Robinson Helicopter Company RTR 660 Maintenance Manual Download

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SEP 2012

R66 Maintenance Manual

Chapter 12 Servicing

Page 12.19

12-82 Desiccant Replacement

Refer to R66 Illustrated Parts Catalog (IPC) Figure 21-7.

NOTE

Replace desiccant when condenser or refrigerant system is

exposed to air. To eliminate moisture, replace desiccant, then

immediately vacuum system for charging per Section 12-81.

1. Remove engine cowling per Section 53-21.

2. Recover refrigerant per Section 12-81, if not previously accomplished. Remove

condenser cap and replace desiccant.

3. Install cap, special torque cap per Section 20-33, and torque stripe.

4. Charge system with refrigerant per Section 12-81.

12-83 Leak Detection

Leaks may be detected using several techniques, depending on equipment available. Leak

detection should not be attempted with the aircraft/system running. In addition to safety

hazards, leaks are more difficult to detect with the varying pressures and temperatures of

an operating system.

An empty system should hold full vacuum (27 to 29 inches mercury vacuum at sea level)

with no assistance from the vacuum pump for 20 minutes minimum. If a vacuumed system

creeps up in pressure, a leak may be present. The technician should be thoroughly familiar

with vacuum equipment to ensure leak is in aircraft system and not in vacuum equipment

or connections.

Leaks in a charged system may be detected using a mild soap and water solution applied

to lines and fittings in suspected leak areas (bubbles indicate leaks) or using commercially

available electronic refrigerant detectors. Follow detector manufacturer’s instructions.

Large leaks may be detected audibly if area is quiet or by formation of frost in area of leak.

NOTE

Frost does not necessarily indicate a leak. Normal system

operation and/or charging procedures can cause frost to

accumulate on some components.

NOTE

System pressure is not a reliable indicator of charge state or

the presence of leaks. Because R134a is a liquid/vapor mixture

with the system at rest, pressure will remain constant as more

liquid vaporizes until majority of charge is lost.

Very small leaks can be detected by charging the system with helium gas. Helium molecules

are smaller than R134a molecules and will leak more quickly. Charge system to 200

psi maximum. Use commercially available electronic helium detector or soap and water

solution to locate leaks.

Leaks are most likely to occur at fittings and crimped transitions between hard line and

flexible hose. Concentrate initial leak detection efforts in these areas.

Summary of Contents for RTR 660

Page 1: ...a m to 12 30 p m HOLIDAYS Please visit www robinsonheli com under the Customer Support tab for a complete list of holidays and company shutdowns CUSTOMER SUPPORT AND ORDERS Please visit www robinsonhe...

Page 2: ...s Service Letters R44 Maintenance Manual Parts Catalog revisions 35 00 R44 II V Future updates to R44 II Pilot s Operating Handbook Safety Notices 15 00 W Future updates to R44 II Pilot s Operating Ha...

Page 3: ...Track and Balance Chapter 20 Standard Practices Chapter 21 Environment Control Chapter 25 Furnishings Chapter 28 Fuel System Chapter 32 Landing Gear Chapter 52 Doors and Windows Chapter 53 Fuselage C...

Page 4: ...ble the information detailed by this form Recommended changes may include but are not limited to general comments corrections omitted information or clarification of instructions Please send recommend...

Page 5: ...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...

Page 6: ...Intentionally Blank Page vi Introduction R66 Maintenance Manual SEP 2012...

Page 7: ...pe Certificate Data Sheet TCDS 4 3 CHAPTER 5 INSPECTION SCHEDULE Section Title Page 5 10 Life Limited Components 5 1 5 11 Time In Service Records 5 1 5 12 Retirement Procedure 5 1 5 20 Scheduled Maint...

Page 8: ...um 6 1 6 30 Method of Measurement 6 1 6 40 External Dimensions 6 3 6 50 Baggage Compartment Dimensions 6 4 6 60 Station Diagrams 6 6 6 61 Fuselage Station FS Locations 6 6 6 62 Tailcone Station TS Loc...

Page 9: ...10 Placard Locations 11 1 11 20 Placard Illustrations 11 3 CHAPTER 12 SERVICING Section Title Page 12 10 Main Rotor Gearbox 12 1 12 11 Servicing 12 1 12 12 Filter Replacement 12 3 12 13 Chip Detector...

Page 10: ...t Control Rigging 18 21 18 40 Main Rotor Blade Rigging 18 23 18 41 Cyclic Travel 18 24 18 42 Collective Travel 18 26 18 50 Tail Rotor Flight Control Rigging 18 28 18 51 Pedals 18 28 18 52 Forward Bell...

Page 11: ...21 9 21 30 Cabin Heat 21 11 21 31 Valve Assembly and Control Rigging 21 11 21 32 Muffler Assembly 21 12 21 33 Diffuser and Tee Assemblies 21 12 CHAPTER 25 FURNISHINGS Section Title Page 25 00 Descrip...

Page 12: ...lacement 32 8 32 40 Fairing Assemblies 32 9 32 50 Maintenance 32 9 32 60 Pop Out Floats Installation 32 11 32 61 Cylinder Assembly 32 11 32 62 Lever Rigging and Shear Rivet Replacement 32 17 32 63 Flo...

Page 13: ...2 1 62 10 Main Rotor Blades 62 1 62 11 Blade Boots 62 6 62 20 Main Rotor Hub 62 7 62 21 Bearing Replacement 62 9 62 30 Main Rotor Assembly 62 11 62 31 Journal and Shim Calculations 62 11 62 32 Adjusti...

Page 14: ...13 64 41 Bearing Replacement 64 13 64 42 Inspection 64 13 CHAPTER 65 TAIL ROTOR DRIVE SYSTEM Section Title Page 65 00 Description 65 1 65 10 Tail Rotor Drive Fan Shaft 65 1 65 20 Tail Rotor Drive Sha...

Page 15: ...5 Bellcrank 67 24 CHAPTER 71 POWERPLANT Section Title Page 71 00 Description 71 1 71 10 Engine 71 3 71 11 Preparing Engine for Rolls Royce Maintenance Facility 71 6 71 12 Preparing Engine for Helicopt...

Page 16: ...System 95 3 95 20 Primary Instruments 95 5 95 21 Vertical Speed Indicator 95 5 95 22 Airspeed Indicator 95 5 95 23 Engine N2 and Rotor Dual Tachometer 95 5 95 24 Altimeter 95 5 95 25 Torquemeter 95 6...

Page 17: ...al Load Analysis 96 9 CHAPTER 98 WIRING DIAGRAMS Figure Title Page 98 1 R66 Electrical System F024 Revision I 98 1 98 2 R66 Electrical System F024 Revision G 98 2 98 3 Air Conditioning Installation 98...

Page 18: ...Intentionally Blank Page xviii Introduction R66 Maintenance Manual SEP 2012...

Page 19: ...0 Introduction 1 1 1 20 R66 Maintenance Manual Revisions 1 1 1 30 R66 Maintenance Authorization 1 1 1 40 R66 Component Overhaul Authorization 1 1 1 50 Notations 1 2 1 60 Definitions and Abbreviations...

Page 20: ...Intentionally Blank Page 1 ii Chapter 1 General R66 Maintenance Manual SEP 2012...

Page 21: ...intenance Manual verify it consists of effective pages A complete list of effective pages is located in the Revision Log in Chapter 100 When a new manual is purchased complete and submit the Subscript...

Page 22: ...are taken for balance purposes with the aircraft in level flight attitude Refer to Section 6 20 for R66 datum location Empty Weight Empty Weight includes the weight of the airframe powerplant require...

Page 23: ...Control Unit FS Fuselage Station locations GCU Generator Control Unit HID High Intensity Discharge LBL Left Butt Line Station locations LED Light Emitting Diode MRDS Main Rotor Driveshaft MRGB Main Ro...

Page 24: ...ervice Directory Please visit www robinsonheli com and click on the Customer Support tab for a complete service directory Procure parts from any R66 Dealer or Service Center or order directly from ass...

Page 25: ...hrough the door Remove main rotor gearbox mounting hardware nylon spacers and upper frame strut assemblies 5 Remove top of main rotor gearbox crate and position crate so gearbox is upright Refer to Se...

Page 26: ...Page 1 6 Chapter 1 General R66 Maintenance Manual SEP 2012 FIGURE 1 1 ASSEMBLY INSTRUCTIONS FOR R66 HELICOPTER CRATED FOR EXPORT FIGURE 1 2 ASSEMBLY INSTRUCTIONS FOR R66 HELICOPTER CRATED FOR EXPORT...

Page 27: ...and F305 5 aft inlet Install tail rotor drive fan shaft fanwheel installed through scroll assembly Install hardware securing aft inlet to scroll assembly Verify security 12 Refer to IPC Figure 65 1 In...

Page 28: ...t shrink over wiring and connect compass pins to airframe sockets polarity is not critical Slide heat shrink over connection and apply heat Install 4 screws securing compass to mount securing wiring a...

Page 29: ...que 60 KIAS a Evaluate vibration level and controllability b Perform momentary 30 left yaw to check for adequate directional control 36 Level flight at 2000 feet density altitude deviate as required f...

Page 30: ...Intentionally Blank Page 1 10 Chapter 1 General R66 Maintenance Manual SEP 2012...

Page 31: ...R 4 AIRWORTHINESS LIMITATIONS Section Title Page 4 10 Airworthiness Limitations 4 1 4 20 Type Certificate Data Sheet TCDS 4 3 25 OCT 2010 R66 Maintenance Manual Chapter 4 Airworthiness Limitations Pag...

Page 32: ...Intentionally Blank Page 4 ii Chapter 4 Airworthiness Limitations R66 Maintenance Manual 25 OCT 2010...

Page 33: ...00 Hours D079 1 Tail Rotor Guard 2000 Hours D196 1 Tail Rotor Drive Shaft 2000 Hours F016 2 Main Rotor Blade 2000 Hours or 12 years F020 1 Upper Frame 2000 Hours F029 1 Tail Rotor Blade 2000 Hours or...

Page 34: ...Intentionally Blank Page 4 2 Chapter 4 Airworthiness Limitations R66 Maintenance Manual SEP 2011...

Page 35: ...4 20 Type Certificate Data Sheet TCDS The Robinson R66 Turbine Type Certificate Data Sheet TCDS reprinted on the following pages is subject to revision Visit the Aircraft Certification Regulatory and...

Page 36: ...Intentionally Blank Page 4 4 Chapter 4 Airworthiness Limitations R66 Maintenance Manual 25 OCT 2010...

Page 37: ...craft Approved October 25 2010 Engine One Rolls Royce 250 C300 A1 Type Certificate number E4CE Fuel Jet A or Jet A 1 conforming to ASTM D 1655 Jet B conforming to ASTM D 6615 JP 4 or JP 5 conforming t...

Page 38: ...660 Datum 100 inches forward of main rotor centerline Leveling Means For weight and balance Level placed laterally and longitudinally on aft tunnel cover immediately forward of aft middle seat If cov...

Page 39: ...omponent Capacity qt STA in Engine 6 126 0 Main Rotor Transmission 2 100 0 Tail Rotor Transmission 0 11 327 0 Hydraulic Reservoir 0 65 110 8 Maximum Operating Altitude 14 000 feet Density Altitude Max...

Page 40: ...ditional placards see the Rotorcraft Flight Manual All placards required in the FAA approved Rotorcraft Flight Manual must be installed in the appropriate locations NOTE 3 Information essential to the...

Page 41: ...tion 5 8 5 41 Ground Check 5 8 5 42 Run Up 5 10 5 43 Flight Check 5 11 5 45 100 Hour Annual Maintenance and Inspection 5 13 5 50 2000 Hour Maintenance and Inspection 5 36B 5 55 12 Year Maintenance and...

Page 42: ...Intentionally Blank Page 5 ii Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...

Page 43: ...helicopter total time Previous time in service must be included when calculating remaining component life or time between overhaul TBO CAUTION Components with mandatory overhaul times or life limits w...

Page 44: ...lic filter per Section 12 32 Drain and flush tail rotor gearbox per Section 12 23 Clean gearbox chip detectors per Section 12 13 12 22 Perform 2000 hour maintenance and inspection per Section 5 50 Ins...

Page 45: ...ction 5 45 for inspection procedures Some aircraft may require maintenance and inspections in addition to the requirements in Table 5 1 Consult aircraft maintenance records Service Bulletins SB aviati...

Page 46: ...ROD END CENTERING FIGURE 5 1 ROD END AND SPHERICAL BEARING PLAY LIMITS AND TORQUE STRIPE APPLICATION Position rod ends for maximum rotation Page 5 4 Chapter 5 Inspection Schedule R66 Maintenance Manua...

Page 47: ...s diameter in unswaged area dents or flattening is not permitted in swaged tapered and threaded ends of tubes 5 33 Rod Ends and Spherical Bearings 1 Maximum axial play 0 020 inch Maximum radial play 0...

Page 48: ...Elastomer Fatigue Elastomer Oil Contamination FIGURE 5 3 ELASTOMERIC BEARING DAMAGE Elastomer Overload Page 5 6 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...

Page 49: ...oads are applied to a bearing weakened by fatigue or oil contamination Overload is indicated by large clean cracks or extrusions from elastomer Elastomer may also separate debond from metal bushings R...

Page 50: ...riction on verify increased resistance but no binding or locking of control Verify power turbine governor rigging as follows a Turn BATTERY switch ON With collective full down hold beep switch actuato...

Page 51: ...ble panel lighting and dimmer control b Map light check function c Digital voltmeter indicates approximately 24 volts d Oil temperature gage slight needle deflection with engine cold e Fuel quantity g...

Page 52: ...horn 15 Engine performance indications are within acceptable parameters 16 Check hydraulic system operation Using cyclic mounted hydraulics switch turn hydraulics OFF Using small longitudinal cyclic i...

Page 53: ...acceptable control forces feedback with hydraulics off e Verify acceptable and normal vibration levels 3 Power Assurance Check Refer to R66 Pilot s Operating Handbook POH Chapter 5 power assurance ch...

Page 54: ...Intentionally Blank Page 5 12 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...

Page 55: ...essure water or solvent as water or solvent may cause corrosion or breakdown of lubricants See RR300 Series Operation and Maintenance Manual OMM for engine cleaning instructions and precautions Access...

Page 56: ...older Inspect condition Verify no defects cracks in plastic or material deterioration Verify security Cabin Chin and Floor Inspect condition Verify equipment security Retrieve and discard trapped debr...

Page 57: ...neatness proper routing and installation and security Fasteners Torque Stripes Inspect condition Verify proper installation and security of fasteners Renew deteriorated torque stripes per Figure 5 1 C...

Page 58: ...on Verify marking legibility Antenna Wiring Connectors Inspect condition Verify no loose chafed frayed or broken wires Verify no damaged connectors Verify neatness proper routing and installation and...

Page 59: ...ion of boot snaps Verify ty rap is properly installed loosely securing boot around collective stick Verify no defects tears or material deterioration Verify security Fuel Valve Knob and Guard Inspect...

Page 60: ...cyclic collective and removable collective boot snaps HORIZONTAL CONTROL TUNNEL Aft seats Covers Inspect condition Verify marking legibility Antenna Wiring Connectors Inspect condition Verify no loose...

Page 61: ...r broken wires Verify proper installation and security of blower and evaporator components Evaporator Drain Tubes and Valve Air Conditioning if installed Remove middle seat assembly and cover and cove...

Page 62: ...d mirror Verify no nicks scratches dents cracks corrosion or loose rivets Verify stiffener security Verify upholstery cleanliness and security Wiring Inspect condition Verify no loose chafed or broken...

Page 63: ...curity Check grommets for proper installation Placards Verify placard legibility proper installation and security Refer to Chapter 11 Fuel Tank Examine accessible portion with inspection light and mir...

Page 64: ...E At 600 hours time in service or annually whichever occurs first remove chip detector and clean off varnish build up from detector s magnetic probe and adjacent metal body a toothbrush dampened with...

Page 65: ...Drain and flush hydraulic system per Section 12 33 if oil has turned dark or emits bad odor Add fluid as required Verify security CAUTION Cleanliness of hydraulic fluid is vital to proper system oper...

Page 66: ...curity of pressure switches snubber and refrigerant lines Refrigerant Hose Assemblies Air Conditioning if installed Verify security no damage and clearance to adjacent structure Verify dust caps insta...

Page 67: ...osion or fretting Inspect weld for cracks or corrosion Verify proper installation security and operating clearance A947 2 Main Rotor Drive Plate Assemblies Inspect condition Inspect flex plate for dis...

Page 68: ...nas mount to cowling Verify security Close Secure Verify foreign objects are removed Verify equipment security Verify cleanliness of interior and of inspection and access doors and cowlings Connect an...

Page 69: ...ilter security Oil Lines Inspect condition Verify no leakage where line connects to tank Verify no leakage chafing or obvious damage to oil lines Verify line clearance to installed equipment and surro...

Page 70: ...be frame is fatigue loaded and therefore susceptible to fatigue cracks Inspect all joints thoroughly Condenser and Fan Assemblies Air Conditioning if installed Inspect condition Verify security of fan...

Page 71: ...earance Verify tail rotor guard mounting screw shanks clear push pull tube Tail Rotor Drive Shaft Hanger Bearing Hanger Inspect condition Inspect bearing for obvious damage Verify integrity of bearing...

Page 72: ...ic inspection cover Longer screws could contact aft flex coupling and yoke Plastic Inspection Cover Clean cover and inspect condition Replace as required C947 3 Tail Rotor Drive Plate Assembly Aft Ins...

Page 73: ...ct condition Inspect rod ends per Section 5 33 Remove and reinstall pitch links with outboard end inboard and inboard end outboard as required to obtain maximum service life Reinstall chordwise weight...

Page 74: ...dment and Tygon Tubes Inspect condition Verify no obstructions cracking chafing pinching or kinking in plastic tubes Inspect vents for cracks or obvious damage Verify proper installation and security...

Page 75: ...r installation and security of fasteners Renew deteriorated torque stripes per Figure 5 1 Close Secure Verify foreign objects are removed Verify equipment security Verify cleanliness of interior and o...

Page 76: ...y Exposed Skin to Spar Bond Line Refinish exposed bond line per Section 62 50 Blade Surfaces Inspect condition Inspect blade surfaces for excessive erosion nicks scratches buckling voids or debonding...

Page 77: ...ecurity of fasteners Renew deteriorated torque stripes per Figure 5 1 D679 Cylinder assembly Pop out floats if installed Inspect condition Verify security Verify pressure gage indicates correct pressu...

Page 78: ...fy security Landing Taxi Lights Inspect condition Verify lens cleanliness clarity and security Verify proper operation Landing Light Retainer Support Inspect condition Verify no cracks where retainer...

Page 79: ...w faa gov Service Bulletins Verify all applicable airframe engine and accessory Service Bulletins have been complied with according to manufacturers instructions Some aircraft may be affected by Servi...

Page 80: ...otor controls 1 9 A947 2 Plate Assembly engine drive line 2 10 B173 5 V Belt compressor drive cabin air conditioning 1 11 B283 12 Hose Assembly Fuel 1 12 B345 4 Pitch Link Tail Rotor 2 13 C005 13 Main...

Page 81: ...ust Weldment 1 45 F169 2 Base exhaust interface 1 46 F173 1 Strut exhaust weldment supports 3 47 F235 13 Strut Upper Frame 2 48 F252 1 Strut Upper Frame 1 49 F579 1 Seal Firewall 1 50 F628 1 Connector...

Page 82: ...4 Line Assembly Heater 1 71 G391 5 Line Assembly Heater 1 72 G400 1 Tee Assembly Heater 1 73 R5352 Main Rotor Blade Crate 1 74 R7982 Main Rotor Gearbox Crate 1 75 R7983 C017 5 Swashplate Installation...

Page 83: ...ng or breakage or buckling of lower vertical stabilizer perform the following inspections in addition to those listed in Step A 1 Perform tail rotor drive shaft runout per Section 65 21 2 Remove tailc...

Page 84: ...ed b Remove tail rotor assembly per Section 64 10 and tail rotor gearbox per Section 65 40 and return to RHC c Visually inspect D224 3 tail rotor drive shaft for evidence of twisting nicks dents or sc...

Page 85: ...uckling or permanent bending is considered sudden stoppage and requires a sudden stoppage inspection of the entire rotorcraft 2 If main rotor blade or blades have contacted ground or a solid object th...

Page 86: ...ect main and tail rotor blades d Check tail rotor drive shaft runout per Section 65 21 2 If an overspeed at or above 112 is reported or suspected or if balance changes or pitch bearing roughness is ev...

Page 87: ...and release allowing rotorcraft to settle then measure from tip of tail skid to ground If less than 38 inches one or both cross tubes must be replaced d Inspect front seat structure for yielding Visu...

Page 88: ...c chromate or epoxy primer and allow adequate drying time 7 Refinish area with gray epoxy top coat or equivalent 5 67 Corrosion on F020 1 Upper Frame 1 Polish out corrosion on steel frame tube members...

Page 89: ...or particles if possible 5 70 Tail Rotor Gearbox TR Chip Light Illumination If the TR CHIP annunciator segment illuminates 1 Drain the gearbox per Section 12 21 straining the oil through a 190 micron...

Page 90: ...Intentionally Blank Page 5 44 Chapter 5 Inspection Schedule R66 Maintenance Manual 25 OCT 2010...

Page 91: ...6 20 Datum 6 1 6 30 Method of Measurement 6 1 6 40 External Dimensions 6 3 6 50 Baggage Compartment Dimensions 6 4 6 60 Station Diagrams 6 6 6 61 Fuselage Station FS Locations 6 6 6 62 Tailcone Stati...

Page 92: ...Intentionally Blank Page 6 ii Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010...

Page 93: ...normally rated at 300 shaft horsepower SHP 270 SHP 5 minute take off rating Maximum gross weight 2700 pounds Primary fuel is Jet A see R66 Pilot s Operating Handbook 74 6 US gallon fuel tank capacity...

Page 94: ...Intentionally Blank Page 6 2 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010...

Page 95: ...FIGURE 6 1 EXTERNAL DIMENSIONS 6 40 External Dimensions 25 OCT 2010 R66 Maintenance Manual Chapter 6 Dimensions and Descriptions Page 6 3...

Page 96: ...50 Baggage Compartment Dimensions FIGURE 6 2 BAGGAGE COMPARTMENT INTERIOR DIMENSIONS Dimensions given are approximate Page 6 4 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010...

Page 97: ...E 6 3 BAGGAGE COMPARTMENT ACCESS DIMENSIONS Dimensions given are approximate 6 50 Baggage Compartment Dimensions continued 25 OCT 2010 R66 Maintenance Manual Chapter 6 Dimensions and Descriptions Page...

Page 98: ...s Tube Forward centerline at strut FS 71 56 7 Baggage Compartment forward wall FS 92 00 8 Main Rotor Drive Shaft centerline FS 100 00 9 Fuel Cell Structure aft wall FS 115 00 10 Engine Firewall Vertic...

Page 99: ...0 3 Aft Edge C023 7 Skin Tailcone Centerline Intersection TS 51 00 4 Aft Edge C023 8 Skin Tailcone Centerline Intersection TS 74 00 5 Aft Edge C023 9 Skin Tailcone Centerline Intersection TS 98 00 6 A...

Page 100: ...box tail rotor and main rotor drive shaft intersection point WL 66 00 7 Baggage Compartment ceiling lowest point WL 45 60 8 Baggage Compartment floor WL 22 59 9 Belly WL 20 78 10 Landing Gear WL 0 79...

Page 101: ...be centerline BL 42 00 3 Door Post between forward aft doors BL 28 25 4 Jack Lug Tab aft strut assembly BL 16 73 5 Ground Handling Ball jack point BL 4 13 6 Origin BL 0 00 7 Teeter Hinge Bolt tail rot...

Page 102: ...FIGURE 6 8 INTERIOR ACCESS INSPECTION PANELS Page 6 10 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual SEP 2012...

Page 103: ...over Assembly Collective Pilot 29 G004 2 Aft Fuselage Assembly Door Fuel Fill 9 F680 1 Cover Assembly Collective Copilot 30 G004 10 Aft Fuselage Assembly Door Access 10 F461 1 Cover Assembly Collectiv...

Page 104: ...CI 177 450 470 CI 177 20 Lower Aft VHF 118 136 CI 122 RH Belly AM FM CI 222 Lower Aft FM 403 512 CI 273 CI 272 1 CI 271 RH Belly FM 403 512 CI 273 CI 272 1 CI 271 800 870 CI 306 8 LH Belly FM 138 174...

Page 105: ...CHAPTER 7 JACKING AND HOISTING Section Title Page 7 10 Jacking 7 1 7 20 Hoisting 7 5 25 OCT 2010 R66 Maintenance Manual Chapter 7 Jacking and Hoisting Page 7 i...

Page 106: ...Intentionally Blank Page 7 ii Chapter 7 Jacking and Hoisting R66 Maintenance Manual 25 OCT 2010...

Page 107: ...pter is raised A Jacking 1 Refer to Figure 7 1 Place one appropriate capacity jack under each landing gear aft strut assembly jack lug tab and under the ground handling ball Install jacking point adap...

Page 108: ...FIGURE 7 1 JACKING Page 7 2 Chapter 7 Jacking and Hoisting R66 Maintenance Manual SEP 2012...

Page 109: ...1 Refer to Figure 7 1 Slowly and simultaneously one person per jack recommended lower each jack ram maintaining helicopter stability Lower aircraft to ground 2 Clear jacks from lugs tabs and ball and...

Page 110: ...FIGURE 7 2 HOISTING Page 7 4 Chapter 7 Jacking and Hoisting R66 Maintenance Manual SEP 2012...

Page 111: ...s through fixture and bushings until pins lock Verify security 4 Connect hoist to lifting fixture Verify security 5 Stabilize helicopter as required by guiding tail skid but do not exert force tail sk...

Page 112: ...ze helicopter as required by guiding tail skid but do not exert force tail skid is secondary structure Slowly lower aircraft to ground 2 Disconnect hoisting equipment remove lifting fixture or nylon r...

Page 113: ...ALANCE Section Title Page 8 10 Leveling 8 1 8 11 Leveling for Weight and Balance 8 1 8 12 Leveling for Rigging 8 3 8 20 Weighing 8 5 8 21 Preparing Helicopter for Weighing 8 5 8 22 Weighing Procedure...

Page 114: ...Intentionally Blank Page 8 ii Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...

Page 115: ...ons 1 Jack helicopter per Section 7 10 2 Refer to Figure 8 1 Place a spirit level laterally on F463 1 aft tunnel cover Verify cover is flat if cover is not flat remove cover and place spirit level acr...

Page 116: ...1 LEVELING FOR WEIGHT AND BALANCE Lateral shown view looking down between aft seat footwells Page 8 2 Chapter 8 Weight and Balance R66 Maintenance Manual SEP 2012 FIGURE 8 2 LEVELING FOR RIGGING Later...

Page 117: ...bolt at location marked LEVEL HERE on top of main rotor hub 4 Adjust jack at landing gear aft strut assembly jack lugs tabs until helicopter is level laterally 5 Release rotor brake and rotate main ro...

Page 118: ...Intentionally Blank Page 8 4 Chapter 8 Weight and Balance R66 Maintenance Manual SEP 2012...

Page 119: ...the wind Weigh helicopter on a flat hard surface in a zero wind environment for accurate scale readings 8 21 Preparing Helicopter for Weighing 1 Defuel helicopter per Section 12 42 2 Service engine oi...

Page 120: ...Page 8 6 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010 FIGURE 8 3 WEIGHING Scale indications for demonstration only...

Page 121: ...Figure 8 3 Place a jack and one 1000 lb capacity minimum scale under each landing gear aft strut assembly jack lug tab and under the ground handling ball 3 Zero scales or record tare weight items betw...

Page 122: ...copter and calculate new weight and CG per the previous steps c If Calculated CG is less than 101 50 and nose ballast is installed determine minimum nose ballast to remove 102 50 Calculated CG X Calcu...

Page 123: ...gitudinal CG arm inches Moment in lb Forward Net x 32 67 Left Net x 127 35 Right Net x 127 35 Unusable fuel add 6 70 x 110 40 739 68 Basic empty weight and longitudinal CG 9 Calculate basic empty weig...

Page 124: ...FIGURE 8 4 NOSE BALLAST View inside lower console assembly with upper console hinged aft Page 8 10 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...

Page 125: ...1 panel 3 Remove or install ballast plates per calculations performed in Section 8 22 Select NAS6603 bolt length to meet torque requirements per Section 20 30 Install hardware torque bolts per Sectio...

Page 126: ...FIGURE 8 5 EMPENNAGE BALLAST Page 8 12 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...

Page 127: ...s While primer is wet install empennage assembly per Section 53 50 Topcoat hardware with colored paint as desired 4 Reweigh and or calculate basic empty weight and CG per Section 8 22 5 Revise Weight...

Page 128: ...ch D301 2 weight remove paint from one flat surface which will clamp against stabilizer 6 Remove tracing media Solvent clean bare metal on horizontal stabilizer and weight clamping surfaces 7 Reweigh...

Page 129: ...Handling Page 9 i CHAPTER 9 GROUND HANDLING Section Title Page 9 10 Ground Handling 9 1 9 11 Ground Handling Wheels 9 1 9 12 Moving Helicopter on Ground Handling Wheels 9 3 9 13 Ground Handling Carts...

Page 130: ...Intentionally Blank Page 9 ii Chapter 9 Ground Handling R66 Maintenance Manual 25 OCT 2010...

Page 131: ...raised WARNING Remove ground handling wheels for flight A Installation NOTE Verify proper inflation of ground handling wheel tires Maximum tire inflation pressure is 70 psi 1 Extend ground handling w...

Page 132: ...of cradle 3 Pull handle in rearward arc to raise helicopter NOTE R66 ground handling wheels are installed inboard of landing gear skid tubes C063 5 LH and C063 6 RH ground handling wheel assemblies ar...

Page 133: ...r extensions NOTE Steer helicopter by gripping the tail rotor gearbox aft tailcone section or inboard part of horizontal stabilizer between tailcone and vertical stabilizers CAUTION Do not steer helic...

Page 134: ...pport point s to prevent tailcone damage 3 Perform one of the following options a Remove main rotor blades per Section 62 10 Pack blades in shipping crate See R66 Illustrated Parts Catalog IPC Figure...

Page 135: ...and Storage Page 10 i CHAPTER 10 PARKING AND STORAGE Section Title Page 10 10 Parking 10 1 10 11 Parking in High Wind or Turbulent Air 10 1 10 12 Main Rotor Blade Tie Downs 10 3 10 13 Main Rotor Blade...

Page 136: ...Intentionally Blank Page 10 ii Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010...

Page 137: ...ulent Air Helicopter should be hangared or moved to a safe area during storm conditions or when storm conditions are forecasted When parking helicopter in high winds or when aircraft is exposed to pro...

Page 138: ...FIGURE 10 1 MAIN ROTOR BLADE TIE DOWNS Page 10 2 Chapter 10 Parking and Storage R66 Maintenance Manual SEP 2012...

Page 139: ...Maximum tie down tension is 5 lb 1 Park helicopter and position blades per Section 10 10 or 10 11 2 Refer to Figure 10 1 Slide MT290 3 tie down jacket over forward lowered main rotor blade tip with wh...

Page 140: ...FIGURE 10 2 MAIN ROTOR BLADE SUPPORTS Page 10 4 Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010...

Page 141: ...tion landing gear eyebolts and roof mounted cleat is required for mounting blade supports 1 Refer to Figure 10 2 Position main rotor blades approximately fore and aft 2 Install MT564 1 cradle assembly...

Page 142: ...ades per Section 64 36 4 Open applicable circuit breakers 5 RemovebatteryperChapter96 Inspect servicebatteryaccordingtobatterymanufacturer s instructions 6 Service engine oil hydraulic fluid and main...

Page 143: ...CHAPTER 11 PLACARDS AND MARKINGS Section Title Page 11 10 Placard Locations 11 1 11 20 Placard Illustrations 11 3 SEP 2012 R66 Maintenance Manual Chapter 11 Placards and Markings Page 11 i...

Page 144: ...Page 11 0 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012 FIGURE 11 1 PLACARD LOCATIONS...

Page 145: ...llective stick 1 18 A654 21 Decal NO STOWAGE KEEP AREA CLEAR 1 19 A654 12 Decal OPEN LH door outside black lettering 2 A654 10 Decal OPEN LH door outside white lettering 2 20 C654 7 Decal STATIC PORT...

Page 146: ...FIGURE 11 2 PLACARD LOCATIONS Page 11 2 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012...

Page 147: ...tructions 1 47 A654 11 Decal OPEN RH door outside black lettering 2 A654 9 Decal OPEN RH door outside white lettering 2 48 F654 24 Decal BATTERY LOCATED BEHIND THIS PANEL 1 49 F654 8 Decal LATCH black...

Page 148: ...9 Decal F654 10 11 Decal F654 1 12 Decal A654 7 13 Cover F445 1 15 Cover F444 1 Page 11 4 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012 10 Decal F654 17 14 Decal A654 45 6 Decal F6...

Page 149: ...ngs Page 11 5 16 Panel Assembly F490 1 11 20 Placard Illustrations continued 17 Decal A654 6 18 Decal A654 21 19 Decal A654 12 20 Decal C654 7 21 Decal C654 8 not shown see No 20 22 Decal F654 5 23 De...

Page 150: ...ions continued 31 Marking A321 19 co pilot weldment 32 Marking A756 24 pilot weldment see No 31 Page 11 6 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012 30 Decal F654 16 29 Decal F65...

Page 151: ...Assembly F463 1 40 Cover C710 1 41 Cover C712 2 11 20 Placard Illustrations continued 42 Handle D119 1 45 Decal A654 16 35 Decal A654 45 see No 14 36 Decal A654 17 38 Decal F654 27 39 Console Assembly...

Page 152: ...49 Decal F654 9 51 Faceplate G598 1 52 Decal A654 3 54 Decal C654 2 11 20 Placard Illustrations continued Page 11 8 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012 47 Decal A654 11 48...

Page 153: ...12 23 Drain and Flush 12 8 12 30 Hydraulic System 12 9 12 31 Servicing 12 9 12 32 Filter Replacement 12 9 12 33 Drain and Flush 12 11 12 34 Bleeding 12 12 12 40 Fuel System 12 13 12 41 Fueling 12 13...

Page 154: ...Intentionally Blank Page 12 ii Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

Page 155: ...ion drain hose overboard into a suitable drain container Jam wedge between support panel stiffener and drain assembly fitting to open valve B Adding Fluid 1 Install chip detector per Section 12 13 if...

Page 156: ...FIGURE 12 1 MAIN ROTOR GEARBOX SERVICING Page 12 2 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

Page 157: ...ector and Sight Gage A Removal 1 Refer to Figure 12 1 Disconnect chip detector wiring as required Remove chip detector from housing NOTE Remove chip detector housing and inspect for obvious damage if...

Page 158: ...FIGURE 12 2 DRAINING MAIN ROTOR GEARBOX OIL Page 12 4 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

Page 159: ...ght gage and special torque per Section 20 33 2 Verify cleanliness of chip detector and housing As required remove and clean chip detector and housing per Parts A and B Install housing and special tor...

Page 160: ...FIGURE 12 3 TAIL ROTOR GEARBOX Page 12 6 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

Page 161: ...evel A Draining Fluid 1 Refer to Figure 12 3 Cut and discard ty raps as required and disconnect chip detector wiring from airframe harness at connectors 2 Place a suitable drain container under gearbo...

Page 162: ...s required Cinch ty raps until snug without over tightening and trim tips flush with heads 4 Turn BATTERY switch ON Verify TR CHIP warning segment illuminates when test button is depressed Turn BATTER...

Page 163: ...ove D516 1 cap and filter and visually inspect element for contaminants If element is clear proceed to step 3 If metal contamination is found use a magnet to determine if metal is ferrous If metal is...

Page 164: ...FIGURE 12 4 HYDRAULIC SYSTEM Page 12 10 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

Page 165: ...aks 7 Simultaneously fully raise collective and move cyclic fully forward then simultaneously fully lower collective and move cyclic fully aft Monitor reservoir fluid level and fill as required Repeat...

Page 166: ...ect hydraulic system for leaks 4 Simultaneously fully raise collective and move cyclic fully forward then simultaneously fully lower collective and move cyclic fully aft Repeat procedure ten times 5 S...

Page 167: ...ed Parts Catalog IPC Figure 28 9 1 Remove engine cowling per Section 53 21 2 Turn BATTERY switch OFF Pull fuel valve control OFF 3 Disconnect B283 12 hose at F670 1 valve raise hose vertically and plu...

Page 168: ...FIGURE 12 5 MAIN ROTOR BLADE PITCH BEARING HOUSING Page 12 14 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

Page 169: ...pply container with sufficient A257 4 fluid approximately 3 feet above spindle Route fill hose assembly into drain container and open brass valve Open supply container plastic valve and purge air from...

Page 170: ...contaminate engine oil Service engine oil system with clean fluid from sealed containers using clean tools NOTE When servicing airframe oil tank full oil quantity is six quarts minimum quantity for t...

Page 171: ...ppropriate cleaning system hose to delivery tube 5 Refer to RR300 Series OMM for compressor rinse and wash procedures To motor engine without ignition system a Release rotor brake b Turn BATTERY switc...

Page 172: ...ualified A Refrigerant Recovery NOTE If a leak or other service problem is encountered after system is charged with refrigerant refrigerant must be recovered before work on system can proceed 1 Remove...

Page 173: ...nician should be thoroughly familiar with vacuum equipment to ensure leak is in aircraft system and not in vacuum equipment or connections Leaks in a charged system may be detected using a mild soap a...

Page 174: ...Intentionally Blank Page 12 20 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

Page 175: ...ting 18 11 18 16 Autorotational RPM Adjustment 18 12 18 20 Tail Rotor Dynamic Balance 18 17 18 21 Preparing Helicopter for Tail Rotor Dynamic Balance 18 17 18 22 Ground Checks 18 19 18 23 Balance Adju...

Page 176: ...Intentionally Blank Page 18 ii Chapter 18 Track and Balance R66 Maintenance Manual SEP 2012...

Page 177: ...once a year or if equipment is dropped misused or calibration is suspect NOTE The Chadwick Helmuth Vibrex system the TEC ACES system the Dynamic Solutions Systems MicroVib system or equivalent equipme...

Page 178: ...FIGURE 18 1 MAIN ROTOR BALANCING EQUIPMENT INSTALLATION Page 18 2 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

Page 179: ...te bracket Set swashplate mounted interrupter to pickup gap to 0 030 inch 0 010 inch and tighten pickup nuts against bracket Safety nuts using 0 020 inch diameter lockwire Recheck gap 5 Pull collectiv...

Page 180: ...50 60 70 80 90 100 110 120 130 140 I I I I I I I I I I I I I I I I I I I I I I FIGURE 18 2 MAIN ROTOR TRACK AND BALANCE CHART TIP WEIGHTS 1 AN960 10 Washer 2 AN960 10L Washers 1 C298 2 Weight 5 AN960...

Page 181: ...Maximum vibration allowance is 0 2 ips inches per second Adjust balance per Section 18 14 as required record data and recheck balance in a hover Repeat step as required until main rotor balance is wi...

Page 182: ...m Length Adjustment Upper Rod End Only One half rod end turn changes blade track 0 25 inch One full rod end turn changes blade angle 0 48 Fine Adjustment Fitting Only One full turn changes blade track...

Page 183: ...without binding Using backup wrench on link assembly torque jam nut per Section 20 32 Safety fitting to link assembly using 0 032 inch diameter lockwire e Repeat steps on opposite pitch link as requir...

Page 184: ...FIGURE 18 4 MAIN ROTOR BLADE TRIM TAB Page 18 8 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

Page 185: ...ting torque rod end jam nut and palnut per Section 20 32 Safety fitting to link assembly using 0 032 inch diameter lockwire e Repeat steps on opposite pitch link as required Torque stripe per Figure 5...

Page 186: ...uired per Figure 18 2 Washers may be trimmed Special torque fasteners securing tip weights per Section 20 33 Install tip cover and standard torque fasteners per Section 20 32 1 AN960 10 or NAS1149F036...

Page 187: ...lacement 2 Excessive Ship Vibration MR out of track and balance Track and balance per Section 18 10 MR teeter or coning hinge friction Adjust hinge friction per Section 62 32 MR teeter or coning hinge...

Page 188: ...eter reading 2 Set the altimeter to 29 92 Hg 1013 2 millibars prior to performing the autorotation Autorotate with the collective control firmly held against the down stop with an airspeed of 50 KIAS...

Page 189: ...side air temperature and draw a vertical line up to pressure altitude b Draw a horizontal line from pressure altitude to rotorcraft gross weight at time of autorotation c Draw a vertical line down fro...

Page 190: ...ll turn of rod ends approximately 3 RPM change One full turn of rod end 1 turns of barrel Example OAT 20 C Hp 2000 ft GW 1800 lb RPM 103 FIGURE 18 5 AUTOROTATION RPM ADJUSTMENT Page 18 14 Chapter 18 T...

Page 191: ...Intentionally Blank 25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance Page 18 15...

Page 192: ...FIGURE 18 6 TAIL ROTOR BALANCING EQUIPMENT INSTALLATION Page 18 16 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

Page 193: ...ns 5 33 and 5 34 2 Track tail rotor blades per Section 64 10 3 Refer to Figure 18 6 If using photocell to obtain clock angle install a target tape spanwise on inboard side of one arm of tail rotor hub...

Page 194: ...shers 2 NAS1149F0632P 1 NAS1149F0663P Washer BALANCE CLOCK IPS ADJUSTMENT CLOCK IPS ADJUSTMENT CLOCK IPS ADJUSTMENT CLOCK IPS ADJUSTMENT PITCH HORN TO PITCH LINK FASTENER CHORDWISE WEIGHTS 1 NAS1149F0...

Page 195: ...Install 0 032 inch diameter lockwire securing cap retaining hardware and safety in pairs WARNING A rotor which is smooth after balancing but goes out of balance within a few flights is suspect and mus...

Page 196: ...FIGURE 18 8 SWASHPLATE AND COLLECTIVE CONTROL RIGGING FIGURE 18 9 A205 5 SWASHPLATE FORK RIGGING Page 18 20 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

Page 197: ...assemblies and fork assembly located between keel panels to the noted rod end center to center dimensions PART NUMBER DIMENSION C121 1 51 15 0 03 inches F121 1 32 36 0 03 inches G205 1 5 40 0 03 inch...

Page 198: ...FIGURE 18 10 MAIN ROTOR BLADE RIGGING Page 18 22 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

Page 199: ...mark the opposite blade s tip height Teeter main rotor hub as required until blade tips are level within 1 inch 2 Refer to Figure 18 10 Using felt tip marker mark upper surface of both main rotor bla...

Page 200: ...ade angles per Section 18 40 Part B to determine the values below Rotate blades 180 and align per step 3 as required BLUE BLADE RED BLADE Pitch horn forward Pitch horn forward Pitch horn aft Pitch hor...

Page 201: ...blade angles must average between 12 5 and 13 5 more than collective down position average Adjust main rotor blade pitch links per Section 18 13 as required one full barrel turn 0 72 until blade angl...

Page 202: ...eft position Adjust swashplate forward left or right push pull tube as required one full turn 0 6 B Cyclic Right 1 Position collective stick full down Position cyclic stick in the longitudinal neutral...

Page 203: ...ustment can be made by adjusting swashplate forward push pull tubes exactly the same amount one full turn 0 6 D Cyclic Aft 1 Position collective stick full down Position cyclic stick in the lateral ne...

Page 204: ...ull tubes as required to obtain a dimension of 5 24 0 03 in from the lower forward NAS6604 9 bolt in C317 5 bellcrank and horizontal pedal torque tube 18 52 Forward Bellcrank Remove the rigging pin an...

Page 205: ...the tail rotor 180 and record the opposite blade angle Pedals Full Left Blue Blade Red Blade 2 18 5 19 0 required 7 Difference between blue and red blade angles may not exceed 0 4 If blade angles exc...

Page 206: ...reater than 35 5 the total travel is too great b If the total travel is too small first increase the right pedal travel by increasing the length of C121 9 push pull tube To increase the left pedal tra...

Page 207: ...Control 20 13 20 60 Priming and Painting 20 13 20 70 Approved Materials 20 16 20 71 Paint Strippers 20 16 20 72 Solvents and Cleaners 20 16 20 73 Fillers and Putty 20 17 20 74 Torque Seal 20 17 20 75...

Page 208: ...Intentionally Blank Page 20 ii Chapter 20 Standard Practices R66 Maintenance Manual 25 OCT 2010...

Page 209: ...ain holes pitot tube or static ports WARNING Refer to appropriate Material Safety Data Sheet MSDS and take necessary safety precautions when working in proximity to hazardous materials A Cleaning Exte...

Page 210: ...ng 3 Leather should be cleaned with saddle soap or a mild hard soap and water D Cleaning Carpet Remove loose dirt with a whisk broom or vacuum For soiled spots and stains use nonflammable dry cleaning...

Page 211: ...AS1305 bolt used with a NAS1068 nutplate is determined as follows NAS1305 bolt 5 indicates 5 16 inch size dry torque per Section 20 32 240 in lb Add 10 because torque must be applied at bolt head 24 i...

Page 212: ...lve for Y T x L 135 x 10 1350 117 39 L A 10 1 5 11 5 Set torque wrench to 117 in lb to torque fastener to 135 in lb Given Symbols Y Unknown Y Torque wrench setting T 135 in lb T Torque applied to fast...

Page 213: ...nd 20 2 4 Proper thread engagement requires 2 4 threads beyond primary self locking nut palnuts excepted 5 Torque wrenches must be calibrated annually when dropped or when a calibration error is suspe...

Page 214: ...UTS 10 32 B330 7 MS27151 7 6 to 15 1 4 28 B330 13 MS27151 13 11 to 25 5 16 24 B330 16 MS27151 16 20 to 40 3 8 24 B330 19 MS27151 19 29 to 60 7 16 20 B330 21 MS27151 21 42 to 85 1 2 20 B330 24 MS27151...

Page 215: ...B nuts 270 300 1 F723 1 line assembly B nuts 330 360 1 F723 2 line assembly B nuts 230 260 1 F723 3 line assembly B nuts 230 260 1 F723 4 line assembly B nuts 230 260 1 F724 1 line assembly B nuts 110...

Page 216: ...ter stud 11 1 G254 2 fitting vent assembly 200 1 G254 6 retainer vent assembly 200 1 MS21042L3 nut securing fuel valve control wire 27 1 B254 3 strainer fuel bladder outlet 150 1 D205 21 hose assembly...

Page 217: ...olt securing landing gear to fuselage supports and shackles 66 FT LB 4 B277 28 clamp securing fairings to struts 15 POP OUT FLOATS OPTIONAL EQUIPMENT 1 D674 2 hose assembly B nuts 230 260 1 D674 6 hos...

Page 218: ...er generator supplied 20 2 nuts securing harness wires to starter generator large terminals starter generator supplied 180 1 nut securing harness wire to ignition exciter box engine supplied 15 2 nuts...

Page 219: ...Unless otherwise noted thread sizes 8 32 smaller are not used for primary structure do not require specific torque 20 34 Push Pull Tube Rod End Adjustment NOTE Refer to Section 18 13 to adjust C258 1...

Page 220: ...Criteria Parts except gears which are inspected by magnetic particle inspection shall be accepted or rejected according to the following criteria Acceptable indications Indications smaller than 0 015...

Page 221: ...tance limits specified If acceptance limits are not specified rejectable surface defects and any of the following Cracks y y Seams y y Cold shuts or laps y y Surface inclusions y y In castings aligned...

Page 222: ...and air dry may be used on a limited basis If a solvent vapor bath is selected a degreaser which incorporates a spray flushing nozzle must be utilized except for specific parts noted herein Clean stee...

Page 223: ...Bolted joints where torque is a specific requirement for clamping action y y Bearing press fit or close tolerance slip fit joints except where wet chromate primer is y y part of the assembly procedur...

Page 224: ...ades and flex plates Plastic Media Blasting System Pauli Griffin Co Vacaville CA Metal parts except blades and unsupported sheet metal less than 0 040 inch thick 20 72 Solvents and Cleaners Product Ma...

Page 225: ...imperfections 051144 05960 Acryl Green Spot Putty 3M Co St Paul MN SBF1191 Gearhead Products Indianapolis IN 20 74 Torque Seal PRODUCT MANUFACTURER SUPPLIER APPLICATION F 900 Any color except red Org...

Page 226: ...bert Chemical Coatings Buffalo NY Total coating thickness allowance is 0 003 to 0 007 inches epoxy and topcoat Coating may exceed maximum thickness in local areas due to part geometry PRODUCT MANUFACT...

Page 227: ...Los Angeles CA G Clear Imron 3480S or 2400S with 193S or 8909S activator H Clear Imron 3480S or 2400S 1 part and RK P 19478 11 parts with 193S or 8909S activator 4 parts J White Imron 2 1 FT flat Poly...

Page 228: ...FIGURE 20 3 FINISH CODE LOCATIONS EXTERIOR Page 20 20 Chapter 20 Standard Practices R66 Maintenance Manual 25 OCT 2010...

Page 229: ...FIGURE 20 4 FINISH CODE LOCATIONS INTERIOR SEP 2012 R66 Maintenance Manual Chapter 20 Standard Practices Page 20 21...

Page 230: ...Inc Cleveland OH United Erie Div of Interstate Chemical Co Erie PA A257 7 Lubri Kote Type A 1040 CR dry film lubricant Mealey Ind Lubricants Cleveland OH A257 8 P 80 rubber lubricant International Pr...

Page 231: ...0 12 Sealant electrical potting 2 part Any color except red MIL PRF 8516 Type II Class 2 Category A or B Any B270 13 Sealant silicone rubber electronic use 1 part Translucent 3145 Dow Corning Corp Mid...

Page 232: ...d service life is on condition with a maximum of 12 years Use invoice or FAA Form 8130 date as start date 3 Store V belts at less than 85 F 30 C with relative humidity below 70 Avoid solvent and oil v...

Page 233: ...AN960 6 washer NAS1149FN632P washer AN960 8L washer NAS1149FN816P washer AN960 8 washer NAS1149FN832P washer AN960 10L washer NAS1149F0332P washer AN960 10 washer NAS1149F0363P washer AN960 416L washe...

Page 234: ...the oven control to determine part temperature Cooling a part for thermal fitting at assembly is not recommended Water vapor from the air will condense on the part and frequently introduce water into...

Page 235: ...1 21 10 Ventilation 21 3 21 11 Nose Vent 21 3 21 20 Air Conditioning 21 5 21 21 Compressor Assembly 21 5 21 22 Condenser and Fan Assemblies 21 7 21 23 Evaporator Assembly 21 8 21 24 Troubleshooting 2...

Page 236: ...Intentionally Blank Page 21 ii Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...

Page 237: ...scoop collects the necessary cooling air for the condenser during forward flight In a hover electric fans help to draw cooling air through the condenser The evaporator blower draws warm cabin air tho...

Page 238: ...FIGURE 21 1 NOSE VENT Page 21 2 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...

Page 239: ...control housing but do not tighten jam nut Install AN742 3 clamp and new as required MS35489 4 grommet on control housing 2 Position control in lower console and install screws securing mount assembly...

Page 240: ...FIGURE 21 2 AIR CONDITIONING SCHEMATIC Page 21 4 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...

Page 241: ...compressor down and inboard as required to disengage B173 5 v belt from pulleys Route belt around drive shaft flange and remove belt 5 Route new B173 5 v belt around drive shaft flange and fit belt on...

Page 242: ...ulley and install hardware securing compressor to G782 1 mount weldment Standard torque bolts per Section 20 32 3 Install hardware securing compressor to G781 1 arm weldment Rotate compressor up and o...

Page 243: ...ser to G787 support assemblies Taking care not to damage line assemblies and condenser fittings carefully remove condenser Cap fittings B Installation 1 Remove caps Install hardware securing G783 1 co...

Page 244: ...cover to middle seat if installed Detach grommet from seat assembly and carefully remove evaporator and attached components forward through seat assembly vertical wall relief Cap fittings B Installati...

Page 245: ...switch All switches should be closed with a properly charged system and aircraft at rest on ground Replace any defective switch Failed Compressor V Belt Inspect belt Replace belt per Section 21 21 as...

Page 246: ...Page 21 10 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012 FIGURE 21 3 CABIN HEAT...

Page 247: ...all clamps spacers and hardware securing line assemblies to aft right keel panel Verify security Hinge seat back 3 Position valve assembly so F621 2 bracket is vertical within 5 special torque line as...

Page 248: ...ity 2 Remove caps and plugs and connect G341 2 and G341 4 line assembly B nuts to muffler assembly fittings Special torque B nuts at AN824 8D tee and muffler assembly and torque stripe per Figure 5 1...

Page 249: ...rd panel and remove panel 2 Refer to Figure 21 3 Hinge aft right and left seats forward Remove hardware securing G394 1 guards and G392 3 diffuser assemblies to aft seat assemblies and remove guards H...

Page 250: ...Intentionally Blank Page 21 14 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...

Page 251: ...1 Seat Assembly Removal and Installation 25 5 25 22 Back Rest Assembly Removal and Installation 25 5 25 23 Back Rest Cushion Replacement 25 5 25 30 Carpet 25 7 25 40 Insulation Foam and Headliner 25 8...

Page 252: ...Intentionally Blank Page 25 ii Chapter 25 Furnishings R66 Maintenance Manual SEP 2012...

Page 253: ...rtment It is accessed via a large door on the aircraft right side The cowl door annunciator illuminates to warn the pilot when the door is not latched A light illuminates the compartment when the batt...

Page 254: ...FIGURE 25 1 SEAT HARNESSES SEAT ASSEMBLIES AND BACK RESTS Page 25 2 Chapter 25 Furnishings R66 Maintenance Manual SEP 2012...

Page 255: ...nchors Remove hardware securing fifth point belts to seat boxes 4 Remove hole plugs then remove inertia reel covers and hardware securing reels to F369 and F370 forward seat backs Remove five point ha...

Page 256: ...assemblies forward 5 Position F424 1 bumper assembly on F423 4 tube assembly and install screws Verify security C Aft Left and Right Seat Harness 1 Refer to Figure 25 1 Install hardware securing iner...

Page 257: ...er Back Rest Assembly 1 Refer to Figure 25 1 Detach back rest assembly hook and loop tape Velcro at bottom slide back rest assembly up and out of keyhole slots 2 Install back rest assembly in keyhole...

Page 258: ...FIGURE 25 2 CARPET AND INSULATION Page 25 6 Chapter 25 Furnishings R66 Maintenance Manual SEP 2012...

Page 259: ...ard Floor Carpet Assembly Installation 1 Refer to Figure 25 2 Attach carpet to floor via hook and loop tape Velcro 2 Install scuff plates install B392 3 left side cover may be installed when pedals ar...

Page 260: ...th wet with acetone B Installation 1 Verify proper insulation fit Trim as required 2 Apply B270 8 adhesive to bonding surface and insulation backing Press insulation to surface smooth wrinkles and rem...

Page 261: ...urity 2 Insert aircraft documents into holder and tuck upper flap into frame 25 53 Map Pocket Replacement Refer to R66 Illustrated Parts Catalog IPC Figure 25 11 A Removal 1 Drill out rivets securing...

Page 262: ...th aircraft specific information prior to installation for the ELT to function The dongle may be removed and shipped to RHC or a Kannad service center for reprogramming B Transmitter Removal and Insta...

Page 263: ...et Removal 1 Unlock fire extinguisher bracket and remove extinguisher 2 Remove hardware securing bracket to cabin under left side windshield frame and remove bracket C Bracket Installation 1 Install h...

Page 264: ...Intentionally Blank Page 25 12 Chapter 25 Furnishings R66 Maintenance Manual 25 OCT 2010...

Page 265: ...Title Page 28 00 Description 28 1 28 10 Bladder Assembly 28 3 28 11 Roll Over Vent Valves 28 6 28 12 Sump Valve 28 6 28 20 Fuel Quantity 28 7 28 21 Fuel Quantity Sender 28 7 28 22 Low Fuel Switch Asse...

Page 266: ...Intentionally Blank Page 28 ii Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...

Page 267: ...over valve to prevent fuel leakage in any attitude The fuel cell is secured inside an aluminum structure The filler cap is located under a cowl door The left and right side vent fittings are interconn...

Page 268: ...Page 28 2 Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010 FIGURE 28 2 FUEL SYSTEM COMPONENTS...

Page 269: ...o G028 1 bladder assembly and F028 1 support assembly and remove cover Remove and discard o ring 5 Cut and discard safety wire securing A729 2 tube to right roll over vent valve and pull tube off vent...

Page 270: ...Page 28 4 Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010 FIGURE 28 3 FUEL SYSTEM SCHEMATIC...

Page 271: ...ape from bladder assembly openings Insert a clean smooth blunt wooden dowel through bladder service opening and press on bladder lower surface to attach hook and loop tape Verify security 6 Install lo...

Page 272: ...vent valve and pull tube off valve 3 Remove G254 2 fitting or G254 6 retainer Remove and discard MS29512 10 packing G254 2 fitting only and A215 015 o ring 4 Install new A215 015 o ring in groove ins...

Page 273: ...Remove hardware securing G271 1 guard to F250 1 cover assembly and remove guard 3 Remove hardware securing F049 04 fuel quantity sender electrical harness wiring to F550 1 sender 4 Remove hardware sec...

Page 274: ...equired remove fuel quantity sender per Section 28 21 and F250 1 cover assembly per Section 28 10 to facilitate A521 2 low fuel switch assembly removal installation CAUTION Avoid contaminating bladder...

Page 275: ...itch drain assembly seal install G930 4 retainer and install screws securing retainer and drain assembly to tray Verify security Seal gap in drain assembly seal where wires pass thru using B270 5 seal...

Page 276: ...FIGURE 28 4 FUEL VALVE Page 28 10 Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...

Page 277: ...igures 28 2 and 28 4 Open sump drain access door Remove palnut and loosen nut securing A462 4 fitting and A522 11 fuel valve control inner wire to F670 1 fuel valve arm 2 Open baggage compartment door...

Page 278: ...assembly from the engine fuel inlet fitting 6 Using a second suitable container push fuel valve ON and drain fuel into second container for a few seconds to purge system of air Then fill the weighed...

Page 279: ...s 32 5 32 30 Skid Tubes 32 7 32 31 Skid Shoes 32 8 32 32 Skid Extension Replacement 32 8 32 33 Ground Handling Wheel Support Replacement 32 8 32 40 Fairing Assemblies 32 9 32 50 Maintenance 32 9 32 60...

Page 280: ...Intentionally Blank Page 32 ii Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

Page 281: ...ng gear attachment 4 Using putty knife or plastic scraper cut sealant securing four cross tube rain caps to landing gear assembly and remove caps Remove sealant residue from caps cross tubes and strut...

Page 282: ...FIGURE 32 1 LANDING GEAR ATTACHMENT Page 32 2 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

Page 283: ...ru right side access hole on baggage compartment aft wall and aft right landing gear attachment Install hardware special torque bolt per Section 20 33 torque stripe per Figure 5 1 5 Insert hardware th...

Page 284: ...FIGURE 32 2 CROSS TUBE REMOVAL Page 32 4 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

Page 285: ...s Using brass drift tap on strut assembly collars to separate struts from cross tube Do not tap on jack tabs C Installation Refer to R66 Illustrated Parts Catalog IPC Figure 32 1 NOTE When installing...

Page 286: ...FIGURE 32 3 SKID TUBES AND FAIRINGS Strut and skid tube angles exaggerated for clarity Page 32 6 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

Page 287: ...um length circumference scratch c 0 500 inch maximum width flat spot 4 Measure the thickness of skid tube s skid shoes five per skid Replace a skid shoe per Section 32 31 if damage exceeds 0 050 inch...

Page 288: ...Remove skid extension 3 Clean interior of skid tube as practical Install new skid extension and align fastener holes 4 Install new A142 1 screws to secure aft skid shoe to skid tube Standard torque sc...

Page 289: ...Remove and trim fairing as required reinstall per preceding steps 32 50 Maintenance 1 Refer to Figure 32 3 Verify drain holes in bottom of skid tubes are free of obstructions two per skid between two...

Page 290: ...FIGURE 32 4 POP OUT FLOATS INSTALLATION Page 32 10 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

Page 291: ...inder valve punctures the metal sealing disk and 4945 psig nominal at 20 C of helium is released into the inflation manifold to inflate both floats The manifold consists of hoses fittings and a check...

Page 292: ...FIGURE 32 5 POP OUT FLOATS CYLINDER ASSEMBLY Page 32 12 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

Page 293: ...efully remove cylinder B Depressurization CAUTION Use appropriate eye and hearing protection Do not service cylinder assembly while cylinder is installed in helicopter 1 Remove cylinder per Section 32...

Page 294: ...d 50 C 122 F or pressure to exceed 5500 psig If limits are approached stop fill and allow cylinder to cool and pressure to drop before continuing Placing cylinder in a water bath and using slow to mod...

Page 295: ...cabin structure in three locations Carefully position cylinder in D669 6 cradle assembly 4 Engage D676 2 cable assembly ball in D760 1 trigger do not kink cable Install MS3367 4 9 ty rap as shown Cinc...

Page 296: ...Page 32 16 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012 FIGURE 32 6 POP OUT FLOATS LEVER RIGGING AND SHEAR RIVET REPLACEMENT...

Page 297: ...d raise collective full up push in and rotate D680 1 lever assembly safety to READY position squeeze lever to remove cable slack and verify 1 25 1 30 in between tip of lever and collective stick as sh...

Page 298: ...Page 32 18 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012 FIGURE 32 7 POP OUT FLOATS FLOAT INSTALLATION...

Page 299: ...Use care when removing C944 retainer strips from girts and when separating girts from skid tube and skid extension Repeat steps for opposite float B Installation 1 Refer to Figure 32 7 Verify outboard...

Page 300: ...Page 32 20 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012 FIGURE 32 8 POP OUT FLOATS FLOAT PACKING...

Page 301: ...ssistance of six or seven people 7 Refer to Figure 32 8 Detail D Align hoses and valve cover flaps Roll float from outboard edge toward skid tube as tightly as possible Hold float on top of skid 8 App...

Page 302: ...ons of float cover and unroll float to expose valves 4 Inflate floats with filtered oil free dry air to 2 0 psig via topping valves 5 Allow float air temperature to stabilize for 5 minutes minimum the...

Page 303: ...ivet Time for floats to attain full shape without wrinkles should be three seconds or less CAUTION Floats inflate rapidly and with a loud noise Keep area clear during inflation and inform all nearby p...

Page 304: ...re drop from initial measurement is 0 20 psi adjusted for any temperature change For example float chamber pressure will decrease 0 6 psig if temperature drops 10 degrees C 8 If leaks are detected rep...

Page 305: ...cription 52 1 52 10 Door Assembly 52 1 52 11 Door Lock Replacement 52 4 52 12 Weather Seal Door Assembly Replacement 52 4 52 13 Gas Springs 52 7 52 20 Door Vent Replacement 52 7 52 21 Weather Seal Doo...

Page 306: ...Intentionally Blank Page 52 ii Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...

Page 307: ...To disconnect door from gas spring mechanism a Forward Doors Pull D573 4 rod up and off of arm assembly ball joint b Aft Doors Insert flat tip screwdriver and pry up spring clip locking C394 1 gas sp...

Page 308: ...FIGURE 52 1 DOOR ASSEMBLY Page 52 2 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...

Page 309: ...against door frame recess 5 Using soft pencil and a straight edge draw cross hairs through centers of door upper hinge assembly pre drilled holes Hold fitted door against frame insert new door mounte...

Page 310: ...s install hardware and tighten screw 5 Bond hole plug in place using B270 9 adhesive 52 12 Weather Seal Door Assembly Replacement Refer to R66 Illustrated Parts Catalog IPC Figures 52 1 and 52 7 1 Rem...

Page 311: ...Intentionally Blank 25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows Page 52 5...

Page 312: ...FIGURE 52 2 GAS SPRINGS AND DOOR VENTS Page 52 6 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...

Page 313: ...dpaper 3 Hold fitted door vent in recess and match drill hinge four 0 098 inch diameter holes Smooth hole edges clean up debris Prepare surfaces for clamping using approved solvents per Section 20 70...

Page 314: ...le edges clean up debris Prepare surfaces for clamping using approved solvents per Section 20 70 4 Refer to Section 52 20 Verify proper vent door fit install rivets securing hinge to door assembly and...

Page 315: ...Intentionally Blank 25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows Page 52 9...

Page 316: ...FIGURE 52 3 WINDSHIELD INSPECTION Page 52 10 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...

Page 317: ...dge of retainer strips with 1 2 masking tape This will catch silicone rubber squeeze out on installation of retainer strips 5 Remove retainer strips 6 To ensure a proper seal run a bead of B270 4 sili...

Page 318: ...door frame in position 4 Hold windshield in place by hand and align it with frame according to contour of frame and windshield 5 Mark windshield for trim using non permanent marker such as grease penc...

Page 319: ...ng 53 3 53 22 Mast Fairing 53 3 53 23 Tailcone Cowling 53 4 53 24 Access and Inspection Panels 53 4 53 30 Frame Assemblies 53 5 53 31 Lower Frames 53 5 53 32 Hydraulic Servo Support Frame 53 9 53 33 U...

Page 320: ...Intentionally Blank Page 53 ii Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

Page 321: ...ss panel under the left front seat or in the main baggage compartment depending on aircraft configuration The engine is located aft of the main baggage compartment The engine compartment is isolated f...

Page 322: ...FIGURE 53 1 FAIRING COWLINGS AND PANELS Page 53 2 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

Page 323: ...3 22 Mast Fairing Refer to R66 Illustrated Parts Catalog IPC Figure 53 3 A Opening and Closing 1 Refer to Figure 53 1 Remove right side screws securing F261 1 mast fairing assembly at aft vertical sea...

Page 324: ...lcone Cowling Refer to R66 Illustrated Parts Catalog IPC Figure 53 5 A Removal and Installation 1 Refer to Figure 53 1 Thru left access door disconnect ELT antenna lead from antenna mounted to F706 1...

Page 325: ...arness assembly as required Cut and discard ty raps as required mark wires and disconnect wires at plastic connectors to liberate frame 4 Using plastic scraper remove sealant around frame weldment s a...

Page 326: ...FIGURE 53 2 LOWER FRAMES Page 53 6 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

Page 327: ...ort weldment is approximately 0 93 inch from tube end to rod end centerline on each side nominal Adjust rod ends as required per Section 5 33 and Figures 5 1 5 2 Install hardware securing weldment to...

Page 328: ...FIGURE 53 3 HYDRAULIC SERVO SUPPORT FRAME Page 53 8 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

Page 329: ...and hardware Lift frame off of gearbox over mast assembly B Installation 1 Refer to Figure 53 3 Lower G201 1 servo support frame over mast assembly onto main rotor gearbox Install gearbox mounting bo...

Page 330: ...19 hoseassemblyandF724 1 lineassemblyfromF823 1 thermostat assembly Plug hose and line and cap fittings Remove hardware securing F651 1 oil filter assembly to frame 12 Remove hardware securing F231 8...

Page 331: ...and hardware securing braces to fuel bladder support and to frame 7 Install hardware securing F651 1 oil filter assembly to frame Standard torque hardware per Section 20 32 and torque stripe per Figu...

Page 332: ...FIGURE 53 4 TAILCONE ASSEMBLY Page 53 12 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

Page 333: ...ssembly do not pinch wiring between tailcone bulkhead and frames Install hardware securing tailcone to frames standard torque bolts per Section 20 32 and torque stripe per Figure 5 1 3 Install hardwar...

Page 334: ...FIGURE 53 5 TAILCONE INSPECTION AND REPAIR Page 53 14 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

Page 335: ...ceeds limits return tailcone assembly to RHC for repair If damage is within limits blend out scratches with a 0 10 inch minimum blend radius Refinish skins using approved materials per Section 20 70 B...

Page 336: ...FIGURE 53 6 EMPENNAGE TAILCONE CASTING Page 53 16 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

Page 337: ...ure 5 1 2 Connect position light wire connectors Secure wires and install hardware securing forward MS21919WDG3 clamp to upper horizontal stabilizer Install MS3367 4 9 or 5 9 ty raps as required to se...

Page 338: ...izer trailing edge 4 Support C043 1 lower vertical stabilizer Remove four bolts threaded and spacers securing C043 1 stabilizer to upper horizontal stabilizer and remove C043 1 stabilizer 5 If replaci...

Page 339: ...Install C042 1 upper vertical stabilizer and C043 1 lower vertical stabilizer per Section 53 51 3 If C044 1 stabilizer was replaced match drill C554 clips 0 144 inch diameter hole through trailing ed...

Page 340: ...FIGURE 53 7 EMPENNAGE TAIL ROTOR GUARD Page 53 20 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

Page 341: ...blocks 2 Lightly coat retaining hardware and mating surfaces of D082 1 tube assembly and D079 1 guard assembly with approved primer per Section 20 70 prior to installation 3 Install D081 1 spacer insi...

Page 342: ...er to Figure 53 7 Install C470 3 spacer inside C470 1 tail skid Install tail skid and two C470 2 blocks inside C043 1 lower vertical stabilizer Install D081 4 block assembly and install hardware secur...

Page 343: ...Rotor Assembly 62 11 62 31 Journal and Shim Calculations 62 11 62 32 Adjusting Hinge Friction 62 15 62 33 Drilling Nuts and Bolts 62 17 62 40 Inspection of Main Rotor Blades 62 19 62 41 Scratches and...

Page 344: ...Intentionally Blank Page 62 ii Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

Page 345: ...e spindle tusk contacts an aluminum droop stop attached to the main rotor shaft to minimize teetering when blades are at rest or turning at low RPM 62 10 Main Rotor Blades WARNING Due to potentially d...

Page 346: ...FIGURE 62 2 TEETER HINGE HUB INSTALLATION FIGURE 62 3 CONING HINGE BLADE INSTALLATION Page 62 2 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

Page 347: ...to R66 Illustrated Parts Catalog IPC Figures 62 1 62 3 and 62 5 1 Verify correct teeter hinge friction per Section 62 32 step 4 2 If previously installed information is unavailable perform coning hin...

Page 348: ...FIGURE 62 4 MEASURING BOLT STRETCH Shown on teeter hinge bolt Page 62 4 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

Page 349: ...be stretched from 0 020 0 022 inch 0 021 0 022 inch for new undrilled bolt to obtain proper clamping force Under stretching or over stretching can cause catastrophic failure of the bolts 10 Connect p...

Page 350: ...inner lip back enough to expose junction of C147 1 spacer and C158 1 spindle Solvent clean and dry boot inner lip spacer and spindle surfaces clamped by boot inner lip Apply an approximately 1 16 inch...

Page 351: ...per Section 20 70 Inspect journals and thrust washers for chipping of chrome plating corrosion and or wear grooves extending through chrome plating 0 0006 inch maximum wear Replace journal or thrust w...

Page 352: ...FIGURE 62 6 MAIN ROTOR HUB BEARING INSTALLATION FIGURE 62 5 MAIN ROTOR HUB BEARING REMOVAL Page 62 8 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

Page 353: ...r and install wet 62 21 Bearing Replacement Refer to R66 Illustrated Parts Catalog IPC Figure 62 3 1 Remove main rotor hub per Section 62 20 2 If main rotor hub is to be reinstalled with same blades m...

Page 354: ...bearing flange contacts hub CAUTION Use MT643 1 support when installing coning hinge bearings Never install coning hinge bearings into unsupported hub 8 Seal between bearing flange and hub with epoxy...

Page 355: ...ust washer and journal Subtract combined measured thickness of selected journal and shims inches Difference inches 4 Subtract measured length of C106 5 journal to be used on nut side inches Difference...

Page 356: ...and thrust washer Deviate from initial trailing edge shim stack up as necessary to meet coning hinge axial play per Figure 62 8 and maintain friction requirements as follows It must be possible to man...

Page 357: ...Intentionally Blank 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor Page 62 13...

Page 358: ...FIGURE 62 7 MEASURING TEETER HINGE FRICTION Page 62 14 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

Page 359: ...sher and C117 shims under nut 3 Refer to Table 62 1 Measure thickness of C117 shims under teeter hinge nut Change shims as necessary to adjust friction Reducing shim stack up by 0 003 0 005 inch will...

Page 360: ...FIGURE 62 8 MEASURING THRUST WASHER AND HUB BEARING GAP Page 62 16 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

Page 361: ...hub bearings NOTE When a shim is replaced with a shim of a different size it will be necessary to install a new nut and bolt Drilled holes in original bolts will not align at required bolt stretch 5...

Page 362: ...FIGURE 62 9 MEASURING BLADE DAMAGE WITH STRAIGHT EDGE Page 62 18 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010 FIGURE 62 10 SCRATCHES AND CORROSION ON SKINS AND DOUBLERS DAMAGE LIMITS...

Page 363: ...damage using a straight edge and a thickness gage Keep straight edge parallel with the leading and trailing edges 2 If blades are installed on the helicopter measure damage using the shortest straigh...

Page 364: ...62 20 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010 FIGURE 62 11 DENTS ON SKINS AND DOUBLERS DAMAGE LIMITS FIGURE 62 12 DENTS ON TRAILING EDGE BOND JOINTS DAMAGE LIMITS FIGURE 62 13 SPAR DA...

Page 365: ...maximum depth dent between RS 70 00 and RS 124 00 d Maximum area of any dent or dents is 12 square inches and maximum length is 2 0 inches between RS 70 00 and RS 162 90 e Maximum area of any dent or...

Page 366: ...er 62 Main Rotor R66 Maintenance Manual 25 OCT 2010 FIGURE 62 15 REPAIRS TO BLADE AND TRIM TAB TRAILING EDGES FIGURE 62 14 ROOT FITTING DAMAGE FIGURE 62 16 MINIMUM CHORD AFTER BLADE AND TRIM TAB TRAIL...

Page 367: ...de Tip 1 Refer to Figure 62 15 and Section 62 50 for repair procedures for damage within limits Blend out nicks and notches in blade trailing edge for 1 0 inch minimum each side of nick or notch with...

Page 368: ...FIGURE 62 17 BLADE TIP REPAIR LIMITS Page 62 24 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010 FIGURE 62 18 TIP CAP SPAR AND TRAILING EDGES VOID AND DEBOND LIMITS...

Page 369: ...e debonded from the outboard tip to 1 0 inch inboard Voids that are separated by less than 0 25 inch shall be considered continuous b Non Critical Areas Area more than 50 inch spanwise or more than 30...

Page 370: ...Page 62 26 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010 FIGURE 62 20 HONEYCOMB VOID AND DEBOND LIMITS FIGURE 62 19 DOUBLERS VOID AND DEBOND LIMITS...

Page 371: ...equired Visually inspect and verify all damage is removed 5 Measure reworked area and verify material removed and or new chord dimension is permissible per Section 62 40 6 Seal and fill per Section 62...

Page 372: ...t abrasive paper or very fine Scotch Brite and wipe down with a lint free cloth dampened with enamel cleaner prior to applying new coat NOTE Best results are achieved if primer is allowed to air dry f...

Page 373: ...M Section Title Page 63 00 Description 63 1 63 10 Engine Shaft Weldment 63 1 63 11 Engine Driveline Forward Flex Plate Shimming 63 2 63 12 Clutch Assembly 63 5 63 20 Main Rotor Gearbox Assembly 63 6 6...

Page 374: ...Intentionally Blank Page 63 ii Chapter 63 Main Rotor Drive System R66 Maintenance Manual SEP 2012...

Page 375: ...453 1 box assembly to F234 1 firewall 4 Remove hardware securing forward A947 2 flex plate assembly to F910 1 main gearbox yoke and F642 1 engine shaft weldment forward flange noting hardware removed...

Page 376: ...ly to F910 1 main gearbox yoke and F642 1 engine shaft weldment forward flange Remove flex plate and temporarily suppport forward portion of shaft weldment 3 Measure flex plate thickness at bonded was...

Page 377: ...een forward A947 2 flex plate and F910 1 main gearbox yoke Shim required between forward A947 2 flex plate and F642 1 engine shaft weldment forward flange 0 041 inch or greater negative number NAS1149...

Page 378: ...FIGURE 63 1 ENGINE DRIVELINE Page 63 4 Chapter 63 Main Rotor Drive System R66 Maintenance Manual SEP 2012...

Page 379: ...on 1 Refer to Figure 63 1 Lubricate F018 1 clutch assembly splines using B270 21 protectant 2 Route clutch assembly through main rotor gearbox compartment insert clutch assembly in Rolls Royce engine...

Page 380: ...19 and D205 20 hose assemblies from F006 1 main rotor gearbox and D500 3 oil pump Cap and plug fittings and hoses 8 Disconnect F059 01 cabin harness assembly plug from F049 01 gearbox harness assembl...

Page 381: ...ly plug to F049 01 gearbox harness assembly receptacle 7 Remove caps and plugs and connect D205 19 and D205 20 hose assemblies to gearbox and D500 3 oil pump Using back up wrench special torque hose n...

Page 382: ...nstall spacer 2 Clean and dry F254 1 cover verify open face of seal points toward gearbox and press in new seal until completely seated 3 Replace A215 149 o ring as required Install cover assembly ove...

Page 383: ...to pinion then remove yoke 4 Remove rotor brake per Section 63 30 5 Remove F255 1 cover with C966 8 seal but do not remove shims under pinion bearing 6 Using hydraulic press press old seal from cover...

Page 384: ...FIGURE 63 2 ROTOR BRAKE Page 63 10 Chapter 63 Main Rotor Drive System R66 Maintenance Manual SEP 2012...

Page 385: ...ure 5 1 4 Install yoke on pinion shaft Place a wood block between firewall and yoke flange to prevent yoke from rotating Install pinion retaining nut and washer and special torque nut per Section 20 3...

Page 386: ...g G110 1 arm assembly to 2 G111 1 bars and B112 2 lever but do not torque 2 Lubricate spacers with A257 1 grease and install in new G109 1 arm assembly Install D774 4 spring and install hardware secur...

Page 387: ...mbly 64 1 64 11 Static Balance 64 5 64 20 Tail Rotor Blades 64 8 64 30 Tail Rotor Blade Inspection and Repair 64 9 64 31 Scratches and Corrosion 64 9 64 32 Dents 64 9 64 33 Erosion 64 11 64 34 Root Fi...

Page 388: ...Intentionally Blank Page 64 ii Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...

Page 389: ...hed to the output shaft 64 10 Tail Rotor Assembly Refer to R66 Illustrated Parts Catalog IPC Figure 64 1 A Removal 1 Refer to Figure 64 1 Tag each pitch link with corresponding blade serial number for...

Page 390: ...FIGURE 64 1 TAIL ROTOR INSTALLATION Page 64 2 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...

Page 391: ...namic check 4 Fabricate a tracking aid using 1x12 inch aluminum sheet make a 90 bend 2 inches from one end With tail rotor horizontal tape tracking aid to tailcone near blade tip 5 Rotate tail rotor d...

Page 392: ...FIGURE 64 2 CHORDWISE STATIC BALANCE Page 64 4 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...

Page 393: ...blade is the light blade 3 To simulate pitch link attachment assemble hardware as shown and install in blade pitch horns Install standard washer nut and palnut on heavy blade fastener Standard torque...

Page 394: ...FIGURE 64 3 SPANWISE STATIC BALANCE Page 64 6 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...

Page 395: ...rson 20 or equivalent balancing stand Hold tail rotor assembly horizontally then allow to fall The falling blade is the heavy blade the rising blade is the light blade 4 Spanwise balancing is achieved...

Page 396: ...ved apply light coat of approved primer per Section 20 70 to outer surface of C138 2 bushings while primer is wet press bushings flush with inboard side of hub inboard arm bushings will seat properly...

Page 397: ...rify damage does not exceed the following limits a 0 008 inch maximum damage between RS 18 00 and RS 30 00 b 0 005 inch maximum damage more than 15 spanwise between RS 18 00 and inboard c 0 008 inch m...

Page 398: ...FIGURE 64 4 TAIL ROTOR BLADE INSPECTION CRITERIA NOTE See text for additional inspection criteria Page 64 10 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...

Page 399: ...Replace any blade where erosion has caused deformation or ripples in the leading edge 64 34 Root Fitting Damage 1 Verify damage does not exceed the following limits a No repairs permitted within 1 5...

Page 400: ...FIGURE 64 6 ELASTOMERIC BEARING INSTALLATION FIGURE 64 5 ELASTOMERIC BEARING REMOVAL Page 64 12 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...

Page 401: ...T556 11 bearing removal and installation tools Wipe away excess primer 3 Repeat steps for second bearing as required 64 42 Inspection 1 Remove tail rotor blades per Section 64 20 and inspect blades pe...

Page 402: ...Intentionally Blank Page 64 14 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...

Page 403: ...00 Description 65 1 65 10 Tail Rotor Drive Fan Shaft 65 1 65 20 Tail Rotor Drive Shaft Assembly 65 3 65 21 Runout 65 5 65 22 Damper Assembly 65 7 65 30 Tail Rotor Driveline Intermediate Flex Plate Shi...

Page 404: ...Intentionally Blank Page 65 ii Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012...

Page 405: ...iate C947 3 flex plate assembly to F196 1 tail rotor fan shaft aft flange and D224 3 tail rotor drive shaft assembly forward yoke noting hardware removed Remove flex plate and temporarily support aft...

Page 406: ...FIGURE 65 1 TAIL ROTOR DRIVELINE Page 65 2 Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012...

Page 407: ...required 2 Install hardware securing drive shaft to aft C947 3 plate assembly as removed and remove support Standard torque fasteners per Section 20 32 and torque stripe per Figure 5 1 Install A558 2...

Page 408: ...FIGURE 65 2 RUNOUT Page 65 4 Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012...

Page 409: ...essing dial indicator firmly against inspection hole edges Have a second person rotate rotor system by turning tail rotor hub 4 Rotate rotor system slowly smoothly and for several revolutions until th...

Page 410: ...FIGURE 65 4 DAMPER ASSEMBLY Page 65 6 Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012...

Page 411: ...stripe per Figure 5 1 3 Attach a calibrated spring scale to Point A Holding link verify force required to rotate arm about Point B is 3 5 5 8 lb Adjust as required per Part C 4 Attach a calibrated sp...

Page 412: ...ch Total 4 inch Flex plate average thickness 3 a Position F196 1 fan shaft aft flange arms and D224 3 tail rotor drive shaft assembly forward yoke flange arms at 3 o clock and 9 o clock positions hori...

Page 413: ...between intermediate C947 3 flex plate and D224 3 tail rotor drive shaft forward yoke 0 017 or greater negative number NAS1149F0432P washer between forward C947 3 flex plate assembly and F908 1 yoke a...

Page 414: ...on tail rotor gearbox assembly on tailcone casting and install mounting hardware Special torque screws per Section 20 33 and torque stripe per Figure 5 1 2 Connect chip detector wiring at plastic conn...

Page 415: ...Clean and dry cap especially seal seating surface and o ring groove 6 Verify open face of seal points toward gearbox and press new seal into cap bore 0 160 inches from external surface Lightly coat n...

Page 416: ...A966 3 seal and C215 140 o ring CAUTION Do not remove C141 2 washer between cap and bearing 4 Using hydraulic press press old seal from cap Remove and discard o ring Clean and dry cap especially seal...

Page 417: ...ction 67 8 67 30 Jackshaft and Strut Assembly 67 8 67 31 Jackshaft 67 8 67 40 Swashplate 67 9 67 41 Swashplate Tilting Friction Adjustment 67 11 67 42 Upper and Lower Scissor Assemblies 67 11 67 50 Hy...

Page 418: ...Intentionally Blank Page 67 ii Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...

Page 419: ...ARNING Assembly of flight controls is critical and requires inspection by a qualified person If a second person is not available the installer must take a 5 minute break prior to inspecting flight con...

Page 420: ...FIGURE 67 1 MAIN ROTOR FLIGHT CONTROLS Page 67 2 Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...

Page 421: ...push pull tube assembly aft through belly B Installation 1 Refer to Figure 67 1 Verify center to center distance between rod end and spherical bearings in G205 5 fork is 5 40 0 03 inches adjust as re...

Page 422: ...7 12 Cyclic Grip Assembly A Removal NOTE This may be accomplished without removal of complete cyclic assembly from rotorcraft 1 Remove forward belly panel 2 Refer to Figure 67 1 Disconnect wiring conn...

Page 423: ...n placed full up Install circular plug 4 Temporarily attach grip assembly wiring to safety wire or lacing exiting atop cyclic stick Carefully pull wires thru cyclic stick Install grommet included with...

Page 424: ...ply collective friction 2 Refer to Figure 6 8 Remove F445 1 forward tunnel cover F680 3 pilot s collective cover F680 1 co pilot s collective cover F463 1 mid tunnel cover and F461 1 collective cross...

Page 425: ...nd torque stripe per Figure 5 1 6 Refer to Figure 6 8 Slide F680 3 collective cover over center collective stick aft of friction assembly 7 Insert A130 4 spacer into lower end of A333 1 collective tra...

Page 426: ...ting jackshaft to G201 1 frame 3 Remove jackshaft B Installation 1 Ensure A105 6 journal is installed in jackshaft aft support on G201 1 frame Position F339 1 jackshaft on G201 1 frame and install bol...

Page 427: ...side of middle of three lugs on lower non rotating swashplate Connect aft push pull tube to right side of aft single lug on lower swashplate Standard torque bolts per Section 20 32 Install palnuts and...

Page 428: ...Section 20 32 Install palnut special torque per Section 20 33 and torque stripe per Figure 5 1 11 Connect upper A205 fork rod end and lower rod end of C258 pitch link to interrupter side swashplate ea...

Page 429: ...friction Decreasing shim stack thickness increases tilting friction while increasing spacer stack thickness decreases tilting friction Install and special torque per Section 20 33 all inner screws on...

Page 430: ...Page 67 12 Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012 FIGURE 67 2 HYDRAULIC FLIGHT CONTROL SYSTEM...

Page 431: ...ervoir and accessible via a left side cowl door A vented filler cap is located on top of the reservoir The pressure shut off valve is solenoid actuated and controlled by the hydraulic switch on the pi...

Page 432: ...ystem per Section 12 34 8 Install a 110 4 Telatemp on aft surface of pump 9 Install tailcone cowling per Section 53 23 67 52 Hydraulic Reservoir A Removal 1 Temporarily install a DO NOT MOVE FLIGHT CO...

Page 433: ...itioning tee fittings as required and special torque per Section 20 33 4 Connect servo supply and return hoses to reservoir Position hose elbows to minimize preload and special torque per Section 20 3...

Page 434: ...FIGURE 67 3B HYDRAULIC SERVO RIGGING FIGURE 67 3A HYDRAULIC SYSTEM SCHEMATIC Page 67 15A Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...

Page 435: ...8 tube s lower rod end to F339 1 jackshaft weldment 5 Disconnect D205 hose assemblies from servo unions and tees Cap and plug fittings 6 Remove hardware securing servo to G201 1 frame weldment and rem...

Page 436: ...otectant and install C343 8 tube Adjust tube on servo s rod end and tube s rod end to the center to center dimension between rod ends recorded during servo removal and with rod ends 90 to each other T...

Page 437: ...34 11 Perform the following measurements on all servos just installed a Measure record dimension between clevis hole center top of servo piston b Apply cyclic and collective frictions With collective...

Page 438: ...FIGURE 67 4 TAIL ROTOR FLIGHT CONTROLS Page 67 18 Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...

Page 439: ...CAUTION DO NOT remove the rod ends or change the length of the push pull tubes 5 Remove six NAS6603 20 bolts three per side which hold the A318 1 and 2 bearing block halves together 6 Remove the lowe...

Page 440: ...1 Verify inner bore of C031 1 pitch control is clean Slide pitch control assembly onto clean output shaft 2 With pitch control s input stud thru short arm of A120 5 bellcrank assembly position bellcra...

Page 441: ...ction 20 33 2 Install support assembly in helicopter and secure with four MS27039C0807 screws 3 C343 11 push pull tube s rod end center to center dimension to 6 00 inches and connect it to the C317 5...

Page 442: ...alnut special torque per Section 20 33 and torque stripe per Figure 5 1 3 Connect F121 9 push pull tube assembly to C317 7 bellcrank and standard torque bolt per Section 20 32 Install palnut special t...

Page 443: ...d standard torque bolt per Section 20 32 Install palnut special torque per Section 20 33 and torque stripe per Figure 5 1 7 Move pedal full travel Verify smooth movement and no interference 8 Install...

Page 444: ...onnect C121 17 push pull tube from A120 5 aft bellcrank 2 Disconnect bellcrank pivot from C021 1 tail rotor gearbox 3 Remove nut holding bellcrank to the pitch control Remove bellcrank and reinstall n...

Page 445: ...r Rolls Royce Maintenance Facility 71 6 71 12 Preparing Engine for Helicopter Installation 71 7 71 20 Induction 71 11 71 21 Air Filter Assembly 71 11 71 22 Cage Assembly 71 12 71 23 Engine Inlet Bellm...

Page 446: ...Intentionally Blank Page 71 ii Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...

Page 447: ...he plenum contains a radial flow air filter at the engine compressor inlet If the air filter becomes blocked spring loaded doors at the front of the filter housing open allowing unfiltered air to the...

Page 448: ...Page 71 2 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012 FIGURE 71 1 ENGINE RIGHT SIDE...

Page 449: ...2 60 drain engine oil per RR300 Operation and Maintenance Manual OMM Refer to Figure 79 2 Remove hardware securing F723 oil line assembly clamps Loosen F723 1 F723 2 and F723 3 line assembly B nuts fr...

Page 450: ...Page 71 4 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012 FIGURE 71 2 ENGINE LEFT SIDE...

Page 451: ...rdware securing line assembly clamps 8 Refer to Figure 79 2 Remove caps and torque check engine oil line fittings per RR300 OMM Remove plugs and connect F723 1 F723 2 and F723 3 line assembly B nuts t...

Page 452: ...and discard ty raps as required and disconnect G426 1 fuel differential pressure switch assembly wire from harness at connectors Cut and discard stand off ty raps at switch wire and F741 1 line assemb...

Page 453: ...torque bolts per Section 20 32 and torque stripe per Figure 5 1 Install 0 032 inch diameter lockwire and safety bolt heads together Seal cover edges with B270 1 sealant 2 Install D745 3 pressure swit...

Page 454: ...nstall engine inlet bellmouth per Section 71 23 Part B steps 1 2 Install bellmouth cover 15 To install F049 09 harness assembly a Position F577 1 bracket assembly on F049 09 harness assembly s D38999...

Page 455: ...to Figure 71 4 Verify F169 2 exhaust base and engine exhaust collector mating surfaces are clean and dry and lay 0 25 inch bead 7020 3 ceramic putty on top of exhaust collector flange Position F169 2...

Page 456: ...FIGURE 71 3 INDUCTION Page 71 10 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...

Page 457: ...rom F059 01 cabin harness at G258 4 strap 4 Loosen B277 4 clamp securing A729 42 tube to G738 1 nozzle pull tube off of nozzle 5 Pull filter forward off of G057 1 cage assembly B Installation 1 Refer...

Page 458: ...ction 65 10 71 23 Engine Inlet Bellmouth Refer to R66 Illustrated Parts Catalog IPC Figure 71 11 A Removal 1 Remove engine per Section 75 10 2 Refer to Figure 71 3 Remove F579 1 bellmouth cover and lo...

Page 459: ...Intentionally Blank SEP 2012 R66 Maintenance Manual Chapter 71 Powerplant Page 71 13...

Page 460: ...FIGURE 71 4 EXHAUST Page 71 14 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...

Page 461: ...re 71 4 If F169 2 base is installed proceed to step 3 Verify base and engine exhaust collector mating surfaces are clean and dry and lay 0 25 inch bead 7020 3 ceramic putty on top of exhaust collector...

Page 462: ...ing Install hardware special torque nuts per Section 20 33 and torque stripe per Figure 5 1 3 Install engine cowling assembly per Section 53 21 71 42 Generator Control Unit GCU Refer to R66 Illustrate...

Page 463: ...rity 2 Connect F059 01 cabin electrical harness EMU plug and F049 07 USB harness plug to EMU 3 Turn BATTERY switch ON After 10 seconds press annunciator panel test button verify EMU amber warning segm...

Page 464: ...Intentionally Blank Page 71 18 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...

Page 465: ...CHAPTER 75 ENGINE AIR SYSTEMS Section Title Page 75 00 Description 75 1 75 10 Engine Anti Ice 75 1 25 OCT 2010 R66 Maintenance Manual Chapter 75 Engine Air Systems Page 75 i...

Page 466: ...Intentionally Blank Page 75 ii Chapter 75 Engine Air Systems R66 Maintenance Manual 25 OCT 2010...

Page 467: ...Operating Handbook The engine anti ice system includes an air valve a solenoid valve and a pressure switch The air valve is mounted on top of the compressor scroll the solenoid valve and pressure swit...

Page 468: ...Intentionally Blank Page 75 2 Chapter 75 Engine Air Systems R66 Maintenance Manual 25 OCT 2010...

Page 469: ...ER 76 ENGINE CONTROLS Section Title Page 76 00 Description 76 1 76 10 Fuel Control Unit FCU 76 1 76 11 FCU Throttle Control Rigging 76 3 76 12 FCU Fuel Cutoff Control Rigging 76 3 76 20 Power Turbine...

Page 470: ...Intentionally Blank Page 76 ii Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...

Page 471: ...itions generated by aggressive flight maneuvers or rapid power changes Other engine controls include a push pull fuel cutoff control on the console face a start button on the pilot s collective a key...

Page 472: ...FIGURE 76 1 FUEL CONTROL UNIT Page 76 2 Chapter 76 Engine Controls R66 Maintenance Manual SEP 2012...

Page 473: ...idle stop Verify sufficient inner wire beyond aft edge of fitting and special torque fitting nut per Section 20 33 8 Rotate twist grip open verify FCU throttle lever contacts maximum throttle stop and...

Page 474: ...FIGURE 76 2 POWER TURBINE GOVERNOR Page 76 4 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...

Page 475: ...al OMM 2 Perform PTG control rigging per Section 76 21 76 21 PTG Control Rigging 1 Remove engine cowling assembly per Section 53 21 Detach center back rest assembly hook and loop tape Velcro at bottom...

Page 476: ...FIGURE 76 3 PTG BEEP ACTUATOR ASSEMBLY Page 76 6 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...

Page 477: ...mbly in keyhole slots and slide down press firmly on back rest assembly hook and loop tape at bottom Verify security 76 22 PTG Rigging Check 1 Turn BATTERY switch ON 2 Refer to Figure 76 2 With collec...

Page 478: ...Intentionally Blank Page 76 8 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...

Page 479: ...L SYSTEM Section Title Page 79 00 Description 79 1 79 10 Scroll and Fanwheel Assemblies 79 3 79 11 Fanwheel to Inlet Gaps 79 3 79 20 Oil Tank Assembly 79 5 79 21 Oil Temperature Sender 79 6 79 22 Sigh...

Page 480: ...Intentionally Blank Page 79 ii Chapter 79 Engine Oil System R66 Maintenance Manual SEP 2012...

Page 481: ...ch is vented to the exhaust pipe The engine oil cooler has an internal thermostat and pressure relief valve The thermostat maintains normal system operating pressure by allowing cool oil to bypass the...

Page 482: ...FIGURE 79 2 SCROLL AND FANWHEEL ASSEMBLIES Page 79 2 Chapter 79 Engine Oil System R66 Maintenance Manual SEP 2012...

Page 483: ...Observing AFT orientation marking on fanwheel plate place G174 1 fanwheel assembly inside F236 1 scroll assembly accordingly Position F305 5 inlets on scroll and install hardware Verify security 2 Low...

Page 484: ...FIGURE 79 3 ENGINE OIL SYSTEM Page 79 4 Chapter 79 Engine Oil System R66 Maintenance Manual SEP 2012...

Page 485: ...bly Verify security Install hardware securing fan shaft to plate assemblies standard torque nuts and palnuts per Section 20 32 and torque stripe per Figure 5 1 7 Measure fanwheel to inlet gaps per Par...

Page 486: ...ckwire and safety tube to drain 9 Service engine oil per Section 12 60 10 Install tailcone cowling assembly per Section 53 23 79 21 Oil Temperature Sender Refer to R66 Illustrated Parts Catalog IPC Fi...

Page 487: ...l per Section 12 60 2 Refer to Figure 79 3 Remove fasteners securing F649 1 oil cooler to F309 1 box assembly 3 Remove hardware securing line assembly clamps 4 Support oil cooler without damaging oil...

Page 488: ...1 Refer to Figure 79 3 Remove caps from unions Torque check F649 1 oil cooler unions and or G689 1 oil tank assembly nuts per Section 20 33 torque check engine oil line unions and or check valve early...

Page 489: ...r 95 5 95 24 Altimeter 95 5 95 25 Torquemeter 95 6 95 26 Magnetic Compass 95 6 95 30 Engine Gages 95 6 95 31 N1 Tachometer 95 6 95 32 Measured Gas Turbine Temperature MGT Gage 95 6 95 33 Engine Oil Pr...

Page 490: ...Intentionally Blank Page 95 ii Chapter 95 Instrument System R66 Maintenance Manual 25 OCT 2010...

Page 491: ...recording time in service Space is provided for optional instruments and avionics The pitot static system supplies air pressure to operate the airspeed indicator altimeter and vertical speed indicator...

Page 492: ...FIGURE 95 1 PITOT STATIC SYSTEM Page 95 2 Chapter 95 Instrument System R66 Maintenance Manual 25 OCT 2010...

Page 493: ...e drain hole and verify airspeed indicator has returned to zero 7 Remove test equipment B Static System Leak Test CAUTION Airspeed indicator altimeter and vertical speed indicator may be damaged if su...

Page 494: ...Page 95 4 Chapter 95 Instrument System R66 Maintenance Manual 25 OCT 2010 FIGURE 95 2 PITOT STATIC SYSTEM...

Page 495: ...earbox has oil pressure Therefore the tachometers will receive power through the bypass circuit whenever the rotors are turning even if the avionics bus is not powered The bypass circuit is disconnect...

Page 496: ...device mounted atop the engine s accessory gearbox adjacent to the hoisting lug 95 32 Measured Gas Turbine Temperature MGT Gage The measured gas temperature MGT gage connects to the engine s thermocou...

Page 497: ...ated by main gearbox oil pressure Another hourmeter on the horizontal panel outboard of the pilot s seat is activated by a combination of main gearbox oil pressure and a raised collective and is appro...

Page 498: ...Intentionally Blank Page 95 8 Chapter 95 Instrument System R66 Maintenance Manual 25 OCT 2010...

Page 499: ...96 1 96 10 Battery 96 2 96 20 External Power 96 5 96 30 Starter and Ignition System 96 5 96 40 Lighting System 96 6 96 50 Annunciator Panel 96 6 96 60 Low Rotor RPM Warning Unit Adjustment 96 7 96 70...

Page 500: ...Intentionally Blank Page 96 ii Chapter 96 Electrical System R66 Maintenance Manual SEP 2012...

Page 501: ...tch controls power to avionics This allows avionics to be switched OFF via a single switch Having sensitive electrical equipment off when the generator is switched ON protects against voltage spikes A...

Page 502: ...Page 96 2 Chapter 96 Electrical System R66 Maintenance Manual SEP 2012 FIGURE 96 1 AFT BATTERY INSTALLATIONS...

Page 503: ...rdware securing G248 1 baggage compartment cover and remove cover 2 Remove hardware securing negative ground cable to battery negative terminal 3 Slide nipple away from battery positive terminal and r...

Page 504: ...t battery Install G248 1 baggage compartment cover and install hardware Verify security Close and latch baggage compartment door 7 Aft battery a If B237 7 battery was removed and B237 8 battery was ju...

Page 505: ...ore the pilot is not required to hold the start button down throughout the start sequence Above 58 percent N1 RPM the GCU automatically switches out of start mode but the generator switch should not b...

Page 506: ...e problem The CHIP segments are illuminated by magnetic chip devices in each gearbox which collect metallic particles in order to complete an electric circuit The engine gearbox has two magnetic chip...

Page 507: ...cation radios intercom and stereo capable auxiliary audio e g music input The system has four modes of operation In normal mode all occupants hear incoming and outgoing radio communications intercom a...

Page 508: ...e when N1 exceeds 30 and MGT is at least 343 C The EMU is intended to be used only as a maintenance aid It is the pilot s responsibility to report any observed exceedances and the operator s responsib...

Page 509: ...0 025 TORQ SENDER 1 0 025 0 025 0 025 0 025 LOW RPM UNIT W HORN 1 0 045 0 160 0 045 0 160 AA12S 600 AUDIO PANEL 1 1 000 1 000 1 000 1 000 N2 GOVERNOR SYSTEM 1 0 000 0 0871 0 000 0 0871 N2 GOV ACTUATOR...

Page 510: ...L WHT 1 0 300 0 300 0 300 0 300 STROBE LIGHT 1 0 670 3 000 0 670 3 000 SUBTOTAL LIGHTS BUS 5 961 15 591 COMPONENT QTY CONTINUOUS AMPS EACH INTERMITTENT AMPS EACH CONTINUOUS TOTAL INTERMITTENT TOTAL AV...

Page 511: ...H RELAY 1 0 060 0 060 0 060 0 060 CLOCK DIGITAL 1 0 003 0 003 0 003 0 003 BATTERY RELAY 1 0 250 6 000 0 250 6 000 START GEN RELAY 1 0 250 6 000 0 250 6 000 GEN LT RELAY 1 0 010 0 010 0 010 0 010 GEN C...

Page 512: ...Intentionally Blank Page 96 12 Chapter 96 Electrical System R66 Maintenance Manual SEP 2012...

Page 513: ...AMS Figure Title Page 98 1 R66 Electrical System F024 Revision I 98 1 98 2 R66 Electrical System F024 Revision G 98 2 98 3 Air Conditioning Installation 98 3 98 4 ADF Installation 98 5 98 5 Standard A...

Page 514: ...Intentionally Blank Page 98 ii Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...

Page 515: ...SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams Page 98 1 FIGURE 98 1 R66 ELECTRICAL SYSTEM INSTALLATION F024 Revision I shown...

Page 516: ...Page 98 2 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012 FIGURE 98 2 R66 ELECTRICAL SYSTEM INSTALLATION F024 Revision G shown...

Page 517: ...SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams Page 98 3 FIGURE 98 3 AIR CONDITIONING INSTALLATION...

Page 518: ...Page 98 4 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012 Intentionally Blank...

Page 519: ...FIGURE 98 4 ADF INSTALLATION SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams Page 98 5...

Page 520: ...Intentionally Blank Page 98 6 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...

Page 521: ...SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams Page 98 7 FIGURE 98 5 STANDARD AUDIO SYSTEM...

Page 522: ...Page 98 8 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012 Intentionally Blank...

Page 523: ...FIGURE 98 6 DUAL AUDIO CONTROL INSTALLATION SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams Page 98 9...

Page 524: ...Intentionally Blank Page 98 10 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...

Page 525: ...FIGURE 98 7 PA SIREN INSTALLATION SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams Page 98 11...

Page 526: ...Intentionally Blank Page 98 12 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...

Page 527: ...CHAPTER 99 SPECIAL TOOLS Section Title Page 99 10 Special Tools 99 1 99 20 Illustrations and Tasks 99 3 25 OCT 2010 R66 Maintenance Manual Chapter 99 Special Tools Page 99 i...

Page 528: ...Intentionally Blank Page 99 ii Chapter 99 Special Tools R66 Maintenance Manual 25 OCT 2010...

Page 529: ...is a list of Robinson R66 special tools R66 special tools are to be used in conjunction with the applicable instructions for continued airworthiness for their designated maintenance task 25 OCT 2010...

Page 530: ...Page 99 2 Chapter 99 Special Tools R66 Maintenance Manual 25 OCT 2010 FIGURE 99 1 SPECIAL TOOLS...

Page 531: ...ROTOR HUB BEARING REPLACEMENT 8 MT352 1 Main Rotor Blade Trim Tab Gage REFER TO SECTION 18 13 MAIN ROTOR BLADE TRACK ADJUSTMENT 9 MT354 4 Teeter Moment Tool REFER TO SECTION 62 32 ADJUSTING HINGE FRIC...

Page 532: ...FIGURE 99 2 SPECIAL TOOLS Page 99 4 Chapter 99 Special Tools R66 Maintenance Manual SEP 2012...

Page 533: ...ols Tail Rotor Hub Bearing Replacement REFER TO SECTION 64 41 TAIL ROTOR HUB BEARING REPLACEMENT 25 MT643 1 Support Weldment Main Rotor Hub Bearing Installation REFER TO SECTION 62 21 MAIN ROTOR HUB B...

Page 534: ...Page 99 6 Chapter 99 Special Tools R66 Maintenance Manual SEP 2012 FIGURE 99 3 SPECIAL TOOLS...

Page 535: ...CHAPTER 100 REVISION LOG Section Title Page Revision Log 100 1 SEP 2012 R66 Maintenance Manual Chapter 100 Revision Log Page 100 i...

Page 536: ...Intentionally Blank Page 100 ii Chapter 100 Revision Log R66 Maintenance Manual SEP 2012...

Page 537: ...4 i 25 OCT 2010 4 ii 25 OCT 2010 4 1 SEP 2011 4 2 SEP 2011 4 3 25 OCT 2010 4 4 25 OCT 2010 4 5 25 OCT 2010 4 6 25 OCT 2010 4 7 25 OCT 2010 4 8 25 OCT 2010 5 i SEP 2012 5 ii SEP 2012 5 1 SEP 2012 5 2...

Page 538: ...11 4 SEP 2012 11 5 SEP 2012 11 6 SEP 2012 11 7 SEP 2012 11 8 SEP 2012 12 i SEP 2012 12 ii SEP 2012 12 1 SEP 2012 12 2 SEP 2012 12 3 SEP 2012 12 4 SEP 2012 12 5 SEP 2012 12 6 SEP 2012 12 7 SEP 2012 12...

Page 539: ...12 25 3 SEP 2012 25 4 SEP 2012 25 5 SEP 2012 25 6 SEP 2012 25 7 SEP 2012 25 8 SEP 2012 25 9 25 OCT 2010 25 10 25 OCT 2010 25 11 25 OCT 2010 25 12 25 OCT 2010 28 i 25 OCT 2010 28 ii 25 OCT 2010 28 1 25...

Page 540: ...16 25 OCT 2010 62 17 25 OCT 2010 62 18 25 OCT 2010 62 19 25 OCT 2010 62 20 25 OCT 2010 62 21 25 OCT 2010 62 22 25 OCT 2010 62 23 25 OCT 2010 62 24 25 OCT 2010 62 25 25 OCT 2010 62 26 25 OCT 2010 62 2...

Page 541: ...P 2012 71 16 SEP 2012 71 17 SEP 2012 71 18 SEP 2012 75 i 25 OCT 2010 75 ii 25 OCT 2010 75 1 25 OCT 2010 75 2 25 OCT 2010 76 i 25 OCT 2010 76 ii 25 OCT 2010 76 1 SEP 2012 76 2 SEP 2012 76 3 25 OCT 2010...

Page 542: ...Page Date Page Date Page Date 98 12 SEP 2012 99 i 25 OCT 2010 99 ii 25 OCT 2010 99 1 25 OCT 2010 99 2 25 OCT 2010 99 3 SEP 2012 99 4 SEP 2012 99 5 SEP 2012 99 6 SEP 2012 100 i SEP 2012 100 ii SEP 2012...

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