Robinson Helicopter Company RTR 660 Maintenance Manual

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Robinson Helicopter Company

2901 Airport Drive

Torrance, California 90505-6115

UNITED STATES

Monday through Friday, 7:30 a.m. to 4:30 p.m., Pacific Time.

Please visit www.robinsonheli.com, under the Customer Support tab,

for a complete list of holidays and company shutdowns.

Please visit www.robinsonheli.com, under the Customer Support tab,

Procure parts from any R66 Dealer or Service Center, or order directly

from assigned

Please visit www.robinsonheli.com, under the Publications tab,

SEP 2012

Type Certificate Number R00015LA

OFFICE HOURS

Lunch hour is 11:30 a.m. to 12:30 p.m.

CUSTOMER SUPPORT AND ORDERS

for a complete service directory.

RHC Customer Service Representative

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to view our publications electronically.

R66 Maintenance Manual

Phone: (310) 539-0508

Fax:

(310) 539-5198

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Page 1 Type Certificate Number R00015LA Robinson Helicopter Company Phone: (310) 539-0508 2901 Airport Drive Fax: (310) 539-5198 Torrance, California 90505-6115 Web: www.robinsonheli.com UNITED STATES OFFICE HOURS Monday through Friday, 7:30 a.m. to 4:30 p.m., Pacific Time. Lunch hour is 11:30 a.m. to 12:30 p.m.
Page 2 Method of Payment: No cash or CODs. We cannot be responsible for cash sent by mail. For faster processing, order online. U.S. Check, Money Order, payable to Robinson Helicopter Company Wire Transfer (subscription will not take effect until wire transfer has been received)
Page 3 CHAPTER LIST Introduction Chapter 1 General Chapter 4 Airworthiness Limitations Chapter 5 Inspection Schedule Chapter 6 Dimensions and Descriptions Chapter 7 Jacking and Hoisting Chapter 8 Weight and Balance Chapter 9 Ground Handling Chapter 10 Parking and Storage Chapter 11 Placards and Markings Chapter 12 Servicing...
Page 4 Recommended changes may include but are not limited to: general comments, corrections, omitted information, or clarification of instructions. Please send recommendations to: Email: techpubs@robinsonheli.com Robinson Helicopter Company Attention: Technical Publications Phone: (310) 539-0508 2901 Airport Drive Fax:...
Page 5 Effective R66 Serial Number 0003 & on Robinson Helicopter Company, Inc. (hereafter referred to as RHC) warrants each new helicopter to be free from defects in material and workmanship appearing within two years from the date of delivery from the RHC factory or during the first one thousand (1000) hours of operation, whichever event occurs first;...
Page 6 Intentionally Blank Page vi Introduction R66 Maintenance Manual SEP 2012...
Page 7: Table Of Contents
CONTENTS INTRODUCTION Section Title Page — Cover Page ..........—...
Page 8: Contents
CONTENTS CHAPTER 5 — INSPECTION SCHEDULE (Continued) Section Title Page 5-61 Tail Skid Strike ........5.37 5-62 Tail Rotor Strike .
Page 9 CONTENTS CHAPTER 9 — GROUND HANDLING Section Title Page 9-10 Ground Handling ..........9-11 Ground Handling Wheels .
Page 10 CONTENTS CHAPTER 12 — SERVICING (Continued) Section Title Page 12-80 Air Conditioning System ........12.18 12-81 Refrigerant Recovery and System Charging .
Page 11 CONTENTS CHAPTER 20 — STANDARD PRACTICES (Continued) Section Title Page 20-74 Torque Seal ........20.17 20-75 Primers .
Page 12 CONTENTS CHAPTER 28 — FUEL SYSTEM Section Title Page 28-00 Description ..........28.1 28-10 Bladder Assembly .
Page 13 CONTENTS CHAPTER 53 — FUSELAGE (Continued) Section Title Page 53-11 Repair ......... . . 53.1 53-20 Fairing, Cowlings, and Panels .
Page 14 CONTENTS CHAPTER 63 — MAIN ROTOR DRIVE SYSTEM (Continued) Section Title Page 63-20 Main Rotor Gearbox Assembly ........63.6 63-21 Yoke and Seal Replacement .
Page 15 CONTENTS CHAPTER 67 — FLIGHT CONTROLS (Continued) Section Title Page 67-30 Jackshaft and Strut Assembly ........67.8 67-31 Jackshaft .
Page 16 CONTENTS CHAPTER 76 — ENGINE CONTROLS (Continued) Section Title Page 76-12 FCU Fuel Cutoff Control Rigging ......76.3 76-20 Power Turbine Governor (PTG) .
Page 17 CONTENTS CHAPTER 96 — ELECTRICAL SYSTEM (Continued) Section Title Page 96-20 External Power ..........96.5 96-30 Starter and Ignition System .
Page 18 Intentionally Blank Page xviii Introduction R66 Maintenance Manual SEP 2012...
Page 19: Introduction
CHAPTER 1 GENERAL Section Title Page 1-10 Introduction ........1-20 R66 Maintenance Manual Revisions .
Page 20 Intentionally Blank Page 1.ii Chapter 1 General R66 Maintenance Manual SEP 2012...
Page 21: Introduction
Operating Handbook (POH), R66 Service Bulletins (SB), R66 Service Letters (SL), RR300 Series Operation and Maintenance Manual (OMM), applicable Rolls-Royce technical publications, and applicable component manufacturer technical publications. Service Bulletins may be issued by Robinson Helicopter Company (RHC), Rolls-Royce, or component manufacturers. Service Bulletin compliance is mandatory.
Page 22: Notations
1-50 Notations The following notations will be found throughout the manual: NOTE A NOTE provides emphasis or supplementary explanation. CAUTION Equipment damage can result if a CAUTION is not followed. WARNING Personal injury or death can result if a WARNING is not followed. 1-60 Definitions and Abbreviations Refer to R66 Pilot's Operating Handbook (POH) Section 1 for additional definitions and abbreviations.
Page 23 PTG: Power Turbine Governor R66 IPC: R66 Illustrated Parts Catalog R66 MM: R66 Maintenance Manual R66 POH: R66 Pilot's Operating Handbook RHC: Robinson Helicopter Company RR300 Series OMM: Rolls-Royce RR300 Series Operation and Maintenance Manual SB: Service Bulletin SL: Service Letter...
Page 24: Service Directory
1-70 Service 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 assigned Customer Service Representative via email, fax, or phone. Page 1.4 Chapter 1 General R66 Maintenance Manual...
Page 25: Assembly Instructions For R66 Helicopter Crated For Export
1-80 Assembly Instructions for R66 Helicopter Crated for Export NOTE Aircraft assembly to be performed by a certificated mechanic. 1. Remove top of cabin assembly crate. Remove wall marked “A” by removing lag bolts painted black. Remove empennage assembly. Remove remaining walls. Remove all parts, except cabin assembly, from crate base.
Page 26 FIGURE 1-1 ASSEMBLY INSTRUCTIONS FOR R66 HELICOPTER CRATED FOR EXPORT FIGURE 1-2 ASSEMBLY INSTRUCTIONS FOR R66 HELICOPTER CRATED FOR EXPORT Page 1.6 Chapter 1 General R66 Maintenance Manual SEP 2012...
Page 27 1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued) 10. For air-conditioned ships: a. Refer to Figure 1-1. Remove shipping supports (ty-raps, foam, tape, etc.) from G777-1 compressor assembly. Install hardware securing G782-1 mount weldment to main rotor gearbox. Standard torque hardware per Section 20-32 and torque stripe per Figure 5-1.
Page 28 1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued) 20. If ship is equipped with attitude horizon, directional gyro, turn coordinator, and/or vertical card magnetic compass: A. Attitude Horizon, Directional Gyro, and Turn Coordinator Installation CAUTION Directional gyro mount screws must not exceed 1-inch in length. 1.
Page 29 1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued) 31. Perform tail rotor dynamic balance per Section 18-20. 32. Remove tail rotor dynamic balance equipment. Install main rotor balance equipment per Section 18-11. CAUTION Mast fairing, cowlings, and panels must be installed for flight. 33.
Page 30 Intentionally Blank Page 1.10 Chapter 1 General R66 Maintenance Manual SEP 2012...
Page 31: Chapter 4 - Airworthiness Limitations
CHAPTER 4 AIRWORTHINESS LIMITATIONS Section Title Page 4-10 Airworthiness Limitations ......4-20 Type Certificate Data Sheet (TCDS) .
Page 32 Intentionally Blank Page 4.ii Chapter 4 Airworthiness Limitations R66 Maintenance Manual 25 OCT 2010...
Page 33 4-10 Airworthiness Limitations The Airworthiness Limitations Section is FAA approved and specifies inspections and other maintenance required under 14 CFR §§ 43.16 and 91.403, unless an alternative program has been FAA approved. A. Fatigue Life-Limited Parts Part Number Description Maximum Service Life C023-21, -34, &...
Page 34 Intentionally Blank Page 4.2 Chapter 4 Airworthiness Limitations R66 Maintenance Manual SEP 2011...
Page 35: Type Certificate Data Sheet (Tcds)
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 Guidance Library online database for TCDS revision status at: http://rgl.faa.gov. Page 4.3 25 OCT 2010 R66 Maintenance Manual...
Page 36 Intentionally Blank Page 4.4 Chapter 4 Airworthiness Limitations R66 Maintenance Manual 25 OCT 2010...
Page 37 Title 14, Code of Federal Regulations. Type Certificate Holder: Robinson Helicopter Company 2901 Airport Drive Torrance, California 90505 I. Model R66 (Normal Category Rotorcraft), Approved October 25, 2010...
Page 38 2. Lateral C.G. limits valid for all gross weights Empty Weight C.G. Range None. The aircraft’s empty weight and empty weight C.G. must be determined by the procedures in Section 8 of the R66 Maintenance Manual, RTR 660. Datum 100 inches forward of main rotor centerline.
Page 39 7.5° to 8.5° Right 6.0° to 7.0° Note: Collective low pitch to be established in accordance with the Maintenance Manual and Instructions for Continued Airworthiness (RTR 660) procedures to obtain proper autorotation RPM. Tail Rotor Blades Left pedal 15.5° to 16.5°...
Page 40 Information essential to the proper maintenance of the helicopter, including retirement time of critical components, is contained in the Robinson R66 Maintenance Manual and Instructions for Continued Airworthiness (RTR 660). Retirement times are listed in the FAA approved “AIRWORTHINESS LIMITATIONS” section. The values of retirement or service lives and inspection intervals cannot be changed without FAA Engineering approval.
Page 41: Chapter 5 Inspection Schedule
CHAPTER 5 INSPECTION SCHEDULE Section Title Page 5-10 Life-Limited Components ......5-11 Time In Service Records .
Page 42 Intentionally Blank Page 5.ii Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...
Page 43: Life-Limited Components
CHAPTER 5 INSPECTION SCHEDULE 5-10 Life-Limited Components 5-11 Time In Service Records It is the operator’s responsibility to maintain accurate time in service records for the aircraft airframe, engine, and life-limited components. Two hourmeters are standard equipment in R66 helicopters: one is mounted in the console and another is located outboard of the pilot's seat.
Page 44 Replace main rotor gearbox filter per • • Section 12-12. Perform 100-hour / annual maintenance • • and inspection per Section 5-45. As required by RR300 Series Operation • • • • • and Maintenance Manual (OMM), perform maintenance and inspection. •...
Page 45: Scheduled Maintenance And Inspections
5-20 Scheduled Maintenance and Inspections The R66 helicopter required inspection intervals are given in Table 5-1. Some aircraft will reach calendar intervals before accumulating the associated service time. Unless noted, use the more conservative inspection interval. Refer to Section 5-45 for inspection procedures. Some aircraft may require maintenance and inspections in addition to the requirements in Table 5-1.
Page 46 FIGURE 5-1 ROD END AND SPHERICAL BEARING PLAY LIMITS AND TORQUE STRIPE APPLICATION Position rod ends for maximum rotation FIGURE 5-2 ROD END CENTERING Page 5.4 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...
Page 47: Standard Inspection Criteria
5-30 Standard Inspection Criteria This section contains standard inspection criteria for 100-hour/annual maintenance and inspection. 5-31 Ball and Roller Bearings The first indication of bearing failure is usually an increase in bearing noise. Noise will almost always start several hours prior to bearing failure. Listen to drive system during start-up and shutdown.
Page 48 Elastomer Fatigue Elastomer Oil Contamination Elastomer Overload FIGURE 5-3 ELASTOMERIC BEARING DAMAGE Page 5.6 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...
Page 49: Elastomeric Bearings
5-34 Elastomeric Bearings Refer to Figure 5-3. Elastomeric bearings are used in the G062-1 tail rotor hub. Fatigue, oil contamination, or overload can degrade the elastomer. Small surface cracks (fatigue cracks) and elastomer dust or “eraser crumbs” are normal and are not cause for replacement.
Page 50: Operation Checks For 100-Hour / Annual Maintenance And Inspection
5-40 Operation Checks for 100-Hour / Annual Maintenance and Inspection Complete the following checklists in conjunction with 100-hour / annual maintenance and inspection. Note and correct any discrepancies. 5-41 Ground Check (aircraft not running) Replace air filter assembly per Section 71-21, if required. Twist Grip: Verify twist grip smooth rotation without binding in full up and full down collective position.
Page 51: Ground Check
5-41 Ground Check (continued) Lighting and Instruments: (Turn BATTERY switch ON) ANNUNCIATOR PANEL Main rotor gearbox temperature / pressure segment illuminates. Engine oil segment illuminates. Generator segment illuminates. Rotor brake segment illuminates (if rotor brake is applied). Low RPM segment illuminates. All segments illuminate when test button is depressed (slight delay on low fuel light).
Page 52: Run-Up
5-42 Run-Up Clean engine gas path per RR300 Series Operation and Maintenance Manual (OMM). Perform Pilot's Operating Handbook (POH) Section 4 “Preflight” checklist. Perform POH Section 4 “Before Starting Engine” checklist. Prior to start, verify rotor brake locks out starter. Perform POH Section 4 “Starting Engine and Run-Up”...
Page 53: Flight Check
5-43 Flight Check (continued) Level Flight: Conduct at typical cruise altitude (weather permitting) and maximum continuous torque. Loading to typical operating conditions or nominal weight and CG in middle of envelope will provide the most useful evaluation. Verify tail rotor pedal position when yaw string is centered. Right pedal 0.25 to 0.75 inch forward of left pedal.
Page 54 Intentionally Blank Page 5.12 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...
Page 55: 100-Hour / Annual Maintenance And Inspection
5-45 100-Hour / Annual Maintenance and Inspection [1 of 25 Pages] RHC recommends retaining a copy of the most recently performed 100-hour / annual checklist with the aircraft’s maintenance records to meet the requirement of 14 CFR § 91.417 (b)(1). Serial No.: Technician Name: Registration No.:...
Page 56 5-45 100-Hour / Annual Maintenance and Inspection [2 of 25 Pages] CABIN FORWARD FOOTWELLS (continued) Adjustable Tail Rotor Pedals: Inspect condition. Verify no cracks in welds. Verify locking pins engage holes to secure adjustable pedals. Verify proper operating clearance and smooth actuation. Co-Pilot Removable Tail Rotor Pedals: Inspect condition.
Page 57 5-45 100-Hour / Annual Maintenance and Inspection [3 of 25 Pages] CONSOLE (continued) Tail Rotor Pedal Bearing Block Supports: Examine accessible portion with inspection light and mirror. Inspect both vertical sheet metal supports inside lower console and verify no cracks. Pay particular attention to area near NAS6603-13 bolts.
Page 58 5-45 100-Hour / Annual Maintenance and Inspection [4 of 25 Pages] CIRCUIT BREAKER PANEL (continued) Copper Bus Bars: Inspect condition. Verify no corrosion or bends in bus bars. Verify bus bar security and isolation from surrounding structure. Wiring: Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify neatness, proper routing and installation, and security.
Page 59 5-45 100-Hour / Annual Maintenance and Inspection [5 of 25 Pages] HORIZONTAL CONTROL TUNNEL (Front seats; continued) Cyclic Horizontal Torque Tube: Examine accessible portion with inspection light and mirror. Verify no nicks, scratches, dents, cracks, or corrosion. Verify no cracks around reinforcement blocks on both ends of torque tube.
Page 60 5-45 100-Hour / Annual Maintenance and Inspection [6 of 25 Pages] HORIZONTAL CONTROL TUNNEL (Front seats; continued) Pitot & Static Lines & Drains: Inspect pitot and static lines for obstructions, cracking, chafing, pinching, or kinking. Remove drain plugs from tee fittings in each line and clear any moisture from system. Install drain plugs.
Page 61 5-45 100-Hour / Annual Maintenance and Inspection [7 of 25 Pages] HORIZONTAL CONTROL TUNNEL (Aft seats; continued) Fuel Cutoff and Throttle Control: Inspect condition. Verify proper fuel cutoff and throttle control clearance to installed equipment and surrounding structure. Verify proper installation and security. Cabin Heater Valve and Control: Inspect condition.
Page 62 5-45 100-Hour / Annual Maintenance and Inspection [8 of 25 Pages] CABIN BULKHEAD Blind Encoder & Engine Monitoring Unit (EMU): Inspect condition. Inspect wiring for obvious damage. Verify no cracks where units mount to bulkhead. Verify proper installation and security. Download EMU data as required per RR300 Series OMM.
Page 63 5-45 100-Hour / Annual Maintenance and Inspection [9 of 25 Pages] BAGGAGE COMPARTMENT (continued) Interior: Inspect condition. Verify no structural damage. Verify general cleanliness of baggage compartment. Verify any installed equipment or passenger cargo are secure. Generator Control Unit (GCU) & Wiring: Inspect condition.
Page 64 5-45 100-Hour / Annual Maintenance and Inspection [10 of 25 Pages] MAIN ROTOR GEARBOX COMPARTMENT (continued) Fuel Tank Sump Drain: Inspect condition. Verify drain valve opens easily, drains fuel freely, springs closed, and seals completely. Inspect drain tube and clamp for defects, tears, or material deterioration.
Page 65 5-45 100-Hour / Annual Maintenance and Inspection [11 of 25 Pages] MAIN ROTOR GEARBOX COMPARTMENT (continued) Main Rotor Push-Pull Tubes: Examine accessible portion with inspection light and mirror. Inspect condition per Section 5-32. Verify no nicks, scratches, chafing, dents, cracks or corrosion. Inspect rod end bearings per Section 5-33;...
Page 66 5-45 100-Hour / Annual Maintenance and Inspection [12 of 25 Pages] MAIN ROTOR GEARBOX COMPARTMENT (continued) Upper Steel Tube Frame: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Verify no chafing where wires, hoses, or clamps attach to frame. Examine each weld for cracks with an inspection light and mirror.
Page 67 5-45 100-Hour / Annual Maintenance and Inspection [13 of 25 Pages] INTERMEDIATE STAGE & SCROLL ASSEMBLY (continued) Emergency Locator Transmitter (ELT; if installed): Inspect condition. Verify proper installation, security, and clearance from drive train components. Comply with 14 CFR § 91.207 (d), if required. Pitot Line &...
Page 68 5-45 100-Hour / Annual Maintenance and Inspection [14 of 25 Pages] INTERMEDIATE STAGE & SCROLL ASSEMBLY (continued) Tailcone Attachment: Inspect condition. Verify no cracks near fasteners attaching tailcone to upper frame. Verify proper installation and security. Upper Steel Tube Frame: Inspect condition.
Page 69 5-45 100-Hour / Annual Maintenance and Inspection [15 of 25 Pages] ENGINE (continued) Cooling Panels: Inspect condition. Verify no cracks or missing or loose fasteners. Verify security. Engine Hoses: Inspect condition. Verify no rips, holes, or collapsed areas. Verify proper installation and security.
Page 70 5-45 100-Hour / Annual Maintenance and Inspection [16 of 25 Pages] ENGINE (continued) Firewalls: Inspect condition. Verify no deformation, buckling, wrinkling, nicks, scratches, dents, cracks, corrosion, fretting, or loose rivets. Pay particular attention to structural attachment points. Inspect condition of engine-to-firewall seal. Verify no open holes. WARNING Open holes in engine-to-firewall seals are potential fire leak paths.
Page 71 5-45 100-Hour / Annual Maintenance and Inspection [17 of 25 Pages] TAILCONE Inspection Plugs: Inspect condition. Verify proper operation of fasteners. Tail Rotor Drive Shaft Assembly: Examine accessible portion through inspection holes with inspection light and mirror. Verify no cracks, corrosion, or fretting in fore and aft weldment. Verify no evidence of drive shaft contact with tailcone bays.
Page 72 5-45 100-Hour / Annual Maintenance and Inspection [18 of 25 Pages] TAILCONE (continued) Anti-Collision Light: Inspect condition. Verify no cracks where anti-collision light mounts to tailcone. Verify lens cleanliness, clarity, and security. Verify proper operation. Tail Rotor Visual Warning Guard: Inspect condition.
Page 73 5-45 100-Hour / Annual Maintenance and Inspection [19 of 25 Pages] TAIL ROTOR & TAIL ROTOR GEARBOX (continued) Empennage: Inspect condition. Verify no nicks, scratches, dents, cracks, corrosion, fretting, or loose rivets on skins or near attachment points. Check tail rotor skid for evidence of tail rotor or tail rotor skid strike.
Page 74 5-45 100-Hour / Annual Maintenance and Inspection [20 of 25 Pages] MAST FAIRING Mast Fairing: Inspect condition. Verify no nicks, scratches, dents, cracks, corrosion, fretting, or loose rivets. Verify no yielding or cracking of pitot line and fuel vent restraint assembly. NOTE Yielding can be caused by over tightening screws in restraint nutplates.
Page 75 5-45 100-Hour / Annual Maintenance and Inspection [21 of 25 Pages] MAST FAIRING (continued) Swashplate Interior: Remove swashplate boot lower ty-rap. Lift boot from swashplate, and verify no boot defects, tears, or material deterioration. Examine swashplate interior with inspection light and mirror. Verify no corrosion or debris between main rotor drive shaft and inside of slider tube.
Page 76 5-45 100-Hour / Annual Maintenance and Inspection [22 of 25 Pages] ROTOR HUB & MAIN ROTOR BLADES (continued) Blade Spindles & Root Fittings: Inspect condition. Verify no cracks, corrosion, or obvious damage to blade spindles and horns. Verify no cracks, corrosion or missing paint in blade root fittings, especially in area adjacent to inboard edges of skin and doublers.
Page 77 5-45 100-Hour / Annual Maintenance and Inspection [23 of 25 Pages] LANDING GEAR (continued) Skid Tubes & Shoes: Inspect condition. Verify skid tube and skid shoe wear is within limits specified in Section 32-30 & 32-31. Verify drain holes are not obstructed. Verify security of rain caps;...
Page 78 5-45 100-Hour / Annual Maintenance and Inspection [24 of 25 Pages] CABIN (continued) Seat Belts & Shoulder Harnesses: Inspect condition. Verify no fraying or broken stitching of seat belts or shoulder harnesses. Check inertia reels for proper operation by pulling harness quickly to verify locking function.
Page 79 5-45 100-Hour / Annual Maintenance and Inspection [25 of 25 Pages] SPECIAL EQUIPMENT (continued) Wiring: Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify neatness, proper routing and installation, and security. PLACARDS Placards: Verify required aircraft placards are properly installed and legible. Refer to Section 2 of Pilot’s Operating Handbook.
Page 80: 2000-Hour Maintenance And Inspection
5-50 2000-Hour Maintenance and Inspection A. Parts Required 1. Replace the following parts when they have accumulated 2000 hours or 12 years time in service, whichever occurs first, since new or since last overhaul: ITEM PART NUMBER DESCRIPTION QUANTITY NUMBER PARTS REQUIRED 1 A120-5 Bellcrank - Aft (tail rotor control) .
Page 81 5-50 2000-Hour Maintenance and Inspection (continued) A. Parts Required (continued) ITEM PART NUMBER DESCRIPTION QUANTITY NUMBER PARTS REQUIRED (Cont’d) 30 D205-19 Hose Assembly - MRGB oil ......31 D205-20 Hose Assembly - MRGB oil .
Page 82: 12-Year Maintenance And Inspection
5-50 2000-Hour Maintenance and Inspection (continued) A. Parts Required (continued) ITEM PART NUMBER DESCRIPTION QUANTITY NUMBER PARTS REQUIRED (Cont’d) 62 F724-1 Line Assembly - MRGB oil ......63 F724-2 Line Assembly - MRGB oil .
Page 83: Special Maintenance And Inspections
5-60 Special Maintenance and Instructions WARNING Do not install or return to service any part removed from a damaged aircraft unless the part can be verified as undamaged. Return suspect parts to RHC, with details of damage history, for airworthiness evaluation. 5-61 Tail Skid Strike A.
Page 84: Tail Rotor Strike
5-62 Tail Rotor Strike The tail rotor strike inspection is listed in two parts. Part 1 concerns damage received by a tail rotor blade due to contact with a small stone, tall grass, or some small object contacting rotor blade in free air. Part 2 is concerned with sudden stoppage of tail rotor due to ground or solid object contact causing bending or shearing of a tail rotor blade or blades.
Page 85: Main Rotor Strike
5-63 Main Rotor Strike The main rotor strike inspection is listed in two parts. Part 1 concerns contact of main rotor blades with object in free air such as small stones, brush, small birds, etc. Part 2 is concerned with sudden stoppage of main rotor due to ground or solid object contact. 1.
Page 86: Rotor/Engine Overspeed
5-64 Rotor/Engine Overspeed 1. For rotor overspeeds between 106 and 112%: NOTE Refer to Part 3 if a power-on overspeed occurs. a. Check main rotor and tail rotor dynamic balance. Compare pre-overspeed and post- overspeed balance. CAUTION Any change in rotor dynamic balance greater than 0.3 ips requires inspection per Part 2.
Page 87: Hard Landing
5-65 Hard Landing The hard landing inspection is listed in two parts. Part 1 concerns yielding (bending) of the cross tubes due to hard landing such as hovering autorotations or run-on landings that do not apply side loads to the landing gear. Part 2 concerns hard landings that, in addition to yielding of cross tubes, have yielding of steel tube frames or fuselage primary structure.
Page 88: Dye Penetrant Inspection Of F020-1 Upper Frame
5-66 Dye Penetrant Inspection of F020-1 Upper Frame 1. Carefully clean all paint, primer, oil, grease, etc from steel tube structure around and adjacent to four tailcone mounts. 2. Apply epoxy paint remover and allow the softening action to complete (temperature affects time required).
Page 89: Main Rotor Gearbox (Mr) Chip Light Illumination
5-69 Main Rotor Gearbox (MR) Chip Light Illumination If the MR CHIP annunciator segment illuminates: 1. Remove main rotor gearbox chip detector per Section 12-13. Inspect any particles found on the chip detector. Examine the particles and perform following appropriate corrective action: a.
Page 90 Intentionally Blank Page 5.44 Chapter 5 Inspection Schedule R66 Maintenance Manual 25 OCT 2010...
Page 91: Chapter 6 Dimensions And Descriptions
CHAPTER 6 DIMENSIONS AND DESCRIPTIONS Section Title Page 6-10 Version Description ........6-20 Datum .
Page 92 Intentionally Blank Page 6.ii Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010...
Page 93: Datum
CHAPTER 6 DIMENSIONS AND DESCRIPTIONS 6-10 Version Description Refer to Section 4-20 for Type Certificate Data Sheet. R66, Turbine: Five place, single-engine, single main rotor, light turbine helicopter. Two- bladed teetering main rotor system with conventional two-bladed tail rotor. Rolls-Royce model 250-C300/A1 turboshaft engine normally rated at 300 shaft horsepower (SHP);...
Page 94 Intentionally Blank Page 6.2 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010...
Page 95: External Dimensions
6-40 External Dimensions FIGURE 6-1 EXTERNAL DIMENSIONS Page 6.3 25 OCT 2010 R66 Maintenance Manual Chapter 6 Dimensions and Descriptions...
Page 96: Baggage Compartment Dimensions
6-50 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: Baggage Compartment Dimensions
6-50 Baggage Compartment Dimensions (continued) FIGURE 6-3 BAGGAGE COMPARTMENT ACCESS DIMENSIONS (Dimensions given are approximate) Page 6.5 25 OCT 2010 R66 Maintenance Manual Chapter 6 Dimensions and Descriptions...
Page 98: Station Diagrams
6-60 Station Diagrams 6-61 Fuselage Station (FS) Locations Datum ............FS 0.00 Nose Bracket (tie-down) .
Page 99: Tailcone Station (Ts) Locations
6-62 Tailcone Station (TS) Locations Page 6.7 25 OCT 2010 R66 Maintenance Manual Chapter 6 Dimensions and Descriptions...
Page 100: Water Line (Wl) Station Locations
6-63 Water Line (WL) Station Locations Teeter Hinge Bolt (main rotor) ......... . WL 138.00 Upper Rib (top) .
Page 101: Butt Line (Bl) Station Locations
6-64 Butt Line (BL) Station Locations Horizontal Stabilizer (outboard point) ..HS 43.00 Skid Tube (centerline) ....BL 42.00 Door Post (between forward &...
Page 102 FIGURE 6-8 INTERIOR ACCESS & INSPECTION PANELS Page 6.10 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual SEP 2012...
Page 103: Access And Inspection Panels
6-70 Access and Inspection Panels ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 1 A412-3 Cover - Pedal Bearing Block 24 F082-2 Fairing Assembly - Landing Gear, Forward (RH) 2 2451 Cover - Floor Panel F082-3 Fairing Assembly - Landing Gear, Forward (LH) 3 A412-1 Cover - Pedal Bearing Block 25 G308-2...
Page 104: Antenna Locations
6-80 Antenna Locations ITEM ANTENNA PART NO. ITEM ANTENNA PART NO. ADF ... . — KA44B Upper Aft COM . . . — CI 121, CI 248-5 Marker Beacon ..—...
Page 105: Chapter 7 - Jacking And Hoisting
CHAPTER 7 JACKING AND HOISTING Section Title Page 7-10 Jacking ......... . 7-20 Hoisting .
Page 106 Intentionally Blank Page 7.ii Chapter 7 Jacking and Hoisting R66 Maintenance Manual 25 OCT 2010...
Page 107: Jacking
CHAPTER 7 JACKING AND HOISTING 7-10 Jacking CAUTION When jacking helicopter, use mechanical or locking hydraulic jacks, when available. Unlocked hydraulic jacks are subject to pressure-loss which can affect critical measurements during leveling or cause a raised helicopter to become unstable. CAUTION Never jack helicopter in windy conditions.
Page 108 FIGURE 7-1 JACKING Page 7.2 Chapter 7 Jacking and Hoisting R66 Maintenance Manual SEP 2012...
Page 109 7-10 Jacking (continued) B. Lowering CAUTION Skids spread as aircraft weight settles on landing gear. 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 clear equipment from area. Page 7.3 SEP 2012 R66 Maintenance Manual...
Page 110 FIGURE 7-2 HOISTING Page 7.4 Chapter 7 Jacking and Hoisting R66 Maintenance Manual SEP 2012...
Page 111: Hoisting
7-20 Hoisting CAUTION Avoid hoisting helicopter in windy conditions. CAUTION Verify ground is free of water, oil, solvent, grease, or residue that could cause equipment or personnel to slip during hoisting procedure. CAUTION Remain clear of area beneath helicopter when helicopter is raised. Minimize personnel movement around raised helicopter.
Page 112 7-20 Hoisting (continued) C. Lowering CAUTION Skids spread as aircraft weight settles on landing gear. 1. Refer to Figure 7-2. Stabilize helicopter as required by guiding tail skid, but do not exert force (tail skid is secondary structure). Slowly lower aircraft to ground. 2.
Page 113: Chapter 8 Weight And Balance
CHAPTER 8 WEIGHT AND BALANCE Section Title Page 8-10 Leveling ......... . 8-11 Leveling for Weight and Balance .
Page 114 Intentionally Blank Page 8.ii Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...
Page 115: Leveling
CHAPTER 8 WEIGHT AND BALANCE 8-10 Leveling NOTE Perform leveling and weighing in a zero-wind environment. NOTE Verify spirit level is calibrated by placing level on a designated surface and noting bubble position. Rotate spirit level 180°; verify bubble is in the same position. 8-11 Leveling for Weight and Balance NOTE Main rotor blade position does not affect weight and balance...
Page 116 FIGURE 8-1 LEVELING FOR WEIGHT AND BALANCE (Lateral shown; view looking down between aft seat footwells) FIGURE 8-2 LEVELING FOR RIGGING (Lateral shown) Page 8.2 Chapter 8 Weight and Balance R66 Maintenance Manual SEP 2012...
Page 117: Leveling For Rigging
8-12 Leveling for Rigging 1. Refer to Figure 8-2. Place cyclic stick in vertical position and apply cyclic friction. Position main rotor blades approximately fore and aft and apply rotor brake. (Teeter hinge bolt is aligned with lateral axis of helicopter.) 2.
Page 118 Intentionally Blank Page 8.4 Chapter 8 Weight and Balance R66 Maintenance Manual SEP 2012...
Page 119: Weighing
8-20 Weighing Reweigh helicopter when helicopter empty weight and empty weight center of gravity have been modified and if the accuracy of additional calculations is suspect. Maintain a continuous record of the helicopter’s weight and balance using the Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6.
Page 120 FIGURE 8-3 WEIGHING (Scale indications for demonstration only) Page 8.6 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...
Page 121: Weighing Procedure And Calculations
8-22 Weighing Procedure and Calculations NOTE • Arm is the distance in inches from datum. • Datum is located 100 inches forward of main rotor centerline. • CG (arm) is determined by dividing total moment by total weight. 1. Refer to Section 8-20. Prepare helicopter for weighing per Section 8-21. 2.
Page 122 8-22 Weighing Procedure and Calculations (continued) 6. Calculate weight and CG per the following table. Adjust ballast per steps 6b thru 6e as required until calculated CG is between 101.50 and 102.50 per step 6a. Longitudinal CG Item Weight (lb) (arm, inches) Moment (in.-lb) Forward Net:...
Page 123 8-22 Weighing Procedure and Calculations (continued) 8. Calculate basic empty weight and longitudinal CG: Longitudinal CG Item Weight (lb) (arm, inches) Moment (in.-lb) Forward Net: 32.67 Left Net: 127.35 Right Net: 127.35 Unusable fuel (add): 6.70 110.40 739.68 Basic empty weight and longitudinal CG: 9.
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: Fixed Ballast
8-30 Fixed Ballast 8-31 Nose Ballast Refer to R66 Illustrated Parts Catalog (IPC) Figure 8-1. NOTE Maximum allowable nose ballast is 15.00 lb. CAUTION Altering fixed ballast can appreciably affect helicopter center of gravity (CG). If fixed ballast information is unknown, reweigh helicopter per Section 8-22.
Page 126 FIGURE 8-5 EMPENNAGE BALLAST Page 8.12 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...
Page 127: Empennage Ballast
8-32 Empennage Ballast Refer to R66 Illustrated Parts Catalog (IPC) Figure 8-1. NOTE Use only approved materials listed in Section 20-70. CAUTION Altering fixed ballast can appreciably affect helicopter center of gravity (CG). If fixed ballast information is unknown, reweigh helicopter per Section 8-22.
Page 128 8-32 Empennage Ballast (continued) B. Installation (continued) 5. Remove paint within traced outlines on stabilizer by block sanding (to maintain flatness). Finish sanding using 320-grit or finer wet-or-dry sandpaper, or using approved stripper per Section 20-71. Similarly, on each D301-2 weight, remove paint from one flat surface which will clamp against stabilizer.
Page 129: Chapter 9 - Ground Handling
CHAPTER 9 GROUND HANDLING Section Title Page 9-10 Ground Handling ........9-11 Ground Handling Wheels .
Page 130 Intentionally Blank Page 9.ii Chapter 9 Ground Handling R66 Maintenance Manual 25 OCT 2010...
Page 131 CHAPTER 9 GROUND HANDLING 9-10 Ground Handling 9-11 Ground Handling Wheels Refer to R66 Illustrated Parts Catalog (IPC) Figure 9-1. NOTE R66 ground handling wheels are installed inboard of landing gear skid tubes. C063-5 (LH) and C063-6 (RH) ground handling wheel assemblies are not interchangeable.
Page 132 1. Insert spindle into skid-mounted support. 2. Verify flange is outboard of cradle. 3. Pull handle in rearward arc to raise helicopter. 4. Handle is in locked position when parallel with the skid. NOTE R66 ground handling wheels are installed inboard of landing gear skid tubes.
Page 133 9-11 Ground Handling Wheels (continued) B. Removal 1. Refer to Figure 9-1. Pull ground handling wheel handle in forward arc (lowers helicopter) until handle is in unlocked position, parallel with the skid. Remove spindle from skid-mounted support and remove wheel assembly. Repeat step to remove second wheel assembly.
Page 134 9-20 Trailering CAUTION Trailering the R66 is not normally recommended. Most trailers large enough to accommodate the helicopter are designed for much heavier loads; the trailer’s springs and shock absorbers will not function properly when lightly-loaded. Also, without support, the tailcone can resonate with trailer vibrations, subjecting the tailcone to greatly amplified loads.
Page 135 CHAPTER 10 PARKING AND STORAGE Section Title Page 10-10 Parking ......... . 10.1 10-11 Parking in High Wind or Turbulent Air .
Page 136 Intentionally Blank Page 10.ii Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010...
Page 137: Parking
CHAPTER 10 PARKING AND STORAGE 10-10 Parking 1. Place cyclic stick in vertical position and apply cyclic friction. 2. Place collective stick full down and apply collective friction. CAUTION Never pull down on main rotor blade. To teeter blades, push up on the opposite blade.
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: Main Rotor Blade Tie-Downs
10-11 Parking in High Wind or Turbulent Air (continued) B. Extreme Conditions (continued) 2. b. Remove hardware securing pitch links to swashplate assembly. 3. Remove tail rotor pitch links per steps below: a. Refer to Figure 64-1. Tag each pitch link with corresponding blade serial number. Disconnect pitch links from tail rotor blades;...
Page 140: Main Rotor Blade Supports
FIGURE 10-2 MAIN ROTOR BLADE SUPPORTS Page 10.4 Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010...
Page 141 10-13 Main Rotor Blade Supports Refer to R66 Illustrated Parts Catalog (IPC) Figure 10-7. CAUTION Do not allow strut assemblies to hang from cradle assemblies installed on main rotor blades. Support strut assemblies during strut removal or installation. A. Removal 1.
Page 142: Storage (Greater Than 30 Days)
10-20 Storage (Greater than 30 days) NOTE Helicopter should be hangared or moved to a safe area during storage. NOTE Periodically inspect aircraft for corrosion and correct as required. Aircraft stored in humid environments are subject to aggressive corrosive reaction and require more frequent inspection. 1.
Page 143: Chapter 11 - Placards And Markings
CHAPTER 11 PLACARDS AND MARKINGS Section Title Page 11-10 Placard Locations ........11.1 11-20 Placard Illustrations .
Page 144 FIGURE 11-1 PLACARD LOCATIONS Page 11.0 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012...
Page 145 11-10 Placard Locations ITEM PART NO. DESCRIPTION A654-18 Decal - "LEVEL HERE" ......... 1 A654-25 Decal - “NEVER PULL DOWN / PUSH UP OPPOSITE BLADE”...
Page 146 FIGURE 11-2 PLACARD LOCATIONS Page 11.2 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012...
Page 147 11-10 Placard Locations (continued) ITEM PART NO. DESCRIPTION F463-1 Cover Assembly - Mid Tunnel ........1 F654-27 Decal (console compartment capacity) .
Page 148 11-20 Placard Illustrations (continued) 6. Decal F654-20 7. Decal F654-19 8. Decal C654-17 9. Decal F654-10 10. Decal F654-17 11. Decal F654-1 12. Decal A654-7 13. Cover F445-1 15. Cover F444-1 14. Decal A654-45 Page 11.4 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012...
Page 149 11-20 Placard Illustrations (continued) 16. Panel Assembly F490-1 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. Decal F654-6 24. Decal F654-15 25. Decal F654-12 26.
Page 150 11-20 Placard Illustrations (continued) 28. Decal A654-38 29. Decal F654-11 30. Decal F654-16 31. Marking A321-19 (co-pilot weldment) 32. Marking A756-24 (pilot weldment, see No. 31) 33. Decal F654-4 (see No. 31) 34. Face Assembly B051-20 Page 11.6 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012...
Page 151 11-20 Placard Illustrations (continued) 35. Decal A654-45 (see No. 14) 41. Cover C712-2 36. Decal A654-17 37. Cover Assembly F463-1 42. Handle D119-1 43. Cover Assembly F436-6 (RH) 38. Decal F654-27 44. Cover Assembly F436-5 (LH) 45. Decal A654-16 39. Console Assembly G749-2 (Ref) 40.
Page 152 11-20 Placard Illustrations (continued) 47. Decal A654-11 52. Decal A654-3 48. Decal F654-24 53. D079-1 Tail rotor guard (Ref) 54. Decal C654-2 49. Decal F654-9 50. Decal F654-7 51. Faceplate G598-1 Page 11.8 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012...
Page 153 CHAPTER 12 SERVICING Section Title Page 12-10 Main Rotor Gearbox ........12.1 12-11 Servicing .
Page 154 Intentionally Blank Page 12.ii Chapter 12 Servicing R66 Maintenance Manual SEP 2012...
Page 155: Chapter 12 - Servicing
CHAPTER 12 SERVICING 12-10 Main Rotor Gearbox WARNING Refer to appropriate Material Safety Data Sheet (MSDS) and take necessary safety precautions when working in proximity to hazardous materials. 12-11 Servicing NOTE Inspect main rotor gearbox and gearbox lubrication system for leaks when “top off”...
Page 156 FIGURE 12-1 MAIN ROTOR GEARBOX SERVICING Page 12.2 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...
Page 157: Filter Replacement
12-12 Filter Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figure 63-13. NOTE Replace main rotor gearbox oil every 600 hours. When replacing a filter after new or overhauled main rotor gearbox has accumulated 100 hours, replacing oil is not required. 1.
Page 158 FIGURE 12-2 DRAINING MAIN ROTOR GEARBOX OIL Page 12.4 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...
Page 159 12-13 Chip Detector and Sight Gage (continued) C. Installation 1. Refer to Figure 12-1. Verify cleanliness and clarity of sight gage. As required, remove sight gage per Part A and clean with approved solvent per Section 20-70. Install sight gage and special torque per Section 20-33. 2.
Page 160 FIGURE 12-3 TAIL ROTOR GEARBOX Page 12.6 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...
Page 161: Tail Rotor Gearbox
12-20 Tail Rotor Gearbox WARNING Refer to appropriate Material Safety Data Sheet (MSDS) and take necessary safety precautions when working in proximity to hazardous materials. 12-21 Servicing NOTE Inspect tail rotor gearbox for leaks when “top off” is required. NOTE Verify aircraft is on level ground when evaluating gearbox oil level.
Page 162: Chip Detector And Sight Gage
12-22 Chip Detector and Sight Gage A. Removal 1. Drain tail rotor gearbox oil per Section 12-21. 2. Remove sight gage, as required. B. Cleaning Chip Detector 1. Clean chip detector per Section 12-13 Part B (main rotor gearbox). C. Installation 1.
Page 163: Hydraulic System
12-30 Hydraulic System CAUTION Do not contaminate hydraulic fluid. Service hydraulic system with clean fluid from sealed containers, using clean tools. WARNING Refer to appropriate Material Safety Data Sheet (MSDS) and take necessary safety precautions when working in proximity to hazardous materials.
Page 164 FIGURE 12-4 HYDRAULIC SYSTEM Page 12.10 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...
Page 165: Drain And Flush
12-33 Drain and Flush NOTE Drain and flush hydraulic system if oil turns dark or emits bad odor. WARNING Keep limbs clear of flight controls when operating test pump. Hydraulic forces can cause injury. 1. Refer to Figure 12-4. Remove filler-vent plug. Place a suitable drain container under F902-1 (pressure) and F902-2 (suction) line assembly T-fittings, and remove caps.
Page 166: Bleeding
12-34 Bleeding WARNING Keep limbs clear of flight controls when operating test pump. Hydraulic forces can cause injury. 1. Remove F902-1 (pressure) line assembly T-fitting cap. Connect MT384 (or equivalent) 0.8-1.2 gpm hydraulic test pump pressure line to T-fitting. (Pressure and suction fittings are different sizes to ensure correct connection.) 2.
Page 167: Fuel System
12-40 Fuel System WARNING Refer to appropriate Material Safety Data Sheet (MSDS) and take necessary safety precautions when working in proximity to hazardous materials. WARNING Always fuel helicopter in a well-ventilated area. No smoking within 100 feet of aircraft during fueling. 12-41 Fueling 1.
Page 168 FIGURE 12-5 MAIN ROTOR BLADE PITCH BEARING HOUSING Page 12.14 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...
Page 169: Main Rotor Blades
12-50 Main Rotor Blades WARNING Refer to appropriate Material Safety Data Sheet (MSDS) and take necessary safety precautions when working in proximity to hazardous materials. 12-51 Pitch Bearing Housing NOTE MT147-1 Main rotor blade spindle air bleed tool includes supply container, hose assemblies, and bleed fittings.
Page 170: Engine Oil Servicing
12-60 Engine Oil Servicing Refer to R66 Illustrated Parts Catalog (IPC) Figures 79-5 and 79-7. A. Draining Fluid 1. Run-up helicopter two to five minutes at 60-70% RPM per R66 Pilot's Operating Handbook (POH) Section 4 to warm engine oil, as required. 2.
Page 171: Engine) Compressor Rinse And Wash
12-70 (Engine) Compressor Rinse and Wash Refer to R66 Illustrated Parts Catalog (IPC) Figure 71-9. CAUTION See RR300 Series Operation and Maintenance Manual (OMM) requirements for compressor rinse and wash intervals. CAUTION Always perform compressor rinse or wash with sufficient clearance for possible rotor system rotation.
Page 172: Air Conditioning System
12-80 Air Conditioning System 12-81 Refrigerant Recovery and System Charging NOTE In the United States, only personnel with EPA certification under Section 609 of the Clean Air Act may charge the system with refrigerant or work on the refrigerant system once it has been charged.
Page 173: Leak Detection
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.
Page 174 Intentionally Blank Page 12.20 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...
Page 175: Chapter 18 Track And Balance
CHAPTER 18 TRACK AND BALANCE Section Title Page 18-10 Main Rotor Track and Balance ......18.1 18-11 Preparing Helicopter for Main Rotor Track and Balance .
Page 176 Intentionally Blank Page 18.ii Chapter 18 Track and Balance R66 Maintenance Manual SEP 2012...
Page 177: Main Rotor Track And Balance
CHAPTER 18 TRACK AND BALANCE 18-10 Main Rotor Track and Balance NOTE Calibrate track and balance equipment per manufacturer's recommendation, at least 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’...
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: Preparing Helicopter For Main Rotor Track And Balance
18-11 Preparing Helicopter for Main Rotor Track and Balance NOTE Use the following track & balance procedures in conjunction with approved equipment manufacturer’s balancing instructions. CAUTION Cable security is critical; helicopter will be flown at V 1. Perform swashplate and rotor hub inspection per Section 5-45. Inspect tail rotor rod ends and elastomeric bearings per Sections 5-33 and 5-34.
Page 180 DATE SERIAL NO. TIP WEIGHTS TEETER HINGE SHIMS PAGE (1) AN960-10 Washer AN960-10L Washers C117-8 0.012 inch CHORD ARM WEIGHTS (1) C298-2 Weight AN960-10 Washers C117-9 0.015 inch (1) A255-1 Weight = (8) AN970-4 Washers (1) C298-3 Weight = (11) AN960-10 Washers C117-10 0.020 inch...
Page 181: Flight Checks
18-12 Flight Checks NOTE Run-up and shutdown helicopter throughout procedure as required per R66 Pilot's Operating Handbook (POH) Section 4. NOTE Refer to Section 18-15 for track and balance troubleshooting procedures. WARNING Tail rotor balancing equipment must be removed for flight. WARNING Do not exceed V of helicopter during flight checks.
Page 182 Coarse Length Adjustment Rod End and Fitting • One full turn changes blade angle 0.88º. Medium 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 0.48º. Fine Adjustment Fitting Only • One full turn changes blade track 0.25 inch.
Page 183: Track Adjustment
18-13 Track Adjustment A. Main Rotor Blade Pitch Link Refer to R66 Illustrated Parts Catalog (IPC) Figure 62-5. NOTE Shorten high pitch blade when adjusting track in a hover. NOTE During rigging, adjust both pitch links exactly the same for collective adjustments.
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 18-13 Track Adjustment (continued) A. Main Rotor Blade Pitch Link (continued) 3. For fine adjustment, adjust fitting only per the following steps: a. Remove and discard pitch link assembly safety wire. Using backup wrench on link assembly, loosen jam nut in middle of pitch link. Using backup wrench on fitting, loosen upper rod end palnut and jam nut.
Page 186: Balance Adjustment
18-13 Track Adjustment (continued) B. Main Rotor Blade Trim Tab (continued) 2. Position MT352-1 gage chordwise across blade upper surface and tab trailing edge. Zero dial indicator on measuring point. 3. Position MT526-8 bending tool on tab per Figure 18-4. Slide tool completely over tab until tool stops contact blade trailing edge.
Page 187: Troubleshooting
18-15 Troubleshooting The following are some of the symptoms and corrections which occur in the Track and Balance operations of the helicopter. Decide on the various causes of a given trouble and then eliminate causes one by one, beginning with the most probable. Symptom Probable Cause Correction...
Page 188: Autorotational Rpm Adjustment
18-16 Autorotational RPM Adjustment Use the following procedure for checking and adjusting autorotational RPM: WARNING Failure to properly adjust autorotational RPM (RPM too low) may prevent the rotorcraft from achieving proper RPM at low gross weights. 1. Perform autorotation RPM check at minimum practical gross weight (less than 1900 lb).
Page 189 18-16 Autorotational RPM Adjustment (continued) 3. After test flight, determine the following: Test # Elapsed Time (in-flight hourmeter reading minus take-off hourmeter reading): Pounds of Fuel Consumed (elapsed time x 140 lb/hr): Test Gross Weight (take-off gross weight minus fuel consumed): Test Longitudinal Center of Gravity: Chart % RPM*: Test % RPM (from in-flight data):...
Page 190 AUTOROTATION RPM COLLECTIVE FULL DOWN 50 KIAS One full turn of rod ends = approximately 3½% RPM change One full turn of rod end = 1⅙ 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 Track and Balance R66 Maintenance Manual...
Page 191 Intentionally Blank Page 18.15 25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance...
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: Tail Rotor Dynamic Balance
18-20 Tail Rotor Dynamic Balance NOTE Calibrate track and balance equipment per manufacturer's recommendation, at least 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 equipment is required to perform dynamic rotor balancing and in-flight track checks.
Page 194 DATE SERIAL NO. PAGE PITCH HORN-TO-PITCH LINK FASTENER (CHORDWISE) WEIGHTS BLADE-TO-HUB OUTBOARD FASTENER (SPANWISE) WEIGHTS (1) NAS1149F0463P Washer NAS1149F0432P Washers (1) C141-23 Washer = (3.5) NAS1149F0663P Washers (1) A214-3 Washer = (3.5) NAS1149F0432P Washers (1) C141-24 Washer (7) NAS1149F0663P Washers (1) A141-14 Washer NAS1149F0432P Washers (2) NAS1149F0632P...
Page 195: Ground Checks
18-22 Ground Checks NOTE Run-up and shutdown helicopter throughout procedure as required per R66 Pilot's Operating Handbook (POH) Section 4. NOTE Use the following balancing procedures in conjunction with approved equipment manufacturer’s balancing instructions. WARNING Tail rotor balancing equipment must be removed for flight. 1.
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: Main Rotor Flight Control Rigging
18-30 Main Rotor Flight Control Rigging NOTE Refer to Section 5-33, and Figures 5-1 & 5-2 for standard rod end adjustment procedures. Refer to Section 18-13 for main rotor pitch link adjustment procedure. For collective adjustments, both pitch links must be adjusted exactly the same.
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: Main Rotor Blade Rigging
18-40 Main Rotor Blade Angle Rigging A. Procedure NOTE Refer to Section 5-33, and Figures 5-1 & 5-2 for standard rod end adjustment procedures. Refer to Section 18-13 for main rotor pitch link adjustment procedure. 1. Perform main rotor flight control rigging per Section 18-30. 2.
Page 200: Collective Travel
18-41 Collective Travel NOTE Lengthening pitch links increases blade angles. NOTE When making adjustments, keep pitch links as close to neutral (mid-travel) position as possible to preserve the adjustment range for flight checks. A. Collective Down 1. Refer to Figure 18-8. Position collective stick full up and apply friction. Place MT759-1 rigging blocks around cyclic stick in cyclic box assembly.
Page 201 18-41 Collective Travel B . Collective Up 1. Position collective stick full up and apply friction. Place MT759-1 rigging blocks around cyclic stick in cyclic box assembly. 2. Rotate blades so pitch links are aligned with helicopter longitudinal axis. 3. Measure and record blade angles per Section 18-40 Part B to determine the values below.
Page 202: Cyclic Travel
18-42 Cyclic Travel A. Cyclic Left 1. Position collective stick full down. Position cyclic stick in the longitudinal neutral (mid travel) position, and against left stop. Apply control frictions; sandbag cyclic stick as required. 2. Rotate blades so pitch links are aligned with helicopter lateral axis. 3.
Page 203 18-42 Cyclic Travel (continued) C. Cyclic Forward 1. Position collective stick full down. Position cyclic stick in the lateral neutral (5 inches to left of right stop) position, and against forward stop. Apply control frictions; sandbag cyclic stick as required. 2.
Page 204: Tail Rotor Flight Control Rigging
18-50 Tail Rotor Flight Control Rigging 18-51 Pedals 1. Insert a 3/16-inch diameter rigging pin through the hole in the right-hand keel panel and the rigging pin holes in the C317-7 bellcrank. 2. Adjust the F121-9 push-pull tubes as required to obtain a dimension of 5.24 ± 0.03 in.
Page 205: Tail Rotor Blade Control Rigging
18-60 Tail Rotor Blade Rigging 1. Level helicopter laterally, and longitudinally via main rotor hub, per Section 8-12. 2. Place left (or right) pedal against its stop. Position tail rotor blades parallel to the tailcone. 3. Refer to Figure 18-11. Tape a tracking stick to tailcone at blade tip. A tracking stick can be made using a 1”...
Page 206 18-60 Tail Rotor Blade Rigging (continued) 11. If the blade angle range for left and right pedal settings cannot be obtained using the preceding steps, the pedal travel is either too great or too small. Use the following procedure to check and adjust pedal travel: a.
Page 207: Chapter 20 Standard Practices
CHAPTER 20 STANDARD PRACTICES Section Title Page 20-10 Cleaning ......... . 20.1 20-20 Lubrication .
Page 208 Intentionally Blank Page 20.ii Chapter 20 Standard Practices R66 Maintenance Manual 25 OCT 2010...
Page 209: Cleaning
CHAPTER 20 STANDARD PRACTICES 20-10 Cleaning NOTE Remove turbine exhaust stains from engine cowling, tailcone, empennage, and tail rotor blades after every flight to prevent permanent discoloration. CAUTION Wash helicopter exterior surfaces, windshields, and windows with mild soap and water. Harsh abrasives, alkaline soaps, or detergents can scratch painted or plastic surfaces, or cause corrosion of metal.
Page 210: Lubrication
20-10 Cleaning (continued) B. Cleaning Windshield and Windows CAUTION Do not use gasoline, other alcohols, benzene, carbon tetrachloride, thinner, acetone, or window (glass) cleaning sprays. 1. Rinse away loose dirt and debris from windshield and windows with clean water. 2. Apply mild soap and clean warm water solution, or aircraft plastic cleaner, to windshield and windows using a clean, soft cloth or sponge in a straight back and forth motion.
Page 211: Torque Requirements
20-30 Torque Requirements A. Tool Calibration Dimensions and tolerances given in this manual are critical. Calibrate measuring tools per manufacturers recommendation at least once a year, when tool is dropped, misused, or calibration is suspect. This includes torque wrenches, micrometers, calipers, dial indicators, and spring scales.
Page 212 Given Symbols Y = Unknown Y = Torque wrench setting T = 135 in.-lb T = Torque applied to fastener L = 10 in. L = Length of torque wrench A = 1.5 in. A = Length of adapter When using an adapter that lengthens torque wrench effective length, calculate torque wrench setting using the formula below: EXAMPLE T x L...
Page 213: Torque Seal
20-30 Torque Requirements (continued) WARNING Two threads minimum must be exposed beyond nut on any installation to insure proper locking of fastener. Four threads maximum may be exposed. More than four threads exposed may allow nut to seat against bolt shank, resulting in insufficient joint clamping.
Page 214: Standard Torques
20-32 Standard Torques EXAMPLE DRY TORQUE FASTENER SERIES SIZE FASTENER (IN.-LB) 10-32 NAS6603 NAS 1300 Bolts 1/4-28 NAS6604 NAS 6600 Bolts 5/16-24 NAS6605 NAS 600 THRU 606 Screws NAS 623 Screws 3/8-24 NAS6606 NAS 1351 Screws NAS 1352 Screws 7/16-20 NAS6607 1/2-20 NAS6608...
Page 215: Special Torques
20-33 Special Torques Special torques supersede standard torques listed in Section 20-32. TORQUE AREA* FASTENER* (IN.-LB)* (1) D795-8 line assembly, B-nuts (1) D799-2 switch assembly (1) D799-3 switch assembly (1) G783-1 condenser, dessicant cap (1) G784-1 evaporator assembly, inlet B-nut to 134-32 TXV AIR CONDITIONING (1) G794-1 hose assembly, B-nuts (OPTIONAL...
Page 216 20-33 Special Torques (continued) TORQUE AREA* FASTENER* (IN.-LB)* (2) C394-2 ball stud, at forward doors, to frame 150 wet DOOR HINGES AND (2) D575-2 and (2) D575-3 ball joints, at forward doors' D573-4 GAS SPRINGS rods (2) F650-1 bolt, forward main rotor gearbox and G201 frame 90 FT-LB mounts Bolt head or nut...
Page 217 20-33 Special Torques (continued) TORQUE AREA* FASTENER* (IN.-LB)* (3) B330-21 palnut, on aft and left servos and on reservoir (1) B330-25 palnut, on reservoir (1) D205-14 line assembly B-nuts 95-105 (1) D205-17 line assembly B-nuts 95-105 HYDRAULIC HOSES & FITTINGS (1) D205-18 line assembly B-nuts 135-150 (1) D205-22 line assembly B-nuts...
Page 218 20-33 Special Torques (continued) TORQUE AREA* FASTENER* (IN.-LB)* New bolt: 0.021-0.022 inch elongation, wet (1) NAS634-105 bolt, teeter hinge and MAIN ROTOR HUB Used bolt: 0.020-0.022 (2) NAS634-105 bolt, coning hinges inch elongation, wet, and cotter pin holes must align MAST TUBE (1) B277-064 clamp, lower rib to mast tube PITCH LINKS...
Page 219: Push-Pull Tube Rod End Adjustment
20-33 Special Torques (continued) TORQUE AREA* FASTENER* (IN.-LB)* (1) MS21042L4 nut, securing C119-2 bumper TAIL ROTOR (1) NAS6606-53 bolt, teeter hinge TAIL ROTOR (1) MS21042L4 nut, outboard of F316-1 bellcrank assembly FLIGHT CONTROLS (1) A610-1 vent assembly (1) B563-1 sight gage (1) B566-2 chip detector (1) AN320-8 nut, input yoke 35-45 FT-LB...
Page 220: Non-Destructive Testing
20-40 Non-Destructive Testing WARNING Refer to appropriate Material Safety Data Sheet (MSDS) and take necessary safety precautions when working in proximity to hazardous materials. 20-41 Magnetic Particle Inspection Ferromagnetic steel parts must be inspected for structural defects using magnetic particle inspection.
Page 221: Fluorescent Penetrant Inspection
20-42 Fluorescent Penetrant Inspection This specification provides for surface inspection of parts fabricated from nonmagnetic materials to detect discontinuities open to the surface, such as cracks, cold shuts, laps, porosity and other surface defects. Applicable requirements and limitations of ASTM E 1417 shall apply. After inspection is complete, solvent clean parts.
Page 222: Priming And Painting
20-60 Priming and Painting (continued) A. Priming (continued) Use only approved materials listed in Section 20-70. Parts shall be prepared in the following manner: 1. Preparing Aluminum Unless otherwise specified, chemical conversion coating using Alodine 1201 is the standard treatment before priming aluminum. Follow manufacturers instructions for application of Alodine.
Page 223 20-60 Priming and Painting (continued) B. Painting This specification provides final paint finish requirements. Do not prime or paint with a top coat finish the following areas (unless directed): Sliding friction joints. Stainless steel parts. Swivel joints and adjustable rod ends. Plastic, rubber, electrical components and wires or similar materials.
Page 224: Approved Materials
20-70 Approved Materials The following items are available from the noted manufacturer(s) or their distributor(s). Check with appropriate regulatory authority(s) for allowable usage of materials. WARNING Refer to appropriate Material Safety Data Sheet (MSDS) and take necessary safety precautions when working in proximity to hazardous materials.
Page 225: Torque Seal
20-72 Solvents and Cleaners (continued) PRODUCT MANUFACTURER/SUPPLIER APPLICATION 815 GD Brulin Corporation Ultrasonic cleaning, general use.** Indianapolis, IN SF50 L&R Mfg. Co. “ “ Kearny, NJ #112 Ammoniated or L&R Mfg. Co. Ultrasonic cleaning, avionics components #222 Nonammoniated Kearny, NJ only.
Page 226: Powder Coat
20-76 Powder Coat Epoxy and topcoat powders are electrostatically applied to steel parts and baked for 10-15 minutes after each powder application. Curing temperature must not exceed 400° F. Zinc rich epoxy powder coating thickness allowance is 0.001 to 0.004 inches. PRODUCT MANUFACTURER 13-7004 Corvel Grey...
Page 227: Paints
20-77 Paints Refer to Figures 20-3 and 20-4 for finish code locations. Paint codes for specific helicopter serial numbers are listed in the front of factory-supplied R66 Airframe Maintenance Record (AMR; logbook). NOTE Use fisheye eliminator, accelerator, or other additives per manufacturer's recommendations.
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 Page 20.21 SEP 2012 R66 Maintenance Manual Chapter 20 Standard Practices...
Page 230: Lubricants
20-78 Lubricants RHC PART NO. MFR. PART NO. MANUFACTURER A257-1 Southwestern Petroleum Corp. (general purpose grease) Fort Worth, TX A257-3 Aero Shell 14 Shell Oil Co. MIL-G-25537 (grease) A257-4 Dexron II or Quaker State or Pennzoil Dexron II/Mercon or Dexron III/Mercon (automatic transmission fluid) A257-5 3120...
Page 231: Adhesives And Sealants
20-79 Adhesives and Sealants RHC PART DESCRIPTION COLOR MFR. PART NO. MANUFACTURER B270-1 Sealant - polysulfide, fuel resistant Gray FS-8907 B-2 PPG Aerospace (2-part) Glendale, CA Sealant - polysulfide, fuel resistant Gray AC-350 B-2 Advanced Chemistry (2-part) & Technology Inc., Garden Grove, CA B270-5 Sealant - synthetic rubber putty...
Page 232: Storage Limits
20-79 Adhesives and Sealants (continued) RHC PART DESCRIPTION COLOR MFR. PART NO. MANUFACTURER B270-23 Sealant - gasket (1-part) Brown GM3H Perfect Seal (Gasket Maker #4) Sealant - gasket (1-part) Brown JV66B Dana Corp.; Churubusco, IN (Victor Reinz Brand) B270-24 Activator/Primer - Translucent 7649 Henkel Loctite Corp.
Page 233: Miscellaneous Practices
20-90 Miscellaneous Practices 20-91 Part Interchangeability The following parts are interchangeable. Unless noted otherwise, whenever one part is referred to in this manual, its substitute part is also permitted. Part Interchangeable with: 354601 & 354602 ... . . D262-1 & D262-2 AN340 nut .
Page 234: Thermal Fitting Parts
20-92 Thermal Fitting Parts General Procedures for using heat to fit parts during assembly or evaluating parts that may have been overheated in service: Aluminum parts must not be heated above 200ºF for more than 5 minutes. Higher temperatures or longer times adversely affect strength and corrosion properties. Scrap any aluminum parts suspected of going above 325ºF regardless of time at temperature.
Page 235: Chapter 21 Environment Control
CHAPTER 21 ENVIRONMENT CONTROL Section Title Page 21-00 Description ........21.1 21-10 Ventilation .
Page 236 Intentionally Blank Page 21.ii Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...
Page 237: Description
CHAPTER 21 ENVIRONMENT CONTROL 21-00 Description Fresh air vents are located in each door and in the nose. Door vents are opened and closed using the knob near the vent door hinge. A rotating knob is provided to seal and lock vents closed.
Page 238 FIGURE 21-1 NOSE VENT Page 21.2 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...
Page 239: Ventilation
21-10 Ventilation 21-11 Nose Vent Refer to R66 Illustrated Parts Catalog (IPC) Figures 21-1. A. Removal 1. Remove hardware securing avionics face to F033-1 lower console and remove face. Unscrew and remove radios. Remove hardware securing radio trays to lower console and remove trays.
Page 240 FIGURE 21-2 AIR CONDITIONING SCHEMATIC Page 21.4 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...
Page 241: Air Conditioning
21-20 Air Conditioning 21-21 Compressor Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 21-3. A. Belt Replacement 1. Remove tailcone cowling per Section 53-23. 2. Remove hardware securing F196-1 tail rotor drive fan shaft to C947-3 plate assemblies, noting hardware removed. 3.
Page 242 21-21 Compressor Assembly (continued) B. Removal 1. Remove tailcone cowling per Section 53-23. 2. Turn BATTERY switch OFF. Cut and discard ty-raps as required and disconnect compressor assembly wiring from airframe harness at connectors. 3. Recover refrigerant per Section 12-81. Remove hardware securing refrigerant hose assemblies to G777-1 compressor assembly.
Page 243: Condenser And Fan Assemblies
21-22 Condenser and Fan Assemblies Refer to R66 Illustrated Parts Catalog (IPC) Figure 21-7. A. Removal 1. Recover refrigerant per Section 12-82. 2. Remove engine cowling per Section 53-21. 3. Turn BATTERY switch OFF. Cut and discard ty-raps as required and disconnect G780-1 fan assembly wiring from airframe harness at connectors.
Page 244: Evaporator Assembly
21-23 Evaporator Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 21-11. A. Removal 1. Recover refrigerant per Section 12-82. 2. Refer to Section 6-70. Detach F931-1 seat assembly (secured via hook and loop tape) from F474-1 cover assembly and remove seat. Remove hardware securing cover assembly and F380-8 angle to F377-1 middle seat assembly;...
Page 245: Troubleshooting
21-24 Troubleshooting 1. If air exiting overhead duct is not cold: POSSIBLE CAUSE TROUBLESHOOT/CORRECTIVE ACTION Low Refrigerant Recover refrigerant per Section 12-82. System should operate normally on Charge/ Refrigerant approximately 2.5 lb refrigerant. Leak If less than 2.5 refrigerant is recovered, perform leak detection per Section 12-83, repair leaks if any, and charge system with refrigerant per Section 12-82.
Page 246 FIGURE 21-3 CABIN HEAT Page 21.10 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...
Page 247: Cabin Heat
21-30 Cabin Heat 21-31 Valve Assembly and Control Rigging Refer to R66 Illustrated Parts Catalog (IPC) Figures 21-31 and 21-35. A. Removal 1. Refer to Section 6-70. Remove hardware securing F794-1 and F794-2 (belly cover) panels and remove panels. Remove engine cowling per Section 53-21. 2.
Page 248: Muffler Assembly
21-32 Muffler Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 21-35. A. Removal 1. Refer to Section 6-70. Remove hardware securing F794-1 and F794-2 (belly cover) panels and remove panels. 2. Refer to Figure 21-3. Loosen B277-12 clamp and pull A785-39 hose off of G400-2 muffler assembly.
Page 249 21-33 Diffuser and Tee Assemblies (continued) B. Forward Diffuser and Tee Assembly Installation 1. Refer to Figure 21-3. As required, install MS21919WCH16 and (two) B277-24 clamps on G400-1 tee assembly. Install tee with clamps, and install hardware securing MS21919WCH16 clamp and tee to angle. 2.
Page 250 Intentionally Blank Page 21.14 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...
Page 251: Chapter 25 Furnishings
CHAPTER 25 FURNISHINGS Section Title Page 25-00 Description ........25.1 25-10 Seat Harnesses .
Page 252 Intentionally Blank Page 25.ii Chapter 25 Furnishings R66 Maintenance Manual SEP 2012...
Page 253: Description
CHAPTER 25 FURNISHINGS 25-00 Description The seats are not adjustable but the pilot-side pedals are adjustable. Each helicopter is supplied with a cushion which can be placed behind the pilot to position him forward. This allows shorter pilots to reach the pedals, the cyclic stick in its most forward position, and the controls on the center console.
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: Seat Harnesses
25-10 Seat Harnesses Refer to R66 Illustrated Parts Catalog (IPC) Figures 25-3 and 25-5. Refer to Figures 25-9, 25- 11, and 25-13 for optional Five-Point Harness Installation. 25-11 Seat Harness Removal A. Forward Seat Harness (Standard) 1. Refer to Figure 25-1. Remove F680-1 and F680-3 collective cover assemblies; hinge seat assemblies forward.
Page 256: Seat Harness Installation
25-12 Seat Harness Installation A. Forward Seat Harness (Standard) 1. Refer to Figure 25-1. Install hardware securing inertia reels to F369 and F370 forward seat backs. Install right side reel cover. 2. Install hardware securing shoulder strap guides to door frames. Standard torque bolts per Section 20-32.
Page 257: Seat Assembly Removal And Installation
25-20 Seat Assemblies and Back Rests Refer to R66 Illustrated Parts Catalog (IPC) Figure 25-1. 25-21 Seat Assembly Removal and Installation WARNING Never repair or modify seat assemblies, including seat assembly fabric, seat pans, or hook and loop tape (Velcro) securing fabric to seat pans.
Page 258 FIGURE 25-2 CARPET AND INSULATION Page 25.6 Chapter 25 Furnishings R66 Maintenance Manual SEP 2012...
Page 259: Carpet
25-23 Back Rest Cushion Replacement (continued) B. Aft Left and Right Back Rest 1. Refer to Figure 25-1. Remove back rest assembly per Section 25-22. 2. Drill out rivets securing back rest cushion to seat back panel and deburr holes. Remove cushion.
Page 260: Insulation (Foam And Headliner)
25-40 Insulation (Foam and Headliner) Refer to R66 Illustrated Parts Catalog (IPC) Figure 25-17. A. Removal NOTE Use caution not to damage surface underneath insulation when removing insulation with tools. NOTE Insulation is installed using adhesive, except under seat assemblies. Order new insulation as required; reuse of removed insulation is not recommended.
Page 261: License Holder Replacement
25-52 License Holder Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figure 25-11. A. Removal 1. Remove aircraft documents from license holder. 2. Drill out rivets securing license holder to cabin under left side windshield frame and remove license holder. Deburr holes and clean up debris. B.
Page 262: Emergency Equipment
25-60 Emergency Equipment 25-61 Emergency Locator Transmitter (ELT) NOTE ELT installation is optional equipment. A. ELT Information and Programming Refer to Section 96-90 for ELT system description. Refer to Section 5-20 for scheduled maintenance. Refer to ELT Kannad 406 AF-Compact/406 AF-Compact (ER) Installation and Operation Manual for maintenance requirements and procedures.
Page 263: Fire Extinguisher
25-62 Fire Extinguisher Refer to R66 Illustrated Parts Catalog (IPC) Figure 25-13. NOTE Fire extinguisher installation is optional equipment. A. Inspection Inspect fire extinguisher monthly according to manufacturer's instructions. Maintenance instructions are located on extinguisher bottle. Record inspection date and findings as required.
Page 264 Intentionally Blank Page 25.12 Chapter 25 Furnishings R66 Maintenance Manual 25 OCT 2010...
Page 265 CHAPTER 28 FUEL SYSTEM Section Title Page 28-00 Description ........28.1 28-10 Bladder Assembly .
Page 266 Intentionally Blank Page 28.ii Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...
Page 267: Fuel System
CHAPTER 28 FUEL SYSTEM 28-00 Description This chapter includes instructions for the removal and installation of the airframe fuel system components. Refer to RR300 Series Operation and Maintenance Manual (OMM) for engine fuel system maintenance procedures. A single bladder-type crash-resistant fuel cell supplies fuel via gravity flow to the engine. The fuel cell incorporates left and right vent fittings, a filler port, a fuel gage sender, a low-fuel switch assembly, a sump drain, and a finger strainer at the fuel outlet.
Page 268 FIGURE 28-2 FUEL SYSTEM COMPONENTS Page 28.2 Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...
Page 269: Bladder Assembly
28-10 Bladder Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figures 28-1 and 28-3. CAUTION G028-1 bladder assembly temperature should be above 65°F before removing, installing, or flexing bladder. A. Removal 1. Defuel helicopter per Section 12-42. 2. Remove tailcone cowling assembly per Section 53-23. 3.
Page 270 FIGURE 28-3 FUEL SYSTEM SCHEMATIC Page 28.4 Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...
Page 271 28-10 Fuel Bladder (continued) B. Installation 1. Refer to Figure 28-2. Dust exterior of G028-1 bladder assembly and F028-1 support assembly floor with talcum powder to facilitate bladder slippage along metal surface. Do not allow powder to enter bladder. 2. Note locations of hook and loop tape on bladder lower surface and support floor. Orient bladder, fold into thirds, place in center of support, and unfold into position.
Page 272: Roll-Over Vent Valves
28-11 Roll-Over Vent Valves Refer to R66 Illustrated Parts Catalog (IPC) Figure 28-1. WARNING R66 roll-over vent valves contain two anodized aluminum balls, the orientation of which are critical to vent valve function. The blue hollow ball on top floats and seals the vent in the event of inadvertent over-filling or in-flight sloshing.
Page 273: Fuel Quantity
28-12 Sump Valve (continued) B. Installation 1. Refer to Figure 28-2. Actuate and lock 1250H (sump) valve to expose stem; install new o-ring in stem seat. 2. Lightly coat valve threads with B270-6 sealant. Remove tape and install valve in G154-1 outlet assembly: standard torque valve per Section 20-32 and torque stripe per Figure 5-1.
Page 274 28-21 Fuel Quantity Sender (continued) C. Calibration 1. Defuel helicopter per Section 12-42. 2. Pull fuel valve knob OFF. Service helicopter with 19.4 gallons of fuel per Section 12-41. 3. Push in GAGES circuit breaker, turn BATTERY switch ON, and read fuel quantity gage.
Page 275 28-22 Low-Fuel Switch Assembly (continued) B. Installation 1. Install new MS29512-05 packing over switch assembly threads. 2. Refer to Figure 28-2. Remove fuel cap. Tape switch assembly wiring to 4-ft length of lockwire; insert other end of wire through fuel cap opening and through switch assembly opening.
Page 276 FIGURE 28-4 FUEL VALVE Page 28.10 Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...
Page 277: Fuel Valve
28-30 Fuel Valve Refer to R66 Illustrated Parts Catalog (IPC) Figure 28-5. A. Removal 1. Defuel helicopter per Section 12-42. 2. Refer to Figures 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.
Page 278: Fuel Flow Check
28-40 Fuel Flow Check 1. Open mast fairing per Section 53-22. Remove engine cowling per Section 53-21. 2. Refer to Figure 28-2. Attach a temporary hose to one of the vent weldment openings. With the fuel cap installed, blow into the hose (do not use compressed air) and verify air blows out the other vent opening.
Page 279: Chapter 32 Landing Gear
CHAPTER 32 LANDING GEAR Section Title Page 32-00 Description ........32.1 32-10 Landing Gear Assembly .
Page 280 Intentionally Blank Page 32.ii Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
Page 281: Description
CHAPTER 32 LANDING GEAR 32-00 Description A spring and yield skid type landing gear is used. Most hard landings will be absorbed elastically. However, in an extremely hard landing, the struts will hinge up and outward as the center crosstube yields (takes permanent set) to absorb the impact. Slight yielding of the aft crosstube is acceptable.
Page 282 FIGURE 32-1 LANDING GEAR ATTACHMENT Page 32.2 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
Page 283 32-10 Landing Gear Assembly (continued) B. Installation Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1. WARNING Landing gear mounting bolts are critical fasteners. See Section 20-30 for torque requirements. CAUTION Support landing gear assembly as mounting bolts are installed. Do not damage forward cross tube hinged inspection cover.
Page 284 FIGURE 32-2 CROSS TUBE REMOVAL Page 32.4 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
Page 285: Cross Tubes
32-20 Cross Tubes A. Inspection For helicopters with F014-1 (standard) landing gear or F014-4 (pop-out float) landing gear, replace aft cross tube if tail skid height is less than 38 inches from ground when aircraft is minimally loaded on level pavement. For helicopters with F014-5 (extended) landing gear, replace aft cross tube if tail skid height is less than 30 inches from ground when aircraft is minimally loaded on level pavement.
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: Skid Tubes
32-30 Skid Tubes Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1. CAUTION Minimize personnel movement around raised helicopter. Use caution when working under raised skid tubes. A. Inspection 1. Install ground handling wheels per Section 9-11. 2. Pull down on tail rotor gearbox and place blocks under skid tubes, forward of forward strut assemblies.
Page 288: Skid Shoes
32-31 Skid Shoes Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1. A. Inspection Inspect skid tubes and skid shoes per Section 32-30. B. Replacement 1. Refer to Figure 32-3. Remove and discard hardware securing skid shoe to skid tube. Discard a shoe damaged beyond limits in Section 32-30.
Page 289: Fairing Assemblies
32-40 Fairing Assemblies Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-5. A. Removal 1. Refer to Figure 32-3. Remove screws securing fairing assembly together at trailing edge. 2. Remove screws securing fairing assembly to strut assembly. Unscrew clamp through fairing inboard access hole and remove fairing.
Page 290 FIGURE 32-4 POP-OUT FLOATS INSTALLATION Page 32.10 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
Page 291: Pop-Out Floats Installation
32-60 Pop-Out Floats Installation Pop-out floats are optional equipment for R66 helicopters. The pop-out float installation includes inflatable floats stowed in protective covers secured to the skid tubes, a pressure cylinder located in the compartment beneath the right aft seat, an inflation manifold, an inflation lever located on the pilot’s collective stick, and a modified aux stabilizer.
Page 292 FIGURE 32-5 POP-OUT FLOATS CYLINDER ASSEMBLY Page 32.12 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
Page 293 32-61 Cylinder Assembly (continued) A. Removal 1. Refer to Figure 32-5. Hinge right aft seat assembly forward. Install MT545-1 pin assembly in D757-1 valve assembly. 2. Disconnect D674-9 hose assembly from valve fitting. Install MT546-1 diffuser on valve fitting and special torque diffuser to 120 in.-lb. Cap hose to prevent foreign object contamination.
Page 294 32-61 Cylinder Assembly (continued) C. Filling CAUTION Use appropriate eye and hearing protection. Do not service cylinder assembly while cylinder is installed in helicopter. WARNING ONLY cylinders labeled “DOT-E 10915-4945” may be refilled. Cylinders labeled “DOT-E 10915-4500” must be returned to RHC for exchange/upgrade.
Page 295 32-61 Cylinder Assembly (continued) C. Filling (continued) 6. Allow cylinder and valve to cool to ambient temperature. Top off with helium to compensate for any pressure loss due to cooling. 7. Remove fill hose and MT546-2 adapter assembly. 8. Remove & discard old o-ring from cap. Lightly coat new MS28778-2 o-ring with A257-19 lubricant and install o-ring on fill-port cap at base of threads.
Page 296 FIGURE 32-6 POP-OUT FLOATS LEVER RIGGING AND SHEAR-RIVET REPLACEMENT Page 32.16 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
Page 297: Lever Rigging And Shear-Rivet Replacement
32-62 Lever Rigging and Shear-Rivet Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-9. WARNING D679 Cylinder contents are under extreme pressure. Install MT545-1 pin assembly in D757-1 valve assembly during maintenance to prevent cylinder discharge. WARNING Install MS20470A2-6-5 (or MS20470A2-6.5) annealed rivet in lever assembly or rivet may be too hard to shear.
Page 298 FIGURE 32-7 POP-OUT FLOATS FLOAT INSTALLATION Page 32.18 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
Page 299: Float Installation
32-63 Float Installation Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-11 and 32-17. WARNING D679 Cylinder contents are under extreme pressure. Install MT545-1 pin assembly in D757-1 valve assembly during maintenance to prevent cylinder discharge. A. Removal NOTE Floats are subject to damage during removal. Remove floats if necessary for repairs.
Page 300 FIGURE 32-8 POP-OUT FLOATS FLOAT PACKING Page 32.20 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
Page 301 32-63 Float Installation (continued) C. Packing 1. Install floats per Section 32-63 Part B. 2. Spread deflated float outboard of skid tube. Vacuum as much air as possible from each float chamber through topping valves. Smooth out wrinkles. 3. Lightly dust float and inside float cover with talcum powder. 4.
Page 302: System Maintenance
32-64 System Maintenance A. Leak Check WARNING D679 Cylinder contents are under extreme pressure. Install MT545-1 pin assembly in D757-1 valve assembly during maintenance to prevent cylinder discharge. 1. Disconnect D674-1 line assembly from presssure cylinder valve. Install protective cap on cylinder valve fitting. Cover D674-1 line fitting to prevent contamination, but do not install an air-tight seal (D674-1 line fitting must be allowed to leak to verify check valve function at each float chamber).
Page 303 32-64 System Maintenance (continued) B. Inflation Check WARNING D679 Cylinder contents are under extreme pressure. Install MT545-1 pin assembly in D757-1 valve assembly during maintenance to prevent cylinder discharge. 1. Unsnap outboard edge of both float covers. 2. Remove locking pin from valve, move inflation lever safety to READY position, and verify area around floats is clear.
Page 304 32-64 System Maintenance (continued) B. Inflation Check (continued) 5. Disconnect D674-1 hose assembly from pressure cylinder valve immediately after initial pressure check. Install protective cap on cylinder valve fitting. Cover D674-1 hose fitting to prevent contamination, but do not install an air tight seal (D674-1 hose must be allowed to leak to verify check valve function at each float chamber).
Page 305: Chapter 52 Doors And Windows
CHAPTER 52 DOORS AND WINDOWS Section Title Page 52-00 Description ........52.1 52-10 Door Assembly .
Page 306 Intentionally Blank Page 52.ii Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...
Page 307 CHAPTER 52 DOORS AND WINDOWS 52-00 Description The R66 has four passenger doors and one main baggage compartment door. Passenger doors may be removed and installed by maintenance personnel or pilots. Passenger doors are constructed of fiberglass and thermoplastics. Passenger doors, locks, weather seal, gas springs, and door vents and hinges may be replaced, and vent pivot friction may be adjusted.
Page 308 FIGURE 52-1 DOOR ASSEMBLY Page 52.2 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...
Page 309 52-10 Door Assembly (continued) C. Replacement CAUTION Use proper respiratory protection when handling fiberglass. CAUTION Protect door windows and paint from scratches or scuff marks when door maintenance is performed on workbench. 1. Refer to Figure 52-1. As required, lay masking tape on surfaces of door frame, new door hinges, and new door, to mark with soft pencil.
Page 310: Door Lock Replacement
52-11 Door Lock Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figure 52-1. CAUTION Protect door windows and paint from scratches or scuff marks when door maintenance is performed on workbench. 1. Remove door per Section 52-10. 2. Refer to Figure 52-1. Remove hole plug opposite key slot on door interior. 3.
Page 311 Intentionally Blank Page 52.5 25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows...
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: Gas Springs
52-13 Gas Springs Refer to R66 Illustrated Parts Catalog (IPC) Figures 52-5 and 52-11. A. Removal 1. a. Forward Doors: Insert flat-tip screwdriver and pry down on caps to unlock D575- 1 gas spring from ball joints. Push gas spring down and off of ball joints. b.
Page 314: Pivot Friction Adjustment
52-22 Door Vent Hinge Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figures 52-1 and 52-7. CAUTION Protect door windows and paint from scratches or scuff marks when door maintenance performed on workbench. 1. Remove door per Section 52-10. 2. Refer to Figure 52-2. Drill out rivets securing hinge to door assembly and door vent. Remove hinge.
Page 315 Intentionally Blank Page 52.9 25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows...
Page 316 FIGURE 52-3 WINDSHIELD INSPECTION Page 52.10 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...
Page 317: Windshield Assembly
52-30 Windshield Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 52-17. A. Removal 1. Remove forward door and hinges. NOTE To prevent scratching windshield, a protective cover should be taped to the inside and outside of the windshield prior to removal.
Page 318 52-30 Windshield Assembly (continued) C. Inspection 1. Inspect windshield for cracks and crazing adjacent to retainer strips per Figure 52-3. If cracks exceed these limits, replace windshields per Section 52-30 Part D. D. Replacement 1. Remove all old sealant on cabin and retainers if they are to be reused. 2.
Page 319: Chapter 53 Fuselage
CHAPTER 53 FUSELAGE Section Title Page 53-00 Description ........53.1 53-10 Cabin Assembly .
Page 320 Intentionally Blank Page 53.ii Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...
Page 321: Description
CHAPTER 53 FUSELAGE 53-00 Description The R66 is a five-place, single main rotor, single engine helicopter constructed primarily of metal and equipped with skid type landing gear. The primary fuselage structure is welded steel tubing and riveted aluminum sheet. The tailcone is a monocoque structure in which aluminum skins carry most primary loads.
Page 322 FIGURE 53-1 FAIRING, COWLINGS, AND PANELS Page 53.2 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...
Page 323: Fairing, Cowlings, And Panels
53-20 Fairing, Cowlings, and Panels CAUTION Mast fairing, cowlings, and panels must be installed for flight. 53-21 Engine Cowling Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-1. A. Removal 1. Refer to Figure 53-1. Open G040-1 engine cowling assembly right and left doors. 2.
Page 324: Tailcone Cowling
53-22 Mast Fairing (continued) C. Installation 1. Refer to Figure 53-1. Install left-side screws securing F261-1 mast fairing assembly to ribs. 2. Remove cap and plug and connect (pitot system) 15-4-N-O union near G201-1 (servo support) frame assembly. 3. Hold fairing closed. Install right-side screws securing fairing to ribs, and screws securing fairing at aft, vertical seam.
Page 325: Frame Assemblies
53-30 Frame Assemblies NOTE See Section 54-40 for F237-1 tailcone attachment frame weldment replacement. WARNING R66 welded steel tube frames are stress relieved. Field weld repairs are not allowed; send frames to RHC for repair. 53-31 Lower Frames Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-7. A.
Page 326 FIGURE 53-2 LOWER FRAMES Page 53.6 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...
Page 327 53-31 Lower Frames (continued) B. Installation 1. Refer to Figure 53-2. a. F046-1 (LH) only: Install hardware securing shackle and frame to F574-8 block (threaded). Special torque bolt per Section 20-33, and torque stripe per Figure 5-1. Install hardware securing frame to F574-5 block (insert bolt thru G246-1 brace, inside baggage compartment).
Page 328 FIGURE 53-3 HYDRAULIC SERVO SUPPORT FRAME Page 53.8 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...
Page 329: Hydraulic Servo Support Frame
53-32 Hydraulic Servo Support Frame Refer to R66 Illustrated Parts Catalog (IPC) Figure 67-19. A. Removal 1. Remove main rotor gearbox per Section 63-20. 2. Remove main rotor hub per Section 62-20. 3. Remove mast fairing per Section 53-22. 4. Remove swashplate assembly per Section 67-40. 5.
Page 330: Upper Frame
53-33 Upper Frame Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-11 and 53-11B. A. Removal 1. Remove main rotor blades per Section 62-10. 2. Remove tailcone assembly per Section 53-40. 3. Remove tail rotor drive shaft weldment per Section 65-10. 4.
Page 331 53-33 Upper Frame (continued) B. Installation 1. Position F020-1 upper frame inside helicopter. Install mounting hardware securing upper frame to firewalls, cabin bulkhead, and fuel bladder support assembly. Standard torque bolts per Section 20-32, and torque stripe per Figure 5-1. Seal around frame weldment edges at firewalls, bulkhead, and support using B270-1 sealant.
Page 332 FIGURE 53-4 TAILCONE ASSEMBLY Page 53.12 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...
Page 333: Tailcone Assembly
53-40 Tailcone Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-15. A. Removal 1. Remove tailcone cowling assembly per Section 53-23. Remove engine cowling assembly per Section 53-21. 2. Refer to Figure 53-4. Cut and discard ty-raps as required and disconnect tailcone wiring at connectors.
Page 334 FIGURE 53-5 TAILCONE INSPECTION AND REPAIR Page 53.14 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...
Page 335: Inspection And Repair
53-41 Inspection and Repair This procedure outlines the inspection criteria and repair limits for the tailcone assembly. Repairs are limited to blending out scratches and refinishing skins. Contact RHC Technical Support if allowable damage is exceeded. A. Scratches 1. Refer to Figure 53-5. Verify damage does not exceed the following limits: a.
Page 336 FIGURE 53-6 EMPENNAGE - TAILCONE CASTING Page 53.16 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...
Page 337: Empennage Assembly
53-50 Empennage Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-19. A. Removal 1. Remove tail rotor guard assembly per Section 53-53. 2. Remove hardware securing forward MS21919WDG3 clamp to upper horizontal stabilizer. Cut and discard ty-raps securing position light and gearbox chip detector wires and connectors together.
Page 338 53-51 Vertical Stabilizer (continued) B. Upper Vertical Stabilizer Installation 1. Refer to Figure 53-6. Position C042-1 stabilizer on empennage. Verify 0.030-0.120 inch gap between C042-1 stabilizer skin edges and upper horizontal stabilizer skins. File vertical stabilizer skin edge(s) as required. 2.
Page 339: Horizontal Stabilizer
53-52 Horizontal Stabilizer Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-19 and 53-23. A. Upper Horizontal Stabilizer Removal 1. Remove C042-1 upper vertical stabilizer and C043-1 lower vertical stabilizer per Section 53-51. 2. Refer to Figure 53-6. Remove hardware securing forward MS21919WDG3 clamp to upper horizontal stabilizer.
Page 340 FIGURE 53-7 EMPENNAGE - TAIL ROTOR GUARD Page 53.20 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...
Page 341: Tail Rotor Guard
53-53 Tail Rotor Guard Refer to R66 Illustrated Parts Catalog (IPC) Figures 53-19 and 53-23. A. Removal 1. Refer to Figure 53-7. Loosen two (forward) fasteners securing D081-2 block and D079-1 guard assembly to C043-1 lower vertical stabilizer. 2. Remove hardware securing guard to D082-1 tube assembly. Slide guard off of tube, then forward through blocks.
Page 342: Tail Skid
53-54 Tail Skid Refer to R66 Illustrated Parts Catalog (IPC) Figures 53-19. A. Removal 1. Refer to Figure 53-7. Support D079-1 guard assembly. Remove hardware securing D081-2 block to C043-1 lower vertical stabilizer and remove block. 2. Support C050-2 aux stabilizer assembly and C470-1 tail skid. Remove hardware securing D081-4 block assembly to C043-1 stabilizer and remove block assembly.
Page 343 CHAPTER 62 MAIN ROTOR Section Title Page 62-00 Description ........62.1 62-10 Main Rotor Blades .
Page 344 Intentionally Blank Page 62.ii Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...
Page 345: Description
CHAPTER 62 MAIN ROTOR 62-00 Description The main rotor has two all-metal blades and a forged-aluminum hub. Blades mount to the hub by coning hinge; the hub mounts to the main rotor shaft by teeter hinge. Coning and teeter hinges have self-lubricated bearings inside the hub. The leading edge of the main rotor blade is a corrosion and erosion resistant stainless-steel spar.
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 62-10 Main Rotor Blades (continued) A. Removal (continued) 3. Refer to Figure 62-3. Remove cotter pins and loosen nuts of blade coning hinge bolts so they are just finger tight. 4. Remove nut, thrust washer, and shims (if used) from trailing-edge side of one blade hinge bolt.
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 62-10 Main Rotor Blades (continued) B. Installation (continued) CAUTION To prevent damage, level and support installed blade until opposite blade is installed. 6. With installed blade level and supported near tip, install opposite blade per steps 1 thru 5. 7. Tighten nut on hinge bolt until journals and thrust washer are firmly seated. Then back nut off until both thrust washers can be freely rotated.
Page 350: Blade Boots
62-11 Blade Boots Refer to R66 Illustrated Parts Catalog (IPC) Figure 62-1. A. Removal 1. Remove main rotor blades per Section 62-10. 2. Place a suitable drain container below main rotor blade spindle assembly. Remove two B289-2 bolts and drain fluid. 3.
Page 351: Main Rotor Hub
62-20 Main Rotor Hub Refer to R66 Illustrated Parts Catalog (IPC) Figure 62-3. A. Removal 1. Remove main rotor blades per Section 62-10. 2. Refer to Figure 62-2. Mark rotor hub using a grease pencil or soft marker as follows: a.
Page 352 FIGURE 62-5 MAIN ROTOR HUB BEARING REMOVAL FIGURE 62-6 MAIN ROTOR HUB BEARING INSTALLATION Page 62.8 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...
Page 353: Bearing Replacement
62-20 Main Rotor Hub (continued) B. Installation (continued) 6. Using wrenches with at least 600 ft-lb torque capacity, tighten nut until drilled hole in nut and bolt align. Reinstall MT122-6 tool and measure bolt stretch; the stretch must be between 0.020-0.022 inch (0.021-0.022 inch for new, undrilled bolt). Remove tool. NOTE If drilled holes in nut and bolt do not align, both nut and bolt must be replaced.
Page 354 62-21 Bearing Replacement (continued) 6. Ensure new bearing mating surfaces are clean and smooth. Coat hub bearing bore and hub bearing mating surfaces with epoxy primer (see Section 20-70). Do not allow primer to contaminate Teflon portion of bearing. Refer to Figure 62-6. If seam of bearing Teflon liner is visible, orient bearing so seam is toward top of hub (as installed on helicopter).
Page 355: Main Rotor Assembly
62-30 Main Rotor Assembly 62-31 Journal and Shim Calculations Refer to Figures 62-2 and 62-3. A. Teeter Hinge Calculation 1. Measure main rotor hub width across the teeter hinge bearing faces: inches 2. Subtract measured width of C251 driveshaft at teeter hinge bolt hole: – inches Calculated empty space: = inches...
Page 356 62-31 Journal and Shim Calculations (continued) B. Coning Hinge Calculation 1. Measure and record main rotor hub width across the coning hinge bearing faces: inches 2. Subtract blade’s spindle width measured across faces at coning hinge bolt bore: – inches Calculated empty space: = inches CAUTION...
Page 357 Intentionally Blank Page 62.13 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
Page 358 FIGURE 62-7 MEASURING TEETER HINGE FRICTION Page 62.14 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...
Page 359: Adjusting Hinge Friction
62-32 Adjusting Hinge Friction A. Teeter Hinge Adjustment NOTE Teeter hinge friction must be checked and adjusted with main rotor blades removed from main rotor hub. If required, remove main rotor blades per Section 62-10. Teeter hinge friction is adjusted by changing C117 shim stack in small increments. NOTE If shim stack is changed per following instructions, a new bolt and nut must be installed per Section 62-10 Part B, steps 3 thru 5.
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: Adjusting Hinge Friction
62-32 Adjusting Hinge Friction (continued) B. Coning Hinge Adjustment Coning hinge friction is adjustable through use of various thickness C117 shims. Shims are installed between the thrust washer and the trailing-edge journal. 1. Check blade hinge friction by lifting blades until spindle tusks clear droop stops. Hold one blade level and cone opposite blade.
Page 362 FIGURE 62-9 MEASURING BLADE DAMAGE WITH STRAIGHT EDGE FIGURE 62-10 SCRATCHES AND CORROSION ON SKINS AND DOUBLERS - DAMAGE LIMITS Page 62.18 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...
Page 363: Inspection Of Main Rotor Blades
62-40 Inspection of Main Rotor Blades This blade repair procedure outlines the repair limits, methods and materials used for repairing main rotor blades. Repairs are limited to blending out scratches, dents, nicks, removing corrosion, and refinishing the blades. The inspections, repairs and limitations contained herein refer to damage sustained in service, including damage during shipping and handling (manufacturing irregularities are treated separately by the factory).
Page 364 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 DAMAGE Page 62.20 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...
Page 365: Dents
62-42 Dents CAUTION Tap-test dented areas in honeycomb. If any voids are found associated with dents, contact RHC Customer Service. Tap-test voids, debonds, and dents in blades using an AN970-4 washer or 1965 or later U.S. quarter dollar coin in good condition. CAUTION When dented areas are found, inspect opposite side of the blade for a bulge.
Page 366 FIGURE 62-14 ROOT FITTING DAMAGE FIGURE 62-15 REPAIRS TO BLADE AND TRIM TAB TRAILING EDGES FIGURE 62-16 MINIMUM CHORD AFTER BLADE AND TRIM TAB TRAILING EDGE REPAIRS Page 62.22 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...
Page 367: Spar Damage
62-43 Spar Damage 1. Refer to Figure 62-13. Spar damage limits exclude leading edge cap. Verify damage does not exceed the following limits: a. 0.020 inch maximum depth between RS 70.00 and RS 198.00. b. Replace blade if erosion has reduced thickness at spar leading edge to 0.040 inch. c.
Page 368 FIGURE 62-17 BLADE TIP REPAIR LIMITS FIGURE 62-18 TIP CAP, SPAR, AND TRAILING EDGES - VOID AND DEBOND LIMITS Page 62.24 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...
Page 369: Voids And Debonds
62-46 Voids and Debonds NOTE Tap-test dented areas in honeycomb. If any voids are found associated with dents, contact RHC Customer Service. Tap-test voids, debonds, and dents in blades using an AN970-4 washer or 1965 or later U.S. quarter dollar coin in good condition. A.
Page 370 FIGURE 62-19 DOUBLERS - VOID AND DEBOND LIMITS FIGURE 62-20 HONEYCOMB - VOID AND DEBOND LIMITS Page 62.26 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...
Page 371: Repair Of Main Rotor Blades
62-50 Repair of Main Rotor Blades CAUTION DO NOT USE power tools or chemical paint strippers to remove blade materials. 1. Measure damage per Section 62-40. 2. Polish out blade damage using 220 grit or finer wet-or-dry aluminum-oxide or silicon-carbide abrasive paper, and finish with 320 grit or finer wet-or-dry abrasive paper.
Page 372: Painting
62-52 Painting CAUTION If force-drying paint, do not exceed 175°F surface temperature on blade; monitor blade temperature by temporarily installing P/N 110-2 Telatemp on blade skin. 1. Mask area to prevent overspray contamination. 2. Clean bare metal to be painted with a lint-free cloth dampened with enamel cleaner (see Approved Materials, Section 20-70).
Page 373 CHAPTER 63 MAIN ROTOR DRIVE SYSTEM Section Title Page 63-00 Description ........63.1 63-10 Engine Shaft Weldment.
Page 374 Intentionally Blank Page 63.ii Chapter 63 Main Rotor Drive System R66 Maintenance Manual SEP 2012...
Page 375: Engine Shaft Weldment
CHAPTER 63 MAIN ROTOR DRIVE SYSTEM 63-00 Description The engine is mounted in a 37º nose-up attitude. A sprag-type overrunning clutch mates directly to the splined engine power take-off (PTO) shaft. The clutch is connected to a shaft with flexible couplings at both ends to transmit power to the main gearbox. A ring and pinion spiral bevel gearset at the main gearbox input reduces speed to tail rotor driveline RPM.
Page 376: Engine Driveline) Forward Flex Plate Shimming
63-11 (Engine Driveline) Forward Flex Plate Shimming NOTE The engine driveline is shimmed for 0.040 / 0.000 inch compressive preload. Preload is alleviated by upward movement of main gearbox during flight. 1. Refer to Figure 53-2. Verify F174-1 support weldment rod end engagement measures 0.93 inch from tube end to rod end centerline (nominal;...
Page 377 63-11 (Engine Driveline) Forward Flex Plate Shimming (continued) 5. Evaluate flange straightness by calculating the difference between the 3 o’clock positions in steps 4a and 4b. Also calculate the difference between the 9 o’clock positions in steps 4a and 4b. If either calculated difference exceeds 0.015 inch, either one or both flanges are bent and require replacement.
Page 378 FIGURE 63-1 ENGINE DRIVELINE Page 63.4 Chapter 63 Main Rotor Drive System R66 Maintenance Manual SEP 2012...
Page 379: Clutch Assembly
63-12 Clutch Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 63-1. A. Removal 1. Remove engine shaft weldment per Section 63-10. 2. Refer to Figure 63-1. Mark F906-1 yoke assembly and A947-2 plate assembly, to facilitate installation. Remove plate assembly, noting hardware removed. 3.
Page 380: Main Rotor Gearbox Assembly
63-20 Main Rotor Gearbox Assembly A. Removal 1. Remove main rotor blades per Section 62-10. 2. Remove tailcone cowling assembly per Section 53-23. 3. Disconnect (pitot system) 15-4-N-O union near G201-1 (servo support) frame assembly. Cap fitting and plug line. 4.
Page 381 63-20 Main Rotor Gearbox Assembly (continued) B. Installation 1. Refer to R66 Illustrated Parts Catalog (IPC) Figure 63-3. If installing new C653-3 (aft) or A653-2 (forward) rubber mounts, lubricate mounts using water or A257-8 lubricant and press into gearbox ears. 2.
Page 382: Yoke And Seal Replacement
63-21 Yoke and Seal Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figure 63-3. A. (Tail Rotor Drive) F908-1 Yoke Assembly and Seal Removal 1. Remove tailcone cowling assembly per Section 53-23. 2. Refer to Figure 63-1. Remove hardware securing C947-3 (forward) plate assembly to F908-1 yoke assembly, and C947-3 (intermediate) plate assembly to F196-1 fan shaft, noting hardware removed.
Page 383 63-21 Yoke and Seal Replacement (continued) C. (Engine-Driven) F910-1 Yoke Assembly and Seal Removal 1. Remove tailcone cowling assembly per Section 53-23. Remove engine cowling assembly per Section 53-21. 2. Refer to Figure 63-1. Remove hardware securing A947-2 (forward) plate assembly to F910-1 yoke assembly, and A947-2 (aft) plate assembly to F642-1 shaft weldment, noting hardware removed.
Page 384 FIGURE 63-2 ROTOR BRAKE Page 63.10 Chapter 63 Main Rotor Drive System R66 Maintenance Manual SEP 2012...
Page 385: Rotor Brake
63-30 Rotor Brake Refer to R66 Illustrated Parts Catalog (IPC) Figure 63-9. A. Removal 1. Remove (engine-driven) F910-1 yoke assembly per Section 63-21, Part C steps 1 thru 2. Refer to Figure 63-2. Detach D126-2 cable assembly from B112-3 spring. Detach B774-3 spring from gearbox cartridge retaining screw or rotor brake assembly link.
Page 386: Pad Replacement
63-31 Pad Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figure 63-9. A. Arm Removal NOTE Rotor brake pad minimum thickness is 0.030 inch on both arm assemblies. Replace arm assemblies when pads are worn beyond limit. 1. Remove rotor brake per Section 63-30. 2.
Page 387 CHAPTER 64 TAIL ROTOR Section Title Page 64-00 Description ........64.1 64-10 Tail Rotor Assembly .
Page 388 Intentionally Blank Page 64.ii Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...
Page 389: Description
CHAPTER 64 TAIL ROTOR 64-00 Description The R66 tail rotor assembly is a conventional, two-bladed teetering rotor system. Tail rotor blades are constructed of a wrap-around aluminum skin, bonded to aluminum honeycomb and a forged aluminum root fitting. Self-lubricating spherical bearings in the root fitting allow blades to change pitch.
Page 390 FIGURE 64-1 TAIL ROTOR INSTALLATION Page 64.2 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...
Page 391 64-10 Tail Rotor Assembly (continued) B. Installation 1. Refer to Figure 64-1. Position tail rotor assembly on tail rotor gearbox output shaft. Verify tail rotor is installed for clockwise rotation when viewed from left side of aircraft. Verify blades cone toward tail rotor gearbox. 2.
Page 392 FIGURE 64-2 CHORDWISE STATIC BALANCE Page 64.4 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...
Page 393: Static Balance
64-11 Static Balance Refer to R66 Illustrated Parts Catalog (IPC) Figure 64-1. A. Chordwise Static Balance 1. Refer to Figure 64-2. Install MT179-4 balance bar into tail rotor assembly. Install teeter hinge bolt, and special torque nut to 350 in.-lb. Using a carpenters square, adjust balance bar until approximately perpendicular to hub.
Page 394 FIGURE 64-3 SPANWISE STATIC BALANCE Page 64.6 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...
Page 395 64-11 Static Balance (continued) Refer to R66 Illustrated Parts Catalog (IPC) Figure 64-1. B. Spanwise Static Balance CAUTION Verify four washers installed under each outboard blade fastener prior to tail rotor assembly installation or dynamic balance. 1. Refer to Figure 64-3. Install standard hardware for initial spanwise static balance check.
Page 396: Tail Rotor Blades
64-20 Tail Rotor Blades Refer to R66 Illustrated Parts Catalog (IPC) Figure 64-1. NOTE Protect tail rotor assembly from damage when maintenance is performed on workbench. A. Removal 1. Remove tail rotor assembly per Section 64-10. 2. Refer to Figure 64-1. Remove hardware securing F029-1 blade assemblies to G062-1 hub assembly.
Page 397: Tail Rotor Blade Inspection And Repair
64-30 Tail Rotor Blade Inspection and Repair This blade repair procedure outlines the repair limits, methods and materials used for repairing tail rotor blades. Repairs are limited to blending out scratches, dents, nicks, removing corrosion, and refinishing the blades. The inspections, repairs and limitations contained herein refer to damage sustained in service, including damage during shipping and handling (manufacturing irregularities are treated separately by the factory).
Page 398 NOTE See text for additional inspection criteria. FIGURE 64-4 TAIL ROTOR BLADE INSPECTION CRITERIA Page 64.10 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...
Page 399: Root Fitting Damage
64-32 Dents (continued) A. Skins 1. Refer to Figure 64-4. Smooth, round bottom dents with 0.060 inch minimum radius may be repaired when damage does not exceed the following limits: a. 0.010 inch maximum depth between leading edge and 0.75 inch aft (chordwise). b.
Page 400 FIGURE 64-5 ELASTOMERIC BEARING REMOVAL FIGURE 64-6 ELASTOMERIC BEARING INSTALLATION Page 64.12 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...
Page 401: Tail Rotor Hub
64-40 Tail Rotor Hub 64-41 Bearing Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figure 64-1. A. Removal 1. Remove tail rotor assembly per Section 64-10. 2. Remove tail rotor blades per Section 64-20. 3. Refer to Figure 64-5. Press bearing(s) from hub using MT556-11 bearing removal (and installation) tools.
Page 402 Intentionally Blank Page 64.14 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...
Page 403 CHAPTER 65 TAIL ROTOR DRIVE SYSTEM Section Title Page 65-00 Description ........65.1 65-10 Tail Rotor Drive Fan Shaft .
Page 404 Intentionally Blank Page 65.ii Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012...
Page 405: Tail Rotor Drive Fan Shaft
CHAPTER 65 TAIL ROTOR DRIVE SYSTEM 65-00 Description The tail rotor driveline consists of an intermediate shaft running aft from the main gearbox and a long tail rotor driveshaft which runs the length of the tailcone. Flexible couplings are located at both ends of the intermediate shaft.
Page 406 FIGURE 65-1 TAIL ROTOR DRIVELINE Page 65.2 Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012...
Page 407: Tail Rotor Drive Shaft Assembly
65-20 Tail Rotor Drive Shaft Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-3. A. Removal 1. Remove C023 tailcone assembly per Section 53-40. 2. Refer to Figure 65-1. Remove hardware securing F172-1 bearing assembly to F193-1 hanger. 3. Refer to Figure 65-3. Using a 3-foot extension, remove bolts securing C041-12 damper assembly arm to D072-1 bulkhead assembly angle.
Page 408 FIGURE 65-2 RUNOUT Page 65.4 Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012...
Page 409: Runout
65-21 Runout 1. Remove (5) A231-1 (tailcone) plug assemblies. 2. Assemble MT260-6 tail rotor drive shaft runout tool and a calibrated dial indicator. 3. Refer to Figure 65-2. Using appropriate combination of extension(s), insert tool through tailcone inspection hole. Verify foot squarely contacts tail rotor drive shaft when pressing dial indicator firmly against inspection hole edges.
Page 410 FIGURE 65-4 DAMPER ASSEMBLY Page 65.6 Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012...
Page 411: Damper Assembly
65-22 Damper Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-7. A. Disassembly 1. Remove tail rotor drive shaft per Section 65-20, if not previously accomplished. 2. Refer to Figure 65-4. Remove hardware securing C041-11 bearing assembly and C041-13 arm to C041-3 link. B.
Page 412: Tail Rotor Driveline) Intermediate Flex Plate Shimming
65-30 (Tail Rotor Driveline) Intermediate Flex Plate Shimming NOTE The tail rotor driveline is shimmed for minimal preload. 1. Refer to Figure 65-1. If not previously accomplished, remove hardware securing intermediate C947-3 flex plate assembly to F196-1 (tail rotor) fan shaft aft flange and D224-3 tail rotor drive shaft assembly forward yoke.
Page 413 65-30 (Tail Rotor Driveline) Intermediate Flex Plate Shimming (continued) 5. Using the smaller average gap from step 3a or 3b, subtract the flex plate average thickness determined in step 2: Smaller average gap between flange arms (step 3a or 3b) inch Subtract flex plate average thickness (step 2) −...
Page 414: Tail Rotor Gearbox Assembly
65-40 Tail Rotor Gearbox Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-9. A. Removal NOTE Drain tail rotor gearbox oil per Section12-21 prior to gearbox removal, or keep gearbox vertical after removal to avoid oil escape thru filler-vent plug. 1.
Page 415: Output Shaft Seal Replacement
65-41 Output Shaft Seal Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-13. 1. Remove tail rotor assembly per Section 64-10. 2. Remove hardware securing push-pull tube assembly to bellcrank assembly. 3. Remove hardware securing bellcrank to tail rotor gearbox assembly output cartridge. Slide (assembled) bellcrank, pitch control assembly, and pitch links off of gearbox output shaft.
Page 416: Input Shaft Seal Replacement
65-42 Input Shaft Seal Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-13. 1. Remove tail rotor gearbox per Section 65-40. Tail rotor assembly and pitch control assembly removal are not required. 2. Remove and discard cotter pin securing tail rotor input yoke retaining nut. On a suitable work bench, place a wood block between yoke and gearbox housing to prevent tail rotor rotation;...
Page 417 CHAPTER 67 FLIGHT CONTROLS Section Title Page 67-00 Description ........67.1 67-10 Cyclic Controls .
Page 418 Intentionally Blank Page 67.ii Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...
Page 419: Cyclic Controls
CHAPTER 67 FLIGHT CONTROLS 67-00 Description Dual controls, which are removable on the left side, are standard equipment. All primary controls are actuated through push-pull tubes and bellcranks. Bearings used throughout the control system are either sealed ball bearings or have self-lubricated Teflon® liners. R66 flight controls operate conventionally.
Page 420 FIGURE 67-1 MAIN ROTOR FLIGHT CONTROLS Page 67.2 Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...
Page 421: Cyclic Control Assembly
67-11 Cyclic Control Assembly (continued) A. Removal (continued) 5. Remove hardware securing C121-1 push-pull tube assembly to D320-8 stick assembly. Remove hardware securing C319-5 torque tube assembly to C177-5 pivot assembly. Move push-pull tube and torque tube assemblies aft, and protect from scratching.
Page 422: Cyclic Grip Assembly
67-11 Cyclic Control Assembly (continued) B. Installation (continued) 8. Connect all electrical plugs at bottom of cyclic stick. Ensure protective sleeving covers maximum amount of wiring possible and sleeving ends are secured with lacing tape. 9. Connect D918-1 cord to D320-8 cyclic stick. Connect D918-2 cord to C177-5 pivot.
Page 423 67-12 Cyclic Grip Assembly (continued) B. Installation 1. Refer to Figure 67-1. Ensure protective sleeving covers wires exiting grip assembly with one grommet in grip and one (for cyclic stick) on wire bundle (spare grommets may be installed if desired). 2.
Page 424: Cyclic Friction Assembly
67-13 Cyclic Friction Assembly NOTE The cyclic friction assembly is located below the forward left corner of the cyclic box. Turning friction knob clockwise applies friction to both longitudinal and lateral cyclic axes. Adjustment is required if friction cannot be applied. A.
Page 425 67-21 Collective Stick Assembly (continued) B. Installation 1. Refer to Figure 67-1. Position A333-1 collective-travel stop parallel to collective stick and apply collective friction. From aft side of co-pilot's seat, carefully position collective stick assembly in helicopter. 2. Pivot pilot's seat bottom to the open position. Install bolt from inside pilot's seat structure thru bearing block into tunnel and secure to inboard end of collective stick assembly.
Page 426: Collective Friction
67-22 Collective Friction 1. Loosen small screw on collective friction lever. 2. Hold friction lever knob fully aft against collective stick. Adjust screw large screw thru A333-1 stop to produce a force of 18-22 pounds at collective grip within hydraulic servo deadbands, then tighten small screw on friction lever screw.
Page 427: Swashplate
67-40 Swashplate A. Removal NOTE Rigging check is not required if push-pull tube rod end center- to-center dimension does not change. 1. Remove main rotor blades and hub per Sections 62-10 and 62-20. 2. Atop of C251 main rotor drive shaft, remove D226 brackets, D151 teeter stops, and C150 droop stops by removing NAS6608 bolt.
Page 428 67-40 Swashplate (continued) B. Installation (continued) 8. If required, fill remainder of rod end threaded hole in upper A205 fork with B270-4 or –13 sealant (see Section 20-70). 9. With bolt heads in direction of rotation, connect upper A205 fork to upper C204 arm and connect arm to C203 yokes.
Page 429: Swashplate Tilting Friction Adjustment
67-41 Swashplate Tilting Friction Adjustment Swashplate tilting friction is established by C197-1 through C197-6 shims controlling clamping force of Teflon®-lined sleeves on the ball assembly. 1. Mark for reassembly and disconnect boot, pitch links and drive linkage (scissors) from upper swashplate and both forward push-pull tubes from lower swashplate. 2.
Page 430 FIGURE 67-2 HYDRAULIC FLIGHT CONTROL SYSTEM Page 67.12 Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...
Page 431: Hydraulic System
67-50 Hydraulic System WARNING Except as instructed in this manual, service on the hydraulic system is limited to component removal and replacement. CAUTION Cleanliness of hydraulic fluid is vital to proper system operation. Use only clean fluid from sealed containers and avoid contamination from dirty funnels, tubing, etc.
Page 432: Hydraulic Reservoir
67-51 Hydraulic Pump (continued) B. Installation 1. Prelubricate new o-ring with gearbox oil and install on pump mounting flange. With pump bracket pointing down, install pump on gearbox and secure. Special torque nuts per Section 20-33. 2. Install both MR rpm senders in pump bracket. Adjust clearance between both senders and both yoke magnets to 0.040/0.020 inch and hand-tighten sender jam nuts.
Page 433 67-52 Hydraulic Reservoir (continued) B. Installation 1. Note alignment of tee fittings and sight gage LED on removed reservoir. Transfer LED and line and hose fittings from removed reservoir to replacement reservoir. Special torque fittings per Section 20-33. 2. Install reservoir on gearbox and secure with three screws. 3.
Page 434 FIGURE 67-3A HYDRAULIC SYSTEM SCHEMATIC FIGURE 67-3B HYDRAULIC SERVO RIGGING Page 67.15A Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...
Page 435: Hydraulic Servos
67-53 Hydraulic Servos A. Servo Removal CAUTION Do not pressurize hydraulic system while any hydraulic system component is disconnected or removed. 1. Remove mast fairing per Section 53-22. Remove tailcone cowling per Section 53-23. 2. Refer to Figures 67-2 and 67-3B. Perform the following measurements on all D212 hydraulic servo assemblies to be removed: a.
Page 436 67-53 Hydraulic Servos (continued) B. Servo Installation CAUTION Do not pressurize hydraulic system while any hydraulic system component is disconnected or removed. CAUTION Refer to Part A. Dimension between clevis hole center and top of servo piston must be 1.40 ± 0.03 inches; dimension between top of servo piston and top of cylinder assembly must be 0.28 ±...
Page 437 67-53 Hydraulic Servos (continued) B. Servo Installation (continued) 8. Refer to Figure 5-2. Verify proper rod end centering on all push-pull tubes attached to servos. 9. Remove caps and plugs. Lubricate new packings using A257-15 hydraulic fluid and install packings on servo unions and tees. Install fittings with associated hardware in servo ports and connect D205 hose assemblies to fittings.
Page 438 FIGURE 67-4 TAIL ROTOR FLIGHT CONTROLS Page 67.18 Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...
Page 439: Tail Rotor Controls
67-60 Tail Rotor Controls 67-61 Pedals A. Removal 1. Soak both front floor carpets with Prep-sol for 15-20 minutes, then lift carpet carefully from the floor on both sides and remove from the cabin. Caution: This is a flammable material. Follow manufacturer’s safety precautions to prevent injury. 2.
Page 440: Pitch Control
67-61 Pedals (continued) B. Installation 1. Fill the grooves in the pedal bearing blocks with A257-1 grease. 2. Install the pedal assemblies into the bearing blocks and torque the bearing block attach bolts per Section 20-32. NOTE If a force greater than 5 lbs is required to move pedals, check the bearing blocks to ensure they are matched correctly.
Page 441: C317-5 Bellcrank
67-70 Bellcranks 67-71 C317-5 Bellcrank A. Removal 1. Remove two screws securing the upper console. Lift up console and disconnect outside air temperature gage wiring. 2. Remove radios, radio panel face plate, and radio rack which is secured with screws to the side panels.
Page 442: C317-7 Bellcrank
67-72 C317-7 Bellcrank A. Removal 1. Refer to Section 6-70. Remove F794-2 aft belly cover, F932-1 middle seat backrest assembly, and F474-2 middle seat cover. 2. Disconnect F121-9 and F121-11 push-pull tubes from the C317-7 bellcrank. 3. Remove nuts and accompanying washers securing NAS6604-67 bolt in F334-1 support assembly.
Page 443: A331-4 Bellcrank
67-73 F316-1 Bellcrank (continued) B. Installation 1. Install one A141-3 washer on C494-2 shaft adjacent to both inboard and outboard end of F316-1 bellcrank. 2. Install bellcrank with washers in helicopter with longer arm pointing up. 3. On inboard end of C494-2 shaft, install two NAS1149F0463P washers followed by MS17825-4 castellated nut.
Page 444: A120-5 Bellcrank
67-75 A120-5 Bellcrank A. Removal 1. Disconnect 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 nut, and shims found between bellcrank and pitch control. B.
Page 445 CHAPTER 71 POWERPLANT Section Title Page 71-00 Description ........71.1 71-10 Engine .
Page 446 Intentionally Blank Page 71.ii Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...
Page 447 CHAPTER 71 POWERPLANT 71-00 Description One Rolls-Royce model 250-C300/A1 (commercial designation RR300) free-turbine turboshaft engine powers the helicopter. The engine is equipped with an ignition exciter, igniter, starter- generator, two tachometer senders, and additional powerplant instrument senders. A direct drive, squirrel cage style cooling fan is mounted to the intermediate shaft and supplies cooling air to the engine and gearbox oil coolers.
Page 448 FIGURE 71-1 ENGINE - RIGHT SIDE Page 71.2 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...
Page 449: Engine
71-10 Engine Refer to R66 Illustrated Parts Catalog (IPC) Chapter 71. NOTE The electronic monitoring unit (EMU) is a serialized component assigned to the engine. When removing the engine, remove the engine's EMU per Section 71-43, as required. A. Removal 1.
Page 450 FIGURE 71-2 ENGINE - LEFT SIDE Page 71.4 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...
Page 451 71-10 Engine (continued) B. Installation 1. Prepare engine for installation in helicopter per Section 71-12, as required. 2. Refer to Figures 71-1 and 71-2. Connect engine hoist to G200-1 engine lifting lug. 3. Remove F579-1 bellmouth cover. Carefully install engine, inserting bellmouth through firewall.
Page 452: Preparing Engine For Rolls-Royce Maintenance Facility
71-11 Preparing Engine for Rolls-Royce Maintenance Facility Refer to R66 Illustrated Parts Catalog (IPC) Chapter 71. NOTE Cap and plug Rolls-Royce engine model 250-C300/A1 engine fluid ports, electrical connectors, etc., and in removed components, progressively during procedure to prevent foreign object contamination.
Page 453: Preparing Engine For Helicopter Installation
71-11 Preparing Engine for Rolls-Royce Maintenance Facility (continued) 8. Remove A919-0D and A919-2D reducers, and G426-1 switch assembly, from fuel pump. 9. Remove hardware securing F593-3 plate to bottom of engine gearbox and remove plate. 10. Remove hardware securing engine-supplied rear PTO pad cover and remove cover. Remove bolt, washer, and G732-1 cap securing F018-1 clutch assembly in engine gearbox and remove clutch assembly.
Page 454 71-12 Preparing Engine for Helicopter Installation (continued) 7. Install engine-supplied rear PTO pad cover, and engine-supplied nuts and spacers. Special torque nuts per Section 20-33 and torque stripe per Figure 5-1. 8. Position F593-3 plate on bottom of engine gearbox and install aft bolt, finger tight. 9.
Page 455 71-12 Preparing Engine for Helicopter Installation (continued) h. Install (2) MS21919WCH4 clamps around harness assembly and install clamps on (bottom of) engine gearbox. Install hardware, special torque nuts per Section 20- 33, and torque stripe per Figure 5-1. i. Stand-off ty-rap G426-1 (fuel differential pressure) switch assembly’s wire from F741-1 line assembly using MS3367-4-9 ty-raps.
Page 456 FIGURE 71-3 INDUCTION Page 71.10 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...
Page 457: Air Filter Assembly
71-20 Induction CAUTION Never operate engine without G057-1 cage assembly installed. F771-1 filter assembly not required for flight. CAUTION Do not perform maintenance near engine inlet without either a filter assembly or a temporary cover installed on G057-1 cage assembly. Contact Rolls-Royce Customer Support if foreign objects enter inlet.
Page 458: Cage Assembly
71-22 Cage Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 71-9. A. Removal 1. Remove tail rotor drive fan shaft per Section 65-10. 2. Remove air filter assembly per Section 71-21. 3. Refer to Figure 71-3. Remove hardware securing G057-1 cage assembly to firewall and remove cage.
Page 459 Intentionally Blank Page 71.13 SEP 2012 R66 Maintenance Manual Chapter 71 Powerplant...
Page 460 FIGURE 71-4 EXHAUST Page 71.14 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...
Page 461: Exhaust Weldment
71-30 Exhaust Weldment Refer to R66 Illustrated Parts Catalog (IPC) Figure 71-13. A. Removal 1. Remove engine cowling assembly per Section 53-21. 2. Refer to Figure 71-4. Remove hardware securing F173-1 struts to F169-1 exhaust weldment and engine, and remove struts. 3.
Page 462: Starter-Generator
71-40 Accessories 71-41 Starter-Generator Refer to R66 Illustrated Parts Catalog (IPC) Figure 71-15. A. Removal 1. Remove engine cowling assembly per Section 53-21. 2. Refer to Figure 71-1. Verify heat shrink stamping is legible (or mark wires and cables) and remove hardware securing wires and cables to starter-generator studs. 3.
Page 463: Engine Monitoring Unit (Emu)
71-43 Engine Monitoring Unit (EMU) Refer to R66 Illustrated Parts Catalog (IPC) Figure 71-19. NOTE The electronic monitoring unit (EMU) is a serialized component assigned to the engine. When removing the engine, remove the engine's EMU per Section 71-43, as required. A.
Page 464 Intentionally Blank Page 71.18 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...
Page 465: Engine Anti-Ice
CHAPTER 75 ENGINE AIR SYSTEMS Section Title Page 75-00 Description ........75.1 75-10 Engine Anti-Ice .
Page 466 Intentionally Blank Page 75.ii Chapter 75 Engine Air Systems R66 Maintenance Manual 25 OCT 2010...
Page 467 CHAPTER 75 ENGINE AIR SYSTEMS 75-00 Description This chapter includes a description of the engine anti-ice system. Refer to RR300 Series Operation and Maintenance Manual (OMM) and manufacturer’s maintenance publications for system-specific inspection, repair, and maintenance procedures. The Rolls-Royce engine model 250-C300/A1 anti-ice system provides hot compressor discharge air to the compressor front support.
Page 468 Intentionally Blank Page 75.2 Chapter 75 Engine Air Systems R66 Maintenance Manual 25 OCT 2010...
Page 469 CHAPTER 76 ENGINE CONTROLS Section Title Page 76-00 Description ........76.1 76-10 Fuel Control Unit (FCU) .
Page 470 Intentionally Blank Page 76.ii Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...
Page 471: Fuel Control Unit (Fcu)
CHAPTER 76 ENGINE CONTROLS 76-00 Description A twist grip throttle control is located on each collective stick. The controls are interconnected and actuate the Rolls-Royce engine model 250-C300/A1 fuel control input lever via a push-pull cable. The throttle is normally not used for control but is set either fully closed (idle position) or fully open.
Page 472 FIGURE 76-1 FUEL CONTROL UNIT Page 76.2 Chapter 76 Engine Controls R66 Maintenance Manual SEP 2012...
Page 473: Fcu Throttle Control Rigging
76-11 FCU Throttle Control Rigging 1. Remove engine cowling assembly per Section 53-21. Remove F461-1 collective cross tube cover and (copilot) F680-1 collective cover assembly (see Section 6-70). 2. Refer to Figure 76-1. Verify FCU throttle lever rigging angle is 48.5° ± 7.5°. As required, remove hardware securing serrated levers and reposition to proper angle.
Page 474 FIGURE 76-2 POWER TURBINE GOVERNOR Page 76.4 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...
Page 475: Power Turbine Governor (Ptg)
76-12 FCU Fuel Cutoff Control Rigging (continued) 5. Push fuel cutoff control knob ON and verify FCU fuel cutoff lever-to-maximum fuel stop clearance is 0.030-0.090 inch. Reposition fitting on wire as required until FCU fuel cutoff lever rests in detent when control is OFF and has required clearance from maximum fuel stop when control is ON.
Page 476 FIGURE 76-3 PTG (BEEP) ACTUATOR ASSEMBLY Page 76.6 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...
Page 477: Ptg Rigging Check
76-21 PTG Control Rigging (continued) 7. Verify PTG pointer indicates 45° on PTG protractor, verify sufficient inner wire beyond bottom edge of bellcrank fitting, and special torque fitting nut per Section 20-33. 8. Install palnut, standard torque per Section 20-32, and torque stripe per Figure 5-1. Trim control wire 0.10-0.30 inch beyond bottom of fitting.
Page 478 Intentionally Blank Page 76.8 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...
Page 479 CHAPTER 79 ENGINE OIL SYSTEM Section Title Page 79-00 Description ........79.1 79-10 Scroll and Fanwheel Assemblies .
Page 480 Intentionally Blank Page 79.ii Chapter 79 Engine Oil System R66 Maintenance Manual SEP 2012...
Page 481 CHAPTER 79 ENGINE OIL SYSTEM 79-00 Description The R66 helicopter has a dry-sump engine oil system. Oil is stored in a remote tank located in the main rotor gearbox compartment. Refer to Section 12-60 for oil servicing instructions. A Rolls-Royce-supplied oil temperature sender is mounted on the inboard side of the oil tank. Oil circulates through the engine oil system via three oil delivery lines.
Page 482 FIGURE 79-2 SCROLL AND FANWHEEL ASSEMBLIES Page 79.2 Chapter 79 Engine Oil System R66 Maintenance Manual SEP 2012...
Page 483: Scroll And Fanwheel Assemblies
79-10 Scroll and Fanwheel Assemblies Refer to R66 Illustrated Parts Catalog (IPC) Figure 79-1. A. Removal 1. Remove F196-1 fan shaft per Section 65-10. 2. Refer to Figure 79-2. Remove perimeter screws securing F236-1 scroll assembly to F306-1 box assembly. 3.
Page 484 FIGURE 79-3 ENGINE OIL SYSTEM Page 79.4 Chapter 79 Engine Oil System R66 Maintenance Manual SEP 2012...
Page 485: Oil Tank Assembly
79-11 Fanwheel-to-Inlet Gaps (continued) B. Trimming Inlets 1. Refer to Figure 79-2. Remove hardware securing F305-5 inlets to F236-1 scroll assembly. 2. If inlets are slotted, carefully twist inlets over F196-1 fan shaft and remove inlets. If inlets are not slotted, remove hardware securing fan shaft to C947-3 plate assemblies, noting hardware removed, and remove inlets.
Page 486: Oil Temperature Sender
79-20 Oil Tank Assembly (continued) B. Installation 1. Refer to Figure 79-3. Remove caps from G689-1 oil tank assembly fittings. 2. Torque check union at oil cooler, and torque check engine (oil line) unions and check valve per Section 20-33. 3.
Page 487: Sight Gage
79-22 Sight Gage Refer to R66 Illustrated Parts Catalog (IPC) Figure 79-5. A. Removal 1. Drain engine oil per Section 12-60. 2. Refer to Figure 79-3. Remove B563-2 sight gage and o-ring from G689-1 oil tank assembly. Discard o-ring. 3. Tape gage opening to protect tank from contaminants. B.
Page 488: Engine Oil Line Assemblies And Fittings
79-40 Engine Oil Line Assemblies and Fittings Refer to R66 Illustrated Parts Catalog (IPC) Figure 79-9. A. Removal 1. Drain engine oil per Section 12-60. 2. Refer to Figure 79-3. Remove hardware securing line assembly clamps. 3. Disconnect F723 line assembly B-nuts from engine, F649-1 oil cooler, and/or G689-1 oil tank assembly fittings, as required.
Page 489 CHAPTER 95 INSTRUMENT SYSTEM Section Title Page 95-00 Description ........95.1 95-10 Pitot-Static System .
Page 490 Intentionally Blank Page 95.ii Chapter 95 Instrument System R66 Maintenance Manual 25 OCT 2010...
Page 491 CHAPTER 95 INSTRUMENT SYSTEM 95-00 Description Standard primary instruments are a vertical speed indicator, airspeed indicator, engine (N2) and rotor dual tachometer, altimeter, torquemeter, and magnetic compass. Engine gages include an N1 tachometer, measured gas (turbine) temperature, oil pressure, oil temperature, and fuel quantity.
Page 492 FIGURE 95-1 PITOT - STATIC SYSTEM Page 95.2 Chapter 95 Instrument System R66 Maintenance Manual 25 OCT 2010...
Page 493: Pitot-Static System
95-10 Pitot-Static System A. Pitot System Leak Test CAUTION Do not apply suction to pitot system or pressure to static system. 1. Open mast fairing per Section 53-22. 2. Refer to Figures 95-1 and 95-2. Seal drain hole in elbow aft of pitot tube with pressure sensitive tape.
Page 494 FIGURE 95-2 PITOT - STATIC SYSTEM Page 95.4 Chapter 95 Instrument System R66 Maintenance Manual 25 OCT 2010...
Page 495: Primary Instruments
95-20 Primary Instruments 95-21 Vertical Speed Indicator The vertical speed indicator indicates rate of ascent or descent. Check vertical speed indicator for a zero-rate needle indication when rotorcraft is in a stationary hover. 95-22 Airspeed Indicator The airspeed indicator displays airspeed in knots and miles per hour. The airspeed indicator operates in forward flight only;...
Page 496: Torquemeter
95-25 Torquemeter The electronic torquemeter indicates percent torque. The torque sensor is an oil pressure transducer mounted on the front of the engine's accessory gearbox. 95-26 Magnetic Compass An internally illuminated, wet-type compass is attached to the center bow between the windshields above the instrument panel.
Page 497: Additional Standard Indicating Equipment
95-40 Additional Standard Indicating Equipment 95-41 Clock A manually set electric analog clock is standard equipment; a digital clock is optional. 95-42 Ammeter The ammeter indicates electrical system loads. System load is measured at the shunt located on the left side of the vertical firewall in the engine compartment. 95-43 Outside Air Temperature (OAT) Gage/Voltmeter NOTE No cutting or splicing of OAT probe wires is permitted.
Page 498 Intentionally Blank Page 95.8 Chapter 95 Instrument System R66 Maintenance Manual 25 OCT 2010...
Page 499 CHAPTER 96 ELECTRICAL SYSTEM Section Title Page 96-00 Description ........96.1 96-10 Battery .
Page 500 Intentionally Blank Page 96.ii Chapter 96 Electrical System R66 Maintenance Manual SEP 2012...
Page 501 CHAPTER 96 ELECTRICAL SYSTEM 96-00 Description CAUTION The installation of electrical devices can affect the accuracy and reliability of the electronic tachometer. A 28-volt DC electrical system is standard. Primary system components are a sealed lead-acid battery, a starter-generator, and a generator control unit. The battery is located beneath the left front seat or in a compartment in the left side of the baggage compartment.
Page 502: Battery
FIGURE 96-1 AFT BATTERY INSTALLATIONS Page 96.2 Chapter 96 Electrical System R66 Maintenance Manual SEP 2012...
Page 503 96-10 Battery NOTE Refer to Concorde Battery Corporation's Owner/Operator's Manual, and Instruction for Continued Airworthiness for battery maintenance procedures. CAUTION B237-7 battery (standard; forward and aft) weighs 42 lb and B237-8 battery (alternate; aft only) weighs 52 lb including electrolyte. Carefully remove/install battery using handle provided to prevent injury.
Page 504 96-10 Battery (continued) 3. Verify G131-2 plate just contacts top of battery (holes are slotted). Adjust as required. 4. Verify battery terminal surfaces are clean to ensure electrical conductivity. Install positive cable on battery positive terminal and install battery hardware. Special torque terminal bolt as noted on battery label, and torque stripe per Figure 5-1.
Page 505: External Power
96-20 External Power A 28-volt MS3506-compatible external power receptacle is located inside the right engine cowl door. When the battery is switched ON, the external power relay and the battery relay both close, connecting external power to the aircraft electrical system and battery The external power relay will not close if reverse polarity is provided to the receptacle.
Page 506: Lighting System
96-40 Lighting System A red anti-collision light is installed on the tailcone and is controlled by the strobe switch on the instrument console. Position lights are installed on each side of the cabin and in the tail and are controlled by the nav lights switch. A light at the top of the windshield and post lights illuminate the instrument panel.
Page 507: Low Rotor Rpm Warning Unit Adjustment
96-50 Annunciator Panel A push-to-test button on the instrument panel should cause all segments on the annunciator panel, as well as the ROTOR BRAKE light, to illuminate when depressed. The LOW FUEL segment takes approximately two seconds before it illuminates due to a time delay in the circuit.
Page 508: Engine Monitoring Unit (Emu)
96-80 Engine Monitoring Unit (EMU) Refer to Section 71-43 for EMU maintenance procedures. The Engine Monitoring Unit (EMU) is a digital recording device mounted behind the right rear seatback panel. The EMU continuously monitors N , engine torque, and MGT. EMU status is indicated by the EMU segment on the annunciator panel.
Page 509: Electrical Load Analysis
96-100 Electrical Load Analysis CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT COMPONENT AMPS EACH AMPS EACH TOTAL TOTAL MAIN BUS WARNING LT PANEL 0.006 0.320 0.006 0.320 ROTOR BRAKE LT 0.044 0.000 0.044 MAPLIGHT 0.020 0.020 0.020 0.020 INTERIOR DOME LT 0.020 0.020 0.020 0.020 OAT GAGE...
Page 510 96-100 Electrical Load Analysis (continued) CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT COMPONENT AMPS EACH AMPS EACH TOTAL TOTAL LIGHTS BUS LANDING LT BALLAST 1.600 5.250 3.200 10.500 LANDING LT RELAY 0.060 0.060 0.060 0.060 CIRCUIT BREAKER LTS 0.001 0.001 0.001 0.001 INSTRUMENT LT 0.500 0.500 0.500...
Page 511 96-100 Electrical Load Analysis (continued) CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT COMPONENT AMPS EACH AMPS EACH TOTAL TOTAL TACH BUS TACH (INCL REG) 0.022 0.022 0.022 0.022 TACH @ 13.75V 0.035 0.035 ROTOR TACH (INCL REG) 0.022 0.022 0.022 0.022 ROTOR TACH @13.75V 0.035 0.035 SUBTOTAL (TACH BUS)
Page 512 Intentionally Blank Page 96.12 Chapter 96 Electrical System R66 Maintenance Manual SEP 2012...
Page 513: R66 Electrical System (F024 Revision I)
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 .
Page 514 Intentionally Blank Page 98.ii Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...
Page 515 FIGURE 98-1 R66 ELECTRICAL SYSTEM INSTALLATION (F024 Revision I shown) Page 98.1 SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
Page 516 FIGURE 98-2 R66 ELECTRICAL SYSTEM INSTALLATION (F024 Revision G shown) Page 98.2 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...
Page 517: Air Conditioning Installation
Page 98.3 FIGURE 98-3 AIR CONDITIONING INSTALLATION SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
Page 518 Intentionally Blank Page 98.4 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...
Page 519: Adf Installation
FIGURE 98-4 ADF INSTALLATION Page 98.5 SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
Page 520 Intentionally Blank Page 98.6 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...
Page 521: Standard Audio System
Page 98.7 FIGURE 98-5 STANDARD AUDIO SYSTEM SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
Page 522 Intentionally Blank Page 98.8 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...
Page 523: Dual Audio Control Installation
FIGURE 98-6 DUAL AUDIO CONTROL INSTALLATION Page 98.9 SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
Page 524 Intentionally Blank Page 98.10 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...
Page 525: Pa/Siren Installation
FIGURE 98-7 PA/SIREN INSTALLATION Page 98.11 SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
Page 526 Intentionally Blank Page 98.12 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...
Page 527: Illustrations And Tasks
CHAPTER 99 SPECIAL TOOLS Section Title Page 99-10 Special Tools ........99.1 99-20 Illustrations and Tasks .
Page 528 Intentionally Blank Page 99.ii Chapter 99 Special Tools R66 Maintenance Manual 25 OCT 2010...
Page 529 CHAPTER 99 SPECIAL TOOLS 99-10 Special Tools The following 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. Page 99.1 25 OCT 2010 R66 Maintenance Manual Chapter 99 Special Tools...
Page 530 FIGURE 99-1 SPECIAL TOOLS Page 99.2 Chapter 99 Special Tools R66 Maintenance Manual 25 OCT 2010...
Page 531 99-20 Illustrations and Tasks Item Part No. Name and Reference Section MT054-1 Main Rotor Gearbox Drain Assembly - Quick Disconnect REFER TO SECTION 12-11 MAIN ROTOR GEARBOX SERVICING MT122-6 Micrometer Assembly - Main Rotor Hub, Bolt Stretch REFER TO SECTION 62-10 MAIN ROTOR BLADES MT146-4 Blocks - Swashplate Rigging (set of 2) REFER TO SECTION 18-30 MAIN ROTOR FLIGHT CONTROL RIGGING...
Page 532 FIGURE 99-2 SPECIAL TOOLS Page 99.4 Chapter 99 Special Tools R66 Maintenance Manual SEP 2012...
Page 533 99-20 Illustrations and Tasks (continued) Item Part No. Name and Reference Section MT525-7 Main Rotor Blade Rigging Fixture REFER TO SECTION 18-40 MAIN ROTOR BLADE ANGLE RIGGING MT525-9 Tail Rotor Blade Rigging Fixture REFER TO SECTION 18-60 TAIL ROTOR BLADE RIGGING MT526-8 Bender Assembly - Trim Tab, Main Rotor Blade REFER TO SECTION 18-13 MAIN ROTOR BLADE TRACK ADJUSTMENT...
Page 534 FIGURE 99-3 SPECIAL TOOLS Page 99.6 Chapter 99 Special Tools R66 Maintenance Manual SEP 2012...
Page 535 CHAPTER 100 REVISION LOG Section Title Page — Revision Log ........100.1 Page 100.i SEP 2012...
Page 536 Intentionally Blank Page 100.ii Chapter 100 Revision Log R66 Maintenance Manual SEP 2012...
Page 537 REVISION LOG SEP 2012 The R66 Maintenance Manual (MM) list of effective pages and effective dates are given below. If a previously issued page is not listed below, it is no longer an effective page and must be discarded. The issue or revision date is in bold at the top of each revision log page. Please visit www.robinsonheli.com, under the Publications tab, to verify the issue or revision date is current.
Page 538 REVISION LOG SEP 2012 Page Date Page Date Page Date 6.4 ..25 OCT 2010 9.1 ..25 OCT 2010 12.12 ..SEP 2012 6.5 .
Page 539 REVISION LOG SEP 2012 Page Date Page Date Page Date 18.27 ..SEP 2012 21.3 ..SEP 2012 28.9 ..25 OCT 2010 18.28 .
Page 540 REVISION LOG SEP 2012 Page Date Page Date Page Date 52.5 ..25 OCT 2010 62.3 ..25 OCT 2010 63.10 ..SEP 2012 52.6 .
Page 541 REVISION LOG SEP 2012 Page Date Page Date Page Date 67.1 ..MAR 2012 71.10 ..SEP 2012 95.ii ..25 OCT 2010 67.2 .
Page 542 REVISION LOG SEP 2012 Page Date Page Date Page Date 98.12 ..SEP 2012 99.i ..25 OCT 2010 99.ii ..25 OCT 2010 99.1 .

Robinson Helicopter Company RTR 660 Maintenance Manual

Intentionally Blank

Chapter 100 - Revision Log

Chapter 99 - Special Tools

Chapter 1 - General

Chapter 4 - Airworthiness Limitations

Page 5.I

Chapter 5 Inspection Schedule

Page 6.I

Chapter 6 Dimensions and Descriptions

Chapter 7 - Jacking and Hoisting

Page 8.I

Chapter 8 Weight and Balance

Chapter 9 - Ground Handling

Chapter 10 - Parking and Storage

Chapter 11 - Placards and Markings

Page 12.I

Chapter 12 - Servicing

Page 18.I

Chapter 18 Track and Balance

Page 20.I

Chapter 20 Standard Practices

Page 21.I

Chapter 21 Environment Control

Page 25.I

Chapter 25 Furnishings

Fuel System/Description

Chapter 28 - Fuel System

Chapter 32 Landing Gear

Chapter 52 Doors and Windows

Page 53.I

Chapter 53 Fuselage

Table of Contents

Chapter 62 - Main Rotor

Chapter 63 - Main Rotor Drive System

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Chapters

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Summary of Contents for Robinson Helicopter Company RTR 660