alloysteel. GEARBOX 7.100 MAIN ROTOR Removal 7.110 Main RotorGearbox al Removethe C706-1 tailconecowling, both engineside panels,and the aft cowling. engine bl Removethe mast fairing per Section4.142. Removethe middleand lower mast fairingribs from the mast tube. 9.111. the c) Remove mainrotor per Section the on dl Disconnect rotorbrakecablepulleys the arm and aux tank. Remove the cablehousingclampon the aux tank channel.

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

7.1 Page

FIC|BINSiGIN

MATNTENANeE MANUAL

MOE'EL

FI44

HOLE VENT

SHAFT C251.1 I4AINROTOR

c908-1YoKE ASSEMBLY PLATE C947-1FLEX

PLATE FLEX ASSETIIBLY

cs47.3il
c02l-l I / TAIL ROTOR / eEmgoxAssEt4BLY

0R c907-1 -2 YoKE
c156-1 -_ - CLUTCH
SHAFT

ASSEI{BLY C018.1CLUTCH -2,.-3, 0R-4 c195-1 .

1'

DRM SHAFr i D224-LTAIL R0T0R

,:lll-tx'*umt
ENGINE

c493-1 SHEAVE
A19O-3V.BELT

SYSTEM 7F IGURE 1 DRIVE

Page 7.2

Change2: 12 Dec 94

FICIBINSiC|N

MATNTENANcE MANUAL

MOEIELF'44

R c261-5,-6 IBS FAIRING c26l-1 MAST ASSEMBLY C121-5PUSH.PULL

(r) ruer

crzt-7 PUSH-PULL

rusr(2)

PUSH.PULL ( GUIDT1) TUBE

l
c?6r-7,-8RIBS .
-4 R b) 1 K C 2 6 1 -3 ,-4 lIB S \

L==
*-/

I
|

.4+=

.\

FIGURE 7-2

REMOVAL GEARBOX MAIN ROTOR

Change 5 May 95 3:

Page7.3

FICIBINSCIN

MATNTENANcE MANUAL

MC|EIELF'44

(cont'dl Removal 7.11Q Main RotorGearbox el Remove the main and auxiliary fuel tanks per Section 12.110. Mark all for connections reinstallation. electrical tubes from the forward and aft push-pull the f) Disconnect iackshaft(C337-11 and the supportstruts. g) Removethe iackshaftsupportstruts (seeSection8.3OOl. hl Disconnectforward flex plate from gearboxyoke and note the washer stack up on each bolt. the il Disconneqt chip.detector,Hall Effect sender,overtempsenderleads,and a groundwire. Tag wires for reassembly. the gearboxleft and right coolinghosesand nozzle' i) Remove lift-tl9 gearbox mountingbolts' .Ca9!1!tV the four main rotor gearbox. kl Remove ' and remove{seeFigure7-21. tubes ijp to cieii-trriloi*iiO dush--pull be that the transmission hoistedusing the MT527-1 1l lt is recommended lifting fixture. helicoPter CAUTION Leveling shims may be instatledbetween-the gearbox .ounif anO ine liame mounting pads. These should rerain Jtticned or mark mounlirig pads with shim for thickness reinstallation. at the the ll Remove droopstopsand disconnect lower scissors the mast. Slide tube' off a3sembly the slider the swashplate lnstallation 7.12O MAinRotorGearbox CAUTION PriOr to operation of a new, overhauledor repaired oeJrboi, G'ounces ot AZSZ-2gearoil must be iniected on int6'inJ'reni noie-tsle Figure7111 the lop ?tt side of 'gearUo'x w1n oil to the level indicated ine riilt tuUe.Fitt vertical must remain The ij^ tf,r iigni glais OEcal. gearbox duringand after filling.

Page 7.4

Change2: 12 Dec 94

FICIBINSCIN

MATNTENANcE MANUAL

MOEIEL

]l.44

K
,,N
'ji:';tili

g.
,!!{,-S10
11

FORWARD

10

"-@

C M. R. GEARBOX UT AWAY FORCLARITY

INSTALLATION FIGURE 7-2A MAIN ROTORGEARBOX

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 Spacer Washer Mount

12 13

Spacer Shim (3 max per padl

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

Page7.44

r l ' , ' 1 1

FlClBINEiClN

MATNTENANcE MANUAL

MoE EL n'44

blank Intentionally

Pa g e7 . 4 8

14: JU L 2OOB Change

FIclElINSiclN
'-

MAINTENANcE MANUAL

Ml:'ElEL

]f,.44

(cont'd) 7.120 Main Rotor GearboxInstallation 1. 2. 3. 4. shimthickness shims. lf original original LevelMRGBmountingpadsby installing pads per Section7'130' is unknown, level mounting Verify two C796-3 spacersare the same thickness and install one C796-3 spaceron each aft mountingpad atop any shim(s). is Assistance Removeforeignobjectsand prepareareafor gearboxinstallation. positiongearbox.PositionMRGBon mountingpads. to desirable h6lp lnstall MRGB mounting hardware per Figure 7-2A. Orient A650 fitting tabs laterallyper Figure8-9, specialtorque per Section 1.330, and torque stripe per 2 F i gu re -1 . Connect forward flex plate, using previouslyrecordedshim washer positions. Standardtorque fastenersper Section 1.320. Installjackshaftsupportstruts and jackshaft(seeSection8.300). Connectmain rotor gearboxcoolinghosesand nozzle. 12.130 and 12.140. f n sta l lfu e l ta n ks p e r S e ctions 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.

'

b. O 6. 7. 8. 9.

1O. lnstallmain rotor per Section9.OOO. 1 1. Installmast fairing and connectpitot tube. per 1 2 . C h e ckcl u tch sh e a vea l i g nm ent Section7.23O. O flex plate shimmingper Section7.33O. 13. Check intermediate 1 4 . l n sta l la l l co w l i n g . Ma 7 . 1 3 0 L e ve l i n g i n R o to rGe a r box Level main rotor gearbox mounting pads laterallyto landinggear aft cross tube and 4l o n g i t u d i na l la t 3 .8 o + O.2 o a n gleto C046- 6tube ( r ef Figur e 2l.Use 4796- 1 s hi m s y 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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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 washer and AN32O-8castellated piniondnatt. InstallC141-10 main roior gearbo'x nut. yokg. flange and a 2. Support yoke for torquing by placin-g- _wood block between^ nut per Section1.330 and installcotter aNS2O-8 hoiiiontaffirewall. Spdciai-toriu'e pin. Remove block. CAUTION magnet gap per Section Check Hall Effect sender-to-yoke 7.141 beforerun-upor turningblades. 3. fnstallclutch assemblyandior forward flex plate per Section7 '22O' Gap 7.141 SettingHaltEffectSender inch, loosenjam nuts on senderand lf Hall Effect Sendergap is not O.O30 t O.O1O iOiuii gtp. Ch""k gads betweenboth yoke magnetsat both senders' 7-2B) Seal(seeFigure Pinion of 7.1b0 Replacement Main RotorGearbox flex plate at tail rotor drive shaft. Mark flex plate a. Disconnect Ag47-Z intermediate 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. per d. Cut safety wire and removerotor brakeassembly Section7.61O. e. RemoveHall Effect senderbracketand gearboxovertempsenderbracket. end coveroff pinionshaft. slidepinionbearing f. Carefully

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45

SENDER OVERTEMP
I

\ \

L-q-

il

l-il
BRAKE ROTOR ASSEMBLY HALL EFFECT SENDER ASSEMBLY

NUMBER 1 2 3 4 5 6 7 B 9 10

NO. PART c2t5-029 c266-l c966-3 c215-156 cl17 cz70-t c908-1 c14r-10 AN32O.B MSz5665-210

DESCRIPTION ''0"-RING SPACER SEAL ,' O' ' - RING SHIM END COVER YOKE ASSEMBLY l\lASHER NUT PIN COTTER

FIGURE 7.28 MAINROTOR GEARBOX PINION REPLACEMENT SEAL

Change 15 Jun 98 5:

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CAUTION end shimsunderpinionbearing coveras they Do not remove gearbacklash' preload and controlbearing g. presssealout of bearing end coverand pressin new seal until it seats. NOTE Openface of sealmust pointtoward gearbox' h. O endcoverover pinionshaft.PlaceHallEffectsenderbracketanO Installbearing per Uiaitlt on cbverand installrotor brakeassembly Section seiOei overremp 7.620. safety Torquescrewsper Section1.330 and safetywith 0.032 inch diameter wire. CheckHall Effectsendergap per Section7 '141' 7.110. MRGB Section a. Remove Per to at gearbacklash andtangential a geartooth, accessible b . Checkandrecord via sightgageor fillerPlughole. washerand shimstackeachfastener, noteand recordposition.of c . Carefully (an of attachpoints equalamount ;i iii CZeC-frirp-t*d ZA+-thousing at sumpandhous-ing eachattachpoint).Alsonote "; Jfiirr-ii i*t.lf"O Uetween identify grounl *ii"i ano iz+l-t baffldattachpoints.Remove, iocationof and shims' washers and retainf-asteners, sumpand o-ring. Remove prelubricate new c215-279 o-ring with A257-2 0it and installon sump. o-ringis not twisted in sumpgroove' Ensure Sump,baffleand groundwires,to -housing .anqsecure assemble Carefully in exactlythe same shimsinstalled an-6 *itn tist"neiC,wasners tinger:iigl-,i in poiitions recorded stePc. n 26!- t housi g to i rnt"rnl r-*rt'""fii,igi il;ft with boii threadsand deforming' int6itering shims

i. i.

Procedure Replacement SumpO-Ring 7.155 MRGB

d. e. f.

position g . Priorto torquingfasteners, 'againstthose shims usedon NAs1352 series from prevent
h.

1'33O per screws Section NAS1352 n boltsperSectio 1.32O.Torque Torque and safetywire PerMS3354O.

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(cont'dl Procedure Replacement SumpO-Ring 7.155 MRGB should in as ex-actly performed step bl. Backlash i) Checkgearbacklash ' in valuerecorded step bl' be wittiin 0.001 inch of 7.12O MRGBper Section il Install lnsoection Overtemp 7.160 Main RotorGearbox or lf the gearboxovertempwarninglight illuminates the orangetemperature be the temperatures, gear.b-ox.must removed dperating abnormal OecaiinO'i'cites facility for inspection overhaul inOieiurned to an approviORoUiisonHelicopter and overhaul. NOTE Light illuminates at 240r 50F. temperature of

Chio Lightlndicator 7.170 Main RotorGearbox to use lf the gearboxchip light illuminates, the following procedure drainthe and chip detector. gearboxand inspectthe lubricant the a) Removemain rotor gearboxchip detectorby disconnecting electrical wire, cutting safety-wire, and' unscrewingthe. chip detector from its hex.) (HoIO lbrgerhex while unscrewing smaller the the housing. drainfitting to drainth-egearboxoil. The bl Use MTO53main rotor gearbox is pushedup into-thechip detectorhousingas.far as ,it will g.o..A fitting underthe drainfitting to keepit in place.Drainthe is smali-wedge pla'ced 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 the detector.Examine paniclesfor size and performfollowingappropriate action: corrective
1 . For tuzz particles: Clean chip detector with compressedair. or

not toothbrush-(do use magnetland reinstall. Normalwear, especially fine tuzz. will new gearboxes, produce per inch: Clein chipdetector.Drainand flushgearbox Section1.120.

or 2 . For flakeparticles sliverslongerthan0.12 inch or wider than O.O2 gearbox and return 3 . For largeferrouschipsor chunkyparticles:Remove for overhaul.

4: Change 1 Jun 97

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(cont'd) ChipLightlndicator 7.170 Main RotorGearbox next 25 hours ggarboxtime-ind) lf, after performingcorrectiveaction, th_e failure may be more particles, a main -rotor g_e_.arbox s6rvice iroduces gearboi overhaulis re^quired.Where possible,include imminentand a gearbox RHC. to particles when refurning per e) Flushmainrotor gearbox Section1.12O. of 7.180 Lubrication Main RotorGearbox See Section1.120 tor Lubrication. ASSEMBLY 7.2OO CLUTCH Removal 7.21O ClutchAssembly Method Removal l. Fanwheel engineaft cowlingand tailconecowling. a) Remove fourscrews. platefromto the C723bulkhead removing by C723-G b) Remove flex cl DisconnectA947-Zintermediate platefrom C195 yoke. NOTE Recordshim locationsof forward and intermediate plateinstallations flex for reassembly. dl Supportforwardend of clutch shaft with suitablewooden block. C9O7yoke from C947-1 flex plate. e) Disconnect f) Mark forward-to-aft orderof drive belts for reinstallation.

g) Remove actuatorper Section7.51O. NOTE The aft end of clutch shaft must be supported. Use a wood blockto preventdamage. h) Remove the drive beltsfrom uppersheaveon clutch. i) Removeclutch per Figure7-3. lf returningclutch to RHC, removeboth yokes and lateralcentering strut to preventdamage.

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CROSSBAR

I
AFT ASSEMBLY ANDUNDER CLUTCH MOVE FRAME CROSSBAR.UPPER

--_)

--F
(\

:::B-/ UP F0RI^IARD AND ASSEMBLY CLUTCH 2 . MOVE CROSSBAR. FRAME UPPER OVER

-_)

- --tr
-:)_:-/ { \

w
Page7.",O

FROM ASSEMBLY CLUTCH REI1OVE AF T BY LOW ERIN G HELICOPTER OF SECTION UPPER REAR THROUGII TAIL BTLOI,J AND FRAME DOWN CONE.

REMOVAL 7-3 CLUTCI-I FIGURE

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FIGURE 7-3A
ALUMINUM PLATE

ASSEMBLY OF REMOVAL C184.2BEARING AND PRESS I'1T528-1 HYDRAULIC USING TOOLS. REMOVAL

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 c184-2 BEARING ASSEMBLV

MT528-1 BEARING REMOVAL TOOL

FIGURE 7-38 REMOVAL Cl84-2 BEARING OF HYDRAULIC hlHEN ASSEMBLY AVAILABLE; IS PRESS NOT MT528-2 AND USEMT528-1 TOOLS. REMOVAL

MT528-11 SPACER (Oneper . cap screw,

Change6: 18 MAR99

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RETAINER

srnr_+$
7.3C FIGURE

ASSEMBLY C184 BEARING

PLUG
\

OIL LEVEL
..)

BEARING OIL -/ TRANSFER BEARING 7FIGURE 3D

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7FIGURE 3E OF INSTALLATIONC184-2BEARING ANDMT528-1 PRESS USINGHYDRAULIC TOOLS. INSTALLATION

WARNING
ACROSS SHEAVE OR DONOTPRESS E,ENTIFES WILL BE DAMAGED.

FIGURE

MTsze-4 L
SCREt.|

BEARING ASSEMBLY INSTALL CL84-2 FACING A}IAY bIITHNUTS ONTO SHAFT CLUTCH. FROM

ASSEMELY MT529-6 TUBE

0 . 3 1 2 " I Ax 1 . 5 0 " D
DOWEL PIN (z Req'd)

c184-2
BEARING ASSEMBLY

FIGURE 7-3G INSTALLATIONC184-2BEARING OF PRESS UNAVAILIS tdHEN HYDRAULIC AND Ptt528-2 ABLE;USEI'tT528-1 TOOLS. INSTALLATION

c018-2 CLUTCH ASSEMBLY

4: Change 1 Jun 97

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nemova nssemOry Z.ZJlt Ctutcn

Method ll. TailconeRemoval 4.311. tailconeper Section a) Remove four screws. by bl RemoveC723-6platefrom C723 bulkhead removing actuatorso beltsare c) Adjustactuatordown limit stop screwand disengage as looseas possible. flex dl DisconnectA947-2intermediate platefrom Cl95 yoke. NOTE of Recordshim locations forward and flex intermediate plateinstallations for reassembly. el Supportforward end of clutch shaft with suitablewoodenblock. f) C9O7yoke from C947'1 flex plate' Disconnect

g) Mark forward-to-aft orderof drive beltsfor reinstallation. strut from upperframe. clutch lateratcentering h) Disconnect i) il from actuator. assembly Cl84 bearing Disconnect belts off uppersheave drive bett, maneuver with forward-most Beginning towards C907 yoke. directlyaft towardstailconeattach points. clutch assembly k) Remove O

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Removal Assembly 7.211 Cl84 Bearino per clutchassembly Section7,21O, a. Remove 7.270. C195yoke per Section b. Remove Cl91-5 stops. c. Remove as assembly follows: bearing d. Remove oress: Usinga hydraulic tool per Figure7-3A. removal 1. lnstallMT528-1bearing pressper Figure 7removal tool on hydraulic 2. SupportMT528-1bearing 3A. platebetween clutchshaftand pressram per Figure73. Installaluminum protect end of shaft. 3A to from the shaft. is 4. Pressuntil Cl8$2 bearing removed CAUTION Hold clutch assemblYto Prevent to clutchfrom falling the floor. press: Withouta hvdraulic removal tools per Figure7-38. 1. InstallMT528-1and MT528-2bearing MT529-4 at Useonly one MT528-11spacer eachcap screw. Ensure screwthreadsare coatedwith anti-seize. screw. handle and tightening by 2. Remove bearing assembly holding , ,

Change 18 MAR99 6:

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A 7 . 2 1 2 C1 8 4 B e a ri n g sse mb l vlnstallation a. Removeloose paint and clean mating area on clutch shaft. lf reusinga bearing assembly,inspectconditionof sealsand inner races' 5 b. Heat Cl84 bearingassemblyto 20OoF maximum(approximately minutes in with a pyrometeror a telatemp. temperature bearing ZOO;f'oven).Mon-itor p,oxyprimer. c. Coat bearingshoulderon clutch shaft with zinc-chromate.or on assembly clutch shaft: Whit" primei is still wet, installbearing NOTE with Be sure to put side of C184 bearingassembly nuts facing away from clutch (seeFigure7-3F)' Usi@Supportc|utchassemb|yatforwardendofc|utch ffibeiisemb|yonc|utchshaftperFigure7-3E.Center Pressbearingassemblyuntil . over inner race of beiring assembly. iub" assemblyshould clutch shaft (bearing of "5"mbly MTs29-6 tube asiembly bottoms on en-d be at dimensionshown in Figure7-3D). CAUTION suPPort clutch NOT Do assembly at sheave or internal will be damaged. bearings @UseMT529-6tubeassembly(inc|udedinMT528-1too| seiffietasshowninFigure7-3G.Centertubeassemb|yover innbt race of c184 bearingassembly' Tightennut onto MT529-4 screw (coat nut untii Mt5Z9-6 tube assemblybottoms on end of face and screw with anti-5eize) shown in Figure7-3D). (bearing assemblyshouldbe at dimension ciutch shaft e. Removebearingpresstooling. f. Check bearingfor smooth rotation. juncturewith primerto minimizecorrosion' g. Seal bearinginner race-to-shaft 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. was alter edby heati ng. if housing or iginal I n s ta l ln e w te l a te mpo n C 184 bear ing

6 Change : 18 MAR 99

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(reference 7-3C& 7-3D) Figures 7.213 ClutchAssemblv SealReplacement

NOTE olderclutch To facilitatefuture spragclutch lubricantservicing, early retainerswith may be upgradedby replacing assemblies t w o C l 6 8 -5 a n d tw o 8 289- 3 scr ews. p cl 1 . R e m o ve u tch a sse mb l y 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. replacing forward 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 and underlyingO-ring. and removeretainer cap screws from retainer socket-head D i s c a rd O-ri n g . CAUTION with internal,tapered roller bearingsutilize Clutch assemblies do bearingpreloadshimsunderretainers; NOT loseshimswhen removinqretainer{s). NOTE 4 A p p ro xi ma te l y fl u i d ounces ( 118 ml) of lubr icantwill dr ain in following step. Retaindrainedfluid in a suitable, from clutch clean container. and rotate clutch shaft so yoke attach holes 5. Positionclutch assemblyhorizontal to drain into container. are vertical. Allow lubricant 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 debrisis noted,removeclutch assembly inO magnetfor metallicdebris. lf metallic

from service. bore. retainer towardsinside.Clean from outside sealout of retainer 7 . Press lip. retainer until it seatsagainst new sealflat face down into retainer 8 . Press

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(cont'd) 7.213 Clutch AssemblySeal Replacement 9. lf replacing aft seal proceed to next step. lf replacing forward seaL lightly in lubribaten-ewO-ringand seal inner lip with A257-4lubricant. Install.O-ring 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 cap sqqw.s from aft retainer previouslyaccomplished, removetwo socket-head 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 to interior. Due to shaft internalplug locationit is necessary fill shaft from aft side. aft 1 1 . ff repfacing seal, lightly lubricatenew O-ringand seal inner lip with A257-4 Ensureany shims are properlypositionedatop bearingouter race. lubricant. Install O-ring in clutch housinggrbove and slide retainerover clutch shaft aft end. screwsare on opposite 1 2 . lf two C168-5 retainers installed, ensureself-sealing are so sidesof clutch shaft. Positionaft retainer two smallerholesare alignedwith cap screws, and tapped holesin sprag clutch housing,installboth socket-head hand tighten screws sufficientto clamp retainerto O-ring.

1 3 . Installtwelve bolts with washersthru retainerswith bolt headstowards short

pattern, standardtorque bolts per side of clutch shaft. Using a criss-cross 2S e cti o n1 .3 2 Oa n d to rq u estr ipeper Figur e 1.

14. Fully tighten by hand all socket-head cap screws and torque stripe per Figure 2-1. per 1 5 . f f r e mo ve d ,i n sta l lC 1 8 4 bear ing assem bly 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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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 support clutch yoke. Reinstall belts in their properorder on sheave.TemporarilY aft end. shaft

CAUTION fore-aftorderand in both in proper Drivebeltsmust be installed

directionof rotation. torquehardware 7-4. Standard to 3. ConnectC9O7^Voke forwardflex plateper Figure I p e r Se cti o n1 .3 2 0 . 4. fnstall actuator assembly per section 7.52O. Remove clutch shaft temporary support. 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' flex plate per Section7'330' 7. Installintermediate 8. fnstall C723-6 plate on C723 bulkhead' 9. Installuppertailconecowling and engineaft cowling'

B . With tailconeremoved:
1. Ensure actuator is fully disengagedand positionedfar right- Lift drive belts points' and insert clutch assembly forward thru upper frame tailbone attach of clutch'dfrat with suitable non-scratching Temporarilysupport forward end 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 . ensuring drivebeltsonto uppersheave, 3. Startingwith aft-mostdrivebelt,maneuver 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 temPorarysupport. t 6 . C h e cksh e a vea l i g n me n p er Section7 ' 23O' 7. Install C723-6 plate on C723 bulkhead. and flex g . I n s t a l l ta i l co np e rS e cti o n 4.312. lnter m ediate plateinstallation shi m m i ng e c h e ck p e r S e ci i o n7 .3 3 0 i s r equir ed.
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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 27 28

PARTNUMBER 8330-19 MS21042L6 AN960-6161 c908-1 NAS660+4 or -5 (as required threadengagement) for c947-1 NAS6606-5or -6 (as required threadengagement) for NAS6606-31 cl91-1 C907-1or -2

DESCRIPTION Palnut Nut Washer Yoke Bolt Flex Plate Bolt Bolt Block Yoke Clutch Assembly Block Tail Rotor DriveShaft Palnut Washer Assembly Bearing Palnut Nut Washer Yoke Flex Plate Bolt Washer Block Nut Washer{seeSection7.230) Washer(seeSection7.3301 Washer(seeSection7.330)

co18-2 c553-1
D224-1 8330-1 6 AN960-416 c184-2 3 8330-1 MS21042L4 AN960-4161 C195-1 ,-2,-3or -4 A947-2 NAS6605-24 AN960-5161 c191-6 MS21042L5 Noneor AN96O-6161 maximum minimumor AN960-4161 maximum AN960-416 or Noneor AN960-416L maximum AN960-416

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I
I

F ORWARD

3.90/4.10 INCHES END ROD CENTER.TOCENTER

t\ -l \

7AND FIGURE 4 FORWARD INTERMEDIATE FLEX INSTALLATION PLATE

\ CLUTCH LATERAL CENTERING STRUT

Change 1 Jun 97 4:

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MOEIEL F,44

BAR ALIGNM ENT SHEAVE F IGU R7 .5 M T331.4 E ASSEMBLY C018.3CLUTCH OPTIONAL SHEAVE UPPER M W ITH 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

ASSEMBLY CO1B-2CLUTCH STANDARD UPPER SHEAVE ANODIZED t,'|ITH

i 0 . 1 3 0n c h i 0.070nch and 0.010-0.030 inchlarger t h a nr i g h t s i d eg a p

HORIZONTAL INE CENTERL OF SHEAVE UPPER

MEASURE AT HORIZONTAL OF CENTERLINE SHEAVE UPPER

UPPER METALIZED HAS SHEAVE ROUGH TO FACES SIMILAR LOI.IER SHEAVE

RIGHT VIEWFROM SIDE

Fh,D LOOKING VIEt^J BAR ALIGNMENT POSITION SHEAVE (Determi upper sheavetYPe.and ne ate use aPPr oPr i dim ensions) DIMENSIONS ALIGNM ENT F IGU R7.6 SHEAVE E Change1O: JUL2OO4

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MAINTENANcE wtAtuUAL

MCfEIEL n44

7.230 Clutch SheaveAlignment Checkingsheavealignment: cl 1 . E n g a g e u tch . aft 2. Hold MT391-4 SheaveAlignmentBar again,st face of lower sheaveextending sheave' center lind of upper bar upward to horizontal 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. maximumlimitthen uppersheaveis too far forward and must lf eithergap exceeds be move? aft by shimmingforward flex plate and/or adjustingC9O7 yoke lenqt_h. by Shimming is accomplished installinga maximum of one NAS1149FO632P washer bltween C947-1 flex plate and both arms of C9O7 and/or C9O8 yoke; right and left gap on NASl 149F0632Pwashersinstalled eitheryoke will decrease yoke has two sets of mounting an amount equalto washerthickness.EachC9O7 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 by y o k e. R i g h ta n d l e ft g a p s w i ll both decr ease 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 by t h e C9 O7 -2yo ke . R i g h ta n d left gaps will both incr ease 0.120 inch with eac h yoke length. i 0 . 1 2 0 i n ch d e cre a sen C 9 07 flex plate shimmingper Section7.330 if shims were added 4. Check intermediate 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 2 . C h e cksh e a vea l i g n me n o n left and r ight side per Figur e7- 6.

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

Page7.23

HEIBINE|GIN

MAINTENANcE

MANUAL

MOE EL F,44

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 right.gap. the righf gap; shortenstrut tb increaseleft gap anddecrea.se increase Check both rod end Strut limits ard4.iOig.gO inchesrod end center-to-center. witness holes after any strut adjustment' contact Robinson measurements, 5. lf alignmentcannot be adjustedwithin required CompanyTechnicalSupportDepartment. Helicbpter 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 : positionclutch assemblyin press method).lf press is available, 1. (Preferred 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 required. difficulty is enc.ountered, oil to yoke-shaftjuncture-as .lf preceding step' in as handleand arranle to use a pre-ss described 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

14: JUL 2008 Change

FICIE|INEiCIN

MATNTENANeE MANUAL

MoE!ELH'44

C9O7 YOKE LENGTH

FIGURE 7-7 REMOVAL YOKE C9O7 EDGE RADIUSED

CLUTCH SHAFT

FIGURE 7-74 C9O7 YOKE REMOVAL

MT3O3-6HANDLE

Change 18 MAR99 6:

Page7.25

FICIBINSCIN

MAIN?ENANeE

MANUAL

MOEIELF'44

(cont'dl and lnstallation 7.260 C9O7Yoke Removal b. yokeand matingportionof clutchshaft with zinc-chromate Coatinsideof C9O7 on or epoxyprimer. Wtiiteprimeris still wet, installygk-e clutch shaftand align shaft holes. (ii applicablel with clutch nbns on yoke mariced an_d_b_olts. yoketo Secure'lnstall shaftwith clamping^blocks .Torqueboltsper Section and torquestripe. per Section1.33O, palnuts, torque 1.32O.

c.

and 7.27O Cl95 YokeRemoval lnstallation To removeyoke: NOTE without clutch removal' Yoke may be removed a. b. c. flexplate. intermediate Remove C195 yoketo clutchshaft' blockssecuring boltsand ctamping Remove Twist yoke out of clutch shaft. toosepaintand cleanmatingareainsideshaft. Remove or of Coatinside clutchshaftandshankof C195yokewith Zinc-chromate epoxy yoke into clutchshaftand alignholes. primer.- ite primeris stillwet, slide Wt Installclampingblocksand bolts. Torquebolts.per Section1.32O. Install palnuts, toriudper Section1.330,and torquestripe' flexplateper Section7.33O. Installintermediate CAUTION washer or Theremustbe oneAN960-416L oneAN960-416 of c195 yokeand4947-2flex plate.see eacharm uetween 7.330. Section

To installyoke: a. b. c. d.

Page7.26

Change6: 18 MAR 99

FIC|BINEiC|N

MATNTENANeE MANUAL

MIJEIELF44

7.28O V-Belts 7.281 V-Belt Removal al Removetailconecgwling. , position. b) Lower clutch actuatorto its fully disengaged 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 Mark the directionof rotation on each belt so that they to be reinstalled. be reversed. cannot flex plate from clutch. Disconnect dl Mark and disconnectthe intermediate the centeringstrut from clutch to upperframe at frame end. e) Removefan and scroll per Section6.20O. fl per Remove actuatorassembly section 7.510.

gl Removebelts from sheave. CAUTION Usedbelts must be reinstalled properorderdue to in individualdifferencesin belt stretch. 7.282 V-Belt Installation WARNING Install V-belts only in matchedsets. Do Not install used V-beltsfrom anotherhelicopter. a) Beforeinstallation new belts, inspectthe sheavegrooves.Replace of any sheaveshowing corrosion,pitting or flaking of the metalized anodized or coatings,wear throughthe anodized coating,roughness, sharpridges. or CAUTION Roughor corrodedgrooves in the upper or lower sheavecan causeV-beltsto roll, break,or come off. Referalso to Section2.160.

Change 12 Dec 94 2:

Page7.27

FIOBINSON

MATNTENANeE MANUAL

MI]EIEL

F,44

i"'

______Jt%%o*
HORIZONTAL

i
I

---l
\ t

tI cosl AcTUATOR

1,,r,""'' t"'-- \ttt:---M P ---I -----, -"Y'!t,

,,FIRtWRtt r.,

?='=rt 7
I I
/'

OF DIRECTION ROTATION

BELT 0RIENTATI0N

MARKs

\L_, t^-,_
\
I
I

___r
-,---

i,
D ARE SHOt^lN MARKE BELTS REINSTALLATION FOR

L__

7-8 FIGURE

REMOVAL V-BELTANDACTUATOR

Page 7.28

2: Change 12 Dec 94

FIC|EIINEiCIN

MAINTENANcE

MANUAL

MOEIELF'44

(cont'd) 7.282 V-Belt Installation in b) paint the.grooves the lower sheavewith a thin coatingof zinc chromateor epoxy primer Per Section 1.400. inspectthem for damage c) Installbeltson sheaves.lf used beltsare reinstalled, arein their proper order with respectto Make sure they p"r-S""tio1,2.15C,; iorelatt position and proper directionof rotation. d) Installthe actuatorassemblyper Section7.52O. flex plate to the clutch' e) Connectthe intermediate f) Installfan and scroll per Section6.2O0.

g) Check clutch sheavealignmentper SectionT-23O. flex plate per Section 7.330. h) Shim and connect intermediate 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 First adjustments of the actuator down limit screw, to with slack,occur relativ.ely.soon regulatenew belt disengage longer periodsbetween later adjustments.Recheck. and the rotor startingto turn of more A delaybetweenclutch switch engagement enginewith slic[. lf rotor rotateswhen cran-king excessive than 5 secondsindicates starter motor, belts may not have enough slack. CAUTION belts too tight can damage During start up and engagement, flex plates anil belts too loose can iump out of grooves. j) Ground run or hover the helicopterfor at least 20 minuteis. I I

k) At the end of the ground run, inspect the sheavegrooves for the contact groovesindicates pattern in the primer.A similarcontact pattern in all eig.ht is compatible. A noticeablydifferent contact combination the belt/sheav-e pattern from groove to groove indicatesthe combination is not compatible. l) re-checksheavealignment, is lf the belt/sheave combination not compatible, combination procedure. lf belt/sheave replacebelts, and repeat installation necessary replacethe lower sheave.The to is'stillnot compatibld,it may be 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

FICIBINSCIN

MATNTENANcEMANUAL

M(fElELF'44

7.283 Belt Tension is for No procedure checkingbelt tensionon the helicopter rqQuirecl. StarterRingGearSuPport. Assembly. and Bearing Fanshaft 7.290 COOT Lower Sheaveand AlternatorBelt Replacement. 7.291 Removal al b) c) V-beltsper Section7.281. Remove Cut the safety wire and removethe six NAS6608 bolts holdingthe fanshaft. Temporarily Remove the COOTfanshaft and bearing assem.bly.. securethe lower sheavewith one of the removedbolts if it is not to be removed. To remove the lower sheave,the use of a soft mallet may be while pullingit off. to required tap the sheave Removalof the starter ring gear support is. requiredto change alternatorbelt or gain accesstb the nosesectionof the engine. belt tension. the alternator 1) Loosen mark on the starter ring gear supp-ortat one 2) Note the zero to Markthis bushing easereinstallation. propeller flangebushing. gearsupport. the 3) Remove starterring 7.292 Installation a) the lnstall a new alternatorbelt at this time if required. Reinstall zero mark on the ring gear startet ring gear support.Align the The bushingand matchinghole bush'ing. ;rpport witn-tne markeO ard btlgntlylargerthan the five other holes.This makesthe incorrect instaltition of- the starter ring gear support difficult but not impossible. Checkthat two lnstallthe lower sheaveand fanshaftassembly. bolt. geO-416washersare installed undereach NAS66O8-42H Afrf bolts. Check for clearancebetween the lower Lightly inug the and starter ring gear support's conical surface. Insert a sh-eav'e bolts. 6 feelergauge-af placbi betweenthe attachment O.OOS-inch support is the wrong starter ring.gear. Lack of clearance-indicates Torque installecl. or installed that the ring gearsupportis improper.ly 'star pattdrntqtlgy."q by a.circular in in6-ootG pei seiiion tl3--30 i dalety wire the bolts in pairs with 0.041 inch diameter i."itetn. steel safety wire. stainless

d) el

b)

Page7.30

Change4: 1 J un 97

FICIBINSC|N

MATNTENANeE MANUAL

MOEIEL F,44

CAUTION

Rilinstallingthe bolts with less than two AN960-816 washers liay cause the bolt shank to bottom on the This conditionwould not flangebushing. enginepropeiler to securely cla-mp lower sheaveand fanshaftassembly the 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. V-belts per Section7.282. Reinstall

dl

O ,.r* ,o,' ^oro*o*u,,"ort

7.31O Tail RotorDriveShaft Removal the al Remove 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 cl using the upper aft tailcone inspectionhole, disco_nnect c947-3 aft flex plate from t-ailrotor gearboxinput shaft flange. Supportthe 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 from tail rotor gearbox lf aft flex plate was disconnected plateto the driveshaft and first connectflex and removed, then insert the drive shaft into tailcone. Torque the NAS6604bolts per Section1.32O. b) Support drive shaft through upper aft tailcone inspectionhole to prevent purposes. damageand for alignment hole,connectthe C947-3 qft-fl_e1 cl Usingthe upperaft tailconeinspection Plale one to gearboxwitn the bolt headsagainstthe flex plate. U_s_e AN960-416L washerunderthe bolt head. Torqueto per Section1.320.

2: Change 12 Dec 94

Page7.31

FICIBINSiCIN

MATNTENANcE MANUAL

MoEIEL F|44

F O RWA R D

INSTALLATION PLATE 7-9 AFT FLEX FIGURE NO. NUMBER PART . 1 ? 3 4 5 6 7 I 8 3 3 0 ,13 NAS679A4 AN960-4161 -3 c947 NAS6604-7 c021-1 NAS6604-4 D224-t DESCRIPTION PALNUT NUT ldASHER (AFT) PLATE FLEX BOLT GEARBOX TAIL ROTOR BOLT ASSEMBLY SHAFT DRIVE TAIL ROTOR

P a g e7 . 3 2

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 , dl lmproperinstallation flex platecan damage of tail rotor drive shdftand gearbox. Through inspection ho.les sideof tailcone, on longitudinal determine alignment of damper arm with tailcone attachmentbracket. lf clearanceor int-erference between arm and bracket is greaterr than 0.12 inches, contact Robinson Helicopter Technical Support Department. clearance interference lessthan lf or is damper assembly tailcone to crossmember. Torque boltsper 9.12 inch,^connect Section1.32O. per Install tailcone Section 4.312. Installand shim intermediate plateper Section7.330. flex Perform rotor driveshaft run-outcheckper Section7.340. tail

el f) gl

7.321 Adjustment Damper of Friction per a) Remove rotordriveshaftfromtailcone Section tail 7.31O. per b) Disassemble damper Figure 7-1O.

c)
dl

(dark grav washers worn for Teflon@ coatins faceland |3;?."rT Sr.lJ;f,[U.
Inspect A141-37 washers and C041-3 arm for indicationsof wear or grooving. Replace required. as

I
I I

e) Reassemble damperper Figure7-1O. Torque pivot bolts per Section1.32O. CAUTION (dark gray) face of CO41-5 DU washer must be Teflon@ 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.

Change : 15 Jun98 5

P a g e7 . 3 3

F|CIBINSiCIN

MAINTENANeEMANUAL

MOETEL]i'44

Ftro
14

lt

il

,dD
o

\W

1'
14

ASSEMBLY DAI'/IPER 7 F I G U R E- 1 0 C O 4 1
NUMBER NUMBER PART 9 l0 05DU04 c041-6 A141-36 NAS679A4 1 B330-3 A041-10 MSl6562-11
PT DESCRI ION B u s hn g i 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

NUMBER NUMBER PART I 2

J

DESCRIPTION Ann Bolt l,lasher t^Jasher

4 6 8

c041-8 6 NAS6604AN96OPD416L A141-37 c041-3 5 c041c 0 4 111 1 A 1 0 5 -2

1tr

12 13 Link 14 Washer Bearing Assemb'lY 1 5

r Jou nal

P a g e7 . 3 4

Change4: 1 J un 97

FIGIBINSCIN

MATNTENANcE MANUAL

MC)E EL FI44

%
ls I
? . r 4t o 3 . 5 0 l b s . t o m o v e l i n k (measured point I'B' at
bs. to move at point "A" point"B").
rota t i n g a b o u t p o i n t " C " ) .

fr
FIGURE 7.114 CO41 DAMPER ASSEMBLY ADJUSTMENT
VIEt,l LOOKING AFT

CO
DAMPER MOUNT ANGLE c041-8 ARM c041-11 BEARING ASSEMBLY

>-

C041-3 LINK

FIGURE 7.118 CO41 DAMPER ORIENTATION

Change : 15 Jun98 5

Page7.35

FICIBINSCIN

MAINTENANeE MANUAL

MC'EIEL H,44

(cont'd) Friction of 7.g21 Adjustment Damper

I I

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 - rtakeh a s p r i n4.25alb e P J q e q d t a c 2.50 to g s c l - to weightto 6ne bolt holein co+t-8 arm. lt should springscaleor dead o!v9t frictionwith CnJc[-uearinfriousing move take2.14 to 3.50 lb to movelink' ii *"ignt"tr. iinf.non. tt sho"uld and c!qc! c^ot1-9.spring-washer bendwasher lf dragis lessthanspgqified, is oi'o-.oos- o,0Zg inbh.If spring.washer correct until it rirJ'Jtblii filight greater 2 end neignt,U"t Oragit Ctilitootow,lap. of .A105-1 iournal'lf dragis springwasherslightly' specified;flatten tha-n CAUTION DoNoTADJUSTDAMPERDRAGBYCHANG|NGBoLT TOROUE.

s)
h)

per frictions damper andrecheck per MS21O42L4nut section1.32O Torque andtorquestripe' B33O-13 balnuts Stepfi. Install 7 fnstalltail rotordriveshaftper Section '32O'

Measurementstaken with intermediateflex plate removed' a) bl c) Engageclutch actuator. Rotate drive flangesof tail rotor shaft and c195 yoke horizontal. 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 2. will be Measurement NOTE Measurement1 and 2 should be similar. lf measurements ire not similar,one or both yokes are bent'
f)

d) e)

between3 o'clock and 9 o'clock gap in Measurement1' difference Determine between3 ;';a;;t ind 9 o'clock gab in Measurement2' difference Determine

P a g e7 . 3 6

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

FICIBINSICIN

MATNTENANeE MANuAL

MOE EL F,44

7.330 Intermediate Flex PlateInstallation Shimmino(cont'dl and gl Use following formula to obtain the calculateddimensionsfor proper shimmingrequired the intermediate plate. flex at NOTE Use the measurementwith the smaller difference between3 and 9 o'clock readings. 9 o'clockreading+ 3 o'clockreading Divideabovesum by 2 Subtract r Dimension Calculated = rAverage thickness of the A947-2 flex plate measuredat the bonded washers. per Shimas required Table7-1. h) Reinstallthe flex plate using the shims determined above. Torque the attach bolts per Section1.320. Installpalnutand torque stripe. Referto Figure7-4. 7.340 Checking Tail RotorDriveShaft Runout The runout check described below is to preventexcessive runout on the tail rotor drive shaft which can causea failurein the intermediate flex couplingor damperassembly. a) Remove the tailconeinspection all coverson the taitcone right side.Engage the clutch. b) Assemblethe Robinson Tool NumberMT26O-6tool and a suitabledial indicator. NOTE The dial indicator included in the Robinson MT122 bolt stretch gaugeis recommended for this tool.

Change 1 Jun 97 4:

Page 7.37

F|GIBINEICIN

MAINTENANGE MANUAL

MOE'ELre44

on the right cl Insert the dial indicator through..tlrqipogction hole fa.rthgstaft presj'ir,-iiiirindic'ator firmly againstthe tailcone when side of the tailcone. the extensionis riding on the drive shaft' at least three dl Have someonerotate the drive shaft at the c166 clutch shaft with each revolution so it full revolutions.The indicator may vary somewnat to will be necessary take an average' in el Repeatprocedure steps C & D at the next inspectionhole forward' extensions' the f) Remove extensionfrom the MT26Otool and, using.the.longer two inspectionholes. lnatt at each of tne other check tnC Orive g)The maximumamount of runout a! any-of the locationsmust not exceed irre drive shaft must be repairedor 0.025 inch. tf the ,rnori il;;;ssive, replaced. 7.35O Two-PieceTail Rotor Drive Shaft one Cl95al The two-piecetail rotor drive shaft consistsof one-C196-1 shaft' blocks -2 and t*o c191 clamping 5 yoke,6h-J-co+r-fo"-firG{erbti, ' See Figure7-12Aasiociaiedhardware. referto Figures assemblyis field replaceable; -' b) The co41-1 damper bearing criteria. dimensional 7-12n and t-{i{tor approfriate cl The D22+1 drive shaft is producedin one length only.

L
SHAFT DRIVE TAIL ROTOR MT26O INDICATOR RUNOUT

CHECK RUNOUT DRIVESHAFT 7-12 TAIL ROTOR FIGURE

Page7.38

2: Change 12 Dec 94

FICJBINSCIN

MATNTENANcEMANUAL

MoE EL n44

TABLE7.1 A947.2 INTERMEDIATE FLEXPLATESHIMTABLE Calculated dimension in inchesfrom Section7.330(gl Total shims required between the flex plate and the clutch shaft's Cl95 yoke (required 2 placesl. is The measurement over the limit and a longer C195 yoke is required. 1 each AN960-416 washersubstitutedfor AN960-4161 1 eachAN96O-416L washer 1 eachAN96O-416L washer 1 eachAN96O-4161 washer ShorterCl95 yoke is required 1 each AN96O-416 washer Total shims required between the flex plate and the TR drive shaft's D224 yoke {required 2 places).

(0.137 or more calculatedl

(0.136) (0.107t (0.1061 to.o77l

1 eachAN960-416 washer 1 eachAN96O-4161 washer No washers for shimming

(o.o76) (o.o47l
(o.046l (0.0171
( O . O 1 6 lr o less calculated number

'

CAUTION: Theremust be an AN960-416L AN96O-416 washerbetween or eacharm of Cl95 yoke and A947-2 flex plate.

Change 3: 5 May 95

Page7.39

FICIBINSCIN

MAINTENANeE MANUAL
c196-t
TAIL ROTOR DRIVESHAFT

MOEIELH44

SIDE FLANGED OFBEARING UNWELDED FACES HOUSING SHAFT. OF END DRIVE c0 41- 1 DAMPER ASSEMBLY

B0LT NAS6604-28 (2 WASHERReq'd) AN960-4161 NUT NAS679A4 PALNUT 8330.13 ( 2 p l ' c s .)

@i
\

t 5 1 . 1 3 0 . 0 3I N C H E S

c191-2 CLAMPING BLOCK (2 Req'd)

o
c195-5YoKE

USING SHAFT ONTO INSTALLBEARING PRIMER. OREPOXY ZINC-CHROMATE AND OF SEALJUNCTURE DRIVESHAFT b|ITH THE SAME INNERRACE BEARING PRIMER.

SHAFT DRIVE 7-1?A TAIL ROTOR FIGURE

c041- 1 DAMPER ASSEMBLY D224-7 TAIL ROTOR SHAFT DRIVE

DIAL iNDICATOR (T0 VERIFY FoRE AFT 0R N0 SHAFT OF MOVEMENTDRIVE DAMPER MEASURiNG bIHEN RUN-OUT) BEARING V.BLOCK O.OO5INCHTIR WHEN MAXIMUM HITH SHAFT DRIVE ROTATING STATIONARY. HOUSING BEARING

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 the tail rotor if push-pulltube lengths are not altered. eliminatere-rigging b) Removethe tail rotor hub and blades. Leavethe pitch control links attachedto the tail rotor blades. c) Disconnectthe A120 bellcrankfrom the push-pulltube. and pitch controlfrom tail rotor gearbox. Disconnect d) RemoveA12O'3 bellcrank A12O-3bellcrankattach bolt from the gearboxoutput cartridgeand slide pitch control, with the bellcrank attached,off the gearboxoutput shaft. Reassemble bellcrankhardwareto bellcrank.

el Workingthroughupperaft inspection holeof tailcone,disconnect aft flex the

coupling from gearboxinput shaft flange. CAUTION Drive shaft must be supportedthrough 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 support 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

flex plate shimmingper section 7.330' e) check intermediate per Section 8'560 if fl Installthe tail rotor pitch control and bellcrank.Re-shim " 6iidinai ii.-Ji- rbiioioinoingi occurs when assemblvis moved' tube to aft bellcrank. cl gl Reconnect 21-17 push-pull hl Installtail rotor hub and blades' i) Connectpitch links to the pitch control arms' 1'300' all i) Ensure bolts are torquedper Section Chio lndicator 7.43O Tail RotorGearbox the lubricantand to use the following procedure 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' found in the oil or on the chip detector' c) Strainthe oil and inspectany particles inch long or O'02 in-ch iarger !O'9.9. the Examine particlesfor ;#;6ilirtpt;q ferrous or nonwidel tfiin-fne tizz tnoimii wtiart should bb identified as and the next found are nurirerou:. Particles. ferrous by using a tagili.'lf more particies,a tail rotor gearboxfailuremay runningof tne gdarboxp-roduces is aGiI toioi gearbox'overhaul required' be impei;id;il gearbox' d) See Section1.130 for flushingand refillingof the tail a) Remove 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

2: Change 12 Dec 94

FIC|BINSCIN

MATNTENANcE MANUAL

MC'E EL F|44

\--'

SEALREPLACEMENT SHAFT FIGURE -13 TAIL ROTOR OUTPUT 7 GEARBOX NUMBER NUMBER PART PTION DESCRI i Housng Seal 0- Ring cap l^lasher Bolt 0.032in. dia Safety t.Iir e

c109-1 c966-2 c215-133 ctLz-2 ANg60-4161 MS20074-04-06

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 stackpreloaddrag. up wili changefa-ctory-set dl Carefullycleanseal seatingsurfaceand O-ringgrooveand dry. el press a new C966-2 seal into the cap bore 0.1.60 inches below the external a surfacewith sJallip io-*ai'Aini geaiUox.Lubricate new C215-133 O-ring in groovein cap' with A257-2 gearoil and install fl Lubricatethe seal seatingareaof the output shaft with A257-2 gear oil' TorqueJhe on gl Slidethe cap-overqheoytptlt shaft and reinstall. !19 gea.rbox' in pairswith 0.032 inch diametersafetv four bottsto 66-in.-ittHd;afeti wire wire. and tail rotor per Section8'562' pitch controlbearing hl Reassemble

to It is not necessary removepitch control assemblyand tail rotor for this Procedure. gearboxfrom tailconeper Section7'41O' al Remove O MS24665-210cotter pin from the nut at the centerof Cl16-1 input bl Remove 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' nut and removethe yoke' dl Removethe AN32O-8castellated bolts' el Cut the safety wire on and removefour MS20074-O+OO the c141-2 washer that is located f) Removecl 1 2-1 cap. Be sure not to los-e the betweencap and biaring. Remove O-ring' gl Pressout otd sealand cleanthe sealseatingsurfaceand O-ringgroove'

Pa g e7 . 4

2 Change : 12Dec94

FIG|BINSCIN

MATNTENANeE MANUAL

MOEIEL

]''44

'tFr'

t. zltt

s
PART NUMBER DESCRIPTION Input Car tr idge cap & input cartridge) t'lasher(between Seal 0-Ring

SEALREPLACEMENT INPUTSHAFT GEARBOX 7-13A TAIL ROTOR FIGURE NUMBER 1 2 3 4 5 6 7 I 9 10 11 L? Change2: 12 Dec 94

c110-1 cl4t-2
A966-3 c215-140 c112-1 MSz4665-210 AN320-8 4141-10 cl 16-1 AN960-4161 MS20074-04-06

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 Input Shaft SealReolacement Gparbox 7.45O Tail .Rotor h) Pressa new A966-3 seal into cap 0.250-inchfrom externalsurfacewith a seal lip toward gearbox. Lubricaie 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 MS2OO74-O4-O6 with AN960-416Lwashersunderhead.Torqueto 6O in.-lband safety wire in pairswith 0.032-inchdiametersafety wire. and AN320-8nut onto gearshaft. washer, Instal C116-1yoke, A141-1O

il

k) Holdthe gearboxand supportyoke flangewith a 2-inchwoodenblock. l) Torquethe nut to 290-410 in.-lb and securewith a new MS24665-21O cotter Pin. m) Installgearboxper Section7 '42O. ASSEMBLY 7.500 ACTUATOR 7.510 ActuatorRemoval aft a) Remove cowlingassemblY. position. clutch to its fullest disengaged b) Disengage coolingfan and scroll per Section6.2O0. c) Remove d) put a six-inchwooden block under the clutch shaft iust forward of the uppei lneaue on the horizontalfirewall. Tliq keeps the sheave from damageto the forward flex plate (seeFigure7-8). lnO-preuents Oiooping to two wiring connections actuator. e) Disconnect f) the Disconnect clutch lateralcenteringstrut from the upperframe.

g) Removethe upper NAS66O5and lower NAS66O4 bolts and remove actuator. 7.520 Actuatorlnstallation per a) Inspectupperand lower clutch actuatorbearings Section2.140.8. actuatorfor installation. b) Position c) Install lower attach bolt with head faclqg aft: Use one AN96O-416L washerundernut. Torqueper *asher underbolt headandone AN96O-416 palnutand torquestripe' Section1,32O,install

P a g e7 . 4 6

4: Change 1 Jun 97

IfClBINSiClN

MATNTENANcE MANUAL

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 Figure -1. 2 e) lf installed,removeblock(s)supportingclutch assembly. f) Connectclutch lateralcenteringstrut, standardtorque bolt per Section1.g2O: installpalnut,and torque stripe per Figure2-1. g) Installfanwheeland scroll per Section 6.220. leadsand ty-rap as required. h) Connectgearmotorand switch harnesselectrical 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 Gearmotor Replacement Actuator gearmotorcan be replacedwith actuatoron helicopter. g leads. 1 . D i s co n n e ct e a rmo to r l e ctr ical e 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.Verify 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 verify actuatorshuts off after column springsyield (indicated "popping"sound). by CAUTION pins are reversed connector,gearmotor lf gearmotor electrical in w i l l o p e ra te a ckw a rd nddown- lim it b a switchandspr ing switches 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

HEIBINSI'CIN

MAINTENAIUcE MANUAL

MtfE'EL

844

AAJl ,l ,6 !
4 5
6

6 \t al>

F OR W A R D
i:

I l.
--E1L--'

'.,-\

7-14 ACTUATORASSEMBLYINSTALLATION FIGURE NUMBER 1 2 3 4 5 6 7 I I

P A R TN U MBER

6 8330-1 MS21042L5 c141-1 ANg60-5161 cA214-8 c105-2 NAS6605-38 cl84-2 c051-1

DESCRIPTION PALNUT NUT W ASHER W ASHER W THRUST ASHER JOURNAL BOLT ASSEMBLY BEARING UPPER ASSEMBLY ACTUATOR

P a g e7 . 4 8

4 Change : 1 Jun 97

FIOE|IN$iCIN

MATNTENANcE MANUAL

Mt'E EL 3,g,4

7.540 Actuator Adiustment 1 . En g a g e d i mi t L The actuatorengagedlimit is determined column springswhich control drive by I belt tension. Columnspringsmay only be adjustedby the factory. (Down-Limit) 2. Disengaged 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 b c l e a r a n ce e tw e e n scre w h eads at scissor sis 0.O15 inch per Figur e7- 15. 3. Maximum Extension Maximumengaged extensionis 1.60 inches,measured shown in Figure7-15. as The extension-limit switch activatesat 1.50/1.6Oinchesextension. DriveV-belts must be replaced when 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 ve ctu a to rp e r S e c tion7.510. a NOTE Switches may be replacedas a complete switches & harness a sse mb l y, r re p l a ce d ndividually installing heat shr inkand o i by wire connections. soldering 2. Remove desired switch by removingattachingscrew,nut, washer,and spacing washersbetweenswitch and plate.

NOTE
Spacing washers ma y be bondedto new switch(es)to ease reassembly. a or, completeswitches and wire harnessassembly if installing single 3. Replace possible. switch, cut wires from faulty switch as closeto switchesas 4. Slide new heat shrink over each cut wire. Solderwires to switch and install heat shrinkover solderconnection. 5. Reassemble switch(es)to plate. Two spacingwashersare installedbetween plate at each attach screw and one undernut. Do not over tighten switch and screws or plasticswitch housingmay crack. actuatorper Section7.520. 6. Reinstall

Cha n g e 4 : J UL 2 0 Oa 1

Page7.49

FICIBIN$}CIN

nlrAINTENANtrE MANUAL

M('EIEL

F|44

FORWARD 1 . 6 Oi n c h e s ExtensionLimit (ENGAGED} Extension Limit Switch

\-- ---/ /l

U,2

Gearmotor (Partiallyremoved for clarity)

A481-1 Switch Assembly

O . O 1 5i n c h m i n . (Disengaged)

AN525 Screws

:==

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^

c 18 5
Brackets

/ ./

1[" /

DO NOTREMOVE

FIGURE S ncruaron urtnr Z-t

Washer NAS62O-4 on 2 required each screw betweenA513-2 Plate and springswitches) (VIEWFROMLEFTSIDE}

Pa g e7 . 5 0

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. switch(esl to plate. Two spacing washcrs are installed e) Reassemble between switch and plate at each attach screw and one under nut. Do not overtighten screwsor plasticswitch housingmay crack. per Reinstall actuatoron helicopter Section7.52O. 7.552 FuseReplacement in An in-linefuse holderis installed the clutch actuatormotor power circuit. in R44 S/N OlOO& prior havethe fuse holderty-rapped the wire bundleabove On S/N O1O7 firewall in the main rotor gearboxcompartment. R/$4 the horizontal the and subsequent fuse holderis mountedon the test switch panel.Replace fuse with 3.0 amp (AGC3.Ol fuse. BRAKE 7.600 ROTOR 7.610 RotorBrakeRemoval tailcone the cowling.Remove forwardflex plate.Markand recordany al Remove betweenthe flex plateand the input yoke to the main shim washersinstalled rotor gearboxor the yoke on the clutch shaft. the the b) Remove cotter pin and the nut securing input yoke on the mainrotor gearbox.Remove yoke. Disconnect springfrom the firewallangle. the the the c) Removethe cable pulleyfrom the lever.Disconnect wiring to the micro switch at the three-pin connector. the dl Cut and remove safetywire, then remove threeboltssecuring rotor the the brake. Record the position of the two small and one long spacersfor reinstallation. Remove the rotor brakeassembly. 7.62O RotorBrakeInstallation a) Placethe rotor brakeassembly over the splinedinput pinionshaft of the main rotor gearbox. in b) Placeone eachof the two small{Cl30-3} spacers placebetweenthe rotor brake assemblyand the pinion end cover. Installone each AN96O-416L washeron the threeNAS1352-4H3OP bolts.Insertthe first bolt throughthe rotor brakeassembly A130-41 spacer.Insertthe secondbolt through and the the Hall Effect senderplate, rotor brakeassembly and the A130-41 spacer. Placeone AN960-416 washerbetweenthe Hall Effect senderplate and the rotor brake bracket,

Change3: 5 May 95

Page7.51

FICIBINSCIN

MAINTENANcEMANUAL

M('E ELt'44

'-/

.r'

)(

181'l

INSTALLATION BRAKE 7FIGURE 16 ROTOR

NUMBER 1 2 3 4
5

PARTNUMBER

DESCRIPTION Micro Sw'itch

NUMBER PART

DESCRIPTION Eracket Spacer Spacer S.pacer PulI ey 0 . 0 3 2i n . dia Safety t,lire

ouz-r
D1 1 101 0123NAS428-3-14 NAS1291-3 c908-t c141-10 AN320-8 MS24665-210 NAS1352-4H30P 6 ANg60-41

Lever ArmAssemblY Arm Assemb'ly B o lt Nut YokeAssemblY tlasher Nut Cotter Pin Screw tlasher

6 7 8 9 10 11

t2 13 14 15 16 t7 18

0114-1 c130-4 A130-41 cl 30-3 AN210-1A

E0240-037-3500S Spri ng

Page7.52

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 tfe Cl30-4 spacer.Fingertigliten the threebolts into the gearbox,then torqu.e safety wire. Attach the bolts to 120 in.-lbahd safety with 0.032 inch diameter ' 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 el set the Hall Effect sender-to-magnet per section 7.141. the fl Attach the cablepulleyto the lever.Reconnect wiring to the micro switch at the three-pinconnector. gl With the brakeengaged,adiust the gap betweenthe NAS428-3-14bolthead -and inch. Lock the on the D123-1 arm the C130-4 spacerto O.O3O-0.035 nut by the MS21O42Lg (seeFigure7-16A1. adjustment tightening position,measure gap betweenthe Dl12the hl With the brakein the released shouldbe 0.030 The 1 leverand the DllGl arm assembly. gap measurement - 0.170 inch. Adjustthe lengthof the beadchainas required obtainproper to 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 flex and shimmingper Section 7.23O. Checkthe intermediate plateinstallation 7.330. 7.630 Rotor BrakePad Replacement inch. al Minimumpad thicknessis O.O3O the bl Brakepad replacement accomplished replacing Dl10-1 and is by Dl23-l arm assemblies.

2: Change 12 Dec 94

Page7.53

FIClBINEiclN

MATNTENANcE MANUAL

MOE'ELF44

D112-1LEVER

ASSEMBLY DIIO-I ARM

BOLT NAS428-3-14 & NUT NAS1291-3

BRAKE ENGAGED

D123-1 ARMASSEMBLY

BETI'IEEN 0.030- 0.035in. GAP C130-4 BoLT NAS428-3-14 AND ENGAGED. I,IITH SPACER BRAKE

F_-.-

.--.r!--

T0 SIIITCH I'!ICR0 ADJUST AT AND OPEN CLOSE A GAP 0F 0.20 - 0.30in. BETI'IEEN AND LEVER D110-1 D112-1 ARM.

c0420-063-2000s SPRING

BRAKE RELEASED

iN. MIN. CLEARANCE O.O1O PADS BETWEEN ANDYOKE.

7FIGURE 164 AND ADJUSTMENTS CLEARANCES BRAKE ROTOR

Pag e7 . 5 4

Change2: 12 Dec 94

t
8. FLIGHT CONTROLS

FIC|BINS|E|N

MATNTENANeE MANUAL

MOEIEL F'44

8 SECTION CONTROLS FLIGHT CONTROLS FLIGHT 8.OOO 8.001 Introduction 8.002 Description FlightControls 8.003 Hydraulic PumpDescription 8.004 Hydraulic Reservoir Description 8.OOSHydraulic ServoDescription 8.006 Hydraulic

coNTRoLS 8.100cYcLtc

l@
8.1 1 1 8.112 Cyclic Assembly Removal 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 8.122 C ycl i cGri p A sse mblyRem oval C ycl i cGri p A sse mblyInstallation

8.130 Longitudinal Cyclic Trim ElasticCords (electric trim systems only) 8.131 8.132 E l a sti c o rd R e moval C ElasticCord Installation

(electric 8.140 Lateral and Longitudinat trim systems only) CyclicTrim Assemblies 8.141 8.142 8.143 8.144 Lateral CyclicTrim Assembly Removal Lateral CyclicTrim Assembly Installation Longitudinal Removal CyclicTrim Assembly Longitudinal Installation CyclicTrimAssembly

8.150 CyclicFriction Assembly 8.151 CyclicFriction Adjustment

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

Page8.i

FI(JBINEiCIN
8.160

MATNTENANcE MANUAL

MODEL r?,44

trim systemsonly) Tube (electric C121-7Push-Pull ,

Tube Removal 8.161 C121-7Push-Pull

Tube Inspection/Repair 8.162 C121-7Push-Pull 8.163 8.164 Installation Tube Sleeve C121-7Push-Pull TubeSleevelnspection C121-7Push-Pull

Tube Installation 8.165 C121-7Push-Pull C 8 . 2 0 0 C O L L EC T IV EON T R OL 8.210 Stick AssemblY Collective

Stick Removal 8.211 .Collective Stick lnstallation 8.212 Collective collectiveFrictionAdjustment 8.213 Pilot-Adjustable Adjustment Friction 8.214 FixedCollective 8.22O controlsonly) springAssembly(manual Collective

& SpringRemoval Servicing 8.221 Collective SpringInstallation 8.222 Collective SpringAdjustment 8.223 Collective 8.230 SYstem RPMGovernor

Removal Controller 8.231 Governor Installation Controller 8.232 Governor Removal AssemblY 8.233 Governor Assemblylnstallation 8.234 Governor Troubleshooting 8.239 Governor STRUTS AND SUPPORT 8.300 JACKSHAFT 8.310 J acksh a ft

R 8 . 3 1 1 Ja cksh a ft e mo va l 8.312 Jackshaftlnstallation 8.320 Support) Strut Assembly(Jackshaft

8.321 JackshaftStrut Removal 8.322 JackshaftStrut lnstallation 8 Page .ii 1 Change 0: JUL2004

FIGIBINSON

MATNTENANeE MANUAL

Mt'DEL

H44

8.400 SWASHPLATE MAINROTOR AND PITCH LINKS

8.410 Swashplate 8.411 Swashplate Removal Installation 8.412 Swashplate 8.413 SwashplateTilting FrictionAdjustment CONTROLS 8.500 TAIL ROTOR 8.510 Tail RotorPedals 8.511 Tail RotorPedalRemoval 8.512 Tail Rotor Pedallnstallation 8.520 C317 Bellcranks Removal 8.521 C317-2 Lower ForwardBellcrank Installation 8.522 C317-2Lower ForwardBellcrank 8.523 C317-1Lower Aft Bellcrank Removal Installation 8.524 C317-1 Lower Aft Bellcrank 8 . 5 3 0 C 3 1 6 -1U p p e rB e l l cra n k 8.531 Bellcrank Removal 8.532 Bellcrank lnstallation 8.540 A331-4 lntermediate Bellcrank Removal 8.541 Bellcrank 8.542 Bellcrank lnstallation 8 . 5 5 0 A1 2 O-3A ft B e l l cra n k 8.551 Bellcrank Removal Installation 8.552 Bellcrank 8 . 5 6 0 C O 3 1 -1 i tchC o n tro l P 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 Removal 8.610 Bearing 8.615 C648'2 BearingInstallation Installation 8.620 81 15-1 Bearing CONTROLS FLIGHT 8.700 HYDRAULIC Removal Reservoir 8.710 Hydraulic Installation Reservoir 8.720 Hydraulic PumPRemoval 8.730 Hydraulic PumpInstallation 8.740 Hydraulic ServoRemoval 8.750 Hydraulic ServoInstallation 8.760 Hydraulic

Pagef .iv

Change13: OC T 2006

FICIE|INSiCIN

MATNTENANcE MANUAL
8 SECTION FLIGHT CONTROLS

rtnETETEL.H.44

CONTROLS 8.OOOFLIGHT

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. (seeFigures8-1 and 8-2) 8.002 Description Dual controls, which are removableon the left side, are standardequipment.All primary used throughout controls are actuatedthrough push-pulltubes and bellcranks. Bearings Teflon@ liners. or have self-lubricated the control system are eithei sealedball bearings different,but the grip R44 flight controlsoperateconventionally.The cyclic stick appears moves as in other helicopters.The cyclic grip is free to move verticallyallowingthe pilot aircraftincludestrain trim-equipped to rest his forearmon his knee if he chooses. Electric gages mountedto the cyclic stick to sensecontrol forces, and electrictrim motors at the minimizethese forces. base of the stick which automatically with a twist grip throttle. When the collectivecontrol The collectivestick is conventional is raised, the engine throttle is opened automaticallyby an interconnectinglinkage. an Additionally, electronic throttle 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 supportingthe main fluid (see lines, A257-15 hydraulic a rotor swashplate, reservoir assembly,interconnecting the the trim springand balances weight Section1.4701. An elasticcord replaces collective of the collectivestick. Figure8-1A shows the hydrauliccontrol system. A schematicdiagramof the system is g i v e ni n F i gu re -1 B . 8 WARNING Except as instructed in this manual, service on the hydraulic is limited to component removaland CAUTION Cleanliness hydraulicfluid is vital to proper system operation. of Useonlyclean containers avoidcontamination and fluidfromsealed from dirty funnels, tubing, etc, Do not use alcoholto clean auliccomponents. Ch a n g e 4 : J UL 2 O0 B 1 Pa ge8.1

FICIEIINEIEIN

MAINTENT\NeE MANUAL

MOE EL F44

8.O04 HvdraulicPumPDescriPtion displacementgear pum.p. rh" The R44 hydraulic system uses a single stage,.p.ositive ring pump oriu"'rr,"tt ; ;6ii;;J to i pinionfiear w6ich'is drivenby thp main ;otor-gearbox pump drive shaft is designed The bear.-ihe purnpgearsare supporteou,in"edle bearings. were to seize. Dual seals prevent crosspr,ite"ctthe mairi gearbox'if-.pg1np io shear to flirids. A vent hole betweenthe sealsalso acts as of contamination gl.-iO"i anAfiyOraulic a drain to indicatsif either seal has failed. Description 8.005 HvdraulicReservoir return reliefvalve,PYmpbypasssolenoid, assemblyincludesa filter, pressure The reservoir Reservoir shut-off valve, 6rd-i;-anJ from'ihe pump ?.n9to and from the servos. level checks is also provided.along ";; pintJ-A-righi giur" for pre-fligrrt.ttuio i" r.i -allow 6t "upi"itv adciition tluio. A 1.25 inch diameterhose directs *iir, iemovabiefiiler-venito coolingfins. " ii1.from the engine-driven fanwheelto the reservoir coofing rated at 1O microns(P/NAN6235-1A),to be replaced cartridge The filter is a disposable filtrationis providedfor all flow from the pump. Fu"ll-flow ouring ioo-norr ihipJction.. qsi. Since the pump The pressurerelief valve regulatessystem pressureto 450-500-fl!_gll conditions, excess during sfu.u,tg piouibei"nougl"' flow to meet servo rbquirerirents unJ"r normalflightconditions.The excessfluid flows throughthe pressure how is availabi-e reliefvatvedirectly back into the reservoir.

allowsth.epilot to shut.offhydraulic.presstrr"^19-:1,"",t:.:I9: The pumpbypasssolenoid which

solenoid, piiotti sripenersiies.the ls only "v"ri"-"ontrol the the.tv"i9T,:Sinceelectrlcpower is onl "tiir,lr'vo;;;.i;;.;iir," oepressurizessystem.._!i199^ul::itl". and depressurizes reservoir to th; opensa ialve io tn6iui"iuoii ;;;;;;;d"; "no systeh,,f_?il.{g, jo::,::l ?ll:f,"1t)9:?,11l: ir't"to required switch .vrt"ln-off, uh 6i""ttical hydraulics i;:,ffiU
"p##" off.
- --;^ -a:-^^ ^l^^+-:^ io anlrr

ir,"'I.unoii'uul6

to ir pr*io"J primarily allowpilottrainingwith

The return shut-off valve closesthe return from the actuatorswheneversystem_pressure functions featureof the actuators that the irreversible oiops ueiow gOpsi. The valveassures pressureis lost' properlyby preventing-hydriuii"tluiOfrom leavingthe servos if system The valve includesa thermal relief feature to pr"u"nt-eilessive piessuredue'to thermal O of expansion the fluid. 8.006 HvdraulicServo Description motion The purpose of the servo is to provide output motion equivalentto pilot input at the The clevis 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; is link if hydrdulicpr'essure lost. With hydraulicpres:urg, prbrioi"g a oirect-mechanical pressure, servo input clevis the matchr" inpri.'.Absenthydraulic i"iuJouiput immediately prior to-causingservo gutput. An irreversible inch total travel l"treeFLv") allows O.O4O tdr""r with hydrlulics off . A 4o-micronfilter is feature is inctudeJto i"oii. piiot maintenance. The pressure "ohii6t duringlocatedat the pressureport to preventcontamination of and return ports are diffLrentsizesto preventincorrectinstallation hydrauliclines.

8 Page .1A

7: Change 06 D ec 99

FIC|BINEICIN

MAt^trENANcE
PUSH.PULL TUBEASSIMBLY

MANUAL

MC|E EL FI44

cL2r-7

c121-3 PUSH-PULL vi ASSEMBL TUBE

-J

l-.
\

c069-1 CYCLIC STICK ASSEMELY

c258- i
PITCH INK L ASSEMBLY

c258-1
P I T C HL I N K ASSEMBLY

ASSEMBLY COIi-1 SI.IASHPLATE

I

/t l
I
I

TUBE ASSEI"IBLY

c121- 5 PUSH-PULL

\ \-----

c056-1 SPRING
ASSEITIBLY -/ ASSEI'IBLY C012.2 COLLECTIVE -/-/' --

c337-1 JACKSHAFT ASSEMBLY

I 1 \

L_

c683-4DAIIIPER ASSEMBLY
c055-6 TRI].,I CYCLIC ASSEMBLY (L0NGITUDIilAL)

(ilEAR srDE) I$q694-eBoLT 4333-1 Al41-ll wAslER nequtneD) (z COLLECTIVE ils21042t4 T t{t (tttttr pitotadJustable frlctlon)

stoP

8330-13 PALilUT

FIXED COLLECTIVE FRICTION

/ I

_1 \

-2 cL77 P I V OT
\
-

8247-5 GOVERNOR ASSEI{8LY

c l 2 l- 1 9 PUSH-PULL TUBE
ASSEI.'IBLY

C038-5 -6 or COLLECTIVE
SPRING ASSE}IBLY A2O5-5FORK ASSEMBLY A1OI-4 END ROD

c048-1

FRICTION ASSEMBLY

cYcLIc

_ ___ct76-2 Y0KE (2 R BELLCRANK EQ'D) ASSEMBLY C121-1 PUSH.PULL TUBE

c918 ELASTIC
CORD

c055-2 CYCLIC TRII4 ASSEIIIBLY (LATERAL )

TUBE C319.3TORQUE ASSEMBLY

FIGURE 8-I

MAINROTOR FLIGHT CONTROLS (Electric Trim System)

P a g e8 . 1 8

Change 06 Dec 99 7:

FICIBINSCIN

MAINTENANcEMANUAL
TUBE C121.31 PUSH.PULL (3 TO SWASHPLATE PLACESI,

MODEL

FI4'I

NAS1149FN832P WASHER

SCISSORS BETWEEN DIREGTION IOVERLAP

NOT CRITICAL)

SEE

FIGURE 8- 1C

CABIN BULKHEAD

D212-1 SERVO {3 placesl

RETURN HOSES
) FORWARD

D203-1
SUPPORT } PRESSURE

DRIP SHIELD 13placesl HOSES PRESSURE c121-24 PUSH.PULL TUBE (2 placesl

c343-8 TUBE ADJUST TO 3.9O -t- O.O3 INCHES BETWEEN ROD END CENTERS

.1
HOSE RETURN D211-1(14V1 OR

D211-2l2avl
ASSEMBLY RESERVOIR

\G
-- - cooLlNG
BLAST

FILTER ACCESS/
--t -/

u.; \7\--2ijA-l. /' i2'' HOSE PRESSURE .z\--/

-/\-/,.--

Y/ DEoo-1 [F)-. i-'.]'1

--

-/

FoR \1- s;ggTRlcAL conxEcro.R

PUMP BYPASSSOLENOID

-.2/4:/j

HosE sucTloN
8-1A FIGURE SYSTEM FLIGHTCONTROL HYDRAULIC
Pag e8 . 2

9: Change FEB2OO3

FIC|BINSCIN

MATNTENANcE MANUAL

MOE ELF44

TO MAIN ROTORSWASHPLATE

COOLING BIAST HOSE

RESERVOIR ASSEMBLY SERVO (3 placesl

PRESSURE..+

-RETURN

-630

sucTtoN+

ON

HYD

swtTcHoN cYcltc
# PRESSURE

2 AMP CIRCUIT BREAKER {TO MAIN BUS)

FIGURE 8.18 SYSTEM SCHEMATIC HYDRAULIC

D200-1 CLEVTS

D200-3 WASHER

1.40 + O.O3 INCHES

scrssoR
(Forward servos onlyl

D200-2

o 3:i3 3[i]+ 'NcH lXYSllUiiS: o3

FIGURE 8-1C

POSITION. SERVO IN WITHSERVO LOWEST RIGGING ()R C121-24 PUSH- (Typical three placesl ADJUST C121-3 AS PULLTUBELENGTH REOUIRED.

(ViewA-A from Figure8-1A) Change FEB2003 9: Page 8.3

FIGIBINSCIN

MATNTENANeEMANUAL

MC'E'EL1t'44

ASSEMBLY A755-5 PEDAL A9I8 ELASTIC ASSEI,IBLY CORO

ASSEI.IBLY A331.4 EELLCRANK

i__
\ C316.1 INTERI,IEDIATE ASSEMBLY BELLCRANK
A755-4 PEDAL A55E}lBLY

-'i.r"\
I

A120-3 EELLCRAIIK
ASSEIIELY

-!-'il1

>jlt" prrciol'o-rirn*
f.l;

PEDAL A55El{ot

nrss-j

f-;+I

A3l8 BEARII{G BLOCKS

ASSEI.IBLY

c334I SUPPORT REAR SUPPORT ASSEMBLY

r c349-

cl21-15 PUSH.PULL IUBEASSTMBLY

c3r7-2
FI,ID LOWER BILLCRANK ASSEI'IBLY

CL?T-T7 PUSH.PULL ASSEI.IBLY TUEE

ASSEIIBLY TUBE C343.I PUSH-PULL

\_-----c343-5 PUSH-PULL ASSEIIBLY TUBE AFT LotlER C346.I RESTRAINT C3l7-l BELLCRANK

----J

A5SEHBLY TUBE CI21.9 PUSH.PULL

CONTROLS FLTGHT 8.2 TAIL ROTOR FIGURE

Page8 . 3 A

Change7: O6 Dec 99

FIOBINEICIN

MATNTENANcE MANUAL

MODEL

F,44

C 8 . 1 0 0 C Y C L I C ON T R OL S

WARNIN
Manual control (electric-trim)R44s require 0.O65 inch wall with C177- 2 pivot t h ickn e ss C 3 1 9 -3 to rq ue tube assemblies yoke. R44s with 1 C1 7 7 -4 p i vo t a sse mbly) and C176- 3 0.049 inch wall thicknessC319fl h yd ra u l i c i g h t co n tro l srequir e with C 1 7 7 - 3p i v o ta n d D 6 9 6 y o k e . 5 torque tube assemblies 8.110 CvclicAssemblv R 8 . 1 1 1 Cycl i cA sse mb l y e mo v al
a) Removebelly panelsand controltunnel covers. b ) Removeroll pin from cyclic friction knob and remove knob. lnstalla pin on shaft

with heat controlknob on shipsequipped carburetor to retainspacers. Remove 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. gaugeand intercom outsideair temperature and disconnect e) Openupperconsole radioface plate. systemcontroller wiring. Remove cyclictrim elasticcords per Section8.131 . f) Remove forwardand 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

Removal {cont'd} 8.111 CyclicAssembly

: gPring retainer^onto.lateraltrim g) InstallMT14-zlateraltrir rbringgs^senlgly c' 6-4Rnut atoplateral andAN31 3 6SS6-t palnrjt per-section e.1ai. nemove from cyclic to irir rpring sn"t. lt is not necessary removemotorassembly assemblY. at connections bottom of cyclicstick. electrical hl Disconnect tube..Move bolt NAS66O4-8 fromforwardendof c1 21-1push-pull Remove push-pull tube p;;h:euli irUe aft and/ormovecyclic grip aft to disconnect from cyclic stick. tube asse1bly forwardend of C319-3torq.ue two boltsconnecting Remove it to disconnect from aft i;Ci77:2 piuot and movet6rquetube assembly pivot. CAUTION ProtectC319-3torquetube from scratches' to two boltsholdingcyclicfrictionassembly but k) Disconnect, do not remove, together' iaUin. epplv frictionto helpkeepassembly l) up cyclicbox to cabin. Lift cyclicassem.bly and screwssecuring Remove trim left side of cyclic box, slide.lateral siiiin fig."ptu'g on disconnect cyclicstick assembly. shafl, and remove arm aJsemUfy ott sirihg bss6mb[ bolts,handtight, to retainboltsand two trictionassdmbly Installnuts ont-o spacers. CAUTION Before removing cyclic, Protect strain gages on silicone-covered with soft cloth or foam. cyclic stick straingagesor wiring will D'amaged trim electronic system. disable compartment' m) RemoveAZgl-9 holeplugsin keelpanelin rightaft baggage -Ooli, n nnecti g C121-7 co a OeOS-+e C130-7'spacer nd hardware R;il"; ruAS push-pull tube lowerrod endsto Cl76'2 yoke' push-pull tube C121-3 connecting bolt NAS66O5-16 andhardware n ) Remove 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

5: Change 15 Jun 98

FICIBINEiCIN

MATNTENANeEMANUAL

MOEIEL1e,44

Installation 8.112 CyclicAssembly (with attachedC121-1push-pull tube C319-3torquetubeassembly a) Install and A2O5-5fork assembly) assembly, C176-2yoke, C958-5bellcranks, verify center-to-center Beforeinstallation, through aft belly of helicopter. and 8115-1bearings A101-4 rod end in A2O5-5fork is between distance inches 3.80 + O.O3 andiam nut and palnutaretorquedper Section1.320. per Figure8-3 and to bl ConnectA2O5-5fork assembly C326-7 bellcrank torque. c) Connectlower end of C121-3 push-pulltube to C958-5 bellcranks and torque. d) Connect C121-7push-pull tubesto Cl76-2 yoke usinga NAS66O5-46 bolt andC130-7spacer torque.Install two A231-9holeplugsin keelpanel. and el Position cyclicstick betweenkeelpanels.Connectstraingagewire plugto arm onto springassembly cyclicbox, carefully slidelateral trim assembly rod shaft,andguide thru all carbheatassist (if installed) box. Install screws fastening cyclicbox to cabin. CAUTION Exercise lateral trim assembly care when installing armonto spring teflonliner shaftto avoiddamaging in bearing bore. f) Connect to C319-3torquetubeassembly Cl77-2 pivotand torque. CAUTION ProtectC319-3torquetube from scratches. cyclicfrictionassembly cabin. to sl Fasten
h l Connect forwardend of C121-1push-pull tube to cyclicstick and torque. il

protective plugsat bottomof cyclic stick. Position Connect electrical all possible sleeving covermaximum to amountof wiring and secure sleeving endswith lacing tape. Finger tightenAN316-4R nut on lateral trim springshaft then installand palnut. Remove torqueB33O-13 MT544-2retainer. Install longitudinal cordsper Section 8.132, cyclictrim elastic and no binding. Turn masterbatteryand trim switcheson and check positions.Usecircuitbreakers clearances trim motorarmsin different with position whicharmsstop. to control at Page .5 8

j) k)

t ) Movecycliccontrol all and through positions verifythat thereareclearances

Change

1 5 J u n9 8

FICIE|INSC|N

MAINTENANeE MANI.IAL

M(]EIEL

F'44

(cont'dl Installation 8.112 CyclicAssembly m)lnstallradiofaceplate,connectOATgage-try-illgicomsystemwiresand ty-rapasrequired.C|oseandsecureupperconso|e. rod actuating carbheatassist cyclicboxcoverpostlightwire,guide nl Connect frictionknob, cover. lnstallc.yclic (if installedl thru nolein i;ver, aiid securd heat i;stalr-carUuret6r control knob on ships with carb heat anOroii'iil.assist. and a19n9V-c-li"^-tjiqk torque per section o) Installc683-4 damperassembly flightcontrolsl. to i.s3o [not applicable hydraulic p) Install Panels. all tubelength it 1O.121 any push-pull per q) Rigmainrotorflightcontrols Section was changed. 14'710' per r) Adiusttrim controller Section 8.120 CyclicGrioAssembly Removal GriPAssemblY 8.121 CYclic from cyclicassembly complete withoutremovalof Thismaybeaccomplished rotorcraft. D140-1trim controller and disconnect C683-4damper remove a) lf installed, wiring. from airframe forwardbellY Panel' b) Remove lacingtape from both endsof protectivesleevingcoverinow1199 c) Remove ' ;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 pin' tapeto one removed or wire lacing nut, and A141-14 washer where grip d) Removecotter pin, castellated to attach6s stickassembly' assembly wiring-att-T::.i:il grommet atopcyclicsticka.1 Oripassembly el Remove grrp plvotand remove asseT.btv tap hammer,'gently cyclic-grip a soft-flc"ed safetv wire or Ensure .rrrrLii anijittaCn'ei *iilng irom stidk'assemb.ly. of stick assemblv' trom !9P,9q!^"lt3m initalled in step ci pr'otiuOej tacing with stlcKassemoly' remain pivot bearings Also,-ensure NOTE whileremoving' bearings Do not damage

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 This pageintentionally blank.

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

Page8.7

FICIBINSiCIN

MATNTENANcE MANI.IAL
ASSEMBLY C334 AFT SUPPORT

M(lErELF'44

NUMBER 1. 2, 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16, 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

PART NUMBER MS21042L3 AN960-101 D336-1 c130-24 A130-21 c130-25 81000-050-s 1 NAS6603-1 8249-6 c315-7 NAS6604-2 MS21042L4 AN960-416 AN960-4161 8330-1 9 MS21042L6 AN960-616 8250-1 1 7 NAS6606-1 8330-1 3 C038-5or -6 c311-1 A141-11 1 NAS6604-1 c343-1 8316-4

DESCRIPTION Nut Washer Plate Spacer Spacer Spacer Spring Washer Bolt Arm Assembly Aft Support Assy Weldment Bolt Nut Washer Washer Palnut Nut Washer Journal Bolt Palnut CollectiveSpring Assy (Ref) Bolt Washer Bolt Tube Push-Pull Assy (Ref) Rod End

PART NUMBER @ 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43, 44. 45. 46. 47, 48. AN316-4R A127-4

DESCRIPTION Nut Rod End

NAS6604-8 Bolt A141-3 A105-3 C317-1 C121-9

Washer Journal BellcrankAssy Tube Push-Pull Assy (Ref)

NAS6604-7 Bolt 4205-5 C130-12 AN316-6R D173-1 C121-19 A130-47

Fork Assembly Spacer Nut Rod End Tube Push-Pull Assy (Refl Spacer

NAS6604-38 Bolt C326-7 8303-1 c130-32 c958-5 AN316-5R 8330-16 A101-4

Bellcrank Bearing Spacer Bellcrank Nut Palnut Rod End

P a g e8 . 8

C h a n g e 7; 06 D ec 99

FIClElINSiClN

MAINTENANcE

MANUAL

M|fElELF|44

Installation 8.122 CyclicGripAssembly rollprnis installedin grip.assemblywith. protruding^ a) Ensure, grommetin jleevingcoverswirei exitinggrip assembly with one 9l^d_lo^Yt protective griPand one on wire bundle, washer, InstallA141-14 in into gripassembly bearings stickassembly. b) Slide nut casteilated and cotter Pin.
CAUTION nut Tiohtencastellated only untilthereis no axialmovement ind cyctic grip issembly. Overtighteningnut will ;ii;;;i"gs damagebearings. wiringto safetywire (or lacing)exitingatop attachgripassembly c ) Temporarily included sticli. Install srgm.met: g.rip L;;i"ilvbrrr *ires thrucVclic ivJr'i[-it'iii1 hole. Route ,Jiih gri;;G;bry *ifing,.into cyclicslicf wiringentrance protecting wires exitingcyclic stick ;G;bty wires triru-'eiiiiingsle'eving safetywire {or lacing). bottom.'Remove

to in pinson eachwire into properposition housings'Refer Figures d ) Install 14-2 and 14'4 for Pin Position. stick bottomto cover on protective sleeving wirinqexiting.cyclic -Secure e ) Position tape. .rorntti*iringlossible. maximum endswith lacing sleeving
f)

s)
h) i)

Mole cycliccontrolthrough wiringandty-r.ap.r cyclicand airframe Connect ind no binbing. Turd masterbattervand ;1 il;iti"rfiinJ uerityclearance with tr:immotor arms in different trim switcheson-inO'cn"cf clearances positions. to i'diltio"i. Uie citcuit Ureaters stop armsin different (manual assembly damper or flightcontrol) C683-4 end Install cap (hydraulic attachingscrews fliqht control)at.ip c'Cfi" siick. Torquedamperassembly pe-r 6.330. Section forwardbellY Install Panel. flight to per Adiusttrim controller section 14.710(not applicable hydraulic controls).

8 Page .10

5 C h a n g e : 15 J u n 9 8

FICIBINSCIN

MATNTENANcE MANUAL

M(lElEL13'44

Cords Trim Elastic Cyclic 8.130 Longitudinal hovering and during stick to cordsareused zerolongitudinalcyclic forces Elastic and 8-4A. 8-4 cruiseflight. Referto Figures cord, in cordsareinstalled the R44.Oneaft (cruisel Oneor two cyclictrim elastic motorcable, to forwardcyclicforce,is connected the longitudinaltrim a whichimparts Oneopti6nalforward(hoverlelasticcord, which impartsan aft cyclicforce, may be any elastic to connebted the bottomof the cyclic stick assembly. Beforereplacing range when thru its full operating motorarmis traveling longitudinaltrim ensure cord, is placedin full forwardand then full aft position. cyclic stick forwardelasticcord is required. forwardin hover,a stronger lf cyclicgripmoves lf cyclic grip moves aft in cruise flight, a stronger aft elastic cord is required. forward(hover) elasticcord strength 5 poundshasthe sameeffectas Decieasing _by (cruisel cord strengthby 1Opounds. elastic increasing-aft a) Removeelasticcord per Section8.131 and determinepart numberfrom identification tag. NOTE The R44 IPC lists elastictrim cords by part numberand installed load(force).
b)

I
l,

to and Usingaboveinformation, amountof force required countercyclicforce, elastic trim cordfrom the lPC. lf cord is old, try replacing select appropriate an it with samepart numbernew cord first. per Install Section 8.132. The if cordwas selected. cyclictrim must Testfly helicopter determine proper to (neutralize) KIASautorotation C.G. station at zero cyclicforcesduringa 1OO 9 9+ . longitudinal cyclicforces. Repeat stepsa) thru d) as required balance to

c) dt

e)

Change : 15 Jun98 5

Page .11 8

FIGIBINSC|N

MATNTENANeE MANUAL

MIfEIELH44

-4 A697 BRACKET

-1 C918-11, 2,or-13 CORD ELASTIC ( II"IPARTS AFT^ FORCE) CYCLTC

KEEL RIGTTT PANEL

6 A697PLATE

I
A697-3 ANCHOR

\/

8-4 FIGURE (H0VER) FoRI.IARD TRIMCORD ELASTIC

thru -7 C918-1 CORD ELASTIC ( IT4PARTS FORI,IARD FORCE CYCLIC ,/ IN CRUISE T . FLTGHT) \.r
CORD ELASTIC ( IMPARTS LEFT A FORCE) PEDAL

/ /
.

c121-9 PUSH-PULL TUBE (TAIL ROTOR CONTROLS )

\tt

V.t

37Lli2I CONNECTOR

ELASTIC 8-4A AFr (CRUISE) FrcuRE CORDS TRIM

ROPE SECURELY WRAP LEFT AND AROUND OVER AMMBLY PEDAL

,77i"-221 3=::;-'-t=';;;

8-48 FIGURE RELIEF TENSION ROPE OUT CONNECTOR BRING

3711T21 CONNECTOR ACCESS THROUGH HOLE

Page .12 8

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 (reference Figure2-2, 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 panel 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 panelhole iust aft of right side tail rotor pedals, through C918 elastic cord nexi to 3711T21 connectorand back through keel panelhole. 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 panel. Removeelasticcord.

2 . F o rw a rde l a sti cco rd (C918- 11,- 12, - 13!.t a) Removeforward belly panel. 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 e : 15 J u n 9 8 5

Page .13 8

FICIBINSCIN

MAINTENANeE

MANUAL

MOEIEL

F|44

8.132 ElasticCord lnstallation 1. Aft elastic cord installation

CAUTION C918-8and -9 elasticcordsmay only be usedwith trim assembly' cYclic COSS-tO keelpanel' a) Hookboth endsof trim cord to A697-3anchoron right trim motor arm in bl Movecyclic to full forwardpositionwith longitudinal uP Position.

one R.ou1e. endof an 8-48.Applyfull rightpedal. to c) Refer Figure holeiust keelpanel

8 foot

biitEt"i nylgliopd tnrouq[r-ignt i;;;ih ;f i7+ inCn cord nextto CglE.elastic ihrougn aft of rightseat'tlii'i6i6i p6Oals, Wrapbothends hole' kdel U5J[inroqOn panel ronn""tJi, 9711T2t ""ii pedaland holdthem securely' of ropearoundleft
between SilltZl connector anO-secu6't-n"' cord. fnstatt 8-4A.slowly Figure Reference cordand coss-7 cableassemuty. elastic rope' on tension rope.Remove release
CAUTION DO NOTallow the c918 elasticcord to applytension to an unsecured 3711T21 connector' WARNING Turn on trim system and ensure clearance is ihe mjintaineOUeiwELn elasticcord hooks, push.-pull lnO wiringthroughoutentirecycliccontroland iuUeC trim sYstemtravel.

I I

pedalto stretchc918 elastic Figure8-4A.Slowrv_arpLl"-ft d ) Reference the C918

all e) Reinstall panelsand the hole plug' f) tri E va l u a te m co rd per Section8' 130( d) '

P a g e8 . 1 4

5 Change : 15 Jun 98

FICIBINSC|N

MATNTENANeE MANuAL

MOE EL F'44

(cont'd) 8.132 ElasticCord Installation 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 maintained between elastic cord hooks, push-pull tubes, and wiring throughoutentire cyclic control and trim systemtravel. cl Install bellypanel. a 8.140 Lateral Longitudinal & CyclicTrim Assemblies (C055-2 CO55-9) 8.141 Lateral CyclicTrim Assembly Removal or a) Remove forward belly paneland panelbetweenforwardseats. roll b) Remove pin from cyclicfrictionknob and removeknob. Installpin on shaft to retain spacers. Removecarburetorheat control knob on ships equipped with carburetor heat assist. c) Remove screwssecuringC444-1cover. Disconnect all post light wire and pointof cyclicstick. secure coverat highest d) Openupperconsoleand disconnect OAT gageand intercomsystem the wiring.Remove radioface 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 I

palnut AN316-4R tospring Remove and nut assembly. :l#o;?,1!*ri3l,?:.t

InstallMT544-2lateralspring assembly retainer securewith heavy-duty and

gl Disconnect lateral trim motorwiring. h) Remove two NAS66O3-26 boltswhich connecttrim assembly C177-2 to pivot. i) j) gearmotor Remove assembly. lf necessary, remove springassembly disconnecting by C591-2blockfrom cabinassembly.

Change : 15 Jun98 5

Page .15 8

F|clEINSclN

MAINTENANeE MANUAL

MOEIELll'44

(cos5-2or CO55-9) Installation cyclic Trim Assembly 8.142 Lateral CAUTION D'l-40:L31d^D1*O:?; part numbers: Thereare two trim controller -6 Co55-2' and
.--r l-^ ..^^) t

with Dffi6-i';ilffiilorreihust 6e-used.9NLY must used gNtYwith be trimlffitroller :'s'J;"1i"'iiihXll.iir,ei. oi+o:z lerand controller trim Incompatible -10 irlm assemb-lies. co55-9, COSS-g, and-ii failure'
"V"fi" will is-s"mUiv(s) resultin trim system block(permanently to attached springlllemtity nottomiin qqptngtt"ttl bolts downward thru two NAS6603-26 forward. Instaltfi;;;;;lnUiv;i

C591-2 install was removed, assembly spring a ) lf CO56-1 screwheads attaching

C..i I tti it s mblv n C i :ib i.1ii!-. itulv:attach to, C177:?PjYo^t [ilgat*: ff ;5iil ii aslimUtvUeto*,andIIo ima se srr ""t3,if t-rim
il;
S e cti o n1 .3 2 O.

boltsper nuts. Torque *aineisand two MS21042108 ANgOO-iOf-

-Movethen installB33O-13palnut b ) lnstallAN316-4Rnut fingertight on_spring^shaft, to reftand remove ii.'o--i"rql"parnliJei becii6nt.320.

uis4,+i

cvcric

retainer' springassembly lat'eral

front of and outboard of cyclic friction c ) Routetrim motor wiring around. trim motorwlrlng' Ty-rap wiring as requiredto prevent Connect assembly. with flight controls. interferehce
d) Turn master battery and trim switcheson' of trim motor e) Move cyclic to left stop and right stop and observe movement binding or with no

of arm througnb-ufiiil'-t|ng". tiauei.lt must.befree off. and furn raJtei battery trim switches interferenc".

f)

systemwires,andtv-ra0f oAT and intercom radiofaceplate,connect Install console' upper iJiequireo. Cloie and secure

rod actuating carbheatassist box g) Connect cy-clic coverpostlightwig,_quide jnd secur6 knob cyclicfriction cover. Install (if instatled) holein c5uei, thru heatcontrolknob on shipswith carb heat and roll;il.'inri'rri ".ruuret6r assist. all h) Install Panels. i) 14'710' per Adjusttrim controller Section (C055-6 CO55-1O) or Removal TrimAssembly Cyclic 8.143 Longitudinat steps a) thru k). per a) Remove cyclic stick assembly^ .Sectiono8.1 1 1,t i o n8 . 1 1 1 a n d l e a v e performstepsa) thru e] a n d g ) f S e c Atternat:vely, -assembly installed' cyclicstick
b)RemovetwoNASl352.oSscrewsconnecting|ongitudinalcyclictrim asstmUtyto cyclic stick. Removetrim assembly' C h a n g e5 : 1 5 J u n 9 8

P a g e8 . 1 6

F|CIEIINSCIN

MATNTENANeE MANUAL

MOE EL F44

(CO55-6 CO55-1O) g.1M Longitudinal or Installation CyclicTrim Assembly CAUTION There are two trim controllerpart numbers:D14O-1and must be usedONLYwith trim controller D14O-2. D14O-1 D14O-2trin: CO55-2,-6 and -8 cyclic trim assemblies. -1O and -11 must be usedONLYwith CO55-9, controller and trim controller cyclic trim assemblies.Incompatible failure. will assembly(sl resultin trim system stick with a ) Refer to Figure 8-4C. Install trim motor assembty^gl qYc-fic nut in lower washer andMS21O42LO8 screwNAS62O-8L NAS1352-OB-12P positionand lightlytighten. Pivotmotor upwardand installNAS1352-08to 32P screw, C{30-11 spacer(maybe secured motor with ty-rapto ease (chamfer pointing washe,r, and aft),NAS62O-8L C13O-2Ospacer installationl, C130position.Fiemove ty-rapusedto position nut MS21O42LO8 in upper nut Torquenutsto 20-25in.-lbs(includes self-locking if 1 1 spacer, installed. torquel. per 8.1 install cyclicstickassembly Section 12 stepse) thru ql. b ) lf removed, connecttrim motorwiring and performstepsk) lf cyclicwas not removed, q) of Section 8.112. thru

per 14.710. c ) Adjusttrim controller Section

MSz104213 NUTl
\r.

NAs62o-81 >A

v9\

CYCLIC STICK

8-4C FIGURE CYCLIC LONGITUDINAL INSTALLATION TRIM ASSEMBLY

\,/-

SPACER c130-20

NAS1352-08-12P SCRE}{ WASHER NAS62O-81 MS21O42LO8 NUT

cl30-11SPACER

TEMPORARY TY-RAP NAS1352-08-32P SCREt,l FORWARD

Change : 15 Jun98 5

Page .17 8

FIEIBINEiCIN

MATNTENANcEMANUAL

MOEIEL F44

PI ROLL

ASSEMBLY FRICTION C048.1CYCLIC

OR AN96O-416 INSTALL HERE WASHER AN96O-4161 0.310'in.

NOTE FRICTION DONOTREMOVE REMOVhlHEN PLATEBOLTS ASSEMBLY ING FRICTION THE FROM HELICOPTER.

c130-2 SPACER
A130- 18 SPACER

!o*nuo-6 1 6 1
t,|ASHE()

BELLEVILLE WASHERS _

n 0 . 0 5 5 / 0 . 0 3i 5 -

AN960-6161 l,'|ASHER AT WASHERS ADDAN96OPD616L AS LOCATION REQUIRED NOTED i T 0 M A I N T A 0N0 5 5 / 0 . 0 3 5n I. DIM ENSION

AND ASSEMBI-Y ADJUSTMENT 8.4D CYCLICFRICTION FIGURE

P a g e8 . 1 8

2: Change 12Dec 94

FICIBINSCIN

MATNTENANeE MANUAL

MOEIEL

F,4ZI

Assemblv 8.150 CyclicFriction The cyclicfrictionassembly locatedbelowthe forwardleft cornerof the cyclicbox. is Turningfriction knob clockwiseappliesfrictionto both longitudinal and lateralcyclic is if axes. Adjustment required frictioncannotbe applied. Adjustment 8.151 CyclicFriction ,

until al Turn frictionknob counter-clockwise it stops. bl Remove pin connecting roll knobto shaft. cl Lift knoboff shaft.

per AN96O-416 -416Lwasher, required, Figure 8-4D so knob dl Install or as rotates1/8 to 1 turn beforeaddingfriction. With frictionon, force required at to movecyclicin a lateral direction should 7-13lb (measured griplwitn be
trim motors in neutral position. el fl Replaceknob and installroll pin. Move flight controls throughout complete clearanceproblemsexist. Verify no binding or

l 8 . 1 6 0 C 1 2 1 - 7 P u s h - P uTl u b e T 8 . 1 6 1 C 1 2 1 -7 P u sh -P u l l u b e Rem oval a) Removeaft belly panel. b) Removemast fairing. c) Removetwo plugs located in aft right baggage compartment.

tube rod ends to d) Remove NAS66O5-46 bolt attaching C121-7push-pull C176-2 yoke. e ) Disconnectbolts fasteningCl21-7 push-pull tubes to swashplate.
f)

Tape sheet metal edgesto preventpush-pulltube damage. Positionswashplateand rotor to slide C121-7 push-pulltube up and clear. Mark right and left tubes for reinstallation.

s)
i)

h l Inspect push-pulltubes and sleevesfor damageper Section 8.162. guide rollersif worn. Inspectpush-pull tube guide rollersfor wear. Replace 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.

Change : 15 Jun98 5

Page .19 8

FIclBINEiClN

MAINTENANeEMANUAL

MOEIEL]e44

TubeInspection/Repair 8.162 C121-7Push-Pull no g1_d more than in a) Nicks,cuts or scratches tube which are |ongit,^dllPl inch andno morethanO.OO5 deep,may be ,"rori t;b; inch O.O1O deep,or. out. Polished must be b) Tubes dented or flattenedmore than five percentof diameter replaced. wear inch per.wall.afterp^olishing tube wear at guideis o.o1_5 cl Maximum wear Any installation. tube sleeVe before ridges.EpoxyprimerepalTirrtaCes installation' new sleeve reqirires of tube worn in excess 0.015 inch after polishing. d) Replace Installation TubeSleeve 8.163 C121-7Push-Pull
NOTE a R e p a i r n y w e a r damageon C121- 7 push- pull.tube tube sleeve p e i S e cti d n8 .1 6 2 pr iorto the push- pull installation.

a ) Cleanpush-pulltube with MEK or acetone'

30.5 inches to b ) Aoolv taDeto restrictadhesive a six-inchlong area.beginning ii6f;'nil"t tube (not end of rod end)' end of push-pull

cl Test paint for paint bubbling;aPPlyf -inch band of B27O-3adhesiveto one primer epoxv paint applv
adhesive. to area beforeaPPlYing

remove arei. tt Ginibubblbs, enodt ii* incri

WARNING

and

to Adhesiveto be aPPlied comPlete tube sleeve' area under Push-Pull will d) Apply adhesivesuppliedin kit to entire six-inch long.area' {Adhesive large quickty set anOUl;bhe iqlngv. Brushon thin coat of adhesivewithout as lumps as raPidlY 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 to heat continuouslY DO NOT aPPIY sa me a rea.

P a g e8 . 2 O

C h a n g e5 : 15 J u n 9 8

FICIBINSCIN

MATNTENANeE MANUAL

MOEIELH'44

(cont'd) Installation TubeSleeve 8.163 CI21-7 Push-Pull g) Allow to cool and apply adhesive seal end of sleeve.Do not allow to will be damaged or of endsabovesurface sleeve sleeve at adhesive sleeve or will not enterguideduringinstallation. TubeSleeve Inspectign. 8.164 C121-7Push-Pull '

gouges, pin torn areas, bubbles, etc. inspect for sleeve wrinkles, holes, Visually areasare found. if or Replace sleeve any damaged suspect TubeInstallation 8.165 C121-7Push-Pull CAUTION C121-7pushExercise extreme carewheninstalling pulltube into guideto prevent damage push-pull to tube sleeve. per push-pull 8.4F, C121-7 tubeand hardware Figure a) Install tubesto swashplate. b) Attach C121-7push-pull mastfairing. SeeFigure 8-48. c) Reinstall NOTE lowerfairingrib to Locate andtightenclampholding priorto closing. masttube assembly protective d) Remove tape from sheetmetaledgesusedto protectpush-pull tubesduringinstallation closemastfairing. and e) Checkfull travelclearances flightcontrols. of f) Verify fasteners torqued. are

plugs. g) Installpanels compartment and baggage was changed, check dimension h) lf push-pull tube rod end center-to-center mainrotor riggingper Section1O.

Change : 15 Jun98 5

P a g e8 . 2 1

FICIBINSiCIN

MATNTENANeE MANUAL

MOCIEL]e44

cL21-7 PUSH-PULL TUBE ASSEMBLY

clzl-7
PUSH.PULL. TUBEASSEMBLY

Ij -::.

o:

liA
c

NAS557-284 GROMMET

ti\

c26t-7
:\\

RIB

AN960-101 I,IASHER

\rorr-,
uurr,rL

A S S E M B L YIi Ir

G U r D E i| ! ;

NUT MS21O42L3

p U S H- pULL ASSEMBLY TUBE

clzr-s

i i!
! I tic

I ' !! ,_,,O

( *1.

c261-8 RIB

ASSEMBLY ciu'.*b#,i i I t i--l ill -4

l-

c43s-7 GUIDE ---."di

fi;i*

i, i'i^-,-j;zit, i E:::{/

GUIDES AND TUBES 8.4E PUSH-PULL FIGURE o ( E l e c t r i c T r i m S Y s t e mn l Y )

P a g e8 . 2 2

Change7: 06 D ec 99

FICIBINSCIN

MATNTENANeEMANUAL cI21-7

MOEIEL

F|44

P U S H -P U L L TUBEASSEMBLY

1 C1 5SP ACER
\

cL21,-7 PUSH.PULL TUBE ASSEMBLY

c130-7

hh
cl15-1 SPACER

SPACER

NAS6605-46 BOLT \\

AN960- 6L 51 WASHER

cL76-2 YOKE

'@vi
\-->. AN960- s161 WASHER MS2104215 8330-16 NUT PALNUT

-\i

INSTALLATION TUBE F IGU R8 -4 E CI2I-7 PUSH-PULL ASSEMBLY E

Change 2: 1 2 D e c 9 4

Page8.23

FICIBINSCIN

MATNTENANeE MANUAL

MOE EL F44

CONTROL 8.2OO COLLECTIVE Stick Assembly 8.21O Collective Stick Removal 8.211 Collective boot a) = Removeforward horizontalpanel,aft vertical panel, both collective 6cated behindforward left seat back. tJr6is, anOtneloliective c6ver bl Installthe MTS44-1springretaineron the collectivespring locatedat the verticattunnel while iolledtive is in full down position. tube from the collectiveby forward end of C121-19Push-Pull c) Disconnect removingNAS6604-9bolt. d l Unplugthe governormotor wiring locatednearleft side of collectivestick. NAS66O3-5 e) Disconnectcollectivestop from the anchor by removing..the. springfrom the collective' th'e UofiinO Oisconneiting overtravel to bolt which connectsthe collectiveassembly one NAS66O/|-17 Remove pilot's seat on the right keel panel. the iird'ii.'Iatije ioCitLO-behind the -removed Remove threescrewsholdingthe c303-1 supportat the left end of the with the collectiveassembly. toireiiiue. The suJpoti G to Oe

sl

h ) Removecollective. 8 . 2 1 2 CollectiveStick Installation

item A332-1 frictionleverper Figure8-5. The spring.washers, a ) Assemble

with their concavesides together. The two i4;th"rld be assembled -tever 'iviin-ilil itt; ib-,-arl-instatpO wlth lh^e^greyTeflono coated surface is threadedonto the 'ai iiriiiiit tr,e A333--i stop iiter 121.The A33z-1 the

ilrXdig'Si:iZ+i iCrLfi
attachmentfitting.

from the screw starts to protrude

NOTE for frictionadiustment finalizing Seecollective friction assembly afier completio-n-of 8.224' to Refer Section installatibn. Coiltctive
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 +

Torqueper Section1.320. narAware. 11 bolt and attacnirifi

c) lnstall collectivestick into rotorcraft. inboard attach bolts.Torqueto per Section1'32O' d l Connectcollective

Pa g e8 . 2 4

lssued:11 Jun 93

FIClElINSiClN

MAtNTENap6=

MANUAL

MtfElEL

F|44

FORWARD

F IGU R8 -5 COLLECT FRICTION E I VE ASSEMBLY

NUMBER I 2 3 4 5 6 7 I 9 l0 11 12

PART NUMBER

DESCRIPTION

PART NUMBER

DESCRIPTION t,lasher Bellevi'lle l,Jasher Screw (A/R) Washer washer(A/R) l,lasher Bolt Nut P a ln u t

MS27039C0806 Screw A332-1 Lever 4431-r Knob 4N960-81 !lasher MS21042108 Nut NASl352-08-t2PScrew 4959-2 End Cap c3481 Anchor A601I G r ip c758 C o l ' l e c t i v eA s s y 30-4 A1 Spacer A333I Stop

13 l4 15 16 t7 18 l9 20 2t

4141-20 80500-022-s NASl352-4-24P AN960-415 AN960-4161 1 AN960- 0L NAS6603-5 MS2104213 8330-7

Ch a n g e1 0 : J U L 2 O O 4

P a g e8 . 2 5

FIEIBINSiCIN

MAINTENANcE

MANUAL

MffEIEL

F|44

(ShiPS/N 0001 thru 99991

{ShipS/N 1oo01 and subsequentl

INSTALLATION SPRING OVERTRAVEL F IGU R8 -6 U P PER E

NUMBER 1 2 3 4 5 6 7 8 9 10

NUMBER PART c758 1 A486A341-1 -L A327 N A S1 49F0332P I MS 2 104213 8330-7 c342-L A4B6-4 c 3 4 11

PT DESCRIION CollectiveAssemblY Screw Spacer 0ver tr avel Spr ing Assem blY W asher Nut Palnut Ar mAssem bly Screw Ar mW eldment

P a g e8 . 2 6

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

FIClElINSiClN

MATNTENANcE MANUAL

MCIEIEL F|44

(cont'd) 8.212 Collective Stick Installation el Connect left support held in place by one upper MS37O39C1-OBscrew, AN96O-1OL washer and MS21O42L3 nut. Installtwo lower MS27O39CO8O6 screws,AN96O-8Lwashersand MS21O42LO8 nuts. f) Installlower end of A333-1 stop to the C348-1 anchor. When installing A3331 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-Pull tube 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. from the collectivespringassembly. the MT544-1 springretainer i) Remove j) Installthe A327-1 overtravel springto 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 arm. Torqueto 28 in.-lbolus nut draq and installpalnut. collective

WARNING
lmproperinstallationcan cause binding,rod end damage or rod with subsequent loss of end separation ne throttle control. see k) For riggingof throttle correlation, Section 1O.15O. l) Verify all bolts and fasteners torqued. all m) Install panels.

Ch a n g e O : J U L 2 0 0 4 1

Page8.27

FI(JBINSiCIN

MAINTENANGE MANUAL

MODEL F'44

(seeFigure 8-5) collectiveFriction 8.213 Pilot-Adjustable screw (6) on frictionlever' 1. Loosen aft of full-forward 2. a. Manual controls- Hold friction lever knob 0.3-0.6 inch be rotated with washers (13) cannot position. Adjust r.r"* ii S) until friction lever screw (6)' iingutt then ti-ghten collective -Aaiujt b. Hydraulicflight controls- Hold friction lever knob futly aft againstcollective (15) to producea force of "18-22poundsat screw stick. grip,theniighten frictionleverscrew (6)' (manual controlsonly, see Figure8-3) g.214 FixedCollective Adjustment Friction verticalcenterpanelbetweenaft seatbacks. 1. Remove to B-3. Tightenbolt (19) as required eliminate 2. a. Manualcontrols- see Figure excessive. without being feedbick loadthroughc6llective and.pilot-adjustqb]e heat LOCKED flight controls- With carburetor b. Hydraulic to NAS66O6 bolt as..required friition fulty oft izeio iriction),adjust. cottective force at collective grip produce 4-5 pounar t.u.tug" of Uottl diiections) within servodeadbands. frictionper Section8.213' collective 3. Adjust pilot-adjustable onlv, see Fiqure8-8) controls sprinqAssemblv(manual 8.220 Cotlective contro! forces -f6g The collective spring assembly is installedto balance the collectiveCO38-6 sprins CO38-5 or spring in the itiglt by the. main.rotoi. p;;"*J-in balanie t6e collectivecontrol after main rotor be'ching.d or aujusted-to may assembly 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 (seeFigure 8-8). & SpringRemoval Servicing 8.221 Collective centerpanelbetweenaft seat backs. aft 1. Remove vertical Install3 MS16633-2018retaining in 2. placethe collective the full down position. loosen locking nuts and rotate rings in groout. ott griO" rods. lf necessary, until collective springuntil groovesin guide rods are expos6d. Carefullyraise ringscontactcap. retaining

Springis undercompresslon.

8 Page .28

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

FIGIBIIVSCIN

MATNTENANcEMANUAL

M(IEIEL

]t44

VISE

e (LUBRTCATE t,lITH 4257-1 SOCKET GREASE) OR SPACER

COLLECT IVE IN G SPR ASSEMBLY t^lITHROD ENDS REMOVED

--\,,o

FIGURE 8-8 METHOD SUGGESTED FOR RELIEVING COMPRESSION SPRING

ASSEMBLY SPRING FIGURE B-7 CO38-5AND-6 COLLECTIVE

NUMBER 1 2 3 4 5 6 7 8 9 PART NUMBER NAS6604-7 4N960-4161 BZ92-4 MS2104214 8 3 3 01 3 MS2104213 DESCRIPTION B o lt l.lasher Rod End ('left-handthread) Nut P a ln u t NUMBER 10 NUMBER DESCRIPTION PAAT A429-11 4429-t2 A429-13 Spring (Strong; for C038-5 Assy) (Medium; Spring A for C038-6 ssy) (Weak; Spring for C038-7Assy) cap

Nut her AN960-PD1OL hlas

c426-t c428-2

cap
Rod

11 L2 13 L4

c426-2 I Nut AN316- 4R I -4 Rod End AL27 M S16633- 3018 e t a i n i n gR i n g ( u s e d R ( 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

C h a n g e1 O :J U L 2 OO4

FIOBINSiON

MAINTENANcE MANUAL

MOEIEL t,44

(cont'd) & SpringRemoval Servicing 8.221 Collective 3. Removebottom springattach bolt. r

upperattachbolt and removespringassembly. springassembly 4. Disconnect S. Removerod ends from spring assembly_ inspect. Verify threadedshanks _a1d are straightand play is with Section2.120 limits' 6. Install spring assembly in vise per Figure 8-8. spring. decompress Remove retaining rings and

rod holes. 7 . Clean C426-2 tower cap and inspect 0.194 inch diameter-guide greater than 0.204 inch diameter or nrpl"". cap if holeJar" 6longuted,'tapered, be !"it"Ut" iize drill bit shank-may used as a go/no-gogauge). i" B . Clean guide rods and inspect visible portions.. Guide rods must be straight, guide'rods bent, tapered,worn or rough' if ;tlfidril;i, lnO l.oot6. Fieplace 9 . Lubricateguide rods with A257-1 grease(ref. Section 1 .470l' and reassemble in springassemblY reverseorder. Springlnstallation 8.222 Collective

WARNING
up Installwith nut end of guiderods pointing (seeFigure8-7).

NING
both rod ends must When installingthe CO38 spring ass^embly, of turn-s {p,292'4rod end has left-hand number extend an equ-al if,ru"a). FailJre to ensure both rod qnd.s protrude equally.can cause either one to run out 6T$reads during adjustmentsand can causebodilyharm. torque 1. Connect B2g2-4 upper rod end to C427 support assembly and NAS6604 bolt per Section1.320' per to 2. Move collective alignrod end into C326 bellcrank.Installbolt and torque 1 S e cti o n .3 2 O. ringsfrom guide removeall three retaining of 3. After installation springassembly, r o d s.

Pa g e8 . 3 0

Change1O: JUL 2004

FICIBINSON

MATNTENANeE MANUAL

MOEIEL R44

(cont'd) SpringInstallation 8.222 Collective 4. Verify coils are not binding with collective stick full down. Adjust spring per as assembly required Section8.223. WARNING to Failure remove retainingrings or allowingspring coils to bind can limit controltravel. collective throughits full rangeof travel and check for any 5. Operate or binding. panels. 6. Installremoved SpringAdjustment 8.223 Collective Small force adjustmentsmay be made by extending or contracting overall length. fully down. 1 . Securecollective panelbetweenaft seatbacks. 2 . Remove

3 . Loosenpalnut and jam nut on A127-4 rod end at bottom of springassembly.

force (lower rod or 4. Rotatespring assemblyto increase decreasecollective-up rod thread and upper rod end is left-handthread).Extending end is right-hand collective-up collective-up force; screwingrod ends in decreases ends increases force.

j 5 . T ig h te na 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. fully up and down and verify spring,move collective collective 6 . Whileobserving no interference. 7 . lnstallremovedpanels.

Ch a n g e 0 : J UL 2 OO4 1

Page .31 8

FICIBINEiCIN

MAINTENANeE MANUAL

MOEIEL t.44

8.230 RPM GovernorSvstem forces to the The governor system senses engine RPM and applies corrective inPut Throttle 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 deadband the ffi"n"uu"ir'. Wiirr=in active range ther.eis a 1olo-wide fl''gl-ri - 'lO2o/o gov;inoi will not tike action provided the rpm is where the 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 left side) and provides a corrective p;ili; in ifre engine right magneto ifreLicopter Ali goveinor controllersoperate on 14 volts; 285ig"ai to trre gori"rnorissemb'iy. 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. connector. electrical 2. Disconnect 3. Removefour screws securinggovernorcontrollerto shelf. 8.232 GovernorControllerInstallation CAUTION . R44 helicoPters require the D278-1 controffer requirethe D278-2 controller. helicopters . to 1 . S e cu reg o ve rn o rco n tro ller shelf R4411

2 . Connectelectricalconnector. 3 . l nsta l lb a ckre st.

Pa g e8 . 3 2 1O: JU L 2OO4 Change

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 replacement the gear motor is permitted.lf the friction of setting is incorrect, or the gear motor operatesincorrectly, removethe completeassemblyand return to RHC. per collective al Remove stick assembly Section8.211. bl Removethe NAS66O3-6bolt from the connectingrod. one NASl351-+28P screw and NAS1291-4nut. cl Remove 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-center distance should be 2.9O inches- 2.93 inches. bl Installtwo AN96O-10L washers,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.O2O inch diametersafety wire. el lnstall collectivestick per Section8.212. I

Change 12 Dec 94 2:

Page8.33

FICIBINEiC|N

MAINTENANcE MANUAL

MODEL re44

8.239 GovernorTroubleshooting (helicopter left The majority of governor probtemsare caused by. the engine-right adjustmentor being out of side) magneto's fachomet6rcontact assembly{points) assembly faulty. Refer to'TdM' M"rtli S"i"i." ManJal''for tachom-etercontact and adjustment. installation rpm. Below When switched on, the governoris active from 8O% to 112o/oengine no action. 80% and above il'Zdt" {ngine rpm the governorwill take will attempt to maintain engine When operatingin the activg rang-e, the.gqye1nor 1D278-2 6r loii'/. t b.'56t"-llzte-t controller) + o.75o/o

;ir ;i:ptr;ii.;i;ti - called "deadband"may a r.p.m.window ffre'Jag6rotlnit loverned controller). is-in siut]t" (no gusts), straight and level flight as be detected whenl"he helicopte.r
follows:

(do.not.exceed 1o4vd' ' 1. Gentfy hold throttle and very-slowly increaserpm governor input (subtlethrottle Note and r".oia engine tp*'indi"ation when is resistance) encountered. ( do not go below 99% ) ' r 2 . G en tl y h o l d th ro ttl e a n d ver y- slowtydecr ease pm governor input (subtlethrottle Note and *"orO engine rp* inai"uiion when is resistance) encountered. 3. Subtract second readingfrom first reading. Result should be approximately 1 o/o D 2 7 g -1 )o r l l zY o (D278_21 l of is not centeredon 1o2o/o indicative a governorcontrollerproblem. A deadband is deadband,but still centeredon 1O2o/o, usuallyindicativeof A wider-than-normal governorfriction' friction and/orinsufficient u*."rJiuu throttle iinf.ig" rod end overtravelspring assemblyuPP-el Check throttle friction by disconnecting end. With throttle from C341l}34z arm and attaching i"spring scale io the rod spring scaleand note assy.with. ur11in iafu poiition,-rf"*iy pulLup o"vertrdvelipling throttle maximum + pounOs-;;;'i"glriciion prior to. tutl,dpen throttle. .Excessive carburetor uy caus"ed Linling.rod ends, control interference, (typically iin[Jge friction oi uiniing carbuietoracceleratorpump "un-u" throttle shaft urrrting o n l Y ). b i n d si n o n e d i re cti o n "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 friction. Breakaway*i"iion'l pouna or gieatei.than moving.frictjon-mayindicate be damaged or contaminated gou"-oi *i.-iion clutch. Moving friction must be friction can 1ni;i;"u- 8 pounds until arri stopi mouing.. Insufficient moving or causedby wear, contamination, 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

(cont'd) 8.239 GovernorTroubleshooting Erratic operation is usually indicative of wiring damage or tachometer point problems. Wiring damagemay be evidenced crushing,pinching,or abrasion,all by 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-lubrication magneto cam follower felt), oxidation of isuch as from an obstructed vent plug or leaking magneto drive seal), or loose contact(s),in additionto installation assemblyerrors. or When flying in turbulence,or if the engine is lightly "loaded" (drive train almost freewheeling) fluctuatingMAP indication expected. is " Any loose connection in throttle linkage (includingworn carburetorthrottle shaft bushings) will result in both RPM & MAP oscillations.

Change O: JUL 2004 1

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FIClEl|NSiClN

MATNTENANeE MANUAL

MOEIEL]3,44

Figure8-91 8.31O Jackshaft-(See 8.311 JackshaftRemoval NOTE if Riooinocheck is not necessary iackshaftsupport strut

are ;;e";Et lno putn-lulltuberooerios not moved'

the al Disconnect push-pulltubes from the iackshaft'

the bl Disconnect two iackshaftsupportbolts at the uppersupportrod ends' O

c ) Remove iackshaft.

8 . 3 1 2 JackshaftInstallation a) Installiackshaftto strut rod ends. Aft support.rod end requiresa andbolthead.

biai-i-;iiery *;sfftei*een

the rodeirdUatl

bt Torquenuts per Section1,32Oand installpalnut'

push-pull to c) connect the cl21-3 and -5 push-pulltubes iackshqft.Bottt tube 21 - Theforryerq-C-l-3 push-pull O ;G;n uortnd.J ioinit,irward tu-d;'

the between and ilHd ;;quites;C14ifi a"f.ry wasfrer C115'1 spacer requires a rod pushpull-tube end rn"-itt Ct21-5 ffi!|a iriO Ubrti"-ab. and rod-end bolthead. the bl4i-f Jitetywisnerbetween

dl Torquenuts per Section1.320 and installpalnut' with control system existsthroughou, el Verify no binding or interference O flight control travel. Supportl 8.32O Strut Assembly(Jackshaft 8.321 JackshaftStrut Removal jackshaftper Section8'311' a) Remove the bl Remove supportstruts from the mainrotor gearbgxfittings. Disconnect Ihe aft strut from the the aft vertical strut libpJr-ioOend to release C345-1 strut weldment.

Page8.34

2: Change 12 Dec 94

FIclBINSiClN

MATNTENANeEMANUAL

MOE'EL

F44

8.322 JackshaftStrut Installation(seeFigure8-91 al Installlowerrod endsto the mainrotorgearbox fittings as shown in Figure 8-9. the aft vertical strut upperrod end as shown in Figure8-9. The bl Reinstall 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 supportrod ends.l cl Installjackshaftand push-pull tubes per Section8.312. dl Verify that all bolts and jam nuts are torquedper Section1.320.

2: Change 12 Dec 94

Page8.35

FIClElINEiclN

MAINTENANcE MANUAL
INSTALLATION JACKSHAFT

MOEIEL F.44

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

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) Tube Assembly(Ref) Push-Pull (Ref) Tube AssemblY Push-Pull

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1O: JUL 2OO4 Change

FICIBINEiCIN

MATNTENANcE MANuAL

MOclEL

F.44

or\
5

\F-,

v
8 \\

Yi'

15 16 5

"'s $,
17 19

:'s"L \}-i\ ii 18\l

q.N

zzr'

"\F

17 19-.-

*.

23

FORWARD

FIGURE 8-9 JACKSHAFTINSTALLATION Cha n g e1 4 : J U L 2 OO8 Page8.37

FIClElINSclN

MAINTENANcE MANUAL
ROTORPITCH

MOEIEL H.44

Dl4 8.4oo SWASHPIarE-AN

8 . 4 1 0 S w a sh P l a te

Removal 8.41'l SwashPlate

Riggingcheck is not requiredif push-pulltube rod end centertolclnier dimensiondoes not ch 9' and hub per Sections 111 and 9' 121' 1 . Re mo vema i n ro to r b l a d es 2. Removedroop stops and teeter stops' upper C2O4arm at C203 yoke' 3. Disconnect a 4 . Di sco n n e ct n d re mo veC2O3yokesand A210 key' 5. Removeswashplateboot by cutting plasticty-raps' A2O5 fork 6. Disconnectthree push-pulltubes and rod end of lower forward swashplate' iti".bly from lower (nbn-rotating) 7. Lift swashplatewith attachedfork and pitch links off slidertube' ( In 8 . 4 1 2 Sw a sh p l a te sta l l a ti onseeFigur e8- 10) 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 three C121-31 push-pull main rotor blades, CO17-4swashplate' tuUes,two C2O3l5 yokes, C2O4-2arm (stainlesssteel, lowerl, C2O4-g arm (stainlsss steet, upperl, C792'4 dual tachometer, D2O1-5 support weldment (forward hydraulic servosl, and D2O4-gsupport 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 on l ow er C o n n e ct a ft p u .;r-p u fi tube to t!gl!^side. of af1, single lug r*rrftp i .te .- i o rq u 'e p er Section 1.32O and install palnuts' tilting friction per Section8.413; adjust as required' 2 . Verify swashplate 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

(cont'd) 8.41 2 Swashplatelnstallation 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 (standard torque) 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, remainder rod end threadedhole in upper 4205 fork with B27O-4 fill of or B27O-13sealant(seeSection1.480). 9. Referto Figures 8-13 & 8-13A. Installupper4205 fork and C2O4arm on C203 yoke and torque per Section 1.320. Verify pivot frictions on upper scissorsare iess than 5 inch-pounds with hydrauliccontrois,or lessthan 2.5 inch-pounds with manual controls; as required,replacebearingsper Section 8.600 or change shim thickness. Verify bolt, arm, and clampedhardwarein upper scissor'spivots rotate together. Installpalnuts. 1O. Verify bolt, arm, and clampedhardwarein lower scissor'spivots rotate together. lower lugs on swashplate. Connectforward push-pull tube rod ends to remaining per Section1.320 and installpalnuts. Torque 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 swashplate ear. Torqueper Section 1.32O and installpalnut. 12. Positionswashplateboot on rotating swashplatewith inner lip contacting 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 blades Sections per 9.122 and 9.112. 15. Verify safety washersand C115 spacers installed all rod ends per Figure2-1. on per Torquestripefasteners Figure2-1. 16. Verify no interference with control movementthroughout flight control travel and swashplatemovementcorresponds with cyclic and collectivemovement. 17. Trackand balance main rotor per Section10.230. Change14: JUL 2OO8 Pag e8.39

I I

FICIEIINSiCIN

MAINTENANeE

MANUAL

MlfElEL

F|44

ASSEMBLY SWASHPLATE NUMBER DESCRIPTION

NUMBERDESCRIPTION 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
Washer Rod End Boot Pitch Link (incfitems 23,32-34, 36 & 37) Bolt Ty-rap Bolt Ty-rap SwashplateAssemblY Bolt Palnut Nut Fitting Bolt Link AssemblY Nut Interrupter Rivet Arm CounterWeight ( 0.70 inch O.D.) Rivet (one per C258-4 Link AssemblY) Link

1 2 3

Bolt Washer counterweight ( 1. 1 0 i n c hO . D . ) Counterweight ( 1 . 9 0i n c hO . D . )

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Nut Palnut Bolt Washer Nut Palnut Yoke AssemblY ( 2 Re q 'd ) Washer Washer Bolt Washer Key Bearing Spaceror Journal Arm Bolt Fork Assembly Spacer

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14: JUL 2008 Change

FIElBINEiclN ./
/

MATNTENANeE MANUAL a----\ 1111? 5 i+ i

:

MOEIELF|44

./ /

./

./

'?l{A',
tllrRjeD

1
-\_

8-13and8-13A See Figures

rl

i J4li<

,,':, iir --:>r _oF *,"2') #"

'lAbr

./;Y

J-(AO-" GrX) /<y

\ -.--(. I

/
\ -.\r

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i- nq-l

ffi
21

J?i' \P
..'1'..:....Dtrcrftt.-32

,2"-P,

.k"ff
.e'.\

4H

lflLF\i '\ ASSEi'tBLy FIGURE 8-10 swASHpLATE

\

\Q\
\A\

\^

t T SET 0 3.70 0.03 INCH CENTER-TO-CENTER

rc

rry-iS

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

P a g e8 . 4 1

FIClElINSiClN

MATNTENANcE MANUAL
qy SCnEw _)#

MC'E'EL P,44
0 . 0 2 0 I N .- D i A l'RE SAFET'

wAsHER -.f
IN O.O2O . DIA l.llRE SAFETY

c200-t

C2O6-1RETAINER

:CD
s----z
\: ,{

I 'f\,,*,,
; \ NAS62O.BL hIASHER

S C218-1 HIELD

ASSEMBLY C205.1SLEEVE -6 THRU SPACERS C197-1 I MUM ( 0 . 1 5 0i n . MAX sTACK)

C218-1 & scREw WASHER (INNER) SHIELD

& ci97-1 c200- SCREt^l WASHER I c205-1 RETAINER (ouTER) THRU SLEEVE ASSEMBLY .6 SHIMS

1 c201BALL ASSEI'IBLY

Q.i+ii;L.
c2L9-2 SPACER
SHIELD

c2t9-t
SPACER

l^l00DEN BLOCK LOhIER S!,IASHPLATE

ASSET'IBI-Y B-11 SI^JASHPI-ATE FIGURE

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FICIBINSiC|N

MATNTENANtrEMANUAL

MC'E ELr|,4,

(ssTUBE SLIDER
S---'i

SCALE SPRING

TILTING FORCE F IGU R8 .1 2 MEASURING E SWASHPLATE

11 Jun93

Page8.43

FICIBINSiC|N

MAINTENANcE

MANUAL

MctDEL r'.44

Adjustment TiltingFriction 8.413 Swashplate Swasholate tiltinq fricticn is establishedby C197-1 through. C197-6 spacers sleeveson the ball assembly' force of Teflon-lined "l"mpi6g """ii"ii6 (sciss.ors) boot, pitch links and drive linkage and 1. Mark for reassembly disconnect tubes from lower swashplate and both forward push-pull from upperil;hpl"te 2. Align upper swashplatearms with lateral axis of helicopter and center cyclic ' 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 to secureretainers ailow accessto innerscrews. Removeinner screws securing o sleeveto lower swashPlate. of thickness C197 spacerstack. Adjust spacerqlgck 4. Raisesleeveand measure tilting 0.150. inch, to achieve-proper exceeding thicknessas required,but not friction while thi6kness increases tilting-. spacer stack friction. Oecie-aiing' spacer st6ck'thickness decreasestilting friction. All inner screws inCreasing friction. and torquedper Section 1 .330 prior to measuring must be instblted 5. Safety wire inner screws with 0.020 inch diameter safety wire. Secure to retainers upp'eiswlshplate with outer screws, torque per Section 1.330, and safety wire. torque per Section tubes to lower swashplate, 6. Connectboth forward push-pull 1.32O,and torquestriPe. (interrupter on 7. Connect both pitch links and drive linkageto upper swa.shplate per Sebtion1.32O,and torquestripe' torque samesideas diive linkage), CONTROLS 8.500 TAIL ROTOR 8.510 Tail RotorPedals l 8 . 5 1 1 T a i lR o to rP e d a R e mo v al 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 to is a flammjbie material. Follow manufacturer'ssafety precautions prevent injury. 2. Removethe screws betweenthe pedalsholdingthe accessplatesto the floor and removethe Plates. the intercomsystem controllerand the outside 3. Lift the consoleand disconnect gaugewiring. air temPerature 4. Removeradios, radio face plate and the radio rack by removingthe screws which secureit to the sidesof the console'

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Change10: JUL 2004

.-

FIGIBINSCIN

MAtNTENrlllss MANUAL

MOE EL rl,44

(cont'd) Pedal Removal 8.511 TailRotor tubesby from assemblies the C343-3and C343-5push-pull both pedal 5. Disconnect bolts. two removing NAS6604-9 CAUTION of the the DO NOTremove rod endsor change length the pushtubes. 6. Remove six NAS6603-20 bolts (three per side) which hold the A318-1 and -2 bearingblock halvestogether. the lower bearingblock halves. 7. Remove 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
the right pedal assemblyis mounted forward in On reassembly, 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. into the bearingblocks and torque the bearingblock 2. Instatlthe pedal assemblies attach bolts per Section1.320. NOTE to lf a force greaterthan 5 lbs is required move pedals,check the bearingblocksto ensurethey are matchedcorrectly. to 3. Connectboth pedal assembties the push-pulltubes and torque the NAS6604-9 per Section1.320 and installpalnuts. boltsto and radiopanelface plate. 4. Installradioracks,radios 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 to adhesive attach carpeting. Ch a n g e 0 : J U L 2 0 0 4 1 Page8.45

FIC|BINSCIN

MAINTENANeE MANUAL

M(fElEL

t,44

8.520 9317Lryer eelgok

BellCrankRemoval 8.521 Cg17-2LowerForward Lift the two screwssecuring upperconsole. up the console -system a) Remove controller and outside air Oisionnect intercom and gaugewiring. temperature b) Removeradios,radio panelface plate and the radio rack which is securedwith screwsto the side panels. tubes and aft -push-pull c) Disconnectforward C343-3 and C343-5 pu.sh-pull all from the bell crank by removing three tube C1Z1-9 bolts. NAS6604-9 screws which securethe C349-1 d) Removefour MS27O39CO807 forwardkeelpanel' to supportassembly the from the ship. supportand bellcrankassembly e) Remove bolt which connectsthe bell crank to the f) RemoveNAS66O4-19 bell Remove crank. suPPort. BellCrankInstallation 8.522 C317-2LowerForward push-pull tubes and also coversriggingof. the lower. This procedure rigging disregard is not required, oiiigging tt pedat'iirbrOtieJ. ie-cnecking sequences. portions and follow installation a) Installtwo A105-3 journalsinsideC317-2 beJlcrank. Placeone A141-gwasneragainstthe outsideends of the A105-3 journals to uponassemblY the support. Tighten pivot nut and check for smooth and free operation. to Mlximuni springscaledragof 2 lbs is acceptable movethe bell 1.320. crank.Torque Section Per to lf a force in excessof 2 lb is required move the bell crank measurethe distancebetween thb 4141-3 washerswith the diameter Using g-ole,inch the washeriheldtightlyagainst iourna.ls. 'a lig.htly l9u11qt,. toot w-itn $.ZSOinch'pilotin 9rye_4105-3 ipoliice - 0.003 inch at 0.002 inch face of eachbearing shaveiho outside lf assembly. a force the bellcrankon the support a time. Ass.mUty to 2 ld is required movethe bell crank,repeatabove in excessof step. in b) Installthe supportassembly !p ship and secureit to the keel of screws. Adjust the-leng.th panetswlh idur MS27O3ECO807 to push-pull tube rod endscenter-to-center 4.42 inch and bg+g-S to JOirit C543-5 rod endscenter-to-center 6.45 inch. Verifythat the by sufficiently checking witnessholes rod endsareengaged the pieceof 0.020 inch safetywire. with a
P a g e8 . 4 6

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

FICIBINSCIN

MATNTENANeEMANUAL

MlfE|EL

F'44I

(cont'd) 8,522 C317-2LowerForwardBellCrankInstallation tubes to C317-2 bell crank. Do not Connectall three push-pull torque the NAS6604-9bolts yet. The lengthof-C121-9 p.ustl-pult tube is the tub6 must be set to 66.0 inch.Ensure 121-9 push-pull at installed throughthe centerof the c346-1 restraint the mid span position. C317-1aft bell tube which connects C343-1push-pull The vertical 13.40 in. rod end crankto C316-1upperbellcrankmust measure center-to-center. tube to the C317-2fwd bell fwd end of C121-9push-pull Connect the C317-1bellcrank.Tighten boltsbut do crankandthe aft endto tube yet. Connectone end of C343-1_push-pull to not torquethem the other end to C316-1 upperbell the C3i7-1 aft bell crankand crank.Tightenthe bolts but do not torquethem yet. in pin fnstalla 3t16 inch diameter throughthe riggingholelocated and push.it .through passenger cargo compartment the right aft adjust hole. With riggingpin installed, C317-1bell ciank'sr-igging push-pull to obtain2.90 in. tubes lengthsof C121-9and-C343-3 stop. betweenright pedaland right-hand full pedaltravel, remove rigging the Afteradjusting ni-n94aqOlV left pedalat stop, adjust lengthof C343-1 to obtain pedal. Witn i-eh 0.10 - O.20in.frdm C121-15forwardrod end to bulkhead.With to left pedal stop,adjustlengthof C121-17push-pulltube obtain at pitchcontrolassembly face and e03t-1 0.35 + 0.03 inin Oetween tube rod ends all push-pull end cap. Check of the tail rotor gearbox witnessholesfor engagement.

NOTE for It is permissible the bell crank arm to foam,as longas acoustical touchand deflect and with free movement it doesnot interfere 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) Bellcrank Installation 8.522 Cg17-2LowerForward Move pedalsfull and ease of operation. -' d) Check for smoothness tiivel. Cnetf for any interferencebetween tubes, wires and structure. to if tail checkcomptete rotor rigging changes C343-1, e ) lf reouired, tube Ca+3-S,C121,9, C121-15oi C121-17 push-pull Cg+3-C,lengthshave beenmade.
f) Verifyall attachboltsand iam nuts torquedper Section1.300.

sl lnstallradio rack, radioface plate, radiosand all the panelswhich

were removed. 8 . 5 2 3 C317-1LowerAft BellCrankRemoval spring or springretainer safety wire the collective a) Installcoltective per Section 8.221. 8.221. springper Section collective b ) Remove
c ) DisconnectC1 21-g and C343-1 push'pulltubes by removing

bolts from the C317-1bell crank' NAS66O4 respective

A2OS-3fork assemblyfrom the C326-1 bell crank d) Disconnect itiemUly-by removingNAS6604-38bolt. Leavefriction assembly to connected c315'1 uppersupport. pushC121-19collective bolt NAS66O4-9 and disconnect e) Remove pull tube from the C326-1bell crank. f) Removefour NAS6604-2bolts which are securingC315-1^rear support assemblyto the left and right panels. RemoveC334 assembly. g) c317-1 aft bell crank is connectedto rear sup^prt..::,e,qql_y_,by to C311-1bolt which is common C317-1to C326-1bell cranks. C317'1 aft bellcrank' the Remove bolt and remove

P a g e8 . 4 8

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

FICIBINEiCIN

MATNTENANcE MANUAL

MOEIEL

F.44

Installation 8 . 5 2 4 C 3 1 7 -1 L o w e r A ft B e l l cr ank 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 washer under head and tw o w i t h N A S 6 6 O4 -1 0 5b o l t, o ne NAS1149FO432P NASl 149F0463P washers under nut. Standardtorque bolt per Section 1.320, install& torque palnut, and torque stripe per Figure2-1. , , b) InstallC334 rear support assemblyin ship and secureit to side panelswith four torque bolts per Section1.320, and torque stripeper NAS66O4-2bolts. Standard 2 Figure -1. tubes to the C317-1 tail rotor control aft c) ConnectC343-1 and C121-9 push-pull beltcrank.Connectthe C1 21-19 push-pulltube to C326-7, C326-8, or C334-4 bellcrank.Verify A697-6 tab orientedO' to 20" outboardfrom vertical. Standard torque bolt per Section1 .32O,install& torque palnut,and torquestripeper Figure 2-1. to distance 3.80 inch t 0.03 inch. center-to-center d) Set upperA2O5-3fork assembly fork assemblyto C326-7, C326-8, or C334-4 bellcrank. A2O5-3 Reconnect to center-to-center 2.300 rod set e) lf applicable, collective-friction end link assembly link assemblyis not adjustable). inch rc327-1 collective-friction inches t O.O1O Installbolts and standardtorque per Section1.320. Install& torque palnuts,and torque stripe per Figure2-1. to springassembly C326-7, or connect bottom rod end of collective f) lf applicable, tor a sse mb l yper Section8.222. Standar d que bolt per Sec ti on C 3 2 6 -8 su p p o rt 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 verify no interferencebetween tubes, wires and structure. bellcranks, 8 . 5 3 0 C 3 1 6 - 1U p p e rB e l l c r a n k R 8 . 5 3 1 B e l l cra n k e mo va l a) Removeaft verticalpanel between seat backs and right rear seatback. assemblyby removingthe b) DisconnectC343-1 push-pulltube from the bellcrank NAS66O4-8bolt. NAS6604-8 by tube from C316-1bellcrank removing 5 C121-1 push-pull c) Disconnect bolt. bo fr d ) D i s c o n n e cC 3 1 6 - 1 b e l l crank om air cr aftby r em ovingNAS13O4- 17 l t fr om t suppor t. bolt fr om outboar d inboardsupportand N A S 6 6O4- 11 1 Ch a n g e 4 : J UL 2 OO8 Page8.49

FIClBINEiclN

MATNTENANeE MANUAL

M.'E'EL

F|44

Installation 8.532 Bellcrank blockand then through bolt throughbearing with NAS13O4-17 t) Installbellcrank bellcrankand NAS66O4-11bolt connectingbellcrankto outboard support. Torquebolts per Section1.320. Installpalnuts,torque per Section1.32O and 2 t o r q u estri p ep e r F i g u re - 1. tube and upperrod end of C343-1 forward end of C121-15push-pull b) Reconnect Torque bolts per Section 1 .320. Install push-pulltube to C316-1 bellcrank. 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. ( 8B 8 . 5 4 0 A 3 3 1 -4 l n te rme d i a te e l l cr ankSeeFigur e 14) R 8 . 5 4 1 B e l l cra n k e mo va l tubes fr om A331- 4 bellcr ank. C a ) D i sco n n e ct 1 2 1 -1 5a n d - 17 push- pull b) DisconnectNAS66O4-35attach bolt and removebellcrank. Installation 8.542 Bellcrank bear ings. One A1 41- 3 was her i s a ) l n sta l ltw o A 1 O5 -3j o u rnalsinto bellcr ank againstA1O5-3 journals(lf required,ream requiredon each side of beltcrank for in. p w A 1 3 9 -1 b e a ri n g i th O.375/0.376 dead- shar r eam er 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. and ease of operation. c) Check for smoothness tubes. A214-3 safety washer is required d) Connect A121-15 and -17 push-pull A331- 4 tube to the u nd e rth e b o l t h e a d w h ich connectsC121- 15push- pull washer is requiredbetween the rod end ball bellcrankand one MS2OOO2-4 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 C 1 2 1 -17 p u sh -P u ltu b e . tube lengthswer e altered. f ) R e -ri g i l ro to r p e r S e ction1O.140if push- pull ta P a g e8 . 5 0 14: JUL 2008 Change

FICIBINSCIN

MATNTENANeE MANUAL

MOE,EL

F|44

(cont'dl 8,542 BellCrankInstallation betweentubes, e) Move pedalsfull travel,checkfor any interference wire, components structure. or Aft 8.550 .A12O-3 BellCrank 8.551 BellcrankRemoval tube from 4120-3 aft bellcrank. a) DisconnectCl2l-17push-pull to bell crank pivot from attach bolt connected tail rotor b ) Disconnect gearbox. c) Removenut holdingbell crank to the pitch control. Removebell nut crankand reinstall andshimsfoundbetweenbellcrankand pitch controlfor bell crank installation. 8 . 5 5 2 Bell CrankInstallation 8.562). {see SeeCO31-1PitchControlInstallation Section 8.560 CO31-1 PitchControl 8.561 PitchControlRemoval tail Mark corresponding assembly. a) Remove rotor hub and blade tail to rotor bladegrips,tail rotor pitch change eachof the pitch control is so ears,for later'reinstallation re-rigging not required. 8.551. aft and b) Disconnect removeA12O-3 bellcrankper Section c) RemoveC031-1 pitch controlfrom tail rotor output shaft. 8.562 PitchControlInstallation onto outputshaft. a) SlideC031-1pitch controlassembly on b l PositionA120-3 bell crank assembly the tail rotor gearboxand washerunderbolt head, installNAS66O+25bolt, one AN960-416L washers,one on each side of the bearingand two MS2OOO2-4 MS21042-4nut. Tightenbut don't torqueat this time. the between A120-3bellcrankearandthe c) Measure gapexisting the Cl17-34, controlstud. lnstallsufficient flats on tne Ct25-1 pitCh fill bellcrankand stud to completely between 35 and -36 washers bearing^after on the gap but not applyany axialpreload the spherical toleranceis t 0.003". all the nuts are tightened.The clearance nut washerand MS21042-5 on protruding fnstallone AN96O-E16L end of stud. Torquenut to 200 in.-lbplus nut drag while holding stud from rotating,and installpalnut.

C h a n g e1 : 2 Ju l 9 3

Page .51 8

FIclBINSlClN

MAINTENANcE MANUAL

MOE'EL

F|41I

{cont'd} 8.562 PitchControlInstallation pivot per Section1.320 and installpalnut. dl Torquenut on A12O-3betlcrank with tube to the A12o-3 bellcrank -bott, el Attach aft end of Cl 21-17 push-pull dnder head, and.A214-3safety-.washer arugeO-+i6L flASeeO+lb nut undeinut nextto iod enO,-forque per Section1.320 and installpalnut. fl Installpitch controllinks per Section8'572' {seeSection9.2121. gl Installtail rotor hub and bladeassembly all h) Ensure 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. the al Disconnect two attach boltson both rod endsof the pitch link. bl Remove Pitchlink. 8.572 Tail RotorPitchLink Installation WARNING A21+Ssafetywashersaretobeinsta||ednextto eachrod end. CAUTION tail One-piece rotorpitch linksmust be usedin sets' pitch links with adiustable DO NOT use one-piece pitch links. NOTE lf installingsame pitch links, match ni!-cnlink.to proper blade grip- and pitcn control ear. lf installing new, length of oi.dpilcf' ove.rall pitch links, measure iOiusta-Utei or iinicwitn niicrometer caliper.Adiustthe new pitch link witnin 112turn of the rod obtaindd to the measurement end.

Pa g e8 . 5 2

Change 3: 5 MaY 95

FIC|BINSiEIN

MATNTENANeE MANUAL

MOEIEL

F|44

(cont'd) 8.572 Tail Rotor Pitch Link Installation WARNING Both pitch links must be same part number (same type and pitch links is materiall. Mixing one-piecewith adiustable-length pitch prohibited. Mixing steel one-piecewith aluminum'one-piece links is R e f e rt o F i gu re9 -1 1 . pitch link{s}: one-piece A. lf installing 1. Connectpitch link to pitch control arm and bladepitch horn. 2. Torqueattach bolts per Section 1.320. Installpalnuts,torque per Sectionl'320, for and torque stripe per Figure2-1. Repeat 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. Verify 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. inches,measuredbetween Adjust rod ends until a dimensionof 2.620 t O.O1O 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. 1 Ch a n g e 3 : O C T 2 0 0 6 Page8.53

F|ClBINEiclN

MAINTENANcE MANUAL

MC'DEL 1n44

8.600 C2O3YOKEAND A2O5 FORKASSEMBLY Removal 8.610 Bearing may be removedwith a press. and C648-2 journalbearings bearings B1 l5-1 Spherical pressfrom inner side of bearings outboardside of yoke or fork. Use while supporting tool to applythe force' a socket or other suitablepressing (0.5625/0.5630 inch diameterbearingbores) 8.61S C648-2 BearinsInstallation 1. Cleanmating surfacesof A2O5 fork or C2O3yoke where C648 bearingis installed. during installation. Deburrany sharpedgesthat may damagebearings 2. Coat yoke or fork bearingboreswith zinc chromateor epoxy primer.While primeris O backsideof fork or yoke. still wet, pressin C648 bearingwhile supporting lnstallation 8.620 B115-1 Bearing 1. Pressout old bearings. 2. Cleanyoke or fork assemblybearingboresof old adhesive. is diameter 0.6260 inches. bores;maximumallowable bearing 3. Measure 4. Lightly coat 81 15-1 bearingouter races with 8270-10 adhesiveand install81 15-1 to bearingsinto bearingbores.Wipe off excessadhesive.Do not allow adhesive enter itself. B115-1 bearing yoke or fork assemblyper Section8.412. Wait is 5. While adhesive still wet, assemble priorto checking instructions has beenallowedto cureper manufacturer's until adhesive bearingpivot force.

P a g e8 . 5 4

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

FIG|BINS|clN

MAINTENANCE
MAIN ROTOR CHORDWEIGHTS

MANUAL

MOEIEL

F,44

ASSEMBLY / c2o3-1YoKE

''*'[\'-r#',;
l:tt'
WASHER ./\-

^-l

NAS1305 OR NAS6605 BOLT (SPECIAL TOROUE 1.3301 PERSECTTON

$,,
w\
I

A
At..o. -U

SPHERICAL BEARTNG

c204
ABM

NUr ttt)-'-ocKrNc

PALNUT

ae

A205 FORK
ASSEMBLY

BEARING

C2O3-3 YOKE ASSEMBLY I2 REOUIRED) PALNUT

WASHER NAS1304 OR NAS660zt BOLT WASHER

+SMALLER INSTALLATION BOLTSTHAN LATERREVISION DIAMETER CHORDARM YOKEINSTALLATIONS 8-13 R44 EARLYREVISION FIGURE R44 (DO NOT USE ON FUEL-INJECTED II} Ch a n g e1 3 : OC T 2 0 0 6 P a g e8 . 5 5

FIGIBINSCIN

MATNTENANcE MANUAL

MOETEL F'44

c203-5 ASSEMBLY YOKE (2 Required) A21O EY K (ROUNDDGE E INBOARD}

N A S 1 3 O 5B O L T (TOROUE IRST} F

WASHER S E L F . L O C K I NN U T G PALNUT

B NAS13O5 OLT* WASHER * C 1 0 5 - 4o r - 5 J O U R N A L *

c648 BEARING
C 1 0 5 - 4o r - 5 J O U R N A L** WASHER NU SELF-LOCKING T WASHER

N A S 1 3 O 5B O L T *

C141WASHER o C1O5-4 r -5 JOURNAL* * A2O5-7 FORKASSEMBLY

PALNUT NU SELF.LOCKING T

C648 BEARING C 1 0 5 - 4o r - 5 J O U R N A L * " C 1 4 1W A S H E R

*Note targerdiameterbolts than on earlierrevision installations. **Select a combination C105-4 or -5 journalsto provide0.001 - O.01Oinch axial of play in joint. Referto Figure 2-9.

ARMrrq-KElNsIA4ArlgNs B-13A R44ll & R44CHORD FTGURE

P a g e8 . 5 6 Change14: JUL 2008

FIClBINSiclN

MATNTENANcE MANUAL

MOEIEL

1t44

c203-5 YOKE ASSEMBLY

(2 Req'd)

PALNUT SELF-LOCKING FIRST) BOLT (TOTIOUE

WASHER
WASHER

WASHER NASl305

't\\
WASHER

sELF-LocKrNG \tR*pALNUT+Ql

'ul >M*

t-:\
BEARING

c 105-6
SHIMS*

NASl305 BOLT WASHER C 1 0 5J O U R N A L

SELF-LOCKING NUT PALNUT SHIMS" WASHER PALNUT SELF-LOCKING NUT

FORK ASSEMBLY

*Sefect a combinationof C1 17-67, -68, and/or -69 shims to provide0.001-0.010 inch axial play in joint. Referto Figure2-9.

CHORDARM YOKE_INSTAL|AIIQNS FIGURE 8-138 R44 ll & R44 LATE REVISION

14: Change JUL2008

Page8.564

FIGIBINSCIN

MAINTENANeEMANUAL

MoE,EL

]f44

blank IntentionallY

P a g e8 . 5 6 8

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

FIG|BINSCIN

MATNTENANcE MANUAL

Mt'EIEL

R44

T NAS66O4.1 BOLT A214-3 WASHER WASHER MS2OOO2-4 NASl 149FO432P TU C 1 2 1 - 1 5P U S H - P U L L B EA S S E M B L Y NAS6605.35BOLT 0 MS21 4214 NUT A105.3JOURNAL

WASHER 3 8330-1 PALNUT

W NASl 149FO432P ASHER 4 1 4 1 . 3W A S H E R W NASl 149F0432P ASHER M S 2 1 O 4 2 LN U T 4 8330.13PALNUT A 1 4 1 . 3W A S H E R

,A) t2,:l'
tA)

A 3 3 1 - 4 B E L LC R A N KA S S E M B L Y A {LONGERRM INBOARD) NAS6604-9 BOLT-\_\\

TUBE CO2O FRAME

AFT VIEW LOOKING

TAILCONE

>

-' ,"'.1\unsr

\-wnsHrR
c121-17

_A'214-3

.*\.-

PUSH.PULL TUBEASSEMBLY WASHER N MS21O42L4 UT 8330.13 PALNUT

149Fo432P l

INSTALLATION FIGURE 8-14 A331.4 BELLCRANK 1 C h a n g e 3 : O C T2 0 0 6

P a g e8 . 5 7

FICIEIINSCIN

MAINTENANcE

MANUAL

MOEIEL

rl44

*E:ll'. )*-- (//

,.=_\ ll'[r=il
\

* FWD

\ ASSEMBLY TLE GOVERNOR THROT

-\\ NOTE:
PART OF STICK ASSEMBLY CLARITY REMOVEDFOR.

THROTTLEGOVERNORASSEMBLY

8-1 FIGURE 5 THROTTLE GqVERNOEINTALLAMN

P a g e8 . 5 8 C h a n g e1 3 : O C T 2 0 0 6

IICIBINSON

MATNTENANeE MANUAL

MOEIEL

F|,44

blank Intentionally

13: OCT20Oo Change

Page8.59

FIG|BINSCIN

MAINTENANcE

MANUAL

MOEIEL

1l'44

CORRECT

INCORRECT

Z(

E ER RETAIN lNsrALlArlQ-NloB HYDBASUc-!!N F|GU 8-16 SEAL RE

Page 8.60

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FICIBINEi9N

MATNTENANeE MANUAL

MOEIEL

1t44

FLIGHTCONTROLS 8.700 HYDRAULIC (seeFigure 8-1A) Reservoir Removal 8.710 Hydraulic CAUTION to Use LPS PreSolve clean hydraulicparts. Do not use alcohol. C706-1tailconecowling. 1 . Remove and cap containerbeneathsuctionline fitting on reservoir. Disconnect 2 . Placea one-liter fluid to drain into container. aft suctionline at reservoir elbow and allow reservoir elbows. 3 . Disconnectand cap one return and two pressurelinesfrom reservoir connector. 4. Disconnectpump bypasssolenoidelectrical bolts securing reservoirto upper 5 . Cut safety wire from and remove four drilled-head frame. Removereservoir. (seeFigure8-1A and Figure8-16) Reservoir Installation 8.720 Hydraulic CAUTION Use LPSPreSolve clean hydraulicparts. Do not use alcohol. to and O-rings. 1 . Installelbows into reservoirwith palnuts,jam nuts, retainers, 2 . Point forward elbows up. Torquejam nuts and palnuts per Section 1.330. Forward elbows are differentsizesand nuts requiredifferenttorques. bolts. Torque bolts per 3 . Positionreservoiron upper frame and installfour drilled-head 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. connectorand ty-rap wires as required. 5 . Connectpump bypasssolenoidelectrical 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. preload on pump pressure to remaining elbowto minimize elbow. Position 7. Connect line jam nut, palnut,and B-nutper Section1.330 and torquestripe. pressure line. Torque C h a n g e1 3 : O C T 2 0 0 6 Page8.61
I

FICIBINSGIN

MAINTENANcE MANUAL

MtfElEL

R44

lnstallation {cont'd) Reservoir 8.720 Hvdraulic structurewhile flight controlsare to 8. Verify line,andsorvo clearance surrounding moved through full rangeof travel. coolingfins. coolinghose is secureand directedat center of reservoir 9. Verify reservoir Adjust as required. with 4257-15 (seeSection1'4701fluid' f 10. Fif reservoir CAUTION of Cteanliness hydraulicfluid is vital to propersystem operation' and containers avoidcontamination onlycleanfluidfrom sealed Use tubing,etc. from dirty funnels, cowlingand connectany attachedantenna. tailcone 1 1. SecureC7O6-1 systemper Section1.190' 12. Bleedhydraulic (seeFigure8-1A) PumpRemoval 8.730 Hvdraulic CAUTION to Use LPS PreSolve clean hydraulicparts, Qg n9llse alcohol. fuel tank per Section12.140. auxiliary 1. Remove filler-vent. 2. Removereservoir and cap hotewith fingerto preventfluid loss. Disconnect filler-vent 3. Coverreservoir suction line at hydraulicpump forward T-fitting' line at hydraulicpump aft T-fitting. 4 . Disconnectand cap pressure pump to gearbox' nuts and washerssecuring four self-locking 5 . Remove between pump and metal cartridge)' 6 . RemovepUffiF,phenolicinsulator(sandwiched insulator).Do not removemetalcartridge. and O-ring(inside

Pa g e8 . 6 2

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FIC|BINSiCIN

MATNTENANcE MANUAL

MOEIEL

F44

(seeFigure 8-16) 8-1A and Figure Pumplnstallation 8.740 Hydraulic CAUTION to Use LPS PreSolve clean hydraulicparts. Do not use alcohol. and new O-ringson T-fittingsand installT-fittingsin 1. Installpalnuts,jam nuts, retainers, pump. Ensurelower arm of both T-fittingsis capped. CAUTION Verify retainershave been installedper Figure 8-16. lmproper will result in loss of hydraulicfluid. installation

'l
I

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. nuts on studs and specialtorque per Section 1.33O. Instatlwashersand self-locking 45 3 . Positionpump T-fittings so that outlets are approximately degreesfrom vertical. Specialtorque jam nuts and palnuts per Section 1.330. Nuts are different sizes and requiredifferenttorques. pressure hose to pump pressure(aft) T-fitting. Specialtorque B-nut 4 . Connectreservoir 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. fuel tank per Section 12.150 and verify minimum0.25 inch clearance 6 . Installauxiliary hosesand fittings as required. with hydraulichosesand fittings. Reposition 7 . Torquestripejam nuts and B-nutsper Figure2-1. systemper Section1.190. 8 . Bleedhydraulic on a 9 . Instalf 11O-4Telatemp easilyvisiblesurfaceof pump.

1 Ch a n g e 4 : J UL 2 0 0 8

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FlclBINSiClN

MAINTENANcE

MANUAL

Mt)E EL F.44

(seeFigure 8-1A) ServoRemoval 8.750 Hydraulic cowling' fairingand C706-1tailcone 1. Remove,mast fuel tank per Section12-140. forward right servo,removeauxiliary 2. a. lf removing b. ff removingforward left servo, removemain fuel tank per Section 12.114. tube lower rod end from servo upperclevis. 3. Disconnectc1 21-25 or -31 push-pull -28 push-pull tube 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 joiningServoscissors' 6 . Disconnectand cap pressureand returnlinesat servo' 7 . Removebolts securingservo cylinderto airframe.
CAUTION Servo input rod end is supportedonly 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. servo, 9 . Rod end at servo input must remain attached to servo. when replacing. rod end is required. Measureand record removalof control tube from servo input control tube bimensionprior to disconnecting controi tube rod end center-to-center co.ntroltube to replacementservo, f-; iouo input rod end. When attaching dimensionas close as possible. miintain originalrod end center-to-center NOTE dimension to Failure maintainoriginalrod end center-to-center main rotor riggingper Section10.120' will require to be servo, D2OO-1upper clevis.mus._t transferred replacement 1 0 . When replacing is servo. Nominaldimensionfor ufjer clevis installation shown in Figure8.].C. actualupperclevisdimension.When installing and rec6id Fiio.to removal,measure servo,coat clevisihreadswith B27O-21protectantand in rbplacement ,ppr. "f"uis to sli clevisdimensionas close as possible originalactual dimension. NOTE mainrotor will clevisdimension require original to Failure maintain ri o o i n o e r S e cti o n1 0 .120. o Pa g e8 . 6 4 14: JUL 2OO8 Change

FICIBINSGIN

MATNTENANcE MANUAL

M('EIEL

]f,'44

ServoInstallation 8.760 Hvdraulic {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 Verify retainershave been installedper Figure 8-16. lmproper installation could result in loss of hydraulicfluid and higherthan normalvibrationsin the fliqht controls.

2 . Installcontroltube onto servo input rod end and adjustcontroltube as closeas possible
recorded duringservo removal. Rodends dimension to originalrod end center-to-center C343-8 tube must remain 90 degreesto each other. Torquejam nuts per Section in 1.320. WARNING Servo input rod end is supported 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. directionnot critical). Ensure forward servo,connectservoscissors(overlap 4 . lf installing and torqueper Section1.330. betweenscissors washeris installed 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. jackshaft. aft b. lf installing servo, connect C343-8 tube's lower rod end to collective Torquejam nuts, palnuts,and bolt per Section1.320 and torquestripe. tube lower rod end to servo upperclevis. 6 . Connect C121-25 or -31 push-pull 7 . Connect pressureand return lines to servo. Positionservo elbow and/or T-fifiings to minimizeline preloadand ensure clearancewith surroundingstructure. Torque jam and returnfittings are different nuts, palnuts,and B-nutsper Section 1.330. Pressure sizesand requiredifferenttorques. fuel tank per Sections12.130 and 8. lf removed,installmain fuel tank and/orauxiliary 12.150. 9. InstallC706-1 tailconecowlingand connectany attachedantenna. position lightwiring (if installed), 10. lnstallmast fairingand connectpitot heat (if installed), and pitot tube. 1 "1 . B l e e d y d ra u l i c h syste mp e r S e ction1.190. 1 Ch a n g e 3 : O CT 2 0 0 6

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MANUAL

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Pa g e8 . 6 6

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

ROTOR SYSTEMS

FICIBINEiCIN

MATNTENANeE MANUAL SECTION 9 ROTOR SYSTEMS

M(fE,EL

]''44

SYSTEMS 9.OOO ROTOR

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 g i tchB e a ri n g o using P H 9.116 Drilling Main 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 Bearing Replacement 9.130 Inspection and Repair Main RotorBlades of 9.2OO TAIL ROTOR 9.210 Tail RotorRemoval 9.212 Tail RotorInstallation with Spherical TeeterBearings 9.213 Tail Rotor Installation with Elastomeric Teeter Bearings 9.214 Tail RotorHub Spherical Bearing Replacement 9.215 Tail RotorHub Elastomeric Bearing Replacement 9.22O Inspection and Repair Tail Rotor Blades of Change13: OCT 2006 Pagef .i (

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ANDCOOS-4 cooS-2
9.31oToo|sRequiredtoPerformBladeRep|acement 9.320 BladeRemoval (Elastomeric TeeterBearing) 9.33O DO62-1Hub Disassembly H 9 . 4 O O T A I L R OT OR U B IN S P E C T ION 9.41 O GeneralInsPection In 9 . 4 2 O D i m e n si o n a l sP e cti o n TAIL ROTORREASSEMBLY 9.50O COOS l 9 . 5 1 O H u b B e a ri n g n sta l l a ti o n Tail Rotor BladeAssembly 9.520 COOS-2 Tail Rotor BladeAssembly 9.530 COOS-4

S 9 . 6 1 O C h o rd w i se ta ti c B a l a n ce S 9 . 6 2 0 S p a n w i se 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 SYSTEMS ROTOR
WARNING

MOE,EL

F'44

Due to potentially destructive results, use of blade tape {antierosiontapel is prohibited. ROTOR SYSTEMS 9.OOO 9.O01 Introduction for proper maintenanceand This section contains proceduresand requirements 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 hinges. Main rotor blades hub havingone centerteeterhingeand two coning(blade) skins bonded to a D-sectionstainless-steel are constructedwith stainless-steel root fitting. Bladepitch spar, an aluminumhoneycombcore, and forged-aluminum stack attachedto a forged stainlessis accomplished six-bearing change through a steel spindlelocatedwithin the bladeroot fitting. The spindleis the attachmentfor bladeto main rotor hub and also containsan integraltusk for droop stop system. aluminumdroop To minimizeteetering,integraltusks contact drive shaft-mounted stops when bladesare at rest or turning at low RPM. The tail rotor system consists of an aluminum hub and two blades. The hub which allow rotor to teeter. Blades bearings, containstwo Teflon-lined elastomeric aluminumskin bondedto aluminumhoneycomb are constructedof a wrap-around and a forged aluminumroot fitting. The root fitting containstwo non-replaceable Teflon-lined spherical bearings, which enablebladesto changepitch. The bladesare l mountedbetweenhub platesand have a set preconeangle.The tail rotor teetering stop consistsof an output shaft-mountedurethanebumper, which contacts 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 e e mo val R Fourpeoplewill be required removethe blades.One personmust supportthe to bfadeapproximatelV its length from the root while anothersupportsthe root and 213 removes installs or the attachedbolt (seeFigure9-1).

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OF OR 9-1 INSTALLATION REMOVAL MAIN ROTORBLADES FIGURE

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( 9 . 1 1 1 Ma i n R o to rB l a d eR e mo val cont' d) hinge nut & bolt, pitch link and rotor 1. Mark one blade and its corresponding 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. pitch links from each main rotor blade. 2. Disconnect 3. Removecotter pins and loosen nuts of blade coning hinge bolts so they are just fingertight. side of one 4. Removenut, thrust washer, and shims (if used)from trailing-edge blade hinge bolt. Cone blade so spindletusk no longer contacts droop stop. While supportingblade at root, carefullyrotate pitch horn down and remove hinge bolt and thrust washer. CAUTION Support 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. blade. 6. RepeatStep 4. to removeremaining

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9 . 1 1 2 Ma i n R o to rB l a d eIn sta llation WARNING Airworthiness Directive Never installCO16-1blade(sl. Reference 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 three C121-31 push-pull main rotor btades,CO17-4swashplate, tubes, two C2O3-5 yokes, C2O4-2 arm (stainlesssteel, lowerl, C2O4-g arm (staintess steet, upperl, C792-4 dual tachometer, D2O1-5 support weldment (forward hydraulic servosl, and weldment (aft hydraulicservo). D204-8 journals into coning hinge bearings. 1 . With rotor hub level, insert appropriate Installthrust washer on coninghinge bolt. -not"ie 2 . positionblade in hub until spindlehole alignswith journalbores,coning blade as iequireO. s id e . pitcn irorn down ant install hinge bolt at leading-edge

NOTE
i temporarilynsert an old bolt from To assistbolt installation, side to align spindlewith our nals. trailing-edge CAUTION

To prevent damage, level and support installed blade until

site bladeis installed. and, shims {if used)and thrrLs_t_w_asher priorto installing 3. Installtrailing-edge compound. ittieads and nut face with A257-9 anti-seize nut, coat Uoit

NOTE or in compound journal-contact hub Do not allow anti-seize

bearingareas.These areasmust be clean anfu per 4 . With installedbladelevel and supportedneartip, installoppositeblade steps 1 thru 3. 5 . Tighten nut on hinge bolt until journalsand thrust washer are firmly seated' nut ott Jntil both thrirst washerscan be freely rotated' fti"n Oacf. 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 tool' dial. Rem ove a d i a l i n d i ca to r n d l o ck i ndicator 14: JUL 2008 Change Pa g e9 . 4

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(AS SHOWNON TEETER HINGEBOLT) BOLTSTRETCH FIGURE 9-2 MEASURING

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( 9 . 1 1 2 Ma i n R o to rB l a d eIn sta l lationcont' d) 7. Usingwrencheswith at least600 ft-lb torquecapacity,tighten nut until drilled MT1 22-6 and measurebolt stretch; the hole in nut and bolt align. Reinstall 'O.O22 inch (0.021 - O.O22inch for new, stretch must be between O.O2O undrilledbolt). Installa new cotter pin with wet epoxy primer.

NOTE holesin nut and boltdo not align,bothnut andbolt must lf drilled
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 or boltl to obtain proper clampingforce. Under-stretching 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. blade. Repeatsteps 1 thru 8 for remaining

9.

positions minimize to mid-travel at 1 0 . positioncyclic and collective approximately 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 contacts spindle. 12. Removelower plug from pitch horn and allow oil to flow. Placea finger over to hole as soon as oii flow decreases 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 2S e cti o n1 .3 3 0 a n d to rq uestr ipeper Figur e 1' 1 4 . Removeplate and sPacers. o 1 5 . Re p e a t 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- 111bolts 2. Placea containerunder pitch horn. Removeupperand lower self-sealing 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.

sealingof boot's inner temperatures, to 3 . lf bladewill be subjected 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 1/16-inchdiameterbead of B27O-1sealantcompletelyaround approximately positionboot innerlip junction. Whilesealant stillwet, properly is spacer-spindle assy. Rotatespindleand verify adequate and installand tighten C165-1 clamp clearancebetween clamp assy and pitch horn. Wipe off excesssealantand recommendations. with sealantmanufacturer allow to cure in accordance WARNING

Use

B27O-1sealant;silicon sealantis NOTE

When installing inner clamp, ensurethat shoulderof boot inner lip is not wedgedbeneathclampor clampmay loosenin service. Inspectboot interiorand verify 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. h 5 . F i l lp i tch b e a ri n g o u si ngper Section9.115. Ch a n g e1 4 : J U L 2 0 0 8 P a g e9 . 7

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1l'44

VALVE OF CONTAINER A257-4 FLUID3 FEETABOVENEEDLE

/
FITTING MT147.2 BLEEDER

c 1 6 5 - 2C L A M P CENTER. BOLTHOLE SPINDLE LINEAND PITCHHORNBOLT MUSTALIGN. HOLE CENTERLINE

VALVE NEEDLE

HQUqNq PITCHBEARING 9-3 FTGURE FILLING

FROMTOP PLATE INSERT H MAiN ROTOR UB c157-2 H PITCH ORN c157-1 H PITCH ORN

BOLT SELF-SEALING

, 'il
l ll lll

K\sBOOT I | MT549.2 PLATE

!rl$ t
-t I \:.

!o

l1
L_-

{View from abovel

sPAcERs ! MT549-1 : (INSERT GAPS WITH

AT TOP AND BOTTOM)

c157-2
P I T C HH O R N

BOoTILEARA\ICE SPINDLE FTGURE 9-3A ADJUSTING

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H P 9 . 1 1 5 F i l l i n g i tchB e a ri n g o using bolts from pitch horn and install 1. See Figure9-3. Remove8289-2 self-sealing fittings in holes. MT147 air-bleed 2. Position MT147 supply container of A257-4 fluid (ref Section 1.4701 approximately feet aboverotor blade. Connecttubing from supplycontainer 3 to lower air-bleedfitting. Connect vent tubing to upper air-bleedfitting and applysuctionuntil tubing from supplycontaineris filled with fluid. Routevent fitting to anothercontainer. tubing from upperair-bleed 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. fitting and install8289-2 self4. When housingis filled, removeupper air-bleed sealingbolt. Roll bladeover. After five minutesinspect boot for leaks. lf no leaks are found, remove air-bleedfitting and install 8289-2 self-sealingbolt. bolts per Section 1 .330 and torque stripe. Torque 8289-2 self-sealing Ma 9 . 1 1 6 D ri l l i n s i n R o to rH u b Bolts New bolts and nuts must be installedand bolts stretchedto Section 1.330 limits into every other nut flat use prior to drilling. Nuts have three blind holes pre-drilled g a s d r i l l i n g 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 pre-drilled hole in nut. lf a shorter length drill is nut and bolt using an accessible used, protect hub from damage due to chuck contact by wrapping chuck and/or covering hub edge with severallayers of tape. Preventchips from contaminating other mechanisms. NOTE for holesin nut are accessible use as a lf none of the predrilled guide after stretchingbolt, loosen nut and repositionbolt and nut. Restretch bolt 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 p 9 1 . R e m o v e a i nr o t o r b l a d e s e r S e c t i o n . 1 1 1 . m 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. bolt, thrust washers,shims,journals,and nut in rotor hub exactly as 4. Reinstall 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 perform_teeter installedinformationis unavailable, removed. lf previoiusly journalsare clearof droop per hingeshim calculation Section9.1 23.A. Ensure stops and fully contact drive shaft. compound,installand 3. Coat nut face and bolt threadswith A257-9 anti-seize 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. 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. Verify 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 or zinc-chromate epoxy primerand installwet'

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Width acrossteeter hingebearings

M('EIEL
Teeter Hinge Bearing

1a'44

Teeter Hinge Bearing C 1 O 6 - 5o r - 6 Journal

Width Dri
Shaft

Thrust Washer
(2 places)

c106-5 Journal c117

Bolt Shims (Head on same side as chord arm) Droop Stop Hub Main Rotor Drive Shaft Teeter Stop Bracket (orientas shown)

c117
Shims

Droop Stop

Chord Arm

HINGE FIGURE TEETER 9-4

Width across.coning+; hinge bearings rConing Hinge Bearing {2 places) Bolt (headon leading-edge side)

Thrust Washer

o C117-A,-9,-10 r - 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

J C 1 0 6 - 7 o u r n a(l 2 p l a c e s ) or o C 1 0 6 - 1- 2 , - 3 , r - 4 J o u r n a(l2 p l a c e s ) ,

DOWNI HINGE FIGURE CONING 9-5 {LOOKING Change14: JUL 2OO8 P a g e9 . 11

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KD

HUB FRONTVIEW OF MAIN ROTOR

T o P v l E Wo F H M A | NR O T O R U B

A G MAXIMUM AP, TorAL oF BorH sIDES: o . o o 5i n . - U S E D 0 . 0 0 3i n . - N E W

GAP FIGURE 9.6 MEASURING BEARING-TO.WASHER

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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 1. Measuremain rotor hub width acrossthe teeter hinge bearingfaces: width of C251 driveshaft teeter hingebolt hole: at 2. Subtractmeasured Calculated empty sp?ci = inches inches inches

lengthof and C117 shimswhich createa combined 3. Selecta Cl06-5, or C106-6,journal Placethrust 1.835 inches. Use as many differentsizeshims as possible. approximately washer, shims, and journalunderteeter bolt head;shims must be placedbetweenthrust washerandjournal. journaland shims: of thickness selected Subtractcombinedmeasured = Difference: lengthof C106-5 journalto be used on nut'side:4. Subtractmeasured inches

inches inches

CAUTION Initial teeter hinge hardware stack-up must be adjusted to empty space. A smaller inch greater than calculated 0.005/O.OO8 initial stack-up could damagethrust washers and hub bearings duringinstallation. dimensional changedue to clampingforce, add: + o.oo5/o'oo8 5. To accommodate

oT-ct-t7-snims
Resultis initialcalculatedC117 shim stack between nut-sidejournal and 6. Preceding thrust w-asher. Use as many different size shims as possibleto facilitate head to shifting during balancing. Deviatefrom initialshim stack as required meet teeter (8-12 poundsis ideal).(Seenext page for ConingfBlade] hingeflictionlequiremehts HingeShim Calculation.)

inch

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MAINTENANcE MANUAL
of the Main Rotor Hub RHC

M()EIEL

F'44

(cont'd) Information Balance

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: = empty SPoGl Calculated inches inches inches

CAUTION
Initial coning hinge hardware stack-up must be adjusted.to empty space. A smaller b.OOZiO.O11-inch dreaterthan calculateci thrust washers and hub bearings iniiiif stack-up co-ulddamage duringinstallation. inch changedue to clampingforce, add: + o.oo7/o'o1t dimensional 3. To accommodate Sum:: _l_inch -4journals whose combinedmeasured sefect a combinationof c106-1 , -2, -3, or and shimsdetermined us6 thiCSum. Alternatively, two Ci 06-7 journals f "ngthr "quat in following steP.

Leadingedgejournallengthsmust be same on both blades. journalsto 4. Subtractcombinedmeasuredlengthsof both Cl06-7 be installed: Result:: inches

oTEtTTsnims

inch

journal trailing-edge between C117shimstackrequired calculated is Result initial b. preceding journal lengrth, as and thrust *uJ6"i. Ouuiat" from initial trailing edge shim stack-up,or hinge axial play.per while m?intaining.coning to necessary r""i trttion requirements 'C',il;g-'6.-it *rrt be possibleto minually cone.each blade without teeteringthe hub shim stack-upor ui when bladesur" frufO off the dioop stopi and lifted at tip. Increasing hingefriction. journallengthdecreases

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lnformation(cont'd) 9.123 Assemblvof the Main RotorHub without RHC Static Balance 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 no hinge, shim s C o ning Coninghinge,no shims no C o ning hinge, shim s no hinge, shim s C o ning T e eter hinge hinge T e eter requires C117 shims Coninghinge(mustusetwo per hinge),

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 5 O.O1 0.020 0.025 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

blades. frictionbeforeinstalling

through use of variousthicknessC117 shims. A . Coninghingefriction is adjustable journal, can be The shims, installedbetween thrust washer and trailing-edge four 0.020, and 0.025 inch).Alternatively, in obtained four sizes(0.012,O.O15, differentlengthsof C106 journalsmay be used. See Figure9-5. CAUTION with a shim of a differentsize, it will be When a shim is replaced to installa new nut and bolt and drillthem. Drilledholes necessary 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

blade'sconing A thicker or thinneras required. thicker shim will decrease hinge friction. A thinner shim will increaseblade's coning hinge friction and any gap between blade'sthrust washersand hub bearings. decrease

3 . Installshim with a new bolt.

new nut and stretchbolt per Section9.112, Bladelnstallation. 4 . Install 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 See Figure9-6. hub bearings installed). are by B. Teeterhingefrictionis adjusted changingC1 17 shimstack in smallincrements. -9 , -1 0 a n d -1 1 shimsar e O.012,O.O15, 0.020, and 0.025 inc hthi c k , C 1 1 7 -8 , respectively. See Figure9-4.

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TEETER MT354-4 MOMENTOOL

SPRING SCALE

MEASUREMENT FRICTION HINGE 9.7 TEETER FIGURE

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9.124 Adjustmentof Hinge Friction(cont'dl NOTE lf shim stack is changed per following instructions, a new bolt per and nut must be installed 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 shim stack-up by O.OO3 0.005 inch necessary adjustfriction. Reducing to will reduceteeter friction. will increbsefriition. lncreasingshim stack-up 4. See Figure 9-7. Install MT354 Teeter Moment Tool into main rotor hub to_teeter coninghingebearings.Usinga springscale,measureforce required reading.Torque main iotor-hub; use sliding force reading, not breakaway 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. 2. 3. 4. Remove cotter pin from teeter hingenut. Removenut, washerand any shims from the teeter hinge bolt. Havetwo peoplecone the main rotor blades. Pushout teeter hingebolt with another bolt. Move or exchangeexistingshims from one side of hub to other as indicated by main rotor balancechart (see Section 1O). In sta l lte e te r h i n g e b olt per Section9.122.

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Replacement 9.126 Main RotorHub Bearing 1. 2. 3. 9.121' mainrotorhub per Section Remove and measure record with lf mainrotorhub is to be reinstalled sameblades, in and locations hub' iil;;i iengtns,shimthicknesses, and recordhub width acrosswidestpoint of teeterand coning Measure faces(totalof threemeasurements)' f,ingebearing CAUTION To prevent hub damageensureall tool and are beaiingsurfaces smooth.
4.

havingan . out old SeeFigure9-7A. Press b-e!rring.(s) of hub.uslng soc.ket extension' an 8-inch and inches of outeriiiameter 1.535-1.555 CAUTION hub is flat on presstableand socketis Ensure hub damage' to on centered bearing prevent

5.

Inspecthub bearingbore. Verify no scoring scratches. Polishout _or of to a maximum.depth. O.001inch (0.005inch on i^;ft'r; and sandpaper "nA - dl -inCf, "oiroiiSn ilOirs-.t edgeof Uot"i-rsing32O-grft finer wet-or-dry if frettingor corrosion hub riinimum Uienaridius. Replace O.2S out cannotbe polished withinlimits' bore are matingsurfaces smooth. Coathub bearing new bearing Ensure or efo-xyprimer{see ttrU U"tting 1n|tingsuifaceswith zinc chromate Teflon portion of "i'tO $".tion i .qqai.' iil n"oiatto* primerto contaminate bearing. s.9 orientbear-1ng is visible, bearing.Te{lon.liner 9-7B. lf seam.of. SeeFigure is Whilg-primer still seamis toward top oi nrU (Jsinstitledon helicopter). *;; pi"i. in new bearingusing MT329-6 plug and MT643-1 support until bearing iirppSri iJ not ,..4 *fi"niressi"ngin teeterhingebearings) flangecontactshub.
CAUTION Use MT643-1 support when installingconing ' Never install coning hinge h i n g e b e a ri n gs. hub. bealings into unsuPPorted

6.

7.

8.

primer' Seal between bearingflange and hub with zinc chromateor epoxy Do not allow 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. steP. 2, subject to Preceding

9.

, h 1 0 . tf re i n sta l l i n g u b o n sam ehelicopterinstallhar dwar eas r emovedi n s tep

P a g e9 . 2 O

Change7: 06 D ec 99

FICIBINSCIN

MATNTENANeEMANUAL

MC'E EL F|44

PRESS

S INCH SOCKET EXTENSION

:7
O DTAMETER socKET: oursrDE
1 . 5 3 5- 1 . 5 5 5I N C H E S

FIGURE 9-7A MAIN ROTOR HUB BEARING REMOVAL

MT643-1 SUPPORT

9.78 FIGURE HUB MAIN ROTOR

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

Page9.20A

FIEIBINSiCIN

MATNTENANcEMANUAL

MC'E'ELF'44

9.130 Inspectionand Repairof Main Rotor Blades

usedfor and materials limits,methods procedure the outlines repa.ir Thisbladerepair dents,nicks, out to are Repairs limit'ed blending scratches, r"priiing ;niin iotoi Ulades.. and repairs limitations thg corrot,on,;;d iefinisiring blades.Theinspebtions, removtng shipping during damage including in s[stained service, ieiei to damage herein contained by sepa.rately the factor-y)..lnare-treated iTregularities inO tanaling (manufacturing and or paintscu-ffing scratches oftentimesfreshly*ilig"n"ralli exhi-bit damige service to in rei.iln the-formof scratch6s the finish. lf thereare any questions^as the Company contact RobinsonHelicopter "ipoieO of a manufacturing irregularity, p6lJiUility SupportDePartment. Technical
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

on corrosion
1) 2l

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.: 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 . o In b o a rd f 2 4 i n ch e sfr om the bladetip, the maximumdepthis 0.0015 i nc h in coriosion. For scratchesru-nning a directionmore than 15o from tor "ny n w i se d i re ction,the m aximum depth.lim it is 0.001 inc h. F or th e sfa the i scra tch e s u n n i n gl eJsthan 15o of spanwise, m aximumis 0.0O 15i nc h deep.

b)

a Dents on skins (See Fiqure 9-8): Measure dents u.s!n.g straight edge of amagedareaand a thicknessgaug.e'Always dOge pdrallel with- the leading and trailing edges when [u"p tf,e str"aigl.tt d m e a su ri n g e p th . 7 Change : 06 Dec 99

P a g e9 . 2 0 8

FIc|E|INSIclN
:
5

MAINTENANCE

MANUAL

MOEIEL

F,44

AND scRA:rcHES_CoRRoSI0N

SKINS O.OOI MAX.HAINROTOR DOUBLERS O.OO2 MAX. MAIN ROTOR

R0T0R sKINS t'lAll'l 0.0015 }4AX. DOUELERS O.OO3MAX.MAINROTOR

I

ti-:: -:.-Z
-;:'t'j:-=
- O.O3O ENT D (FILLONLY) - O.O9O DENT (FILLONLY) - 0 . 1 2 5D E N T (FILLONLY)

-t
0 .s 0
TYP. 1.5 TIP CAP

7't--, 'f':jj

i7:j

DENTS OTHER AND DEFORMATION

-'r-=j--z

- O.OO2 DENT

-#:;
-r----

(FrLL or,rLY)

#=
:ittu, 7:a=
.:---'t':"---

- 0 . 0 1 5D E F 0 R T T A T I O N

- 0.060 DEFORMATION ANo {STRATGHTEN FILL) - O.O1OEEP D ( B L E NO N L Y ) D

-7--:;-j_

1---

_ O.060 EEP D (BLENo 0NLY) - O.O2O EEP D ( B L E NO N L Y ) D

L0 . 3 5 (O.OO2 MATERIAL MAX IN REMOVAL THIS AREA) ARE NOTE:ALL I+IEASUREHENTSEXPRESSED IN INCHES
(o-RtllcGRooVE)

LII'IITATI0NS BLADE DAI4AGE FIGURE 9-8 MAINR0T0R Ch a n g e : 1 8 MA R 9 9 6 P a g e9 . 2 1

FIGIBINSCIN

MATNTENANeE MANUAL

M(IEIEL

Fl44

c160 SPAR

INTERNAL ALUMINUM TIP CAP

crca4
SKIN (TYP 15

3.0

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

ICAL - CRIT AREA BOND -CR - SEMI IT ICAL ARTA EONO CRITICAL - NON AREA BOND - NOBOND IN THISAREA

0.50 (TYPICAL) TRIM TAB

c93s
DOUBLERS

0.30 c161

r$orott*n-q
SPLICE& HONEYCOMB ENDOF ONETRAILING DOUBLER EDGE

AREAS BONDED 9-9 MAIN ROTORBLADEADHESIVE FIGURE GiiO" shown foreshortened,all dimensionsin inches)

P a g e9 . 2 2

14: JU L 2OO8 Change

FICIBINSICIN

MATNTENANcE MANUAL

MOE'EL F|44

rnarurue {
EDGE L

BLADE C

CHORD LINE

REPAIRS ALLOWABTE EDGE TRAITING BLADE 9-9A MAIN ROTOR FIGURE

O I & 1 . O | N C HB O N DC O 1 6 - 2 C O 1 6 - 5 N B O A R D F R . S . 1 2 2 O O I N C HB O N DC O 1 6 - 5 U T B O A R D F R . S . 1 2 4 1. 5
0 . 2 I N C HS P A C E

Bo 7 . oI N C H E S N D - + l *

1 . S 5* 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
IN NO DENTSPERMITTED T H I S0 . 7 I N C H - W I D A R E A E O M C 9 . 9 I N C H E S I N I M U MC H O R D 0 1 6 - 2 ,a n d C 0 1 6 - 5I N B O A R D F R . S . 1 2 2 O C l O . 4 I N C H E S I N I M U MC H O R D O 1 6 . 5O U T B O A R D F R . S . 1 2 4 M

9.9B MINIMUMCHORDLENGTH FIGURE

C934 DOUBLER (Top and Bottom of Blade)

*l

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

MATNTENANeE MANUAL

MOE EL F.44

TIP BLADE MAIN ROTOR

LEADINGEDGE
{ TO REMOVE UP TO PERMISSIBLE 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. TO CHORDLINE;REFER FIGURE TRAILINGEDGEBOND SEAL EXPOSED MAIN JOINT. TRACKAND BALANCE ROTORPERSECTION1O.

c016-2

DRAIN MINIMUM O.75 inch RADIUS /

O.75 inch

EDGE TRAILING

rl

l*l

1 . O On c h i inches-)>

l+4.0

LIMITS 9.9D C016.2 MAIN ROTORBLADETIP REPAIR FIGURE

EDGE LEADING

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 9-9A. TO CHORDLINE;REFER FIGURE EDGEBOND TRAILING SEAL EXPOSED MAIN JOINT. TRACKAND BALANCE 'IO. PERSECTION ROTOR

v
MINIMUM 0.75 inch RADIUS

co16-5
BLADETIP N ROTOR

0.75 inch

EDGE TRAILING

l*
l--

i 1 . O On c h

4.0 inches

LIMITS BLADETIP REPAIR 9-9E C016.5 MAIN ROTOR FTGURE Page9.22B, 13: OCT 20Oo Change

FICIBINSiCIN

MATNTENANcE MANUAL

MI'EIEL

]t.44

h|HENEVER MEASURING DENT, NICK, ORSCRATCH DEPTH ALI,IAYS KEEPSTRAIGHT EDGE I'JITH PARALLEL BLADE LEAD. IffiND-TRAILING EDGE.

NOTE FOR I,|HEN CHECKING DAMAGE TO BLADES INSTALLED A ON HELICOP ALI'IAYS ER, TAKE .INTO THE ACCOUNT NATURAL BY BOt,l CAUSED DROOP OF THEBLADE.

TRAILING EDGE
BLADEDAMAGE DEPTHMEASUREMENT

}JHITE
IEADI116 EDGT

YELLOW IIHITE

BLACK SEMI.GLOSS

E TMITING OGE

TRAItI116EDGE

SIDE BOTTOM OF BLADE

BLACK SEMI-GLOSS

CO16-1MAIN ROTOR BLADEPAINTSCHEME

FIGURE REPAIR 9.10 MAINROTOR BLADE

Ch a n g e1 4 : J UL 2 0 0 8 Pa ge9.23

FICIBINSiCIN

MATNTENANcE MANUAL

MC]EIEL F'44

Black Semi-Gloss

LEADINGEDGE

BLADEPAINTSCHEME CO16-2MAIN ROTOR

LEADINGEDGE

BLADEPAINTSCHEME CO16-5MAIN ROTOR

BLADEPAINT FIGURE9-1OA MAIN ROTOR 14: JU L 2OOB Change

P a g e9 . 2 3 A

FIIJB|NSiCIN

MATNTENANcE MANUAL

MclEtEL p'44

blank Intentionally

Change14: JUL 2OO8

Pag e9.23B

FICIBINSCIN

MATNTENANcE MANUAL

MI'EIEL

1f,.44

and Repairof Main Rotor Blades(cont'd) 9.130 Inspection When checkingfor damageto bladesinstalledon helicopter,use the shortest areas.Usinga straightedgeof excessive to straightedgepossible spandamaged length will cause a false readingdue to natural bow caused by droop of the minimumradiusand blade.Smoothroundbottom dents which have a O.O6-inch within areasof the bladeare acceptable and unsupported occur in honeycornb voids are the limits shown below. Tap test dented areasin honeycomb.lf any found associatedwith dents, contact 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 inch. th i s g re a te r a n O.O1 O 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. a 3 ) B e tw e e n1 O3 .5 O 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 joints, the repairlimit is the
same as for scratches. CAUTION Do not repair any dent that has a sharp cut or break in the locallypenetrantinspect, keepingpenetrant skin. lf necessary, away from bond jointsmaterials c ) 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 "dge The blendedareamust extend for 1.0 inch minimumon each side of the nick or notch with a minimumradiusof 12.a inches.The minimumchord width after a repairis calledout in Figure9-9B'
d)

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 .

P a g e9 . 2 4

14: JUL 2OOB Change

FICIEIINSCIN

MATNTENANcE MANUAL

MOETEL F|44

(cont'd) of and 9.130 Inspection Repair MainRotorBlades mustbe damage All.spar oq e) Dents,dingsandscratqhes sp?r(SggFigure__9-8):
blendradlusas Tollows: blended out with a minimum1.Oanch inch. maximumdepth is O.O2O 1) 103.5 inchesfrom bladetip and outboard: inch. tip: 21 103.50 to 136.00 inchesfrom 'blade maximumdepth is O.O1O maximumdepth is 0.030 inch. 3) 136.00 inchesfrom bladetip and inboard: if f) Erosionon spar leadingedge:Replaceblade. erosionhas reducedthickness .o40inch.Rep|aceanyb|adeshowingripp|esor deformationof leadingedge due to erosion.

s)
follows:

and corrosionon

All damage

must

a usrng

radiusas

inch. 1) Outsidediameterof flange:maximumdepth is O.O4O inch. 2l Root areaO.35 inch outboardof flange:maximumdepth is O.OO2 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 securely bondeilwith no singlevoidslargerthan O.1Osquareinch.Voids continuous. by separated lessthan O.25 inch shallbe considered lf 2) Voids or debondsin doublersare not field repairable. any voirls or debonds are detectedin doublers,beyondlimits in Figure9-9C, contact Robinson Helicopter CompanyTechnicalSupport.

Change13: OCT 2006

Page9.25

FIClElINSlClN

MATNTENANeE MANUAL

MtfE,EL

F,44

(cont'd) of and 9.130 Inspection Repair MainRotorBlades Process: i) Rework file 9-9A, 9-98,9-9Dand9-9E. A fine-toothed may be usedto 1) Refer Figures to tiP trim blade withinlimits. using 22O grit.orfiner wet-or-dry dentsand corrosion 2) Polishout all scratches, paper,and finish with 32O grit or abrasive oxideor siliconcarbide aluminum the be.used-.along spar file paper.A fine-toothed may_ abrasive finer wet-or-dry grit or finerwet-or-dry with 32O edie, provideithe areais finished andtrailing in or piperl Mbte sureall sanding filing is accomplished the spanwise abrasive direction.
CAUTION to DO NOT USE power tools or chemicalpaint s.triqqejg remove maximum surfacetemperatureis 175oF. Remove material.The 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) Measuring the MaterialRemoved: areas,the foltowing two methods of checkingthe amount of For locally-reworked materialremovedare suggested: 1) Use calipers or micrometers and compare measurementsbefore and after blending. (2) inches I in 2l Forareas the skinsand sparwhere reworkedareasare lessthan two gaugemay be used. See Figure9-1O' it*igh,i eOg- uncithickness acr;*

9.26 Page

Change13: OCT 20Oo

FIClBINElclN

MAINTENANeE MANUAL
air of Main Rotor Blades(cont'

MtfElEL

1t44

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 joints 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 the same shapeas the bladeairfoil. Use 240 or finer grit wet-ormaintaining any dry aluminumoxide or siliconcarbideabrasivepaper. DO .NOTREMOVE metal while sanding. is d) Sand the remainingpaintedsurfacesuntil about 75o/o down to the original paint primeror to metal. Keepthe amount of bare metal to a minimum. (S P a i n t i n g e eF i g u re9 -1 O) with a tack r ag. and a ) Cl e a nw i th 1 ,1 ,1 , T ri chlor oethylene wipe lint- fr ee b) Apply a 2 to 3-inch wide strip of epoxy primeralong all exposedbond joints. c) Apply two full coats of epoxy primerto all exteriorsurfaces.Allow first coat to dry to touch before applyingsecondcoat. lf 8 hours is exceededbetween thinnerwipe lacquer primercoats,scuff with 320 grit or very fine Scotch-Brite, Best results are achieved and mist primer before applyingnext coat. NOTE: 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

black. then paint bottom semi-gloss 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. Alumiprep 33 Stock No. DX533

HenkelCorporation Parker& Amchem ProductsCo. 300 Brookside Ambler,PA 19002 Tel: 215-628-1OOO HenkelCorporation Parker& Amchem ProductsCo' 3M ComPanY 3M Center St. Paul,M N 55144- 1000 T e l :6 1 2 - 7 3 3 - 1 O 0 3M Company DuPont Los Angeles,CA

2. Alodine 1201 Stock No. DX5O3 3. Scotch-Weld StructuralAdhesive # 2 2 16 B /A Spot Putty 4. Acryl-Green P / N0 5 1 1 4 4 -0 5 9 6 0 5. EpoxyPrimer see Section1.450

6. FIat Black lmron Polyurethane Dupont 3 E n a me l 7 3 -P -2 9 9 5 O 7. Dark Gray lmron Polyurethane Dupont EnamelDSO2OHK 8. White lmron Polyurethane K E n a me l O7 7 4 H K 9. Yellow lmron Polyurethane E n a me K O6 S OH K l Dupont Dupont

& U.S. Chem ical Plastics 1 0 . Ea s yWh i te B o d y F i l l e r ProductCode 1OO1O 1446 W. TuscarawasSt' 2OO-92 Canton,OH 44702 1 Tel: 12161455- 431

Pa g e9 . 2 8

14: JU L 20OB Change

F|GIEINSC|N

MAINTENANcE MANUAL

Mt'ElEL

]?.44

(VIEWLOOKING FORWARD} I!
FOURALUMINUMSPANWISE ON WASHERS BALANCE BLADE HEAVIER

C137.2 SPACER (LARGER, OUTBOARD) NAS66O4-17{to -22} BOLT (as required) A1 41 -14, A214-3, NASl 149FO463P (AS OR NASl149FO432PWASHERS FORBALANCE) REOU]RED WASHER NAS1149FO432P 41 15.1SPACER (8 Req'd) A214.3 WASHER (O.688inch diameter) {2 Req'd) GEARBOX TAIL ROTOR OUTPUTSHAFT {palnutnot required)

8345 PITCHLINK (TWO MUST BE SAME PLACES; TYPEAND MATERIAL}

WASHER A14'1.14 {0.750 inch diameter) C119-2 BUMPER C 1 3 8 - 1B U S H I N G Req'd) {2 ( c 1 3 7 - 1 S P A C E R6 Req'd)

(LARGER SPACER OUTBOARD)

c137-2 SPACER

WASHERS BALANCE FOURSPANWISE (PLACE CLOSEST WASHERS LARGEST TO HUB ASSEMBLYI

INSTALLATION ASSEMBLY TAIL ROTOR FIGURE9-11 COOS-4 1 Ch a n g e 3 : OC T 2 0 0 6 Pa ge9.29

FIG|BINSictN

MAINTENANCE

MANUAL
LOOKING INBOARD

M(]DEL

F|44

c134-1, -2 SPANWISE BALANCE WEIGHTS

co29- 1
BLADE ASSEMBLY
I I

, I

, NAS6605-32 BOLT (4 places)

---+-i
I

I I t t t

cl29-2 HUB PLATE

c129-1 HUB PLATE

co30-1
HUB ASSEMBLY

t I I

/l
ll

I
I

'J-.!-l 2 . O O ON .

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

INSTALLATION ASSEM BLY TAIL ROTOR 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 to and must be reinstalled the same blade (see Figure9-1 1). Z. 3. teeterstop) bumper(urethane palnut,nut, and A141-14 washersecuring Remove to output shaft. 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 8330- 13 PALNUT

WASHER AN96O-4161

*="s>,
AN960-4161

TAIL ROTOR HUBPLATES TAIL ROTOR HUB

MS2104214 NUT

REPLACEMENT FOR HUB 9-13 TAIL ROTOR REMOVAL BEARING FIGURE

P a g e9 . 3 2

2: Change 12 Dec 94

FIC|EIINSiCIN

MATNTENANcE MANUAL

MoE EL F44

TO HEAD TAPONBOLT
BEARING. OPPOSITE REMOVE

,ISCRAP" OR NAS66O6 AN6 LONG HEAD BOLT. GRIND BOLT OFF TO AND CORNERS PAINTYELLOI.I STATUS. INDICATE "TOOL"

N A N 3 10 RA N 3 I 6 U r .' G R I N D 5 SO DIAMETER OFFCORNERS MAX MINIMUM THAN OF NUTIS LESS HUB OF DIAMETER TAIL ROTOR BORE. \

BEARING SPHERICAL

HUB TAIL ROTOR PORTION ENSURE THREADED PROTRUDES THROUGH OFBOLT NUT MODIFIED TOACTAS A BoLT "PILoT"(T0 CENTER IN BEARING ANDPREBALL DAMAGE). VENT BoRE HUB
BEARING SPHERICAL

9-134 TAIL ROTOR FIGURE HUB BEARING REMOVAL SPHERICAL

PRESSING I[T252BEARING FIXTURE

BEARING
HUB TAIL ROTOR

HUB 9-138 TAILROTOR FIGURE

REPLACEMENT BEARING SPHERICAL

Chan g e7 : 06 Dec

Page9.33

FIG|E|INSICIN

MAINTENANcEMANUAL

MtfEIEL

F44

with sphericalTeeter Bearings 9.212 Tail Rotor Installation teeter bearings) Section-g.213if tail rotbr has elastomeric isee 1. inspectfollowing: Beforeinstallation, fr a . C 1 3 O-1S p a ce r s: Faceswor n or deep indentations om bear i ngbal l are cause for rePlacement. or .spacer bolt hole b. TRGBOutput Shaft: Shaft worn at flats for_Cl3_O-1 by RHC. .ldng.i"d-areiause for repairof CO21-1TR Gearbox 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 rotorassembly tailrotor place hub inside andinstalltail spacers C130-1 directionof geirUor ortpul-sf,itt-per Figure .?-12... Verify clockwise iotation(whbnviewedfrom left sideof aircraft)'
WARNING in Ensurebladesare installed properdirectionof and large C137-2 spacers installed rotation, 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 underteeterhinge nut' No washersare installed under head of NAS66O6-53 No washer is used 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 . markedline in relationto output shaft. b. Teetertail rotor while observing

P a g e9 . 3 4

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

F|clBINSiClN

MAINTENANcE

MANUAL

MOETEL T,44

g.212 Tail Rotor Installation Teeter Bearings(cont'd) with Spherical teeter bearings) (see Section 9.213 if tail rotbr has elastomeric 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 and/ornut move when lf bearingball, bolthead, teetering tail rotor, insufficient clamp-up is action causesand corrective indicated. Possible for insufficientclamp-upare: 1. 2. 3. 4. Wo rn C l 3 O- 1 spacer s r eplacespacer s Hub teeter bearingstiff - manuallywork-in bearingby moving ball. Output shaft flat at pivot bolt hole worn - returngearboxto RHC fo r re p a i r. 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 . Connect pitch links to tail rotor blade. Torque nuts and palnuts per Section 1.32O and torque stripe. Dynamicallybalancetail rotor per Section 10.240.

7. 8.

Teeter Bearings 9 . 2 1 3T a i lRotor lnstallationwith Elastomeric teeter bearings) {seeSection 9.212 if tail rotor has spherical

1.

Align tail rotor bladeswith same pitch link from which removed. Install tail rotor on tail rotor gearboxoutput shaft, and verify clockwisedirection of rotation (when viewed from left side of aircraft). See Figure9-1 1. Verify bladescone toward tail rotor gearbox. Installtail rotor teeter hinge bolt, washers, and nut. Tighten nut until elastomericbearingmetal spacerscontact output shaft. Connect pitch links to bladesand torque fastenersper Section 1.32O. See Figure 10-7. With tail rotor horizontal,tape a tracking stick to tailcone at blade tip.

2. 3.
4. 5.

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

P a g e9 . 3 5

FICIBINSiCIN

MAINTENANcE

MANUAL

MOE EL F|44

Teeter Bearings(cont'd) g.213 Tail Rotor Installation with Elastomeric sphericalteeter bearings) (sie section 9.212it tail rotor has NOTE A tracking stick can be made from sheet metal 1 a p p ro xi ma te l y inch wide x 12 inches long wiitr a 90o bbnd 2 inchesfrom one end. 6. 7. 8. g. Rotatedrivetrain at ctutchshaft. Mark trackingstick where forward drain hole of each blade tiP Passes. Reposition(teeter)tail rotor on outp'lt :ltqtl until both blade tips pass the sa me p o i n t o n th e tr ackingstick + 0.125 inch' track per step 6 and Torqueteeter hingebolt per Section1 .330. Recheck adjust per step 7, if required. 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. Verify teeter hinge bolt, bearingmetal und nuts remainstaiionarywhen tail rotor is teetered. spacers,*"ihlri WARNING Movement of teeter hinge bolt, washer(s), or spacer(s), nut(s)indicateinsufficientclampu'p, which can result in loss of tail rotor.

1.32O'O nut an{ washer, 1yt. Torque perSection bumper, urethane 12. Install torquestripe. Installpalnui,torqudper Section1.32O,and
13. Dynamicallybalancetail rotor per Section 1O.24O. Replacem ent Bear ing 9 . 2 1 4 T a i l R o to r H u b S p h e ri cal 1. 2. 3. 4. b. R e mo veta i t ro to r per Section9' 21O' 9 M a r k h u b P e rF i g u r e - 1 3 . Loosenfour blade retainingbolts. Removetwo center bolts securinghub between hub Platesand remove hub' per Figur e9- 13A' R e mo vew o rn b e a r ings Clean hub bore, removing old primer and metal shavings which might preventbearingsfromseatingatbottomofbores.

P a g e9 . 3 6

Change7: O6 D ec 99

HCIEIINEiCIN

MATNTENANcE MANUAL

MOEIEL

F|44

(cont'd) Bearing Replacement 9.214Tail Rotor Hub Spherical CAUTION Bearinqsare a sliqht press fit in hub bores. Inspect bores for frelting. lf frettin-g is found, tail rotor hub assembly is UNAIRWORTHY. into hub as tool MT252-1,installbearings 6. See Figure9-138. Usingspecial follows: NOTE installation maximumto easebearing Hub may be heatedto 17OoF installation and help primer to originalprimed bore. Bearingis to be Apply Section 1.45O-approved bore to instalfed bottont of hub bore. Apply primeror A257-7 lubricant remaining to too far, spacersand and installbearingflush with top of hub. lf bearingis installed hub will not fit over gearboxoutput shaft. NOTE lnstall tail rotor without delay if using primer in both bearing bores. mark (seeFigure9-13). Torque hub betweenhub plates,per reference 7. Reinstall per Section1.320 and installpalnuts. two center hub attach bolts tail 8. Install rotor per Section9.212. 9.215 Tail Rotor Hub Elastomeric BearingReplacement 1 . R e mo ve i l ro to r p e r S e ction9.21O. ta 2. Removefour blade retainingbolts and removeblades. tool MT556, pr essout wor n bear ing . 3 . S e e F i g u re9 -1 3 C . U si ngspecial 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 . primer. While Coat bottom of bearing bore with Section 1.45O-approved p r i me ri s sti l l w e t, p re ssbear ingfully into hub using specialtool M T5 56- 11 perFigure -13D. 9 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

(cont'd) BearingReplacement 9.215 Tail Rotor Hub Elastomeric of 7. Seal between circumference each bearingand h',rbwith primeras required in two places. 8. Assemblebladesto hub. Verify clockwisedirectionof rotation.Verify correct of orientation of bolts and correct location/orientation 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

FIC|BINSCIN

MATNTENANcE MANUAL

MOEIEL

F|.44

(cont'd) BearingReplacement 9.215 Tail Rotor Hub Elastomeric

BEARING OPPOSITE PRESS REMOVE TO

v
AN6.34ABOLT (Supplied with tool)

DO62-1
HUB ASSEMBLY

s M T S 5 6 - 1 6C A p ( B e v e l e d i d ef a c i n g bolt and concave side againstbearing to be removed)

MTs56-15 SUPPORT

BEARING REMOVAL FIGURE 9-13C ELASTOMERIC Cha n g e1 3 : O CT 2 0 0 6 Page9.37B

FIclBINEiClN

MATNTENANeE MANUAL
(cont'd)

MOE'EL

F.44

Bear 9.215 Tail Rotor Hub Elastomeric

TO PRESS INSTALLBEARING

MT556-12MANDREL

8 3 6 1 - 2B E A R I N G

HUBASSEMBLY

MT556-15 SUPPORT

l-

' '-l

e-13D ELASTOMERI@TIqN FTGURE

P a g e9 . 3 7 C

Change13: OCT 2006

FlElBINEiClN

MATNTENANcE MANUAL

MOEIEL

F|44

DEPTH I'IAX 0 . 0 0 5i n . MAX DEPTH

r1.00tr---+l

i15'
15'
I

IIAXDEPTH 0 . 0 0 8l n .

SCRATCHES

0.030 in. llAXDEPTII

FIBER ROOT FITTING,CARBOII AREAS:0.008 l|AXDEPTH ln. B0llDED

DENTS

AREA: TIP CAPBONDED DEPTH 0.008 in. l4AX

BLACK TE hJHI

r/
2.75" TY?. PAINT BLADES OF TAIL ROTOR 9 F IGU R E -1 4 IN S P E CTION/REPAIR

*l L

Pa g e9 . 3 8

Change13: OCT 2OOG

FIC|BINSiGIN

MATNTENANeE MANUAL

MOEIEL

F,44

and Repair Tail Rotor Blades of 9.220 Inspection This procedureoutlinesthe inspectionand repairlimits for tail rotor blades. Repairsare scratches,nicks, removingcorrosion,filling dents and limited to blendingout mechanical the blades. refinishing WARNING Any damagedtail rotor blade that cannot be repairedwithin the limits of this section must be removedfrom service immediately and marked as "scrap." Inspection: and Corrosion(SeeFigure9-14): A) Scratches out with a 0.10 inch blend radiuswithin the following Bladeskins may be polished limits: of 1) Outboard 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 inch. direction.The maximumdepthlessthan 15o is O.OO8 spanwise 9-14): B) Dentson Skins(SeeFigure dents which have a 0.06 inch minimumradiusand occur Smooth, round-bottomed from the leadingedgeto a point O.75 inch aft of the leadingedge and are limitedto within the edgedentsare acceptable inch.Aft of O.75 inchfrom the leading O.O1O following limits: 1. Outboard 8 inchesfrom the bladetip, dentscannotexceedO.O9inch depth. of of 2. Inboard 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 joint 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 joints. Ch a n g e1 4 : J UL 2 0 0 8 Pag e9.39

FICIBINSiCIN

MAINTENANeE MANUAL

MOEIEL

444

of and Repair Tail Rotgr Blades(cont'd) 9.220 Inspection 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. any Edge:Replace bladewhereerosionhascauseddeformation of D. Erosion the Leading or ripplesin the leadingedge. on and Corrosion the Root Fitting: Damageon root fittings must E. Dents, Scratches, out using0.10 inch radiuswithin the followinglimits: be blended from the center of each 1. No repairs allowed within 1.5 inch diameter-circle bearing. inch all other areas. 2. Maximumdepth of O.O4O F. Lework Processand Measurementof Material Removed: See Main Rotor Blade Section9.130. Repair, (SeeFigure 9-14): G. Painting with a tack rag' 1. Cleanwith OSOL22Oand wipe lint-free 2. Apply a 2to 3-inch wide strip of epoxy primeralong all exposedbond joints. 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. black stripesand root fitting. 5. Sprayfinish coat semi-gloss all 6. Remove maskingmaterials.

Page 9.4O

13: OCT 2006 Change

FIGIE|INEiC|N

MATNTENANcE MANUAL

M(tElEL

1t44

BLADEREPLACEMENT ASSEMBLY TAIL ROTOR 9.300 COO8.2AND COOS-4 for necessary C008-4 (CO29-2tail rotor bladereplacement) This section containsprocedures 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. to 9.31O Tools Required PerformBladeReplacement Part No. Description QuantitY 1 1 1

Wheels- T.R. MT179-3 Static Balancing Bar MT179-4 Static Balancing - T.R. T.R. BearingRemovaland Installation MT556-11 Tools - Elastomeric 9 . 3 2 0 B l a d eR e mo va l

to 1. Removefour NAS66O5-31bolts attachingCO29-1 blade assemblies CO3O-1 assemblyor; hub and carefullyremovebladesfrom 2. Removetwo NAS66O4-31and two -35 bolts attachingCO29-1or CO29-2blade teeter bearing hub assembly and carefully to assemblies D062-1 Elastomeric 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) y 9 . 3 3 0 D O 6 2 -1H u b D i sa sse mb l ( Elastomer ic to a 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 e c io llM 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

HUBINSPECTION 9.400 TAILROTOR InsPection, 9.410 General ''

per 9.220. inspect Section are 1. lf one or bothtail rotorblades to be reused,

2. CleanDO62-2hub with solvent. 3. Removedata plate and retain for reinstallation. Strip paint from D062-2 hub. within limits found in Section9.320. Removecorrosionif necessary penetrant inspection or hub usingeitherdye penetrant fluorescent 4. fnspectDO62-2 procedures. 5. Visually inspect for indicationsof damage, wear, nicks, dings and corrosion. inspect any suspect areas to ensure they are within the limits Dimensionally the outlinedbelow. lf a part fails to meet any of the followingspecifications, part (seeFigure9-1). or must be scrapped sent back to RHCfor further inspection Inspection 9.42O Dimensional DO62-2 Hub (Elastomeric) or condition gal l i ng bor Bear ing esfor over size 1 . C h e ck 1 .3 4 3 5 t1 .3 4 3 0d i a meter - 1 . 3 4 4 5m a x . from distortionallowed no 2. Check bolt holesfor elongation, elongation (reference Figure9-1).

3 . C h e cka rmsa re fl a t w i th i n O.010 inch bow end to end'

inch max as shown in Figur e9- 1. n 4 . C h e cka rm stra i g h tn e ss o tto exceedO.O1O

5 . No corrosionallowedon clamp-upsurfaces. Blendto 0.002 inch max in clampto , p a r e a s,o th e r a re a sma y be blended o.o1o inch max depth.

REASSEMB-LY TAILROTOR 9.500 COOs lnstallation 9.510 Hub Bearing 9.215. hub per Section into bearings DO62-2 8361-2Elastomeric Install

Page9.42

14: JUL 2OO8 Change

FICIBINEiCIN

MATNTENANcE MANUAL

M(IEIEL

1f,.44

1.3435/1.3430 1.344MAX (TWO PLACES}

o . 0 1 0T I R (TWOPLACES)

0 . 3 1 7 / 0 . 3 1D I A M E T E R 5 TWO PLACES THRU

o . o 1 0T I R

S D R 0 . 3 1 5 / 0 . 3 ' I 4 I A M E T EN E A R I D E R O , 4 3 7 8 1 O . 4 3D 5A M E T EF A RS I D E 7I (TWOPLACES)

INSPECTION HUB DIMENSIONAL 9 F IGU R E .1 5 T A IL R OTOR Change1 4 : J U L 2 0 0 8 Page9.43

FIClBINElclN

MATNTENANcE MANUAL

MOE'EL

F|44

Assemblv TailRotorBlade 9.520 CO08-2 blademountboltsblack. 1. Paintheads NAS66O5 of

hol inboard es inch diameter 2 . t n s t a l f(1 ) C 1 3 8 -1 b u sh i n gi nto each0.43781O.4375 of hub arm until it is flush with insideface of arm per Section 1.45O - approved wet primer. 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 they are installedin correct position. a preconeangle. Ensure 4. Installsecondtail rotor blade with pitch horn pointing in the oppositedirection. alignholesand installNAS6605-31boltsand attachinghardware spacers, Position facing uP. with bolt heads p 5 . B a l an ce e r S e cti o n9 .5 0 0 . a 6 . V e r i fy p re co n e n g l e(ti p sa ngletowar d C138- 1 bushings) . nuts per Section1.320. Installpalnuts,torque per Section 7 . Torqueall MS21O42L5 1 . 3 2 O,a n d to rq u estri p ep e r Figur e2- 1. Tail Rotor BladeAssemblv 9.53O COOS-4 1. Paintheadsof NAS6605 blademount bolts black. D 2 . Pr e pa re 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 alignholes,installNAS6605- 31and - 35 l e f t . P o si ti o nC 1 3 7 -1a n d - 2 spacer s, bolts and attachinghardwarewith bolt headsfacing up, but DO NOT TOROUE. 4. Installsecondtail rotor blade with pitch horn pointing in the oppositedirection. alignholesand installNAS66O5-31and -35 bolts and attaching Positionspacers, hardwarewith bolt headsfacing up. p 5 . B a l an ce e r S e cti o n9 .5 0 0 . a 6 . V e r ify p re co n e 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. 14: Change JUL 2008 Pa g e9 . 4 4

3 . Refer to Figure 9-3. Hold DO62-1 hub horizontalwith bushingsfacing down.

FICIBINSiC|N

MATNTENANcE MANUAL

M()trEL n44

>2

o
TAIL ROTORASSEMBLY 9 FIGURE - 1 6 COOS-4 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 bearing 7 Elastomeric 8 Balance Washers I Hub 10 Tail RotorBlade 11 Bushing 12 Bumper Pa ge9.45

FIClBINSiclN

MAINTENANcE MANUAL

MODEL ]r44

FOURALUMINUMSPANWISE ON WASHERS BALANCE BLADE HEAVIER

Cl37.2 SPACER

OUTBOARD) {LARGER, (to NAS66O4-17 -22) BOLT

(as required) 8345 PITCHLINK (TWO MUST BE SAME PLACES; TYPEAND MATERIAL)

4 A 1 4 1 - 1 , A 2 1 4 - 3 ,N A S 1 1 4 9 F O 4 6 3 P (AS WASHERS OR NASl149FO432P FOR BALANCE) REOUIRED 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 G2 R e q ' d ) ( C 1 3 7 - 1S P A C E R6 R e q ' d )

(LARGER SPACER OUTBOARD)

c137-2 SPACER

WASHERS BALANCE FOURSPANWISE CLOSEST (PLACE WASHERS LARGEST TO HUB ASSEMBLY}

9-17 TAIL ROTORINSTALLATION FIGURE P a g e9 . 4 6 Change1 4 : J U L 2 O O 8

FICIEIINEIC|N

MATNTENANcE lrnANUAL

MOE,EL

F|44

COOS-2 and -4 ASSEMBLIES 9.600 STATICBALANCING 9.610 ChordwiseStatic Balance with ( 1) NAS66O6-53 t bol 1 . I n s t al lMT 1 7 9 -4 b a l a n ceb ar into tail r otor assem bly (1) MS 2 1O4 2 L O u t a s shown in Figur e9- 18. Tor queto 350 in.- lb. n and assemblywith MT179-4 balancingbar installedon Anderson2O 2. PlaceCOOS-4 balancingstand, and determinewhich CO29-2blade is heavieras or equivalent s h o wn i n F i g u re9 -1 9 .

BOLT NAS66O6-53

m
.\ / MS21042L6 NUT

ffi
,P

MT179-4 BALANCING BAR

TAIL ROTORFORBALANCING 9-18 PREPARING FIGURE

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

Page9.47

FIC|BINEICIN

MATNTENANcE MANUAL

MOE'EL

F,44

IS LIGHTEA-? THIS THE

EDGE FIRST FALLSTRAILING

FIRST EDGE FALLSLEADING BLADE. THIS IS HEAVIER

SHOWN ASSEMBLY TAIL ROTOR COOS-4

l$i
N./

BAR MT179.4 BALANCE

2O ANDERSON (Or Equivalent) STAND BALANCING

.a'

BLADE HEAVIEST 9-19 DETERMINING FIGURE

P a g e9 . 4 8

1 Change 4: JUL 2008

FICIBINEiCIN

MATNTENANcE MANUAL

MCIEIEL FI44

9.610 ChordwiseStatic Balance(Cont'd) 3. Prepare NAS66O4-17bolts as shown in Figure9-20. {2)

B 11 5 - 1 B E A R I N G

BOLT NAS6604.17

A214-3 WASHER

4115.1SPA

BALANCE BOLT FORCHORDWISE FIGURE 9.20 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 N A S 11 4 9 F O4 3 2 P r A 1 4 1 - 14 washer sand ( 1) 8330- 13 palnuton lighttai l r otor bfadeto bring chordwisebalance(see Figure9-21l'. NOTE Bolt length may vary from NAS6604- 17to NAS6604-22 tor requirementsand also to ensure proper locking of balancing: the fastener after washers are added (see R44 MM Section 1.320).

1 Change 4: JUL2008

P a g e9 . 4 9

FIclElINEiClN

MAINTENANcE MANUAL

MOE,EL

1'.44

HEAVYBLADE

9,/ @'
I

3 8330-1 PALNUT / I NAS1149Fo432P f ,/ wASHER

THRU.22 NAS66O4-17 BOLT

i ,.1xl /'-l-r'rRso604-1 7 BoLr 11 wASHER if llI ;l l. I aztq's

+l, \il $fli @ \ 'lll lrunst NUr o42L4 l tvtszt

\tJ sencen A11s-1

A115-1 "rOrr
/{l+f

\H A214-3wesHen

\^e
\b fl

(2 Req'dl ilfll||ltlllfliftlf'AcERwASHER v' 149Fo432P

Yt
*-

+l

PALNUT I B33o-13

BEARING_+$

1ilN\rDEN'FYNUrsrDE
FELTTIP MARKER

\ al\) 3i'J1"'il3fl,''I'fl1+-

WA R o R N AS 1 1 4 eF o 4 6 3 PS H E{n s -1 5
requiredfor chordwise balancel N MS21O42L4 UT

l+, l fitrv'+Jzr, \z l+-.t, \lAol A141--14, IA214-3, lNASl 1. 49FO432P,

l a'ilr) K

a
LIGHTBLADE

8330.13PALNUT

SHOWN ASSEMBLY COOB. TAIL ROTOR

STATIC BALANCE 9 F IGU R E -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 NAS1149D0432K,NAS1149D0463K,or A1 411. I n sta l lN A S 11 4 9 F O4 6 3 P, 14 washers as requiredonto outboardtail rotor mount bolts {minimumof four NAS1149DO463Kwasherson the heavy blade)to bring in spanwise balanceas shown in Figure9-94). can be achieved span and chordwisebalance. Chordadjustments 2. Recheck or A b y e xch a n g i n g 1 4 1 -1 4, A214- 3,NAS1149FO432P, NAS1149FO463P washers.

WARNING There must be at least four washers under each nut at outboard mount bolts

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

P a g e9 . 5 1

FIclBINSclN

MAINTENANcE MANUAL

M!]EIEL

F,44

LIGHTBLADE , N A S l 1 4 9 D 0 5 3 2 KN A S l 1 4 9 D 0 5 6 3 K , c008-4 , N A S l 1 4 9 F O 5 6 3 PA N 9 7 0 - 5 , O B A 1 4 1 - 2 0 ASSEMBLY W A S H E R S S R E O U I R E T O B R I N GI N TAILROTOR D A BALANCE, SPANWISE

H E A V YB L A D E A I N S T A L L M I N I M U MO F { 4 } N A S l 14 9 D O 5 6 3 KW A S H E R S .

t
)
I

ee;

7-'.,
\!/

t
I

- -/ -/l 20 ANDERSON t BALANCING ./,-\ t\)

STAND I--I

I t"' I I
I
I
\ - - - - l

\ \ \ \ \ \ \ I

F
l I I l

===:=r=-l\,
-1

r\l \ iz
\

r
I I

It
I '

\i
rl ll !

l
I

g-22 COOS-4 STATICBALANCE SPANWISE FIGURE

P a g e9 . 5 2

1 Change 4: JUL 2008

FICIBINEiCIN

MATNTENANcE MANUAL

MC'E EL H,44

I.D. PLATE

ASSEMBLY TAIL ROTOR COOS-4

I.D.PLATE

I.D.PLATE

PLATEPLACEMENT FIGURE 9-23 IDENTIFICATION

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

Pa ge9.53

FICIBINSiCIN

MATNTENANcE MANUAL

MOE EL ]t44

9.63O FinalAssemblv bar MT 1 . R e r n o ve 1 7 9 -4 b a l a n ci ng fr om tail r otor assem bly. NAS66O4-53bolt and MS21O42L4nut into tail rotor assembly. 2. Reinstall plate on DO62-1tail rotor hub as shown in Figure9-9, and 3. Installidentification plateson them. ensurethat both CO29tail rotor bladeshave identification 4. Final inspect C0O8 tail rotor assembly checking for precone angle and that NAS66O4bolt headsare paintedblack.

P a g e9 . 5 4

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

o
10. RIGGING, TRACK AND BALANCE

FICIBINEICIN

MATNTENANcE MANUAL

MOEIEL

F|44

1O SECTION TRACK,AND BALANCE RIGGING, TFACK..qNDBALANCE RIGGING. 1O.O0O 10.001 Introduction Procedures 10.002 Rod EndAdjustment 10.100 RIGGING 10.110 Main RotorFlightControls 10.111 CyclicControls 1O.112 Swashplate 10.113 Control Collective

10.120 MainRotor 10.121 CyclicTravelRigging TravelRigging 10.122 Collective 10.130 Tail RotorFlightControls 3 10.1 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 TRACKAND BALANCE 1O.2OO Requirements 10.210 Equipment Installation 1O.22O Equipment Installation 10.221 Main RotorEquipment

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

1 Page 0.i

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MAINTENANcE

MANUAL

MlfE,EL]e,44

(cont'dl TRACKAND BALANCE 1O.2OO Installation 10.222 Tail RotorEquipment Procedure 10.230 Main RotorTrackand Balance Adiustments 10.231 Main RotorBalance 10.232 Main RotorPitchLink Adiustment Trim Tab Adjustment 10.233 Main RotorBlade Trouble-Shooting 10.294 Main RotorTrack and Balance Procedure 1O.24O Tail RotorBalance RPMAdjustment 10.250 Autorotational

P a g e1 O . i i

1 Change : 2 Jul93

FICIBINSCIN

MATNTENANcE MANUAL 1O SECTION AND BALANCE RIGGING, TRACK,

M('EIEL

F44

TRACK, AND BALANCE 1O.OOO RIGGING, Introduction 1O.OO1

This section contains proceduresnecessaryto rig the main rotor flight controls, tail in rotor flight controls and throttle correlation. The track and balanceprocedures this balancingequipment section are to be used in conjunction with Chadwick-Helmuth 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 is The following procedure standardfor adjustmentof rod ends: 1. Loosenpalnut and jam nut on rod end shank. 2. Screw rod end in or out of push-pull to tube or pitch link as required obtainproper riggingadjustment. 3. After any rod end adjustment,verify rod end threadedshank blocks passageof tube or pitch link inch diameterwire thru the witness hole in the push-pull O.O2O 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-pull tube 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. Decrease angleby screwingfitting into lower pitch link. One f u l l tu rn ch a n g e s l a d eangleby appr oximately O.88 degr ees. b

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

P a g e1 0 . 1

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MAINTENANeE MANUAL

MlfE'EL

F|44

(cont'd) for 1O.OO2Rod End AdiustmentProcedures Rigging are b. Mediumlengthadjustments madeby rotatingupperlodend olly'Disconnect by blade.angle. rod ends from blade ano looien rod bnd jam-nuts..lncrease angle by. screwing-rode.nd^in19 pitlh link. Decreise unscredini-ioo 0.48 iurn changesblade ingle-by approximately full rod pitch tint."One ""i]-r "r|o degrees.

'ff adius11",:f^?:'^T:3:P;'o,t:ll3-o,:'J c. Fine.rensth remainconnected.Loosenja.m.nutsat upper-.rot =t3ru3;3JJl51e;jjt;"e to*6t rod'ends

angleby screwing I']lilg in irt" riOOi"ot piti,f,iin[.-lnCt"a"eblade "na in rha rnirldla ^f nitch link- lncrease blade an-qle bv.screwiryfitti
pltcr fitting into-lower by bv utto"-tnsle scre*iry.I1$ i*o"l:Y:r pjtchlink' decrease i;il; pit"f,iint. d;;;;"* blade.angle screwing i;;; pit"r,iinri. O'40 degrees' approximatelv arigle O;;iJlilrrn ot tltiingihang"s blade

9u.1 9f

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 1 19-.1 1 Cvclic Controls and is controlledby the The cyclic control travel is non-adjustable attacliedto cyclic box assemblY' NOTE The following push-pulltube assembliesand fork assembly UetweLntfre [.eblpanelsare to be adjustedto the noted centerto-centerdimensions: A211-2 stop plate

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 and at mid-point of total biiiii"" irTo in"rrel io-in._right of full-left travel full fore and aft travel or use MTs59-1 iigging blocks. Placecollectivecontrol down.
b ) Apply full cyclic and collectivefriction'

NOTE Care must be taken not to move cyclic control from neutral

P a g e1 0 . 2

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

FICIBINSCIN

MATNTENANcE MANUAL

MOEIELF|44

VIEhlLOOKING Fl,lD

T'---: L]
FULL LEFT

CYCLICCONTROL LATERAL NEUTRAL POSITION

TMVEL TOTAL TRAVEL MID POINTOF TOTAL CONTROL CYCLIC LONGITUDINAL NEUTRAL POSITION FULLFORl,l

POSITION STICK NEUTRAL F IGU R1 0 .1 CYCLICCONTROL E

2: Change 12 Dec 94

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FIOBINSC|N

MATNTENANcE MANUAL

MOEIELF4

10.112 SwashPlate

a constant aoilsi'ir,'d-ciiit;f,d ql2\i puln-prttigb^ep^tg'obtain 1o-2}. MT146-2 ?iiti'if, r.beg {seeFisure '6d oi 6r fromthe franse ine czgr-r to as u-sed a spacer set the 1.o69 inch iri'd}ib'r"t6-iigsiig6i6"rc r.i
dimension. Control 10.113 Collective

controlslockedin positionper section 1o'111' with the cyclic and collective clearance

full this since the coltectivesliderstop is non-adiustable,. check is.t9 ensure with the swashplatetravel. coniib-rl,ivliis 6uiiineo ind-oobs nof inter'fere al Lift the swashplateboot so the uniballand slidertube may be observed' o bl pull the coilectivecontrol f,u!l.up, The uniballmust be flush with the top inbhes.lf this doesnot occur, turn the upper ot tni-lriOiiiu6e wiiniii-O.O3 to tubes in or out equallv roo e-noioi ine-crzi:b6d Cizt-7 push-pull raiseor lower the swashplate. 1O.120 Main Rotor Bladea,ngle the The main rotor is riggedby determining avrageblade-angle. main rotor (or 49.5 inchesin from o]zs-raoiusoithe ;iiil aiJiir; measurem"nrc the bladetipl.

[%'J]qJ$yl".T ,YJ,?i'* . rerrll,3,Tiltil3"?i"J.1,3lBi?1,'##T,1t3ffi1'?;lf to 0se tne followingpr6cedure set up for rigging:

are.setto the-properlength a) Verify that the A2O5-5forks at the swashpla.te centdr lines, the lower fork assemblv tb (see Figure 1O-3). rvrga_i,;iinl oof should be 3.85 shoutdffi 3.tb-; ij.oiiriin-eJ and the upperforli assembly * O.O3inches. bl Levetthe rotorcraftper Section1,22O(Method2, Main Rotor Hubl' cl Placea trackingstick at the end of one rotor bladeand markthe heightof the

rotor track of * 1 inch' to Teeter the main rotor as necessJry obtain a m-ain dl ;feuei'ffeie;.-ffre protractorto the main rotor hub at the location marked -' zero the propeller drotractormusi be placedparallelto ths teeter hinge bolt'

btade notrir-ih. ;i;'iab; tip.

blade tip' the Jnornart< heish! 911!-.:PL9tlt"

Page10.4

Change 2: 12 Dec 94

FIClBINEiclN

MATNTENANcE MANUAL

MOEIEL

F'44

INCHAT TOP OF BALL FLUSHWITH TUBEWITHINO.O3O COLLECTIVE FULL.UP

LOWER,NON-ROTATING SWASHPLATE

h ) 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 S i g h 0.969 INCHhigh MT'|46-3 (usewith CO17-4Swashplate)

CLEARANCE FIGURE 1O-2 LOWERSWASHPLATE

(Rotating) 0.03 INCHES UPPER - LOWER(Non-Rotating) 0.03 ]NCHES

FOR 1 F IGU R E O-3 A 2O5.5FORKDIM ENSIONS SCISSORS SWASHPLATE

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

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FIGIBINSICIN

MAINTENANcE

MANUAL

MtfEIEL

]r44

PROTRACTOR PROPELLER

0
MT525-1 MAIN ROTOR F RIGGING IXTURE

tlt--h' s.Q:;,
BLADE MAIN ROTOR

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 1O-4 PLACEMENT PROTRACTOR FIGURE

Page1O.6

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FICIBINSiCIN

MATNTENANcE MANUAL

MOEIEL ]l+4

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 the face or dial of the tape. When makingbladeanglereadings, 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. such as red or blue. This f) Mark each rotor bladewith a differentcolor designation 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. priorto measuring Hydraulic flight controlsmust be pressurized
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 . axis of the b) Rotatethe bladesso the pitch links are alignedwith the longitudinal Placethe tracking stick at one of the blade tips for referencewhen helicopter. rotatingthe rotor.

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

P a g e1 O . 7

FIGIBINSCIN

MATNTENANcE MANUAL

MOE EL F|44

{cont'd) 1O.121 CyclicTravelRigging cYclic: c) Forwardlongitudinal 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 . oa:
-

required) 4.25 13.50degrees | 11

Red BladePosition Pitch horn aft Pitch horn forward

CyclicFullForward
o +2=

o nose up o nose down

requireO) t tl +.ZS I g.SOOegrees full turn : 2l Adjust the aft swashplatepush-pulltube as required_{one 0 .4 4 o ) to o b ta i n b l ade anjle aver agesbetween 13.500 and 14.250. adjusting the is adiustmen-t availible by simultaneo.usly Additionafc-oarse both must be adjustedexactly the tubes but they two forwarOpusfr-pull sa mea mo u n t. cYclic: d) Aft longitudinal 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

required) (14.251 13.50 degrees Red BladePosition Pitch horn aft Pitch horn forward Cvclic Full Aft nose down --o o nose up +
o +2 =-o

required) 13.50 degrees 4.251 11

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Change9: FE B2OO3

FICIEIINSiCIN

MATNTENANeE MANUAL

MC'EIEL ]t44

(co 1 0 . 1 2 1 C ycl i cT ra ve lR i g g i n g nt' d) tube as required(one full turn : 0.440) to 3) Adjust the aft swashplatepush-pull obtain blade angle averagesbetween 13.50o and 14.250. Additionalcoarse adjustingthe two forward push-pull adjustmentis availableby simultaneously tubes, but they both rnust be adjustedexactly the same amount.

NOTE blade angles, aft to lf adjustment required obtain cycliccontrol is

the forward cvclic must be rechecked. e) Left LateralCyclic: (mid travel)and hold 1) Placethe cyclic control in the neutralpositionlongitudinally 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

nose up nose down o Average -2= ( 8.5i7.5 degr ees equir ed) r

Red Blade Posilioq Cvclic Full Left Pitch horn right Pitch horn left +

nose up nose down o Average +2= ( 8.5/7.5degr ees equir e d) r

tubes as required(onefull turn = 0.6 4) Adjust eitherof the two forward push-pull to between7.5o and 8.5o. d e g r e e ) o b ta i nb l a d ea n gleaver ages f) Right lateralcyclic: (mid travel)and hold 1) Placethe cyclic control in the neutralpositionlongitudinally the cyclic againstthe right stop.

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

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FIclBINSiClN

MAINTENANcE MANUAL

MtfElEL

H.44

(co 1 0 . 1 2 1 C v c l i cT ra ve lR i g g i n g 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

nosedown noseup o Average +2= (7.0/6.0degrees required)

Red Blade Position Cvclic Full Risht Pitch horn right + Pitch horn left

nosedown noseup +2=

o Average

(7.Ol6.O degreesrequired) tubes as required(onefull turn = 0.6 3) Adjust eitherof the two forward push-pull between 6.0o and 7.oo. degree)to obtain bladeangteaverages

NOTE to is lf adjustment required obtainright cyclic control blade

angles,the left cyclic must be rechecked' T 1 0 . 1 2 2 C o l l e cti ve 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.
axisof the helicopter' b) Rotatethe main rotorto alignpitchlinkswith the longitudinal 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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Change9: FE B2003

FIclBINEiClN

MATNTENANcE MANUAL

M('EIEL

F|'44

(cont'd) TravelRigging 10.122 Collective NOTE The MT525-1 fixture is placedon top of the bladeat 49.5 inches from bladetip. The fixture must be heldtightly againstthe leading must be edoe to ensure accurate readings. All measurements readinqs. edge taken with protractorfacing markedblade. then rotate rotor 180o and againrecordangles. Adjust the pitch Recordbladeangles, of link of each bladeuntilthe two bladeanglesare within 0.2 degrees each other when pitch horn is in the forward position. Checkthe bladeangleswith each blade the blade pitch horn aft. Averageof these anglesmust be within O.2 degreesalso.

FULLDOWN COLLECTIVE
Blue Blade Pitch horn forward + _o Pitch horn aft o nose up nose up
o +2: o

Red Blade + _o o noseup nose up

o +2= o

(1.Ol2.O required) degrees d) Raisecollectivecontrol to the full up position. Apply full collectivefriction. below. the bladeanglesper Step c) above and recordaverages Measure 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:

for (Average12.5o113.5o required rigging; degreesabove collective-down will determinefinal angle) rpm adjustment autorotation main rotor per Section10.200e) Trackand balance 1 0 . 1 3 0T a i ln o to r H i sh t C o n

(See 1o-5) 1o.rcl Pedqlg Figure

riggingis accomplished follows: as Pedal diameter rigging pin through the hole in the right-handkeel a) Insert a 3116-inch paneland the riggingpin holesin the C317-1 bellcrank. of to tubes as required obtain a dimension 2.9O b) Adjust the C121-9 push-pull pedal to the right hand stop locatedon the side of the t O.O3inchesfrom the forward console(doesnot apply to heliIopterswith6ut stop on lower console). 1 Change 4:JUL 2OOB P a g e1 0 , 11

FICIBINEICIN

MAINTENANcE

MANUAL

MOEIEL

F|44

{S 10.132 C 3 1 6 B e l l cra n k 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.3q 0.5 p u l h - q u .t9.- -1 ano butkhead rod-end f,eiw"en"c316-1 tubeto obtaino.1O- O.20inches ibif,"ti"opterswithoutpedalstopon lowerconsole). 33 1O.1 A12O-3 Bellcrank
to With left pedalat stop, adjustthe C121-17 push-pulltube length as.required assembly and the obtainO.35 t O.O3inch betweeni*o tac"i of fitctr control (SeeFigure 10-71. housing.

10.134 Tail RotorPitch!=i!rlq

inchesbetween r od end Adjust the pitch links to a dimensionof 2.620 + O.O1O 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). to b) Rotatethe tail rotor until the bladesare parallel the tailcone. c) Tape a trackingstick to the tailconeat the tip of the fwd blade'

NOTE
sti A tra cki n g 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 bladepasses. is e ) Rotatethe tail rotor 180o, using the forward flex couplingso.teeterangl-e stick. Mark not disturbed,uniil tf,e oppoiitdbtade tip is alignedwith tracking the stick. the f) Teeter the tail rotor to positionthe blade tip 19 the mid point between the above marks. Rotatethe iail io[or anOcheck that th'ebladestrack. Repeat to procedure necessary track the tail rotor' as p..rii'the stick. stick. Ff#" bedal

s) Placethe left pedalagainstits stop. Mark the trackingstick .whergthe bladetip againstits stop and mark the tracking tfrl right

P a g e1 O . 1 2

1 Change 4: JUL 20OB

FICIBINSiCIN

MATNTENANeE MANUAL

MOEIEL

tt44

CONTROLS TAIL ROTOR

c317-1
BELL CRANK

RIGGING HOL E PIN

0 . 1 0- 0 . 2 0 i n . (t-ett pedalagain stop )

PEDAL STOP

c121-9 PUSH-PULL TUBE

1O- 5 TAIL ROTOR CONTROL FIGURI R PEDAL I G G I N G

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

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FICIBINSiCIN

MAINTENANeE MANUAL

M('EIEL

F|44

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 PITCH CONTROL ASSEMBLY

RIGGING BELL CRANK F IGU R1 0 -6 A12O- 3 E

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

FIClElINSiClN

MATNTENANcE MANUAL

M('clEL

H44

AFT MACHINED FACE c 1 4 8 - 1TAILCONE BULKHEAD CLOSURE

A12O-3 BELLCRANK

TUBE c121-17PUSH-PULL

-i (t ASSEMBLY I I TA|LROTOR \ .-l L

' . _ _(9J : ; re_: \ y -

tvr I ozo-z

Mrs2s-2
RIGGING FIXTURE \

INCHES FROMTIP DISTANCE BLADE OF TAIL ROTOR

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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FIEIBINSGIN

MAINTENANcE MANUAL

MoE'EL

A44

(co 1 O . 1 4 0T a i l R o to rR i g g i n g n t'd ) ' 2l Measurethe tail rotor blade anglesas follows: blue. a) Using a soft markeror greasepencilmark each bladeas red or maskingtape e b) Measurein from each blad 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 mas MT525-2fixturemuststraddle

bladeangleand recordbelow. Rotatetail protractormeasure e) using a propeller rotoi 18o degreesand recordoppositebladeangle' PedalsFull Left Blue Blade Red Blade + o nose right o nose right
o +2:

required) (18.511 degrees 9.O 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 replace blade(s).Co NOTE Adjustablepitch link jam nuts must be tight to ensureaccurate bladeanglemeasurements.

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

FIG|BINEiCIN

MATNTENANcE MANUAL

MC'DEL

F'44

(co 1 0 . 1 4 0 T a i l R o to rR i g g i n g 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 necessary obtain 18.5 to 19.0 degrees. to
g . Place right pedal against its stop. Measureblade angles and record below

using right pedaltrack mark. PedalsFull Right BlueBlade Red Blade +

o nose left

o nose left
o -2:

(15.5/16.5 degrees required) tube as necessary obtain bladeanglesof 15.5 to to h. Adjust C121-17 push-pull 16.5degrees.

NOTE left lf adjustment required obtainrightpedalbladeangles, is to

pedalanglesmust be rechecked. i. lf bladeanglerange,for left and right pedalsettings,cannot be obtainedusing this indicatespedaltravel is either too great or too small. above procedure, to Use following procedure 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 left pedaltr avel, de c r eas e tube. To incr ease l e n g th o f C 1 2 1 -9 p ush- pull push-pull tube. length of C343-3 P a g e1 0 . 1 7

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

FlclBINBClN

MAINTENANeE MANUAL

MOE'EL

H44

COLLECTIVE

------.-\
a\

J\
\

/\ ' \ /t \ /\

7t PUSH.PULL /t
OVERTRAVEL SPRING ASSEMBLY

c336
PUSH-PULL TUBE

/ TUBE

FORWARD

ts

,l

i\
\_---AND THROTTLE COLLECTIVE F U L L YC L O S E D I D L ER P M ADJUSTMENT TOROUE NUT 20-60 SCREW POUNDS INCH

.,

\ \ \ \ \ \

PIN COTTER MS24665-132 THROTTLE STOP

(X.BURETOR
c336
PUSH-PULL TUBE

o . 0 1 0- 0 . 0 3 0l N c H
P L THROTTLE EVER OSITION C A R BF U L LO P E N
27,50!7.50

la

9.o*t
RIGGING CORRELATION 10.8 THROTTLE FIGURE (CARBURETED SHIPS} P a g e1 0 . 1 8 Change1 4 : J U L 2 0 0 8

FIclElINSiclN

MAINTENANCE

MANUAL

MOEIEL

F.44

COLLECTIVE

ll

i\

FORWARD

3l

JI

/\

PUSH.PULL

OVERTRAVEL SPRING ASSEMBLY

,/'1"'

A336 PUSH-PULL TUBE

FUELCONTROL

WITH FULL-UP 3.OOINCHES COLLECTIVE AND THROTTLE FULLYCLOSED

F U E LC O N T R O L

0 . 0 1 0- 0 . 0 3 0
IDLERPM

-V
\

r ADJUSTM ENT VIEW ' ' 4"

(VIEWLOOKING AFT}

ull

RIGGING FIGURE 1O-8A THROTTLE CORRELATION (F U EL INJECTED SHIPSI C h a n g e1 4 : J U L 2 O O 8 P a g e1 0 . 1 8 A

FIClBINEiclN

MAINTENANeE MANUAL

MOETEL F|44

blank IntentionallY

P a g e1 0 . 1 8 8

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

FICIBINSiCIN

MATNTENANcE MANUAL

MOEIEL

N44

(cont'd) 10.140 Tail RotorRigging 3) To decrease total travel,shortenthe C121-9 push-pull the tube for right pedal travel and increasethe length of C343-3 or C343-9 push-pulltube for left I pedaltravel. 4) Recheck the tail rotor bladeanglesper steps e) through h) above. j) Ensureall rod ends are installed properlyby checkingthe push-pulltubewitness holes.Tightenall rod end palnutsand jam nuts. Torquestripe all nuts. k) Balance rotor per Section10.240. tail (seeFigure10-8) 10.150 ThrottleCorrelation Rigging For in-service check and adjustment: and throttle closed. 1. Verify idlerpm is correctwith enginewarm, clutchfully engaged, Adjust 0-540 idle to 53-57o/o and lO-540 idle to 58-620/o. 2. Shut down helicopter. to 3. Rotatetwist-grip throttle fully closedthrough overtravelspring pressure positive stop. Holdingthrottle tight against stop, raise collectivefull up while observing throttle arm on carburetor fuel control,as applicable.Throttle arm should move or 0.O10-0.030inch off of idle stop screw when collectiveup-stopis reached. or tube at carburetor fuel control,as 4. lf necessary, adjustlengthof throttle push-pull applicable. 5. Standardtorque jam nut(s) per Section 1.32O, check witness holes, and torque stripeper Figure2-1. 10.160 ActuatorRigging belt No field adjustmentof actuator-engaged tensionis permitted. Adjust actuator'sdownlimit stop screw so there is a delayof lessthan 5 secondsbeforerotor starts turning when actuatoris engagedat start up. 1O.2OO TRACKAND BALANCE Vibrex system, the TEC ACES system, the Dynamic Solutions The Chadwick-Helmuth Systems' MicroVib system, or equivalentequipmentis requiredto perform dynamic rotor balancing and in-flighttrackingchecks. I

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

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MAINTENANcE

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MOEIEL

F|44

Requirements 10.210 Equipment 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 equiPment or equivalent b) Strobex Chadwick-Helmuth ModelNumber 135M-10* 1 3 5 M - 1 0 A * B * a n dC * , 1 135M-1 equiPment or equivalent

* 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;; pickupc abl e Magnetic 10808- 25 33tg- t or Accelerometer 4177 AccelerometerCable 4296-1 and -2 Target Patches 33OO Target Patches 4270 Velocimeter 7310 VelocimeterCable 112i}-2ot-5o * d) Brackets* R o b i n s oM T 1 2 1 - 1MagneticPickuPBracket n e) Charts*" Robinson Main Rotor Chart Tail RotorChart

** As required the balancing beingused. equipment by lnstallation 10.220 EquiPment (seeFigure1O-9A) lnstallation 10.221 Main RotorEquipment Refer to specific manufacturer'sinstallationinstructions when using .balancing equipmentas tnin oraowic[-uelmuth, InstallChadwick-Helmuth Lquip..,.'"nrbiri"i f o l l o w s: attachment under the a) Install accelerometer/velocimeter the upperconsoleleft-side screw with cableconnectorpointingoutboard'

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FICIE|INSCIN

MATNTENANcE MANUAL

M(IE'ELF'44

WIDTH TARGET
IJ.J

a/,

= z
tt'l

o-

4270 ttl.R. TARGET

F IGU R1 0 .9 MAIN E ROTOR TARGET PATCH LOCATION

Change 12 Dec 94 2:

Page10.21

FICIBINEiCIN

MAINTENANeE rvtANUAL

M3fElELF,44

TAPE DUCT

3030 MGNETIC PICKUP

4777 ACCELEROMETER

BALANCING 10.9A MAINROTOR FIGURE INSTALLATION PMENT EQUI

Pag e 1 0 . 2 2

6: Change 18 MAR99

FICIBINSCIN

MATNTENANcE MANUAL

MC'E EL F|44

10.221 Main RotorEquipment Installation {cont'dl b) Install MT121-1 Bracket onto the lower right-handside of the swashplate. WABNING Ensure attachment bolts are torquedto 200 in.-lb plus nut drag.The MT121-1Bracket will remain installedfor in-flight track and balance. pickupontothe MT121-1Bracket. the the c) Install 3030 magnetic Set pickupgap to 0.030" t O.O1O". interrupter pickup.Pullcollectivestick full up dl Attachthe cableto the magnetic and cyclic stick full left. Securethe cableto the mast fairing with duct tape. Route the cableto the lowerfront of the left door frame. Secure cableevery 12 incheswith duct tape. the CAUTION Security of the cable is essentialas the helicopter be flown at Vne. will mountedon the e) Attach the cableto the accelerometer/velocimeter Securewith duct tape. forwardholddown screwof the console. left CAUTION Ensure the cable cannot becomeentangled with tail rotor pedals. and secureexcesscableto the f) Attach the cablesto the balancer in front of the left seat. bracket g) Appfy the 427Otargettapesto the main rotor bladesper 10-9. Figure I I

Change 2 Jul 93 1:

Page10.23

FICIBINEiCIN

MAINTENANcE MANUAL

MOEIELF,44

10-9C and 1O-gD) (seeFigures Installation 10.222 Tail RotorEquipment

no smooth, debriiJnoer-tip'c6vers..isqu?l9,Ipelastomeric and 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 shown in Figure1O-gC' between velocimeleianOvelocimeterbracket sp.anwisefacing a, 3 . lf using Strobex to obtain clock angle,.-install tl1get. tape. photocell 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

are clean and Prior to installingbalancingequipment,verify b]ad.e.s

;66F1 f"fi;;d ;;d ffit

tape.

times. several .iouno taitcone

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 1n*"rn"nt. tt-riing ph.otocellto obtain clock angle, cables 6-d;;;"t "iUI" into cabin and seclured with duct tape to prevent cable may be ,orteJ movement. to 6. Connectcable(s) balancer.

Pag e1 0 . 2 4

9: Change FEB2OO3

FICIBINSICIN

MATNTENANeEMANuAL
TAPE

MC'EIEL

H44

(S) cABLE

BALANCERSTROBEX

OPTIONAL CABLE ROUTING PHOTOCELL }{HEN USING

CABLE

ACCELERoMETER/V ELoCMETER r
PHOTOCELL IF USED)

oc)o

_5..J

TARGET TAPE (TNSTALL SH0l^lN AS USING l^lHEN STROBEX. INSTALL ON INBOARD PER SIDE FIGURE 10.9D}IHEN PH0T0CEL L.) usr NG

FIGURE 1O-gC INSTALLATION TAIL ROTORBALANCINGEOUIPMENT

Ch a n g e9 : F E B2 OO3

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FICIE|INEICIN

MAINTEIUANcE

wIANUAL

MCIE'EL

F|dIA

reauT oFPHorocELL I

TARGET ENSURE TAPEIS IN PATH

PHOTOCELL

o
(vrEw LooKlNG FORWARDI

FIGURE1O-9D INSTALLATION PHOTOCELL TAIL ROTOR

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FIclBINEic|N

MATNTENANeE MANuAL

MOE'EL

FI44

10.230 Main RotorTrack and BalanceProcedure NOTE Priorto installing balancing verify bladesare cleanand equipment, smooth, rod ends and sphericalbearingsplay are within limits, corrept swas;tplatetilting friction, and correct teeter and coning hingefrictions. In-flight track and balance is accomplished using 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 e rt 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 a track at each airspeed and 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. within 3i8 5. RepeatSteps 3 & 4 as requireduntil track will remainon at all airspeeds inch. main rotor balancein a hover (maximumO.2 IPS). 6. Readjust RPM per Section 10.250. Adjust as required. 7. Check autorotational aircraftonly). 8. Evaluate collectivetrim and adjust as required(non-hydraulic in 9. Checkmain rotor balance a hover. Adjustas required.

1 Cha n g e 4 : J UL 2 OO8

Page10.27

FIclBINSiClN

MAINTENANeE MANUAL

MOE EL F|44

(cont'd) 10.230 Main Rotor Track and BalanceProcedure 10.231 Main Rotor BalanceAdiustments weight as indicated are adjustments madeby addingor subtracting Spanwisebalance and changing the chart. weight is changedby removing bladetip cover 1OL by the balance was her s or be c 2 9 8 t i p w e i g h ts. F i n ea d j u stmentsm ay made with AN960- 10 and also bY trimming washers. rotor hub (see by Coarseadjustmentof chordwisebalanceis accomplished shifting of chart. Fineadjustment chordwisebalance Sectiong.1241as indicatedon balance -2 chord weights or AN97O-4 by is accomplished 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 can be madeon the main rotor pitch link' coarseadjustment Two lengthadjustments from blade is made by looseningupper rod end jam nut, disconnectingrod end changestrack turn of rod end pitch horn and turning rod end up or down (one-half a p p r o xi ma te l0 .2 5 i n ch ). y Fine adjustmentis made by leavingrod end connectedto pitch horn and loosening barreljam nut, and then screwingbarrelup or down' One rod end jam nut, loosening can to barrelrevolutionis equivalent one-halfturn of rod end. Partialturns of barrel be made by countingnumberof hex flats rotated (see Figure10-11)' CAUTION After adjustingpitch tink,verify o.o2o inch diametersafety wire cannot pass through witness holes.

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FICIBINSC|N
SHIPS/N

MATNTENANcE MANuAL
I|AIN ROTOR M1vr a,,...

MC'EIEL FI44

Page

of Page

TRACKAND BALANCE C]|ART rro*tt;y rEou

,#T;,

"fflx'?r
.o30

l'louNT AccqLERoMETE;r 0NLEFT

SIDEOF CONSOLE POII'ITED LEFT

FOR}|ARD BLADE

t| rnrrnnuPTER oN ./
MAG PICK-UP

ARM INSIDE LEAD OF SWASHPLATE

SPANWISE NEIGHTS = (1)AN960-10 (2)AN960-101 WASHER WASHERS CHORD I.IEIGHTS ARM = (1)C298-2WEIGHT (5)Ar,1950-10 WASHERS = (1)A25s-1 = WASHERS (11)AN960-10 IIEIGHT IIASHERS (1)c298-3 |.lEIGHT (B)AN970-4 = (3)A255-1l.lEIGHTS (1)A255-2l,tEIcHT = (4)c298-3 wElcHTS (1)c298-4 hIEIGHT

( TRACKKNoTS)

I I
CHANGE I4ADE:

I I
I I

I
I

I I

I I I I

I I

I
I

I I
CIIANGE MDE:

I I I I
l I

I
I

I
I I l

I
I

I I 6: Change 18 MAR99

I I

I I

Page10.29

FICIEIINEiC|N

MAINTENANeE

MANIIAL

M(IEIEL

FI44

ROD UPPER END

HOLES I,IITNESS

LINK PITCH 10-11 MAINROTOR

I'11526-1 BENDER TAB

DOI.|N BEND
DIFFERENCE NOTE

ROTOR 10.12 MAIN FIGURE TABADJUSTMENT TRIM

BEND UP

P a g e1 0 . 3 0

5 Change : 15 Jun 98

FIGIBINSIGIN

MATNTENANcE MANUAL

MOEIEL r|.44

MT352-1 TRIMTAB
GAGE

DIAL INDICATOR SPINDLE

MT352-1 TRIMTAB GAGE TAB Too! bottom edge must contacttrim tab trailingedge. MEASUREHERE

3 MEASURING

EOUALLY SPACED

't

) -/ ,/

10.13 MAIN ROTOR TRIMTAB MEASUREMENT FIGURE

Change1 4 : J U L 2 0 0 8

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FIClBINSiclN

MAINTENANcE MANUAL

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]l'44

10.233 Main Rotor BladeTrim Tab Adiustment are made using the MTs26-1 .tab benderand Main rotor bladetrim tab adjustments 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. trim tab gagechordwiseacrossuppersurfaceof blade points.Place spacedmeasuring on a marked measuring and trim tab trailingedge with dial indtaior stylus resting measuring point. Set dial indiiator scale to zero. Similarlymeasureboth remaining pointsandverifytheyarewithin0.oo5inchoffirst. CAUTION MT352-lgagemustcontacttrimtabtrailingedge.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 Ensure tab trailingedge as far toward leadingedge as possible. bolt to bend contacts 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 bendingtrim tab upward can increase trim tab upward unlessabsolutelynecessary; 0.o15 inch will movetip o f m ai n A c y c l i cs ti ck sh a ke . tri m ta b b endof appr oxim ately trim tab with MT352-1 gage' Adjust 0.2 inch. Remeasure rotor bladeapproximately points within 0'OO5inch' to bend in trim tab as required keep three measuring CAUTION tools manufactured Do not use mainrotor bladetrim tab bending Use of these tools will by other helicopter manufacturers. damaqemain rotor blade.

Pa g e 1 0 . 3 2

1 Change 4: JUL 2OO8

FIClElINSiClN

MATNTENANcE MANUAL

MI]EIEL

F'44

10.234 Main Rotor Track and Balance Troubleshooting The following are some of the symptoms and correctionswhich occur in the Track and Balanceoperationsof the helicopter.Decideon the variouscausesof a given trouble with the most probable. and then eliminatecausesone by one, beginning Sy$pl"t 1. ProbableCause Correction Track and Balancewith ChadwickHelmuthBalancing Equipment Replace referto Section8.6 of or Maintenance Manual ServiceCenteror RHC replacement of SpindleBearings Featherin rough edgesor repaint

Cyclic Main RotorOut of Track Excessive or Stick Shake Roughor Binding42055 Fork Assy (Upper Swashplate) Brinelled SpindleBearing (roughmovement) Bladesurfacerough paint {chipped}

I I

pitch link rod ends for smooth Roughor BindingPitch links Replace operation boot or realign.Boot should M.R. BladeBoot Misaligned Replace

g,?"1: "j[ lj! 11',,"., fr ::fr travel ili?,1',i'..3 arc or

| I BendTrim Tabs down evenly of RHC replacement blade(s)

per Bearings Section9.126 M.R. Hub Teeteror Coning Replace or rework for smooth operation HingeBinding M.R. BladeTrim Tabs Bent Upward BladeMatch 2. Ship Excessive Vibration

with ChadwickMain Rotorout of Track and Track and Balance Equipment HelmuthBalancing Balance M.R. Hub Teeteror Coning Referto Section9.123 of Manual Maintenance HingeFrictionlmproperly Adjusted bearingper Section9' 126 or Sticky ConingHingeBearing Replace referto Section9.123 in M.R. Hub SpindleBearings Brinelled {roughmovement) of ServiceCenteror RHCreplacement SpindleBearing

per M.R. Hub bearings in Worn TeeterBearing M.R. Replace Section 9.126 Hub

Change JUL2005 12:

Page 10.33

F|CIBINEiCIN

MAINTENANeE MANUAL

MOEIEL

FI44

3.
4.

(cont'd) 10.234 Main Rotor Track and BalanceTroubleshooting Correction Probable ause Symptom -C, or Center RHC (rough Service SpindleBearings Cyclic Brinelled Excessive Bearings of replacement SPindle movement) StickForces

9.123 to Blade M.R. Hub Teeteror ConingHinge Refer Section lntermittent Friction lmproPerlY Adjusted TrackPicture

In Hinse glieky.coning Bearinss $:fl?"3ff?:1ff rt S::rtff'!l? M.R.Hub

Teeter Hinge not Broken-in Adjust track to minimizeerror (rough ServiceCenteror RHC SpindleBearings Brinelled Bearings of replacement SPindle movement) 5. in Changes Worn Teeter HingeBearings Radical M.R. Hub to CyclicTrirfr' M.R. Hub Bearings Replace Per Sebtion 9.126

(rough ServiceCenteror RHC SpindleBearings Brinelled of replacement SpindleBearings movement)

6.

or *"sneto ensrne Vibration Aircraft i%l'i?i,lSfi1;:

10.240 Tail Rotor BalanceProcedure

Lateral triil-rmittent

due misfiring to Engine il;]i,.;;iiiil in "spaltplugs,

to Refer Textron;Lyc.oming Instructions Maintenance

equipment instructionswhen using balancing installation Referto specificmanufacturer's Vibrex system. other than Chadwick-Helmuth equipmentper Section 10.222. Set FunctionKnob on Balancer tnstalfChadwick-Helmuth i;-;pprpiiite cf,"nnei. Set'b"lanc"r heM nange knob to X1O and set RPMto 231. With with Strobex. Tune Balancer 6lriJopi,irrrnning *iin go,r"rnorON, view taillolor assembly and *nile viewing taigei iaffand adjusiing RPlvldial on Balancer. Recordcl^oc_!.1qsle IPS is lessthan 0.2 lPS. on tail rotor Salinte ch'irt. Adju3t as rlquired until balance for Spanwisebalanceadjustments CO29-1square-tipbladesmade.byadding,subtracting, cover. Use C134-1 or:? tip weightsor oi-"ic6.nging weigfrfi-rnAerthe removable'tip -8L washersmay bd trimmed as a very fine adjustment. AN96O-B5r -Et-*i"1.t"r.. differenldiameter by arq for Spanwisebalance CO29-2round-tip.blades mad.e er<.changing has sufficientlength washersunder nut .""uilng bt"Oe'soritboardretainingbolt. The bolt changes;verify 2-4 threadsprotruding past nut after to allow n""".r"iy ;p;;i;t*"igf't torquingper Section1.320. AN96Oo.r Chordwisebalanceis adjustedby adding, s.ubJrgcting, exchang.ing.41.41L4, pitch link attaching.bolt. Cf."ngg pitch blade's 41Gor -416L washers under nut'securin-g lint, attacrringooii l"ngih as requiredfor-properthread engagement(see Section 1.300, lengths)' referto IPCfor allowable

P a g e1 0 . 3 4

1 Change 2: JUL 2OO5

FICIEIINSiCIN
SHIPS/N Page of Page

MAINTENANcE

MANuAL

MC'E'ELF,,44

COO8.2 TAIL ROTOR TIP IREMOVABI."E COVERSI TRACKAIID BALAI{CE CHART

TARGET BLADE REFLECTIVE TARGET

TARGET REFLECTIVE ITOUIITEO OPPOSITE ANYCHORD }'EIGHT INSTALLED PREVIOUSLY

BLANK BLADE
.^ . A -e8 ^ E

ACCELEROI,IETER IiOUNT I.IITH ONGEARBOx cONPOIIITED IIECTOR UP.

SPANI{ISE I.'EIGHTI = (2)AN960-81 I'IASHERS(1)AN960-8}IASHER = (14)AN960-81 I{ASHERS(t)C134-1 l.lEtGHT

CHORDI.IISE t,,EIGHTS = (1)AN960-416 (2)AN960-4161 HASHER WASHERS = (1)A141-14 (5)AN960-4161 I,TASHERS |{ASHER

RUN

CLOCK

IP S

CHANGE MADE BEFORE NEXTRUN

NOTE PROGRESS ANGLES CLOCK WITH PHOTOCELL, WHENUSINGVIBREX2OOO (11 o'CLOCKBECOMES o'CLOCK, 1 FROM12 o'CLOCK ANT|-CIOCKWISE MAN. 2OOO TO BECOMES O'CLOCK, ETCI. REFER VIBREX 2 10 O'CLOCK INSTRUCTIONS. UFACTURER'S

Change FEB2OO3 9:

Page10.35

FICIBINEICIN
SHI PS / N of Page Page -

MAINTENANcE

MAN

M('E

EL F|44

COO84TAIL BOTOR (ROUND.TIP BLADESI CHART' BALANCF TRACKAND

r.

TARGET BLADE REFLECTIVE TARGET TARGET REFLECTIVE OPPOSITE I,IOUNTED }IEIGHT CHORD ANY II{STALLED PREVIOUSLY

i-=-"1
Et- rl
e . @

$w;!*

'.?6
, 1 6 - A

:qa

2'

og? ,
Ga

BLANK
BLADE
'

vv? ,i! z

ot

'-.r3--Z
'aEJ-,
P4,

ACCELEROI4ETER I.OUNT I.,ITH CONONGEARBOX UP. POINTED I{ECTOR

?Ei
'rll.'

I.IEIGHTS SPANWISE

co-=' -rag z

}|EIGHTS CHORD}'|ISE

= (r)AN960-416 I{ASHER WASHERS I',ASHER (2)AN960-4161 (5)NAS1149F0563P = (l)C141-20 t'lASHEp5 = ulASHEs5 (1)A214-3hfAsHER = (1)At{970-5 }lAsHER (3.s)AN960-4r61 (13)NASll49F0s63P }IASHERS = }fASHERS(1)Ar4l-14 I{ASHER (5) At{960-4161

RUN

CLOCK

TPS

NEXT I.,IADE CHANGE BEFORE RUN

NOTE PROGRESS ANGLES CLOCK WITHPHOTOCELL, 2OOO VIBREX WHENUSING 1 (1',lo'cLocK BECOMES o'CLOCK' FROM12 o'CLOCK ANTI-CLOCKWISE MAN' 2OOO TO ETCI. REFER VIBREX 2 BECOMES O'CLOCK, 1OO'CLOCK INSTRUCTIONS. UFACTURER'S
P a g e1 0 . 3 5 A Change9: FEB2OO3

FICIEINSCIN

MATNTENANeEMANUAL

MorlEL p,41r

INTENTIONALLY BLANK

Change9: FEB2OO3

P a g e1 0 . 3 5 8

FICIBINEiC|N

MAINTENANeE MANUAL

MOEIEL]t,44

Usethefo||owingprocedureforcheckingandadjustingautorotationa|RPM: WARNING I I RPM-(RPM Failureto properlyadiust autorotational tne rotorcraftfrom achieving ioo lowl maV-preirent P.Per RPMbi low grossweights' gross weight' a) perform autorotation RPM check at less than 19OO lb Recordthe time on tn" Catcutate t"GJtt d.ir welght of the helicopter. the hour meter. Take-Offgrossweight Take-Offhourmeterreading performing the to bl set the altimeter 29.92".Hg (101.3.2.millibars).prior.to. againstthe firmly held control ini Autoiotate-wittr cottective autorotataon. of iiop with an airspeed 5O KIAS' Ooi"n 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 overthe speeding rotor.

I
I

I I

foot altitude intervals. at Take at least 3 RpM readings 5OOto l OOO Recordthe following in-flightdata: Test #
1

Hourmeter CJJOing OAT

Pressure Altitude

Test o6RPM

2 3
4 5

Page10.36

3: Change 5 May 95

FIOBINSiON

MATNTENANcE MANuAL

MODEL

F'44

-su#E
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cYl ol rl
C h a n g e1 O : J U L 2 0 0 4

FIClEINEiclN

MAINTENANcE MANUAL

MtftrtEL rf,'44

c) ri

q
o o
,F

to o r-{

o ct) c o
F

@ tt

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

P a g e1 0 . 3 8

HEATING AND VENTILATION

FICIBINSiCIN

MATNTENANeE MANuAL
SECTION1 1

MOEIEL

F|44

HEATING, VENTILATION AIRCONDITIONING AND 11.OOO AND VENTILATION HEATING 11.001 Introduction 11.OO2Description 11.1OOCABIN HEATER
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 Recovery 11.321 Refrigerant t 1 1. 3 2 2 R e fri g e ra nC h a rg e 11.323 Leak Detection 1 1 . 3 3 0 C o mp re sso r r 1 1 . 3 3 1 C o mp re ssoB e l t R e p lacement r 1 1. 3 3 2 C o mp re ssoR e mo va l r 1 1 . 3 3 3 C o mp re ssoIn sta l l a tion 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

AssemblY 1 1.34O Evaporator AssemblyRemoval 11.941 Evaporator "l1.342 Evaporator AssemblyInstallation r 1 1 . 3 4 3 E va P o ra toD ra i nS ystem 1 1.350 Full ThrottleCut-Out Switch Rigging

CARTEIpGE 11.400 DRIVE

S 1 1 . 4 1 0 D r i veC a rtri d g e e a l R e moval Seal Installation 11.42O Drive Cartridge

Page 1 f .ii

1 Change 4: JUL 2008

FIC|BINSCIN

MATNTENANGE MANuAL SECTION1 1 ANDVENTILATION HEATING

MCIE'EL

F'44

11.OOO ANDVENTILATION HEATING 11.001Introduction necessary replacement the heaterand for of This sectioncontainsthe procedures components. ventilation systems 11.OO2 Description The cabinheatersystemconsistsof a heatshroudoverthe muffler,a controlvalveon and the forwardsideof the firewall,an outletgrillforwardof the pilot'stail rotorpedals, by Air is supplied the enginecooling ducts betweencomponents. the interconnecting The heat on heatcontrolis located the face of the lowerconsole. fan. The push-pull air eitherinto the cabinor out an the controlactuates controlvalvewhich directsthe of discharge the underside the cabin. on overboard A in Fresh ventsare located eachdoorand in the noseof the helicopter. push-pull air on controlfor the nosevent is located the faceof the lowerconsole. (See 1 HEATER Figure 1-11 11.10O CABIN
NOTE in to The cabin heateris required be installed 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 paneland 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. the end (if applicable)and looseningthe d) Remove the control wire by straightening A462-1 fitting clampingthe wire. I I

Change12: JUL 2OO5

P a g e1 1 . 1

FICIBINSG|N

MAINTENANcE MANUAL

MOE EL ]|.44

(cont'd) andValveReplacement Cable 11.11OControl the 4623-1 inlet,remove two hosesand the e) To remove AO19-3valveass.embly.and firewall' the through four the remaining screws the oPqlqqpgr console'Remove cableiam nut the controlcablecasing, f) To remove to casing the chin. clampholding.the tac" aiJ'inJhr.rz+z'-3 the behind towerconsote of removethe blamp' Outboard the compartment, Insidethe right forwardbaggage the from the top to. 99ce9.s cablecasing' right aft ttoor,'iemou"tt'," 5ItU'ottO the "itp"t the Remove two fla.pi unoo iri" p.ndt outboardgf th.9right aft seat. Remove and pull the casingout throughthe ;iilp r,oioing'ii" ;;i'.6 to-irr" u"rticatfirewall face. lowerconsole grommet is or verifythat an MS35489-4 AN931-3-5 casing, cable g ) To installthe control 6 grommet installed is NAS557-3A vatveandan tii t|,re in instalted the tunn"i*ill placethrough place ";ii irri caiing.pa?sq:.(each ,except,one hoi"r ir,.ubn *rti.r', ;i;;;i" at a verticalfirewallstiffenerand thro;gf,if,e bulkhead. the front of the right forward face and cable the tower console baooaoe comoart;"ntl.lnJi.U the iZsing through through..tt9right.forward of irifi"ri,it, irii",IJir-in" stitieneron the sid-e th-econsole, '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 casingwith AN742-3 0.8 inchel into the tunnel,Fasten "oit"p.?ir*t, .pproiimately bi "nO ".sing five places. clamps sealant. with B27O-4 and reseal the valveand inlet,cleanoff the old sealant h ) To install valveandinletandfastenwith screwsin four places. lnstall to.give approximately controlcablewire throughthe A462-1fitting and adiust i ) fnstaff -when Vgfy_ controloperates the valve is fully cJose{.r O.b6bipringUactit tlre knob the fittlng. O.O1 wire freely.Cut e-xcess approximately inchor lessfrom verify the valve and box are sealant. fnstailthe c625-1 box and sealwith B27O-1 to low and i"lf"O UVtrp,ngthe bellynoteCtosed applying air press-ure the inlet. Check stick. ioileits'insiOeif,elunnfi by usinga pieceof yarnat the end of a C753over AA k) tnstall one inchthick Microlite insulation the C625-1box and installthe 1 cover. beltycover,andcloseupperconsole. bellycowling. Install hoses. heater Install

Pa g e1 1 . 2

Change12: JUL 2005

FICIB|NSICIN

MATNTENANeE MANUAL

MOCIELF|44

14

G;?'

,l\

,/

11-1 CABIN HEATER FIGURE (srNGLE oUTLET)

OESCRIPTION l. 2. 3. 4. 5. 6. 7. 8.
o

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 n i r C o n t r o '(lR e f . ) A CabinHeaterContro'l HeaterOut'let Hose ati I nsu'l on of Foi'l Tape(Foruard item 7) Foi'l Tape(Aft of item 7) B u l k h e a( R e f . ) d C'lip C]ip Duct I nsu'l ation Hose ValveAssembly Box Cover Hose Assemb'ly Shroud Hose C o oifn g S c r o l I ( R e f . )

10. 11 T2 13 14 15 -16 t7 '18 19

4: Change 1 Jun 97

P a g e1 1 . 3

FIGIBINEiCIN

MAINTENANcE MANr.rAL

MOEIELFl44

t"/'" --.:::i
It

HEATER 11-1A CABIN FIGURE (MULTIPLE OUTLET)

NUMBER PART
2 3 4 5 6 7 I 9 10 11 t2 13 14 15 16 17 18 19 DESCRIPTTON CabinAir Control(Ref) CabinHeaterControl HeaterOutlet Hose outlet (LH) Hose I nsulati on Foi'l Tape(Fonrardof ite+ 9) (Ref) Bulkhead Foil Tape(Aft of item e) Duct Hose Cover Box Assembly Va'lve Assembly Shroud Hose S Cooling croll Hose

c522-5 A522-8
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

P a g e1 1 . 4

Change4: 1 J un 97

FICIBINS|CIN

MATNTENANeE MANuAL

MOEIEL

F,44

11.120 MufflerShroudReplacement al Remove the D040-1 aft enginecowling. bl Remove tail pipe from the exhausthangerat the enginecoolingscroll. the c) Disconnect two heaterhosesfrom the shroud. the dl Remove screwsat the top of the shroudand removethe shroudover the the tail pipe. el To installthe shroud,reverse steps a throughd. 11.2O0 yENT|LAT|ON 11.210 CabinAir Vent CableRemoval {SeeFigure 11-2} al Openupperconsole. bl Remove cotter pin and clevispin at the forwardcabinvent. cl Remove attaching clamps. cablejam nut at lower consoleface and removecable. d) Remove (See 11.220 CabinAir Vent Cable Installation Figure 11-21 in a) Installor replace MS3548-4grommet the vent box, if required. the bl Insertthe A5225-5 cablethroughthe holein the lowerconsoleandtightenthe jam nut. clevispin cl Securethe controlwire to the vent door usingone MS2O392-2C13 pin. and one MS24665-73cotter d) Install the cable clamps.Adjust cable casing for proper operationof vent. Then tighten clampssecurely insurecasingdoes not slide when operating to the vent control knob. e) Closeand secureupperconsole. 11.230 DoorVent (SeeFigure 11-31 if by The door vent hinge is rivetedin placeand can be replaced, damaged, drillingout the rivetsand replacing vent door and/orhingeas required. the if usingB27OThe A226-3seal aroundthe vent door can be replaced damaged 4 or B27O-13 adhesive. the The frictioncan be adjusted the doorvent by tightening NASl291-08 nut on holding knobon the centerpivot of the doublearm linkage. the Change 1 Jun 97 4:
P a g e1 1 . 5

F|C|E|INEICIN

MAINTENANeE

MANUAL

M('EIEL

F|41t

t47039?I CLEVS ?ttt*t!-

\rtr

MSz4665-73 PIN COTTER AN742-3CLAMP scREl'l MS27039C1-06 NUT NAS679A3

AIR C522-5CABIN CONTROL VENT

CLAMP AN742-3 SCREW MS27039C0806

hIASHER AN96O-81

NUT NAsozgnoaffi r

l^IASHER AND JMNUT

CABINAIR VENTINSTALLATION

/ -sz6o-g
SEAL

l'1s204704D3 c285-1KNoB

FIGURE VENT DOOR

P a g e1 1 . 6

4: Change 1 Jun 97

FICIE|INSiCIN

MATNTENANeE MANuAL

MOE'EL

F,44

11.300 ArRCONDtTtONtNc 1 1.301 lntroduction Thissection coversmaintenance troubleshooting procedures the optional and for cabin ' 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. Differentrequirements may apply in countries other than the United States. 1 1 . 3 0 2 D escri p ti o n in The optionalcabin air conditioning system is shown schematically Figure11-4. The similar to conventionalautomotive and light aircraft systems and consists of system is through the left engine cowl door, a condensermountedon a compressoraccessible the left side of the enginecoolingfan scroll,an evaporatorand fan assemblymounted linesand hoses. The outlet duct, and interconnecting to the aft cabinwall, an overhead system uses R134a refrigerant. The compressoris belt-drivenfrom an engine accessorydrive cartridge and equipped with an electromagnetic clutch. When the system is off, the compressorclutch is pulleyto freewheel. allowingthe compressor disengaged, inletgrilland evaporator fan The evaporator draws warm cabinair thoughthe evaporator the fan and blown throughthe overhead where it is cooled. Cooledair is drawn through duct. duct which allowsselection by The system is controlled a toggle switch on the overhead engaged switching by is of off , low, and highfan settings. The compressor automatically when evaporator the switch disengages compressor the fan on. A temperature {freeze) the switchesdisengage compressor dropsbelow freezing.Safety (pressure) temperature pressure excessive.A full-throttle is leakage occursor if refrigerant if excessiverefrigerant when the engine is near full throttle to ensurethat the compressor switch disengages clutch and fan circuitsare protected is aircraftperformance not affected. The compressor by the A/C circuit breaker.

Change13: OCT 2006

Page11.7

FIclBINEiClN

MAINTENANcE MANUAL

MOEIEL

FI44

LOW PRESSURE CUT.OUTSWITCH OPENSAT 4.6 PSI & closEs AT 32-34 PSI

HIGH PRESSURE CUT.OUT SWITCH oPENS AT 340-37 CLOSESAT 240.2

\ \

iT* ---+J _

J._.._

COOLEDCABIN AIN VAL THERMALEXPANSION

TEMPERATURE

TEMPERATURE

=tJ
FULLTHROTTLE CUT.OUTSWITCH

A COOLING IR FROM S ENGINE CROLL

AMBIENTCABIN AIR

+ 28 VDC

SWITCH FREEZE OPENSAT 34OF & A CLOSES T 38OF

ENGINECOMPARTMENT
FIREWALL

SYSTEM 11-4 AIR COIUOITIONING FIGURE

P a g e1 1 . 8

13: OCT 2006 Change

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. Failure cool the air flowing throughthe evaporator to and overheadduct. 2. Excessive conddnsate (water) in the evaporator box area when the system is operating. Failure cool is most likelycausedby eitherrefrigerant to lossor interruption the compressor of (by one of the in-lineswitches or a wiring fault, see Figure 1 1-4 clutch power supply schematic). Excessivecondensate is most often caused by an improperly assembledor blockedevaporator drainsystem. Both difficultiescan usuallybe correctedwith minimum effort and expenseif carefultroubleshooting donepriorto majorcomponentmaintenance. is A troubleshooting chart follows.

1 Cha n g e 3 : O C T 2 0 0 6

P a g e1 1 . 9

FICIB|NSICIN

MAINTENANcE

MANUAL

MOEIEL

FI44

(cont'd) 1 1.310 System Troubleshooting ACTION rnouelesHo oT/GoRRECTVE

Section11'321' ?y:tgp R"c".rtr t"f"gerantper. u' on normally approxlmately /c operaie should Charge/ to 1.25 lb refrigerant. Low Refrigerant leak is. ir"r"s ihun o:i5lb refrigerant recovered' RefrigerantLeak if leaks anv,and repair i;;ip*5t"iiqn tt.szi 11.322 reehbroe Section oer switch turn on Master ait"r"ft not running, !Vitl', duct {loWor high ove-rhead on ;;'Alft*iictr listento andobserve Hau"observer rLttii'tl "tt. Jlutch throush lefl cowl door' ;;;;r%;;"t against ci;i;h-ahould engage(clickand.snap on' A/C is switched pulley) whenever D798-1 switch (behind 6;;'( ;iii"t ai treeze or WiringProblem evaporator low press-ure Switch high and assembly), fullInterruptingComPressor;;iI"h;Jiuerrina lefi'reai seatback),.and (incontroltunnel)' Clutch Power Fgpgi' ihrottlecuioutswitch ;;y'eilPged wiring'or connectors' Verify -Section Air is not cold 1 1'350' Check correct rlgglngper each switch. All switches -de "olitinritv"irrrdugh with a properlv tharsed itosEd ;il;id aircraftatrest on grouncl'Heplace system_and
Belt FailedComPressor Inspectbelt.

11.331as required' aLLU"ltper Section

Excessive condensate around DamagedInsulation evaporator assemblyand overheadduct ExtremeHumiditY

lnsufficient Condenser Airflow to seals ensure repair and/or blockage R',Li,?;" airflow through core. in may res.ult Extremetemperatureand hum.idity ExtremeEnvironmental a typical automobile' effeit lessthan Conditions "ootinq No coirectiveaction available. normally.After several Voifv tvttem is draining Blockedor Kinked conditions h-umid yi1[11 'i';;;;;ier ;fiui#siound run.in Drain Line Evaporator srroulobe seen drainingfrom the -water drain tube. drainage is not -ob^served,inspect tt drain line (see S-ection1 1.343). Correct any damaqedor kinked lines. Cleansediment.trap is ieduireO. Verify proper function of check assemblyald duct insulation Verltv evaporator (seeR44 ire iri.tattddcorrectlyand undamaged PartsCatalog). Correctany insulationdeficiencies. in Some condensationis unavoidable extreme hum idity. itt frestrair vents closed. Lirnitopening il;"* to ana ltosing cabin doors as much as practical limit humiiiity enteringcabtn. Changet3: OCT 20Oo

-Veirv l".p""t .ondenser installation(left side of fan no blockage and all seals in ;;;6lli.-

P a g e1 1 . 1 0

FIGIBINSC|N

MATNTENANeE MANUAL

MOEIEL tr'44

11.320REFRIGERANT
1 1.321 Refrigerant Recovery lf a leak or other service problem is encountered after system is charged with refrigerant,refrigerantmust be recoveredbefore work on system can proceed. AutomotiVe-style conditioningserviceequipmentis requiredto recoverrefrigerant. air This equipmentis availablefrom many manufacturers varying levelsof automation in and complexity. Minimum componentsincludea vacuum pump, storagecontainer, pressure/vacuumgauge, and appropriate lines and fittings. Ensure equipment is qualifiedbefore compatiblewith R134a refrigerantand technicianis appropriately 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. Charge 1 1.322 Refrigerant 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/vacuum gauge, and appropriatelines and fittings. Servicesystem only with qualifiedbeforeattempting R134a refrigerant, and ensuretechnicianis appropriately refrigerantcharge. CAUTION wear. Verify lubrication required minimize Proper is compressor to charge oil compressor levelper Section1 1.333.5 beforebeginning procedure. with a traditional system is not equipped The R44 air conditioning receiver-dryer.Ensuresystem is under full vacuum to eliminate all moisture before c high and low side system service ports are located on the vertical Automotive-style firewall insidethe left-handenginecowl door. Connectserviceequipmentto system serviceports, vacuum system, and chargewith per instructions.Correctchargeis 1.25 R134arefrigerant equipmentmanufacturer's lb (1 lb 4 oz, or 0.567 kg) refrigerant. CAUTION Do not overcharge system. lf a slow leak is suspected,find and per Section 1 1.323 first, then use correct charge. correct

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 to An empty system should hold full vacuum |.27 29 in Hg system from the vacuum pump ior 2Q minutesor more. lf a vacuumed no assistance 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 quiet or insiructions. Largeleaksmay be detectedaudiblyif area is manufacturer,s by formation of frost in area of leak. NOTE operation a indicate teak.Normalsystem Frostdoesnot necessarity and/or charging procedurescan cause frost to accumulateon
some componenrs.

NOTE System pressureis not a reliableindicatorof chargestate or the mixture with pi"."n"" of leaks. BecauseR134a is a liquid/vapor the system at rest, pressurewill remainconstant as more liquid majority chargeis lost. vaporizesuntil maioritvof ch Very small leaks can be detected by chargingthe system with helium gas' Helium and will leakmore quickly. Chargesystem are molecules smallerthan R134a molecules electronichelium detector or soap available to 2OOpsi maximum. Use commercially and water solutionto locate leaks. Leaksare most likelyto occur at fittings and crimpedtransitionsbetween hard line and initialleak detectionefforts in these areas. flexiblehose. Concentrate

P a g e1 1. 1 2

13: OC T 2OOo Change

FIC|BINSiC|N

MATNTENANcE MANuAL

M('EIEL

F'44

1 1 . 3 3 0 C OMP R E S S OR 1 1.331 Compressor Belt Replacement Compressor belt replacement basedon belt condition. Replace is any belt exhibiting frayed edges,excessive cracking,heat damage,or rubberdeterioration. To replacebelt, loosen NAS66O4 bolt through D782-3 adjustingarm slot, and loosen all three NAS66OG boltsthroughcompressor lugs. Rotatecompressor and inboard up 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; handlecompressor body or s, Slip new belt over both pulleys,and rotatecompressor down and outboardto tension belt. Tensionbelt such that a 4.5 to 5.5 lb force appliedmid-spanproduces0.14 inch belt deflection. Tightencompressor mount and adjustment hardware. 1 1 . 3 3 2 C o mp re ssoR e mo va l r e 1 . R e m ove n g i n el e ft co w l i n g. 2. Disconnect and remove battery as required compressor for access. per Section 11.321. 3. Recoverrefrigerant 4. Disconnect compressor clutch wiring from airframeharness. refrigerant linesfrom compressor. Protectall open linesand fittings 5. Disconnect from contamination. dr 6 . R e m o veb e l t fro m co mp re ssor ive pulleyper Section1 1.331. in 7. Removethree compressorlug bolts loosened step 6, and removecompressor.

Cha n g e1 3 : O C T 2 0 0 6

P a g e1 1 . 13

FIC|EIINSCIN

MAINTENANcE MANUAL

MOE EL F.44

Installation 1 1.333 ComPressor bolts at mount lugs and NAS6604 bolt using three NAS66OO 1. Installcompressor PartsCatalogfor hardware at D782-3 adjustingarm slot. Referto R44 lllustratei compressor' stack up. Leaveall hardwarelooseenoughto rotate mount and drive belt, tensionper Section1 1'331' and tighten 2. Installcompressor adjustinghardware. (large)fitting to 3. connect refrigerantrines to compressor. Torque row-pregsure (small)fitting Io 210 in'-lb' 3OOin.-lb. Torquehigh-pressure 4. Connectcompressorclutchwiringtoairframeharness. oil 5 . Check and adjust compressor quantityas follows:

Recoverrefrigerantprior to checki cap on upperoutboardsurface oil a. Removecompressor fill cap (blackhex-head body behindclutch and pulley)' of compressor is shaft clockwiseuntil clutch platecounterweight positioned b. Turn compressor perFigure 1-5. 1 dipstickper Figur e11- 5, and tak e oi l c . l n se rtA i rp roP /N 9 0 -3 0 28 or equivalent 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 are compressors. Compressors typically shippedat least partiallyfilled oil. l e . R e i n sta lfi 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. per Section 11'322' 7. Chargesystem with refrigerant 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 '

P a g e1 1 . 14

14: JUL 2008 Change

FICIBINSiCIN

MATNTENANcE MANuAL

MOEIEL

F'44

INTOOIL FILLER DIPSTICK INSERT HOLEUNTILSTOP IS FLUSHAGAINST CASE COMPRESSOR

COUNTERWEIGHT POSITION APPROX AT 2:30 O'CLOCK

COUNTERWEIGHT

OIL 1 F IGU R E 1 .5 COM PRESSOR FILL

1 Ch a n g e 3 : O C T 2 0 Oo

P a g e1 1 . 1 5

F|CIEIINSC|N

MAINTENANeE

MANUAL

M('E

EL F,44

ASSEMBLY 1 1 .340 EVAPORATOR AssemblvRemoval 1 1.341 Evaporator per Section 11'321' 1. Recoverrefrigerant 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' connector. electrical d. Disconnect 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 duringdilassemblyand note hardwarearrangement retainspacers ,

for re-assemblv.
NOTE to (headliner) coveris secured the evaporator The entiredecorative and may be removedif box via hook and loop fasteningmaterial to desired. lt is necessary removethe headsethangersin order to removethe cover. ilefer to R44 ltlustratedParts Catalogfor details. between seats, and removeleft rear seat back' 4. Removetrim securingheadliner b. Removeand discardsafety wire, and removedraintube from drain fitting at base box {right side). of evaporator 6. Disconnectrefrigerantlines at vertical connectionnuts near upper inboardseat back corner. and remove 6 screws securingevaporatorbox 7. push back headlineras required, box forward and lift up and flangesto aft cabin bulkhead. Tilt top of evaporator 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 Evaporator AssemblyInstallation 1. Secure evaporator box to aft cabin bulkhead using 6 screws through box flanges. ,. line connection 2. Verify O-ringsare cleanand undamaged, and connectrefrigerant line l n u t s . T o rq u ei n su l a te di n eto 210 in.- lband uninsulated to 150 in.- lb . 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 PartsCatalog from Section11.341or referto R44 lllustrated retained arrangement for hardwaredetails. 5. lnstalloverheadduct as follows: feed rotor brake knob through slot in duct, and a. Position duct approximately, connector. connect electrical b. Slide duct up and aft such that tabs engage evaporatorbox fan opening and windshieldframe. c. Installscrew aft of rotor brake knob. systemper S ec ti on Char ge 6 . Ve r i fy n o l e a ks{re fe rto S e ction11.323 as r equir ed) . 11.322. betweenseat backs usingtrim. 7. Installleft rear seat back, and secureheadliner

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

P a g e1 1. 1 7

FICIBINEIGIN

MAINTENANcE rtnANUAL

Mt'E EL H44

r 1 1 . 3 4 3 E va p o ra toD ra i nS vstem 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 for are passenger compartment.All components necessary properdrainage'Blockage near the or kinkingof a drain line may result in water damageto the cabin interior box. evaporator to The flexibletube drainscondensate the tee located behindthe right rear seat back. severalinches down to a plug. The sediment-tube At tee, a sediment-tubeextends to is designedto allow contamination settle out without clogging the main drain periodically. Removeplug and clean out tube if sediment system-. Inspect tube 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 should and out the belly. Normalsystemoperationin humid conditions compartment there may drippingfrom the tube. In extremelydry conditions resultin condensation to assembly verify drain inspectevaporator be little or no condensation.Periodically it has not been damagedor dislodged.

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MATNTENANeE MANUAL

MOEIEL

R44

EVAPORATOR

TUBE DRAIN EVAPORATOR

VERTICAL FIREWALL I FORWARD ) TUBE TUBE DRAIN

DRAINSYSTEM FIGURE 11-6 EVAPORATOR

1 Ch a n g e 3 : O CT 2 OOG

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F44

11.35O FullThrottleCut-Out Switch Riggins clutch A full-throttle cut-out switch is designed to disengage the compressor that air conditioning 1 approximately inch MAp below {ull throttle. This guarantees is operation does not affect aircraft performancea_taltitude. Full throttle cut-out of controlledvia a microswitchlocated near the bellcrankassemblyat the aft end closed tube in the main controltunnel. The switch is normally the throttle push-pull (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'

Assembly D731-'tBellCrank 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 i r e 3

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 11.7 AIR CONDITIONING FIGURE {View lookingoutboardfrom centerlinel

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MATNTENANeE MANUAL

MOEIEL

F.44

11.400 DRIVE CARTRIDGE

1 1 . 4 1 0 D ri veC a rtri d g e e a lR emoval S 1. Removeengineleft cowling. 2. Disconnect and removebattery as required access. for 3. Loosenbelt tensionand removebelt from pulley. palnutand M S21O42L6 nut. B33O- 19 4 . Re fe rto F i g u re1 1 -7 . R em ove 5. Removepulleyfrom shaft to exposeA966-5 seal and woodruff key. tool beingcarefulnot to damagehousing. Do 6. Removeseal usingappropriate not removeshims underseal. 1 1.420 DriveCartridge Seal 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. 9 torque per Section1.33O. InstallB33O-1 4. InstallMS21O42L6nut and special pafnut and standardtorque per Section 1.32O. Apply B27O-22protectorant to exposedsurfacesof shaft. d 5 . I n sta l l co mp re sso r ri ve belt, tension per Section 11.331, and ad j us ti ng hardware.

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Mt:ElEL

H44

PULLEY

ffi
. DRIVE ASSEMBLY COMPRESSOR 11.7 CARTRIDGE FIGURE P a g e1 1. 2 2 1 Change 4: JUL 2008

o
12. FUEL SYSTEM

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F|44

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MAINTENANcE MANuAL
SECTION 12 FUELSYSTEM

M(fEIEL

F|4'T

FUELSYSTEM 12.OOO 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. illustrated Figure12-1B. in 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 instrumentpanel 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 warning light if the strainerbecomescontaminated.Fueltravelsfrom the FUELFILTER fuel pump, then to the gascolator the electricfuel pump, then to the engine-driven to hoses. A fuel control, then to the flow divideratop the enginevia flexiblefire-sleeved pressure the switch abovethe electricfuel pump illuminates AUX FUELPUMPwarning falls below 23 psi. The electricfuel pump is light if the electricpump output pressure 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 providingcoolingof fuel inlet to the aux fuel tank allows this excessfuel to recirculate system componentsupstreamof the fuel control. Under low enginedemandsuch as providingsignificant idle. almost all of the electric pump output is being recirculated flow is controlled by a cooling and improved hot idle performance. Recirculation pressurerelief valve mounted above the horizontal firewall. The relief valve maintains pump is return line and thus fuel control inlet pressureat 28 psi. The engine-driven conditions, also capableof supplyingmore fuel than enginedemandunderall operating 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 will open and no fuel recirculation occur.

2003 Change FEB 9:

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MOEIEL]r'44

(cont'd) 12.OO2Desc-riPtion (priming)'but runs for "'ftreThe R44 ll electricfuel pump is only necessary engine-glgltilg position in*oh. switcF PRIME(momentarv) in flight to provide reoirnain"y. After start' the operatesthe elecirlctuel puryb toi'bilffing prior to engine.start' and t:: eng'11e oil.pressure CLUTCH pump runs continuously Ioiig;;itie etectric with eitheror both fuel pumps ". oferatenorm-ally switch is ENGAdio. itt" engine*itt pump tunctioiris indicatedby.normal engine functioning. prop"i and before shutdown while "ngin"-Oiiuin-iu.l operationafter enginesJartprior'to-ciuichbngagement, by 5e conducted pullingthe aux fuel tiV afs6 clutch is disenga;;1f. A-utiO "n".rc for er'if p*p Ut6"-t necessary troubleshooting' "it"rii TANK 12.100 FUEL TankRemoval 12.11O MainFuel
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
f)

"orp"rtr"nt.located Removethe two rear mountingbolts connectedto the upper frame'

on the forward lefiside of the horizontalfirewall.

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

MCIE EL r|44

C73I.1VENT INES L

4729-t7 INTERCONNECTING LINE VENT

A689-6FILLER CAP

C028.1MAINFUEL TANK c550-1 FUELQUANT SENDER 8254_1 FUELSTRAINER \T 8254-1 FUEL STRAINER \
(: \

"rl

FUEL QUANTITY SENDER A761-1

DRAIN VALVE

c726-7 t AUX-TO-MAIN,, L As21- 1 F U E L I N E I :l LOl^l FUEL I ->J_ St,lITCH

c726-2 I
\ \ \

HORIZONTAL FI REWALL B2B3-3 FUELHOSE

C670-1a FUEL ON/OFF -

V A L V E c7 4 1 _ 1
FUELLINE

CARBURETOR A666-1 GASCOLATOR

FIGURE 12.1 (0.540) FUEL SYSTEM

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VENTLINES INTERCONNECTING TUBE VENT CAP FILLER TANKMAINFUEL

TANK AUXFUEL

C FILLER AP

) / FUEL QUANTITY SENDER ,/,,,. \ STRATNER \'\v r\t t\t FUELDRAIN- l, \ VALVE ----=/FUEL SHUT-OFF tl. illOg

\t \
I

FUELQUANTITY SENDER FUEL NER STRAI

N AUX-TO-l.,|AI FUEL INE L t t

Ff-1 lt\
.1
\ - l

st---_I >Yal

FUEL DRAINVALVE FUELRETURN L IN E HORIZONTAL FI REWALL

-'
\__:__=:_S

LOt,lFUEL St^llTCH I

il\-,

_-:>,Jffirru**
FIREWALL \ \ FUEL SHUT-OFF VALVE ENGINE.DRIVEN PUMP FUEL (TO FUEL HOSE DIVIDER) FLOW PRESSURE FUEL St,lITCH

F OR W A R D

FUEL / GASCOLATOR ELECTRIC CONTROL FUEL PUMP FUELFILTER INSULATIoN pur,ip PRESSURE PUMP INTAKEMANIFOLD DIAPHRAGM St,lITCH LEAK-CHECK F U E L R A I N D LEAK-CHECK DRAIN ("SNIFFLE") DRAIN VALVE FUELLINE

12.14 FIGURE (IO.54O} SYSTEM FUEL

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MOE EL 1l,44

and 12.120 Inspection Repair the FuelTank of for The interiorof the fuel tank shouldbe inspected signsof peeling the slosh of with B27O-3sealant are sealer.lf any indications found,the tank shouldbe re-sloshed per the manufacturer's instructions. Pressure checkthe tank by pluggingall vents and to soap and water solution fittings and pressurizing 1 psi. Checkfor leakswith a ,:nild ensurethet the vent line is open. Reinstall all seams.After re-sloshing, the appliedto the low fuel warningswitch. Reinstall 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. the screwsconnecting fuel tank to the center the bl Reinstall threerearmounting bulkhead. cl Connectthe two rear mountingbolts and torque per Section1.320. from the left firewall,accessible d) Installthe two screwsthroughthe horizontal sideof the engine compartment. 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,uppertailcone coverand left enginecowling. FuelTank Removal 12.140 Auxiliary a) Drainall fuel from aircraft. cowling.Openmastfairingfrom right side only. b) Remove tailcone wires at the connector. the c)Disconnect vent line and fuel quantitysender the dl Disconnect fuel line at the Aux tank and plug both sides. e) Disconnectforward clamp, holdingrotor brake cable housingto Aux tank and removeupperpulleyfrom Aux tank channel. channel f) Remove two screwsunderthe Aux tank at the cabinbulkhead. g) Remove forward mountingscrews. all

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MATNTENANeE MANUAL

MC'EIELF,4/I

to Aux fuel tank channel CO20-1upper bolt connecting the hl Remove NAS66O4 cowling to center the two ttie*s ionilecting the Aux tank frame. Remove bulkhead. Aux fuel tank. i) Remove FuelTank Installation 12,150 Auxitiary Aux tank in Place. al Position Aux tank the b) lnstall all forward mountingscfew.s.including two under the which connectit to the forwardbulkheacl' the bolt connecting Aux tank to upperframe' torque the NAS66O4 cl Gonnect per Section 1.320. Aux tank cowl to cabin bulkhead' d) Installthe two screwsconnecting el Connectthe forward clampwhich holdscable housingto Aux tank channel' upperrotor brakepulley. Reinstall fuel line going to Aux tank, upper vent line and fuel quantity f) Re-connect senderconnector. cowling' tailcone gl Closemastfairingand install h) Add a smallamountof fuei to Aux tank and check for any leaksat the fuel tank outlet. ValveRemoval 12.160 SumpDrain using 112" deepsocket,removethe valve body from the sump housing Valve"O" RinoReolacement 12.170 SumoDrain a) Holdvalvebodyfirmlyand pressin on valvestem' "O' ring and rePlace. b) Remove ValveReolacement 12.180 SumpDrain or portionof the valvebody with Bakerseal a suitablefuela) Coatthe threaded compound' threadsealing resistant andtorqueto 6O in.-lbs. b) Installthe valvein the housing

Page 12.4

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MATNTENANeE MANuAL

MC'E EL F|44

o
/

INSTALLATION VALVE FIGURE 12.2 FUEL

Nul,tsrir

PARTNO.

DESCRIPTION R OL L IN P KNOB SHAFT ANCHOR

NUMBER PART NO. 10 11 c670- 1 c741.-L

DESCRIPTION FUEL VALVE LINE FUEL

MSl6562-5 c499-1 1 c79 -3 c3481 c79-t-2

t2
13 14

7 8 9

TUBE 0 . 0 3 2i n . S A F E T Y 15 t,JIRE 16 P M S 1 6 5 6 2 - 1 6 OL L IN R t7 c79L-4 SPACER 18 L F U E L INEASSY c726-2

SCREt^J MSz7039C0806 BRACKET c798- 1 F IR VERTIC AL E( W A L LR e f . ) AN500A4-3 NAS620-4 AN960-8 NAS679A08 SCREt^J I/,IASHER WASHER NUT

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MAINTENANcEMANUAL

MOE ELFd4,

SYSTEM 12.200 FUELOUANTITY Removal Sender 12.210 FuelOuantity hole' a) Drainthe fuel tank untilthe levelis belowthe sendermounting WARNING The masterbattery switch must be off' senderunit to the fuel tank and remove securing.the the -' b) Remove 5 fasteners unit from the fuel tank' the sender unit and insertit thru the mount in the fuel al lnstallthe gasketon the sender tank. b) Installfive boltsand torqueto 27 in'-lb' Calibration' Sender c) CheckFuelOuantity Calibration Sender 12.230 FuelOuantity end and the fuel line from the fuel strainerat the carburetor a) Disconnect drainthe fuel tanks. completelY b) Closethe fuel valve. 'one c) pour g.ZS ga[ons (55 lbs] of clean fuel into main tank ttnis includes -' .ppio*ir?.iy fiiffon-ui,nicncross feeds into Aux tank plu-sdrained five unusableiu;li. Allofr approximately minutesfon fuel to crossfeed. lhe. gage dl Turn on the masterbatteryswitch and readthe fuel qu-antity.gag9, below needlewidths neediJ*iOtnto one and one-half shoutdreiO one-naH (seeFigure12'4l'. futl one-quarter

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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 .

FIGURE 12-3

SENDER LOl'l FUELSENDER AND FUELQUANTITY NUMBER DESCRIPTION NUMBER PART

4058-9 MS29512-s 5D AN9248289-1 7740-15-423 c550-1 A550I

Low Fuel Switch ket Gas Nut Bo' lt ket Gas ( S e n d e r M a i nT a n k ) Sender( Aux Tank)

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\ il 1ao

READING MINIMUM

MAXIMUM READING

CALIBRATION GAUGE F IGU R1 2 -4 FUEL E QUANTITY

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MATNTENANeE MANuAL

MOEIEL

]l,44

12.230 Fuel,,Ouantity Sender fcont'd) Calibration e) lf the gage does not give an indicationas describedin Step d), use the followingprocedure adjustthe fuel quantitysender{float). to 1l Remove tu6l quantitysender. tne 2l Bendfloat arm up for a gagethat readstoo high. Bendarm down for a gagethat readstoo low. Makeslight bendsand reinstall checkgage. to Torqueall completethe final installation. 3) When the gaugeis calibrated, fasteners 27 in.-lbs.plus nut drag. to (SeeFigure12-31 Removal Sender 12.240 Low FuelWarning the a) Remove fuel tank per Section12.110. the senderto the bottom of the fuel tank, remove b) Remove the nut securing and removethe senderthroughthe the senderwires from the pin connector, filler neck in the top of the fuel tank. (SeeFigure12-31 Installation 12.250 Low FuelWarning Sender portion. unit over the threaded a) lnstallthe new O-Ring the sender on lengthof safety wire and threadthe wire b) Tapethe senderleadsto a 3O-inch throughthe fillerneckand sendermounthole. pull down, carefully the senderinto place. c) With the tank upside nut d) Coatthe threadsof the senderunit with B27O-1.Installthe retaining and torqueto 150 in.-lb. e) Install the maintank per Section12.130.

12.260 FuelFlowCheck
in Fuelflow may be reduced an obstruction eitherthe fuel linesor in the vent by for lines. Whenchecking 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 may damagethe tanks). lf flow is tube {Do not use compressed the pressure air; in for obstructions the vent linesor fuel tanks. restricted, check fuel. Fora with eitherfull fuel or minimum A fuel flow checkmay be performed gallons any emptymaintank.Check for to fuel,addapproximately 2 checkat minimum properfuel flow as follows:

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MAINTENANcE

MANUAL

M(fE'ELF,44

of al Obtaina container known volume: 1 U.S.Gallon Gallon 1 lmperial 4 Liters available' Also havea secondcontainer the b) Turn the fuel valve off and disconnect fuel line at the carburetor. air from -' c) Turn fuel valve on and atlow fuel to draina few secondsto remove and recordthe time to fill. ini'iyri61n. in"h- nii container dl Checkdraintime againstthe chart below: Time Maximum Ouantitv 1 U.S.Gallon Gallon 1 lmperial 4 Liters FullFuel 1 min 12 sec 1 min 24 sec 1 min 16 sec MinimumFuel 1 min 30 sec 1 min 48 sec 1 min 35 sec

fuel lines, in checkfor obstructions the gascolator, e) lf fuel flow is insufficient, fuel valve,or fuel tank strainer' Check 12.27O Low FuelSender when the low fuel senderfloat The low fuel warning light shouldilluminate the on drops.ttrt inl i6i,oii 6v tulniiglhe master.battery-switch. and eitherdraining the fuel the fuet untittn. ir,rii oropJbr by liniiv oepiessing float with a stick through the when depressing dut odeEnot'ilturirinate doesilluminate filler neck. lf ;;;ingiight ihdsender per Section12'240' test button, replace 12.300 GASCOLATOR tllg 12.310 Cleaning Gascolator cowling. right engine a) Remove b) Turn fuel valve off. bowl clip the c) Cut the safetywire that secures thumb screw to.the gascolator bowl' the remove Uowtclip to the sidean-d tne the;;;;.-6;ing and loosen or d) Cleanthe bowl of any sediment 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'-'i./ t\,/

-".

,'

-lg+--

NAs679Ao8

tluo"uroi*t

-\

A454-1

6P;
4741-1 FUELLINE ASSEMBLY A455-1 PLUG

- MszTo3ecosob
SCREt,l

A 6 66 -1 GASCOLATOR 8283.3 HOSE ASSEMBLY

@----t'fr?Bll;uo
A729-8 TUBE 4728-2 STIFFENER

---/

0 . 0 3 2i n . HIRE SAFETY

(2 P L ' c s . )
BELLY

NAS557-8A GROMMET

12-5 GASCOLATOR INSTALLATION FIGURE

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MOE,ELF44

filter screenlocatedin the cap and clean' the gascolator e) Rembve filter screenand bowl. Swing bowl clip underthe bowl and tighten f) Reinstall 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' (SeeFigure12-5) Removal 12.320 Gascolator cowling. right engine a) Remove b) Turn the fuel valveoff. c) Drainthe gascolator. and plug the open end. the dl Disconnect fuel linesfrom the gascolator mountingstud nut and remove. the gascolator e) Remove (SeeFigure12-5) Installation 12.330 Gascolator stud throughthe firewallmount,Installthe nut mounting a) Installthe gascolator and torqueto 70 in.-lbs. to b) uncapthe fuel linesand connect the gascolator. aligndrainwith hole in bellyby rotatingthe sedimentbowl. c) lf necessary, valveon and checkfor leaks' dl Turn the fuel selector air the rightenginecowling. Connect intakehose. e) Install

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INSTRUMENTS

FIClBINEiclN

MATNTENANtrEMANUAL

MOE ELF'44

13 SECTION INSTRUMENTS 13.OOOINSTRUMENTS 13.001 13.002 Introduction Description

. 13.100 PITOT STATICSYSTEM INSTRUMENTS 13.200 FLIGHT 13.210 13.220 13.230 13.24O 13.250 lndicator Airspeed Altimeter VerticalSpeedIndicator OutsideAir Temperature Compass

TRAINAND POWERPLANT INSTRUMENTS 13.300 DRIVE 13.310 13.320 13.330 13.340 Engine RotorTachometer ManifoldPressure Gauge Carburetor Temperature Air Engine Instruments Cluster

13.341 Oil Pressure Gauge 13.342 Oil Temperature Gauge 13.343 Cylinder HeadTemperature Gauge 13.344 FuelOuantityGauge 13.345 Ammeter 13.400 TROUBLE-SHOOTTNG GUtpE

Change3: 5 May 95

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left This pageintentionally blank.

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MATNTENANcE MANUAL
SECTION 13 INSTRUMENTS

MC'EIEL

F'44

1 3 . O O OI N S T R U ME N T S t This section containsa basicdescriptionof instrumentationinstalledin R44 Helicopters, procedures. procedures generalmaintenance and 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 compass. Engine cluster gauges include an ammeter, oil pressure, cylinder head temperature and fuel quantities. Also provided are a oil temp-erature, gauge (for carbureted engines), clock and a digitaloutside a carburetorair temperature 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. doors;one on each side of cabin. Water Dual static ports are locatedaft of rear passenger can be drainedfrom pitot-staticlines by removingplasticdrain plugs which are accessible panelon underside cabin. Drainingthese linesshouldonly of inspection through removabte or be requiredif operatiohof airspeed altimetersystems appearerratic. Openingsof both frequentlyfor bugs or other obstructions. pitot and static sourcesshouldbe inspected IN 1 3 . 2 0 0 F L I GH T S T R U ME N T S ic for Handbook specif instrumentmarkings. Referto Section2 of R44 Pilot'sOperating In 1 3 . 2 1 0 Ai rsp e e d d i ca to r in indicatordisplaysairspeed knots and miles per hour. Airspeedindicator The airspeed correct in will be operative forward flight only. Backwardor lateralflightwill not indicate up forward airspeeds to a maximumof 130 indicatorwill indicate The airspeed airspeed. knots (RedLine). 1 3 . O O 1 l n tro d u cti o n

Change13: OCT 2006

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B240-2 E BLIND NCODER

Mt)EtEL

H44

.STATIC VERTICAL PRESSURE SPEED AIRSPEED PORT INDICATOR INDICATOR \

)tL
TRANSPONDER l (VIEWLOOKING AFT) PITOTTUBE TO PITOTTUBE

) \ ALTIMETER

TRANSPONDER

B.240-2 E BLIND NCODER

STATICPRESSURE PORTS (LH & RH FUSELAGE PANELS}

DRAINPLUGS

T F IGU R E 3 .1 P IT OTAND STATICSYSTEMINSTALLATION

Page 13.2

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M(fE EL r|.44

13.211Pitotlineleaktest CAUTION to Do not applysuctionto pitot systemor pressure 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. pump plungeruntil airspeed to b. SLOWLYapply pressure pitot line by depressing 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 leak is indicated.After leak has been repaired,retest per sections unacceptabte (a)thru (d). e. Removetape from pitot tube drain hole and verify 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. to b. SLOWLYapply pressure pitot line by rollingflexibletubing around rolleruntil supplyat flexible indicatorreads80 mph {70 knots). Pinchoff pressure airspeed tube. indicatorglassto removefriction effects. c. Gentlytap airspeed 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 verify airspeedindicatorgoes to zefo. f. Remove test apparatus from pitot tube after acceptable test results are obtained. 13.22O Altimeter pressure to relative sea levelwhen barometric altitudeinformation The altimeterprovides 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 Page13.3

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13.221Staticlineleaktest
CAUTION altimeterand vertical When applyingsuction to static line,-airspeed,. if suition is appliedor removed 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. indicatorhas stabilized. After d . Gently tap glass on altimeteruntil rate-of-climb 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' retest per sectionsa thru e. f . After leak has been repaired, 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 shouldbe adjustedto next higher 100 foot mark and then stabilizationlahimeter timed for one minute. Changeof leis than 100 feet in elevationin one minute is acceptable. e . SLOWLYremovesuction from static line retest per sectionsa thru e. f . After leak has been repaired,
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. (OAT) 13.240 OutsideAir Temperature from chin of indicatorhas a stainless steel probe protruding The outsideair temperature gaugeby a calibrated length of cable. rotorcraftand is connectedto NOTE No cutting or splicingof OAT probe wires is permitted.

TRAIN INSTRUMENTS AND POWERPLANT 13.300 DRIVE

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 sensespassageof two magnets attached to main rotor gearbox input yoke assembly.Each tachometer circuit has a from the other. They can be separatecircuit breakerand is completelyindependent 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 and reliability can of Installation electricaldevices affect accuracy of electronictachometers. Therefore,no electricalequipment may be installedin the R44 helicopterunless installationis RPMof engine,engine approvedby RHC. At l OOo/o specifically and rotor tachometer needles must indicate lOoo/o + 1o/o. For adjustmentof rotor tachometer,see Section 14.1OODual Adiustment. Tachometer

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Ga 1 3 . 3 2 0 M a n i fo l dP re ssu re u g e pressure-in engine The manifold pressuregauge providesan indicationof absoluteair intake manifold. neO tiile dn gauge indicatesmaximum manifold pressurefor which gaugeshouldindicate ioiorcraft is type."rtiti".t"d at-1odw rotor RPM.Manifoldpressure pressure when engineis not running. barometric within 0.3 incher Hajoi;.bient Air 13.330 Carburetor Temperature heat gaugeon panelis used to determinewhen carburetor A carburetorair temperature such as high humidity. Applv condition_s, i. ;;q"f"d durinj p"iriUiJ cirbu-retor-'icing gauge io neai ii requireO keep needle out of y_elpwband. Carburetorair temperature QAt gaugewhen engineis cold' the sfroufdread approximatbly same as t 1 3 . 3 4 0 E n q i n el n stru me n C l u ster Ga 1 3 . 3 4 1 Oi l P re ssu re 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 switch. compartmentnext to hourmeterpressure Ga 1 3 . 3 4 2 Oi l T e mp e ra tu re u ge its and receives electrical gaugeindicates engineoil temperature The oit temperature oil pressurescreen housing or oil filter piob." -"orntea in engine iig"Jf t-"i " adapter. Gauge H 1 3 . 3 4 3 C yl i n d e r e a dT e mp e r atur e of tem_perature cylinder#2 (0-540), The cylinderhead temperaturegaugeindicates signalfrom a probe installedin bottom 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 variableftodt indi6ator(see Section 12.000 for adjustment). resistor-tybe

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(cont'd) 13.340Engine Instrument Cluster 13.345Ammeter The ammeter indicates loadsin electrical system.The systemloadsare measured at shuntlocated lowerright-hand of verticalfirewall the engine on in compartment. side 13.4O0TROUBLE.SHOOTING GUIDE Trouble-Shooting Chart lnstrument
Problem ProbableCause

1. Blockage pitot tube. of pitot 2. Disconnected tube.

No Indication

3. Kinks(bends) pitot lineunder in upperconsole. 4. Defective indicator.

Loose pitot or static line connection.

Airspeed lndicator

Erraticlndication

pitot line. 2. Broken 3. Water in pitot-static system. 4. Defective instrument.

1 . Blockagein static line.

Altimeter

No lndication Erraticlndication Climb indication with no returnto zero in levelflight.

2 . Defective instrument.
1. Water in static line. 1. Blockagein the static line.

VerticalSpeed lndicator

1 . Waterin static system.

Erraticlndication No Indication NOTE

2 . Defective indicator.
1. Defectiveindicator.

For trouble-shooting procedures for instruments, see Section 14.000.

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MATNTENANcE MANUAL SECTION 14 ELECTRICAL AVIONICS AND SYSTEMS

MC'EIEL

FI44

14.OOO ELECTRICAL AVIONICS AND SYSTEMS 14.OO1Introduction 14.OO2Description 14.100 DUAL TACHOMETER ADJUSTMENT
14.2OO LOW RPMWARNINGUNITADJUSTMENT 14.300 CHARGING SYSTEM VOLTAGE CHECK

14.400 TROUBLE-SHOOTING
14.405 A569 Low Rotor RPM WarningUnit 14.41O Electrical Trouble-Shooting Trouble-Shooting 14.420 Instrument Trouble-Shooting 14.430 ClutchActuator Electrical AccuracyCheck 14.440 Electrically PoweredInstruments 14.500 COMPONENT LOADS 14.600 ELECTRICAL SYSTEMS SCHEMATICS 14.7OOELECTRIC TRIM SYSTEM Adjustment 14.710 Trim Controller Troubleshooting 14.720 Trim System Electrical LOCATIONS 14.800 ANTENNA SCHEMATICS 14.9OOAVIONICS

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SECTION 14 ELECTRICAL AVIONICS AND SYSTEM

MODEL

F|44

ELECTRICAL AVIONICS 14.OOO AND SYSTEMS 14.0O1 lntroduction

This section containsinformation correctingdifficultiesthat may arise in the electrical for description and some test and adjustmentprocedures. system. lt includesa general 14.002 Description 14-volt electricalsystems includea 14-volt, 7o-amperecapacity alternator(limitedto 50 amps continuous), battery relay,alternator control 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 130limitedto 85 amps continuous,is standardon the Policeversion. amp capacityalternator, The bafiery is in a fiberglass containerlocatedon the lower left steel tube frame, in the compartment. Policeand E.N.G. nose underthe upperconsole,or in the left-frontbaggage from the tailcone. versionshave the battery suspended Circuit breakersare located on the ledge just forward of the left-front seat. The breakers type. and are of the push-to-reset are markedto indicatetheir function and amperage 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. systemvoltageat the ammetershunt via a remote The alternator controlunit (ACU)senses alternatoroutput voltageto sensewire. The 14-voltACU has three f unctions: it regulates the low-voltageby illuminating maintaina battery voltageof 13.7-13.9 volts, it warns of volts, and it protectsagaingtov_e_rto ALT warning light if voltagedecreases 12.55-12.95 to field if voltage increases 15.75-16.25 volts. The 28voltage by shutting off alt-ernator the volt ACU alsohas three functions: it warns of low-voltageby illuminating ALT warning protects against over-voltageby shutting volts, it to light if voltage decreases 24.OO-26.OO to off alternatorfield if voltage increases 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. fuse a the In additionto a circuitbreaker, clutch actuatorcircuit incorporates low-amperage to preventa motor overloadfrom trippingthe circuit breakerand turning off the CLUTCH motor overload.This also light prematurely, to preventmotor burnoutdue to prolonged and protection. A time delay is also includedin the circuit resultsin drive belt overtensioning due to springswitch to prolongactuatorspringswitch life, and to preventovertensioning gearmotoroperationonly vibration. The time delay affects flutter resultingfrom excessive during Engagecycle; the time delaydoes not affect CLUTCHlight operationand does not cycle. The time delayallows gearmotoroperation0.25 seconds functionduringDisengage (indicated CLUTCHlight illumination). Any circuit interruption after circuit completion by (indicated CLUTCHlight extinguishing) instantlyresetsthe time delay. by Ch a n g e1 0 : JU L 2 0 0 4 Page 14.1

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{cont'd) 14.002 DescriPtion lights, lights,two landing light,navigation the systeminctudes anti-collision The lighting lightsare ' map light' Landing ino lightsfor.instrumenis an-overhead post and internal Postandinternal n"lignt" off when didengaged' wiredthroughtne ciutifr switch,triiinJ olt.ships, rheostalon early 14-v. via it ia]r.iJtubrJ a irvire-w_ound light brig#; instrument dimmer dimmeron lateii+-uoit and all 28-voltships. The electronic or via an electronic when short is circuiudimnierwill reset will shut down lt'"""i,.inl"ring a irro'rt-t;:g;Jund cleared. low panelincludeclutch,low oil pressure, fuel' main Waminglightson the instrument enginefire.{sensor tiin totor gearboxover-temp, iighit, rotor and tail rotor ;;;d;; "f'rip tiglrl,lovivoltage(ALT),rotor brake,andstarter at --wi1 activates 275 + 1OoF),low .'otoi-npM

ffi;!"!-.

rr.

warning lights.

monoxide and in"iroJtueititier,auxfuil pump, carbon "Joiti6hJrv

cylinder head I The gage cluster includes an ammeter, oil .pressure,oil temperature.' on.this circuit are the irriduintiii"t. temperatureand riin ina-u*iti.ry '"ny) {ts9 nro_vra.ea and outsideair terirperature.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. magneto(helicopter Jr points) in the engine-right uiJemurv tFr*t enginetach is . power from, the rotor tachometersenses "onti"i r"iiria"i. A Hall rtteli sensorfoi, and receiving of independent the other. Ur*ier and i" has a separate "o-pretely "il"uii alternator oi1h" ubtt"ry a.ndieceive current from two redundant the po*"rro-uv and alternator "itrrrr sources. powerto the tachometeris interruptedonly.whenthe masterbattery on 14 volts; operate ai;"ng"gub. rul tachometers -"hin switchesare off and the clutch swiic'trii ge 28 volts to the 14 volts requiredby zii-""riinlpi Jtitir" two voltag" r"tuiutoir to both tachometers. CAUTION of .jf The installation electricaldevicescan affect-the accur?cy?nq qefre, no eleitrical

sensors from Sisnals input.voke. -Each these b;;*dbrt*o rnl;;;i;; th".;4" rotot.se"rSox circuit tachometer ""oriJ.ijtecircuiilinlia6 dual iachometer. the uv areconditioned They can be

o r.j 'ri;iiad . ii"biiiw ili i'e Htr; iii' ia;'iiomet-e ihe icopt6runless d;fi "; Ll6l".ini'mivbt I n llyapproved ihef acto that .lhJ ii4+ hbt ry. by a ii: iribCrtic aiidn' ;;ft6ri;i' ini'iiil
CAUTION
connectorsare upper console,ensuremulti-p-in When installinq have electricalsv'stem.

1 of numb.er' connector -C;osiin #;i;i.r;i;;;;;%iif.'-bdih'I';ffei e lt I' i^i[iiilsir-,p'e.!' iiinheltions wilI resu in damag to

panel9l ll" circuitbreaker right-side eachhavean additional, versions and police E.N.G. E.N.G' the optional for breakers just forwaroof t!9 nilot;sseai-contuini"g-uit'"irEuit ledge to a 28-voltbus. is breakers connected or policeequipmeni.tr,Jt"rward ro* of circ-uit whileon versions to is connecied a 14-voltbus on E.N.G. the aft row of circuitbreakers to is connected a aft irr" ouiui"ra section-'of-the row of circuitbreakers iifi* A gepapteMaster converter' "*rion" bV is 1 -voltbus. The i+--uoirUus powered a 28-to 14-volt powerto all E.N.G. police or pan"lcontrols the switchon the left sideof "ir"uii'nreulier equipment.
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14.100 DUALTACHOMETER ADJUSTMENT

The C792 DualTachometer pre-setat the factory. Slightvariationsbetweenrotorcraftmay is requirereadjustment the rotor side of the tachometer. To adjust: of 1. Removescrews securinginstrument,face upper consoleand carfullypull face aft. to engine 2. Groundrun the helicopter at'lO2o/o tachometerindication.Adjust screw on back of tachometerso rotor tachometerindicates1O2%. Turn adjustmentscrew clockwise to increaseand counter-clockwise decreaserotor tachometer indication(O.4 turn to approximately change). 17o equals 3. Installface. 4. lf tachometercannot be adjusted,replaceor returnto RHCfor repair. 14.2OO LOW ROTORRPM WARNINGUNIT ADJUSTMENT at When the collectiveis raised0.2 to O.4 inches (measured grip) above fully down, the low-rotor RPM warning unit must activatethe low-rpm warning horn and low-rpm light at rotor RPM. 97o/o 96% rotor RPM; horn and light mustturn off above g60/oto 97o/o to The low rotor RPM warning unit is insidethe upper console mounted on the left vertical by panel. Adjustmentsare made by turningan exposedscrew on warning unit, accessible plug from a 3/8-inchdiameterhole on the left verticalpanel.The removinga black-plastic 2 screw sensitivityis approximately turns per 1% change. A569 wbrningunit's adjustment be replaced. lf warning unit cannot be adjustedto rangestated above, it must 14.300 (RESERVED) 14 . 4 0 0 T R O U B L E -S H OOT IN G trouble eliminatecauses When investigating Followingare some troublesand corrections. probable. with the most one by one, beginning 14.405 4569 Low Rotor RFM WarningUnit A569 low rotor-rpmwarning unit: Performfollowingtests prior to replacing 1. Verify: a. Low RPM light bulb is functional. b. Master switch off. c. Full-downcollective. i d . H o r n ci rcu i tb re a ke r n . 2. Accessand disconnect both horn and A569 low rotor-rpmwarningunit from airframe wiring. electrical 3. Turn Masterswitch on and verify 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 P a g e1 4 . 3

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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 verify 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 verify Horn Start circuit breaker exists in light illuminates. lf Horn Start circuit breakerpops I!9n- a short-to-ground repairas required' V3-1 switch; -76 wire and/or-78 wire and/orcoliective-activated V3-1 switch is faulty then collective-activated lf Low neU tilfrt Ooesnot illuminaie -76 wires' -70, -75, or an or misadjusted'and/or open exists in manipulating while simultaneously fully severaltimes 7. Slowlyraiseand lower collective RPM light remains throttle. Vurity Ho. Start circuit'breakerremainsin and Low breakerpops then illuminatedwhenevercollectiveis raised.. lf Horn Start circuit -76 wires and/or collectiveconditionis tccurring in -70, -75, or a short-to-ground wiring movement. Checkfor pinched/rubbing activatedV3-1 switch due to collective and repairas required. 8. Turn Master switch off. Connecthorn to airframewiring. g. Turn Masterswitch on. Raisecollectiveand verify 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 then horn is faulty andlor poor is faulty; ,"p"i, as required. lf tone is inconsistent exist; repairas required. connections 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 mixture at idle cut-off' rotor brake released, 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 and a buz z i ng fo a m m e te r; 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 should make no noise).Selectkey 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. 4 and jum p pins 1Oand 11 on b . D i s co n n e ct 5 6 9 l o w -i p m war ningunit' s connector 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 verify Clutch light illuminatesthen disengage throughoutthis sequence). clutch completely(switch to remaindisengaged c. Masterswitch off. plug's pin 1 thru a D6O2time delay connector.Groundairframe-side d. Disconnect suitablevoltage (post-light type) lamp.

CAUTION
voltage lamp (such as Failureto ground p i n 1 thru a suitable grounding) d direct result in wirinq for for ohms (20 ohm nominal 14-volt system;70 ohm nominal e. Verify lessthan 2OO groundat pin 4 and at pin 5 on ship side of A569 connector. 28-volt system)to f. Master switch on. g. With A569-5 unit connectedto airframeharness,verify 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 mixture at idle cut-off. released, i. Select key switch to Start positionand crank engine. Failureof engineto crank indicatesproblemin A569 unit. tests, a faulty A569 low rotor-rpmwarning unit may 13. Upon completionof preceding be replacedand adjustedper Section 14.2OO. C h a n g e1 3 : O C T 2 0 0 6 P a g e1 4 . 3 8

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Trouble-Shooting 14.41 0 Electrical

TROUBLE
CAUSE PROBABLE CORRECTION

1. No electrical power

Batteryterminalscorroded Bad or no ground Trippedcircuit breaker Low batterY voltage

Cleanter m inals Cleanground Path Check circuit, if circuit checks ok, reset circuit breaker Check battery. Rechargeif necessary

wiring, Low or no alternatoroutput Check alternatorbelt tension, control unit and alternator Bad wire or terminal Low battery voltage lnsufficient drive belt deflection Replace Serviceor rePlacebatterY Adjust actuatordown-limitscrew

c 2 . E n q i n e r a nks but will slo-wly, not start

Corrodedor dirtY batterYor Cleanterminals starterterminals defectiveParts Replace Bad starter relay, wires or terminals c 3 . E n g i n e r an ks, Key switch in OFFPosition Placeswitch in BOTH Postition (ro-540) but will not start switch Replace Bad ignitionswitch' Bad startingvibrator Incorrectretardtiming 4 . Starterfails to operate Rotor brake engaged Low battery charge triPPed Circuitbreakers Actuator not fullY disengaged Looseconnections Defectivewiring Startermotor - burned w i n d i n go r b a d br ushes' F a u l tyA 5 6 9 l ow- RPM w a rn rn gu n l t
Page 14.4

Repairor replacevibrator Adjust retardmagnetointernaltiming rotor brake Release Check and rechargeif necessarY Resetboth HORNSTARTand CLUTCH STARTcircuit breakers then EngageactuatormomentarilY, disengage fully Check all wiring (referto wiring diagr am) . Checkall wir ing ( r eferto wir ing diagr am) . Repairor replacestarter. Check unit per Section 14.405 C h a n g e1 3 : O C T 2 O O o

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(cont'd Trouble-Shooting 14.410 Electrical TROUBLE 5) Discharged PROBABLE CAUSE Batteryworn out Chargingrate not set correctly CORRECTION Replace battery control unit Checkalternator if output. Replace below 13.4 volts Removeand rechargebattery if for left in unusedhelicopter four or more weeks. listedfor those Sameremedies troubles.

Standingtoo long

6)

Starter- tow crankingspeed

Sameelectrical causes as listed under "starter fails to operate" lmpuritiesin electrolyte rate Low charging

7l

Batterylife is short

battery. Replace CheckACU output. lf below 13.4 volts replacethe unit. Drainand keep batteryat proper fluid leveland specificgravity.

8)

runs out Electrolyte of battery Chargingrate too

high.

Too much water added to battery. Checkthe ACU output if voltage.Replace necessary.

9)

Excessive electrolyteinside container

Spillage from overfilling Use care in addingwater.

or Vent linesleaking clogged ratetoo high Charging

Repair clean. or

CheckACU output voltage. if Replace necessary.

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(cont'd Trouble-Shooting 14.410 Electrical TROUBLE 1O) Batteryconsumes excessivewater CAUSE PROBABLE CoRRECTIOI_{ ,

Chargingrate too high (if in CheckACU outPut if voltage.RePlace all cells) necessary. CheckACU outPut if voltage.RePlace or RePair necessary. replacewiring to field circuit. Measurethe retard breakerlead connection. Connectorlead must be 0.609 in. + 0.1O.Ther e must be a small amount when the of springback is Placedinto connector the magneto. Trace ignitionvibrator wiringfrom ignition switch to magneto. Correctas required.

ACU failureOPenfield 1 1 ) Alternatorfails to circuit wiring supply charging current with engine operating.

Retardbreakercontact 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) contact

Incorrectignitionvibrator wiring

Bad ignitionswitch Bad ignitionvibrator

ignitionswitch. Replace vibrator Replace

Incorrectinternalmagneto Correctas required ConsultTCM Aircraft retard breakertiming. Productsliterature. Engineleft magneto Opencircuitin ignition vibrator wiring circuit wiring or Repair rePlace for ignitionvibrator

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(cont'd) 14.430 Clutch Actuator Electrical Trouble-Shooting

TROUBLE
Actuator diserigaged will not engage WARNING(yellow)

PROBABLE CAUSE

Lighton X X X X

Lisht off 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. tripped. Circuitbreaker closed). Up limit switch stuck (Normally -88 wire not grounded.

X X X X

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TROUBLE
Actuator disengaged will not engage W AR N I N G(ye l l o w )

CAUSE PROBABLE

Lighton X X X X

Lisht off 1) 2l 3) 4l 5) 6) 7l 8) seized. M otor assemblY Motor fuse blown (3-amp). Open circuit in motor wiring' switch assy tripped' Overtravel No voltageat circuit breaker. tripped. Circuit breaker closed)' Down limit switch stuck (Normally -88 wire not grounded.

X X X X

P a g e1 4 . 8

14: JUL 2008 Change

F|C!BINEiC!N

MATNTENANeEMANuAL

MC]DELF44

14.420 Instrument Trouble-shooting TROUBLE 1) gauge(sl Engine not reading PROBABLE CAUSE Trippedcircuitbreaker CORRECTION Checkcircuit.lf circuit checksok resetcirCuitoreafter. Checkpower and groundwires. Checkwith new one, replace sender or wire if necessary. Checkwith new gauge.Replace if necessary. Checkall three. Tachometer will be erraticwhen alternatorswitch turned off if there is a bad battery connection. Checkwith new gauge. Checkcircuit

No poweror ground Bad senderor wire

Bad gauge

2l

Erraticor intermittent reading

Loosepower,groundor sender wire. Loosebatteryconnection

3t

Excessively high or low gauge readings

Badgauge

Crossed shortedwire or

l s s u e d 1 1 Jun 93 :

Page 14.9

FIOBINSiGIN

MAINTENANcE

MANUAL

MoE ELe,44

left This pageintentionally blank'

P a g e1 4 . 1 O

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

FICIBINS|CIN

MATNTENANcE MANUAL

M('EIEL

F44

14.430 Clutch Actuator Electrical (cont'd) Trouble-Shooting TROUBLE !n flight Actuator engaged warning (yellow) Flickers 1) 2l 3) 4l Actuator leaf springimproperly adjusted. C190 drive belts not matchedproperly. Open circuitin motor wiring C184-1or C0O7-3bearing runningrough. Normaloperation actuatoras it re-tensions of drive belts. 1) Drivebelts stretchedbeyondlimit of actuator overtravel switch. Beltsmust be replaced. 2l Actuator overtravel switch activatedby outside force. Comeson for over 1O seconds 1) Checksheavesand belts for excessivewear. 2l Checkcolumnspringsfor operation. 3) Verifyfanwheelbalance. 4l Checkor changeout time delay. 5) Removeactuatorand send to RHCfor evaluation.

PiOBABLECAUSE

Comes on for 1-6 seconds

Comeson for over 6 seconds

Cha n g e1 4 : J U L 2 0 0 8

P a g e1 4 . 11

FICIEIINSCIN

MATNTENANeE MANUAL

MOE'EL

F|44

check Accuracv lnstruments Powered 14.440 Electricallv + of capabre dispraying 1 rpm (or barancing.equipment similar) using Vibrex 2OOO accuracy.pe-r.{ollowing within o#'v;ut,'Jerity^tachometer and caribrated resorution (MM)sections Manuar vtuintenance *iiti nzz in tabres.connectequipment accoid"ari* at aircraft operate 6-44)_. insiealof strobel perFigure 6.240 (usephotocerr 10.221and Tachometer rpmsas specified' and indications .i"i',tylngineinarotor notedtachometer wide. are needles 1olo C792-xDuqlleghometer
Tachometerindication 960/o l OOo/o 1O2o/o EngineRPM 2556-2561 2662-2667 2715-2721

RPM ROtOr 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 O degrees : 89.68/91.O8 hms o l5 d e g r e e s : 9 5 .6 7 1 9 8 .0 7 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 o 2 0 d e g r e e s = 9 7 .8 3 1 1 0 0 .2 3 h ms o 9 8 .2 7 1 1 0 0 .6 7 h ms 21 degrees : g 8 . 7 O t 1 O 1 . 1o h m s O 22 degrees : . 2 3 d e g r e e s : 9 9 . 1 3 / 1 0 15 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 O2 2 5 d e g r e e s = 1 0 0 .0 0 /1 .4 Oo h ms

c degr ees 77 .4Oohms = - 3Ot 2 c 8 1 . 7 3o h m s = - 2 O + 1 . 7 5 d e g r e e s c 86.05 ohms : -10* 1'5 degrees c degr ees ot1 90.38 ohms = c g4.71 ohms = 10 + 1 ' 5 degr ees c 99.03 ohm s = 2Ox' 1' 75 degr ees c degrees 1 0 3 . 3 6o h m s = 3 0 + 2

1OO-ohm a the carburetorair temperatureprobe^witl'r !. to 1-watt Example:Replacing 21 .degrees c (measureexact resistor should result in a indiclii;; ;i ap.proximately Stytofoam'cupfull of crushedice resistorvalue & referto above)'"4-iton"-iibptO in p.er " above table. Probeinstallation and water should indicate so.ie' ;[;; iesisiance in damage' pr o i o t q u "l J g to 4 i n c6 -p o u n d s; ver - tor quing obewill r esult

Pa g e1 4 . 1 2

14: JUL 2008 Change

FICIB|NSiC|N

MATNTENANeE MANUAL

]vl('DEL

H'44

14.440 Electricallv Poweredlnstruments Accuracvcheck (cont'd) Following instrument cluster gages are calibratedat 20 to 25 degree angle from horizontal. Fuel level sendersshould have 90 + 2 ohms resistance when 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 potentiometers have 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" potentiometer adjustedso gage indicatesempty at O.7 ohm sender is circuit resistance;"Gain" is adjustedso gage indicateshalf at 42 ohms sendercircuit resistance. Calibration valuesare:

FuelOuantityGages (14V1 6246-00716 (28V) 6246-00473 & -1,+O pointer O.7O ohm : E (empty) width
2 1 . 2 Oo h m s 42 .OOo h ms 67.50 ohms 9O.OO ohms 114tull + 112 tull + 3i4 full + F (full) + 1 1 1 1 pointerwidth pointerwidth pointerwidth pointerwidth

- 1 O 4m V -5 2 mV OmV +52 mV + 104 mV CHT Probe 3080-38 (14V & 28Vl 2OOdegreesF = 745 ohms 475 degrees : F 3 8 o h ms 5OOdegreesF = 32 ohms

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 GHT Gages 6246-00088 (14V1& 6246-00718 (28V1 745 ohms = 2OOdegreesF + 1 pointer width 1 10 ohm s = 350 degr ees + 1 pointerwidth F 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

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 = 119131 ohms 87 psi 1 1 5 p s i : 1 4 5 - 1 6 1o h m s Cha n g e1 4 : J U L 2 OO8

I
fl

FIClEttNgiClN
14.440 Electrical

MAINTENANeE MANUAL
ed Ins k (cont'd

MOEIEL

F.44

F 1 O Od e g r e e s : 4 9 7 o h ms F 150 degrees = 179 ohms 7 2 o h ms F 2 O Od e g r e e s : 250 degreesF = 34 ohms

75 degreesF + 1 pointerwidth 903.5ohms ohms 180 degr eesF + 1 pointerwidth 1OO 36 ohms 245 degreesF t 1 pointer width

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) BatteryRelay StarterRelay StarterMotor Belt TensionActuator Warning Lights(engine oil pressure, alternator-off actuator-on, fuel, main low rotor gearbox chip, main rotor gearbox overtemp, tail rotor gearbox chip) Position Lights Anti-Collision Light Landing Light Instrument Lights Digital O.A.T.Gauge Engine Gauge Cluster Com Transmit Com Receive Low RPMHornand Relay Map Light LOADS 0.75 4.50 150.00 1.20 O.O8each

x
X X X

X X X X X X

X X

2.20 3.20 8.30 each O.O8each 0.13 0.50 3.66 0.70 o.35 0.58

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

Page14.15

F|OBINSGIN

MAINTENANeEMANUAL

_-

MclE ELn,44,

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13: OCT 2006 Change

FICIBINSiCIN

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FORWARD BATTER

MOEIEL

F|44

CONSOLE ELECTRICAL

c0r{NEcT0Rs
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1.0 AMP FUSE 661

BREA(ER CIRCUIT "GAGES'

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A999 MASTER RELAY RADIO

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T E S TS H ] T C H

AND FUELPUMPSCHEMATIC STARTING FIGURE14.1E R/T4II {IO-54O} Ch a n g e1 4 : J U L 2 0 0 8 P a g e1 4 . 1 8 C

FIclBINEiclN

MAINTENANCE

MANUAL

MOEIEL

F,44

(Cont'd) SCHEMATICS SYSTEMS 14.600 ELECTRICAL

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P a g e1 4 . 1 9 A
Change 1O: JUL 2OO4

FICIBINEiCIN

MAINTENAIIcE

MANUAL

MOE'EL

F|44

(CONt,d) SCHEMATICS SYSTEMS 14.600 ELECTRICAL

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FIClElINSclN

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M(fEIEL 'r44

r
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INslL.) HoRIzoN ATTTTuDE (8191-1

DCGROUND DC POWER INT. LIGHT

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c059-513 c059-514

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14FIGURE 3 ( HORIZON J . E . T . E L E C T R 0 N I C s ) 8 1 9 1- 3ATTITUDE GYRO i,:.r.r. ELEcrRoNi cs) DIRECTIONAL 8191-4 C0RP. (ELEC. GYR0 ) COORDINATOR 8 3 29- 1TURN

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FlClBlNsioN

MATNTENATvcEMANUAL

MorlEL n44

14.600ELECTRICAL (Cont,d) SYSTEMS SCHEMATICS

TOOPPOSITE SEATINSTALLATION

RED
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Cha n g e1 0 : J UL 2 0 0 4

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G11430

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14-3C FIGURE I,IIRING SIGNAL BOX GENEVA AUDIO DIAGRAM CONNECTOR fon'lardLH seat, view looking down) (Locatedbeneath (ENG only) helicopters Page14.20C

FICIBINSCIN

MATNTENANeE MANUAL

MOE'ELt'44

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FICIEIINSC|N

MATNTENANcE MANI.IAL

MOEIELF'4/I

TR|M 14JOO ELECTRTC SYSTEM The R44is equipped with an automatic electric trim system.The systemincludes cyclic strain gages,a trim controllerin the left front baggage stick-mounted compartment and lateral and longitudinal electric at trim actuators the baseof the cyclicstick.Thestraingages processes straingage sensecyclicstick forcesappliedby the pilot.The trim controller the signalsand sendscompensating trim force commands the trim actuators.A thr,rmbto activated trim controlswitchon the right handcyclicgripallowsfine adiustment the trim of controller. The automatic trim controller consistsof two independent motorcontrollers housedin the samebox. Eachsectionhas inputsfor power,straingagesignal,and offsetcontrolas well as outputs for motor and regulatedstraingagespower. A singleon-off switch on the cyclic centerstick deactivates trim actuatoroutputs while signalprocessing the circuits remainon and stabilized. is per lf a problem evident, then checkandadjusttrim controller Section14.710. Refer to Section14.720if problems encountered are whenadjusting trim controller.ContactRHC Technical Support trim controller if adjustment troubleshooting not corrector identify and do problem. 14.710 Trim Controller Adjustment CAUTION part There two trimcontroller numbers: are D14O-1 D14O-2.Dl40-1 and -6 trim controller mustbe usedONLYwith the CO55-2, and-8 cyclictrim assemblies. D140-ztrim controller mustbe usedONLY with the CO55-9, -10 and -11 cyclic trim assemblies. Incompatible controller and trim ' assembly(s) resultin trim systemfailure. will 1) Prepare helicopter: a) Shipon levelground. b) Cyclicstick must haveC683-4damperfirmly attached. grip or C683-6damper c) Removable installed. co-pilot d) Cyclicboot installed and secured. e) Cyclicstickvertical. f) Cyclicfrictionfully on.

g) Trim switch "OFF". (but not mounted). h) Trim box connected airframe harness to i) Attachtest cord from MT547-1set-upbox to trim controller. Remove cover potentiometers. nuts from longitudinal lateralbalance and

Change 15 Jun 98 5:

Page14.21

FIEIBINSC|N

MAINTENANeE MANUAL

MOE EL]r44

(28V aincraft. gnly) i. Pull all circuit breakersexcept warning.lights,.trim aircraft (14v ontvl. trim and'rati'rar bnryt,

iilf;irc'at i"iibiir'oi*iilin..

k. Turn on masterbatterYswitch.

2.
3.

minutesto stabilize in) Note: Systemmust be on (circuitbreakers 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 sensitive scalahign impedlnce etc). Fluke8O5OA, fiute 8O1OA, potentiott"' O balance and Switchon set-upboxto LONG-TP1 adiustlong.itrldinal to screwdriver adiust

ioi'i'ieiii";

do potentiometer; not looseniam nut' shouldbe O.OmV + O'2 mV' TP2. Reading Switch set-upbox to LONG mV Recordreading: pressand hold trim controlthumb switch in forward direction.Meterlqqding
should go In poslrlve olrecrloll

o?b.ti;v

;-5.O ;v.

smin brade Lise

5.

mV * 325 ,"rrr v too l u q1ni1in.,'r q P r ' ' 5ffi"rjfdill;'iiil; oiiiiiionL+gz' r o l r r r r(forr9l9p^ptot'"19y.911!19[ controller)' Dl4O-2trim mv
Ii;; Dl TO-tfrim lbntrolt"'i;
Recordreading: mV

6.

Metertttd'f?)tJr"-gt thumbswitchin aft direction' and Press holdtrim control -72mY (D14( Oitictlo-n'i;;;;iimum of approximatelv ir|in neqitiue

;lv'iDiAo-ii.n."oidreaoins:

mV

7.

to Thetime required travelfrom full t + ).to.fqJlJ:) viceversa)is approximately lgt iiinei 6 secbnos(Dl4o-11or 4 seconds(D140-21' reading, at O Note: Somemetersmay take up to 1 secondto stabilize the new be acceptable. could inlrLtoie a 1 secondlongerreaciing turn.master"oFF" then back "oN"' For 28V For 14V aircraft,momentarily power connector iirtratt. ro-r"ni"iiiy JisConhectthen reconnect lo-pin. shouldreturnto giit trim controller. Meterreading 6 (containing i,u-ilei-or ano or O.OmV * O.2 mV. mV Recordreading: -

8.

9.

;r it.o ;;i#;1"r";?"'Ji'Jr"6 'V * s.o.my, Y'1!I1!:!F'-19.1.:19':^ until as Readiustrequired tefision.

ffi6'ffihi;iilr""i;iii".p"6itg:T&"'-initti balancepotentiometer reinstalilongitudinal
readingstays *,ttiin li;i6. Then cover nut. Recordreading: mV

T|Q. box set-up to LoNG n1el 1om!nutes--ry.1tlY-p-1.19j*t.l^"ryi*9 Switch rap po1

of to forceapplied middle stickshouldresult 1O. An approximately 1t? lb forward ? 2 112lbaft forceapplied if in a reading -1bo iiV to -r s'omV nn .aooroximately of 1oo mV to to middleof stick shouldt"rji in a similai'butpositivereading + + 1 5 Om V . movestick' Note: Do not actuallY Page14.22
Change6: 18 MAR 99

FIC|BINSCIN

MATNTENANeE MANIIAL

MOE ELF|,44

(cont'dl Adiustment 14.71O Trim Controller as 11. No force on stick shouldresultin samereading in step 9, * 2.5 mV. mV Recordreading: mV for of balance a reading O.O 12. Switchset-uppoxto LATTP1andadjustlateral * 5.O,mv. shouldbe eitherO.OmV * 0.2 mV 1 3 . Switch set-upbox to LAT TP2. Reading (Dl4O-2). (Dl4O-1lor +2O.O mV * 0.2 mV mV reading: Record Meterreaolngsnoulo should 1 4 . Pressand holdtrim controlthumbswitch in len direction, Pressand hold tramcontrol tnumD swrtcn In left orreclron,Meler reading
or go in positive direction to a maximum of approximately +92 mV (D14O-11

reading: Record +75mV (D14O-21.

mV

Meterreading should switchin rightdirection. 1 5 . Press and holdtrim controlthumb -92 go in the negative of to direction maximum approximately mV (Dl40-11or mv reading: Record 35 mV (D140-21. -

7 1 6 . The time required travelfrom full ( + I to (-l (or vice versalis approximately to or seconds(D14O-11 6 secondslD14O-21. at Note: Somemetersmay take up to 1 secondto stabilize the new reading, couldbe acceptable. therefore 1 secondlongerreading a turn master "OFF" then back "ON". For 28V 1 7 . For 14V aircraft, momentarily aircraft, momentarilydisconnectthen reconnect lo-pin power connector (containing shouldreturn wires616 and 619) at trim controller.Meterreading mV * 0.2 mV (Dl40-21. mV * 0.2 mV (D14O-1)or 2O.O to O.O mV Record reading: presstrim a. For systemswith D14o-2 trim controllerONLY: Momentarily a stablereading O.OmV + 0.2 mV is obtained. of controlswitch until at Note:Voltageat LAT TP2 must remain O.OmV * 0.2 mV thru step 20. The poweris not interrupted the and voltagewill be correctprovided trim controller switch is not moved. trim control 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 lateral tension,readjustas requireduntil readingstays within limits. Reinstall potentiometer cover nut. balance mV Recordreading: to 1 9 . An approximately 112lb left force applied middleof stick shouldresultin a 2 2112lb rightforceapplied reading -1OO to -15OmV. An approximately of mV mV of to middleof stick shouldresultin a similarbut positivereading + 1OO to + 150 mV. Note:Do not actuallymovestick. * 2.5 mV. reading: Record

in 20. No forceon the stickshouldresultin the samereadings step 18, mV

Change 18 MAR 99 6:

Page14.22A

FICIBINSCIN

MAINTENANcE

MANUAL

MOE'ELt44

(cont'd) Adiustment 14.710 Trim Controller and 21. With thumb switch, adjustLAT TP3 to +1O0mV. Turn trim switch oN trim '{urn trim actuatorresponle;it should observe IgllTootryYJo !lpJtof'. trim switch -100mV.'Turn switchoFF. with thumb.*ii"r,,'iojutt LATTP3to run it should slgglhly to the stop' Turn trim actuatoi-re.'ponie; ONandobserve mV. Turn J*ittr,, againadjustLAT TP3to + 1OO Wt6 tf,umU trim switchOFF.to it respohse; shouldrun sm-oothly the trim actuato-r trim switch ONandobserve Turntrim switchand master actuitorlt it doesnot run smoothly. ;6p: nepiace switch OFF. TP3. With thumbswitch' 22. TurnmasterswitchON. Switchset-upbox to LONG oN and observetrim actuator ;iil;f Ioirtb TFs to--t oomV. Turn tiim switch -i''ibo sJgp. Turn trim switch OFF. With thumb rt response; shouldrun smooi6ry-to trim mV.' Turntrim switch oN and observe ;*ii;h;i'ojuri lotrtc rp3 to if actuator it does Replace to ,un'rmoothly the stop. r"Jpon*; iisnoulO actuator not run smoothly. Turntrim switch OFF' thumbswitchfor o.o mV t O'2 mV' TP2andadjust 23. Switchset-upboxto LONG + Switchseti;6;; i; rni-ri2 tnO aajustthumbswitchfor 0.0 mV 0.2 mV' sureit locksin cap. receptacle (make meterandtest cableand install 24. Disconnect not be running. politionf Turntrim systemJ*itcn "ON". Motbrsshould .causelongitudinal 25. A lightfingerpushto stick in forwardor aft direction.should when pushstops' Motor shouldstop motorto run down or up, respectively. from stop to stop' run smoothly Motor should push' Note: Motor runsfasterwith stronger motor lateral shouldcause 26. A lightfingerpushto stickin the left or rightdirection shouldrun . to run left oirigr,t.- Motor .nouio stop-whenpush stops. Motor from smoothly 'MotorstoPto stoP. push' runsfastei with stronger Note: motorto run and viceversa' pushshould not causelongitudinal 27. Lateral function-s and verify only lateraltrim actuator 2g. pull LONGTRIMcircuitbreaker stick. ResetLONG to forcesare'_6pplidd cy-clic when laterali-io l""gituainil (Not appticable 28 volt aircraft.) to TRIMcircuiibieaker.functions trim and 29. pullLATTRIMcircuitbreaker verifyonlylongitudinal actuator TRIM LAT iq .pritieo cyclicstick. Reset f";;d;;;6 and when taterat - tonsitudinai to circuitbreaker. (Noi applicable 28 volt aircraft.) -lf release cyclic friction. Hold cyclic grip and moveit in all directions' 30. Partially motion(or backand resists Motorsshouldmovewith m6i'lon. m6torp"ushes to movessideways force),thereis a wiringerror' of for clearance all combinations stickand motorarmpositions' Verifyadequate and cyclicstick wires' for motorwires Verity;a"q";i; "l-"i13n." all switches'OFF". Reset circuit andmaster motorsandturntrim system 31. Center breakers. out harness and trim controller, routeD161-1trim controller screws' and secure 32. lnstall (sheet metal' edges fromany sharp .nJ compartment of baggage "*"y etc).
Page 14.228 7 Change : 06 Dec99

FICIBINEICIN

MATNTENANeE MANuAL

MOEIEL

F,44

14.72O Trim SvstemElectrical Troubleshooting PerformTrim ControllerAdjustmentper section 14.710 whenevera problem is suspectedin trim system. or . ff.LONG LAT TPl is in excessof t2.OO volts and will not adjust,theremay be a brokenctraingagesignalwire. Refer Figure 14-4Automatic TrimControlschematic. to Lateral circuitsignalis pin S & pin R. Longitudinal circuitsignalis pin T & pin U. (balancel it is not lf LONGTPl & TP3 (or LAT TPl & TP3l adjustsatisfactorily but possibfe- obtain t 1OO-15OmV to reading whenpushing stick (refSection14.710 cyclic slepg10 & !9), theremay be a brokenstraingagepowerwire. Lateral circuitpower is pin A & pin P. Longitudinal circuitpower is pin-V& pin N. Checkfollowingif straingagewiring faultsare suspected. 1. StrainGageBridge Resistance Readings: Disconnect 19-pinsignalconnector at trim controller measure pins. and resistance between following harness connector lf infiniteresistance found betweenany 3 combinations one circuitthen an is in ope! circuitexists. A damaged straingageis indicated resistance if readings do 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

elo to PlO = Resistance

V T V V
N N

Longitudinal Gircuit

N U T U T U

350*3 ohms 350*3 ohms 262*.3 ohms 262x.3 ohms 262*.3 ohms 262+3 ohms

StrainGageBridge Insulation 19-pinsignalconnector Resistance: Disconnect at trim controller must be in excess and measure harness at resistance connector; of 20 megohms eachof the following: for Lateral Gages Pin A to ship ground LateralGagesto-shield Pin A to Pin G Longitudinal Gages Pin V to ship ground
LongitudinalGagesto-Shield Pin V to Pin G

Lateral Gages-toLongitudinal Gages Pin A to Pin V Shield Pin G to ShipGround

Change 1 8 M A R9 9 6:

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 TRIM CONTROLLER

{{JE

ti':
@ F

SYSTEM CONTROL sr.lITcH

FINE TRIMADJUST S}IITCH

l ,o ,r*ru* BREATER'
| (14-V0LT $|lPS)

TOCIRCUIT BREAKERS (28-V0LT SHIPS)

FIGURE 14-4 AUTOMATIC TRIM CONTROI. SCHEMATIC

Change 15 Jun 98 5:

Page 14.23

FICIBINSiCIN

MAINTENANcE

MANUAL

MoE'ELn44

left This pageintentionally blank'

Page14,24

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

FIC|BINSiCIN

MATNTENANcE MANUAL

MOE EL F'44

14.800 ANTENNA LOCATIONS

,o, -\_P
5**

LOCATIONS 14-5 ANTENNA FIGURE

N o . ANTENNA

T R A N S P ONDER *COM Antenna at this positionif ELT is installed * * Use this NAV antennawith RAVENll

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 B MA R K E R EACON

t2: Change JUL 2OO5

Page14.25

FICIBINSCIN

MAINTENANcE

MANUAL

MtfE'EL

F|44

blank IntentionallY

Page 14.26

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

FICIEfINSC|N

MATNTENANeE MANUAL

MODELF,44

SCHEMATICS 14.900 AVIONICS include to wiringcommon all the Com.radioconfigurations The basiccommunications provides voice-activated intercomand Pilot and Co-Pilot a a N.A.T. IntercomSystemthat switch at eachof the 2 rearseatscan also cyclic stick switches. In addition,an intercom 'activate the intercom. and headphone individual The pilot's and co-pilots iacks are mountedto the ceiling. a passenger are contained in headphone heads. The rear llttle behindtheir respective iacks portionof the cabinceiling. The pilot can use the a com box centeredat the rear most Pilot "lsolate" switch which will remove him from the Intercom bus; he can then over the com radiowithout disturbances. communicate

l s s u e d1 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

(Cont'd) 14.90O AVIONICSSCHEMATICS

KY197A COM TRANSCEIVE R

-t

272 (ADF* AUDr0)

656 (or 706**) ORANGE)

PHONES SHIELD GND I4IKE AUDIO INTERCOM AUDIO

il
I
I I I I

657 (or 707**)

655 (or 705**)

I4IKEKEY SHIELD GND

Lightlng powerfrrrn consolellghts termInal block (or Audio Control**)

25.rlst,l
RISISTOR 200 (or 703**)
POt,lER Sl.l POI,IER LIGHTING HI

TO INTERCOMTo optional radlos requiring I.IIRING poh,er variable for lighting.

7 I

267
*If installed. **For secondary 197Ai n s t a l l a t i o n o n l y . KY ***14-volt ships only.

I
201 (or 704**)

sl'l PoHER POI.IER GROUND

,62
POLARIZ.ING KEY
AECDEFH.'XLIINPRS

267

I I

POI^|ER GROUND
t 2 3 4 5 5 7 8 9101112t314Is KING 197ACOM KY TRANSCEIVER FRoNT EX-CoNI'IECroR Vt (LOOKING FROI.| IN FRONT RACK) OF

LIGHTING LO REIOTE TRANSFER 2L2 or l2l4 COM P.NTENNA

FI G U R1 4 . 6 BENDIX/KING E KX197A COM TRANSCEIVER NOTE: DOES APPLY ENG THIS SCHEMATIC NOT TO SHIPS
!{ITHGENEVA AUDIO SYSTEM.

Cha n g e5 : 1 5 J u n 9 8

Page14.29

FIclBINEiclN

MAINTENANeE MANUAL
--T ?oLARlalrc
rl^lr cof{tEcron PLArE xgan nEAR 9 w E w r v n

MC'OEL],'44
-t:
t

(Cont'd) SCHEMATICS 14.9O9 AVIONICS

K X1 55 V H F , - NAV/COMM TRANSCEIVER ANT. COM

v,eweo Fno[

FnoNT OF UiltT

fL

r
I

I
I

TO COM ANTENNA

(B0TToM PLUG) P4o1

H AU D IO I H NAVA U D IO I LO AUDIO COT4 LO AUDIO NAV COM MIC AUDIO
I I
I

I I
I

ADF*AUDIO)

I I
I I I
l I
I

656 (oRANGE)

1i657
655 (I^IHITE)

INTERCOM MIC IN P O WE R IN PO WE R A/C GRoUND A/C GROUND OUT ShIPOI.IER IN Sl,lPOWER IN POWER Sl^| OUT SI.J POWER 267 267 267 AVIONICS BUSBAR TO INTERCOM I.IIRING

I
l I I

I
I
I I I
I

lIro
z'L
240
,| *IF INSTALLED

I L S E N E R GIZ E OUT VOR/LOC

I I VORNST'1. W IR IN G

I I

TO NAV ANTENNA

NAVANT.

14 F T GU R E -7 P a g e1 4 . 3 0

TRANSCEIVER KX B E N D IX/KING 155 VHFNAV/CoM M

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

FICIBINEiCIN

MAINTENANeEMANUAL

MtfE'ELF,44

(Cont'd) SCHEMATICS 14.900 AVIO\||CS

TO NAVRECEIVER

ILS ENERGIZE COMPOSITE GROUND + 14 VDC

F IGU R1 4 -8 E

B ENDIX/KING 203 VOR KI INDICATOR

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

Page 14.31

FICIBINSCIN

MATNTENANcEMANUAL

Mt'DELF44

lCont'd) 14.900 AVIONICSSCHEMATICS J871 ,p87 1 RF INPUT oor ** tt

J441 P441 \

KA44BANTENNA

RECEIVER

\#

I
\

'l
./

3 I
9
D I

2 P87 \2
I
6
7

i-T--

/ \

powEn ANTENNA (RED)

(cREEN) EN1qLE i LooP

r t r

t ? 4
)

Tt

uz<lgoo(etRcr)

I I

15
I

ffisr;1tD1er-ue)
(CABLE (s;-ffi

\ -/

7 J2271

2 3
D CS I N O U T
| ,tLUJ\ DCCosouT

DRAINt^tIRE) tiTj *lilEfi'PnrH" pzzT

2s3
254 257 ?67 AVIONICS BUSBAR )
\

r+4.5V OM. C

AN T .P O S I T BOTTOM

illI
't

l_ KI 2 oo'lr c I ADFINDrcAr0Rl I
t

ronlE
9

q
A

D 270
H F J

i' 28V DIMMER V 14VDIMMER GROUND

^,r* 14VDC POWER 1 3 |

28V DIMMER 14V DIMMER H AUDiO IGH GROUND

:ll rr
10
tl

GHI
n

20-4 E

* 272

FROM JUMPER RACK RADIo

))

HooK-uP* #z7zcom I wrne |

M
P

><
\ \

lbl

lrr*

?67 257 267. 267

|_n

[I i, fIffi l?l^ r'*'r I I

255

f'
L M
N P

L_
ABCOEFHJ

KLMNPRS

+ L
)_

27rr
?=

_-J
t o * o 1 to -a -o
OU

AIRFRAME GROUND 14FIGURE 9

PR[ili';?-'Illi^i8r I -r,1 o @aa oooa=

a-.4
KR BENDIX/KING 87 ADFRECEIVER

VIE}I CONNECTOR FROi.I OF 87 FROIIT KR

rasls67891ol!2!41,

Page 1 4 . 3 2

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

FIC|E|INSiCIN

MAINTENANcEMANUAL

MtfElEL

TI44

(CONt,d} 14.90O AVIONICSSCHEMATICS KT76A TRANSPONDER

AVION IC S BUSBAR

26L

TO LIGHTS AVIONICS BLOCK TERM.

260

204

KY 197A TRANSCEIVER COM

KA 60 ANTENNA

*FOR DMEINSTALLATION CONNECTPIN TO ONLY.

I'KIIOF KN 63 DME.

KT F IGU R1 4 -1 0 BENDIX/KING 76ATRANSPONDER E

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

Page14.33

FICIBINSiCIN

MATNTENANeE MANuAL

MOEIELF,44,

14.900 AVIONICS SCHEMATICS {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. CONNECTP IN TO

I'KII OF KN 53 DME.

F I GU R1 4 -1 1 B E N D IX /K ING 76ATRANSPONDERBLIND E KT W ITI.I ENCODER Page 1 4 . 3 4

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

FIEIBINSiON

MATNTENANeE MANUAL

MOEIELF,44

(Cont,dl 14.9O0 AVIONICSSCHEMATICS

M-1A RECEIVER

PHR P}JR

I I I

I
I
I
BLOWER MOTOR

I
I

I
I I I

I
I

GND GND

ANTE COUPLER

AN 1OO ANTENNA

M-1A C FIGURE 14-T2 NORTHSTAR LORAN RECEIVER

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

Page14.35

FICIBINSIC|N

MAINTENANcE

MANUAL

MOE'ELF,44

(Cont'dl SCHEMATICS 14.9O0 AVIONICS

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 VDCPOWER

ANTENNA APOLLO 820 - A-31 ANTENNA . APOLLO 8OO A-16 ANTENNA APOLLO 618 . A- 16 ANTEN N A II
7531

RECEIVER

EEEEEH E EEE EEEE

14 12. 10 I

VIE!'lCONNICTOR FRONT

( L O O K I N G O R E A Rr u n l r ) FR M o F IGURE 74 14APOLLO FLYBUDDY RECEIVER 820 GPS APOLLO FLYBUDDY LORAN RECEIVER 8OO PLUS C A P OL L6 1 8 TCALORAN RECEIVER O C

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

Page14.37

FIC|BINSGIN

MAINTENANeEMANUAL

MtfE

EL F'44

(Cont'dl SCHEMATICS 14.900 AVIONICS

GARMIN AVD 1OO GPSRECEIVER

2
BUSBAR

1OO F IGU R1 4 .1 5 GARMIN AVDGPSRECEIVER E

P a g e1 4 . 3 8

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

FlC|EllNEtClN

MAINTENANcEMANUAL

MOE'ELH,44

KLN89 RECEIVER P891 (25PIN) LT 14V LT 28V/ L0 TO JUMPER I,|IRE#204

A/C GROUND

A/C GROUND PoWER 11-33 VDC MONITOR POWER

BLOl,lER MOTOR

468

cI-4510-7C vHF/cPS ANTENNA

RECEIVER KLN 14-16 BENDIX/KING 89 GPS FIGURE

4: Change 1 Jun 97

Page14.39

FICIBINEiCIN

MATNTENANeE MANuAL

M3)E!ELF|44

(Cont'd) 14.90O AVIONICS SCHEMATICS

K L N9 0 R E C E IV E R

R . D .R C V ' A . D .R C V I B R

B 429XMIT 429XMITA

GN D L T . GN D LT. POWER TO CONSOLE LIGHTS TERMINAL BLOCK

RS-232 IN BUSBAR

cI -4510-7C VHF/GPS ANTENNA

RECEIVER KLN F IGU R 1 4 -L 7 BENDIX/KING 90 GPS E

Page14.40

4: Change 1 Jun 97

GARMIN 4@t420t430 (1ST INST'L)

GARMIN 400t420t430 (2ND INST'L) SHIEI.OGND

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POWER POWER GROUND GROUNO

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JUMPERTO CO59.204 WIRE CONNECTOR

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ARINC 429 OUT B ARINC 429 IN 1 A AR|NC 429 tN 1 I ANNUNCIATEE

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GLIDESCOPE ANT,

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GROUND GBOUNO 14/28 VDC 14t2A VOC MIC KEY MIC HI

-201 {COM 1).

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AAr2S-O05 {t4Vt AA't25-002 {28V)

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GPS ANT.

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VOR/LOCANT.

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15. FT}RNISHINC

FIclElINETC|N

MAINTENANCE

MANUAL

MOEIEL F'44

15 SECTION FURNISHINGS FURNI 15.OOO 15.001 15.002 Introduction DescriPtion

15.1OOSEATBELT 15.11O 15.120 SeatBelt Removal SeatBeltInstallation

Or s.zoo sEAT ASSEMBLY 15.210 15.220 and Installation Seat BottomAssemblyRemoval and Installation Removal Seat BackAssembty

15.300 CARPET 15.310 15.320 Removal CarPet Installation CarPet

15.400 FOAMINSTALLATION 15.41O 15,42O FoamRemoval FoamInstallation

15.51O 15.520

Removal Map HolderRemoval MaP Installation MaPHolder

EXTINGUISHER 15.600 FIRE 15.610 15.620 Removal Holder FireExtinguisher HolderInstallation FireExtinguisher

HOLDER LICENSE 15..700_ 15.710 15.720 Removal Holder License HolderInstallation License
P a g e1 5 . i

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

FIOBINEiCIN

MAINTENANeE MANUAL

MoEIEL tt44

15.800 OPERATOR'S MANUALSTFAP 15.810 15.820 StrapRemoval StrapInstallation

P a g e1 5 . i i

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FIClBINEiclN

MATNTENANcE MANuAL

MODEL

]t,44

SECTION 15 FURNISHINGS 15.OOO FURNISHINGS 15.001 Introduction This section contains the proceduresnecessaryfor removal, instattation, replacement, maintenance interior and of furnishings. 15.O02 Description A baggage spaceis locatedundereachseat,and the seat bottom hingesup and forward for access.Eachseat is equipped with a combinedseat belt and inertiareel shoulder strap. , .,

@
15.110 SeatBeltRemoval inertiareelis held by four screws. al The aft passengers' thru the vertical cabin nutplates. to permanently The forwardinertiareelsare held attached bulkhead to by four screws and nuts. Eachbelt has a guide which is secured the airframe a bolt. by the eachend of the lap portionof the seat belt. b) Remove bolt holding (SeeFigure 15-11 15.120 SeatBeltInstallation assemblies identified follows: as The connector are C628-1 C628-2 C628-3 C628-4 Left Forward Right Forward Aft Both Sides BuckleAssembly(all)

TorqueNAS6604 Secureinertiareel with four screws and the guideto the airframe. bolts per Section1.320. The end fittings must be installedon the inboardsides of the bracketsusing the required spacerwith a washeron eachside of the spacer. inboard; torquenut to 100 in.-lbplus locking a) The bolt headis to be installed torque.

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

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FIclBINSiClN

MAINTENANcE MANUAL

MOE ELt44

attaching sideof the anchor on is b) The buckleassem.bly.installed the inboard side' Thebolt head must on each i washer tn" tugusing r"iriii[tni..i*iin at assembly slot in buckle Foiceto toi.tE dela.a guckle ino-oird. be pointing bv spacermaybedecreased shaube 1.5 to 2.5 lbs. Lengih';ietaO-S! force). increases spdcer ishorter rl"li"g it required
CAUTION on No sharpedgesor burrsareallowed the roundknurled or the latching Plate, lockingbar 15.200 SEATASSEMBLY

To removethe seat bottom: nuts and screwsat the hinge' the a) Remove sevenattaching the bl Remove seat bottomfrom the helicopter and tighten the To installthe seat bottom,set seat in placeand position hinge.Install screws. the attaching

To remove the aft seat back: screws aroundthe perimeterof the seat back. a) Removethe MS27O39CO8 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 usingscrews. attaching a the seat backcushionneedto be replaced, new back can be installed Should onto the seat backPanel. the 1) Remove aft seat backsfrom the helicopter' panel, to the drill 2) Carefuily, out the eightrivetsholding cushion the seat back the or so as not to elongate enlarge hole'

P a g e1 5 . 2

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FIC|BINSCIN

MATNTENANeE MANUAL

MC'E'ELF,44

15.22O SeatBackAssemblv Removal and Installation {cont'd} 3l Positionthe replacement cushion againstthe seat back panel. Using the #30 holesin the seatbackpanel, existing markand drillthe eightholesin the crLslrion match the seat back panel. to , 4) UsingAVDELrivets(1693-0414 rivet,I eachpanel) install cushion the the to panel. seat back assembly. 5) Reinstall Shouldthe front seat back cushionsneedto be replaced, follow thesesteps: llDrill out the twelve rivetsholding cushion the seat backpanel. the to on 2l Position replacement the cushion the seatbackpaneland centerit from the sides. #3O holesin the seatbackpanel,markand drillthe twelve 3) Usingthe existing holesin the cushion matchthe seat backpanel. to 4) UsingAVDELrivets(1693-0414rivet,twelveeachpanel)installthe cushion to the panel. the around front seat backcrosstube using 5) Bondthe top part of the cushion -8, B27O-7, or -14 adhesive. 15.300 CARPET 15.310 Caroet Removal CAUTION must be Caution Carpetis installed usingadhesive. carpetif it is to be reinstalled. usedin removing the carpetglueand then slowlypullcarpetback.A putty knife to Use Prep-Sol loosen the may be usefulto facilitatebreaking bond.

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

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FICIBINSG|N

MAINTENANeEMANUAL

MOE EL F|44

15.320 CarpetInstallation NOTE

to Use B27O-7,-9, or -14 adhesive securethe structure' carpetto the underlying a}Checkcarpetforproperfitandtrimifrequired. of the carpet and to b) Apply the adhesive the structureand the bottom side areas' on adioining caretltivlniiiii so as hot to teaveexcessadhesive beforethe upon installation surfaceimmediately c) Ensuresmooth wrinkle-free sets. adhesive 15.409 FOAM INSTALLATION 15.41O FoamRemoval NOTE Foamisinsta|ledusingadhesive.Remova|offoam Do for later reuseis not recommended' not damage operation' in structure removal underlying a)Pee|the|argestportionsofthefoamoffbyhand. foam pieceswith a putty knife' b) carefullyremoveremaining 15.420 Foamlnstallation NOTE the '8, to UseB27O-7, or -14adhesive, secure foam structure. to the underlYing a) Checkfoam for properfit and trim if required' to b) Apply the adhesive the structureand the bottom side of the foam and -'car'etuly areas. on adhesive adjoining instail-iois not to leaveexcess beforethe upon installation surfaceimmediately smoothwrinkle-free c) Ensure sets. adhesive

P a g e1 5 . 4

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FIC|EltNSiclN

MATNTENANcE MANUAL

MC'EIEL TI44

POCKET 15.500 MAP HOLDER 15.510 Map Holder Removal right seat. b) Remove the map holderand the two retaining strips. 15.520 MaBHolder Installation al Foldthe edgeof the map holdermaterial aroundthe long strip and positionat its matching holesin seatfront.Using rivets(1693-04141, threeAVDEL install with the rivet headon the insideof the baggage compartment and placinga AN960-6 washeronto the rivet next to the materialon the outside,rivet in place. b) Pullthe material taut, fold the material around smallstrip and positionover the its matchingholes.Cut off excessmaterial this time. Using two AVDEL at rivets,followingthe procedure above,rivet the smaller strip and material in place. (ootional) EXTINGUISHER 15.600 FIRE 15.610 FireExtinguisher HolderRemoval al Drillout the rivetsholding strap.Do not elongate enlarge holes. the or the b) Remove rivetsholding trim strip at the keelpanel. the the 15.620 FireExtinouisher HolderInstallation a) Locatethe pocketassembly overthe holesin the keelpanel.Alignthe holes in the edgestripsover the holesin the keelpanelwith a pointer tool. b) Rivetthe pocketto the keel panelwith AVDEL1693-0414 rivets usingan AN96O-6L washerunderthe headand againstthe pocket. Rivetfrom the outsideof the keelpanel. c) The strapassembly installed the samemanner the pocketassembly. is in as 15.700 LTCENSE HOLDEB 15.710 License Holder Removal Drillout the two rivetsholding bottomof license the holder,do not elongate or enlarge holes.

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

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FICIBINSfC|N

MAINTENANcE

MANUAL

MOEIELF'44

Holderlnstallation 15.720 License

'' , Drill the two #3O al Positionthe licenseholderon the front of the left seat' 1696-0414 rivets two AVDEL lnstatl the (.128) holes, if necessdiy,--"nJ and compartment witn {t'rijtiuet headoutiide the baggage -Afijgoo-G throughin"-noio"r washerunderthe rivet head' in hold the top of the licenseholderto b) Installthe velcro strip with adhesive-to -9, oi -14 adhesive attachthe strip. to the front of the teft seat.'usi e270-7.

MANUALSTRAP 15.800 OPERATOR'S 15.81O StrapRemoval the strapto the structure' Dritlout the four rivetsholding
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

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F|CIEIINEiCIN
784041 COVER --

MATNTENANcE MANUAL

MOEIELF|44

ilszI04zL4 HASHER
4130-44 SPACER NAS6504-21 BOLT

AN970-4

I connecron

c628-1

I ASSEI'IBLY LH) I (Fl,tD, c628-2 CONNECTOR ASSEMBLY (Ft'f0, RH)

A141-14 . WASHER

(-

c628-4 BUCKLE ASSEMBLY ASSEMBLY (F}tD AFT, F}ID& AFT LHor RH) ANg60-416L ,',"{
bIASHER :

I
{

*:s-.'...
784041
COVER

,/"'i3+"0

AN970-4 I,{ASHER A130-44 SPACER

NAS5604-5 BOLT

At41-14 b{ASHER
,nt tI iltr -\

I
\*,; CONNECTOR

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tyF
, f

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FIGURE 15-1 SEAT BELT INSTALLATION (C0NNECT0RBUCKLE AND ASSEMBLTES) Change 1 Jun 97 4:

ASSEMBLY (AFT,LH or RH)

. NAS5504-18 BoLT -/

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FIClE|INSlclN

MAINTENANcEMANUAL

MOE EL H44

c528-3
CONNECTOR ASSEMBLY -.,.\ ( A F T ,L H o r R H ) .

a./rt

4
NAS6604-5

BoLT

^t ll q..-J

^\'^'rt-J-t'II ASSEMBLY \ i tffi5lit\

I nNqno-atn

connrcron

C628-1

A4r-t"i"'-'.'{

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6v;p

MS21o42L3

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4'=-";
15-14 FIGURE

\l

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i}5

,i,

BELT SEAT INSTALLAT'N_ hHlfffi

(CONNECTOR ASSEMBLIES)

P a g e1 5 . 8

4: Change 1 Jun 97

FICIBINEIC|N

MATNTENANcEMANuAL

MOE EL FI44

c628-2 CONNECTOR ASSEMBLY (Fl,lD,RH)

,,#jlr
r

4N960-l0L I.IASHER Ir,lS21042L3 NUT

i' /

,/

-t1t-tttlt-ii

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,to#l'lilufl
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CONNECTOR ASSEMBLY

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.2

At42-1 scREl,l

502260

---rl_ covEn

FIGURE 15-18 SEAT BELT INSTALLATION ( c0NNECT0R ASSEMBLIES) 4: Change 1 Jun 97 P a g e1 5 . 9

FIOBINSG|N

MAINTENANeEMANuAL

--

MclElELp'a,zr

left blank' This page intentionally

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16.

SPECIALTOOLS

FlClEllNSClN

rvrarrureruarvce TvTANUAL

MoclEL r.44

SECTION 16 SPECIAL TOOLS 16.000 SPECIAL TOOLS 16.001 lntroduction

16.100 TooLLtsT

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MAINTENANcE -o*'

left blank' This page intentionally

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FloEllNSiC|N

MATNTENANeE MANuAL
SECTION 16 SPECIAL TOOLS

MclE EL n44

1 6 . 0 0 0 S P E C IA L OOL S T 1 6 . O O 1 I n tro d u cti o n The following sectioncontainsa list of specialtools available from Robinson Helicopter for use with the procedures this manuatto properlymaintainthe R44 helicopter. in 16 . 1 0 0 T O O L L |S T E n g i n e o i st H Main Rotor RiggingFixture Tail Rotor RiggingFixture Main Rotor Hub Bolt stretch Measuring Tool 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 e i n gGearHotder R (i 9 ) M T 5 9 2 -1 F a n P u l l e r n ctitem 10) 10) MT092-3 S p a ce r 1 1 ) M T 1 2 1 -1 B ra cke t Ma gneticPickup 121 MT146-2 B l o cks- S w ashplate Rigging( 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 e e rator ' s anual( Lycoming t no.) Op M par 141 MT173-5 Torque Wrench ExtensionTool Set - Fan Nut (R22 and R44; i n cl u d e ste m s 15 thr u 19) i 15) MT173-6 TorqueWrench WeldedAssembly 16) 9HT4441* Extension Bar 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 Bearing Pressing Tool - Tail Rotor Hub 221 MT549-2 Flat Plate 23) MT549-1 Spacer- SpindleBoot Adjustment 241 MT527-1 HelicopterLifting Fixture 251 MT527-5 Bushing *SearslCraftsman part no. C h a n g e1 4 : J U L 2 O O 8 p a g e1 6 . 1 1) 2l 3) 4l 5) MT548-1 MT525-1 Mf525-2 MT122-6 MTO53-1

| |

FIclEtINSiclN

MAINTENANeE MANUAL

MC'E'EL

]1'44

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 part no' FABLB) Hex Driver(Snap-on 30) MT357-4 NippleChuck 31) MT357-8 part no' FRDHlOl) TorqueAdapter (Snap-on 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 Tool Valve SpringComPressor 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 hydraulicpress) Tool (For use when clutch Bearing{c184) Removalilnstallation 38) MT528-2 hydraulicPressis 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 14 Plug (hub bearinginstallation) 44!- MT329-6 Support (hub bearinginstallation) 45) MT643-1 SpringScale 46) MT359-1 Tool BearingRemoval/lnstallation Support Tail Rotor Elastomeric 47!' MTs56-11 (includes items 46 thru 49) Support 481 MT556-15 ca p 49) MT556-16 MandrelAssemblY 50) MT556-12 Bolt 51) AN6-34A Valve Tool AssemblY Parallel 521 MT133-1 (0-320, 0-360, & 0-540 engines;not shown) Angle Valve Tool Assembly(l0-540 engines;not shown) 53) MT133-5 valve wiggle; not shown) Adapter (for measuring 54) MT133-9 and H yd ra u l i cP ump Assem bly ( 115V, 6OHz for USA' Cana da 55) MT384-1 Mexico; not shown) for PumpAssemblyl22OV,SOHz outsideNorth America; Hydraulic 5 6 ) M T 3 4 8-2 not shown) *Sears/Craftsman Part no' * * S n a P - o n a r tn o . P P a g e1 6 . 2 14: JUL 2008 Change

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REVISION LOG 1 7 . O O O E V I S IONOG R L Upon re_ceiving change-packagq this manual,insert revised pages. Destroy superseded a to pages.Retainin Section 17 only the most currentrevisionlog. Explanation ChangeSymbols: of 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. Correction minor inaccuracies, of punctuationor retocation material, such as spelling, of unlesschangealters meaningof instructiveinfoimationand/or procedures.

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The following is a list of all revisedpagesand pagesaddedto R44 Maintenance Manual and Instructionsfor ContinuedAirworthinessissued 11 JUN 93. The most current revisiondate is given for each page. Previous changescan be ordered,for a fee, from RHC Publications Department.Manualsmissingany preceding changesmust be replaced. Page Revision Page Revision Page Revision Number Date Number Date Number Date
I

ai iii iv v vi vii viii ix x xi xii f .i f.ii 1.1 1.2 1.3 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

JUL 2OO8 JUL 2OO8

1.13 1.14 1.15 1. 1 6 1.17 1.18 1.19 1.19A 1.198 1.20 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 2OO5 5 May 95

ocr 2006 ocT 2006

O6 Dec 99 06 Dec 99

ocT 2006 ocT 2006 06 Dec99

06 Dec99 FEB2OO3 ocT 2006 ocT 2006 JUL2OO8 JUL 2OO8 JUL2OO8 JUL 2OO4 JUL2OO4 JUL 2OOB JUL2OO8 ocT 2006 ocT 2006 ocT 2006 ocT 2006 ocT 2006 JUL 2OO8 ocT 2006 ocT 2006 JUL2OO4 06 Dec99 11Jun93 11Jun93 1 Jun 97 1 J u n9 7 ocT 2006 ocT 2006

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 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

JUL 2OO8

ocT 2006 ocT 2006 ocT 2006 ocT 2006 ocT 2006
JUL 2OO8

ocT 2006
JUL 2OO8

ocT 2006 ocT 2006 ocT 2006 ocT 2006 ocT 2006 ocT 2006 ocT 2006
JUL 2OO8 JUL 2OO8 JUL 2OOB JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OOB JUL 2OO8 JUL 2OOB

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NO' 14 LOG RE-V|S|ON (cont'd) CHANGE 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
4.i 4.ii 4.1 4.2 4.3 4.4 4.5 4.6 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 5.12 5.13 5.'14

Revision Date
JUL 2OO8 JUL 2OO8 JUL 2OO8 JAN 2OO5

Page Number
5.15 5.16 5.17 5.18 9 5.1 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30 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 6.19 6.19A 6 . 19 B 6 . 19 C

Revision Date
06 Dec 99 06 Dec 99 O6 Dec 99 O6 Dec 99 06 Dec 99 06 Dec 99

ocT 2006 ocr 2006

JUL 2OO8 JUL 2OO8 1 Jun 97 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 JUL 2OO8 JUL 2OO8 06 Dec 99 06 Dec 99

ocr 2006 ocr 2006

JUL 2OO5 JUL 2OO5 JUL 2OO5 JUL 2OO5 JUL 2OO5 JUL 2OO5 JUL 2OO5 JUL 2OO5

ocr 2006 2OO3 FEB

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

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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6.1 D 9 6.20 6.20A 6.208 6.21 6.22 6.23 6.24 FEB2OO3 FEB2OO3
7.23 7.24 7.25 ', 7.26 7.27 7.28 7.29 7.30 7.31 7.32 7.33 7.34 7.35 7.36 7.37 7.38 7.39 7.40 7.41 7.42 7.43 7.44 7.45 7.46 7.47 7.48 7.49 7.50 7.51 7.52 7.53 7.54 f.i 8.ai 8.iii B.iv 8.1 B.1A 8.18 8.2

Revision
JUL 2OO8 JUL 2OO8 18 MAR99 18 MAR99 1 2 D e c9 4 1 2 D e c9 4 06 Dec 99 1 Jun 97 12 Dec 94 11Jun93 15 Jun98 1 Jun 97 15 Jun98 15 Jun98 1 Jun 97 12 Dec 94 5 May 95 5 May 95 06 Dec 99 1 2 D e c9 4 11Jun93 1 2 D e c9 4 12 Dec94 1 Jun 97 JUL 2OO8 1 Jun 97 JUL 2OOB JUL 2OO8 5 May 95 12 Dec94 12 Dec94 1 2 D e c9 4 O6 Dec 99 JUL 2OO4

Page Number
8.3 8.3A 8.38 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8 . 11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 8.19 8.20 8.21 8.22 8.23 8.24 8.25 8.26 8.27 8.28 8.29 8.30 8.31 8.32 8.33 8.33A 8.338 8.34 8.35 8.36 8.37 8.38 8.39

Revision Date
FEB2OO3 06 Dec 99 JUL 2OO4 15Jun 98 15Jun98 15 Jun98 11Jun93 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 JUL 2OO4 JUL 2OO4 JUL 2OO4 JUL 2OO4 JUL 2OO4 JUL 2OO4 JUL 2OO4 12 Dec94 JUL 2OO4 JUL 2OO4 12 Dec94 12 Dec94 JUL 2OO4 JUL 2OO8 JUL 2OO8 JUL 2OO8

ocr 2006 ocT 2006

JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 1 Jun 97 JUL 2OO8 15 Jun98 15 Jun98 11 Jun93 "12Dec 94 5 May 95 12 Dec94 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 15 Jun 98 18 MAR99 1 Jun 97 1 Jun 97 1 Jun 97 11 Jun 93 18 MAR99 12 Dec 94 1 Jun 97 1 Jun 97 18 MAR99 1 Jun 97 18 MAR99 JUL 2OO8 JUL 2OO8 JUL 2OO8 11Jun93 1 Jun 97 1 Jun 97 JUL 2OO4

7.a
7.ii 7.iai
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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 7.19 7.20 7.21 7.22

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Revision

irti,'iu"r
8.40 8.41 8.42 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

lrlulnber
9.1,0 9.11 9.12 9.13 9.14 9.15 9.16 9.17 9.18 9.19 9.20 9.20A 9.208 9.21 9.22 9.224 9.228 9.23 9.23A 9.238 9.24 9.25 9.26 9.27 9.28 9.29 9.30 9.31 9.32 9.33 9.34 9.35 9.36 9.37 9.37A 9.378 9.37C 9.37D 9.38 9.39 9.40

Date

Page Number
9.41 9.42 9.43 9.44 9.45 9.46 9.47 9.48 9.49 9.50 9.51 9.52 9.53 9.54 10.i 10.ii 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 10.13 10.14 10.15 10.16 10.17 8 10.1 10.18A 10 . 18 8 10.19 10.20 10.21 10.22 Change

Revision Date
JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OOB JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 11Jun93 2 Jul 93 JUL 2OOB JUL 2OO8 1 2 D e c9 4 1 2 D e c9 4 JUL 2OOB JUL 2OO8 JUL 2OO8 FEB2OO3

JUL 2OO8 JUL 2OO4 JUL 2OO4 11 Jun93 JUL 2OO4 JUL 2OO4 11Jun93 11 Jun93 11 Jun93 JUL 2OO8 JUL 2OO8 2 Jul 93 5 May 95

JUL 2OO8 JUL 2OOB JUL 2OOB JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 O6 Dec 99 O6 Dec 99 06 Dec 99 06 Dec 99 1 8 M A R9 9 JUL 2OO8 JUL 2OOB

ocr 2006 ocr 2006 ocr 2006

JUL 2OO8 JUL 2OO8

ocT 2006
JUL 2OO8 JUL 2OOB JUL 2OO8 JUL 2OO8

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2006 2006 2006 2006 2006 2006 2006

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11Jun93 JUL 2OO8

JUL 2OO8 JUL 2OO8

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JUL 2OO8 JUL 2OO8 JUL 2OOB JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUr- 2008 JUL 2OO8 JUL 2OO8

ocr 2006 ocr 2006 06 Dec99

12 Dec 94 06 Dec 99 OODec 99 06 Dec 99 O6 Dec 99

ocr 2006
FEB2OO3 JUL 2OO8 JUL 2OO8 11Jun93 11 Jun93

ocr 2006
JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2008 FEB2OO3 12 Dec 94 18 MAR99

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MATNTENANcE MANUAL
CHANGE NO. 14 Page
1 1. 2 1 11.22 12.4 12.ii 12.1 12.1A 12.18 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12."t 1 12.12 13.i 13.ii 13.1 13.2 13.3 13.4 13.5 13.6 13.V 13.8 14.i 14.ii 14.1 14.2 14.3 14.3A 14.38 14.4 14.5 14.6

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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
11.i 11.ii 11 . 1 11.2 11.3 11.4 11 . 5 11 . 6 '11.7 11.8 11.9 11 . 1 0 11.11 I't.12 11 . 1 3 1 1. 1 4 11.15 11.16 1 1. 1 7 11 . 1 8 1 1. 1 9 11.20

Revision Date
2 Jul 93 FEB2OO3 FEB2OO3 FEB2OO3 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 1 Jun97 1 Jun97 OCT 2006 O C T2 0 0 6 oCT 2006 oCT 2006 oCT 2006 oCT 2006 oCT 2006 JUL2008 oCT 2006 oCT 2006 oCT 2006 J U L2 0 0 8 oCT 2006 JUL 2008

Revision
JUL 2OO8 JUL 2OO8 JUL 2OO5 11 Jun93 JUL 2OOB JUL 2OO8 JUL 2OO8 JUL 2OOB 11Jun93 11Jun93 11Jun93 11Jun93 11Jun93 11Jun93 11Jun93 11Jun93 11Jun93 11Jun93 5 May 95 11Jun93

Page Number
14.7 .14.8 14.9 14.10 14.11 14.12 14.13 14.14 14.15 14.16 14.17 14.17A 14.178 14.18 14 . 18 A 14.188 14.18C 14.18D 1 4 .1 9 14 . 19 A r 4 . 19 8 't4.20 14.20A 14.208 14.20C 14.20D 14.20E 14.20F 14.20G 14.20H 14.21 14.22 14.224 't4.228 14.22C 14.22D 14.23 14,24 14.25 14.26 14.27

Revision Date
JUL 2OO8 JUL 2OO8 11 Jun 93 11Jun93 JUL 2OO8 JUL 2OO8 JUL 2OO8 JUL 2OO8 11Jun93 11Jun93

ocT 2006 ocr 2006 ocT 2006 ocr 2006 ocT 2006 ocT 2006
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ocr 2006
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

ocT 2006 ocT 2006 JUL2OO5

JUL 2OO5 ocT 2006 ocT 2006 JUL 2OO5 JUL 2OO5 JUL 2OO8

ocr 2006
JUL 2OO4

ocT 2006 ocr 2006 ocT 2006 ocT 2006 ocr 2006
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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 15.4 15.5 15,6 15.7 15.8 15.9 15 . 1 0 16.i 16.ii 16.1 16.2 16.3 16.4 16.5 16.6 11 Jun93 15Jun98 11Jun93 11 Jun93 11Jun93 11Jun93 11Jun93 11 Jun93 1 2 D e c9 4 11 Jun93 11 Jun93 1 Jun 97 1 Jun 97

Revision

Date

Paqe Nr-imber

Revision Date

17.i 17.4i 17.1 17.2 17.3 17.4 17.5 17.6

ocr 2006 ocr 2006

JUL 2OO8 JUL 2OO8 JUL 2OOB JUL 2OO8 JUL 2OO8 JUL 2OOB

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15 Jun98 1 Jun 97

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