Robinsons R66 Maintenance Manual
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Robinsons R66 Maintenance Manual

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Table of Contents

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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
Please visit
Procure parts from any R66 Dealer or Service Center,
or order directly from
Please visit
MAY 2015
Type Certificate Number R00015LA
OFFICE HOURS
Lunch hour is 11:30 a.m. to 12:30 p.m.
for a complete list of holidays and company shutdowns.
CUSTOMER SUPPORT AND ORDERS
www.robinsonheli.com
RHC Customer Service
PUBLICATIONS
www.robinsonheli.com
Phone: (310) 539-0508
Fax:
(310) 539-5198
Web:
www.robinsonheli.com
HOLIDAYS
for a complete service directory.
via email, fax, or phone.
to view our publications electronically.
Introduction
Page i

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Summary of Contents for Robinsons R66

  • Page 1 CUSTOMER SUPPORT AND ORDERS Please visit www.robinsonheli.com for a complete service directory. Procure parts from any R66 Dealer or Service Center, or order directly from RHC Customer Service via email, fax, or phone. PUBLICATIONS Please visit www.robinsonheli.com...

  • Page 2: Subscription Order And Renewal Form

    $45.00 Future updates to R66 Pilot’s Operating Handbook & Safety Notices $15.00 Future updates to R66 Pilot’s Operating Handbook & Safety Notices, R66 Service Bulletins & Service Letters $25.00 Future updates to R66 Pilot’s Operating Handbook & Safety Notices, R66 Service Bulletins, Service Letters, &...

  • Page 3: Chapter List

    CHAPTER LIST Introduction Chapter 1 General Chapter 4 Airworthiness Limitations Chapter 5 Inspections 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 Chapter 18...

  • Page 4: Recommended Change Report

    TECHNICAL PUBLICATIONS RECOMMENDED CHANGE REPORT Please direct recommended changes to RHC Technical Publications via the email address listed below, by phone, or by submitting a duplicate of this completed form by fax or mail. Please include or have available the information detailed by this form.

  • Page 5: Limited Aircraft Warranty

    LIMITED AIRCRAFT WARRANTY 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 MAY 2015...

  • Page 7: Table Of Contents

    1-70 Service Directory ............1.4 1-80 Assembly Instructions for R66 Helicopter Crated for Export ......1.5 CHAPTER 4 —...

  • Page 8: Contents

    CONTENTS CHAPTER 5 — INSPECTIONS (Continued) Section Title Page 5-34 Elastomeric Bearings ..........5.7 5-35 Telatemp Indicators .
  • Page 9 CONTENTS CHAPTER 7 — JACKING AND HOISTING Section Title Page 7-10 Jacking ............. 7.1 7-20 Hoisting .
  • Page 10 CONTENTS CHAPTER 12 — SERVICING Section Title Page 12-10 Main Rotor Gearbox ........... . . 12.1 12-11 Servicing .
  • Page 11 CONTENTS CHAPTER 18 — TRACK AND BALANCE (Continued) Section Title Page 18-42 Cyclic Travel ............18.26 18-50 Tail Rotor Flight Control Rigging .
  • Page 12 CONTENTS CHAPTER 21 — ENVIRONMENT CONTROL Section Title Page 21-00 Description ............21.1 21-10 Ventilation .
  • Page 13 CONTENTS CHAPTER 25 — FURNISHINGS (Continued) Section Title Page 25-53 Map Pocket Replacement ..........25.9 25-60 Emergency Equipment .
  • Page 14 CONTENTS CHAPTER 32 — LANDING GEAR (Continued) Section Title Page 32-64 System Maintenance ..........32.22 CHAPTER 33 —...
  • Page 15 CONTENTS CHAPTER 53 — FUSELAGE (Continued) Section Title Page 53-41 Inspection and Repair ..........53.15 53-50 Empennage Assembly .
  • Page 16 CONTENTS CHAPTER 64 — TAIL ROTOR Section Title Page 64-00 Description ............64.1 64-10 Tail Rotor Assembly .
  • Page 17 CONTENTS CHAPTER 67 — FLIGHT CONTROLS (Continued) Section Title Page 67-41 Swashplate Tilting Friction Adjustment ........67.11 67-42 Upper and Lower Scissor Assemblies .
  • Page 18 CONTENTS CHAPTER 76 — ENGINE CONTROLS (Continued) Section Title Page 76-21 PTG Control Rigging ..........76.5 76-22 PTG Rigging Check .
  • Page 19 97-50 Avionics for R66 S/N 293, 520, 522 & Subsequent .......
  • Page 20 R66 Electrical System (F024-2 Revision P) ........

  • Page 21: Chapter 1 General

    1-10 R66 Maintenance Manual Revisions ....... 1.1 1-20 R66 Maintenance Authorization ........1.1 1-30 Component Overhaul Authorization .
  • Page 22 Intentionally Blank Page 1.ii Chapter 1 General MAY 2015...

  • Page 23: Introduction

    Always read instructions completely before performing a task. 1-10 R66 Maintenance Manual Revisions Before using the R66 Maintenance Manual, verify it consists of effective pages. The list of effective pages is located in the Revision Log in Chapter 100. When a new manual is purchased, complete and submit the Subscription Order and Renewal Form located in the Introduction.

  • Page 24: Maintenance Record

    The Airframe Maintenance Record is available online at www.robinsonheli.com. Airframe Maintenance Record blank PDF forms may be used for R22-series, R44-series, and R66 Turbine helicopters. Component Record blank PDF forms may be used for life-limited or TBO components. Blank paper copies are available for purchase (P/N R8478 Airframe Maintenance Record and P/N R8479 Component Record [pack of 20]).

  • Page 25: Definitions And Abbreviations

    1-60 Definitions and Abbreviations Refer to R66 Pilot's Operating Handbook (POH) Section 1 for additional definitions and abbreviations. A. Definitions 14 CFR § 27.602 A part identified as a 14 CFR § 27.602 critical part within this manual Critical Part: is subject to special inspection requirements.

  • Page 26: Service Directory

    Water Line Station locations 1-70 Service Directory Please visit www.robinsonheli.com for a complete service directory. Procure parts from any R66 Dealer or Service Center, or order directly from RHC Customer Service via email, fax, or phone. Page 1.4 Chapter 1 General...

  • Page 27: Assembly Instructions For R66 Helicopter Crated For Export

    Open crate containing blades, skid tubes, and tailcone. 2. Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1. Install hardware securing forward and aft strut assemblies (cross tubes installed) onto skid tubes. Standard torque bolts per Section 20-32 and torque stripe per Figure 5-1.
  • Page 28 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 29 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 § 20-32 and torque stripe per Figure 5-1.
  • Page 30 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.
  • Page 31 1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued) 28. Depreserve the engine after storage per RR300 Series Operation and Maintenance Manual (OMM). Install starter-generator cooling hose. Install engine cowling per § 53-21. 29. Install tail rotor dynamic balance equipment per § 18-21.
  • Page 32 Intentionally Blank Page 1.10 Chapter 1 General MAY 2015...

  • Page 33: Chapter 4 Airworthiness Limitations

    CHAPTER 4 AIRWORTHINESS LIMITATIONS Section Title Page 4-10 Airworthiness Limitations ........4.1 4-20 Additional Limitations .
  • Page 34 Intentionally Blank Page 4.ii Chapter 4 Airworthiness Limitations DEC 2014...
  • Page 35 FAA Approved: This page constitutes the Airworthiness Limitations Section in its entirety, is considered segregated from the rest of the document, and sets forth the FAA approved mandatory replacement times for the fatigue life-limited parts listed above. Page 4.1 SEP 2011 R66 Maintenance Manual Chapter 4 Airworthiness Limitations...
  • Page 36 Intentionally Blank Page 4.2 Chapter 4 Airworthiness Limitations R66 Maintenance Manual SEP 2011...

  • Page 37: Additional Limitations

    4-20 Additional Limitations 4-21 Parts with a Recommended Time Between Overhauls (TBO) Remove the following components for overhaul when they have accumulated 2000 hours time in service since new or since last overhaul. Maintenance procedures are listed for reference and are subject to revision. Part Number Description Reference...

  • Page 38: Airframe And Engine Accessory Limits

    Rolls-Royce maintenance facility per § 71-11 as required. 4-30 Type Certificate Data Sheet (TCDS) The Robinson R66 Type Certficate Data Sheet (TCDS) reprinted on the following pages is subject to revision. Visit the FAA Aircraft Certification Regulatory and Guidance Library online databases for TCDS revision status at: http://rgl.faa.gov.
  • Page 39 Type Certificate Holder: Robinson Helicopter Company 2901 Airport Drive Torrance, California 90505 I. Model R66 (Normal Category Rotorcraft), Approved October 25, 2010 Engine One Rolls-Royce 250-C300/A1, Type Certificate number E4CE Fuel Jet A or Jet A-1 conforming to ASTM D 1655...
  • Page 40 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 41: Hydraulic Reservoir

    Page 3 of 5 R00015LA Number of Seats 5 (4 for Police Version) Seat Locations Pilot and forward occupant at STA 49.0 in Aft outboard occupants at STA 80.0 in Aft center occupant at STA 78.0 in Maximum Compartment Main baggage compartment Weights Maximum weight is 300 lb at STA 107.0 in Maximum loading density is 50 lb/ft...
  • Page 42 NOTE 3. 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 “AIRWORTHINESS LIMITATIONS” section.
  • Page 43 Number AT14992LA-R-S-1, dated February 20, 2013. The exemption allowed a powered flight control system without considering the jamming of a control valve as a possible single failure. There is no impact to R66 helicopters that have been delivered or are in service. --- END --- Page 4.9...
  • Page 44 Intentionally Blank Page 4.10 Chapter 4 Airworthiness Limitations MAY 2015...

  • Page 45: Chapter 5 Inspections

    CHAPTER 5 INSPECTIONS Section Title Page 5-10 Life-Limited Components ........5.1 5-11 Time-In-Service Records .
  • Page 46 Intentionally Blank Page 5.ii Chapter 5 Inspections MAY 2015...

  • Page 47: Life-Limited Components

    If a part is fatigue life-limited or has a mandatory overhaul requirement and is interchanged between an R44 and an R66 helicopter, and if the part life-limit or overhaul requirement is different between an R44 and an R66 helicopter, the shorter life-limit or overhaul requirement must be used.
  • Page 48 TABLE 1 SCHEDULED MAINTENANCE AND INSPECTIONS Replace main rotor gearbox oil and filter • • per § 12-12. Perform 100-hour / annual maintenance • • and inspection per § 5-45. As required by RR300 Series Operation • • • • •...

  • Page 49: Scheduled Maintenance And Inspections

    5-20 Scheduled Maintenance and Inspections The R66 helicopter required inspection intervals are given in Table 5-1. Required inspection intervals are maximum 100 hours time in service or 12 calendar months, whichever occurs first; the inspection interval may be extended up to 10 hours, without accumulation, if allowed by local regulations.
  • Page 50 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 Inspections MAY 2015...

  • Page 51: Standard Inspection Criteria

    Assembly of flight controls is critical and requires inspection by a qualified person. If a second person is not available, RHC recommends the installer take a 5-minute break prior to inspecting flight control connections he has assembled. Page 5.5 SEP 2012 R66 Maintenance Manual Chapter 5 Inspection Schedule...
  • Page 52 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 53: Elastomeric Bearings

    60°C / 140°F — 88°C / 190°F 110-3 82°C / 180°F — 110°C / 230°F 110-4 104°C / 220°F — 132°C / 270°F FIGURE 5-4 TELATEMP WITH DRAWN REFERENCE LINE Page 5.7 SEP 2012 R66 Maintenance Manual Chapter 5 Inspection Schedule...

  • Page 54: Operation Checks For 100-Hour / Annual Maintenance And Inspection

    Tail Rotor Pedals: Verify smooth actuation without binding. Verify proper pedal position for pilot and locking pin security. Removable Controls (if installed): Verify proper operation and locking pin security. Page 5.8 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...
  • Page 55 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. Cowl door segment illuminates when one, two, or all of the following doors are open: fuel filler door, right side engine...

  • Page 56: Run-Up

    5-41 Ground Check (continued) Aircraft Documents: (Additional documents may be required in countries other than the US.) Inspect condition and verify R66 MT699-1 laminated pilot's checklist is current revision. Check revision status online at: www.robinsonheli.com. Inspect condition and verify R66 Pilot’s Operating Handbook is current revision and contains correct Equipment List/Weight &...

  • Page 57: Flight Check

    5-42 Run-Up (continued) Check hydraulic system operation. Using cyclic-mounted hydraulics switch, turn hydraulics OFF. Using small longitudinal cyclic inputs, there should be approximately one-half inch of freeplay before encountering stiffness and feedback. Return cyclic to neutral. Turn hydraulics ON. Controls should be free with no feedback or uncommanded motion (“motoring”).
  • Page 58 5-43 Flight Check (continued) Power Assurance Check: Refer to R66 Pilot's Operating Handbook (POH) Chapter 5 power assurance chart. Conduct at typical cruise altitude (weather permitting) and maximum continuous torque (83%). Turn heater, generator, and anti-ice switches OFF. Stabilize N2/R at 100% (beep as required) and record the following...

  • Page 59: 100-Hour / Annual Maintenance And Inspection

    Inspect condition. Check for looseness or play in pedal bearings. Maximum allowable play is 0.080 inch axially and 0.030 inch radially. Verify bearing block security. Page 5.13 SEP 2012 R66 Maintenance Manual Chapter 5 Inspection Schedule...
  • Page 60 HID Landing Lights: Inspect condition. Verify proper installation and security of wiring and equipment. Flight & Engine Instruments: Inspect condition. Verify proper instrument markings per R66 POH Section 2. Verify proper installation and security of wiring and equipment. Post Lights: Inspect condition.
  • Page 61 Fuses and Fuse Holders: Inspect condition. Verify security and no corrosion. Verify correct fuse installation. Circuit Breakers: Inspect condition. Check airworthiness directive applicability. Verify proper installation and security. Page 5.15 SEP 2012 R66 Maintenance Manual Chapter 5 Inspection Schedule...
  • Page 62 Verify proper installation, security, and operation. Cyclic Pivot: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Inspect spherical bearings per Section 5-33. Verify proper installation, security, and operating clearance. Page 5.16 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...

  • Page 63: 100-Hour / Annual Maintenance And Inspection

    5-45 100-Hour / Annual Maintenance and Inspection [5 of 26 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 64 5-45 100-Hour / Annual Maintenance and Inspection [6 of 26 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 65 Verify proper actuator installation, security, and operation. Tunnel Interior: Verify general cleanliness of tunnel interior. Inspect for fluid leaks or seepage; investigate cause and correct. Seat Backs: Inspect condition. Verify upholstery cleanliness and security. Page 5.19 SEP 2012 R66 Maintenance Manual Chapter 5 Inspection Schedule...
  • Page 66 Inspect hinges and latches for obvious defects. Verify security and proper latching/locking function. Carpet: Inspect condition. Verify no defects, tears, or material deterioration. Verify proper installation and security. Page 5.20 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...
  • Page 67 Verify proper safety wire installation and security. Verify 0.25 inch minimum clearance between cable assembly and vent assembly Tygon® tube; adjust cable as required. Verify no obstructions in vents. Page 5.21 SEP 2012 R66 Maintenance Manual Chapter 5 Inspection Schedule...

  • Page 68: Hydraulic Servos

    Inspect jackshaft aft support frame attachment and forward attachment rod end per Section 5-33. Inspect C343-8 tube and rod ends linking jackshaft to aft servo. Verify security and proper operating clearance. Page 5.22 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...
  • Page 69 Verify proper installation and security. Hydraulic Pump: Inspect condition. Inspect Telatemp per Section 5-35. Verify no significant leakage. Verify proper installation and security. Page 5.23 SEP 2012 R66 Maintenance Manual Chapter 5 Inspection Schedule...
  • Page 70 (several positions). If gap does not meet minimum limit, trim inlets per Section 79-11. Verify proper installation, security, and operating clearance. Verify no cracks or damage to scroll assembly. Page 5.24 Chapter 5 Inspection Schedule R66 Maintenance Manual SEP 2012...
  • Page 71 Verify no leakage from fuel tanks. Engine Oil Tank: Inspect condition. Verify no leakage or obvious damage to oil tank exterior. Check tank interior for foreign objects. Add oil as required per R66 POH Section 8. Verify tank security. Page 5.25...
  • Page 72 5-45 100-Hour / Annual Maintenance and Inspection [14 of 26 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 73 Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify no damaged connectors. Verify neatness, proper routing and installation, and security. Engine Oil and Oil Filter: Add oil as required per R66 POH Section 8. Change oil and oil filter as required per RR300 OMM. Verify filter security. Oil Lines: Inspect condition.
  • Page 74 5-45 100-Hour / Annual Maintenance and Inspection [16 of 26 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 75 5-45 100-Hour / Annual Maintenance and Inspection [17 of 26 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 76 5-45 100-Hour / Annual Maintenance and Inspection [18 of 26 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 77 5-45 100-Hour / Annual Maintenance and Inspection [19 of 26 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 78 5-45 100-Hour / Annual Maintenance and Inspection [20 of 26 Pages] TAIL ROTOR & TAIL ROTOR GEARBOX (continued) Wiring: Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify neatness, proper routing and installation, and security. Fasteners & Torque Stripes: Inspect condition.
  • Page 79 5-45 100-Hour / Annual Maintenance and Inspection [21 of 26 Pages] MAST FAIRING (continued) Swashplate Lower Scissors: Inspect condition. Verify bearing play within limits referenced in § 67-42. Closely examine scissor linkage while a second person raises and lowers collective stick. Verify bolts and washers rotate together through full control travel without binding.
  • Page 80 5-45 100-Hour / Annual Maintenance and Inspection [22 of 26 Pages] ROTOR HUB & MAIN ROTOR BLADES Hub: Inspect condition. Verify no nicks, scratches, gouges, dents, cracks, or corrosion. Verify no brown or black residue indicating bearing wear. Verify proper installation and security.
  • Page 81 5-45 100-Hour / Annual Maintenance and Inspection [23 of 26 Pages] ROTOR HUB & MAIN ROTOR BLADES (continued) Blade Boots: Inspect condition. Verify no boot defects, tears, material deterioration, or pinholes resulting in oil leakage. Verify proper boot position and security. Verify sufficient clearance from hub assembly through full control travel.
  • Page 82 5-45 100-Hour / Annual Maintenance and Inspection [24 of 26 Pages] LANDING GEAR Landing Gear Attach Points: Inspect condition. Verify no buckling, cracks, fretting, or loose fasteners. Inspect mounts and verify no loose swages or worn bearings. Fasteners & Torque Stripes: Inspect condition.
  • Page 83 5-45 100-Hour / Annual Maintenance and Inspection [25 of 26 Pages] CABIN (continued) Yaw String: Inspect condition. Verify minimum string length is 3 inches on each side of clip. Verify security. Landing & Taxi Lights: Inspect condition. Verify lens cleanliness, clarity, and security. Verify proper operation. Landing Light Retainer &...

  • Page 84: Lubrication

    5-45 100-Hour / Annual Maintenance and Inspection [26 of 26 Pages] LIFE-LIMITED PARTS, PARTS WITH A RECOMMENDED TBO OR REPLACEMENT TIME, ADs, & SBs Airframe and Engine Accessories: Refer to § 4-20 and accessory manufacturer’s maintenance publications. Verify accessories correspond with aircraft maintenance records. Verify accessories scheduled for maintenance have sufficient time remaining for projected operations.

  • Page 85: 2000-Hour Maintenance And Inspection

    5-50 2000-Hour Maintenance and Inspection NOTE Fuel bladder is on condition. 1. Order one R8480 2000-Hour Maintenance and Inspection Kit from any R66 Dealer or Service Center. 2. Refer to helicopter maintenance records and § 4-10. Replace life-limited parts as required.
  • Page 86 Intentionally Blank Page 5.40 Chapter 5 Inspections MAY 2015...

  • Page 87: 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 88: 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 89: 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 90: 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 91 Intentionally Blank Page 5.45 MAY 2015 Chapter 5 Inspections...
  • Page 92 FIGURE 5-5 SYMMETRY CHECK Page 5.46 Chapter 5 Inspections MAY 2015...

  • Page 93: 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 94: 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 95: 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 § 12-13. Inspect any particles found on the chip detector. Examine the particles and perform following appropriate corrective action: a.

  • Page 96: Lightning Strike

    5-72 Lightning Strike Lightning strikes are extremely rare for helicopters operating in VFR conditions. If a lightning strike does occur, RHC recommends performing a 100-hour inspection per § 5-45 and performing the inspection for lightning strike damage per Rolls-Royce RR300 Operation and Maintenance Manual (OMM).
  • Page 97 CHAPTER 6 DIMENSIONS AND DESCRIPTIONS Section Title Page 6-10 Version Description ......... . 6.1 6-20 Datum .
  • Page 98 Intentionally Blank Page 6.ii Chapter 6 Dimensions and Descriptions MAY 2015...

  • Page 99: Chapter 6 Dimensions And Descriptions

    Rolls-Royce model 250-C300/A1 turboshaft engine normally rated at 300 shaft horsepower (SHP); 270 SHP 5-minute take-off rating. Maximum gross weight 2700 pounds. Primary fuel is Jet-A (see R66 Pilot's Operating Handbook); 74.6 US gallon fuel tank capacity. 6-20 Datum The datum is located 100 inches forward of main rotor centerline.
  • Page 100 Intentionally Blank Page 6.2 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010...

  • Page 101: 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 102: 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 103 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 104: Station Diagrams

    Engine Cowling (aft point) ..........FS 171.45 FIGURE 6-4 FUSELAGE STATION LOCATIONS Page 6.6 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010...

  • Page 105: 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 106: Water Line (Wl) Station Locations

    Origin ............WL 0.00 FIGURE 6-6 WATER LINE STATION LOCATIONS Page 6.8 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010...

  • Page 107: Butt Line (Bl) Station Locations

    Teeter Hinge Bolt (tail rotor) ....LBL 11.01 Jack Tab (aft strut assembly) ....LBL 16.73 FIGURE 6-7 BUTT LINE STATION LOCATIONS Page 6.9 SEP 2012 R66 Maintenance Manual Chapter 6 Dimensions and Descriptions...
  • Page 108 FIGURE 6-8 INTERIOR ACCESS & INSPECTION PANELS Page 6.10 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual SEP 2012...

  • Page 109: 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 110: B526 Screws And B527-08 Washers

    6-71 B526 screws and B527-08 washers B526 (TORX Plus®) truss head screws may be used to secure cowlings and access panels. A B527-08 nylon washer may be used under a B526 screw head to further protect thin or painted surfaces. B526 screws are interchangeable with MS27039C080_ screws used to secure cowlings and access panels as follows: PART:...

  • Page 111: Antenna Locations

    6-80 Antenna Locations ITEM ANTENNA PART NO. ITEM ANTENNA PART NO. 1 Glidescope ..— CI 193 12 Cowling GPS ..— GA 35 2 ADF ... . — KA44B Cowling XM .
  • Page 112 Intentionally Blank Page 6.14 Chapter 6 Dimensions and Descriptions MAY 2015...

  • Page 113: Chapter 7 - Jacking And Hoisting

    Hoisting ......... . Page 7.i 25 OCT 2010 R66 Maintenance Manual Chapter 7 Jacking and Hoisting...
  • Page 114 Intentionally Blank Page 7.ii Chapter 7 Jacking and Hoisting R66 Maintenance Manual 25 OCT 2010...

  • Page 115: Jacking

    Sandbag jacks for increased stability, as required. 3. Actuate jacks slowly and simultaneously (one person per jack recommended), maintaining helicopter stability. Raise helicopter to required height. CAUTION Minimize personnel movement around raised helicopter. Page 7.1 SEP 2012 R66 Maintenance Manual Chapter 7 Jacking and Hoisting...
  • Page 116 FIGURE 7-1 JACKING Page 7.2 Chapter 7 Jacking and Hoisting R66 Maintenance Manual SEP 2012...
  • Page 117 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 Chapter 7 Jacking and Hoisting...
  • Page 118 FIGURE 7-2 HOISTING Page 7.4 Chapter 7 Jacking and Hoisting R66 Maintenance Manual SEP 2012...

  • Page 119: Hoisting

    Connect hoist to nylon rope. Verify security. 4. Stabilize helicopter as required by guiding tail skid, but do not exert force (tail skid is secondary structure). Raise helicopter to required height. Page 7.5 25 OCT 2010 R66 Maintenance Manual Chapter 7 Jacking and Hoisting...
  • Page 120 (tail skid is secondary structure). Slowly lower aircraft to ground. 2. Disconnect hoisting equipment, remove lifting fixture or nylon rope from main rotor hub, and clear equipment from area. Page 7.6 Chapter 7 Jacking and Hoisting R66 Maintenance Manual 25 OCT 2010...

  • Page 121: Chapter 8 Weight And Balance

    Empennage Ballast ......8.13 Page 8.i 25 OCT 2010 R66 Maintenance Manual Chapter 8 Weight and Balance...
  • Page 122 Intentionally Blank Page 8.ii Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...
  • Page 123 4. Position spirit level longitudinally on aft tunnel cover, or atop left or right keel panel if cover is removed. Adjust jack under ground handling ball until helicopter is level longitudinally. Page 8.1 SEP 2012 R66 Maintenance Manual Chapter 8 Weight and Balance...
  • Page 124 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 125 Apply rotor brake. Verify cyclic stick is in vertical position with friction applied. 6. Adjust jack under ground handling ball until helicopter is level longitudinally. Remove spirit level. Page 8.3 SEP 2012 R66 Maintenance Manual Chapter 8 Weight and Balance...
  • Page 126 Intentionally Blank Page 8.4 Chapter 8 Weight and Balance R66 Maintenance Manual SEP 2012...

  • Page 127: Weighing

    3. Clean aircraft per Section 20-10. Ensure helicopter is completely dry prior to weighing. 4. Remove foreign objects from baggage compartments and stowage areas. 5. Verify cowlings, removable panels, cabin doors, removable controls, and R66 Pilot’s Operating Handbook (POH) are installed.
  • Page 128 FIGURE 8-3 WEIGHING (Scale indications for demonstration only) Page 8.6 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 129: Weighing Procedure And Calculations

    If removed, carefully replace F463-1 aft tunnel cover, unsecured, on top of keel panels. 5. Calculate net weights: Weighing Point Scale Indication Tare Weight Net Weight Forward: – Left: – Right: – Page 8.7 SEP 2012 R66 Maintenance Manual Chapter 8 Weight and Balance...
  • Page 130 Round up to nearest 0.25 lb. Install nose ballast per Section 8-31. Reweigh helicopter and calculate new weight and CG per the previous steps. 7. Lower helicopter per Section 7-10. Secure aft tunnel cover. Page 8.8 Chapter 8 Weight and Balance R66 Maintenance Manual SEP 2012...
  • Page 131 (arm, inches) Moment (in.-lb) Forward Net: 4.13 Left Net: – 16.73 Right Net: 16.73 Unusable fuel (add): 6.70 – 20.70 – 138.69 Basic empty weight and lateral CG: Page 8.9 25 OCT 2010 R66 Maintenance Manual Chapter 8 Weight and Balance...
  • Page 132 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 133: Fixed Ballast

    Verify security. 5. Reweigh and/or calculate basic empty weight and CG per Section 8-22. 6. Revise Weight and Balance Record in R66 Pilot's Operating Handbook (POH) Section 6 to reflect ballast removal or installation using the following data:...
  • Page 134 FIGURE 8-5 EMPENNAGE BALLAST Page 8.12 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 135: Empennage Ballast

    2. Solvent-clean bare metal around and between bolt holes on horizontal stabilizer upper and lower surfaces. 3. Temporarily install D301-2 weights per R66 IPC Figure 8-1. Torque bolts per Section 20-32. 4. Trace outline of weights onto horizontal stabilizer upper and lower surfaces using felt-tip, non-permanent marker or tape.
  • Page 136 6. Remove tracing media. Solvent-clean bare metal on horizontal stabilizer and weight clamping surfaces. 7. Reweigh and/or calculate basic empty weight and CG per Section 8-22. 8. Revise Weight and Balance Record in R66 Pilot's Operating Handbook (POH) Section 6 to reflect ballast installation using the following data: Weight...
  • Page 137 Trailering ......... Page 9.i 25 OCT 2010 R66 Maintenance Manual Chapter 9 Ground Handling...
  • Page 138 Intentionally Blank Page 9.ii Chapter 9 Ground Handling R66 Maintenance Manual 25 OCT 2010...

  • Page 139: Chapter 9 - Ground Handling

    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 140 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. C063-5 (LH) and C063-6 (RH) ground handling wheel assemblies are not interchangeable. When wheels are installed and in locked position, both handles point aft.

  • Page 141: Moving Helicopter On Ground Handling Wheels

    9-13 Ground Handling Carts The R66 can be handled by one person using the MT950-1 Universal ground handling cart. Product specifications, as well as MT950 Operating Instructions, Maintenance Manuals, and Illustrated Parts Catalogs are available on our website, www.robinsonheli.com, under the Customer Support tab.

  • Page 142: Trailering

    2. Support the tailcone. Cushion support point(s) to prevent tailcone damage. 3. Perform one of the following options: a. Remove main rotor blades per Section 62-10. Pack blades in shipping crate. See R66 Illustrated Parts Catalog [IPC] Figure 99-11. b. Install main rotor blade supports per Section 10-13.

  • Page 143: Chapter 10 Parking And Storage

    Storage (Greater than 30 days) ......10.6 Page 10.i 25 OCT 2010 R66 Maintenance Manual Chapter 10 Parking and Storage...
  • Page 144 Intentionally Blank Page 10.ii Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010...
  • Page 145 Mark an "X" on one pitch link lower rod end and corresponding swashplate ear using a colored grease pencil. Mark an "O" on opposite link and corresponding swashplate ear. Page 10.1 SEP 2012 R66 Maintenance Manual Chapter 10 Parking and Storage...
  • Page 146 FIGURE 10-1 MAIN ROTOR BLADE TIE-DOWNS Page 10.2 Chapter 10 Parking and Storage R66 Maintenance Manual SEP 2012...

  • Page 147: Main Rotor Blade Tie-Downs

    Wrap strap 1¾ times around tailcone forward of strobe light, twist strap around strobe light base, and secure tie-down hook and loop tape. Push up on secured blade to remove slack in tie-down strap. Page 10.3 25 OCT 2010 R66 Maintenance Manual Chapter 10 Parking and Storage...
  • Page 148 FIGURE 10-2 MAIN ROTOR BLADE SUPPORTS Page 10.4 Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010...

  • Page 149: Main Rotor Blade Supports

    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 150: Storage (Greater Than 30 Days)

    8. Clean aircraft per Section 20-10. Ensure helicopter is clean and dry prior to storing. Open door vents and doors to ventilate cabin and baggage compartment as required. 9. Close and latch all access doors. Install engine exhaust cover. Page 10.6 Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010...

  • Page 151: Chapter 11 - Placards And Markings

    Placard Illustrations ........11.3 Page 11.i SEP 2012 R66 Maintenance Manual Chapter 11 Placards and Markings...
  • Page 152 FIGURE 11-1 PLACARD LOCATIONS Page 11.0 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012...
  • Page 153 B051-20 Face Assembly - R66 (Phaostron) ....... . . 1 A654-45 A950-3 Guard Assembly (fuel cutoff) .
  • Page 154 FIGURE 11-2 PLACARD LOCATIONS Page 11.2 Chapter 11 Placards and Markings R66 Maintenance Manual SEP 2012...
  • Page 155 Decal - “DANGER” Arrow (tail rotor) ....... 2 11-20 Placard Illustrations NOTE Placards (decals) and markings are not to scale. 1. Decal A654-18 2. Decal A654-25 3. Decal A654-94 4. Decal F654-21 5. Decal F654-21 Page 11.3 SEP 2012 R66 Maintenance Manual Chapter 11 Placards and Markings...
  • Page 156 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 157 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. Decal F654-3 Page 11.5 SEP 2012 R66 Maintenance Manual Chapter 11 Placards and Markings...
  • Page 158 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 159 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. Cover C710-1 46. Decal F654-25 Page 11.7 SEP 2012 R66 Maintenance Manual Chapter 11 Placards and Markings...
  • Page 160 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 161 Leak Detection ......12.19 Page 12.i SEP 2012 R66 Maintenance Manual Chapter 12 Servicing...
  • Page 162 Intentionally Blank Page 12.ii Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

  • Page 163: Main Rotor Gearbox

    Check gearbox oil level and adjust level as required. 4. Install filler-plug and special torque plug per Section 20-33. 5. Run-up helicopter approximately five minutes at 60-70% RPM per R66 Pilot’s Operating Handbook (POH) Section 4. 6. Check gearbox oil level, and adjust level per steps 2 thru 6 as required.
  • Page 164 FIGURE 12-1 MAIN ROTOR GEARBOX SERVICING Page 12.2 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

  • Page 165: 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.
  • Page 166 FIGURE 12-2 DRAINING MAIN ROTOR GEARBOX OIL Page 12.4 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...
  • Page 167 Parts A and B. Install housing and special torque per Section 20-33. Install chip detector. 3. Turn BATTERY switch ON. Verify MR CHIP warning segment illuminates when test button is depressed. Turn BATTERY switch OFF. Page 12.5 SEP 2012 R66 Maintenance Manual Chapter 12 Servicing...
  • Page 168 FIGURE 12-3 TAIL ROTOR GEARBOX Page 12.6 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

  • Page 169: Tail Rotor Gearbox

    1. Install chip detector per Section 12-22. 2. Refer to Figure 12-3. Remove filler-vent plug and fill gearbox with A257-22 lubricant to center of sight glass. 3. Install plug and special torque per Section 20-33. Page 12.7 SEP 2012 R66 Maintenance Manual Chapter 12 Servicing...

  • Page 170: Chip Detector And Sight Gage

    SAE20W50 straight mineral engine oil to gearbox. Install plug and special torque per Section 20-33. 4. Run-up helicopter approximately five minutes at 60-70% RPM per R66 Pilot's Operating Handbook (POH) Section 4. 5. Drain tail rotor gearbox oil (mineral oil) per Section 12-21.

  • Page 171: Hydraulic System

    3. Lubricate packing inside new filter with A257-15 fluid and install filter in reservoir. Install cap and special torque per Section 20-33. 4. Service hydraulic reservoir per Section 12-31. Page 12.9 SEP 2012 R66 Maintenance Manual Chapter 12 Servicing...
  • Page 172 FIGURE 12-4 HYDRAULIC SYSTEM Page 12.10 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

  • Page 173: Drain And Flush

    11. Remove cap and filter and visually inspect element for contaminants. If debris is found, repeat drain and flush procedure. If filter is clean, install filter & cap and special torque cap per Section 20-33. 12. Service hydraulic reservoir per Section 12-31. Page 12.11 SEP 2012 R66 Maintenance Manual Chapter 12 Servicing...

  • Page 174: Bleeding

    8. Disconnect test pump pressure line from pressure line T-fitting and install cap. Special torque caps per Section 20-33 and torque stripe per Figure 5-1. 9. Service hydraulic reservoir per Section 12-31. Page 12.12 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

  • Page 175: Fuel System

    2. Ground helicopter and ground fuel vehicle. Open fueling cowl door and connect fuel vehicle ground cable to helicopter at location identified by decal. 3. Verify proper grade of aviation fuel. See R66 Pilot's Operating Handbook (POH) Section 2 for approved fuel grades and instructions for use of anti-ice additive.
  • Page 176 FIGURE 12-5 MAIN ROTOR BLADE PITCH BEARING HOUSING Page 12.14 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

  • Page 177: Main Rotor Blades

    (bottom) bleed fitting, and install other bolt. 8. Torque B289-2 bolts per Section 20-33 and torque stripe per Figure 5-1. 9. Repeat steps for opposite blade. Page 12.15 SEP 2012 R66 Maintenance Manual Chapter 12 Servicing...

  • Page 178: 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. Remove engine cowling per Section 53-21.

  • Page 179: Engine) Compressor Rinse And Wash

    § 20-32. Close access door. 7. Refer to RR300 Series OMM for returning engine to service. To perform ground run: a. Refer to R66 Pilot's Operating Handbook (POH) Section 4 for run-up and shutdown procedures. 8. Install engine cowling per § 53-21.

  • Page 180: 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 181: 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.
  • Page 182 Intentionally Blank Page 12.20 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...
  • Page 183 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 184 Intentionally Blank Page 18.ii Chapter 18 Track and Balance MAY 2015...

  • Page 185: Track And Balance

    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 18.1 25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance...
  • Page 186 FIGURE 18-1 MAIN ROTOR BALANCING EQUIPMENT INSTALLATION Page 18.2 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 187: Preparing Helicopter For Main Rotor Track And Balance

    If strobe light is used, battery power may be accessed thru auxiliary power socket located on circuit breaker panel. Neatly stow and secure excess cables. 7. Verify security of installation. Page 18.3 25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance...
  • Page 188 C298-3 Weights C117-11 0.025 inch BALANCE TRACK (KNOTS) CLOCK HOVER Adjustment: CLOCK HOVER Adjustment: CLOCK HOVER Adjustment: CLOCK HOVER FIGURE 18-2 MAIN ROTOR TRACK AND BALANCE CHART Page 18.4 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 189: 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.
  • Page 190 Fine Adjustment Fitting Only • One full turn changes blade track 0.25 inch. • One full turn changes blade angle 0.40º. FIGURE 18-3 MAIN ROTOR PITCH LINK Page 18.6 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 191: 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 192 FIGURE 18-4 MAIN ROTOR BLADE TRIM TAB Page 18.8 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...
  • Page 193 1. Using felt tip marker, ink mark main rotor blade trim tab per Figure 18-4. Mark line with a measuring point in the center of the tab (approximate). Page 18.9 25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance...

  • Page 194: Balance Adjustment

    1. Balance rotor assembly chordwise by adjusting chord arm weights or washers per Figure 18-2. Total weight not to exceed four A255-2 weights (or equivalent). (1) A255-1 Weight (8) AN970-4 Washers (1) A255-2 Weight (3) A255-1 Weights Page 18.10 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 195: Troubleshooting

    5. Radical Changes to MR teeter hinge bearings worn. Replace bearings per Section 62-21. Cyclic Trim Brinelled spindle bearing Send blade(s) to RHC for spindle bearing (rough movement). replacement. Page 18.11 25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance...

  • Page 196: Autorotational Rpm Adjustment

    Take at least 3 RPM readings at 500 to 1000 foot altitude intervals. Record the following in-flight data: Hourmeter Pressure Test % Test # Reading Altitude Page 18.12 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...
  • Page 197 6. Repeat previous steps as required until the RPM correction is ± 1% of chart RPM. Page 18.13 25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance...
  • Page 198 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 25 OCT 2010...
  • Page 199 Intentionally Blank Page 18.15 25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance...
  • Page 200 FIGURE 18-6 TAIL ROTOR BALANCING EQUIPMENT INSTALLATION Page 18.16 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 201: Tail Rotor Dynamic Balance

    20 feet to left of tail rotor. Place sandbags (or similar) on cable to prevent cable movement. 6. Connect cable(s) to balancer. Verify security of installation. Page 18.17 SEP 2012 R66 Maintenance Manual Chapter 18 Track and Balance...
  • Page 202 (7) NAS1149F0663P Washers (1) A141-14 Washer NAS1149F0432P Washers (2) NAS1149F0632P (1) NAS1149F0663P Washer BALANCE CLOCK ADJUSTMENT: CLOCK ADJUSTMENT: CLOCK ADJUSTMENT: CLOCK ADJUSTMENT: FIGURE 18-7 TAIL ROTOR DYNAMIC BALANCE CHART Page 18.18 Chapter 18 Track and Balance R66 Maintenance Manual SEP 2012...

  • Page 203: Ground Checks

    RHC before further flight. 18-23 Balance Adjustment Refer to R66 Illustrated Parts Catalog (IPC) Figure 64-1. Refer to Section 64-11 for tail rotor assembly static balance procedure. A. Pitch Horn-to-Pitch Link Fastener (Chordwise Balance Adjustment) Chordwise dynamic balance is achieved by varying NAS6604 bolt length and nut-side washers on tail rotor blade pitch horn-to-pitch link fastener.
  • Page 204 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 205: Main Rotor Flight Control Rigging

    7. Refer to Figure 18-9. Adjust swashplate A205-5 lower fork assembly (non-rotating) to 3.70 ± 0.03 inch, and upper fork assembly (rotating) to 3.85 ± 0.03 inch. Page 18.21 25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance...
  • Page 206 FIGURE 18-10 MAIN ROTOR BLADE RIGGING Page 18.22 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 207: Main Rotor Blade Angle Rigging

    4. Position MT525-1 fixture on top of the blade’s tape at 49.5 inches, and tight against the leading edge. Position protractor on top of fixture, point protractor face toward the blade with hanging tape, and take blade angle reading. Page 18.23 SEP 2012 R66 Maintenance Manual Chapter 18 Track and Balance...

  • Page 208: Collective Travel

    0.030 inch per Figure 18-8. Adjust all swashplate push- pull tubes exactly the same amount as required (one full turn = 0.48°). Lengthening all push-pull tubes increases blade angles. Page 18.24 Chapter 18 Track and Balance R66 Maintenance Manual SEP 2012...
  • Page 209 0.030 inch per Figure 18-8. Adjust all swashplate push- pull tubes exactly the same amount as required (one full turn = 0.48°). Lengthening all push-pull tubes increases blade angles. Page 18.25 SEP 2012 R66 Maintenance Manual Chapter 18 Track and Balance...

  • Page 210: Cyclic Travel

    (one full turn = 0.6°). NOTE Remeasure cyclic left blade angles after making adjustment for cyclic right blade angles. Page 18.26 Chapter 18 Track and Balance R66 Maintenance Manual SEP 2012...
  • Page 211 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 212: Tail Rotor Flight Control Rigging

    18-50 Tail Rotor Flight Control Rigging Refer to R66 Illustrated Parts Catalog (IPC) Figures 67-29 thru 67-39. 18-51 Pedals 1. Refer to Figure 67-4. 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.

  • Page 213: Tail Rotor Blade Rigging

    18-60 Tail Rotor Blade Rigging 1. Level helicopter laterally, and longitudinally via main rotor hub, per § 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 214 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, pedal total travel is either too great or too small. Use the following procedure to check and adjust pedal travel: a.
  • Page 215 Intentionally Blank Page 18.31 MAY 2015 Chapter 18 Track and Balance...
  • Page 216 FIGURE 18-12 FAN SHAFT AND ENGINE SHAFT BALANCING Page 18.32 Chapter 18 Track and Balance MAY 2015...

  • Page 217: Fan Shaft And Engine Shaft Balancing

    18-70 Fan Shaft and Engine Shaft Balancing 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 218: Ground Checks

    18-72 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 Fan shaft and engine shaft balancing equipment must be removed for flight.
  • Page 219 CHAPTER 20 STANDARD PRACTICES Section Title Page 20-10 Cleaning ..........20.1 20-20 Lubrication .
  • Page 220 Intentionally Blank Page 20.ii Chapter 20 Standard Practices MAY 2015...

  • Page 221: Standard Practices

    4. Rinse all surfaces thoroughly. 5. If desired, polish painted surfaces with a good quality automotive wax using soft cleaning cloths, or a chamois cloth, free of abrasive debris. Page 20.1 25 OCT 2010 R66 Maintenance Manual Chapter 20 Standard Practices...

  • Page 222: Lubrication

    All R66 bearings are sealed or self-lubricating and do not require periodic lubrication. The engine oil tank, the main and tail rotor gearboxes, and the hydraulic reservoir require servicing when indicated by sight gage level. Additionally, change engine, gearbox, or hydraulic oil and clean respective sight gage when oil becomes so dirty its level cannot be determined.

  • Page 223: Torque Requirements

    A secondary locking mechanism is required on all critical fasteners. B330 stamped nuts (palnuts) serve as secondary locking mechanisms in most areas on the helicopter, and are torqued per Section 20-32. The R66 Illustrated Parts Catalog (IPC) lists secondary locking mechanisms for specific fasteners.
  • Page 224 Solve for Y = = 158.82 L – A 10 – 1.5 Set torque wrench to 159 in.-lb to torque fastener to 135 in.-lb. FIGURE 20-2 SHORTENING TORQUE WRENCH EFFECTIVE LENGTH Page 20.4 Chapter 20 Standard Practices R66 Maintenance Manual 25 OCT 2010...

  • Page 225: Torque Requirements

    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 226: 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 227: Special Torques

    20-33 Special Torques Special torques supersede standard torques listed in § 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) D799-9 switch assembly (1) G783 condenser, dessicant cap (1) G784-1 evaporator assembly, inlet B-nut to TXV AIR CONDITIONING (1) G794-1 hose assembly, B-nuts (OPTIONAL...
  • Page 228 20-33 Special Torques (continued) TORQUE AREA* FASTENER* (IN.-LB)* (16) MS51861-37C screws, securing door hinge assemblies (2) 94830A030 nuts, securing G904-1 gas spring ball studs at baggage compartment door DOOR HINGES AND (2) 94830A030 nuts, securing D575-1 gas spring ball studs at aft GAS SPRINGS doors (2) C394-2 ball stud, at forward doors, to frame...

  • Page 229: Special Torques

    20-33 Special Torques (continued) TORQUE AREA* FASTENER* (IN.-LB)* (2) AN815-3D union 95-105 (2) AN815-4D union 135-150 (1) AN820-4 cap, on reservoir AN804D4 T-fitting (1) AN820-6 cap, on reservoir AN834-6D T-fitting (2) D452-3 nuts, on aft and left hand servos (3) D452-4 nuts, on aft and left hand servos and on reservoir (1) D452-6 nut, on reservoir (2) B330-19 palnut, on aft and left hand servos...
  • Page 230 20-33 Special Torques (continued) TORQUE AREA* FASTENER* (IN.-LB)* (2) D770-1 valve assembly (2) D770-2 valve assembly POP-OUT FLOATS (2) D770-3 valve assembly (OPTIONAL EQUIPMENT; (2) D770-4 valve assembly CONT'D) (2) D770-5 valve assembly (2) D770-6 valve assembly (2) B289-2 bolts, per blade, self-sealing 60-80 MAIN ROTOR BLADE...
  • Page 231 20-33 Special Torques (continued) TORQUE AREA* FASTENER* (IN.-LB)* (2) nuts, securing harness wires to starter-generator large terminals, starter-generator supplied (1) nut, securing harness wire to ignition exciter box, engine-supplied (2) nuts, securing harness and (2) MS21919WCH4 clamps to engine accesory gearbox, engine-supplied (4) nuts, securing F577-1 bracket assembly, engine-supplied (2) tee bolts, securing F173-1 struts to engine, engine-supplied 35-40...

  • Page 232: Push-Pull Tube Rod End Adjustment

    20-34 Push-Pull Tube Rod End Adjustment NOTE Refer to § 18-13 to adjust C258-1 main rotor pitch links. The following procedure is standard for adjusting push-pull tube rod ends: 1. Loosen palnut and jam nut on rod end shank. 2. Remove hardware securing push-pull tube rod end to attachment point per respective instructions.
  • Page 233 Intentionally Blank Page 20.11B MAY 2015 Chapter 20 Standard Practices...

  • Page 234: 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 235: Fluorescent Penetrant Inspection

    A. Priming This specification outlines preparation and application requirements for primers. Primers provide corrosion protection and a final finish or a base for the final finish. Page 20.13 25 OCT 2010 R66 Maintenance Manual Chapter 20 Standard Practices...
  • Page 236 Dry parts at least (6) hours before using. 4. Inspection Inspect for complete coverage and excessive thickness. If primer is excessively thick, strip part using plastic media blast and re-prime. Page 20.14 Chapter 20 Standard Practices R66 Maintenance Manual 25 OCT 2010...
  • Page 237 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 238: 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 239: Fillers And Putty

    20-72 Solvents and Cleaners (continued) PRODUCT MANUFACTURER/SUPPLIER APPLICATION #112 Ammoniated or L&R Mfg. Co. Ultrasonic cleaning, avionics #222 Nonammoniated cleaning Kearny, NJ components only. & rinse solution * May be used on acrylic plastic. ** Mix 5%-20% by volume; titration not required. 20-73 Fillers and Putty PRODUCT MANUFACTURER/SUPPLIER...

  • Page 240: Powder Coat

    FIGURE 20-3 PAINT CODES (Refer to Chapter 62 for rotor blade paint dimensions. Exterior surface codes are D & F unless otherwise specified.) 20-76 Powder Coat (continued) PRODUCT MANUFACTURER 49/72460 Smooth Glossy Tiger Drylac USA Gray RAL 7043 Cucamonga, CA Polyester Topcoat Powder* 49/22460 Smooth Glossy “...

  • Page 241: Paints

    20-77 Paints Refer to Figures 20-3 & 20-4 for paint code application. Paint codes for specific helicopter serial numbers are listed on the inside cover of Airframe Maintenance Record (logbook). NOTE Use fisheye eliminator, accelerator, or other additives per manufacturer's recommendations. CODE MATERIAL MANUFACTURER...
  • Page 242 FIGURE 20-4 PAINT CODES Page 20.20 Chapter 20 Standard Practices MAY 2015...

  • Page 243: Lubricants

    20-77 Paints (continued) For limited touch-up of interior and landing gear only: CODE MATERIAL MANUFACTURER Krylon 1613 (shelf life 2 years) Krylon Div. of Borden Semi-Flat Black (aerosol can) Columbus, OH NYBC 14 (shelf life 2 years) New York Bronze Powder Co. Semi-Flat Black Scranton, PA Cardinal A-2000-05...

  • Page 244: Adhesives And Sealants

    20-78 Lubricants (continued) RHC PART MANUFACTURER’S LUBRICANT TYPE MANUFACTURER PART NO. A257-21 Petrolatum P-16 Panef Corp. lubricant Milwaukee, WI A257-22 Gear oil Mobil SHC 629 Exxon Mobil Corp. synthetic A257-23 Turbine oil Per AS5780 Class HPC 20-79 Adhesives and Sealants DESCRIPTION COLOR MFR.

  • Page 245: Adhesives And Sealants

    20-79 Adhesives and Sealants (continued) RHC PART DESCRIPTION COLOR MFR. PART NO. MANUFACTURER B270-12 Sealant - electrical potting (2-part) Any color MIL-PRF-8516 except red Type II, Class 2, Category A or B B270-13 Sealant - silicone rubber, Translu- 3145 Dow Corning Corp. noncorrosive (1-part) cent Midland, MI...

  • Page 246: Storage Limits

    20-80 Storage Limits 1. B283 hoses have a shelf storage life of 5 years. Hose service life is “on condition”, with a maximum of 12 years or 2000 hours, whichever occurs first. 2. Elastic cords have a shelf storage life of 5 years. Elastic cord service life is “on condition”, with a maximum of 12 years.

  • Page 247: 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: 110- __ Teletemp ......F110-__ Teletemp 22K1-048 Cap nut .

  • Page 248: Part Interchangeability

    20-91 Part Interchangeability (continued) PART: INTERCHANGEABLE WITH: AN960-416 Washer ..... . . NAS1149F0463P Washer AN960-516L Washer ..... . NAS1149F0532P Washer AN960-516 Washer .

  • Page 249: 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 250: Crimp Inspection

    20-94 Crimp Inspection Refer to Figure 20-5. FIGURE 20-5 CRIMP INSPECTION Page 20.28 Chapter 20 Standard Practices MAY 2015...
  • Page 251 Muffler Assembly ......21.12 21-33 Diffuser and Tee Assemblies ....21.12 Page 21.i SEP 2012 R66 Maintenance Manual Chapter 21 Environment Control...
  • Page 252 Intentionally Blank Page 21.ii Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...

  • Page 253: 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 254 FIGURE 21-1 NOSE VENT Page 21.2 Chapter 21 Environment Control MAY 2015...

  • Page 255: 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 256 FIGURE 21-2 AIR CONDITIONING SCHEMATIC Page 21.4 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...

  • Page 257: 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 § 53-23. 2. Remove hardware securing F196-1 tail rotor drive fan shaft to C947-3 plate assemblies, noting hardware removed.
  • Page 258 21-21 Compressor Assembly (continued) B. Removal 1. Remove tailcone cowling per § 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 § 12-81. Remove hardware securing refrigerant hose assemblies to G777-1 compressor assembly.

  • Page 259: 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 260: 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 261: Troubleshooting

    Extreme Humidity Some condensation is unavoidable in extreme humidity. Ensure all fresh air vents closed. Limit opening and closing cabin doors as much as practical to limit humidity entering cabin. Page 21.9 SEP 2012 R66 Maintenance Manual Chapter 21 Environment Control...
  • Page 262 FIGURE 21-3 CABIN HEAT Page 21.10 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...

  • Page 263: 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.

  • Page 264: 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 265 B-nuts per Section 20-33, and torque stripe per Figure 5-1. 3. Install G394-1 guards and hardware securing guards to aft seat assemblies. Verify security. Hinge seats back. 4. Install (belly cover) panel, and install hardware. Verify security. Page 21.13 SEP 2012 R66 Maintenance Manual Chapter 21 Environment Control...
  • Page 266 Intentionally Blank Page 21.14 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...
  • Page 267 CHAPTER 22 AUTOPILOT Section Title Page 22-00 Description ..........22.1 22-10 (Pitch) Servo Assembly .
  • Page 268 Intentionally Blank Page 22.ii Chapter 22 Autopilot MAY 2015...

  • Page 269: Description

    Additional modes, which may be used simultaneously when in SAS mode, are described in the Normal Procedures section of the R66 Pilot's Operating Handbook (POH) Autopilot Supplement. The control panel has a row of buttons to control autopilot modes and annunciators to indicate mode status.
  • Page 270 FIGURE 22-1 AUTOPILOT SYSTEM Page 22.2 Chapter 22 Autopilot MAY 2015...

  • Page 271: Pitch) Servo Assembly

    22-10 (Pitch) Servo Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 22-1. A. Removal 1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit breaker at panel. 2. Remove F680-3 and F445-1 collective covers and F444-1 cyclic cover. Hinge front right seat forward.

  • Page 272: Roll) Servo Assembly

    22-20 (Roll) Servo Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 22-3. A. Removal 1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit breaker at panel. 2. Remove F680-3 and F445-1 collective covers. Remove G702-7 cover assembly under pilot's seat.

  • Page 273: Flight Control Computer

    FIGURE 22-2 FLIGHT CONTROL COMPUTER 22-30 Flight Control Computer Refer to R66 Illustrated Parts Catalog (IPC) Figure 22-5. A. Removal 1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit breaker at panel. 2. Remove G702-7 cover assembly under pilot's seat.

  • Page 274: Control Panel

    § 22-61. 7. Install G702-7 cover assembly under pilot's seat. 22-40 Control Panel Refer to R66 Illustrated Parts Catalog (IPC) Figure 22-1. A. Removal 1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit breaker at panel.

  • Page 275: Cyclic Grip Assembly

    22-50 Cyclic Grip Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figures 22-1 & 67-11. A. Grip Angle Adjustment 1. Loosen cap screws securing pilot's cyclic grip, block assembly, and bar to grip weldment. 2. Rotate grip about weldment to desired angle. Special torque cap screws to 40 in.-lb.

  • Page 276: Maintenance

    22-60 Maintenance 22-61 Scheduled Maintenance and Inspections A. Ground Checks NOTE Perform the following ground checks after component replacement or other repairs have been performed on the autopilot system. Perform ground checks after an accident or incident that may have affected autopilot or related equipment prior to return to service.
  • Page 277 22-61 Scheduled Maintenance and Inspections (continued) A. Ground Checks (continued) 6. Refer to step 2. Engage SAS and verify SAS disengages when control panel's SAS button is depressed or when AP OFF button on the cyclic grip is depressed. Verify four beeps in headset and control panel SAS LED is white, other LEDs are dark: FOUR BEEPS SAS LED IS WHITE,...

  • Page 278: Special Maintenance And Inspections

    22-62 Special Maintenance and Inspections A. Troubleshooting CAUTION Adjustment to autopilot equipment is not permitted. PROBLEM ACTION Control panel lights do not illuminate or Verify computer is getting power. flash when master switch is turned on. Return computer to RHC. System does not enter standby-mode Verify attitude indicator bank angle less (lights flash continuously).
  • Page 279 22-62 Special Maintenance and Inspections (continued) A. Troubleshooting (continued) PROBLEM ACTION Cyclic vibrates erratically, SAS does not Manually override SAS, system should disengage. disengage automatically. Contact RHC Technical Support. Helicopter enters low frequency pitch Return computer to RHC. oscillation when ALT engaged; helicopter diverges nose-up or nose-down when ALT engaged.
  • Page 280 Intentionally Blank Page 22.12 Chapter 22 Autopilot MAY 2015...
  • Page 281 Fire Extinguisher ......25.11 Page 25.i SEP 2012 R66 Maintenance Manual Chapter 25 Furnishings...
  • Page 282 Intentionally Blank Page 25.ii Chapter 25 Furnishings R66 Maintenance Manual SEP 2012...

  • Page 283: Description

    (Velcro) securing fabric to seat pans. Seat assembly energy-absorption design is critical to occupant safety. To preserve crashworthiness, maintenance is limited to seat assembly replacement. Page 25.1 SEP 2012 R66 Maintenance Manual Chapter 25 Furnishings...
  • Page 284 FIGURE 25-1 SEAT HARNESSES, SEAT ASSEMBLIES, AND BACK RESTS Page 25.2 Chapter 25 Furnishings R66 Maintenance Manual SEP 2012...

  • Page 285: 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 286: Seat Harness Installation

    3. Install hardware securing F628-6 buckle assembly to inboard right side anchor, and lap belt fitting to outboard left side anchor. Standard torque bolts per Section 20-32. 4. Install F931-1 seat assembly. 5. Install tailcone cowling per Section 53-23. Page 25.4 Chapter 25 Furnishings R66 Maintenance Manual SEP 2012...

  • Page 287: Seat Assemblies And Back Rests

    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 288 FIGURE 25-2 CARPET AND INSULATION Page 25.6 Chapter 25 Furnishings R66 Maintenance Manual SEP 2012...

  • Page 289: Carpet

    4. Attach back rest cushion to seat back panel with rivets. 5. Install back rest assembly per Section 25-22. 25-30 Carpet Refer to R66 Illustrated Parts Catalog (IPC) Figure 25-15. A. Forward (Floor) Carpet Assembly Removal 1. Refer to Figure 25-2. Remove adjustable and/or removable pedals, as required.

  • Page 290: 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 291: 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.

  • Page 292: Emergency Equipment

    ELT transmitter, and remove dongle. 2. Connect programmed dongle to plastic connector and ELT transmitter, and install ty-raps as required. Cinch ty-raps until snug without over-tightening, and trim tips flush with heads. Page 25.10 Chapter 25 Furnishings R66 Maintenance Manual 25 OCT 2010...

  • Page 293: 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 294 Intentionally Blank Page 25.12 Chapter 25 Furnishings R66 Maintenance Manual 25 OCT 2010...
  • Page 295 Fuel Flow Check ........28.12 Page 28.i 25 OCT 2010 R66 Maintenance Manual Chapter 28 Fuel System...
  • Page 296 Intentionally Blank Page 28.ii Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...

  • Page 297: Description

    The drain is opened by extending the plastic tube clear of the aircraft and pushing up on the drain. FIGURE 28-1 FUEL SYSTEM OVERVIEW Page 28.1 25 OCT 2010 R66 Maintenance Manual Chapter 28 Fuel System...
  • Page 298 FIGURE 28-2 FUEL SYSTEM COMPONENTS Page 28.2 Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...

  • Page 299: 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.
  • Page 300 FIGURE 28-3 FUEL SYSTEM SCHEMATIC Page 28.4 Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...
  • Page 301 28-10 Bladder Assembly (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 302: 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 gold hollow ball on top (earlier ball was blue) floats and seals the vent in the event of inadvertent over-filling or in-flight sloshing.

  • Page 303: Fuel Quantity

    3. Fit A729-43 tube onto valve; wrap tube with two turns 0.032-inch diameter lockwire and safety tube to valve. 28-20 Fuel Quantity 28-21 Fuel Quantity Sender Refer to R66 Illustrated Parts Catalog (IPC) Figure 28-1. CAUTION Avoid contaminating bladder interior. Cover arms with sleeves and use lint-free gloves when working inside bladder.

  • Page 304: Low-Fuel Switch Assembly

    6. Install G271-1 guard and hardware securing guard to F250-1 cover assembly. Verify security. Close fueling cowl door. 28-22 Low-Fuel Switch Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 28-3. NOTE As required, remove fuel quantity sender per Section 28-21 and F250-1 cover assembly per Section 28-10, to facilitate A521-2 low-fuel switch assembly removal/installation.
  • Page 305 A521-2 (low-fuel) switch assembly float; verify LOW FUEL annunciator segment illuminates. 4. Remove rod, install fuel cap, and close cowl door. 5. Turn BATTERY switch OFF. Page 28.9 25 OCT 2010 R66 Maintenance Manual Chapter 28 Fuel System...
  • Page 306 FIGURE 28-4 FUEL VALVE Page 28.10 Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...

  • Page 307: 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 308: Fuel Flow Check

    (inside bladder at outlet), and repeat check until fuel flow is satisfactory. 9. Close mast fairing per Section 53-22. Install engine cowling per Section 53-21. Page 28.12 Chapter 28 Fuel System R66 Maintenance Manual 25 OCT 2010...
  • Page 309 CHAPTER 29 HYDRAULICS Section Title Page 29-00 Description ..........29.1 29-10 Hydraulic Pump .
  • Page 310 Intentionally Blank Page 29.ii Chapter 29 Hydraulics MAY 2015...
  • Page 311 CHAPTER 29 HYDRAULICS 29-00 Description 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 312 FIGURE 29-1 HYDRAULIC FLIGHT CONTROL SYSTEM Page 29.2 Chapter 29 Hydraulics MAY 2015...
  • Page 313 29-10 Hydraulic Pump (continued) A. Removal (continued) 2. c. Remove hardware securing G779-1 pulley to F908-1 yoke assembly and slide pulley aft (do not scuff paint on tail rotor drive fan shaft). 3. Remove hydraulic reservoir filler-vent and temporarily install an air-tight plug. 4.
  • Page 314 FIGURE 67-3A HYDRAULIC SYSTEM SCHEMATIC FIGURE 67-3B HYDRAULIC SERVO RIGGING Page 29.4 Chapter 29 Hydraulics MAY 2015...
  • Page 315 29-20 Hydraulic Reservoir A. Removal 1. Temporarily install a "DO NOT MOVE FLIGHT CONTROLS" sign in cockpit. 2. Remove tailcone cowling per § 53-23. 3. Place a one-liter container beneath suction tee fitting on reservoir. Remove cap from tee fitting and allow reservoir fluid to drain into container. Reinstall cap and special torque per §...
  • Page 316 29-30 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 § 53-22. Remove tailcone cowling per § 53-23. 2. Refer to Figures 29-1 and 29-3. Perform the following measurements on all D212 hydraulic servo assemblies to be removed: a.
  • Page 317 29-30 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 318 29-30 Hydraulic Servos (continued) B. Servo Installation (continued) 7. a. Forward Servo: Install hardware securing servo to F121-5 push-pull tube’s upper rod end. Standard torque fastener per § 20-32 and torque stripe per Figure 5-1. b. Aft Servo: Install hardware securing C343-8 tube’s lower rod end to F339-1 jackshaft weldment.
  • Page 319 32-64 System Maintenance ......32.22 Page 32.i SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear...
  • Page 320 Intentionally Blank Page 32.ii Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

  • Page 321: Landing Gear Assembly

    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 322 FIGURE 32-1 LANDING GEAR ATTACHMENT Page 32.2 Chapter 32 Landing Gear MAY 2015...
  • Page 323 10. Remove nut, washer, and spacer from aft, left mounting bolt (bolt stays in place). Carefully lower forward cross tube below belly, then move assembly aft, off of aft left bolt. B. Installation Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1. WARNING Landing gear mounting bolts are critical fasteners. See § 20-30 for torque requirements.
  • Page 324 FIGURE 32-2 CROSS TUBE REMOVAL Page 32.4 Chapter 32 Landing Gear MAY 2015...

  • Page 325: Cross Tubes

    Do not tap on jack tabs. C. Installation Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1. NOTE When installing A936-3 (ground) wire assembly, verify finish is removed from surface under wire terminal.
  • Page 326 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 327: 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 328: 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.

  • Page 329: 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 330 FIGURE 32-4 POP-OUT FLOATS INSTALLATION Page 32.10 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

  • Page 331: Pop-Out Floats Installation

    A modified aux stabilizer improves controllability at high airspeeds with floats inflated. 32-61 Cylinder Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-7. NOTE Cylinders are discharged during float inflation check every 3 years.
  • Page 332 FIGURE 32-5 POP-OUT FLOATS CYLINDER ASSEMBLY Page 32.12 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
  • Page 333 Finish bleeding cylinder with bleed fitting fully in. When noise ceases, verify cylinder pressure gage indicates zero. Remove bleed fitting. 4. Install cap in valve assembly and special torque cap to 40 in.-lb. 5. Evaluate cylinder life and hydrostatic test status. Page 32.13 SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear...
  • Page 334 Attach fill hose to adapter. 5. Fill with 99.98% minimum purity (industrial grade) helium per chart below: Ambient Temperature (ºC) Pressure (psig) 4268 4437 4606 4776 4945 5114 5283 Page 32.14 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
  • Page 335 Orient hose as required to maintain miminum 0.25 inch clearance to cylinder and adjacent vertical panel. Special torque B-nut per Section 20-33 and torque stripe per Figure 5-1. 10. Rig inflation lever and replace shear-rivet per Section 32-62. Page 32.15 SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear...
  • Page 336 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 337: 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 338 FIGURE 32-7 POP-OUT FLOATS FLOAT INSTALLATION Page 32.18 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

  • Page 339: 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 340 FIGURE 32-8 POP-OUT FLOATS FLOAT PACKING Page 32.20 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
  • Page 341 10. Refer to Figure 32-8 Detail F. Tuck-in cord ends and secure hook and loop fasteners. Secure hook and loop fasteners at end caps. 11. Verify all fasteners are properly secured. Verify floats are rolled tight, with no lumps or loose areas. Page 32.21 SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear...

  • Page 342: System Maintenance

    8. Connect D674-1 line assembly to cylinder valve and torque per Section 20-33. 9. Pack float per Section 32-63 Part C. NOTE Annually apply A257-7 dry-film lubricant (see Section 20-78) to float cover snap mating surfaces. Page 32.22 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
  • Page 343 Chamber Chambers 1.30 1.00 0.60 10-14 1.60 1.30 0.90 15-19 1.90 1.60 1.20 20-24 2.20 1.90 1.50 25-29 2.50 2.20 1.80 30-34 2.80 2.50 2.10 35-39 3.10 2.80 2.40 Page 32.23 SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear...
  • Page 344 11. Remove cylinder assembly and depressurize cylinder per Section 32-61 Parts A & B. Return cylinder to RHC for overhaul-exchange. 12. Install serviceable cylinder assembly per Section 32-61 Part D. Page 32.24 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

  • Page 345: Description

    CHAPTER 33 LIGHTS Section Title Page 33-00 Description ..........33.1 33-10 Exterior Lights .
  • Page 346 Intentionally Blank Page 33.ii Chapter 33 Lights MAY 2015...

  • Page 347: Description

    CHAPTER 33 LIGHTS 33-00 Description A red anti-collision light is installed on the tailcone and is controlled by the strobe switch. Position lights are installed on each side of the cabin and in the tail and are controlled by the nav lights switch.

  • Page 348: Navigation Lights

    33-11 Strobe Light(s) (continued) B. Installation 1. Turn battery switch off. Pull out STROBE circuit breaker (5 amp, or 7½ amp if forward strobe is installed) at panel. 2. Install hardware securing A708 strobe light assembly's ground wire to tailcone mount, if ground is installed at mount.

  • Page 349: Landing Lights

    33-13 Landing Lights A. Removal 1. Turn battery switch off. Pull out LAND LT circuit breaker (7½ amp) at panel. 2. Remove screws securing C526-1 retainer to chin and remove retainer. 3. Disconnect landing light cable from lamp and remove lamp. B.
  • Page 350 Intentionally Blank Page 33.4 Chapter 33 Lights MAY 2015...
  • Page 351 Windshield Assembly ....... . . 52.11 Page 52.i 25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows...
  • Page 352 Intentionally Blank Page 52.ii Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...

  • Page 353: Description

    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 354 FIGURE 52-1 DOOR ASSEMBLY Page 52.2 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...
  • Page 355 Remove door and bevel edges using 60- grit sandpaper. 10. Prepare surfaces with solvent and touch-up door using approved materials per Section 20-70. Install new door per Section 52-10. Page 52.3 25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows...

  • Page 356: Door Lock Replacement

    5. Bond hole plug in place using B270-9 adhesive. 52-12 Weather Seal (Door Assembly) Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figures 52-1 and 52-7. 1. Remove damaged weather seal using plastic wedge or putty knife. Remove hardened adhesive using approved solvent per Section 20-70, or 60-grit sandpaper, as required.
  • Page 357 Intentionally Blank Page 52.5 25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows...
  • Page 358 FIGURE 52-2 GAS SPRINGS AND DOOR VENTS Page 52.6 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...

  • Page 359: 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.

  • Page 360: Door Vent Hinge Replacement

    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.
  • Page 361 Intentionally Blank Page 52.9 25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows...
  • Page 362 FIGURE 52-3 WINDSHIELD INSPECTION Page 52.10 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...

  • Page 363: 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 364 7. Hold windshield in place and check for fit. Re-trim as necessary. 8. After windshield is fitted, carefully sand or scrape edges smooth. 9. Install windshield per Section 52-30 Part B. Page 52.12 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...
  • Page 365 Tail Skid ........53.22 Page 53.i 25 OCT 2010 R66 Maintenance Manual Chapter 53 Fuselage...
  • Page 366 Intentionally Blank Page 53.ii Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

  • Page 367: 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 368 FIGURE 53-1 FAIRING, COWLINGS, AND PANELS Page 53.2 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

  • Page 369: 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. Loosen clamp securing starter-generator hose to air inlet. Slide hose off of inlet.

  • Page 370: Tailcone Cowling

    4. Perform pitot line leak test per Section 95-10. 53-23 Tailcone Cowling Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-5. A. Removal and Installation 1. Refer to Figure 53-1. Thru left access door, disconnect ELT antenna lead from antenna mounted to F706-1 tailcone cowling assembly, as required.

  • Page 371: Frame Assemblies

    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.
  • Page 372 FIGURE 53-2 LOWER FRAMES Page 53.6 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...
  • Page 373 Install hardware securing battery cable harness clamp, external power block, and stiffener clamp to F046-2 lower frame. Standard torque hardware per Section 20-32, and torque stripe per Figure 5-1. 7. Install engine per Section 71-10. Page 53.7 25 OCT 2010 R66 Maintenance Manual Chapter 53 Fuselage...
  • Page 374 FIGURE 53-3 HYDRAULIC SERVO SUPPORT FRAME Page 53.8 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

  • Page 375: 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.

  • Page 376: 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.
  • Page 377 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 § 20-32, and torque stripe per Figure 5-1. Seal around frame weldment edges at firewalls, bulkhead, and support using B270-1 sealant.
  • Page 378 FIGURE 53-4 TAILCONE ASSEMBLY Page 53.12 Chapter 53 Fuselage MAY 2015...

  • Page 379: Tailcone Assembly

    53-40 Tailcone Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-15. A. Removal 1. Remove tailcone cowling assembly per § 53-23. Remove engine cowling assembly per § 53-21. 2. Refer to Figure 53-4. Cut and discard ty-raps as required and disconnect tailcone wiring at connectors.
  • Page 380 FIGURE 53-5 TAILCONE INSPECTION AND REPAIR Page 53.14 Chapter 53 Fuselage MAY 2015...

  • Page 381: Inspection And Repair

    One dent permitted per tailcone station (inch). d. 4.000 inch minimum distance between dented tailcone stations. 2. If damage exceeds limits, replace tailcone or return to RHC for repair. Page 53.15 25 OCT 2010 R66 Maintenance Manual Chapter 53 Fuselage...
  • Page 382 FIGURE 53-6 EMPENNAGE - TAILCONE CASTING Page 53.16 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

  • Page 383: 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 384 #30 drill. Deburr holes and install rivets.) Torque stripe fastener per Figure 5-1. 4. Install aux stabilizer assembly per Section 53-52, and tail skid per Section 53-54, as required. 5. Install tail rotor guard assembly per Section 53-53. Page 53.18 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

  • Page 385: Horizontal Stabilizer

    53-52 Horizontal Stabilizer Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-29. A. Upper Horizontal Stabilizer Assembly Removal 1. Remove upper vertical stabilizer assembly and lower vertical stabilizer assembly per § 53-51. 2. Remove hardware securing forward clamp to upper horizontal stabilizer assembly.
  • Page 386 FIGURE 53-7 EMPENNAGE - TAIL ROTOR GUARD Page 53.20 Chapter 53 Fuselage MAY 2015...

  • Page 387: Tail Rotor Guard

    53-53 Tail Rotor Guard Refer to R66 Illustrated Parts Catalog (IPC) Figures 53-25 and 53-29. 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 388: Tail Skid

    53-54 Tail Skid Refer to R66 Illustrated Parts Catalog (IPC) Figures 53-25. 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 389 Painting ........62.28 Page 62.i 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
  • Page 390 Intentionally Blank Page 62.ii Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

  • Page 391: Main Rotor Blades

    “O”, on the other blade, nut, bolt, pitch link and rotor head location. 2. Disconnect pitch links from each main rotor blade. FIGURE 62-1 SUPPORTING MAIN ROTOR BLADES DURING BLADE REMOVAL OR INSTALLATION Page 62.1 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
  • Page 392 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 393 6. Repeat step 4 to remove remaining blade. B. Installation Refer to R66 Illustrated Parts Catalog (IPC) Figures 62-1, 62-3, and 62-5. 1. Verify correct teeter hinge friction per Section 62-32, step 4. 2. If previously installed information is unavailable, perform coning hinge journal and shim calculation per Section 62-31.
  • Page 394 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 395 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 396: Blade Boots

    62-11 Blade Boots Refer to R66 Illustrated Parts Catalog (IPC) Figure 62-1. A. Removal 1. Remove main rotor blades per § 62-10. 2. Place a suitable drain container below main rotor blade spindle assembly. Remove two B289-2 bolts and drain fluid.

  • Page 397: 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 398 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 399: Bearing Replacement

    62-21 Bearing Replacement Refer to R66 Illustrated Parts Catalog (IPC) Figure 62-3. 1. Remove main rotor hub per Section 62-20. 2. If main rotor hub is to be reinstalled with same blades, measure and record shim thicknesses and locations in hub.
  • Page 400 Section 62-31. 10. If reinstalling hub on same helicopter, install hardware as removed in step 2, subject to preceding step. Reinstall hub per Section 62-20. Page 62.10 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

  • Page 401: Main Rotor Assembly

    Use as many different size shims as possible to facilitate head shifting during balancing. Deviate from initial shim stack as required to meet teeter hinge friction requirements (8-12 pounds is ideal). Page 62.11 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
  • Page 402 Teeter hinge; Coning hinge trailing-edge side C117-11 0.025 Teeter hinge; Coning hinge trailing-edge side TABLE 62-1 HINGE FRICTION JOURNALS AND SHIMS (Journal length and shim thickness values given in inches) Page 62.12 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...
  • Page 403 Intentionally Blank Page 62.13 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
  • Page 404 FIGURE 62-7 MEASURING TEETER HINGE FRICTION Page 62.14 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

  • Page 405: Adjusting Hinge Friction

    4 thru 6. Drill new bolt and nut per Section 62-33; coat new cotter pin with epoxy primer and install wet. 6. If required, install main rotor blades per Section 62-10. Page 62.15 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
  • Page 406 FIGURE 62-8 MEASURING THRUST WASHER AND HUB BEARING GAP Page 62.16 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

  • Page 407: Drilling Nuts And Bolts

    If none of the predrilled holes in nut are accessible for use as a guide after stretching bolt, loosen nut and reposition bolt and nut. Restretch bolt per Section 20-32. Page 62.17 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
  • Page 408 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 409: Inspection Of Main Rotor Blades

    62-40 Inspection of Main Rotor Blades NOTE Main rotor blades are 14 CFR § 27.602 critical parts. Notify Technical Support when voids exceeding the limits specified in the instructions below are found, providing blade serial number, helicopter serial number, time in service for the rotor blade, and location and size of the voids that exceed the limits.
  • Page 410 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 MAY 2015...

  • Page 411: Dents

    1. Verify damage does not result in a crack or tear and dent depth does not exceed 0.020 inch. 2. Dents do not require blending or filling. Dents may be blended with a 0.10 blend radius. Page 62.21 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
  • Page 412 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 413: Spar Damage

    Blend out nicks & notches in trim tab trailing edges, 1.0 inch minimum each side of nick or notch (with a minimum 12 inch blend radius) keeping edge parallel with blade trailing edge. Page 62.23 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
  • Page 414 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 415: Voids And Debonds

    2.50 inch chordwise or 20.00 inch spanwise maximum continuous void between RS 121.00 & RS 196.50. Total area of any void may not exceed 15.0 square inches. Page 62.25 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
  • Page 416 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 417: Repair Of Main Rotor Blades

    Do not remove metal. 4. Hand-sand surrounding painted surface until 25% primer remains. Keep bare metal to a minimum. Page 62.27 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...

  • Page 418: Painting

    Allow Imron paint to cure at least 72 hours before flying in erosive conditions (such as drizzle, rain, or dust). 5. Remove masking materials. FIGURE 62-21 MAIN ROTOR BLADE PAINT SCHEME Page 62.28 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...
  • Page 419 Rotor RPM ........63.12 Page 63.i SEP 2012 R66 Maintenance Manual Chapter 63 Main Rotor Drive System...
  • Page 420 Intentionally Blank Page 63.ii Chapter 63 Main Rotor Drive System R66 Maintenance Manual SEP 2012...

  • Page 421: Description

    The main gearbox also drives the flight control hydraulic pump. 63-10 Engine Shaft Weldment Refer to R66 Illustrated Parts Catalog (IPC) Figures 63-1 and 63-3. A. Removal 1. Remove tailcone cowling assembly per Section 53-23. Remove engine cowling assembly per Section 53-21.

  • Page 422: Engine Driveline) Forward Flex Plate Shimming

    Rotate F642-1 (engine) shaft weldment 180º, and repeat step a: (3 o’clock position) inch (9 o’clock position) + inch Total = inch ÷ inch (Average gap between flange arms) Total Page 63.2 Chapter 63 Main Rotor Drive System R66 Maintenance Manual SEP 2012...
  • Page 423 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 424 FIGURE 63-1 ENGINE DRIVELINE Page 63.4 Chapter 63 Main Rotor Drive System MAY 2015...

  • Page 425: Clutch Assembly

    63-12 Clutch Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 63-1. A. Removal 1. Remove engine shaft weldment per § 63-10. 2. Refer to Figure 63-1. Mark F906 yoke assembly and A947-2 plate assembly, to facilitate installation. Remove plate assembly, noting hardware removed.

  • Page 426: Main Rotor Gearbox Assembly

    F121-7 push-pull tube assembly to F339-1 jackshaft weldment, and F121-5 push-pull tube assemblies to D212-5 servo assemblies. 6. Refer to R66 IPC Figure 63-9. Detach cable assembly from (rotor brake assembly) B112-3 spring. 7. Refer to R66 IPC Figure 63-9. Using back-up wrench, disconnect D205-19 and D205- 20 hose assemblies from F006-1 main rotor gearbox and D500-3 oil pump.
  • Page 427 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.

  • Page 428: 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 § 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 429 63-21 Yoke and Seal Replacement (continued) C. (Engine-Driven) F910-1 Yoke Assembly and Seal Removal 1. Remove tailcone cowling assembly per § 53-23. Remove engine cowling assembly per § 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 430 FIGURE 63-2 ROTOR BRAKE Page 63.10 Chapter 63 Main Rotor Drive System MAY 2015...

  • Page 431: 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 § 63-21, Part C steps 1 thru 3. 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 432: 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 § 63-30.
  • Page 433 Inspection ....... . 64.13 Page 64.i 25 OCT 2010 R66 Maintenance Manual Chapter 64 Tail Rotor...
  • Page 434 Intentionally Blank Page 64.ii Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...

  • Page 435: Tail Rotor Assembly

    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 436 FIGURE 64-1 TAIL ROTOR INSTALLATION Page 64.2 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...
  • Page 437 8. Install C119-2 bumper, A141-14 washer, and nut. Standard torque nut per Section 20- 32 and torque stripe per Figure 5-1. 9. Dynamically balance tail rotor per Section 18-20. Page 64.3 25 OCT 2010 R66 Maintenance Manual Chapter 64 Tail Rotor...
  • Page 438 FIGURE 64-2 CHORDWISE STATIC BALANCE Page 64.4 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...

  • Page 439: 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 440 FIGURE 64-3 SPANWISE STATIC BALANCE Page 64.6 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...
  • Page 441 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 442: 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 443: Tail Rotor Blade Inspection And Repair

    WARNING Any damaged tail rotor blade that cannot be repaired within the limits of this section must be removed from service immediately and marked "scrap." Page 64.9 25 OCT 2010 R66 Maintenance Manual Chapter 64 Tail Rotor...
  • Page 444 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 445: Erosion

    Blend out nicks and notches in blade trailing edge for 1.0 inch minimum each side of nick or notch. 64-36 Painting Refer to Figure 64-4. See Section 62-52 (main rotor) for painting procedures. Page 64.11 25 OCT 2010 R66 Maintenance Manual Chapter 64 Tail Rotor...
  • Page 446 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 447: 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 448 Intentionally Blank Page 64.14 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...
  • Page 449 Output Shaft Seal Replacement ....65.11 65-42 Input Shaft Seal Replacement ....65.12 Page 65.i SEP 2012 R66 Maintenance Manual Chapter 65 Tail Rotor Drive System...
  • Page 450 Intentionally Blank Page 65.ii Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012...

  • Page 451: Tail Rotor Drive Fan Shaft

    The cooling fan is mounted to the intermediate shaft. The tail gearbox contains a single 90º splash-lubricated spiral-bevel gearset which increases speed to tail rotor RPM. 65-10 Tail Rotor Drive Fan Shaft Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-1. CAUTION Do not damage F196-1 fan shaft aft yoke or G174-1 fanwheel assembly mid plate during fan shaft removal or installation.
  • Page 452 FIGURE 65-1 TAIL ROTOR DRIVELINE Page 65.2 Chapter 65 Tail Rotor Drive System MAY 2015...

  • Page 453: 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 F172-3 (bearing) housing to F193-2 hanger. 3. Refer to Figure 65-3.
  • Page 454 FIGURE 65-2 RUNOUT Page 65.4 Chapter 65 Tail Rotor Drive System MAY 2015...

  • Page 455: Runout

    65-21 Runout 1. Remove A231 (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 456 FIGURE 65-4 DAMPER ASSEMBLY Page 65.6 Chapter 65 Tail Rotor Drive System MAY 2015...

  • Page 457: 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 § 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.

  • Page 458: 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 tail rotor drive shaft assembly forward yoke.
  • Page 459 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 460: 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 § 12-21 prior to gearbox removal, or keep gearbox vertical after removal to avoid oil escape thru filler-vent plug.

  • Page 461: 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.

  • Page 462: 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 463 CHAPTER 67 FLIGHT CONTROLS Section Title Page 67-00 Description ..........67.1 67-10 Cyclic Controls .
  • Page 464 Intentionally Blank Page 67.ii Chapter 67 Flight Controls MAY 2015...

  • Page 465: Description

    Teflon® liners. R66 flight controls operate conventionally. The cyclic stick appears different, but the grip moves the same as in other helicopters due to the free hinge at the center pivot. The cyclic grip is free to move vertically allowing the pilot to rest his forearm on his knee if he chooses.
  • Page 466 FIGURE 67-1 MAIN ROTOR FLIGHT CONTROLS Page 67.2 Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...
  • Page 467 6. Connect C319-5 torque tube assembly to C177-5 pivot and standard torque bolts per Section 20-32. 7. Connect forward end of C121-1 push-pull tube to D320-8 cyclic stick and standard torque bolts per Section 20-32. Page 67.3 25 OCT 2010 R66 Maintenance Manual Chapter 67 Flight Controls...

  • Page 468: Cyclic Grip Assembly

    Ensure safety wire or lacing attached to internal wiring protrudes from top and bottom of stick assembly. Also, ensure pivot bearings remain with stick assembly. NOTE Do not damage bearings while removing. Page 67.4 Chapter 67 Flight Controls R66 Maintenance Manual 25 OCT 2010...
  • Page 469 8. Turn BATTERY switch on and verify correct function of all switches on grip assembly and cyclic stick. 9. Install forward belly panel. Page 67.5 25 OCT 2010 R66 Maintenance Manual Chapter 67 Flight Controls...

  • Page 470: Cyclic Friction Assembly

    7. Pivot pilot's seat bottom to the open position. Remove bolt securing collective stick assembly to pilot's seat structure. 8. Carefully move collective stick assembly aft and remove from helicopter. Page 67.6 Chapter 67 Flight Controls R66 Maintenance Manual 25 OCT 2010...
  • Page 471 10. Refer to Figure 6-8. Install and secure F445-1 forward tunnel cover, F680-3 pilot's collective cover, F680-1 co-pilot's collective cover, F463-1 mid-tunnel cover, and F461-1 collective cross tube cover. 11. Adjust collective friction per Section 67-22. Page 67.7 25 OCT 2010 R66 Maintenance Manual Chapter 67 Flight Controls...

  • Page 472: Collective Friction

    Install A115-1 spacer, A214-3 washer and nut. Standard torque bolt per Section 20-32, install palnut, and torque stripe per Figure 5-1. 4. Verify no binding and/no interference with control system exists throughout flight control travel. Page 67.8 Chapter 67 Flight Controls R66 Maintenance Manual 25 OCT 2010...

  • Page 473: Swashplate

    7. Install previously removed chord arm weights and standard torque bolt per Section 20- 32. Install palnut, special torque per Section 20-33, and torque stripe per Figure 5-1. Page 67.9 25 OCT 2010 R66 Maintenance Manual Chapter 67 Flight Controls...
  • Page 474 16. Verify no interference with control movement throughout flight control travel and swashplate movement corresponds with cyclic and collective movement. 17. Track and balance main rotor per Section 18-10. Page 67.10 Chapter 67 Flight Controls R66 Maintenance Manual 25 OCT 2010...

  • Page 475: 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 476 FIGURE 67-3 TAIL ROTOR FLIGHT CONTROLS Page 67.12 Chapter 67 Flight Controls MAY 2015...

  • Page 477: Tail Rotor Controls

    67-50 Tail Rotor Controls Refer to R66 Illustrated Parts Catalog (IPC) Figures 67-29 thru 67-39. 67-51 Pedals A. Removal 1. Peel back carpet as required to access pedal covers per § 25-30 Part D. 2. Remove screws securing pedal covers to cabin floor and remove covers.

  • Page 478: Pitch Control

    67-51 Pedals (continued) B. Installation (continued) 3. Connect both pedal assemblies to the push-pull tubes and torque the NAS6604-9 bolts to per § 20-32 and install palnuts. 4. Move the pedals through the full range of travel to ensure there is no interference or binding.

  • Page 479: Bellcranks

    67-60 Bellcranks Refer to R66 Illustrated Parts Catalog (IPC) Figure 67-37. 67-61 C317-5 or C317-9 Bellcrank A. Removal 1. Remove screws securing upper console to side panels; pivot console up and aft. 2. Remove installed avionics located in center console per Chapter 97.

  • Page 480: C317-7 Bellcrank

    67-62 C317-7 Bellcrank A. Removal 1. Refer to § 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 481: F316-1 Bellcrank

    67-63 F316-1 Bellcrank A. Removal 1. Remove main rotor gearbox per § 63-20. 2. Disconnect F121-11 push-pull tube from F316-1 bellcrank assembly. 3. Disconnect F121-13 push-pull tube from F316-1 bellcrank assembly. 4. Remove nuts and spacer from outboard end of C494-2 shaft. Move shaft slightly inboard and remove washer from between frame tab and bellcrank.

  • Page 482: A331-4 Bellcrank

    67-64 A331-4 Bellcrank A. Removal 1. Disconnect F121-13 and C121-17 push-pull tubes from A331-4 bellcrank. 2. Disconnect NAS6604-35 attach bolt and remove bellcrank and two A105-3 journals. B. Installation 1. Install two A105-3 journals in C331-4 bellcrank's pivot bearings. Install an NAS1149F0432P washer under head of an NAS6604-35 bolt followed by an A141-3 washer and insert bolt thru journals.
  • Page 483 Generator Control Unit (GCU) ....71.16 71-43 Engine Monitoring Unit (EMU) ....71.17 Page 71.i SEP 2012 R66 Maintenance Manual Chapter 71 Powerplant...
  • Page 484 Intentionally Blank Page 71.ii Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...

  • Page 485: Description

    A temperature switch is mounted to the firewall above the engine to detect a fire in the engine compartment. Abnormally high temperature causes the ENGINE FIRE annunciator to illuminate. Page 71.1 SEP 2012 R66 Maintenance Manual Chapter 71 Powerplant...
  • Page 486 FIGURE 71-1 ENGINE - RIGHT SIDE Page 71.2 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...

  • Page 487: 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 488 FIGURE 71-2 ENGINE - LEFT SIDE Page 71.4 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...
  • Page 489 14. Perform ground check per Section 5-41. Remove the air from the engine fuel system, then perform fuel flow check, per RR300 OMM. Perform run-up per Section 5-42, and PTG rigging check per Section 76-22. 15. Install engine cowling assembly per Section 53-21. Page 71.5 SEP 2012 R66 Maintenance Manual Chapter 71 Powerplant...

  • Page 490: 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 491: Preparing Engine For Helicopter Installation

    (top of) engine gearbox, and remove mount and cover. Remove residual B270-1 sealant. 71-12 Preparing Engine for Helicopter Installation Refer to R66 Illustrated Parts Catalog (IPC) Chapter 71. NOTE Remove protective caps and plugs progressively during procedure to prevent foreign object contamination.
  • Page 492 Install and tighten hardware; verify security. g. Connect harness plugs to anti-ice valve assembly solenoid, anti-ice pressure switch assembly, and N speed pick-up assembly. Verify security. Page 71.8 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...
  • Page 493 Figure 5-1. Position A785-36 hose and B277-8 clamp over fitting and tighten clamp. Verify security. Position (2) MS21919WCH14 clamps over hose and install and tighten hardware securing clamps to engine vertical fireshield and F577-5 bracket. Verify security. Page 71.9 SEP 2012 R66 Maintenance Manual Chapter 71 Powerplant...
  • Page 494 FIGURE 71-3 INDUCTION Page 71.10 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...

  • Page 495: Induction

    G057-1 cage assembly. Contact Rolls-Royce Customer Support if foreign objects enter inlet. 71-21 Air Filter Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 71-9. NOTE Replace F771-1 air filter assembly “on-condition”. A. Removal 1.

  • Page 496: 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 497 Intentionally Blank Page 71.13 MAY 2015 Chapter 71 Powerplant...
  • Page 498 FIGURE 71-4 EXHAUST Page 71.14 Chapter 71 Powerplant MAY 2015...

  • Page 499: Exhaust Weldment

    71-30 Exhaust Weldment Refer to R66 Illustrated Parts Catalog (IPC) Figure 71-13. A. Removal 1. Remove engine cowling assembly per § 53-21. 2. Refer to Figure 71-4. Remove hardware securing F173-1 struts to F169-1 exhaust weldment and engine, and remove struts.

  • Page 500: Accessories

    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 § 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.

  • Page 501: Engine Monitoring Unit (Emu)

    3. Turn BATTERY switch ON. After 10 seconds press annunciator panel test button; verify EMU amber warning segment illuminates, and is solid, indicating normal EMU operation. (See R66 Pilot's Operating Handbook Section 7 for complete description.) Turn BATTERY switch OFF.
  • Page 502 Intentionally Blank Page 71.18 Chapter 71 Powerplant R66 Maintenance Manual SEP 2012...

  • Page 503: Engine Anti-Ice

    Engine Anti-Ice ........75.1 Page 75.i 25 OCT 2010 R66 Maintenance Manual Chapter 75 Engine Air Systems...
  • Page 504 Intentionally Blank Page 75.ii Chapter 75 Engine Air Systems R66 Maintenance Manual 25 OCT 2010...
  • Page 505 An anti-ice switch located on the cyclic box cover is selected by the pilot in certain conditions (see R66 Pilot's Operating Handbook). The engine anti-ice system includes an air valve, a solenoid valve, and a pressure switch. The air valve is mounted on top of the compressor scroll;...
  • Page 506 Intentionally Blank Page 75.2 Chapter 75 Engine Air Systems R66 Maintenance Manual 25 OCT 2010...
  • Page 507 PTG Rigging Check ......76.7 Page 76.i 25 OCT 2010 R66 Maintenance Manual Chapter 76 Engine Controls...
  • Page 508 Intentionally Blank Page 76.ii Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...

  • Page 509: Description

    76-10 Fuel Control Unit (FCU) Refer to R66 Illustrated Parts Catalog (IPC) Figure 76-1. A. Removal 1. Pull fuel valve OFF. Remove engine cowling assembly per Section 53-21.
  • Page 510 FIGURE 76-1 FUEL CONTROL UNIT Page 76.2 Chapter 76 Engine Controls R66 Maintenance Manual SEP 2012...

  • Page 511: Fcu Throttle Control Rigging

    AN742-4 clamps to F577-1 bracket assembly. 4. Refer to detail in Figure 76-3. Verify sufficient inner wire beyond aft edge of fitting, and special torque fitting nut per Section 20-33. Page 76.3 25 OCT 2010 R66 Maintenance Manual Chapter 76 Engine Controls...
  • Page 512 FIGURE 76-2 POWER TURBINE GOVERNOR Page 76.4 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...

  • Page 513: Power Turbine Governor (Ptg)

    5-1. Trim control wire 0.10-0.30 inch beyond aft edge of fitting. 7. Install engine cowling assembly per Section 53-21. 76-20 Power Turbine Governor (PTG) Refer to R66 Illustrated Parts Catalog (IPC) Figures 76-5 and 76-7. A. Removal 1. Remove engine cowling assembly per Section 53-21.
  • Page 514 FIGURE 76-3 PTG (BEEP) ACTUATOR ASSEMBLY Page 76.6 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...

  • Page 515: Ptg Rigging Check

    3. Adjust PTG control rigging as required per Section 76-21; repeat previous steps until PTG is rigged for proper mechanical range. 4. Run-up helicopter per R66 Pilot's Operating Handbook, Section 4. Verify “beep” range is 97 to 103% rotor RPM with collective full down and twist grip open.
  • Page 516 Intentionally Blank Page 76.8 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...
  • Page 517 79-40 Engine Oil Line Assemblies and Fittings ....79.8 Page 79.i SEP 2012 R66 Maintenance Manual Chapter 79 Engine Oil System...
  • Page 518 Intentionally Blank Page 79.ii Chapter 79 Engine Oil System R66 Maintenance Manual SEP 2012...

  • Page 519: Description

    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.
  • Page 520 FIGURE 79-2 SCROLL AND FANWHEEL ASSEMBLIES Page 79.2 Chapter 79 Engine Oil System R66 Maintenance Manual SEP 2012...

  • Page 521: 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.
  • Page 522 FIGURE 79-3 ENGINE OIL SYSTEM Page 79.4 Chapter 79 Engine Oil System R66 Maintenance Manual SEP 2012...

  • Page 523: Oil Tank Assembly

    7. Measure fanwheel-to-inlet gaps per Part A. Repeat procedure as required for minimum 0.10 inch gap at forward and aft inlets. 79-20 Oil Tank Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figure 79-5. A. Removal 1. Drain engine oil per Section 12-60.

  • Page 524: Oil Temperature Sender

    9. Service engine oil per Section 12-60. 10. Install tailcone cowling assembly per Section 53-23. 79-21 Oil Temperature Sender Refer to R66 Illustrated Parts Catalog (IPC) Figure 79-5. A. Removal 1. Drain engine oil per Section 12-60. 2. Remove tailcone cowling assembly per Section 53-23.

  • Page 525: Sight Gage

    1. Refer to Figure 79-3. Remove tape from G689-1 oil tank assembly gage opening and verify tank interior is free of contaminants. 2. Lubricate new o-ring using approved turbine engine oil per R66 Pilot’s Operating Handbook (POH) Section 8. Install o-ring on B563-2 sight gage, and install gage in tank.

  • Page 526: 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 527 CHAPTER 95 INSTRUMENT SYSTEM Section Title Page 95-00 Description ..........95.1 95-10 Pitot-Static System .
  • Page 528 Intentionally Blank Page 95.ii Chapter 95 Instrument System MAY 2015...

  • Page 529: Description

    Pitot and static sources should be inspected frequently for bugs or other obstructions, or if condensation appears inside connected instruments. Page 95.1 25 OCT 2010 R66 Maintenance Manual Chapter 95 Instrument System...
  • Page 530 FIGURE 95-1 PITOT - STATIC SYSTEM Page 95.2 Chapter 95 Instrument System R66 Maintenance Manual 25 OCT 2010...

  • Page 531: Pitot-Static System

    4. Change of less than 100 feet indication in one minute is acceptable. SLOWLY remove suction from static port. Locate and repair leak(s) if altimeter indication changes 100 or more feet in one minute. Retest after any repairs. 5. Remove test equipment. Page 95.3 25 OCT 2010 R66 Maintenance Manual Chapter 95 Instrument System...
  • Page 532 FIGURE 95-2 PITOT - STATIC SYSTEM Page 95.4 Chapter 95 Instrument System R66 Maintenance Manual 25 OCT 2010...

  • Page 533: 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 534 “beep” actuator to minimum (RPM) setting. Close throttle and turn battery switch off. 4. a. Start engine and run-up helicopter per R66 Pilot’s Operating Handbook (POH) Section 4, establish stable idle, and record dual tachometer’s % N2 indication.

  • Page 535: Altimeter

    95-24 Altimeter The sensitive altimeter provides altitude information relative to mean sea level when the barometric pressure correction scale is properly set. Check altimeter calibration by setting correction scale to the current altimeter setting and checking the altimeter reading against location elevation;...

  • Page 536: Additional Standard Indicating Equipment

    95-50 Instrument Markings See R66 Pilot's Operating Handbook (POH) Section 2 for instrument markings. 95-60 Troubleshooting Guide Vertical Speed Indicator...
  • Page 537 Intentionally Blank Page 95.9 MAY 2015 Chapter 95 Instrument System...
  • Page 538 FIGURE 95-3 GARMIN G500H UPPER CONSOLE WITH GARMIN GDU 620 DISPLAY FIGURE 95-4 GARMIN G500H UPPER CONSOLE PITOT-STATIC SCHEMATIC Page 95.10 Chapter 95 Instrument System MAY 2015...

  • Page 539: Garmin G500H Electronic Flight Instrument System (Efis)

    95-70 Garmin G500H Electronic Flight Instrument System (EFIS) 95-71 Garmin GDU 620 Display Installation NOTE Refer to Garmin G500H Instructions for Continued Airworthiness. A. Description The Garmin G500H is an integrated avionics display system that provides flight instrument, moving-map navigation, and additional situational awareness information to the flight crew via the Garmin GDU 620 Display.
  • Page 540 95-71 Garmin GDU 620 Display Installation (continued) E. Scheduled Maintenance and Inspections Refer to Garmin G500H Instructions for Continued Airworthiness. F. Special Maintenance and Inspections 1. Turn battery & avionics switches off. Open circuit breaker panel and upper console. 2. Inspect condition of and verify no obvious damage to Garmin GDU 620, copper bus bars, circuit breaker, and wiring.
  • Page 541 Intentionally Blank Page 95.13 MAY 2015 Chapter 95 Instrument System...
  • Page 542 FIGURE 95-5 EIGHT-INSTRUMENT CONSOLE WITH ASPEN PFD FIGURE 95-6 ASPEN PFD PITOT-STATIC SCHEMATIC Page 95.14 Chapter 95 Instrument System MAY 2015...

  • Page 543: Aspen Efd Electronic Flight Instrument System (Efis)

    95-81 Aspen EFD500H & EFD1000H Display(s) Installation A. Description R66 options include a single screen Aspen PFD or a dual screen Aspen PFD and MFD. The Aspen PFD (Primary Flight Display) is an LCD unit with displays for attitude, altitude, airspeed, heading, and optional NAV (HSI/CDI). The Aspen PFD is a situational awareness aid, to be used in conjunction with required VFR instruments (altimeter, airspeed indicator, and magnetic compass).
  • Page 544 FIGURE 95-7 EIGHT-INSTRUMENT CONSOLE WITH ASPEN PFD AND MFD FIGURE 95-8 ASPEN PFD AND MFD PITOT-STATIC SCHEMATIC Page 95.16 Chapter 95 Instrument System MAY 2015...
  • Page 545 6. Perform appropriate functional checks per Aspen EFD1000H PFD / EFD500H MFD Pilot's Guide. Turn battery and avionics switches off. 7. Perform pitot-static leak check. E. Antenna Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6. NOTE Do not use magnetized tools. Removal 1.
  • Page 546 95-81 Aspen EFD500H & EFD1000H Display(s) Installation (continued) F. Scheduled Maintenance and Inspections The internal battery must be tested for proper operation every 12 months. calibration is necessary. Other maintenance is on condition. Contact Aspen Avionics www.aspenavionics.com for instructions for continued airworthiness. G.
  • Page 547 Electrical Load Analysis ....... 96.9 Page 96.i SEP 2012 R66 Maintenance Manual Chapter 96 Electrical System...
  • Page 548 Intentionally Blank Page 96.ii Chapter 96 Electrical System R66 Maintenance Manual SEP 2012...

  • Page 549: Description

    If the GEN annunciator illuminates in flight, turn off nonessential electrical equipment and switch generator to reset (momentary position) and then ON. If the GEN annunciator remains illuminated, land as soon as practical. Page 96.1 SEP 2012 R66 Maintenance Manual Chapter 96 Electrical System...

  • Page 550: Battery

    FIGURE 96-1 AFT BATTERY INSTALLATIONS Page 96.2 Chapter 96 Electrical System R66 Maintenance Manual SEP 2012...
  • Page 551 If the battery being installed is the same part number as the battery that was removed: Verify security, proper orientation, and installation of G131-1 shim and G131-2 plate. Carefully install battery. Page 96.3 SEP 2012 R66 Maintenance Manual Chapter 96 Electrical System...
  • Page 552 Verify security. Close and latch baggage compartment door. 7. Aft battery: a. If B237-7 battery was removed and B237-8 battery was just installed, revise Weight and Balance Record in R66 Pilot's Operating Handbook (POH) Section 6 to incorporate the following data: Subtract: Weight Long.

  • Page 553: External Power

    NOTE Start button is active when battery switch is ON, even if igniter switch is OFF. Rotor brake may be left engaged after shutdown to disable start button. Page 96.5 SEP 2012 R66 Maintenance Manual Chapter 96 Electrical System...

  • Page 554: Lighting System

    The EMU (Engine Monitoring Unit) segment indicates the EMU status with either steady, flashing, or no illumination. The EMU segment will illuminate only when the test button is depressed. Page 96.6 Chapter 96 Electrical System R66 Maintenance Manual SEP 2012...

  • Page 555: Low Rotor Rpm Warning Unit Adjustment

    Auxiliary audio may be plugged in to a jack on the forward face of the circuit breaker panel. In normal mode, auxiliary audio is automatically muted during radio communication. Page 96.7 SEP 2012 R66 Maintenance Manual Chapter 96 Electrical System...

  • Page 556: Emergency Locator Transmitter (Elt)

    The red indicator will extinguish when unit is reset. For more detailed instructions on ELT operation, maintenance, and required tests, refer to manufacturer's instructions supplied with the unit. Page 96.8 Chapter 96 Electrical System R66 Maintenance Manual SEP 2012...

  • Page 557: Electrical Load Analysis

    96-100 Electrical Load Analysis To calculate the total electrical load for a specific helicopter, identify all items of equipment installed on the helicopter from the table below and sum the corresponding continuous and intermittent loads. Maximum continuous generator load is 160 amps. Intermittent loads are provided for reference. Alternately, the electrical load may be measured directly at the battery output terminal with the generator switched off and all other equipment turned on.
  • Page 558 96-100 Electrical Load Analysis (continued) CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT EQUIPMENT AMPS EACH AMPS EACH TOTAL TOTAL MAIN BUS (continued) AVIONICS RELAY 0.060 0.060 LOW FUEL RELAY 0.010 0.010 WARNING LIGHT TEST CB 0.020 0.020 TACH PWR TEST RELAY 0.060 0.060 BOSE HEADSET 0.025 0.500...
  • Page 559 96-100 Electrical Load Analysis (continued) CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT EQUIPMENT AMPS EACH AMPS EACH TOTAL TOTAL AVIONICS BUS (continued) HSI (PICT NAV SYSTEM) 1.730 1.730 1.730 1.730 ATTITUDE HORIZON 0.270 0.700 0.270 0.700 TURN COORDINATOR 0.350 0.350 0.350 0.350 RADAR ALTIMETER 0.727 0.727 0.727...
  • Page 560 96-100 Electrical Load Analysis (continued) CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT EQUIPMENT AMPS EACH AMPS EACH TOTAL TOTAL OTHER EQUIPMENT TACH RELAY 0.060 0.060 0.060 0.060 CLOCK (DIGITAL) 0.003 0.003 0.003 0.003 CLOCK (STD) 0.002 0.002 0.002 0.002 BATTERY RELAY 0.250 6.000 0.250 6.000 START/GEN RELAY...
  • Page 561 96-100 Electrical Load Analysis (continued) CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT EQUIPMENT AMPS EACH AMPS EACH TOTAL TOTAL POLICE EQUIPMENT (continued) INTERIOR LIGHT 0.220 0.220 0.220 0.220 AUX STROBE LIGHT 0.670 3.000 0.670 3.000 AMS42 AUDIO PANEL 0.250 0.250 0.250 0.250 POLICE EQUIP RELAY 0.280 0.280 0.280...
  • Page 562 Intentionally Blank Page 96.14 Chapter 96 Electrical System OCT 2014...
  • Page 563 97-40 Garmin GDL 69A XM Receiver Installation ......97.15 97-50 Avionics for R66 S/N 293, 520, 522 & Subsequent ....97.17 97-51 Cyclic Grip Assembly .
  • Page 564 Intentionally Blank Page 97.ii Chapter 97 Avionics MAY 2015...

  • Page 565: Lru Installation – Gdu 620 Display

    Refer to § 95-70 for Garmin GDU 620 Display maintenance procedures. 97-12 LRU Installation – GDC 74H Air Data Computer Refer to R66 Illustrated Parts Catalog (IPC) Figure 97-5. A. Description The GDC 74H Air Data Computer (ADC) compiles information from the pitot-static system and an Outside Air Temperature (OAT) sensor.
  • Page 566 97-12 LRU Installation – GDC 74H Air Data Computer (continued) D. Installation 1. Turn battery & avionics switches off and pull out EFIS (5 amp) circuit breaker at panel. 2. Place GDC 74H air data computer on F950-2 support assembly and install screws. Verify security.

  • Page 567: Lru Installation – Grs 77H Ahrs

    97-13 LRU Installation – GRS 77H AHRS Refer to R66 Illustrated Parts Catalog (IPC) Figure 97-9. A. Description The Garmin GRS 77H Attitude and Heading Reference System (AHRS) provides aircraft attitude information to the G500H EFIS system. The GRS 77H interfaces with both the GDC 74H Air Data Computer and the GMU 44 magnetometer.

  • Page 568: Lru Installation – Gmu 44 Magnetometer

    3. Secure circuit breaker panel. Perform ground checks per Part D steps 4 thru 6. 97-14 LRU Installation – GMU 44 Magnetometer Refer to R66 Illustrated Parts Catalog (IPC) Figure 97-13. A. Description The GMU 44 magnetometer senses the earth’s magnetic field. Data is sent to the GRS 77H AHRS for processing to determine aircraft magnetic heading.
  • Page 569 97-14 LRU Installation – GMU 44 Magnetometer D. Installation 1. Turn battery & avionics switches off and pull out EFIS (5 amp) circuit breaker at panel. 2. Position MS21919WDG12 clamp on GMU 44 magnetometer connector. 3. Install hardware securing magnetometer to F950-4 bracket. Verify security. 4.

  • Page 570: Gps Installation

    97-15 GPS Installation Refer to R66 Illustrated Parts Catalog (IPC) Figure 97-1. NOTE Refer to Garmin GTN 600/700 series Maintenance Manual and Instructions for Continued Airworthiness. A. Description The G500H system requires connection to at least one WAAS-enabled GPS receiver.
  • Page 571 97-15 GPS Installation (continued) E. Antenna Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6. NOTE Antenna installation depends on number of COM installations and additional equipment installed. Removal 1. Turn battery & avionics switches off and pull out GPS 1 (5 amp) and GPS 2 (5 amp) circuit breakers as required at panel.
  • Page 572 97-15 GPS Installation (continued) F. Scheduled Maintenance and Inspections Every 100 hour or annual inspection, determine software and database versions and update per Garmin GTN 600/700 series Pilot's Guide as required. NOTE Garmin requires database information be updated regularly to ensure information is current.

  • Page 573: Radar Altimeter Installation

    97-20 Radar Altimeter Installation Refer to R66 Illustrated Parts Catalog (IPC) Figures 97-15, 95-17, and 95-19. A. Description The FreeFlight RA-4500 radar altimeter has ARINC 429 output for communication with electronic displays such as the G500H EFIS system. Radar altitude data can be displayed on the PFD portion of the Garmin GDU 620 display.
  • Page 574 97-20 Radar Altimeter Installation (continued) D. Installation RAD-40 Indicator 1. Turn battery & avionics switches off and pull out RADAR ALT (2 amp) circuit breaker at panel. 2. Connect console harness to RAD-40 Indicator. 3. a. For Above-Console Installation: Install hardware securing B560 faceplate to indicator and install hardware securing B560 enclosure assembly to instrument console.
  • Page 575 97-20 Radar Altimeter Installation (continued) E. Antenna Refer to § 6-80 for antenna locations & R66 Illustrated Parts Catalog (IPC) Chapter 6. Removal 1. Turn battery & avionics switches off and pull out RADAR ALT (2 amp) circuit breaker at panel.

  • Page 576: Garmin Gtx 33 Transponder Installation

    97-30 Garmin GTX 33 Transponder Installation Refer to R66 Illustrated Parts Catalog (IPC) Figure 97-21. NOTE Refer to Garmin GTX 33 Transponder Maintenance Manual and Instructions for Continued Airworthiness. A. Description The Garmin GTX 33 is a remote-mounted transponder with extended-squitter ADS-B broadcast capability.
  • Page 577 97-30 Garmin GTX 33 Transponder Installation (continued) E. Antenna Refer to § 6-80 for antenna locations & R66 Illustrated Parts Catalog (IPC) Chapter 6. NOTE Antenna installation depends on optional equipment installed. Removal 1. Turn battery & avionics switches off and pull out XPDR (5 amp) circuit breaker at panel.
  • Page 578 97-30 Garmin GTX 33 Transponder Installation (continued) G. Special Maintenance and Inspections 1. Turn battery & avionics switches off. Open circuit breaker panel. 2. Remove GTX 33 transponder per Part C. Inspect condition of and verify no obvious damage to transponder, radio tray, copper bus bars, circuit breaker, and wiring. Verify no loose, chafed, or broken wires or terminals.

  • Page 579: Garmin Gdl 69A Xm Receiver Installation

    97-40 Garmin GDL 69A XM Receiver Installation Refer to R66 Illustrated Parts Catalog (IPC) Figure 97-23. NOTE Refer to Garmin GDL 69A XM Receiver Instructions for Continued Airworthiness. A. Description The GDL 69A XM Satellite Radio receives broadcast weather data and audio entertainment.
  • Page 580 97-40 Garmin GDL 69A XM Receiver Installation (continued) E. Antenna Refer to § 6-80 for antenna locations & R66 Illustrated Parts Catalog (IPC) Chapter 6. NOTE Antenna installation depends on optional equipment installed. Removal 1. Turn battery & avionics switches off and pull out XM (2 amp) circuit breaker at panel.

  • Page 581: Avionics For R66 S/N 293, 520, 522 & Subsequent

    97-50 Avionics for R66 S/N 293, 520, 522, & Subsequent 97-51 Cyclic Grip Assembly Refer to R66 Illustrated Parts Catalog (IPC) Figures 67-1 & 67-9. A. Description of New Features The angle of the pilot’s cyclic grip can be adjusted fore and aft relative to the cross tube.

  • Page 582: Garmin Gtr 225B Com Radio Installation

    5. Perform appropriate functional checks per Garmin GTR 225B Pilot's Guide. Turn battery & avionics switches off. E. Antenna Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6. NOTE Antenna installation depends on number of COM installations and additional equipment installed.
  • Page 583 97-53 Garmin GTR 225B COM Radio Installation (continued) E. Antenna (continued) Removal 1. Turn battery switch off and pull out COM radio (5 amp) circuit breaker at panel. 2. Using plastic scraper, remove B270-1 sealant from around COM antenna at corners where it attaches to tailcone.

  • Page 584: Garmin Gdl 88 Ads-B In Receiver Installation

    GPS-based surveillance (rather than radar-based surveillance). ADS-B "In" equipment receives data from other aircraft or from air traffic control. The R66 may be equipped with ADS-B Out or with ADS-B Out and ADS-B In systems. Refer to § 97-15.
  • Page 585 97-54 Garmin GDL 88 ADS-B In Receiver Installation (continued) E. Antenna Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6. NOTE Antenna installation depends on number of COM installations and additional equipment installed. Removal 1.

  • Page 586: Garmin Gtx 330 Es Transponder Installation

    ADS-B In equipment is not required for R66 operation in the United States. The R66 may be equipped with ADS-B Out or with ADS-B Out and ADS-B In systems. Both ADS-B systems operate mostly automatically. ADS-B equipment is programmed with aircraft specific-data at installation.
  • Page 587 5. Perform appropriate functional checks per Garmin GTX 330 ES Pilot's Guide. Turn battery & avionics switches off. E. Antenna Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6. NOTE Antenna installation depends on optional equipment installed.

  • Page 588: Garmin Gtn 600/700-Series Gps Installation

    A. Description of New Features The new C831 GPS (Garmin GTN 600/700 series) includes similar navigation features available in the earlier R66 GPS (Garmin GNS 400/500 series), but the interface offers a combination of touch screen technology with traditional buttons and knobs.
  • Page 589 5. Perform appropriate functional checks per Garmin GTN 600/700 series Pilot's Guide. Turn battery & avionics switches off. E. Antenna Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6. NOTE Antenna installation depends on number COM installations and additional equipment installed.
  • Page 590 97-56 Garmin GTN 600/700-series GPS Installation (continued) E. Antenna (continued) Installation 1. Turn battery switch off and pull out GPS 1 (5 amp) and GPS 2 (5 amp) circuit breakers as required at panel. 2. Remove paint & primer from antenna mating surfaces to ensure electrical ground. 3.

  • Page 591: Electrical System Installation

    97-57 Electrical System Installation A. Description of New Features 1. Main Switch Panel The main switch panel is located at the top of the avionics stack. Rocker-style switches are utilized for ergonomic comfort for this new location, and for the new console geometry (earlier R66s utilized paddle-style switches).
  • Page 592 97-58 Intercom System Installation (continued) E. Antenna Refer to § 6-80 for marker beacon antenna location and R66 Illustrated Parts Catalog (IPC) Figure 6-13. Removal 1. Turn battery switch off and pull out ICS (5 amp) circuit breaker at panel.
  • Page 593 Page 98-1 R66 Electrical System (F024-2 Revision P) ......98.1 98-2 R66 Electrical System (F024-1 Revision J) ......98.2 98-3 Air Conditioning Installation .
  • Page 594 Intentionally Blank Page 98.ii Chapter 98 Wiring Diagrams MAY 2015...

  • Page 595: R66 Electrical System (F024-2 Revision P)

    FIGURE 98-1 R66 ELECTRICAL SYSTEM (F024-2 REVISION P) MAY 2015 Chapter 98 Wiring Diagrams Page 98.1...

  • Page 596: R66 Electrical System (F024-1 Revision J)

    FIGURE 98-2 R66 ELECTRICAL SYSTEM (F024-1 REVISION J) Page 98.2 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 597: Air Conditioning Installation

    Page 98.3 FIGURE 98-3 AIR CONDITIONING INSTALLATION SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
  • Page 598 Intentionally Blank Page 98.4 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...

  • Page 599: Adf Installation

    FIGURE 98-4 ADF INSTALLATION Page 98.5 SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
  • Page 600 Intentionally Blank Page 98.6 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...
  • Page 601 Page 98.7 FIGURE 98-5 STANDARD AUDIO SYSTEM SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
  • Page 602 Intentionally Blank Page 98.8 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...

  • Page 603: Dual Audio Control Installation

    FIGURE 98-6 DUAL AUDIO CONTROL INSTALLATION Page 98.9 SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
  • Page 604 Intentionally Blank Page 98.10 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...

  • Page 605: Pa/Siren Installation

    FIGURE 98-7 PA/SIREN INSTALLATION Page 98.11 SEP 2012 R66 Maintenance Manual Chapter 98 Wiring Diagrams...
  • Page 606 Intentionally Blank Page 98.12 Chapter 98 Wiring Diagrams R66 Maintenance Manual SEP 2012...

  • Page 607: Autopilot Installation

    FIGURE 98-8 AUTOPILOT INSTALLATION Page 98.13 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 608 Intentionally Blank Page 98.14 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 609: Garmin Gdu 620 Display Installation

    FIGURE 98-9 GARMIN GDU 620 DISPLAY INSTALLATION Page 98.15 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 610 Intentionally Blank Page 98.16 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 611: Garmin Gdc 74H Air Data Computer Installation

    FIGURE 98-10 GARMIN GDC 74H AIR DATA COMPUTER INSTALLATION Page 98.17 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 612 Intentionally Blank Page 98.18 Chapter 98 Wiring Diagrams MAY 2015...
  • Page 613 FIGURE 98-11 GARMIN GRS 77H AHRS INSTALLATION Page 98.19 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 614 Intentionally Blank Page 98.20 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 615: Garmin Gtn 600/700-Series Gps Installation (G500H Efis)

    FIGURE 98-12 GARMIN GTN 600/700-SERIES GPS INSTALLATION (G500H EFIS) Page 98.21 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 616 Intentionally Blank Page 98.22 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 617: Radar Altimeter Installation

    FIGURE 98-13 RADAR ALTIMETER INSTALLATION Page 98.23 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 618 Intentionally Blank Page 98.24 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 619: Garmin Gtx 33 Transponder Installation

    * One required on ships with Traffic Information System (TIS-A). FIGURE 98-14 GARMIN GTX 33 TRANSPONDER INSTALLATION Page 98.25 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 620 Intentionally Blank Page 98.26 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 621: Garmin Gdl 69A Xm Receiver Installation

    FIGURE 98-15 GARMIN GDL 69A XM RECEIVER INSTALLATION Page 98.27 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 622 Intentionally Blank Page 98.28 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 623: Aspen Efd500H Display Installation

    * Connect to GTX 330 Traffic (TIS-A) only if no other traffic system installed (i.e. GDL 88 [TIS-B]). FIGURE 98-16 ASPEN EFD500H DISPLAY INSTALLATION Page 98.29 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 624 Intentionally Blank Page 98.30 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 625: Aspen Efd500H & Efd1000H Displays Installation

    * Connect to GTX 330 Traffic (TIS-A) only if no other traffic system installed (i.e. GDL 88 [TIS-B]). FIGURE 98-17 ASPEN EFD500H & EFD1000H DISPLAYS INSTALLATION Page 98.31 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 626 Intentionally Blank Page 98.32 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 627: Garmin Gtr 225B Com Radio Installation

    FIGURE 98-18 GARMIN GTR 225B COM RADIO INSTALLATION Page 98.33 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 628 Intentionally Blank Page 98.34 Chapter 98 Wiring Diagrams MAY 2015...
  • Page 629 * GDL 88 Traffic wiring is in lieu of GTX 330 traffic wiring. FIGURE 98-19 GDL 88 ADS-B IN RECEIVER INSTALLATION Page 98.35 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 630 Intentionally Blank Page 98.36 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 631: Garmin Gtx 330 Es Transponder Installation

    * One required on ships with Traffic Information System (TIS-A). FIGURE 98-20 GARMIN GTX 330 ES TRANSPONDER INSTALLATION Page 98.37 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 632 Intentionally Blank Page 98.38 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 633: Garmin Gtn 600/700-Series Gps Installation (Pilot-Side Console)

    FIGURE 98-21 GARMIN GTN 600/700-SERIES GPS INSTALLATION (PILOT-SIDE CONSOLE) Page 98.39 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 634 Intentionally Blank Page 98.40 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 635: Intercom System Installation (Garmin Gma 350 Audio Control)

    FIGURE 98-22 INTERCOM SYSTEM INSTALLATION (GARMIN GMA 350 AUDIO CONTROL) Page 98.41 MAY 2015 Chapter 98 Wiring Diagrams...
  • Page 636 Intentionally Blank Page 98.42 Chapter 98 Wiring Diagrams MAY 2015...

  • Page 637: Special Tools

    Illustrations and Tasks ....... . 99.3 Page 99.i 25 OCT 2010 R66 Maintenance Manual Chapter 99 Special Tools...
  • Page 638 Intentionally Blank Page 99.ii Chapter 99 Special Tools R66 Maintenance Manual 25 OCT 2010...
  • Page 639 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...
  • Page 640 FIGURE 99-1 SPECIAL TOOLS Page 99.2 Chapter 99 Special Tools R66 Maintenance Manual 25 OCT 2010...

  • Page 641: Illustrations And Tasks

    Hydraulic Test Pump (U.S / Canada / Mexico - 110-volt) REFER TO SECTION 12-34 HYDRAULIC SYSTEM BLEEDING MT384-2 Hydraulic Test Pump (Outside North America - 220-volt) REFER TO SECTION 12-34 HYDRAULIC SYSTEM BLEEDING Page 99.3 SEP 2012 R66 Maintenance Manual Chapter 99 Special Tools...
  • Page 642 FIGURE 99-2 SPECIAL TOOLS Page 99.4 Chapter 99 Special Tools R66 Maintenance Manual SEP 2012...
  • Page 643 Washer - Tap Test Tool (or 1965 or later U.S. quarter dollar coin in good condition; not shown) REFER TO SECTIONS 62-40 MAIN ROTOR BLADE INSPECTION AND REPAIR AND 64-30 TAIL ROTOR BLADE INSPECTION AND REPAIR Page 99.5 SEP 2012 R66 Maintenance Manual Chapter 99 Special Tools...
  • Page 644 FIGURE 99-3 SPECIAL TOOLS Page 99.6 Chapter 99 Special Tools R66 Maintenance Manual SEP 2012...
  • Page 645 CHAPTER 100 REVISION LOG Section Title Page — Revision Log ..........100.1 Page 100.i MAY 2015 Chapter 100 Revision Log...
  • Page 646 Intentionally Blank Page 100.ii Chapter 100 Revision Log MAY 2015...
  • Page 647 REVISION LOG MAY 2015 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.
  • Page 648 REVISION LOG MAY 2015 Page Date Page Date Page Date 8.10 ..25 OCT 2010 12.4 ..SEP 2012 6.i ... MAY 2015 8.11 .
  • Page 649 REVISION LOG MAY 2015 Page Date Page Date Page Date 18.19 ..25 OCT 2010 20.18 ..MAY 2015 22.8 ..MAY 2015 18.20 .
  • Page 650 REVISION LOG MAY 2015 Page Date Page Date Page Date 29.1 ..MAY 2015 33.1 ..MAY 2015 53.17 ..25 OCT 2010 29.2 .
  • Page 651 REVISION LOG MAY 2015 Page Date Page Date Page Date 63.i ..SEP 2012 65.5 ..MAY 2015 71.7 ..SEP 2012 63.ii .
  • Page 652 REVISION LOG MAY 2015 Page Date Page Date Page Date 79.8 ..SEP 2012 96.14 ..OCT 2014 98.4 ..SEP 2012 98.5 .
  • Page 653 REVISION LOG MAY 2015 Page Date Page Date Page Date 98.42 ..MAY 2015 99.i ..25 OCT 2010 99.ii ..25 OCT 2010 99.1 .
  • Page 654 Intentionally Blank Page 100.8 Chapter 100 Revision Log MAY 2015...

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