Robinson R66 Maintenance Manual
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Robinson R66 Maintenance Manual

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Download this manual
AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
Robinson Helicopter Company
2901 Airport Drive
Torrance, California 90505-6115
United States of America
Monday through Friday, 7:30 a.m. to 4:30 p.m., Pacific Time.
Please visit
www.robinsonheli.com
Please visit
or order directly from RHC Customer Service via email, fax, or phone.
Please visit
APR 2019
R66 MAINTENANCE MANUAL
RTR 660 VOLUME I
Production Certificate Number 424WE
Type Certificate Number R00015LA
Lunch hour is 11:30 a.m. to 12:30 p.m.
for a complete list of holidays and company shutdowns.
CUSTOMER SUPPORT AND SPARES ORDERS
www.robinsonheli.com
Procure parts from any R66 Dealer or Service Center,
www.robinsonheli.com
Phone: (310) 539-0508
Fax:
Web:
OFFICE HOURS
HOLIDAYS
for a complete service directory.
PUBLICATIONS
to view our publications electronically.
Introduction
(310) 539-5198
www.robinsonheli.com
Page i

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Summary of Contents for Robinson R66

  • Page 1 CUSTOMER SUPPORT AND SPARES 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 to view our publications electronically.
  • Page 2 SUBSCRIPTION ORDER AND RENEWAL FORMS Subscription order and renewal forms are located at www.robinsonheli.com. WARRANTY INFORMATION Helicopter and parts warranty information is located at www.robinsonheli.com. Page ii Introduction APR 2019...

  • Page 3: Introduction

    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 Intentionally Blank Page iv Introduction JUL 2020...
  • Page 5 Please include or have available the information detailed in this form. Recommended changes may include but are not limited to general comments, corrections, omitted information, or clarification of instructions. Please send recommendations to: Email: techpubs@robinsonheli.com Robinson Helicopter Company Phone: (310) 539-0508 Attention: Technical Publications Fax: (310) 539-5198...
  • Page 6 Intentionally Blank Page vi Introduction APR 2017...

  • Page 7: Table Of Contents

    1-10 R66 Maintenance Manual Revisions ......1.1 1-20 R66 Maintenance Authorization ....... . . 1.2 1-30 Component Maintenance Authorization .
  • Page 8 Intentionally Blank Page 1.ii Chapter 1 General JUL 2020...

  • Page 9: R66 Maintenance Manual Revisions

    The R66 Instructions for Continued Airworthiness (ICA) includes the R66 Maintenance Manual (MM), R66 Illustrated Parts Catalog (IPC), R66 Service Bulletins (SB), R66 Service Letters (SL), RR300 Series Operation and Maintenance Manual (OMM), applicable Rolls-Royce technical publications, and applicable component manufacturer technical publications.

  • Page 10: R66 Maintenance Authorization

    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 11: Notations

    1-50 Notations The following notations will be found throughout the manual: NOTE A NOTE provides emphasis or supplementary explanation. CAUTION Equipment damage can result if a CAUTION is not followed. WARNING Personal injury or death can result if a WARNING is not followed. 1-55 Maintenance Manual and Illustrated Parts Catalog References Maintenance Manual and Illustrated Parts Catalog Section and Figure references are subject to relocation and renumeration.

  • Page 12: 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 Critical Part: manual is subject to special inspection requirements.
  • Page 13 Main Rotor Drive Shaft MRGB: Main Rotor Gearbox OEM: Original Equipment Manufacturer PTG: Power Turbine Governor R66 IPC: R66 Illustrated Parts Catalog R66 MM: R66 Maintenance Manual R66 POH: R66 Pilot’s Operating Handbook RBL: Right Butt Line Station locations Right-hand...

  • Page 14: Service Information

    All parts shipped to RHC must include a signed Component Return/Authorization (CRA) Form available online at www.robinsonheli.com. 1-73 Ordering and Shipping Procure parts from any R66 Dealer or Service Center, or order directly from assigned RHC Customer Service Representative via email, fax, or phone. 1-74 Warranty Claims Complete CRA Form (refer to §...

  • Page 15: 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 16 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 17 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 18 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 19 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 20 TABLE 1 SCHEDULED INSPECTIONS Consult latest revision of listed publications for specific applicability. Replace main gearbox oil filter per § 12-12. • • Perform 100-hour / annual inspection per § 5-45. • • Perform main rotor blade tip maintenance per § •...

  • Page 21: Helicopter Servicing

    1-90 Helicopter Servicing 1-91 Scheduled Maintenance and Inspections Required maintenance and inspection intervals are given in Table 1. Publications listed are subject to revision. Also consult the following for specific applicability, as some aircraft may require maintenance and inspections in addition to the requirements in Table 1: •...

  • Page 22: Additional Component Maintenance

    1-92 Additional Component Maintenance NOTE RHC-manufactured parts not listed in § 1-92 as requiring additional component maintenance, or replacement per § 4-30, are "on condition". A. 12 YEARS Remove the following components when they have accumulated 12 years time in service and less than 2000 hours time in service since new, since last overhaul, or since last 12-year maintenance, and perform action indicated: Part Number...
  • Page 23 1-92 Additional Component Maintenance (continued) A. 12 YEARS (continued) Part Number Description Action Disassemble and visually inspect exterior and C343-8 Tube interior. Verify no corrosion. D211-3 Hydraulic Reservoir Assembly Perform 12-year inspection per § 5-54, or replace with new or overhaul exchange. D212-5, -6 Hydraulic Servo Assembly Perform inspection per §...
  • Page 24 1-92 Additional Component Maintenance (continued) B. 2000 HOURS Remove the following components when they have accumulated 2000 hours time in service since new or since last overhaul, and perform action indicated: Part Number Description Action A120-5 Bellcrank – Aft Replace with new. A130-48 Spacer (at A462-4 fittings) Replace with new.
  • Page 25 1-92 Additional Component Maintenance (continued) B. 2000 HOURS (continued) Part Number Description Action C649-4 Oil Cooler (main rotor gearbox oil) Replace with new, or overhaul oil cooler. C947-3 Flex Plate Assembly (tail rotor driveline) Replace with new. D082-1 Tube Assembly (tail rotor guard mount) Magnetic particle inspect or replace with new.
  • Page 26 1-92 Additional Component Maintenance (continued) B. 2000 HOURS (continued) Part Number Description Action F771-7 Filter – G918-1 Box Assembly Replace with new. F792-1 Dual Tachometer Replace with new. G732-2 Cap (with C130-62 spacer) Replace with G732-3 cap. A880-908 or Union – Engine Oil Outlet (replaces CV26-77 Replace with new.
  • Page 27 Prepare engine for Rolls-Royce maintenance facility per § 71-11 as required. D. Airframe and Engine Accessory Maintenance Refer to accessory manufacturer’s instructions for continued airworthiness for accessory maintenance. Remove accessories per R66 Maintenance Manual or RR300 Operation and Maintenance Manual (OMM) as applicable. Page 1.17 Chapter 1 General...
  • Page 28 Intentionally Blank Page 1.18 Chapter 1 General JUL 2020...
  • Page 29 CHAPTER 4 AIRWORTHINESS LIMITATIONS Section Title Page 4-10 Life-Limited Components ........4.1 4-11 Time-in-Service Records .
  • Page 30 Intentionally Blank Page 4.ii Chapter 4 Airworthiness Limitations JUL 2020...

  • Page 31: Airworthiness Limitations

    CHAPTER 4 AIRWORTHINESS LIMITATIONS 4-10 Life-Limited Components 4-11 Time-In-Service Records It is the operator’s responsibility to maintain a record of time in service for the engine, airframe, and all life-limited components, as well as the number of start cycles for the engine.

  • Page 32: Fatigue Life-Limited Parts

    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 33 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 34 Flight Manual (RTR 661) for expanded limits with external load. Empty Weight C.G. Range None. The aircraft’s empty weight and empty weight C.G. must be determined by the procedures in Chapter 8 of the R66 Maintenance Manual, RTR 660. Datum 100 inches forward of main rotor centerline.
  • Page 35 With External Load: 2900 lb (See Note 8 for external load limitations) Minimum Crew 1 pilot in forward right seat. See R66 Pilot’s Operating Handbook and FAA Approved Rotorcraft Flight Manual (RTR 661) for configurations that allow 1 pilot in forward left seat.
  • Page 36 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 37 R66 helicopters that have been delivered or are in service. NOTE 8. R66 helicopters equipped with the G132 Cargo Hook installation may be operated at up to 2900 pounds gross weight when the portion above 2700 pounds is jettisonable load on the cargo hook and the helicopter is operating at or below 7000 feet density altitude.
  • Page 38 Intentionally Blank Page 4.8 Chapter 4 Airworthiness Limitations JUL 2020...

  • Page 39: Airworthiness Limitations

    4-30 Airworthiness Limitations The Airworthiness Limitations Section is FAA approved and specifies inspections and other maintenance required under 14 CFR §§ 43.16 and 91.403, unless an alternative program has been FAA approved. R66 Fatigue Life-Limited Parts Part Number Description Maximum Service Life C023-21, -24, -34, &...
  • Page 40 Intentionally Blank Page 4.10 Chapter 4 Airworthiness Limitations JUL 2020...
  • Page 41 CHAPTER 5 INSPECTIONS Section Title Page 5-10 Introduction ..........5.1 5-20 [Reserved] .

  • Page 42: Section Title

    CHAPTER 5 INSPECTIONS (Continued) Section Title Page 5-75 Inspection After Stabilizer Damage ......5.52 Page 5.ii Chapter 5 Inspections JUL 2020...

  • Page 43: Introduction

    INSPECTIONS 5-10 Introduction The R66 helicopter must be inspected periodically to verify it is in airworthy condition. Required inspection intervals are maximum 100 hours time in service or 12 calendar months (annually), whichever occurs first; the inspection interval may be extended up to 10 hours, without accumulation, if allowed by local regulations.
  • Page 44 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 5.2 Chapter 5 Inspections JUL 2020...

  • Page 45: Push-Pull Tubes

    5-32 Push-Pull Tubes 1. Nicks, cuts, or scratches in tube not more than 0.010 inch deep and not more than 1/4 of tube circumference may be polished out in lengthwise direction using 320-grit or finer wet-or-dry abrasive paper to 1 inch minimum blend radius. Replace push-pull tube if depth exceeds these limits.
  • Page 46 Elastomer Fatigue Elastomer Oil Contamination Elastomer Overload FIGURE 5-3 ELASTOMERIC BEARING DAMAGE Page 5.4 Chapter 5 Inspections JUL 2020...

  • Page 47: Elastomeric Bearings

    5-34 Elastomeric Bearings Refer to Figure 5-3. Elastomeric bearings are used in the G062-1 tail rotor hub assembly. Fatigue, oil contamination, or overload can degrade the elastomer. Small surface cracks (fatigue cracks) and elastomer dust or “eraser crumbs” are normal and are not cause for replacement.

  • Page 48: Telatemp Indicators

    5-35 Telatemp Indicators Refer to Figure 5-4. Self-adhesive Telatemp indicators record increases in operating temperatures of the hydraulic pump and tail rotor gearbox. To use a Telatemp, draw a reference line between the highest temperature square which has darkened during normal operation and the next undarkened square.

  • Page 49: Torque Stripes

    5-36 Torque Stripes If, during inspection, the remaining torque stripe on a fastener is insufficient to determine joint integrity, then remove accompanying palnut as required and apply specified torque to fastener. If fastener moves, disassemble joint and inspect parts for damage such as fretting, thread deformation, hole elongation, etc.;...

  • Page 50: Operation Checks For 100-Hour/Annual Inspection

    5-40 Operation Checks for 100-Hour / Annual Inspection Complete the following checklists in conjunction with 100-hour / annual inspection. Note and correct any discrepancies. 5-41 Ground Check (aircraft not running) Twist Grip: Verify twist grip smooth rotation without binding in full up and full down collective position.
  • Page 51 5-41 Ground Check (continued) Lighting, Instruments, and Audio Alerts: (Turn battery switch on.) ANNUNCIATOR PANEL AND ROTOR BRAKE LIGHTS MR TEMP PRESS segment illuminates. ENGINE OIL segment illuminates. GEN segment illuminates. LOW RPM segment illuminates. HYD segment illuminates (if hydraulic switch is OFF; later helicopters).
  • Page 52 (Turn battery switch off.) 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 53: Run-Up

    5-42 Run-Up Clean engine gas path, if required, per RR300 Series Operation and Maintenance Manual (OMM). Perform Pilot's Operating Handbook (POH) Section 4 “Preflight” checklist. Perform POH Section 4 “Before Starting Engine” checklist. Prior to start, verify rotor brake locks out starter. Prior to start, review the Cautions and Notes in POH Section 4 “Starting Engine and Run-Up”.
  • Page 54 5-42 Run-Up (continued) Transmit on 118.0, 125.0, and 135.0 MHz. Verify no variation in dual tachometer readings during transmission. Briefly operate the heater at 100% N2 to ensure system functions and is clear of debris. Check engine anti-ice system. Green anti-ice indicator should illuminate accompanied by small MGT increase when anti-ice is switched ON.

  • Page 55: Flight Check

    5-43 Flight Check Hover: Verify normal gage indications. Verify controllability in left and right pedal turns. Verify hydraulic system zeros cyclic stick forces. Evaluate vibration levels; if unacceptable, measure imbalance and correct. Level Flight: Conduct at typical cruise altitude (weather permitting) and maximum continuous torque.
  • Page 56 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 57 Access and Inspection Panels: Refer to R66 Illustrated Parts Catalog Chapter 6 for access and inspection panel locations. Remove or open necessary panels, doors, covers, fairings, and cowlings in accordance with 14 CFR Part 43, Appendix D, paragraph (a).
  • Page 58 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. Page 5.14...
  • Page 59 5-45 100-Hour / Annual Inspection (continued) CONSOLE (continued) Post Lights: Inspect condition. Verify proper function and equipment security. Fuel Cutoff Control and Guard: Inspect condition. Verify cable and mounting bezel security. Verify proper adjustment and smooth operation of knob. Verify guard is attached to console. Radios and Radio Trays: Inspect condition.
  • Page 60 5-45 100-Hour / Annual Inspection (continued) PILOT-SIDE CONSOLE (Optional equipment) Pilot Avionics Support Weldment: Inspect condition. Verify no significant nicks, scratches, or dents on console shell. Verify no cracks in welds. Verify weldment mounting security. CIRCUIT BREAKER PANEL CAUTION Ensure BATTERY switch is turned off while circuit breaker panel is open.
  • Page 61 5-45 100-Hour / Annual Inspection (continued) HORIZONTAL CONTROL TUNNEL (Front seats; continued) Covers: Inspect condition. Verify marking legibility. Antenna Wiring & Connectors: Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify no damaged connectors. Verify neatness, proper routing and installation, and security. Cyclic Box Assembly: Inspect condition.
  • Page 62 Intentionally Blank Page 5.16B Chapter 5 Inspections APR 2017...
  • Page 63 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 5-45 100-Hour / Annual Inspection (continued) HORIZONTAL CONTROL TUNNEL (Aft seats; continued) Fuel Cutoff and Throttle Control: Inspect condition. Verify proper fuel cutoff and throttle control clearance to installed equipment and surrounding structure. Verify proper installation and security. Cabin Heater Valve and Control: Inspect condition.
  • Page 66 5-45 100-Hour / Annual Inspection (continued) CABIN BULKHEAD Blind Encoder & Engine Monitoring Unit (EMU): Inspect condition. Inspect wiring for obvious damage. Verify no cracks where units mount to bulkhead. Verify proper installation and security. Download EMU data as required per RR300 Series OMM. Fuse Block and Fuses (Air Conditioning;...
  • Page 67 5-45 100-Hour / Annual Inspection (continued) BAGGAGE COMPARTMENT Door: Inspect condition. Verify proper operation of micro switch and COWL DOOR warning segment. 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 68 Secure hose at tab near drain valve. MT183-1 Tool Kit: Inspect condition. Remove kit and verify kit contains loose parts listed in R66 Illustrated Parts Catalog. Clip kit to aux tank and verify security. MAIN ROTOR GEARBOX COMPARTMENT Cowling Doors: Inspect condition.
  • Page 69 5-45 100-Hour / Annual Inspection (continued) MAIN ROTOR GEARBOX COMPARTMENT (continued) Fuel Tank Rollover Vents: Inspect condition. Inspect Tygon® tube for defects, tears, or material deterioration. 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.
  • Page 70 5-45 100-Hour / Annual Inspection (continued) MAIN ROTOR GEARBOX COMPARTMENT (continued) Hydraulic Servo Support Frame: Inspect condition. Inspect rod ends per § 5-33. Use an inspection light and mirror to inspect all parts of each weld. Verify no cracks or corrosion in servo support. Verify proper installation and security.
  • Page 71 5-45 100-Hour / Annual Inspection (continued) MAIN ROTOR GEARBOX COMPARTMENT (continued) Hydraulic Servos: Inspect condition. Inspect rod ends per § 5-33. Verify approximately 0.040 inch total free play at servo valve input. Verify no significant servo leakage. Clean servo input rod end/clevis area with no-residue, non-alcoholic solvent as required. Verify no obvious defects and security of scissors at upper clevis of servos.
  • Page 72 FIGURE 5-4A FLEX PLATE INSPECTION 5-45 100-Hour / Annual Inspection (continued) MAIN ROTOR GEARBOX COMPARTMENT (continued) Compressor Assembly (Air Conditioning; if installed): Inspect condition, including integrity of belt-tension slotted plate. Verify security of mounting. Verify no loose, chafed, frayed, or broken wires. Verify proper installation and security of pressure switches, snubber, and refrigerant lines.
  • Page 73 5-45 100-Hour / Annual Inspection (continued) MAIN ROTOR GEARBOX COMPARTMENT (continued) C947-3 (Tail Rotor Drive) Plate Assemblies, Forward and Intermediate: Refer to Figure 5-4A. Inspect condition. Verify no distortion, nicks, scratches, cracks, corrosion, or fretting. If fretting is detected, contact RHC Technical Support. Verify bonded washers are installed on both sides of each flex plate ear.
  • Page 74 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. Tailcone Attachment: Inspect condition.
  • Page 75 5-45 100-Hour / Annual Inspection (continued) MAIN ROTOR GEARBOX COMPARTMENT (continued) Antennas: Inspect condition. Verify no cracks where antennas mount to cowling. Verify security. Close & Secure: Verify foreign objects are removed. Verify equipment security. Verify cleanliness of interior and of inspection and access doors and cowlings. Connect antenna leads and ground wires, if installed.
  • Page 76 Intentionally Blank Page 5.26 Chapter 5 Inspections APR 2019...
  • Page 77 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. Page 5.27...
  • Page 78 Refer to Figure 76-2. Verify D333-13 fitting in PTG input lever moves in and out slightly with light finger pressure. If D333-13 fitting does not move in response to light finger pressure then follow compliance procedure in R66 Service Bulletin SB-01. Fuel Control Unit (FCU) and Control Rigging: Verify proper routing and security of throttle and fuel cutoff controls;...
  • Page 79 5-45 100-Hour / Annual Inspection (continued) ENGINE (continued) Engine Mounts: Inspect condition. Verify no cracks or corrosion in engine mount weldment. Verify safety wire and security of mounting bolts. Lower Steel Tube Frame: Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Verify no chafing where wires, hoses, or clamps attach to frame.
  • Page 80 5-45 100-Hour / Annual Inspection (continued) 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 81 5-45 100-Hour / Annual Inspection (continued) TAILCONE (continued) Tailcone Exterior: Inspect condition. Refer to § 53-41. Inspect tailcone exterior for nicks, scratches, dents, cracks, corrosion, fretting or loose rivets. Verify no obstructions in drain hole at forward edge of each bay (except forward bay). Antennas: Inspect condition.
  • Page 82 5-45 100-Hour / Annual Inspection (continued) TAIL ROTOR & TAIL ROTOR GEARBOX NOTE Verify proper hardware installation securing plastic inspection cover. Longer screws could contact aft flex coupling and yoke. Plastic Inspection Cover: Clean cover and inspect condition. Replace as required. C947-3 (Tail Rotor Drive) Plate Assembly, Aft: Refer to Figure 5-4A.
  • Page 83 5-45 100-Hour / Annual Inspection (continued) TAIL ROTOR & TAIL ROTOR GEARBOX (continued) Pitch Control Bearing Assembly & Aft Bellcrank: Inspect condition. Verify pitch control assembly has less than 0.25 inch rotational play measured at pitch link attach bolt. Verify no leakage at bearing seals. Verify no nicks, scratches, dents, cracks, or corrosion on pitch control housing or bellcrank.
  • Page 84 5-45 100-Hour / Annual Inspection (continued) MAST FAIRING Mast Fairing: Inspect condition. Verify no nicks, scratches, dents, cracks, corrosion, fretting, or loose rivets. Verify no yielding or cracking of pitot line and fuel vent restraint assembly. NOTE Yielding can be caused by over tightening screws in restraint nutplates.
  • Page 85 5-45 100-Hour / Annual Inspection (continued) MAST FAIRING (continued) Swashplate Lower Scissors: Inspect condition. Verify bearing play within limits referenced in § 67-40, steps 9 and 10. 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 86 5-45 100-Hour / Annual Inspection (continued) 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. Hinge Bolts: Inspect condition.

  • Page 87: 100-Hour/Annual Inspection

    5-45 100-Hour / Annual Inspection LANDING GEAR Landing Gear Fairings (if installed): Open as required to access landing gear structure for inspection. Inspect condition. Verify no nicks, scratches, dents, cracks, corrosion, fretting, or loose rivets. Verify hose clamp security and acceptable general cleanliness of fairing interior. Close and secure fairings.
  • Page 88 5-45 100-Hour / Annual Inspection CABIN General Interior: Inspect condition. Verify general cleanliness of cabin and seat compartment interior. Verify no loose objects or equipment, which could foul controls or injure occupants in a hard landing. Verify legibility of placards and markings. Verify serviceable condition of switches, knobs, handles, and other controls.
  • Page 89 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 90 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 91: 2000-Hour/12-Year Inspection

    5-50 2000-Hour/12-Year Inspection NOTE Fuel bladder(s) are on condition. NOTE KI-6602 2000-Hour Inspection Kit contents are available online www.robinsonheli.com for review. NOTE 12-Year Inspection is only required for helicopters that have accumulated 12 years in service and less than 2000 hours time in service since new, since last 2000-hour inspection, or since last 12-year inspection.

  • Page 92: C258-5 Main Rotor Pitch Link Assembly Inspection

    5-50 2000-Hour/12-Year Inspection (continued) 13. Balance tail rotor per § 18-20. Track and balance main rotor per § 18-10. Perform flight checks per § 5-43. 14. Drain and flush tail rotor gearbox per § 12-23. 15. Make appropriate maintenance record entries. Enter maintenance performed (such as part replacement, equipment adjustments, weighing, servicing, and lubrication) and inspection data.

  • Page 93: Swashplate Assembly 12-Year Inspection

    If revision letters are “AD” or subsequent, proceed to step 2. If revision letters are “AA”, “AB”, or “AC”, perform R66 Service Bulletin SB-30. 4. Refer to Figure 12-7. Remove (10) NAS1352 screws (with washers) securing C206-2 & C200-3 retainers to upper swashplate. Remove both retainers and C219-3 spacer and set aside.

  • Page 94: Landing Gear Assembly 12-Year Inspection

    5-53 Landing Gear Assembly 12-Year Inspection 1. Inspect cross tubes per § 32-20. 2. Remove landing gear per § 32-10. 3. Remove left skid tube, and remove rain cap and skid extension from tube. 4. Remove fasteners securing struts to cross tubes. Using a twisting motion, remove left struts from cross tubes.

  • Page 95: Hydraulic Reservoir 12-Year Inspection

    5-54 Hydraulic Reservoir 12-Year Inspection 1. Perform hydraulic system drain and flush per § 12-33 step 1. Remove D516-1 cap. 2. Refer to Figure 5-5. Suction remaining fluid using suitable, clean, plastic tube (do not use metal tool). Wipe out any residue from both traps with clean, foam-tip swab. 3.
  • Page 96 Intentionally Blank Page 5.40 Chapter 5 Inspections JUL 2020...

  • Page 97: 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 98: 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 99: 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 100: 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 101 Intentionally Blank Page 5.45 APR 2019 Chapter 5 Inspections...
  • Page 102 FIGURE 5-6 SYMMETRY CHECK Page 5.46 Chapter 5 Inspections APR 2019...

  • Page 103: Hard Landing

    5-65 Hard Landing NOTE RR300 Operation and Maintenance Manual requires special engine inspection (subtask 05-50-00-210-002) when a hard landing exceeds 10g. While there is no single indicator for a 10g impact, an impact was less than 10g if there was no contact between the fuselage belly or landing gear cross tubes and the ground.
  • Page 104 5-65 Hard Landing (continued) 2. e. Visually inspect tailcone for buckling or loose rivets. f. Visually inspect landing gear skid tube-to-strut attach points for bending and cracks. g. Hard landings can be accompanied by tail skid strikes, tail rotor strikes, main rotor blade strikes, etc.
  • Page 105 Intentionally Blank Page 5.47B APR 2017 Chapter 5 Inspections...

  • Page 106: 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 107: 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 108: 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 109: Main Rotor Gearbox Internal Visual Inspection

    FIGURE 5-7 MAIN GEARBOX INTERNAL VISUAL INSPECTION 5-74 Main Rotor Gearbox Internal Visual Inspection 1. Refer to Figure 5-7. Gain access to and remove main gearbox filler plug. 2. Via filler plug hole and using borescope, miniature camera, or smartphone camera with flash, visually inspect specified area of gear carrier.
  • Page 110 5-75 Inspection After Stabilizer Damage For damage to an installed C042-1 upper vertical stabilizer, C043-1 lower vertical stabilizer, and/or C044 horizontal stabilizer that results in denting, tearing, or cracking of stabilizer metal: 1. On associated tailcone’s aft casting, strip paint from cross-hatched surfaces shown in Figure 5-8.
  • Page 111 CHAPTER 6 DIMENSIONS AND DESCRIPTIONS Section Title Page 6-10 Version Description ......... . 6.1 6-20 Datum .
  • Page 112 Intentionally Blank Page 6.ii Chapter 6 Dimensions and Descriptions APR 2017...

  • Page 113: 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 114 Intentionally Blank Page 6.2 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010...

  • Page 115: 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 116: 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 117 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 118: 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 119: 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 120 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 121 6-64 Butt Line (BL) Station Locations Horizontal Stabilizer (outboard point) ..BL 46.75 Skid Tube (centerline) ....BL 42.00 Door Post (between forward &...
  • Page 122 6-70 Access and Inspection Panels Refer to R66 Illustrated Parts Catalog Chapter 6 for access and inspection panel locations. 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.
  • Page 123 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 124 Intentionally Blank Page 6.12 Chapter 6 Dimensions and Descriptions APR 2017...
  • Page 125 Hoisting ......... . Page 7.i 25 OCT 2010 R66 Maintenance Manual Chapter 7 Jacking and Hoisting...
  • Page 126 Intentionally Blank Page 7.ii Chapter 7 Jacking and Hoisting R66 Maintenance Manual 25 OCT 2010...
  • Page 127 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 128 FIGURE 7-1 JACKING Page 7.2 Chapter 7 Jacking and Hoisting R66 Maintenance Manual SEP 2012...
  • Page 129 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 130 FIGURE 7-2 HOISTING Page 7.4 Chapter 7 Jacking and Hoisting R66 Maintenance Manual SEP 2012...
  • Page 131 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 132 (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 133 Empennage Ballast ......8.13 Page 8.i 25 OCT 2010 R66 Maintenance Manual Chapter 8 Weight and Balance...
  • Page 134 Intentionally Blank Page 8.ii Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 135: Leveling

    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 136 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 137: Leveling For Rigging

    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 138 Intentionally Blank Page 8.4 Chapter 8 Weight and Balance R66 Maintenance Manual SEP 2012...

  • Page 139: 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 140 FIGURE 8-3 WEIGHING (Scale indications for demonstration only) Page 8.6 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 141: 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 142 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 143 (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 144 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 145: 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 146 FIGURE 8-5 EMPENNAGE BALLAST Page 8.12 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 147: Empennage Ballast

    § 53-50. Topcoat hardware with colored paint as desired. 4. Reweigh and/or calculate basic empty weight and CG per § 8-22. 5. Revise Weight and Balance Record in R66 Pilot's Operating Handbook (POH) Section 6 to reflect ballast removal using the following data: Longitudinal...
  • Page 148 Solvent-clean bare metal on horizontal stabilizer and weight clamping surfaces. 7. Reweigh and/or calculate basic empty weight and CG per § 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: Longitudinal...
  • Page 149 Trailering ......... Page 9.i 25 OCT 2010 R66 Maintenance Manual Chapter 9 Ground Handling...
  • Page 150 Intentionally Blank Page 9.ii Chapter 9 Ground Handling R66 Maintenance Manual 25 OCT 2010...
  • Page 151 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 152 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 153 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 154 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 155 Storage (Greater than 30 days) ......10.6 Page 10.i 25 OCT 2010 R66 Maintenance Manual Chapter 10 Parking and Storage...
  • Page 156 Intentionally Blank Page 10.ii Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010...

  • Page 157: Parking

    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 158 FIGURE 10-1 MAIN ROTOR BLADE TIE-DOWNS Page 10.2 Chapter 10 Parking and Storage R66 Maintenance Manual SEP 2012...

  • Page 159: 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 160: Main Rotor Blade Supports

    FIGURE 10-2 MAIN ROTOR BLADE SUPPORTS Page 10.4 Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010...
  • Page 161 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 162: 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 163 CHAPTER 11 PLACARDS AND MARKINGS Section Title Page 11-10 Placards and Markings ........11.1 Page 11.i APR 2017 Chapter 11 Placards and Markings...
  • Page 164 Intentionally Blank Page 11.ii Chapter 11 Placards and Markings APR 2017...
  • Page 165 CHAPTER 11 PLACARDS AND MARKINGS 11-10 Placards and Markings Refer to R66 Illustrated Parts Catalog Chapter 11 for placard and marking locations. A. Removal To remove previously installed decals, start at corners and slowly peel off decal by hand or using a plastic wedge. Avoid damaging or removing paint or primer from surfaces.
  • Page 166 Intentionally Blank Page 11.2 Chapter 11 Placards and Markings APR 2017...
  • Page 167 CHAPTER 12 SERVICING Section Title Page 12-10 Main Rotor Gearbox ........12.1 12-11 Servicing .
  • Page 168 Intentionally Blank Page 12.ii Chapter 12 Servicing JUL 2020...

  • Page 169: 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 170 FIGURE 12-1 MAIN ROTOR GEARBOX SERVICING Page 12.2 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

  • Page 171: Filter Replacement

    12-12 Filter Replacement NOTE Replace main rotor gearbox oil every 600 hours. When replacing a filter after new or overhauled main rotor gearbox has accumulated 100 hours, replacing oil is not required. 1. Drain main rotor gearbox oil per § 12-11, if required. 2.
  • Page 172 FIGURE 12-2 DRAINING MAIN ROTOR GEARBOX OIL Page 12.4 Chapter 12 Servicing APR 2019...
  • Page 173 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 174 FIGURE 12-3 TAIL ROTOR GEARBOX Page 12.6 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

  • Page 175: 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 176: 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 177: 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 178 FIGURE 12-4 HYDRAULIC SYSTEM Page 12.10 Chapter 12 Servicing R66 Maintenance Manual SEP 2012...

  • Page 179: 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 180: 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 181: Fuel System

    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 182: Defueling

    12-42 Defueling A. Main Fuel System 1. Remove engine cowling per § 53-21. 2. Turn battery switch off. Pull fuel valve control to Off position. 3. Disconnect B283-12 hose at engine and install cap on engine inlet fitting. 4. Position hose into a suitable, grounded drain container. NOTE If desired, perform low-fuel switch assembly check per §...
  • Page 183 Intentionally Blank Page 12.13B APR 2017 Chapter 12 Servicing...
  • Page 184 FIGURE 12-5 MAIN ROTOR BLADE PITCH BEARING HOUSING Page 12.14 Chapter 12 Servicing APR 2017...

  • Page 185: Main Rotor Blades

    12-50 Main Rotor Blades WARNING Refer to appropriate Material Safety Data Sheet (MSDS) and take necessary safety precautions when working in proximity to hazardous materials. 12-51 Pitch Bearing Housing NOTE MT147-1 Main rotor blade spindle air bleed tool includes supply container, hose assemblies, and bleed fittings.

  • Page 186: Engine Oil Servicing

    12-60 Engine Oil Servicing A. Draining Fluid 1. As required, run-up helicopter two to five minutes at 60-70% RPM per R66 Pilot's Operating Handbook (POH) Section 4 to warm engine oil. 2. Remove engine cowling per § 53-21. 3. Place a suitable drain container below B289-2 bolt in bend of F723-1 line assembly, and below AS5169D04 (drain) fitting in F649-1 oil cooler assembly.

  • Page 187: 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 188: Drainage Spotface Inspection During Cleaning Or Rinsing Of Rr300 Engine 12.17A

    12-71 Drainage Spotface Inspection During Cleaning or Rinsing of RR300 Engine Follow published Rolls-Royce guidance (subject to revision) to maximize RR300 engine corrosion prevention: • RR300 Operation and Maintenance Manual (OMM) Task 05-50-00-100-801, Clean the Engine after Operation in a Corrosive Environment, and •...
  • Page 189 Intentionally Blank Page 12.17B Chapter 12 Servicing JUL 2020...

  • Page 190: 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 191: Desiccant Replacement

    12-82 Desiccant Replacement NOTE Replace desiccant when condenser or refrigerant system is exposed to air. To eliminate moisture, replace desiccant, then immediately vacuum system for charging per § 12-81. 1. Remove engine cowling per § 53-21. 2. Recover refrigerant per § 12-81, if not previously accomplished. Remove condenser cap and replace desiccant.
  • Page 192 12-83 Leak Detection (continued) Very small leaks can be detected by charging the system with helium gas. Helium molecules are smaller than R134a molecules and will leak more quickly. Charge system to 200 psi maximum. Use commercially available electronic helium detector or soap and water solution to locate leaks.

  • Page 193: Lubrication Of Swashplate Bearings

    1. Determine revision (“REV”) letters on C017-6 swashplate data plate. If revision letters are “AD” or subsequent, proceed to step 2. If revision letters are “AA”, “AB”, or “AC”, perform R66 Service Bulletin SB-30. 2. Remove ty-rap securing C480 boot to upper (rotating) swashplate.
  • Page 194 12-90 Lubrication of Swashplate Bearings (continued) WARNING Assembly of flight controls is critical and requires inspection by a qualified person. If a second person is not available, the installer must take a 5-minute break prior to inspecting flight control connections he has assembled. 15.
  • Page 195 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 196 Intentionally Blank Page 18.ii Chapter 18 Track and Balance APR 2019...

  • Page 197: 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 198 FIGURE 18-1 MAIN ROTOR BALANCING EQUIPMENT INSTALLATION Page 18.2 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 199: 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 200 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 201: 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 § 18-15 for track & balance troubleshooting procedures. WARNING Tail rotor balancing equipment must be removed for flight.
  • Page 202 FIGURE 18-3A C258-5 MAIN ROTOR PITCH LINK Page 18.6 Chapter 18 Track and Balance APR 2017...

  • Page 203: Track Adjustment

    18-13 Track Adjustment A. Main Rotor Blade Pitch Link NOTE Shorten high pitch blade when adjusting track in a hover. NOTE During rigging, adjust both pitch links exactly the same for collective adjustments. 1. For fine adjustment: a. C258-5 Pitch Link: Adjust barrel assembly only per the following steps: i.
  • Page 204 FIGURE 18-3B C258-1 MAIN ROTOR PITCH LINK Page 18.7A Chapter 18 Track and Balance APR 2019...
  • Page 205 18-13 Track Adjustment (continued) A. Main Rotor Blade Pitch Link (continued) 2. For medium length adjustment, adjust upper rod end per the following: a. Refer to Figure 18-3A or 18-3B. Using backup wrench on barrel assembly or fitting, loosen upper rod end palnut and jam nut. Remove hardware securing rod end to pitch horn.
  • Page 206 18-13 Track Adjustment (continued) A. Main Rotor Blade Pitch Link (continued) 3. b. C258-1 Pitch Link: Adjust link assembly per the following: i. Refer to Figure 18-3B. Cut and discard pitch link assembly safety wire. Using backup wrench on link assembly, loosen 21FKF-813 nut. Remove hardware securing lower rod end to swashplate.
  • Page 207 Intentionally Blank Page 18.7D APR 2017 Chapter 18 Track and Balance...
  • Page 208 FIGURE 18-4 MAIN ROTOR BLADE TRIM TAB Page 18.8 Chapter 18 Track and Balance APR 2017...
  • Page 209 CAUTION Do not use other helicopter manufacturers' trim tab bending tools. Use of these tools will damage Robinson blades. CAUTION MT352-1 gage must contact trim tab trailing edge. If gage does not contact tab trailing edge, tab is bent beyond limit.
  • Page 210 FIGURE 18-4A MAIN ROTOR BLADE TIP Page 18.10 Chapter 18 Track and Balance APR 2017...

  • Page 211: Balance Adjustment

    18-14 Balance Adjustment WARNING A rotor which is smooth after balancing but goes out of balance within a few flights is suspect and must be examined by RHC before further flight. A. Tip Weights (Spanwise Balance Adjustment) 1. Remove screws securing tip cover to blade. Balance rotor assembly spanwise by adjusting tip weights as required per Figure 18-2.
  • Page 212 Intentionally Blank Page 18.10B Chapter 18 Track and Balance APR 2017...

  • Page 213: 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 214: 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 215 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 216 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 217 Intentionally Blank Page 18.15 25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance...
  • Page 218 FIGURE 18-6 TAIL ROTOR BALANCING EQUIPMENT INSTALLATION Page 18.16 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 219: Tail Rotor Dynamic Balance

    18-20 Tail Rotor Dynamic Balance NOTE Calibrate track and balance equipment per manufacturer's recommendation, at least once a year, or if equipment is dropped, misused, or calibration is suspect. NOTE The Chadwick-Helmuth Vibrex system, the TEC ACES system, the Dynamic Solutions Systems’ MicroVib system, or equivalent equipment is required to perform dynamic rotor balancing and in-flight track checks.
  • Page 220 DATE SERIAL NO. PAGE PITCH HORN-TO-PITCH LINK FASTENER (CHORDWISE) WEIGHTS BLADE-TO-HUB OUTBOARD FASTENER (SPANWISE) WEIGHTS (1) NAS1149F0463P Washer NAS1149F0432P Washers (1) C141-23 Washer = (3.5) NAS1149F0663P Washers (1) A214-3 Washer = (3.5) NAS1149F0432P Washers (1) C141-24 Washer (7) NAS1149F0663P Washers (1) A141-14 Washer NAS1149F0432P Washers (2) NAS1149F0632P...

  • Page 221: 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 222 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 223: 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 224 FIGURE 18-10 MAIN ROTOR BLADE RIGGING Page 18.22 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010...

  • Page 225: 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 226: 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 227 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 228: 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 229 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 230: 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 231: 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 232 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 233 Intentionally Blank Page 18.31 MAY 2015 Chapter 18 Track and Balance...
  • Page 234 FIGURE 18-12 FAN SHAFT AND ENGINE SHAFT BALANCING Page 18.32 Chapter 18 Track and Balance MAY 2015...

  • Page 235: 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 236 FIGURE 18-13 FAN SHAFT BALANCING CHART Page 18.34 Chapter 18 Track and Balance APR 2019...

  • Page 237: 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 238 FIGURE 18-14 ENGINE SHAFT BALANCING CHART Page 18.36 Chapter 18 Track and Balance APR 2019...
  • Page 239 CHAPTER 20 STANDARD PRACTICES Section Title Page 20-10 Cleaning ..........20.1 20-20 Lubrication .
  • Page 240 Intentionally Blank Page 20.ii Chapter 20 Standard Practices JUL 2020...

  • Page 241: Standard Practices

    CHAPTER 20 STANDARD PRACTICES 20-10 Cleaning WARNING Review appropriate Safety Data Sheet (SDS) when working in proximity to hazardous materials. Specific recommendations for use of personal protective equipment are located in the SDS. A. Cleaning Exterior Surfaces NOTE Remove turbine exhaust stains from engine cowling, tailcone, empennage, and tail rotor blades after every flight to prevent permanent discoloration.
  • Page 242 20-10 Cleaning (continued) B. Cleaning Windshield and Windows 1. Remove dirt, mud, and other loose particles from exterior surfaces with clean water. 2. Wash with mild soap and warm water or with aircraft plastic cleaner. Use a soft cloth or sponge in a straight back and forth motion. Do not rub harshly. 3.

  • Page 243: Lubrication

    Specific recommendations for use of personal protective equipment are located in the SDS. 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.
  • Page 244 Intentionally Blank Page 20.2B Chapter 20 Standard Practices JUL 2020...

  • Page 245: 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 246 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 247: Torque Stripe

    20-30 Torque Requirements (continued) E. Torque Requirements CAUTION Never substitute AN bolts for NAS bolts. NAS bolts have higher tensile strength. 1. Any self-locking nut whose drag has deteriorated appreciably must be replaced. Damaged hardware must be replaced. 2. Bolt and nut are to be clean and dry except when assembly procedure specifies anti-seize or thread-locking compound.

  • Page 248: Standard Torques

    20-32 Standard Torques NOTE 1. Torque values are in inch-pounds unless otherwise specified. 2. Torque values include nut self-locking torque. 3. Increase torque values 10% if torqued at bolt head. 4. Wet indicates threads lubricated with A257-9 anti-seize. 5. For elbow and tee fittings which require alignment, torque to indicated value, then tighten to desired position.
  • Page 249 20-33 Special Torques Special torques supersede standard torques listed in § 20-32. NOTE 1. Torque values are in inch-pounds unless otherwise specified. 2. Torque values include nut self-locking torque. 3. Increase torque values 10% if torqued at bolt head. 4. Wet indicates threads lubricated with A257-9 anti-seize. 5.
  • Page 250 20-33 Special Torques (continued) TORQUE AREA FASTENER (IN.-LB) (1) AN832-10D union, at firewall 330-360 COOLING SYSTEM (2) AN924-8D nuts, at firewall (ENGINE (1) AN924-10D nut, at firewall & MAIN (2) AN924-6D nuts, securing F823-1 thermostat assembly to firewall GEARBOX (2) AS5169D04L fitting, on F649-1 oil cooler OILS) (Cont’d) (1) MS28034-1 oil temperature sender, to tank...
  • Page 251 20-33 Special Torques (continued) TORQUE AREA FASTENER (IN.-LB) FUEL SYSTEM (1) D210-3 nut, securing control wire (Cont’d) (5) B289-4 bolts, fuel sender (1) D205-35 hose assembly, nuts (large tank; drain) (2) D205-36 hose assembly, nuts AUXILIARY (1) D205-37 hose assembly, nuts (small tank; drain) FUEL SYSTEM (2) G764-5 fittings (1) G768-3 sensor assembly...
  • Page 252 20-33 Special Torques (continued) TORQUE AREA FASTENER (IN.-LB) (1) D487-3, filler-vent HYDRAULIC (1) D516-1, filter cap RESERVOIR (1) B563-2, sight gage (1) D210-08 nut, attaching D200-2 scissors HYDRAULIC SERVOS (1) B330-6 palnut on D200-2 scissor apex fastener 5-10 (4) NAS6604-46 bolts, securing ground handling wheel support weldments to skid tubes (4) NAS6607P20 bolt, securing landing gear to fuselage LANDING...

  • Page 253: Special Torques

    20-33 Special Torques (continued) TORQUE AREA FASTENER (IN.-LB) (1) A880-1208 or AN814-8D plug, main rotor gearbox filler plug MAIN ROTOR GEARBOX (1) MS21245L8 nut, securing input yoke to main gearbox 40 FT-LB (Cont’d) (1) chip detector wire terminal nut New bolt: 0.021- 0.022 inch elongation, wet (1) NAS634-105 bolt, teeter hinge and...
  • Page 254 20-33 Special Torques (continued) TORQUE AREA FASTENER (IN.-LB) (6) NAS6605H3 bolts, securing (2) F593-1 support assemblies to engine POWERPLANT (2) NAS6605H4 bolts and (1) NAS6605H2 bolt, securing F174-1 (Cont’d) weldment and F593-3 plate to engine (1) CV26-77 check valve, engine oil outlet (superseded; early R66s) (26) NAS1352N08-8 screws, securing spacers, sleeve assembly, 35 wet shield, and retainers...

  • Page 255: Push-Pull Tube Rod End Adjustment

    20-34 Push-Pull Tube Rod End Adjustment NOTE Refer to § 18-13 to adjust C258 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 256: A880 Flared Tube Components

    20-36 A880 Flared Tube Components A. Nuts – Flare Dash Allowable Part Numbers Material REF Tube OD REF Numbers -102 AN818-2D, AN818-2W, AS5175W02 1/8-inch -103 AN818-3D, AN818-3W, AS5175W03 3/16-inch -104 AN818-4D, AN818-4W, AS5175W04 1/4-inch -105 AN818-5D, AN818-5W, AS5175W05 5/16-inch -106 AN818-6D, AN818-6W, AS5175W06 3/8-inch -108...
  • Page 257 20-36 A880 Flared Tube Components (continued) B. Sleeves Dash Allowable Part Numbers Material REF Tube OD REF Numbers -302 MS20819-2D, AS3220D02, AS3220W02 1/8-inch -303 MS20819-3D, AS3220D03, AS3220W03 3/16-inch -304 MS20819-4D, AS3220D04, AS3220W04 1/4-inch -305 MS20819-5D, AS3220D05, AS3220W05 5/16-inch -306 MS20819-6D, AS3220D06, AS3220W06 3/8-inch -308 MS20819-8D, AS3220D08, AS3220W08...
  • Page 258 20-36 A880 Flared Tube Components (continued) C. Adapters – NPT to Flare Dash Allowable Part Numbers Material REF Tube OD REF Numbers -502 AN816-2D, AS5194D0202 1/8-inch -503 AN816-3D, AS5194D0302 3/16-inch -504 AN816-4D, AS5194D0402 1/4-inch -505 AN816-5D, AS5194D0502 5/16-inch -506 AN816-6D, AS5194D0604 3/8-inch -508 AN816-8D, AS5194D0806...
  • Page 259 20-36 A880 Flared Tube Components (continued) D. Elbows – 90°, NPT to Flare Dash Allowable Part Numbers Material REF Tube OD REF Numbers -602 AN822-2D, MS20822-2D, AS5195W0202 1/8-inch -603 AN822-3D, MS20822-3D, AS5195W0302 3/16-inch -604 AN822-4D, MS20822-4D, AS5195W0402 1/4-inch -605 AN822-5D, MS20822-5D, AS5195W0502 5/16-inch -606 AN822-6D, MS20822-6D, AS5195W0604...
  • Page 260 20-36 A880 Flared Tube Components (continued) E. Elbows – 45°, NPT to Flare Dash Allowable Part Numbers Material REF Tube OD REF Numbers -702 AN823-2D, MS20823-2D, AS5196W0202 1/8-inch -703 AN823-3D, MS20823-3D, AS5196W0302 3/16-inch -704 AN823-4D, MS20823-4D, AS5196W0402 1/4-inch -705 AN823-5D, MS20823-5D, AS5196W0502 5/16-inch -706 AN823-6D, MS20823-6D, AS5196W0604...
  • Page 261 20-36 A880 Flared Tube Components (continued) F. Elbows – 90°, Bulkhead Flare to Flare Dash Allowable Part Numbers Material REF Tube OD REF Numbers -802 AN833-2D, AS1038D0202, AS1038W0202 1/8-inch -803 AN833-3D, AS1038D0303, AS1038W0303 3/16-inch -804 AN833-4D, AS1038D0404, AS1038W0404 1/4-inch -805 AN833-5D, AS1038D0505, AS1038W0505 5/16-inch -806...
  • Page 262 20-36 A880 Flared Tube Components (continued) G. Unions – Flare to Flare Dash Allowable Part Numbers Material REF Tube OD REF Numbers -902 AN815-2D, AS5174D0202, AS5174W0202 1/8-inch -903 AN815-3D, AS5174D0303, AS5174W0303 3/16-inch -904 AN815-4D, AS5174D0404, AS5174W0404 1/4-inch -905 AN815-5D, AS5174D0505, AS5174W0505 5/16-inch -906 AN815-6D, AS5174D0606, AS5174W0606...
  • Page 263 20-36 A880 Flared Tube Components (continued) H. Nuts – Hex Dash Allowable Part Numbers Material REF Tube OD REF Numbers -1002 AN924-2D, AN924-2W, AS5178W02 1/8-inch -1003 AN924-3D, AN924-3W, AS5178W03 3/16-inch -1004 AN924-4D, AN924-4W, AS5178W04 1/4-inch -1005 AN924-5D, AN924-5W, AS5178W05 5/16-inch -1006 AN924-6D, AN924-6W, AS5178W06 3/8-inch...
  • Page 264 20-36 A880 Flared Tube Components (continued) I. Tees – NPT to Flare Dash Allowable Part Numbers Material REF Tube OD REF Numbers -1102 AN826-2D, MS20826-2D, AS5198W020202 1/8-inch -1103 AN826-3D, MS20826-3D, AS5198W030203 3/16-inch -1104 AN826-4D, MS20826-4D, AS5198W040204 1/4-inch -1105 AN826-5D, MS20826-5D, AS5198W050205 5/16-inch -1106 AN826-6D, MS20826-6D, AS5198W060406...
  • Page 265 20-36 A880 Flared Tube Components (continued) J. Plugs without Holes Dash Allowable Part Numbers Material REF Tube OD REF Numbers -1202 AN814-2D, AN814-2W, AS5169D02, AS5169W02 1/8-inch -1203 AN814-3D, AN814-3W, AS5169D03, AS5169W03 3/16-inch -1204 AN814-4D, AN814-4W, AS5169D04, AS5169W04 1/4-inch -1205 AN814-5D, AN814-5W, AS5169D05, AS5169W05 5/16-inch -1206 AN814-6D, AN814-6W, AS5169D06, AS5169W06...
  • Page 266 20-36 A880 Flared Tube Components (continued) K. Plugs with Holes Dash Material Tube OD Allowable Part Numbers Numbers -1302 AN814-2DL, AN814-2WL, AS5169D02L, AS5169W02L 1/8-inch -1303 AN814-3DL, AN814-3WL, AS5169D03L, AS5169W03L 3/16-inch -1304 AN814-4DL, AN814-4 WL, AS5169D04L, AS5169W04L 1/4-inch -1305 AN814-5DL, AN814-5WL, AS5169D05L, AS5169W05L 5/16-inch -1306 AN814-6DL, AN814-6WL, AS5169D06L, AS5169W06L...
  • Page 267 Intentionally Blank Page 20.11N Chapter 20 Standard Practices JUL 2020...

  • Page 268: Non-Destructive Testing

    20-40 Non-Destructive Testing WARNING Review appropriate Safety Data Sheet (SDS) when working in proximity to hazardous materials. Specific recommendations for use of personal protective equipment are located in the SDS. 20-41 Magnetic Particle Inspection Ferromagnetic steel parts must be inspected for structural defects using magnetic particle inspection.

  • Page 269: Fluorescent Penetrant Inspection

    20-42 Fluorescent Penetrant Inspection This specification provides for surface inspection of parts fabricated from nonmagnetic materials to detect discontinuities open to the surface, such as cracks, cold shuts, laps, porosity and other surface defects. Applicable requirements and limitations of ASTM E 1417 shall apply. After inspection is complete, solvent clean parts.
  • Page 270 20-60 Priming and Painting (continued) WARNING Refer to appropriate Material Safety Data Sheet (MSDS) and take necessary safety precautions when working in proximity to hazardous materials. A. Priming 1. Preparing Aluminum Unless otherwise specified, chemical conversion coating using Alodine 1201 is the standard treatment before priming aluminum.
  • Page 271 20-60 Priming and Painting (continued) A. Priming (continued) 4. Inspection Inspect for complete coverage and excessive thickness. If primer is excessively thick, strip part and re-prime. Refer to § 20-70 for approved materials. B. Painting Prior to liquid topcoat application, ensure surfaces have been cleaned and primed. In general, most parts will be cleaned and primed as detail parts.

  • Page 272: 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 Review appropriate Safety Data Sheet (SDS) when working in proximity to hazardous materials. Specific recommendations for use of personal protective equipment are located in the SDS.

  • Page 273: Fillers And Putty

    20-72 Solvents and Cleaners (continued) PRODUCT MANUFACTURER/SUPPLIER APPLICATION 815 GD Brulin Corporation Ultrasonic cleaning, general Indianapolis, IN use.** SF50 L&R Mfg. Co. “ “ Kearny, NJ #112 Ammoniated or L&R Mfg. Co. Ultrasonic cleaning, avionics #222 Nonammoniated cleaning Kearny, NJ components only.

  • Page 274: Primers

    20-75 Primers A. Non-chromate Primers Corlar 13580S* Desoprime CA7502* Desoprime CA7422* Manufacturer Axalta Corlar 13580S Base CA7502A CA7422A Epoxy Primer Corlar 13180S Activator CA7502B CA7422B Epoxy Activator 13756S VOC-Exempt Reducer CA7502C CA7422C Reducer Base: Activator: Reducer 4:1:1 4:4:1 4:4:1 Viscosity 17-21 sec in Zahn #2 15-19 sec in Zahn #2 15-19 sec in Zahn #2...

  • Page 275: Powder Coat

    20-76 Powder Coat PRODUCT MANUFACTURER Interpon 100-AL101QF Gray AkzoNobel Zinc Rich Epoxy Powder* Santa Fe Springs, CA 81-2158 Vitralon Grey Pratt & Lambert Chemical Coatings Zinc Rich Epoxy Powder* Buffalo, NY 39/80020 Smooth Matte Tiger Drylac USA Black Cucamonga, CA Polyester Topcoat Powder* 49/72460 Smooth Glossy Tiger Drylac USA...

  • Page 276: Paints

    FIGURE 20-3 PAINT CODES (Refer to Chapter 62 for rotor blade paint dimensions. Exterior surface codes are D & F unless otherwise specified.) 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).
  • Page 277 13110S Activator Light Gray Imron 13100S Activator Baggage Axalta; Wilmington, DE N0020 AF400/AF700 13110S Activator compartment Silver Bullet AM Tracer 16-CURE-F4 Burke; R66 Middle Black 20-452AM-F1 Activator Ridgefield, WA seat 20-452AM-F1 Cardinal A-2000 Cardinal; A2000- Interior and Flat Black Cleveland, OH...
  • Page 278 FIGURE 20-4 PAINT CODES Page 20.20 Chapter 20 Standard Practices JUL 2020...

  • Page 279: Lubricants

    20-78 Lubricants MANUFACTURER’S LUBRICANT TYPE MANUFACTURER PART NO. PART NO. A257-1 Grease Southwestern Petroleum Corp. (general purpose) Fort Worth, TX A257-3 Grease Aero Shell 14 Shell Oil Co. MIL-G-25537 A257-4 Dexron II or (automatic Dexron II/Mercon or transmission fluid) Dexron III/Mercon A257-6 Grease Fuelube...
  • Page 280 20-79 Adhesives and Sealants DESCRIPTION COLOR MFR. PART NO. MANUFACTURER PART NO. B270-1 Sealant – manganese-cured, Gray AC-730 B-* 3M Co. fuel resistant (2-part) St. Paul, MN B270-2 Substitute B270-1 B270-4 Substitute B270-13 B270-5 Sealant - synthetic rubber putty White Q4-2805 Dow Corning Corp.
  • Page 281 20-79 Adhesives and Sealants (continued) RHC PART DESCRIPTION COLOR MFR. PART NO. MANUFACTURER B270-21 Protectant – corrosion, non- Amber Max Wax Corrosion drying (1-part) Technologies Corp. Garland, TX Lt. Amber LPS 3 LPS Laboratories, Inc. Tucker, GA B270-22 Substitute B270-21 Protectant –...

  • Page 282: 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 283: Miscellaneous Practices

    20-90 Miscellaneous Practices 20-91 Part Interchangeability Refer to R66 Illustrated Parts Catalog for part interchangeability information. 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.

  • Page 284: Crimp Inspection

    20-94 Crimp Inspection Refer to Figure 20-5. FIGURE 20-5 CRIMP INSPECTION Page 20.26 Chapter 20 Standard Practices APR 2017...
  • Page 285 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 286 Intentionally Blank Page 21.ii Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...

  • Page 287: 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 288 FIGURE 21-1 NOSE VENT Page 21.2 Chapter 21 Environment Control MAY 2015...

  • Page 289: 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 290 FIGURE 21-2 AIR CONDITIONING SCHEMATIC Page 21.4 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...

  • Page 291: 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 292 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 293: 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 294: 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 295: Troubleshooting

    21-24 Troubleshooting 1. If air exiting overhead duct is not cold: POSSIBLE CAUSE TROUBLESHOOT/CORRECTIVE ACTION Recover refrigerant per § 12-82. System should operate normally on Low Refrigerant Charge/ Refrigerant approximately 2.5 lb refrigerant. Leak If less than 2.5 refrigerant is recovered, perform leak detection per § 12-83, repair leaks if any, and charge system with refrigerant per §...
  • Page 296 FIGURE 21-3 CABIN HEAT Page 21.10 Chapter 21 Environment Control JUL 2020...

  • Page 297: 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 298: 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 299 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 300 Intentionally Blank Page 21.14 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012...
  • Page 301 CHAPTER 22 AUTOPILOT Section Title Page 22-00 Description ..........22.1 22-10 (Pitch) Servo Assembly .
  • Page 302 Intentionally Blank Page 22.ii Chapter 22 Autopilot MAY 2015...

  • Page 303: 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 304 FIGURE 22-1 AUTOPILOT SYSTEM Page 22.2 Chapter 22 Autopilot MAY 2015...

  • Page 305: Pitch) Servo Assembly

    22-10 (Pitch) Servo Assembly 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. Remove G702-7 cover assembly under pilot's seat. 3.

  • Page 306: Roll) Servo Assembly

    22-20 (Roll) Servo Assembly 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. CAUTION Do not change the length of A336-8 push-pull tube and A127-3 rod ends center-to-center dimension (4.27–4.33 inches).

  • Page 307: Flight Control Computer

    FIGURE 22-2 FLIGHT CONTROL COMPUTER 22-30 Flight Control Computer 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. 3. Disconnect D323 harness assemblies and D354 servo assembly harnesses from 01311-03-11 flight control computer's J1 PITCH, J2, J3 ROLL, and J4 receptacles.

  • Page 308: Control Panel

    22-30 Flight Control Computer (continued) B. Installation 1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit breaker at panel. 2. Position 01311-03-11 flight control computer under pilot's seat and install screws securing computer to D358-1 support assemblies. Tighten screws. Verify security. 3.

  • Page 309: 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 310: 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 311 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 312: 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 313 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 314 Intentionally Blank Page 22.12 Chapter 22 Autopilot MAY 2015...
  • Page 315 CHAPTER 25 FURNISHINGS Section Title Page 25-00 Description ..........25.1 25-10 Seat Harnesses .
  • Page 316 Intentionally Blank Page 25.ii Chapter 25 Furnishings APR 2019...

  • Page 317: 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 318 FIGURE 25-1 SEAT HARNESSES, SEAT ASSEMBLIES, AND BACK RESTS Page 25.2 Chapter 25 Furnishings R66 Maintenance Manual SEP 2012...

  • Page 319: 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 320: 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 321: Seat Assemblies And Back Rests

    25-20 Seat Assemblies and Back Rests 25-21 Seat Assembly Removal and Installation WARNING Never modify seat assemblies, including seat assembly fabric, seat pans, or hook and loop tape (Velcro) securing fabric to seat pans. Seat assembly energy-absorption design is critical to occupant safety.

  • Page 322: Back Rest Assembly Removal And Installation

    25-22 Back Rest Assembly Removal and Installation A. Aft Left and Right Back Rest Assembly Removal 1. If heated seats are installed, turn battery switch off and pull out SEAT HEATERS circuit breaker (20 amp) on circuit breaker panel. 2. Refer to Figure 25-1. Remove hardware securing back rest assembly to cabin bulkhead.

  • Page 323: Back Rest Cushion Replacement

    25-23 Back Rest Cushion Replacement A. Forward Back Rest 1. If heated seats are installed, turn battery switch off and pull out SEAT HEATERS circuit breaker (20 amp) on circuit breaker panel. Disconnect F940-3 wire harness from F939-2 pad assembly wiring at connector. 2.

  • Page 324: Heated Seats

    25-24 Heated Seats A. Description Heated seat bottoms and backrests for the forward seats and outboard rear seats are an option. Switches to control low and high heat settings for all four heated seats are located on the panel above the right-side collective boot. The seat heaters operate only when the generator switch is in the ON position to reduce the likelihood of inadvertently draining the battery before the engine is started.
  • Page 325 Intentionally Blank Page 25.9 APR 2019 Chapter 25 Furnishings...
  • Page 326 FIGURE 25-2 CARPET AND INSULATION Page 25.10 Chapter 25 Furnishings APR 2019...

  • Page 327: Carpet

    25-30 Carpet A. Forward (Floor) Carpet Assembly Removal 1. Refer to Figure 25-2. Remove adjustable and/or removable pedals, as required. 2. Remove hardware securing scuff plates (and carpet) to cabin floor. Detach carpet from floor via hook and loop tape (Velcro). B.

  • Page 328: Insulation (Foam And Headliner)

    25-40 Insulation (Foam and Headliner) 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. 1.

  • Page 329: License Holder Replacement

    25-52 License Holder Replacement A. Removal 1. Remove aircraft documents from license holder. 2. Drill out rivets securing license holder to cabin under left side windshield frame and remove license holder. Deburr holes and clean up debris. B. Installation 1. Cleco license holder to cabin holes under left side windshield frame. Remove clecos and install rivets.

  • Page 330: Emergency Equipment

    25-60 Emergency Equipment 25-61 Emergency Locator Transmitter (ELT) A. Description The ELT activates when subjected to a significant change in velocity (as in a crash), by remote control switch located on the cyclic control panel, or by a switch on the ELT transmitter.

  • Page 331: Fire Extinguisher

    25-62 Fire Extinguisher CAUTION Extinguisher is rated for a max storage and operating temperature of 120°F (49°C). If operating conditions would expose extinguisher to higher temperatures (e.g. long term parking in the sun in a hot climate), remove extinguisher and store it in a cooler area between flights.
  • Page 332 Intentionally Blank Page 25.16 Chapter 25 Furnishings APR 2019...

  • Page 333: Cargo Hook Installation

    25-70 Cargo Hook Installation 25-71 Description See R66 Pilot’s Operating Handbook Cargo Hook Supplement (Section 9) for complete system description. The cargo hook installation includes a cargo hook, electric release buttons on left and right side cyclic, mechanical release knobs at left and right front seat, hydraulic and...

  • Page 334: Cargo Hook

    25-73 Cargo Hook A. Schematic Refer to Figure 98-29 for cargo hook wiring schematic. B. Removal 1. Turn battery switch off and pull out (10 amp) HOOK RELEASE and (10 amp) EXT LOAD (if installed) circuit breaker(s) on circuit breaker panel. 2.
  • Page 335 25-73 Cargo Hook (continued) C. Installation (continued) CAUTION The cargo hook must be able to swing freely in all directions. Incorrect restraining of the mechanical release control cable could cause uncommanded cargo hook release if hook were to strain against cable’s inner wire. 8.
  • Page 336 (2) MS27039C0816 screws, (2) AN742-4 clamps, and (2) A130-38 spacers to secure control cable assembly to belly. Verify cable and hardware security. e. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6 to incorporate the following data: Subtract: Weight Long.
  • Page 337 Install cargo hook per Part C steps 3 thru 10. e. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6 to incorporate the following data: Add: Weight Long.

  • Page 338: Cyclic Grips, Electric Cargo Hook Release, Remote Equipment Provisions, And Left-Seat Collective

    25-74 Cyclic Grips, Electric Cargo Hook Release, Remote Equipment Provisions, and Left- Seat Collective A. Schematics Refer to Figure 98-29 for cargo hook wiring schematic. Refer to Figure 98-30 for external load controls wiring schematic. Refer to Figure 98-31 for copilot instrument installation wiring schematic. B.
  • Page 339 Intentionally Blank Page 25.23 APR 2019 Chapter 25 Furnishings...
  • Page 340 FIGURE 25-3 LOCK INDICATOR FIGURE 25-4 MECHANICAL RELEASE CONTROL RIGGING (Shown with cover removed) Page 25.24 Chapter 25 Furnishings APR 2019...

  • Page 341: Mechanical Cargo Hook Release Control Rigging

    25-75 Mechanical Cargo Hook Release Control Rigging CAUTION Cargo hook load beam must be closed and locked when rigging mechanical release control. 1. Verify HOOK RELEASE knob adjacent to collective stick is positioned full down. Verify cargo hook load beam is closed and locked. 2.

  • Page 342: Load Cell And Meter

    25-76 Load Cell and Meter A. Schematic Refer to Figure 98-29 for cargo hook wiring schematic. B. Removal Load Cell Remove load cell per § 25-73 Part B steps 1 thru 3. Insert thru bolt temporarily to support cargo hook while load cell is removed. Remove G140-7 harness assembly as required;...

  • Page 343: Left-Seat Instruments

    25-77 Left-Seat Instruments A. Schematic Refer to Figure 98-31 for copilot instruments installation wiring schematic. B. Removal 1. Turn battery switch off and pull out (10 amp) HOOK RELEASE circuit breaker on circuit breaker panel. 2. Remove hardware securing G135-5 cover and G138-4 face to F353-1 panel and remove face with attached F600-2 torquemeter and T1221MK900C010 MGT gage (and 210-095-00 load meter).

  • Page 344: Doors With Bubble Windows And Fans

    25-78 Doors with Bubble Windows and Fans A. Schematic Refer to Figure 98-32 for bubble door fans installation wiring schematic. B. Removal Bubble Door 1. Turn battery switch off and pull out AUX PWR (10 amp) circuit breaker on circuit breaker panel. 2.
  • Page 345 Refer to § 5-45 100-Hour/Annual inspection. E. Configurations for Flight 1. Door(s) Off Operation a. Remove bubble door(s) per Part B. b. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6 to incorporate the following data: Right Door Subtract: Weight Long.

  • Page 346: Skid-Mounted Mirrors

    Remove skid-mounted mirror(s), including G138 support(s) per Part A. b. Reinstall screws in skid tube(s) to prevent debris and moisture from entering tube(s). c. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6 to incorporate the following data: Right Skid-Mounted Mirror Subtract: Weight Long.

  • Page 347: Cabin Interior Hardpoint Installation

    2. Configuration for Flight with Skid-Mounted Mirror(s) Installed a. Remove screws from skid tube(s) and install skid-mounted mirror(s) per Part B. b. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6 to incorporate the following data:...
  • Page 348 Intentionally Blank Page 25.32 Chapter 25 Furnishings APR 2019...
  • Page 349 CHAPTER 28 FUEL SYSTEM Section Title Page 28-00 Description ..........28.1 28-10 Bladder Assembly .
  • Page 350 Intentionally Blank Page 28.ii Chapter 28 Fuel System JUL 2020...

  • Page 351: Description

    CHAPTER 28 FUEL SYSTEM 28-00 Description A single bladder-type crash-resistant fuel cell supplies fuel via gravity flow to the engine. The fuel cell incorporates left and right vent fittings, a filler port, a fuel gage sender, a low- fuel switch assembly, a sump drain, and a finger strainer at the fuel outlet. The low-fuel switch assembly activates the LOW FUEL segment on the annunciator panel, indicating approximately five gallons of usable fuel remaining.
  • Page 352 FIGURE 28-1 MAIN FUEL SYSTEM Page 28.2 Chapter 28 Fuel System APR 2019...

  • Page 353: Bladder Assembly

    28-10 Bladder Assembly CAUTION G028-1 bladder assembly temperature should be above 65°F before removing, installing, or flexing bladder. A. Removal 1. Defuel helicopter per § 12-42. 2. Remove tailcone cowling assembly per § 53-23. 3. Remove fuel quantity sender per § 28-21. 4.
  • Page 354 28-10 Bladder Assembly (continued) B. Installation 1. Refer to Figure 28-1. 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 355: Rollover Valves

    28-10 Bladder Assembly (continued) B. Installation (continued) 12. Service helicopter with minimum two gallons fuel per § 12-41. Verify no leaks, especially at bladder outlets. Install G004-4 (right side, aft fuselage) skin and install hardware securing skin to cabin; verify security. 13.

  • Page 356: Sump Valve

    28-12 Sump Valve A. Removal 1. Defuel helicopter per § 12-42. 2. Refer to Figure 28-1. Cut and discard safety wire (if installed) securing A729 tube to A761-2 or 1250H (sump) valve and remove tube. 3. Remove valve from G154-1 outlet assembly; tape bladder opening. 4.

  • Page 357: Fuel Quantity

    28-20 Fuel Quantity 28-21 Fuel Quantity Sender CAUTION Avoid contaminating bladder interior. Cover arms with sleeves and use lint-free gloves when working inside bladder. A. Removal 1. Turn battery switch off and pull out (2 amp) GAGES circuit breaker at panel. 2.
  • Page 358 FIGURE 28-2 FUEL SENDER CHECK Page 28.8 Chapter 28 Fuel System JUL 2020...
  • Page 359 28-21 Fuel Quantity Sender (continued) B. Installation (continued) CAUTION Rotation of fuel sender center stud or base nut is not permitted. 5. a. Main tank: Using a backup wrench, install hardware securing F049-04 harness assembly to fuel sender. Special torque nuts per § 20-33, standard torque palnuts per §...
  • Page 360 FIGURE 28-3 FUEL INDICATION CHECK 28-21 Fuel Quantity Sender (continued) D. Fuel Indication Check 1. a. Main bladder fuel indication check: Defuel main bladder per § 12-42. b. Aux tank fuel indication check: Verify main bladder has no more than 65 gallons fuel;...
  • Page 361 Intentionally Blank Page 28.9B Chapter 28 Fuel System JUL 2020...

  • Page 362: Low-Fuel Switch Assembly

    28-22 Low-Fuel Switch Assembly CAUTION Avoid contaminating bladder interior. Cover arms with sleeves and use lint-free gloves when working inside bladder. A. Schematic Refer to Figure 98-1 or 98-2 for (single) low fuel warning installation wiring schematic. Refer to Figure 98-33 for (dual) low fuel warning installation wiring schematic. B.
  • Page 363 28-22 Low-Fuel Switch Assembly (continued) C. Installation (continued) 4. Secure A729 tube to drain assembly using D277-6 clamp; verify security. 5. Perform operation check per Part D. D. Operation Check 1. Service helicopter with 7 gallons fuel per § 12-41. 2.

  • Page 364: Fuel Flow Meter Installation

    28-23 Fuel Flow Meter Installation A. Description The fuel flow meter installation consists of a fuel flow transducer installed in the engine fuel line, and a fuel flow signal adapter installed behind the left rear seatback on the cabin bulkhead. The output signal from the adapter provides fuel information including flow rate, calculated fuel remaining, and fuel range rings on either Garmin GTN-series or Avidyne IFD-series moving-map navigation displays.
  • Page 365 28-23 Fuel Flow Meter Installation (continued) C. Removal (continued) Adapter 1. Remove aft left back rest assembly per § 25-22. 2. Turn battery & avionics switches off and pull out GPS (5 amp) circuit breaker on panel. 3. Disconnect airframe harness electrical connector from AIS-380 adapter. 4.
  • Page 366 7. Install aft left back rest assembly per § 25-22. E. Configuration Configure AIS-380 fuel flow adapter per Shadin Avionics M833811-01 Installation Manual Section 5. Make the following selections for R66 installation: Field Selection Serial Port Autopopulated (may change depending on connection...
  • Page 367 28-23 Fuel Flow Meter Installation (continued) F. Scheduled Maintenance Every 12 Months: Transducer Visually inspect fuel control unit-to-transducer fuel tube connections, transducer, and reducer connections to transducer and check valve for evidence of leakage. Visually inspect components for any obvious damage; verify proper installation and security.
  • Page 368 FIGURE 28-4 FUEL VALVE Page 28.12 Chapter 28 Fuel System JUL 2020...

  • Page 369: Fuel Valve

    28-30 Fuel Valve A. Removal 1. Defuel helicopter per § 12-42. 2. Refer to Figures 28-1 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. 3.

  • Page 370: Fuel Flow Check

    28-40 Fuel Flow Check 1. Open mast fairing per § 53-22. Remove engine cowling per § 53-21. 2. Refer to Figure 28-1. Attach a temporary hose to one of the vent weldment openings. With the fuel cap installed, blow into the hose (do not use compressed air) and verify air blows out the other vent opening.
  • Page 371 Intentionally Blank Page 28.15 Chapter 28 Fuel System JUL 2020...
  • Page 372 FIGURE 28-5 AUX FUEL SYSTEM (LARGE TANK SHOWN) Page 28.16 Chapter 28 Fuel System JUL 2020...

  • Page 373: Bladder

    28-50 Aux Fuel System A. Description The auxiliary fuel system consists of a removable fuel tank located in the forward section of the baggage compartment, hoses connecting the auxiliary tank to the main fuel tank, and a small control panel on the instrument console. The auxiliary fuel tank includes a crash-resistant bladder in an aluminum and fiberglass enclosure, an internal fuel transfer pump, a quantity sender, a filler port, and a sump drain.
  • Page 374 (2) AN806-6D plugs installed on D205-36 hose assemblies and hoses are stowed in G769-1 bracket assembly (see above instructions). 6. As required, revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6 to reflect aux tank assembly removal using the following data: Subtract:...
  • Page 375 5. Connect G768-4 harness assembly to airframe harness at connectors. Verify security. 6. As required, revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6 to reflect aux tank assembly installation using the following data: Add:...
  • Page 376 G769-1 bracket assembly (refer to § 28-51). G755 support assembly installation is optional when tank is removed. 3. As required, revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6 to reflect support assembly removal using the following data: Subtract:...
  • Page 377 28-53 Aux Fuel System – Bladder CAUTION Avoid contaminating bladder interior. Cover arms with sleeves and use lint-free gloves when working inside bladder. A. Removal 1. Remove aux fuel tank per § 28-51. 2. Cut ty-rap securing D205 (drain) hose assembly to G762-11 scupper. Using a back-up wrench, disconnect hose from drain fitting, release hose at tab, and remove hose.
  • Page 378 28-53 Aux Fuel System – Bladder (continued) B. Installation (continued) 4. Position G765-1 pump assembly, G764-1 drain weldment, and tubes (with connected G759-1 cover assembly) inside bladder and install screws. Verify security. 5. Inside bladder, install clamp securing drain tube to fitting. Verify security. 6.
  • Page 379 Intentionally Blank Page 28.23 APR 2019 Chapter 28 Fuel System...
  • Page 380 FIGURE 28-6 AUX FUEL SYSTEM ELECTRICAL SCHEMATIC Page 28.24 Chapter 28 Fuel System APR 2019...
  • Page 381 28-54 Aux Fuel System – Fuel Quantity Sender Refer to § 28-21 for fuel quantity sender maintenance instructions. 28-55 Aux Fuel System – Pump Assembly CAUTION Avoid contaminating bladder interior. Cover arms with sleeves and use lint-free gloves when working inside bladder. A.
  • Page 382 FIGURE 28-7 FUEL PUMP Page 28.26 Chapter 28 Fuel System JUL 2020...
  • Page 383 28-55 Aux Fuel System – Pump Assembly (continued) B. Installation 1. Turn battery switch off and pull out (5 amp) AUX FUEL PUMP circuit breaker on circuit breaker panel. Open main baggage compartment door. 2. Remove tape from opening of G756 bladder. Verify bladder is free of wrinkles across lower surface of tank and is properly located.
  • Page 384 Intentionally Blank Page 28.28 Chapter 28 Fuel System JUL 2020...
  • Page 385 CHAPTER 29 HYDRAULICS Section Title Page 29-00 Description ..........29.1 29-10 Hydraulic Pump .
  • Page 386 Intentionally Blank Page 29.ii Chapter 29 Hydraulics MAY 2015...
  • Page 387 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 388 FIGURE 29-1 HYDRAULIC FLIGHT CONTROL SYSTEM Page 29.2 Chapter 29 Hydraulics MAY 2015...
  • Page 389 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 390 FIGURE 29-2 HYDRAULIC SYSTEM SCHEMATIC FIGURE 29-3 HYDRAULIC SERVO RIGGING Page 29.4 Chapter 29 Hydraulics JUL 2020...
  • Page 391 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 392 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 393 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 394 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 395 29-30 Hydraulic Servos (continued) C. Inspection 1. Disconnect servo from upper push-pull tube per § 29-30 Part A steps 1 thru 3. 2. Remove clevis, scissor, and D200-3 washer from servo, as applicable. 3. Visually inspect threaded bore in piston with borescope. Replace servo if corrosion is detected.
  • Page 396 Intentionally Blank Page 29.10 Chapter 29 Hydraulics JUL 2020...
  • Page 397 32-64 System Maintenance ......32.22 Page 32.i SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear...
  • Page 398 Intentionally Blank Page 32.ii Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

  • Page 399: 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 400 FIGURE 32-1 LANDING GEAR ATTACHMENT Page 32.2 Chapter 32 Landing Gear MAY 2015...

  • Page 401: Cross Tubes

    32-10 Landing Gear Assembly (continued) A. Removal (continued) 9. If air conditioning is installed, remove hardware securing G787-3 and G787-4 brackets to condenser support and remove brackets. 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.
  • Page 402 32-10 Landing Gear Assembly (continued) B. Installation 9. Refinish landing gear as required per Chapter 20. 10. When surfaces are dry, install engine cowling per § 53-21. Refer to § 6-70; install G308-2 and two F475-6 cross tube covers. Install fairing assemblies per § 32-40. 11.
  • Page 403 Intentionally Blank Page 32.3B APR 2017 Chapter 32 Landing Gear...
  • Page 404 FIGURE 32-2 CROSS TUBE REMOVAL Page 32.4 Chapter 32 Landing Gear APR 2017...
  • Page 405 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 406 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 407: 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 408: 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 409: Fairing Assemblies

    32-40 Fairing Assemblies 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. B. Installation 1.
  • Page 410 FIGURE 32-4 POP-OUT FLOATS INSTALLATION Page 32.10 Chapter 32 Landing Gear APR 2019...

  • Page 411: 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 412 FIGURE 32-5 POP-OUT FLOATS CYLINDER ASSEMBLY Page 32.12 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
  • Page 413 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 414 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 415 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 416 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 417: 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 418 FIGURE 32-7 POP-OUT FLOATS FLOAT INSTALLATION Page 32.18 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...

  • Page 419: 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 420 FIGURE 32-8 POP-OUT FLOATS FLOAT PACKING Page 32.20 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012...
  • Page 421 32-63 Float Installation (continued) C. Packing 1. Install floats per § 32-63 Part B. 2. Spread deflated float outboard of skid tube. Vacuum as much air as possible from each float chamber through topping valves. Smooth out wrinkles. 3. Lightly dust float and inside float cover with talcum powder. 4.

  • Page 422: System Maintenance

    32-64 System Maintenance A. Leak Check WARNING D679 Cylinder contents are under extreme pressure. Install MT545-1 pin assembly in D757-1 valve assembly during maintenance to prevent cylinder discharge. 1. Disconnect D674-9 hose assembly from presssure cylinder valve. Install protective cap on cylinder valve fitting. Cover D674-9 hose fitting to prevent contamination, but do not install an air-tight seal (D674-9 hose fitting must be allowed to leak to verify check valve function at each float chamber).
  • Page 423 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 424 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 425 CHAPTER 33 LIGHTS Section Title Page 33-00 Description ..........33.1 33-10 Exterior Lights .
  • Page 426 Intentionally Blank Page 33.ii Chapter 33 Lights MAY 2015...
  • Page 427 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 428 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 429 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 430 Intentionally Blank Page 33.4 Chapter 33 Lights MAY 2015...
  • Page 431 CHAPTER 52 DOORS AND WINDOWS Section Title Page 52-00 Description ..........52.1 52-10 Door Assembly .
  • Page 432 Intentionally Blank Page 52.ii Chapter 52 Doors and Windows JUL 2020...

  • Page 433: Door Assembly

    DOORS AND WINDOWS 52-00 Description The R66 has four passenger doors and one main baggage compartment door. All four cabin 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 434 FIGURE 52-1 DOOR ASSEMBLY Page 52.2 Chapter 52 Doors and Windows JUL 2020...
  • Page 435 52-10 Door Assembly (continued) D. Replacement CAUTION Use proper respiratory protection when handling fiberglass. CAUTION Protect door windows and paint from scratches or scuff marks when door maintenance is performed on workbench. 1. Refer to Figure 52-1. As required, lay masking tape on surfaces of door frame, new door hinges, and new door, to mark with soft pencil.

  • Page 436: Door Lock Replacement

    52-11 Door Lock Replacement CAUTION Protect door windows and paint from scratches or scuff marks when door maintenance is performed on workbench. 1. Remove door per § 52-10. 2. Refer to Figure 52-1. Remove hole plug opposite key slot on door interior. 3.
  • Page 437 Intentionally Blank Page 52.5 25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows...
  • Page 438 FIGURE 52-2 GAS SPRINGS AND DOOR VENTS Page 52.6 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010...

  • Page 439: 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 440: 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 441 Intentionally Blank Page 52.9 Chapter 52 Doors and Windows JUL 2020...
  • Page 442 FIGURE 52-3 WINDSHIELD INSPECTION (ACRYLIC WINDSHIELD SHOWN) Page 52.10 Chapter 52 Doors and Windows JUL 2020...

  • Page 443: Windshield Installation

    52-30 Windshield Installation 52-31 Standard (Acrylic) Windshield Installation A. Description Acrylic windshields are sandwiched between thin aluminum retainers that are screwed to the door and windshield frames. An adhesive/sealant is applied between the retainers and the windshields for security and weatherproofing. B.
  • Page 444 52-31 Standard (Acrylic) Windshield Installation (continued) E. Installation NOTE Prior to installation, if not previously accomplished, tape protective paper or film to the inside and outside of the windshield to prevent damage. 1. Verify sealant has been removed from cabin, parts, and windshield. 2.
  • Page 445 52-31 Standard (Acrylic) Windshield Installation (continued) F. Replacement NOTE Prior to installation, if not previously accomplished, tape protective paper or film to the inside and outside of the windshield to prevent damage. 1. Verify sealant has been removed from cabin and parts. 2.

  • Page 446: Impact-Resistant (Polycarbonate) Windshield Installation

    52-32 Impact-Resistant (Polycarbonate) Windshield Installation A. Description The polycarbonate windshield installation is similar to the acrylic windshield installation, but the windshields fasten to the door and windshield frames via small stainless steel straps. If a wire strike provisions kit is installed, a different stainless steel strap configuration secures the polycarbonate windshields to a strengthened bow.
  • Page 447 NOTE Refer to R66 Illustrated Parts Catalog Chapter 52. Note location of G367 ties, straps, pads, and tabs on work table or by marking on tape at fasteners to facilitate installation.
  • Page 448 52-32 Impact-Resistant (Polycarbonate) Windshield Installation (continued) E. Installation (continued) 5. Align G367 ties and straps perpendicular to retainers within 2°. Install F367-12 stiffener (or G933-2 bow assembly) and special torque screws per § 20-33. Match drill #40 pilot holes through windshield and install clecos. 6.
  • Page 449 52-32 Impact-Resistant (Polycarbonate) Windshield Installation (continued) E. Installation (continued) 9. At door frame: a. Remove door and hinge assembly. Remove G367 straps and expand pilot holes to 0.169–0.175 inch diameter holes thru windshield. Finish holes with reamer; deburr back side of holes using plastic razor. Clean up debris. b.
  • Page 450 Intentionally Blank Page 52.18 Chapter 52 Doors and Windows JUL 2020...
  • Page 451 CHAPTER 53 FUSELAGE Section Title Page 53-00 Description ..........53.1 53-10 Cabin Assembly .
  • Page 452 Intentionally Blank Page 53.ii Chapter 53 Fuselage APR 2017...

  • Page 453: Cabin Assembly

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

  • Page 455: Fairings, Cowlings, And Panels

    53-20 Fairing, Cowlings, and Panels CAUTION Mast fairing, cowlings, and panels must be installed for flight. 53-21 Engine Cowling 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. 3.

  • Page 456: Tailcone Cowling

    53-22 Mast Fairing (continued) C. Installation 1. Refer to Figure 53-1. Install left-side screws securing F261-1 mast fairing assembly to ribs. 2. Remove cap and plug and connect (pitot system) 15-4-N-O union near G201-1 (servo support) frame assembly. 3. Hold fairing closed. Install right-side screws securing fairing to ribs, and screws securing fairing at aft, vertical seam.

  • Page 457: Frame Assemblies

    NOTE See § 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 A. Removal 1. Remove engine per § 71-10.
  • Page 458 FIGURE 53-2 LOWER FRAMES Page 53.6 Chapter 53 Fuselage JUL 2020...
  • Page 459 53-31 Lower Frames (continued) B. Installation 1. Refer to Figure 53-2. a. F046-1 (LH) only: Install hardware securing shackle and frame to F574-8 block (threaded). Special torque bolt per § 20-33, and torque stripe per Figure 5-1. Install hardware securing frame to F574-5 block (insert bolt thru G246-1 brace, inside baggage compartment).
  • Page 460 FIGURE 53-3 HYDRAULIC SERVO SUPPORT FRAME Page 53.8 Chapter 53 Fuselage JUL 2020...

  • Page 461: 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 462: 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 463 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 464 FIGURE 53-4 TAILCONE ASSEMBLY Page 53.12 Chapter 53 Fuselage MAY 2015...

  • Page 465: 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 466 FIGURE 53-5 TAILCONE INSPECTION AND REPAIR Page 53.14 Chapter 53 Fuselage MAY 2015...

  • Page 467: 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 468 FIGURE 53-6 EMPENNAGE - TAILCONE CASTING Page 53.16 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010...

  • Page 469: Empennage Assembly

    53-50 Empennage Assembly A. Removal 1. Remove tail rotor guard assembly per § 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. Disconnect position light at connectors. 3.

  • Page 470: Vertical Stabilizer

    53-51 Vertical Stabilizer A. Upper Vertical Stabilizer Removal 1. Refer to Figure 53-6. Remove fastener securing vertical stabilizer C554 clips to upper horizontal stabilizer trailing edge. 2. Support C042-1 upper vertical stabilizer. Remove four bolts (threaded) and spacers securing C042-1 stabilizer to upper horizontal stabilizer, and remove C042-1 stabilizer.

  • Page 471: 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 472 FIGURE 53-7 EMPENNAGE - TAIL ROTOR GUARD Page 53.20 Chapter 53 Fuselage MAY 2015...

  • Page 473: 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 474: 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 475 CHAPTER 62 MAIN ROTOR Section Title Page 62-00 Description ..........62.1 62-10 Main Rotor Blades .
  • Page 476 Intentionally Blank Page 62.ii Chapter 62 Main Rotor JUL 2020...

  • Page 477: 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 478 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 479 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 480 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 481 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 482: 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 483: 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 484 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 485: 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 486 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 487: Inspection And Repair

    FIGURE 62-6A MAIN ROTOR HUB REPAIR LIMITS 62-22 Inspection and Repair 1. Remove main rotor hub bearings per § 62-21 steps 1 thru 4. 2. Remove hub paint by dry media blasting. 3. Refer to Figure 62-6A. If required, polish surfaces using 320-grit or finer wet-or-dry sandpaper to 0.25 inch minimum blend radius.
  • Page 488 62-22 Inspection and Repair (continued) 4. Fluorescent penetrant inspect hub per § 20-42. 5. Prime hub per § 20-60. 6. Install bearings per § 62-21 steps 6 thru 8. 7. Mask bearings and topcoat hub assembly per § 20-60. 8. When top coat has sufficiently cured, remove masking. Page 62.10B Chapter 62 Main Rotor JUL 2020...

  • Page 489: 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 490 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 491 Intentionally Blank Page 62.13 25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor...
  • Page 492 FIGURE 62-7 MEASURING TEETER HINGE FRICTION Page 62.14 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

  • Page 493: 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 494 FIGURE 62-8 MEASURING THRUST WASHER AND HUB BEARING GAP Page 62.16 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010...

  • Page 495: Drilling Nuts And Bolts

    62-32 Adjusting Hinge Friction (continued) B. Coning Hinge Adjustment Coning hinge friction is adjustable through use of various thickness C117 shims. Shims are installed between the thrust washer and the trailing-edge journal. 1. Check blade hinge friction by lifting blades until spindle tusks clear droop stops. Hold one blade level and cone opposite blade.
  • Page 496 FIGURE 62-8A MT524-2 MAIN ROTOR STATIC BALANCE FIXTURE ASSEMBLY Page 62.17A Chapter 62 Main Rotor JUL 2020...

  • Page 497: Static Balance

    62-34 Static Balance CAUTION Ensure surfaces contacting blade skins and trailing edges are sufficiently cushioned to prevent blade damage. 1. Refer to Table 62-1. Assemble main rotor blade & spindle assembly to main rotor hub by selecting a combination of C106-7 coning hinge journals and C117 coning hinge shims to obtain total axial clearance between 0.002–0.006 inch.
  • Page 498 62-34 Static Balance (continued) 6. Refer to Figure 62-8C. Insert depth micrometer (or calipers) thru (either) hole of MT524-3 end plate until dowel contacts MT524-4 shaft and mark dowel at edge of end plate; repeat on opposite side of hub. Determine side of hub with smaller measured distance and mark top of hub with letter "N"...
  • Page 499 Intentionally Blank Page 62.17D Chapter 62 Main Rotor JUL 2020...

  • Page 500: Inspection Of Main Rotor Blades

    FIGURE 62-9 MEASURING MAIN ROTOR BLADE DAMAGE 62-40 Inspection of Main Rotor Blades NOTE Main rotor blades are 14 CFR § 27.602 critical parts. Notify RHC 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 501: Scratches And Corrosion

    62-40 Inspection of Main Rotor Blades (continued) A. Measuring Damage 1. Refer to Figure 62-9. Measure blade damage using a straight edge and a thickness gage. Keep straight edge parallel with the leading and trailing edges. 2. If blades are installed on the helicopter, measure damage using the shortest straight edge possible to span damaged area.

  • Page 502: Dents

    FIGURE 62-11 DENTS ON SKINS AND DOUBLERS – DAMAGE LIMITS (TOP AND BOTTOM OF BLADE) FIGURE 62-12 DENTS ON TRAILING EDGE BOND JOINTS – DAMAGE LIMITS (TOP AND BOTTOM OF BLADE) 62-42 Dents CAUTION Tap-test dented areas in honeycomb. If any voids are found associated with dents, contact RHC Customer Service.
  • Page 503 62-42 Dents (continued) CAUTION Do not repair any dent that has a sharp cut or break in the skin. If necessary, locally penetrant inspect, keeping penetrant materials away from bond joints. A. Skins and Doublers 1. Refer to Figure 62-11. Smooth, round bottom dents with 0.060 inch minimum radius that occur in honeycomb and unsupported areas of the blade as listed below may be repaired when damage does not exceed the following limits: a.

  • Page 504: Spar Damage

    FIGURE 62-13 SPAR DAMAGE FIGURE 62-14 ROOT FITTING DAMAGE 62-43 Spar Damage 1. Refer to Figure 62-13. Spar damage limits exclude leading edge cap. Verify damage does not exceed the following limits: a. 0.020 inch maximum depth between RS 70.00 and RS 198.00. b.

  • Page 505: Root Fitting Damage

    62-44 Root Fitting Damage 1. Refer to Figure 62-14. Verify damage does not exceed the following limits: a. 0.040 inch maximum depth on outside diameter of flange. b. 0.002 inch maximum depth on area 0.35 inch outboard of flange. c. 0.060 inch maximum depth on other root fitting exposed areas. 2.
  • Page 506 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 APR 2019...

  • Page 507: Nicks And Notches

    62-45 Nicks and Notches A. Blade Trailing Edge (see also Blade Tip) 1. Refer to Figure 62-15 and § 62-50 for repair procedures for damage within limits. Blend out nicks and notches in blade trailing edge for 1.0 inch minimum each side of nick or notch (with a minimum 12 inch blend radius).
  • Page 508 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 APR 2019...

  • Page 509: Voids And Debonds

    62-46 Voids and Debonds WARNING Voids or debonds in rotor blades are not field repairable. Notify RHC 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 510 FIGURE 62-19 DOUBLERS - VOID AND DEBOND LIMITS FIGURE 62-20 HONEYCOMB - VOID AND DEBOND LIMITS Page 62.26 Chapter 62 Main Rotor JUL 2020...

  • Page 511: Repair Of Main Rotor Blades

    62-50 Repair of Main Rotor Blades WARNING Unauthorized repairs to rotor blades have caused fatal crashes. CAUTION Do NOT use power tools, chemical paint strippers, or chemical corrosion removers to repair main rotor blades. NOTE Refer to § 20-70 for approved materials. 1.

  • Page 512: Painting

    62-52 Painting CAUTION If force-drying paint, do not exceed 175°F surface temperature on blade; monitor blade temperature by temporarily installing P/N 110-2 Telatemp on blade skin. 1. Mask area to prevent overspray contamination. 2. Clean bare metal to be painted with a lint-free cloth dampened with enamel cleaner (see Approved Materials, §...

  • Page 513: Main Rotor Blade Tip Maintenance

    62-60 Main Rotor Blade Tip Maintenance After removing rounded tip covers, use 10X magnification when visually inspecting blade tip to verify no loose or blistered paint, white-powder corrosion products, or pitting of skins aft of skin-to-spar bond lines (upper & lower). If bare metal (other than spar leading edge) or corrosion is detected, proceed as follows: WARNING Review appropriate Safety Data Sheet (SDS) when working in...
  • Page 514 62-60 Main Rotor Blade Tip Maintenance (continued) 3. Clean bare metal area with lint-free cloth dampened with acetone and allow to dry. 4. Seal exposed bond joints, including bond joints on vertical surfaces, with smooth layer of B270-1 sealant (poly-sulfide, refer to § 20-79) and allow to cure. 5.
  • Page 515 CHAPTER 63 MAIN ROTOR DRIVE SYSTEM Section Title Page 63-00 Description ..........63.1 63-10 Engine Shaft Weldment .
  • Page 516 Intentionally Blank Page 63.ii Chapter 63 Main Rotor Drive System APR 2017...

  • Page 517: Engine Shaft Weldment

    CHAPTER 63 MAIN ROTOR DRIVE SYSTEM 63-00 Description The engine is mounted in a 37º nose-up attitude. A sprag-type overrunning clutch mates directly to the splined engine power take-off (PTO) shaft. The clutch is connected to a shaft with flexible couplings at both ends to transmit power to the main gearbox. A ring and pinion spiral bevel gearset at the main gearbox input reduces speed to tail rotor driveline RPM.

  • Page 518: Engine Driveline) Forward Flex Plate Shimming

    63-11 (Engine Driveline) Forward Flex Plate Shimming NOTE The engine driveline is shimmed for 0.040 / 0.000 inch compressive preload. Preload is alleviated by upward movement of main gearbox during flight. 1. Refer to Figure 53-2. Verify F174-1 support weldment rod end engagement measures 0.93 inch from tube end to rod end centerline (nominal;...
  • Page 519 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 520 FIGURE 63-1 ENGINE DRIVELINE Page 63.4 Chapter 63 Main Rotor Drive System JUL 2020...

  • Page 521: Clutch Assembly

    63-12 Clutch Assembly 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. 3. Remove bolt securing G732 cap, spacer (if installed), and F018-1 clutch assembly to Rolls-Royce engine model 250-C300/A1.

  • Page 522: Main Rotor Gearbox Assembly

    63-20 Main Rotor Gearbox Assembly A. Removal 1. Remove main rotor blades per § 62-10. 2. Remove tailcone cowling assembly per § 53-23. 3. Disconnect (pitot system) 15-4-N-O union near G201-1 (servo support) frame assembly. Cap fitting and plug line. 4.
  • Page 523 63-20 Main Rotor Gearbox Assembly (continued) B. Installation CAUTION If F006-1 main gearbox is to be installed in a helicopter equipped with a cargo hook or agricultural sprayer, verify gearbox has B900-12 modification plate adjacent to the gearbox S/N data plate, or has been overhauled (see maintenance records).

  • Page 524: Yoke And Seal Replacement

    63-20 Main Rotor Gearbox Assembly (continued) B. Installation (continued) 12. Install main rotor blades per § 62-10. CAUTION Prior to operation of a new, overhauled, or repaired main rotor gearbox, inject 5–6 ounces A257-22 oil into mast tube vent hole (not required if main gearbox has C251-3 Rev Q or subsequent main drive shaft installed).
  • Page 525 FIGURE 63-2 F908-1 YOKE ASSEMBLY INSTALLATION 63-21 Yoke and Seal Replacement (continued) B. (Tail Rotor Drive) F908-1 Yoke Assembly and Seal Installation (continued) 6. In two places, install 0.020-inch diameter lockwire and safety plug to yoke with pigtails inside recess of plug as shown. 7.
  • Page 526 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. Drain main gearbox oil per § 12-11. 3. 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 shaft weldment, noting hardware removed.
  • Page 527 Intentionally Blank Page 63.11 APR 2017 Chapter 63 Main Rotor Drive System...
  • Page 528 FIGURE 63-3 ROTOR BRAKE Page 63.12 Chapter 63 Main Rotor Drive System APR 2017...

  • Page 529: Rotor Brake

    63-30 Rotor Brake A. Removal 1. Remove (engine-driven) F910-1 yoke assembly per § 63-21, Part C steps 1 thru 3. 2. Refer to Figure 63-3. Detach D126-2 cable assembly from B112-3 spring. Detach B774-3 spring from gearbox cartridge retaining screw or rotor brake assembly link. 3.

  • Page 530: Pad Replacement

    63-31 Pad Replacement 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. 2. Remove hardware and spacers securing G109-1 arm assembly to (2) G111-1 bars and G113-1 &...
  • Page 531 CHAPTER 64 TAIL ROTOR Section Title Page 64-00 Description ..........64.1 64-10 Tail Rotor Assembly .
  • Page 532 Intentionally Blank Page 64.ii Chapter 64 Tail Rotor APR 2019...

  • Page 533: 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 534 FIGURE 64-1 TAIL ROTOR INSTALLATION Page 64.2 Chapter 64 Tail Rotor APR 2019...
  • Page 535 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 536 FIGURE 64-2 CHORDWISE STATIC BALANCE Page 64.4 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010...

  • Page 537: Static Balance

    64-11 Static Balance NOTE Tail rotor assembly received from RHC was statically-balanced at factory. 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 538 FIGURE 64-3 SPANWISE STATIC BALANCE Page 64.6 Chapter 64 Tail Rotor JUL 2020...
  • Page 539 64-11 Static Balance (continued) B. Spanwise Static Balance CAUTION Verify four washers installed under each blade’s outboard 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 540: Tail Rotor Blades

    64-20 Tail Rotor Blades NOTE Protect tail rotor assembly from damage when maintenance is performed on workbench. A. Removal 1. Remove tail rotor assembly per § 64-10. 2. Refer to Figure 64-1. Remove hardware securing F029 blade assemblies to G062-1 hub assembly.
  • Page 541 Intentionally Blank Page 64.9 APR 2019 Chapter 64 Tail Rotor...
  • Page 542 FIGURE 64-4 SCRATCHES AND CORROSION Page 64.10 Chapter 64 Tail Rotor APR 2019...

  • Page 543: Tail Rotor Blade Inspection And Repair

    64-30 Tail Rotor Blade Inspection and Repair This blade repair procedure outlines the repair limits, methods and materials used for repairing tail rotor blades. Repairs are limited to blending out scratches, dents, nicks, removing corrosion, and refinishing the blades. The inspections, repairs and limitations contained herein refer to damage sustained in service, including damage during shipping and handling (manufacturing irregularities are treated separately by the factory).
  • Page 544 FIGURE 64-5 DENTS Page 64.12 Chapter 64 Tail Rotor APR 2019...

  • Page 545: Dents

    64-32 Dents CAUTION Tap-test dented areas in honeycomb. If any voids are found associated with dents, contact RHC Customer Service. Tap-test voids, debonds, and dents in blades using an AN970-4 washer or 1965-or-later U.S. quarter dollar coin in good condition. CAUTION When dented areas are found, inspect opposite side of the blade for a bulge.

  • Page 546: Erosion

    64-33 Erosion Replace any blade where erosion has caused deformation or ripples in the leading edge. 64-34 Root Fitting Damage 1. Verify damage does not exceed the following limits: a. No repairs permitted within 1.5-inch diameter circle from center of spherical bearing. b.
  • Page 547 Intentionally Blank Page 64.15 APR 2019 Chapter 64 Tail Rotor...
  • Page 548 FIGURE 64-6 ELASTOMERIC BEARING REMOVAL FIGURE 64-7 ELASTOMERIC BEARING INSTALLATION Page 64.16 Chapter 64 Tail Rotor APR 2019...

  • Page 549: Tail Rotor Hub

    64-40 Tail Rotor Hub 64-41 Bearing Replacement A. Removal 1. Remove tail rotor assembly per § 64-10. 2. Remove tail rotor blades per § 64-20. 3. Refer to Figure 64-6. Press bearing(s) from hub using MT556-11 bearing removal (and installation) tools. B.
  • Page 550 Intentionally Blank Page 64.18 Chapter 64 Tail Rotor APR 2019...
  • Page 551 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 552 Intentionally Blank Page 65.ii Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012...

  • Page 553: Description

    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 554 FIGURE 65-1 TAIL ROTOR DRIVELINE Page 65.2 Chapter 65 Tail Rotor Drive System MAY 2015...

  • Page 555: 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 556 FIGURE 65-2 RUNOUT Page 65.4 Chapter 65 Tail Rotor Drive System MAY 2015...

  • Page 557: 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 558 FIGURE 65-4 DAMPER ASSEMBLY Page 65.6 Chapter 65 Tail Rotor Drive System MAY 2015...

  • Page 559: 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 560: 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 561 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 562: 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 563: 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 564: 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 565 CHAPTER 67 FLIGHT CONTROLS Section Title Page 67-00 Description ..........67.1 67-10 Cyclic Controls .
  • Page 566 Intentionally Blank Page 67.ii Chapter 67 Flight Controls MAY 2015...

  • Page 567: Cyclic Controls

    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 568 FIGURE 67-1 MAIN ROTOR FLIGHT CONTROLS Page 67.2 Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012...
  • Page 569 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 570: 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 571 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 572: 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 573 67-21 Collective Stick Assembly (continued) B. Installation 1. Refer to Figure 67-1. Position A333-1 collective-travel stop parallel to collective stick and apply collective friction. From aft side of co-pilot's seat, carefully position collective stick assembly in helicopter. 2. Pivot pilot's seat bottom to the open position. Install bolt from inside pilot's seat structure thru bearing block into tunnel and secure to inboard end of collective stick assembly.

  • Page 574: Collective Friction

    67-22 Collective Friction Adjust friction on F334-1 to produce a force within servo dead bands of 4–5 lb when pulling up at collective grip with friction on collective full off, then adjust friction on collective as required to produce a force of 18-22 lb when pulling up at grip when full on. 67-30 Jackshaft and Strut Assembly 67-31 Jackshaft A.

  • Page 575: Swashplate

    67-40 Swashplate A. Removal NOTE Rigging check is not required if push-pull tube rod end center- to-center dimension does not change. 1. Remove main rotor blades and hub per §§ 62-10 and 62-20. 2. Atop of C251 main rotor drive shaft, remove D226 brackets, D151 teeter stops, and C150 droop stops by removing NAS6608 bolt.
  • Page 576 67-40 Swashplate (continued) B. Installation (continued) 8. If required, fill remainder of rod end threaded hole in upper A205 fork with B270-4 or –13 sealant (see § 20-70). 9. With bolt heads in direction of rotation, connect upper A205 fork to upper C204 arm and connect arm to C203 yokes.

  • Page 577: 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 578 FIGURE 67-3 TAIL ROTOR FLIGHT CONTROLS Page 67.12 Chapter 67 Flight Controls MAY 2015...

  • Page 579: Tail Rotor Controls

    67-50 Tail Rotor Controls 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. 3. Remove screws securing upper console to side panels; pivot console up and aft. CAUTION Do not change the length of or remove rod ends from C343-11 and -13 push-pull tube assemblies.

  • Page 580: 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 581: 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 582: 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 583: 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 584: 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 585 CHAPTER 71 POWERPLANT Section Title Page 71-00 Description ..........71.1 71-10 Engine .
  • Page 586 Intentionally Blank Page 71.ii Chapter 71 Powerplant JUL 2020...

  • Page 587: Description

    CHAPTER 71 POWERPLANT 71-00 Description One Rolls-Royce model 250-C300/A1 (commercial designation RR300) free-turbine turboshaft engine powers the helicopter. The engine is equipped with an ignition exciter, igniter, starter-generator, two tachometer senders, and additional powerplant instrument senders. A direct drive, squirrel-cage style cooling fan is mounted to the intermediate shaft and supplies cooling air to the engine and gearbox oil coolers.
  • Page 588 FIGURE 71-1 ENGINE - RIGHT SIDE Page 71.2 Chapter 71 Powerplant JUL 2020...

  • Page 589: Engine

    71-10 Engine NOTE The electronic monitoring unit (EMU) is a serialized component assigned to the engine. When removing the engine, remove the engine's EMU per § 71-43, as required. A. Removal 1. Remove engine cowling assembly per § 53-21. 2. Refer to Figures 71-1 and 71-2. Verify heat shrink stamping is legible (or mark wires and cables) and remove hardware securing wires and cables to starter-generator studs.
  • Page 590 71-10 Engine (continued) A. Removal (continued) 10. Connect engine hoist to G200-1 engine lifting lug. Support engine during mounting hardware removal. 11. Cut and discard safety wire and remove two bolts securing bottom engine mount to F174-1 support weldment. Cut and discard safety wire and remove two bolts (one per side) securing side engine mounts to F046 lower frames.
  • Page 591 Intentionally Blank Page 71.3B Chapter 71 Powerplant JUL 2020...
  • Page 592 FIGURE 71-2 ENGINE - LEFT SIDE Page 71.4 Chapter 71 Powerplant JUL 2020...
  • Page 593 71-10 Engine (continued) B. Installation 1. Prepare engine for installation in helicopter per § 71-12, as required. 2. Refer to Figures 71-1 and 71-2. Connect engine hoist to G200-1 engine lifting lug. 3. Remove F579-1 bellmouth cover. Carefully install engine, inserting bellmouth through firewall.
  • Page 594 71-10 Engine (continued) B. Installation (continued) 12. Refer to Figure 79-3. Remove caps and torque check engine (oil line) fittings per RR300 OMM. Remove plugs and connect F723-1, F723-2, and F723-3 line assembly B-nuts to engine. Special torque B-nuts at engine, F649-1 oil cooler, and G689-1 oil tank assembly per §...

  • Page 595: Preparing Engine For Rolls-Royce Maintenance Facility

    71-11 Preparing Engine for Rolls-Royce Maintenance Facility 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. 1. Refer to Figures 71-1 and 71-2. Remove hardware securing MS21919WCH clamp(s) to engine vertical firewall and F577-5 bracket (earlier R66s).
  • Page 596 71-11 Preparing Engine for Rolls-Royce Maintenance Facility (continued) 6. Disconnect F741-1 line assembly from G426-1 switch assembly and fuel pump’s A919-0D reducer and remove line. 7. Disconnect F727-1 line assembly from fuel pump’s AN919-2D reducer. Disconnect F727-2 line assembly from engine fireshield’s drain fitting. Remove hardware securing MS21919WCH4 clamp the combustion section’s plug flange and remove lines.

  • Page 597: Preparing Engine For Helicopter Installation

    71-12 Preparing Engine for Helicopter Installation NOTE Remove protective caps and plugs progressively during procedure to prevent foreign object contamination. 1. Refer to Figures 71-1 and 71-2. Position G200-1 engine lifting lug on top of engine gearbox, as desired (optional). Install (2) NAS6605-3 bolts and (2) NAS1149F0532P washers, special torque bolts per §...
  • Page 598 71-12 Preparing Engine for Helicopter Installation (continued) 12. Connect F727-1 line assembly to fuel pump’s AN919-0D reducer. Connect F727-2 line assembly to engine fireshield’s drain fitting. Install one MS21919WCH4 clamp around each line, install hardware securing lines to combustion section’s plug flange, and tighten screw.
  • Page 599 71-12 Preparing Engine for Helicopter Installation (continued) 15. h. Install (2) MS21919WCH4 clamps around harness assembly and install clamps on (bottom of) engine gearbox. Install hardware, special torque nuts per § 20-33, and torque stripe per Figure 5-1. i. Stand-off ty-rap G426-1 (fuel differential pressure) switch assembly’s wire from F741-1 line assembly using MS3367-4-9 ty-raps.
  • Page 600 FIGURE 71-3 INDUCTION (STANDARD FILTER SHOWN) Page 71.10 Chapter 71 Powerplant JUL 2020...

  • Page 601: Induction

    71-20 Induction NOTE Refer to § 12-70 for (Engine) Compressor Rinse and Wash procedures. CAUTION Never operate engine without G057-1 cage assembly installed. F771-1 (foam) filter assembly not required for flight; 146150- 101 (inlet barrier filter) filter assemblies not required for flight. CAUTION Do not perform maintenance near engine inlet without cage and filter(s) or a temporary cover installed.
  • Page 602 FIGURE 71-4 INDUCTION (INLET BARRIER FILTER SHOWN) Page 71.12 Chapter 71 Powerplant APR 2019...
  • Page 603 71-21 Air Filter Assembly (continued) B. Removal Standard Filter: 1. Remove tailcone cowling assembly per § 53-23. 2. Refer to Figure 71-3. Vacuum exterior of F771-1 filter assembly. 3. Disconnect F049-08 (bypass) switch assembly harness from airframe harness at connectors. 4.
  • Page 604 71-21 Air Filter Assembly (continued) C. Installation (continued) Inlet Barrier Filter: 1. Service inlet barrier filter per Part D. 2. Refer to Figure 71-4. Remove temporary cover. Insert 146150-101 filter in G058-1 cage assembly brackets; handle filter by the potting to avoid damaging pleated media.
  • Page 605 71-21 Air Filter Assembly (continued) D. Servicing (continued) Inlet Barrier Filter (continued): d. Rinse filter in direction of airflow per step 2c. e. Rotate filter top to bottom and perform steps 2c and 2d. CAUTION Do not use compressed air, or heat from any source, to dry filter assemblies.
  • Page 606 71-21 Air Filter Assembly (continued) E. Scheduled Inspections Standard Filter: Refer to § 5-45 100-Hour/Annual Inspection. Inlet Barrier Filter: Refer to § 5-45 100-Hour/Annual Inspection. Service 146150-101 filters per Part D every 300 hours or 1 year, whichever occurs first. Replace 146150-101 filters at the next service interval after 15 cleanings.

  • Page 607: Cage Assembly

    71-22 Cage Assembly A. Removal 1. Remove tail rotor drive fan shaft per § 65-10. 2. Remove air filter assembly per § 71-21. 3. Remove hardware securing G057-1 or G058-1 cage assembly to firewall and remove cage. Install suitable barrier to prevent foreign objects from entering engine inlet.
  • Page 608 FIGURE 71-5 EXHAUST Page 71.18 Chapter 71 Powerplant JUL 2020...

  • Page 609: Exhaust Weldment

    71-30 Exhaust Weldment A. Removal 1. Remove engine cowling assembly per § 53-21. 2. Refer to Figure 71-5. Remove hardware securing F173-1 struts to F169-1 exhaust weldment and engine, and remove struts. 3. Loosen clamp(s) securing (accessory gearbox vent) tubes/hose to exhaust; pull tubes/hose off of exhaust weldment.

  • Page 610: Accessories

    71-40 Accessories 71-41 Starter-Generator 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. 3.

  • Page 611: 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 612 71-43 Engine Monitoring Unit (EMU; continued) D. Troubleshooting (continued) 4. Access EMU behind right, aft seatback assembly, then disconnect and reconnect EMU electrical connector. 5. Turn battery switch off and connect battery ground cable to battery negative terminal. 6. While observing the built-in indicator light on the EMU, turn battery switch on and verify light illuminates but does not flash.
  • Page 613 Engine Anti-Ice ........75.1 Page 75.i 25 OCT 2010 R66 Maintenance Manual Chapter 75 Engine Air Systems...
  • Page 614 Intentionally Blank Page 75.ii Chapter 75 Engine Air Systems R66 Maintenance Manual 25 OCT 2010...
  • Page 615 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 616 Intentionally Blank Page 75.2 Chapter 75 Engine Air Systems R66 Maintenance Manual 25 OCT 2010...
  • Page 617 PTG Rigging Check ......76.7 Page 76.i 25 OCT 2010 R66 Maintenance Manual Chapter 76 Engine Controls...
  • Page 618 Intentionally Blank Page 76.ii Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...
  • Page 619 CHAPTER 76 ENGINE CONTROLS 76-00 Description A twist grip throttle control is located on each collective stick. The controls are interconnected and actuate the Rolls-Royce engine model 250-C300/A1 fuel control input lever via a push- pull cable. The throttle is normally not used for control but is set either fully closed (idle position) or fully open.
  • Page 620 FIGURE 76-1 FUEL CONTROL UNIT Page 76.2 Chapter 76 Engine Controls JUL 2020...
  • Page 621 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 622 FIGURE 76-2 POWER TURBINE GOVERNOR Page 76.4 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...
  • Page 623 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 624 FIGURE 76-3 PTG (BEEP) ACTUATOR ASSEMBLY Page 76.6 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...
  • Page 625 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 626 Intentionally Blank Page 76.8 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010...
  • Page 627 CHAPTER 79 ENGINE OIL SYSTEM Section Title Page 79-00 Description ..........79.1 79-10 Scroll and Fanwheel Assemblies .
  • Page 628 Intentionally Blank Page 79.ii Chapter 79 Engine Oil System APR 2017...

  • Page 629: Description

    When draining the oil system, residual oil is trapped in the bottom corner of the oil cooler due to the oil cooler installation angle in the R66. An oil cooler drain plug allows the technician to drain trapped oil during servicing.
  • Page 630 FIGURE 79-2 SCROLL AND FANWHEEL ASSEMBLIES Page 79.2 Chapter 79 Engine Oil System APR 2019...

  • Page 631: Scroll And Fanwheel Assemblies

    79-10 Scroll and Fanwheel Assemblies A. Removal 1. Remove F196-1 fan shaft per § 65-10. 2. Refer to Figure 79-2. Remove perimeter screws securing F236-1 scroll assembly to F306-1 box assembly. 3. Remove aluminum tape sealing gaps & joints, or gently pull scroll away from box assembly and, using a scribe or similar sharp instrument, tear aluminum tape sealing gaps &...
  • Page 632 FIGURE 79-3 ENGINE OIL SYSTEM Page 79.4 Chapter 79 Engine Oil System APR 2017...

  • Page 633: Oil Tank Assembly

    79-11 Fanwheel-to-Inlet Gaps (continued) B. Trimming Inlets 1. Refer to Figure 79-2. Remove hardware securing F305-5 inlets to F236-1 scroll assembly. 2. If inlets are slotted, carefully twist inlets over F196-1 fan shaft and remove inlets. If inlets are not slotted, remove hardware securing fan shaft to C947-3 plate assemblies, noting hardware removed, and remove inlets.

  • Page 634: Oil Temperature Sender

    79-20 Oil Tank Assembly (continued) B. Installation 1. Torque check associated oil cooler and engine unions per § 20-33. 2. Refer to Figure 79-3. Position G689-1 tank assembly in helicopter and install hardware securing tank to F384-3 angles. Verify security. 3.

  • Page 635: Sight Gage

    79-22 Sight Gage A. Removal 1. Drain engine oil per § 12-60. 2. Refer to Figure 79-3. Remove B563-2 sight gage from G689-1 tank assembly. Discard o-ring; tape tank opening. B. Installation 1. Refer to Figure 79-3. Remove tape and verify G689-1 tank assembly interior is free of contaminants.

  • Page 636: Engine Oil Line Assemblies And Fittings

    79-50 Engine Oil Line Assemblies and Fittings A. Removal 1. Drain engine oil per § 12-60. 2. Refer to Figure 79-3. Remove hardware securing F723 line assembly clamps. 3. Disconnect line assembly from associated components; cap fittings. Remove line. B. Installation 1.
  • Page 637 90-155 F075-8 EFIS Installation ........90.14 90-156 F817-9 (Garmin G500H) GDU 1060 Display (R66 Police) Installation ..90.14 90-157 F818-11 (G070 Console) GTN 6XX-series GPS/NAV/COM Installation .
  • Page 638 Intentionally Blank Page 90.ii Chapter 90 Police Version JUL 2020...

  • Page 639: Police Version

    Some aircraft have a cockpit configuration that does not include the left side cyclic grip in order to prevent interference with the observer’s LCD monitor. There are two basic cockpit configurations (refer to R66 Pilot’s Operating Handbook Section 9 Police Version Supplement for illustrations). One configuration uses a modified cyclic control without a left-side grip because the flat screen monitor would interfere.
  • Page 640 FIGURE 90-1 POLICE VERSION Page 90.2 Chapter 90 Police Version JUL 2020...
  • Page 641 90-00 Description (continued) A transmit switch for the left front seat is provided on the floor near the observer’s right heel. An intercom switch for the left front seat is provided either near the observer’s right heel or at the outboard base of the seat box. An optional transmit switch for the left rear seat is also available.
  • Page 642 90-00 Description (continued) The searchlight is installed on a motorized gimbal under the belly. The searchlight power junction box is located in the right rear under-seat compartment. The searchlight is steerable in azimuth and elevation and is operated from the left front seat via a remote control. An optional slaving system allows the searchlight to be slaved to follow the camera.

  • Page 643: C023-34 Tailcone Assembly

    90-40 C430-2 Five-Point Harness Installation (Optional) Refer to Figure 90-1. The C430-2 five-point harness installation was optional equipment for earlier Police helicopters, and now is optional for all R66 Turbines (see § 6-10 for version descriptions). Refer to § 25-10 for seat harness maintenance procedures.

  • Page 644: C813 Transceiver Installation (Optional)

    90-60 C813 Transceiver Installation (Optional) A. Description The Technisonic TDFM-600/6000/7000 series (C813-2; 5-band) and TDFM-9000 series (C813-4 and C813-5; 6-band) airborne transceivers are wired through the Technisonic A711L series audio control panel to allow for separate and simultaneous operation on each band. The C813-2 transceiver (earlier Police helicopters) is located at the observer’s station.
  • Page 645 90-60 C813 Transceiver Installation (Optional; continued) D. Installation C813-2 (Technisonic TDFM-600) Transceiver: Refer to Figure 90-1. Turn battery & avionics switches off and pull out (10 amp) circuit breaker at panel. 2. Position C813-2 transceiver in D413-1 box assembly and engage slotted turnlock fasteners.

  • Page 646: C823-16 Audio Control Installation

    90-60 C813 Transceiver Installation (Optional; continued) E. Scheduled Maintenance and Inspections Refer to Technisonic Industries Limited Installation and Operating Instructions. F. Special Maintenance and Inspections 1. Turn battery & avionics switches off. Open circuit breaker panel and remove transceiver per Part C, as required. 2.

  • Page 647: C849-4 Blower Installation (Optional)

    90-80 C849-4 Blower Installation (Optional) Refer to Figure 90-1. The C849-4 blower installation is optional equipment for the Police Version. A. Removal 1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker. 2. Remove screws securing securing B050-22 or -23 upper console assembly to F033-1 lower console assembly and hinge upper console aft.

  • Page 648: D301 Ballast Installation

    90-90 D301 Ballast Installation CAUTION Altering fixed ballast can appreciably affect helicopter center of gravity (CG). CAUTION Maximum allowable empennage ballast is 21.00 lb on Police Versions. One upper and one lower weight are required. Available combinations provide total weight of 3, 6, 9, 12, 15, &...

  • Page 649: F051-1 Camera System Installation

    90-130 F051-1 Camera System Installation A. Gimbal Assembly Removal NOTE Removal of nose-mounted camera causes a large shift in CG of empty helicopter. Calculate weight and balance prior to flight with camera removed to assure aft CG limit is not exceeded. 1.

  • Page 650: F060 Intercom System Installation

    90-130 F051-1 Camera System Installation (continued) D. Controller Assembly Installation 1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker. 2. If removed, position D417-5 box on circuit breaker panel and install screws. Verify security. 3. Connect D616-1 (FLIR camera) controller assembly plug to G458 harness receptacle. Verify security.

  • Page 651: F075-2 Efis Installation

    90-150 F075-2 EFIS Installation 90-151 C831-12, -13, & -14 (GTN-XXX Series) GPS/NAV/COM Installation A. Description The Garmin GTN 600/700-series GPS for the Police version with Garmin G500H integrated display system is installed in the pilot-side console location. B. Maintenance Refer to § 97-56 for maintenance procedures. 90-152 G060-4 (Garmin G500H) Upper Console Assembly Installation A.

  • Page 652: F075-8 Efis Installation

    90-155 F075-8 EFIS Installation 90-156 F817-9 (Garmin G500H) GDU 1060 Display (R66 Police) Installation A. Description The Garmin GDU 1060 Display is installed in the pilot-side console location for the Police Version F075-8 EFIS installation. B. Maintenance Refer to § 95-71 for maintenance procedures.

  • Page 653: F079-1 Pa/Siren System Installation

    90-160 F079-1 PA/Siren System Installation A. Speaker Removal 1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker. 2. Cut safety wire securing speaker cone to F644-1 bracket. 3. Unscrew cone and remove cone and speaker horn. Cut and discard remaining safety wire from inside of cone.
  • Page 654 90-160 F079-1 PA/Siren System Installation (continued) D. Amplifier Installation 1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker. 2. Open baggage compartment door; remove aft left back rest per § 25-22, if not previously accomplished. 3.

  • Page 655: F081 Searchlight Installation

    90-170 F081 Searchlight Installation CAUTION The searchlight is very bright and can disorient other pilots or ground personnel at long distances. CAUTION The searchlight beam is very hot. Exposure to the beam at close range for more than a few seconds can result in burns. A.

  • Page 656: F082-21 Fairing Installation

    90-180 F082-21 Fairing Installation Refer to § 90-80. The F082-21 fairing installation have (longer) fairing skins for extended landing gear. Refer to § 32-40 for fairing assembly maintenance procedures. 90-190 G415-1 DVR Installation (Optional) A. DVR Removal 1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker. 2.

  • Page 657: G416 Monitor Installation

    90-200 G416 Monitor Installation A. Description The G416-1 monitor installation (earlier helicopters) hinges forward and down for stowing. The G416-4 and G416-5 monitor installation hinges forward at the right edge to stow alongside the console. B. Schematic Refer to Figure 90-12 for G416-1 monitor installation wiring schematic. Refer to Figure 90-13 for G416-4 monitor installation wiring schematic.
  • Page 658 90-200 G416 Monitor Installation (continued) D. Installation G416-1 Monitor Installation 1. Install screws securing D763-3 visor assembly to V-R1041-RH monitor. Verify security. 2. Turn battery switch off and pull-out MONITOR (2 amp) circuit breaker at panel. Position monitor on D409-8 pivot assembly; install A483-1 knob with associated hardware, and DK-225 knob with associated hardware, securing monitor to pivot assembly.

  • Page 659: G423-1 Aux Electrical System Installation

    90-210 G423-1 Aux Electrical System Installation A. Schematic Refer to § 90-280 for aux electrical system schematics. 90-220 G425-1 Wall Installation A. Removal 1. Refer to Figure 90-1. Open baggage compartment door. Release quarter-turn slot and wing head fasteners securing G428-1 wall assembly to G238-1 bulkhead and G428-2 angles.

  • Page 660: G437-1 Lojack Installation

    90-230 G437-1 Lojack Installation A. Display Removal 1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker. 2. Disconnect cable from 4106-0006-00 display. 3. Remove screws securing D600-3 visor assembly and display to D436-6 support. Remove visor and display. B.

  • Page 661: G460 Audio Control Installation

    90-240 G460 Audio Control Installation A. Description Two Technisonic A711L-series audio control panels are installed. The observer’s audio control panel is installed in the main avionics stack, and the pilot’s panel is installed in the pilot’s side console. (Earlier police version helicopters had a dual audio panel located in the avionics stack;...

  • Page 662: G608 Gps Mapping System Installation

    90-250 G608 GPS Mapping System Installation A. Description The GPS mapping computer is installed in the main baggage compartment behind the interior wall and allows an overhead view of the helicopter’s area of operation to be displayed on the LCD monitor. The computer contains a database of streets, landmarks, and topography enabling direct navigation to street addresses and other points on the ground.
  • Page 663 90-250 G608 GPS Mapping System Installation (continued) D. Installation Viewsync3D Computer 1. Turn battery switch off and pull out VIEWSYNC (5 amp) circuit breaker at panel. 2. Position Viewsync3D computer on isolator mounting tray and install hardware. Verify security. 3. Connect cables to computer. 4.
  • Page 664 90-250 G608 GPS Mapping System 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 switch off and pull out GPS MAP (5 amp) circuit breaker at panel.

  • Page 665: G749-1 Console Installation

    90-270 G749-1 Console Installation A. Removal 1. Refer to Figure 90-1. Unlatch G750-1 tray and remove contents from G749-2 console assembly. Latch tray. 2. Remove screws securing console assembly to F377-1 support assembly, and remove console. B. Installation 1. Refer to Figure 90-1. Unlatch G750-1 tray and remove contents from G749-2 console assembly.
  • Page 666 Intentionally Blank Page 90.28 Chapter 90 Police Version JUL 2020...

  • Page 667: Wiring Schematics

    90-280 Wiring Schematics FIGURE 90-2 CO60-3 INTERIOR LIGHT INSTALLATION WIRING SCHEMATIC Page 90.29 Chapter 90 Police Version JUL 2020...
  • Page 668 Intentionally Blank Page 90.30 Chapter 90 Police Version JUL 2020...
  • Page 669 90-280 Wiring Schematics (continued) FIGURE 90-3 C058-11 GRIP ASSEMBLY WIRING SCHEMATIC Page 90.31 Chapter 90 Police Version JUL 2020...
  • Page 670 Intentionally Blank Page 90.32 Chapter 90 Police Version JUL 2020...
  • Page 671 90-280 Wiring Schematics (continued) FIGURE 90-4 C813-2 TRANSCEIVER INSTALLATION WIRING SCHEMATIC Page 90.33 Chapter 90 Police Version JUL 2020...
  • Page 672 Intentionally Blank Page 90.34 Chapter 90 Police Version JUL 2020...
  • Page 673 90-280 Wiring Schematics (continued) FIGURE 90-5 C813-4 TRANSCEIVER INSTALLATION WIRING SCHEMATIC Page 90.35 Chapter 90 Police Version JUL 2020...
  • Page 674 Intentionally Blank Page 90.36 Chapter 90 Police Version JUL 2020...
  • Page 675 90-280 Wiring Schematics (continued) FIGURE 90-6 C813-5 TRANSCEIVER INSTALLATION WIRING SCHEMATIC Page 90.37 Chapter 90 Police Version JUL 2020...
  • Page 676 Intentionally Blank Page 90.38 Chapter 90 Police Version JUL 2020...
  • Page 677 90-280 Wiring Schematics (continued) FIGURE 90-7 C823-16 AUDIO CONTROL INSTALLATION WIRING SCHEMATIC Page 90.39 JUL 2020 Chapter 90 Police Version...
  • Page 678 Intentionally Blank Page 90.40 Chapter 90 Police Version JUL 2020...
  • Page 679 90-280 Wiring Schematics (continued) FIGURE 90-8 F051-1 CAMERA SYSTEM INSTALLATION WIRING SCHEMATIC Page 90.41 Chapter 90 Police Version JUL 2020...
  • Page 680 Intentionally Blank Page 90.42 Chapter 90 Police Version JUL 2020...
  • Page 681 90-280 Wiring Schematics (continued) FIGURE 90-9 F079-1 PA/SIREN SYSTEM INSTALLATION WIRING SCHEMATIC Page 90.43 Chapter 90 Police Version JUL 2020...
  • Page 682 Intentionally Blank Page 90.44 Chapter 90 Police Version JUL 2020...
  • Page 683 90-280 Wiring Schematics (continued) FIGURE 90-10 F081-1 SEARCHLIGHT INSTALLATION WIRING SCHEMATIC Page 90.45 JUL 2020 Chapter 90 Police Version...
  • Page 684 90-280 Wiring Schematics (continued) FIGURE 90-11 F081-2 AND F081-3 SEARCHLIGHT INSTALLATION WIRING SCHEMATIC Page 90.46 Chapter 90 Police Version JUL 2020...
  • Page 685 90-280 Wiring Schematics (continued) FIGURE 90-12 G415-1 AND G416-1 MONITOR INSTALLATION WIRING SCHEMATIC Page 90.47 Chapter 90 Police Version JUL 2020...
  • Page 686 Intentionally Blank Page 90.48 Chapter 90 Police Version JUL 2020...
  • Page 687 90-280 Wiring Schematics (continued) FIGURE 90-13 G415-1 AND G416-4 AND MONITOR INSTALLATION WIRING SCHEMATIC Page 90.49 Chapter 90 Police Version JUL 2020...
  • Page 688 Intentionally Blank Page 90.50 Chapter 90 Police Version JUL 2020...
  • Page 689 90-280 Wiring Schematics (continued) FIGURE 90-14 G416-5 MONITOR INSTALLATION WIRING SCHEMATIC Page 90.51 Chapter 90 Police Version JUL 2020...
  • Page 690 Intentionally Blank Page 90.52 Chapter 90 Police Version JUL 2020...
  • Page 691 90-280 Wiring Schematics (continued) FIGURE 90-15 G437-1 LOJACK INSTALLATION WIRING SCHEMATIC Page 90.53 Chapter 90 Police Version JUL 2020...
  • Page 692 Intentionally Blank Page 90.54 Chapter 90 Police Version JUL 2020...
  • Page 693 90-280 Wiring Schematics (continued) FIGURE 90-16 G445 AND G467 AUX ELECTRICAL AND CB WIRING INSTALLATION WIRING SCHEMATIC Page 90.55 Chapter 90 Police Version JUL 2020...
  • Page 694 Intentionally Blank Page 90.56 Chapter 90 Police Version JUL 2020...
  • Page 695 90-280 Wiring Schematics (continued) FIGURE 90-17 C460-1 AND C460-2 AUDIO CONTROL INSTALLATION WIRING SCHEMATIC Page 90.57 JUL 2020 Chapter 90 Police Version...
  • Page 696 90-280 Wiring Schematics (continued) FIGURE 90-18 G608 GPS MAPPING AND MDT INSTALLATION WIRING SCHEMATIC Page 90.58 Chapter 90 Police Version JUL 2020...
  • Page 697 CHAPTER 92 ENG VERSION Section Title Page 92-00 Description ..........92.1 92-10 A826-18 Transceiver Installation (FM1) .
  • Page 698 CHAPTER 92 ENG VERSION (Continued) Section Title Page 92-190 Antenna Installations ........92.33 92-191 G457-1 Antenna Installation (Transponder) .
  • Page 699 ENG VERSION 92-00 Description The Electronic News Gathering (ENG) version of the R66 helicopter (R66 Turbine Newscopter) is configured for a typical news crew consisting of a pilot (in standard, right front seat), an onboard reporter in the left front seat, and a camera operator in the left aft seat.
  • Page 700 FIGURE 92-1 ENG VERSION Page 92.2 Chapter 92 ENG Version JUL 2020...

  • Page 701: A826-18 Transceiver Installation (Fm1)

    Transceiver Instruction Manual. Turn battery & avionics switches off. E. Scheduled Inspections Every 100-hour or annual inspection, inspect A824-18 transceiver for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part D steps 4 and 5. F. Special Inspections 1.

  • Page 702: C023-24 Tailcone Assembly

    92-20 C023-24 Tailcone Assembly A. Description Refer to Figure 92-1. The C023-24 tailcone assembly has wiring provisions for the ENG version’s D097-38 HD micro camera (tail). B. Maintenance Procedures Refer to § 53-40 for tailcone assembly maintenance procedures. 92-30 C599-7 Airspeed Indicator A.

  • Page 703: D097-36 Hd Micro Camera Installation (Windshield Bow)

    Manual. Turn battery & news equipment switches off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect CV345-CS/CSB micro camera for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 5 and 6. D. Special Inspections 1.

  • Page 704: D097-37 Hd Micro Camera Installation (Aft-Center Cabin)

    92-52 D097-37 HD Micro Camera Installation (Aft-center Cabin) A. Removal 1. Remove ILED-MA (aft talent) light per § 92-232. 2. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out MICRO CAMS (2 amp) circuit breaker at panel. 3.
  • Page 705 Intentionally Blank Page 92.7 Chapter 92 ENG Version JUL 2020...

  • Page 706: D097-38 Hd Micro Camera Installation (Tail)

    FIGURE 92-2 ENG VERSION 92-53 D097-38 HD Micro Camera Installation (Tail) A. Removal 1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out MICRO CAMS (2 amp) circuit breaker at panel. NOTE Use caution not to overstretch or sharply-bend HD camera’s cable assembly;...
  • Page 707 Operation Manual. Turn battery & news equipment switches off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect CV200-M/MB micro camera for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 5 and 6. D. Special Inspections 1.

  • Page 708: D097 Hd Micro Camera Controller

    CV345-CS/CSB Operation Manual. Turn battery & news equipment switches off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect CV505/345-10FTCBLE and/or CV200-M/MB cable controllers for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 5 and 6. D. Special Inspections 1.

  • Page 709: F003-19 Seat Removal

    F628-4 connector assembly, center F628-6 buckle assembly, F931- 1 seat assembly, A752-3 angle, & (2) NAS1352-04-8 screw. Associate hardware is replaced or omitted; refer to R66 Illustrated Parts Catalog for installation information. 92-70 Landing Gear Assembly A. Description Refer to Figure 92-1.

  • Page 710: F075-1 Efis Installation

    Refer to § 32-40 fairing assemblies for maintenance procedures. 92-110 F461-4 Cover Assembly Refer to Figure 92-1. Refer to R66 Illustrated Parts Catalog Chapter 6 for access and inspection panel locations. F461-4 cover assembly replaces F461-1 cover assembly. 92-120 G197-13 Window A.

  • Page 711: G425-1 Wall Installation

    92-130 G425-1 Wall Installation A. Removal 1. Refer to Figure 92-1. Open baggage compartment door. Release quarter-turn slot and wing head fasteners securing G428-1 wall assembly to G238-1 bulkhead and G428-2 angles. Carefully remove wall. B. Installation 1. Refer to Figure 92-1. Open baggage compartment door. Verify no foreign objects aft of wall mounting points.

  • Page 712: G448 Aft Monitors Installation

    92-150 G448 Aft Monitors Installation A. Description The aft monitor installation consists of one large main LCD monitor mounted to the cross tube between the front seatbacks and either one or two smaller LCD monitors mounted near the longitudinal tube running above the rear center equipment console. The large, main LCD monitor is mounted on a pivoting arm.

  • Page 713: G448-1 10-Inch Monitor

    & news equipment switches off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect HD10CINEROB monitor for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 4 and 5. D. Special Inspections 1.

  • Page 714: G448-1 Five-Inch Left Hand Monitor

    Turn battery & news equipment switches off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect VFM-056W monitor for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 4 and 5. D. Special Inspections 1.

  • Page 715: G448-2 Five-Inch Right Hand Monitor

    Turn battery & news equipment switches off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect VFM-056W monitor for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 4 and 5. D. Special Inspections 1.

  • Page 716: G449 Forward Monitors Installation

    Manual. Turn battery & news equipment switches off. E. Scheduled Inspections Every 100-hour or annual inspection, inspect BVB07 monitor(s) for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part D steps 4 and 5. F. Special Inspections 1.

  • Page 717: G454-1 Camera System Installation

    92-170 G454-1 Camera System Installation A. Description The nose-mounted camera system consists of a gyro-stabilized, gimbal-mounted video camera in the chin and a power junction box in the main baggage compartment. A fairing between the camera ball and chin minimizes the aerodynamic effects of the camera.
  • Page 718 92-171 D050-14 Gimbal Installation (continued) C. Function Checks 1. Power switch: (Locking Toggle) ‘Off’ LED is illuminated when system power is off. Moving the locking switch up powers up the camera, laptop controller, and gimbal. Wait 60 seconds after power is switched to on. The wait period ensures that gimbal finishes its initialization sequence.
  • Page 719 92-171 D050-14 Gimbal Installation (continued) C. Function Checks (continued) 10. Coarse Pan (AZ) Drift Knob: Controls Pan Drift while PAN/TILT Mode is in “A”. Inactive when PAN/TILT Mode is in “C”. 11. OPT EXT Lens Switch: (Two-position toggle) Controls position of lens extender. Position selected is illuminated. 2x: Lens extender inserted 1x: Lens extender extracted 12.
  • Page 720 92-171 D050-14 Gimbal Installation (continued) C. Function Checks (continued) 17. Joystick Rate Knob: Controls Joystick Rate Scaling based on Joystick Rate Mode Switch. Manual Mode: CCW: Decrease Joystick Rate CW: Increase Joystick Rate Automatic Mode: Zoom in picture to maximum (narrowest field of view) and set desired joystick rate using Joystick Rate Knob.
  • Page 721 92-171 D050-14 Gimbal Installation (continued) C. Function Checks (continued) 24. Joystick: When Pan / Tilt mode is in “A”, X and Y axes Joystick movements control Pan and Tilt Gimbal movements respectively. Inactive when Pan / Tilt mode is in “C”. When Roll Mode is in “A”, Joystick rotation in Z axis controls Roll position.
  • Page 722 92-171 D050-14 Gimbal Installation (continued) D. Scheduled Inspections Every 100-hour or annual inspection, inspect E801-1 gimbal assembly for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 5 and 6. E. Special Inspections 1.

  • Page 723: E002-2 Laptop Assembly

    4. Perform appropriate function checks per § 92-171 Part C. C. Scheduled Inspections Every 100-hour or annual inspection, inspect E002-2 laptop assembly for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 3 and 4. D. Special Inspections 1.

  • Page 724: E003-7 Aux Box Assembly

    7. Perform appropriate function checks per § 92-171 Part C. C. Scheduled Inspections Every 100-hour or annual inspection, inspect E003-7 aux box assembly for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 6 and 7. D. Special Inspections 1.

  • Page 725: G456-1 Microwave System Installation

    92-180 G456-1 Microwave System Installation A. Description The microwave transmitting system consists of a microwave transmitter, power amplifier, control panels, and a directional antenna pod. The microwave transmitter is located in the main baggage compartment. The control panel for the transmitter is located in the rear equipment console. The directional antenna pod is located beneath the aircraft belly at approximately the center of the cabin, and the power amplifier is mounted on top of it.
  • Page 726 92-181 D588-5 Controller Assembly (continued) C. Scheduled Inspections Every 100-hour or annual inspection, inspect D588-5 controller assembly for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 5 and 6. D. Special Inspections 1.

  • Page 727: Arc-Cm-Tx-Rx-Cr-01 Controller

    5. Perform appropriate post-installation function checks. Turn battery switch off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect ARC-CM-TX-RX-CR-01 controller for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 4 and 5. D. Special Inspections 1.

  • Page 728: Cmtx7-Lite Transmitter

    8. Perform appropriate post-installation function checks. Turn battery switch off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect CMTX7-LITE transmitter for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 7 and 8. D. Special Inspections 1.

  • Page 729: Pa16-Series Pod Antenna

    7. Perform appropriate post-installation function checks. Turn battery switch off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect PA16-series pod antenna for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 5 and 6. D. Special Inspections 1.
  • Page 730 Install clean, dry plastic bag over bagged cables/ connectors; secure with ty-raps. Verify security. d. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6 to incorporate the following data: Subtract: Weight Long.
  • Page 731 Intentionally Blank Page 92.31B Chapter 92 ENG Version JUL 2020...

  • Page 732: Gps-1270Fw Antenna

    5. Perform appropriate post-installation function checks. Turn battery switch off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect GPS-1270FW antenna for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 4 and 5. D. Special Inspections 1.

  • Page 733: Antenna Installations

    & avionics switches off. D. Scheduled Inspections Every 100-hour or annual inspection, inspect CI 105-16 transponder antenna for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part C steps 7 and 8. Page 92.33...

  • Page 734: G457-2 Antenna Installation (Tv Tuner)

    92-191 G457-1 Antenna Installation (Transponder; continued) E. Special Inspections 1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit breaker panel. 2. As required, remove CI 105-16 transponder antenna per Part A. Inspect condition of and verify no obvious damage to antenna, circuit breaker, and wiring. Verify no loose, chafed, or broken wires or terminals.

  • Page 735: G457-3 Antenna Installation (Scanner)

    92-192 G457-2 Antenna Installation (TV Tuner; continued) D. Scheduled Inspections Every 100-hour or annual inspection, inspect CI 273 TV tuner antenna for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part C steps 6 and 7. E. Special Inspections 1.

  • Page 736: G470-1 Aft Console Installation

    & news equipment switches off. D. Scheduled Inspections Every 100-hour or annual inspection, inspect CI 285 antenna for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part C steps 7 and 8. E. Special Inspections 1.
  • Page 737 UHF FM Transceiver Instruction Manual. Turn battery & new equipment switches off. E. Scheduled Inspections Every 100-hour or annual inspection, inspect A824 transceiver(s) for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part D steps 5 and 6. F. Special Inspections 1.

  • Page 738: G489-1 Scanner Installation

    & new equipment switches off. E. Scheduled Inspections Every 100-hour or annual inspection, inspect BCD996XT scanner for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part D steps 5 and 6. F. Special Inspections 1.

  • Page 739: G490-1 Talent Light Installation

    Verify talent light switches on and off using switch. B. Scheduled Inspections Every 100-hour or annual inspection, inspect D553-1 light assembly for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part A step 5. Page 92.39...

  • Page 740: Iled-Ma (Aft Talent) Light

    Verify talent light switches on and off using switch. C. Scheduled Inspections Every 100-hour or annual inspection, inspect ILED-MA light for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B step 4. 92-240 G491 TV Receiver Provision Installation A. Description Refer to Figure 92-1.

  • Page 741: Distribution Amp

    C. Scheduled Inspections Every 100-hour or annual inspection, inspect 11-911-102 distribution amp(s) for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 5 and 6. D. Special Inspections 1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit breaker panel.

  • Page 742: Digital Tv Receiver

    C. Scheduled Inspections Every 100-hour or annual inspection, inspect CTDVBT-288X digital TV receiver(s) for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 5 and 6. D. Special Inspections 1.

  • Page 743: G492-1 Audio System Installation

    92-250 G492-1 Audio System Installation A. Description The audio system consists of four audio control panels and an audio junction box. The audio junction box is located beneath the right rear seat. Power is supplied via a 5-amp circuit breaker in the main circuit breaker panel on the left hand side of the aircraft. Power to the audio system is not disconnected by the news equipment master switch.

  • Page 744: Forward Audio Panels

    & news equipment switches off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect G11431-00102-1 audio panel(s) for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 5 and 6. D. Special Inspections 1.

  • Page 745: Aft Console Audio Panels

    & news equipment switches off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect G11431-00102-1 audio panel(s) for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 5 and 6. D. Special Inspections 1.

  • Page 746: Digital Router

    & news equipment switches off. C. Scheduled Inspections Every 100-hour or annual inspection, inspect G13000 router for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B steps 4 and 5. D. Special Inspections 1.

  • Page 747: G493-1 Video Components Installation

    430 Guide. Turn battery & news equipment switches off. E. Scheduled Inspections Every 100-hour or annual inspection, inspect BENXT430X video router and RH-AB video switch for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part D steps 5 and 6. Page 92.47...

  • Page 748: G496-1 Dvr Installation

    92-260 G493-1 Video Components Installation (continued) F. Special Inspections 1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit breaker panel. 2. As required, remove BENXT430X video router and RH-AB video switch per Part A. Inspect condition of and verify no obvious damage to video router, video switch, circuit breaker, and wiring.

  • Page 749: Aux Electrical System Installation

    92-270 G496-1 DVR Installation (continued) E. Scheduled Inspections Every 100-hour or annual inspection, inspect ODYSSEY7Q or ODYSSEY7QPLUS monitor/recorder for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part D steps 4 and 5. F. Special Inspections 1.
  • Page 750 Intentionally Blank Page 92.50 Chapter 92 ENG Version JUL 2020...

  • Page 751: Wiring Diagrams

    92-290 Wiring Diagrams FIGURE 92-3 A826-18 TRANSCEIVER INSTALLATION (FM1) WIRING DIAGRAM Page 92.51 Chapter 92 ENG Version JUL 2020...
  • Page 752 92-290 Wiring Diagrams (continued) FIGURE 92-4 D097 HD MICRO CAMERA INSTALLATION WIRING DIAGRAM Page 92.52 Chapter 92 ENG Version JUL 2020...
  • Page 753 92-290 Wiring Diagrams (continued) FIGURE 92-5 G445-2 AUX CIRCUIT BREAKER PANEL INSTALLATION WIRING DIAGRAM Page 92.53 Chapter 92 ENG Version JUL 2020...
  • Page 754 92-290 Wiring Diagrams (continued) FIGURE 92-6 G448 AFT MONITORS INSTALLATION WIRING DIAGRAM Page 92.54 Chapter 92 ENG Version JUL 2020...
  • Page 755 92-290 Wiring Diagrams (continued) FIGURE 92-7 G449 FORWARD MONITORS INSTALLATION WIRING DIAGRAM Page 92.55 Chapter 92 ENG Version JUL 2020...
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  • Page 757 92-280 Wiring Diagrams (continued) FIGURE 92-8 G454-1 CAMERA SYSTEM INSTALLATION WIRING DIAGRAM Page 92.57 JUL 2020 Chapter 92 ENG Version...
  • Page 758 Intentionally Blank Page 92.58 Chapter 92 ENG Version JUL 2020...
  • Page 759 92-290 Wiring Diagrams (continued) FIGURE 92-9 G456-1 MICROWAVE SYSTEM INSTALLATION WIRING DIAGRAM Page 92.59 Chapter 92 ENG Version JUL 2020...
  • Page 760 92-290 Wiring Diagrams (continued) FIGURE 92-10 G487-1 FM TRANSCEIVERS INSTALLATION WIRING DIAGRAM Page 92.60 Chapter 92 ENG Version JUL 2020...
  • Page 761 92-290 Wiring Diagrams (continued) FIGURE 92-11 G489 SCANNER INSTALLATION WIRING DIAGRAM Page 92.61 Chapter 92 ENG Version JUL 2020...
  • Page 762 92-290 Wiring Diagrams (continued) FIGURE 92-12 G490-1 TALENT LIGHT INSTALLATION WIRING DIAGRAM Page 92.62 Chapter 92 ENG Version JUL 2020...
  • Page 763 92-290 Wiring Diagrams (continued) FIGURE 92-13 G491 TV RECEIVER PROVISION INSTALLATION WIRING DIAGRAM Page 92.63 Chapter 92 ENG Version JUL 2020...
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  • Page 765 92-280 Wiring Diagrams (continued) FIGURE 92-14 G492-1 AUDIO SYSTEM INSTALLATION WIRING DIAGRAM Page 92.65 JUL 2020 Chapter 92 ENG Version...
  • Page 766 Intentionally Blank Page 92.66 Chapter 92 ENG Version JUL 2020...
  • Page 767 92-290 Wiring Diagrams (continued) FIGURE 92-15 G493-1 VIDEO COMPONENTS INSTALLATION WIRING DIAGRAM Page 92.67 Chapter 92 ENG Version JUL 2020...
  • Page 768 92-290 Wiring Diagrams (continued) FIGURE 92-16 G496-1 DVR INSTALLATION WIRING DIAGRAM Page 92.68 Chapter 92 ENG Version JUL 2020...
  • Page 769 CHAPTER 95 INSTRUMENT SYSTEM Section Title Page 95-00 Description ..........95.1 95-10 Pitot-Static System .
  • Page 770 Intentionally Blank Page 95.ii Chapter 95 Instrument System JUL 2020...
  • Page 771 CHAPTER 95 INSTRUMENT SYSTEM 95-00 Description Standard primary instruments include an airspeed indicator, engine (N ) and rotor dual tachometer, altimeter, torquemeter, and magnetic compass. Engine gages include an N tachometer, measured gas (turbine) temperature, oil pressure, oil temperature, and fuel quantity.
  • Page 772 FIGURE 95-1 PITOT - STATIC SYSTEM INSTALLATION Page 95.2 Chapter 95 Instrument System APR 2017...

  • Page 773: Pitot-Static System

    95-10 Pitot-Static System A. Pitot System Leak Test CAUTION Do not apply suction to pitot system or pressure to static system. 1. Open mast fairing per § 53-22. 2. Refer to Figures 95-1 and 95-2. Seal drain hole in elbow aft of pitot tube with pressure sensitive tape.
  • Page 774 FIGURE 95-2 PITOT - STATIC SYSTEM INSTALLATION Page 95.4 Chapter 95 Instrument System APR 2017...

  • Page 775: Primary Instruments

    FIGURE 95-3 PITOT - STATIC SYSTEM SCHEMATIC 95-20 Primary Instruments 95-21 Vertical Speed Indicator A. Description 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. B.
  • Page 776 95-21 Vertical Speed Indicator (continued) D. Installation CAUTION Protect instrumentation using foam padding or equivalent. Handle instruments like eggs. 1. Turn battery switch off and pull out applicable circuit breaker(s). 2. Remove caps and plugs and connect pitot/static lines. Verify security. 3.

  • Page 777: Airspeed Indicator

    95-22 Airspeed Indicator A. Description The airspeed indicator displays airspeed in knots and either miles or kilometers per hour. The airspeed indicator operates properly in forward flight only; backward or lateral flight will not indicate correct airspeed. B. Schematic Refer to Figure 95-3 for pitot-static system schematic. C.

  • Page 778: Engine (N 2 ) And Rotor Dual Tachometer

    95-23 Engine (N ) and Rotor Dual Tachometer A. Description CAUTION Installation of electrical devices can affect accuracy and reliability of electronic tachometers. An electronic engine (N2) and rotor dual tachometer is standard. Engine tachometer signal is provided by a transducer on the engine gearbox. Rotor tachometer signal is provided by magnets on the main gearbox tail rotor driveline yoke.
  • Page 779 Turn battery switch on, open throttle, and “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 % N indication.
  • Page 780 1% change. Adjusting screw is accessed by removing instrument face perimeter screws and pulling face aft. 8. Shut down helicopter per R66 POH Section 4. 9. Install perimeter screws securing face to console. Verify security. E. Scheduled Maintenance and Inspections Refer to §...
  • Page 781 95-24 Altimeter A. Description 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 field elevation;...
  • Page 782 95-25 Torquemeter A. Description The electronic torquemeter indicates percent torque. The torque sensor is an oil pressure transducer mounted on the front of the engine’s accessory gearbox. B. Schematic Refer to Figure 98-1 for electrical schematic. C. Removal Remove torquemeter per § 95-21 Part C. D.

  • Page 783: Magnetic Compass

    95-26 Magnetic Compass A. Description An internally illuminated, wet-type compass is attached to the center bow between the windshields above the instrument panel. B. Schematic Refer to Figure 98-1 for electrical schematic. C. Removal 1. Remove hardware securing B339-2 mount to windshield bow. 2.

  • Page 784: Engine Gages

    95-30 Engine Gages 95-31 N Tachometer A. Description The electronic N tachometer indicates percent RPM of the engine’s gas producer section. The N sensor is a sealed variable-reluctance, permanent-magnet device mounted atop the engine’s accessory gearbox adjacent to the hoisting lug. B.

  • Page 785: Measured Gas (Turbine) Temperature (Mgt) Gage

    95-31 N Tachometer (continued) F. Special Maintenance and Inspections 1. Inspect wiring for loose, chafed, frayed, or broken wires. Verify no damaged connectors. Verify wiring neatness, proper routing and installation, and security. 2. Perform appropriate function checks per § 5-40. If accuracy of engine gage is suspected, remove G144-6 instrument cluster per Part C, and return to RHC for inspection.

  • Page 786: Engine Oil Pressure Gage

    95-33 Engine Oil Pressure Gage A. Description The engine oil pressure gage is electronic. The oil pressure sensor is a transducer mounted on the lower front of the engine’s accessory gearbox. B. Schematic Refer to Figure 98-1 for electrical schematic. C.

  • Page 787: Fuel Quantity Gage

    95-35 Fuel Quantity Gage A. Description The electric fuel quantity gage indicates relative fuel quantity. The variable resistance sender is mounted near the fuel cap. B. Schematic Refer to Figure 98-1 for electrical schematic. C. Removal Remove G144-6 instrument cluster per § 95-31 Part C. D.

  • Page 788: Additional Standard Indicating Equipment

    95-40 Additional Standard Indicating Equipment 95-41 Clock A. Description A manually set electric analog clock is standard equipment; a digital clock is optional. B. Schematic Refer to Figure 98-1 for electrical schematic. C. Removal 1. Remove perimeter screws securing face to console and pull face aft, or remove screws securing upper console to lower console and tilt upper console aft, as applicable.
  • Page 789 95-42 Ammeter A. Description The ammeter indicates electrical system loads. System load is measured across the A780-71 cable (shunt; cable is calibrated, do not alter cable) located between the starter/generator and relay on right side of engine compartment. B. Schematic Refer to Figure 98-1 for electrical schematic.

  • Page 790: Outside Air Temperature (Oat) Gage/Voltmeter

    95-43 Outside Air Temperature (OAT) Gage/Voltmeter A. Description NOTE No cutting or splicing of OAT probe wires is permitted. The outside air temperature gage is connected via a calibrated, twisted pair wiring harness to a stainless steel probe protruding from the chin. B.
  • Page 791 95-44 Hourmeters A. Description Two hourmeters are standard. One hourmeter is mounted above the ammeter and is activated by main gearbox oil pressure. Another hourmeter on the horizontal panel outboard of the pilot’s seat is activated by a combination of main gearbox oil pressure and a raised collective and is approved for recording time in service.

  • Page 792: Console Assemblies

    95-50 Console Assemblies NOTE Refer to R66 Pilot's Operating Handbook Section 7 for views of typical instrument panels, and the Optional Avionics Supplement for views of panels with electronic flight displays. A. Opening Console Upper instrument panels that do not include Electronic Flight Displays (EFDs) or other avionics may be "opened"...
  • Page 793 Intentionally Blank Page 95.23 APR 2019 Chapter 95 Instrument System...
  • Page 794 FIGURE 95-4 GARMIN G500H UPPER CONSOLE WITH GDU 1060 FIGURE 95-5 GARMIN G500H UPPER CONSOLE PITOT-STATIC SCHEMATIC Page 95.24 Chapter 95 Instrument System APR 2019...

  • Page 795: Electronic Flight Displays

    95-70 Electronic Flight Displays 95-71 Garmin Display Unit (GDU) 1060 NOTE Refer to Garmin G500H Instructions for Continued Airworthiness. A. Description The GDU 1060 integrates with the Garmin G500H Electronic Flight Instrument System (EFIS). Similar to the GDU 620, the GDU 1060 electronically displays primary flight instrumentation via a primary flight display (PFD) and moving map, weather, traffic, terrain and other functionality via a multifunction display (MFD), but includes touch-screen technology on one large 10.6 inch display.
  • Page 796 FIGURE 95-6 GARMIN G500H UPPER CONSOLE WITH GDU 620 95-71 Garmin Display Unit (GDU) 1060 (continued) E. Scheduled Maintenance and Inspections Refer to Garmin G500H Instructions for Continued Airworthiness. NOTE All factory-installed Garmin units are “on condition” and do not require scheduled periodic maintenance.

  • Page 797: Garmin Display Unit (Gdu) 620

    95-71 Garmin Display Unit (GDU) 1060 (continued) F. Special Maintenance and Inspections 1. Remove GDU per § 95-71 Part C. 2. Open circuit breaker panel and upper console. 3. Inspect condition of and verify no obvious damage to GDU, copper bus bars, circuit breaker, and wiring.
  • Page 798 FIGURE 95-7 EIGHT-INSTRUMENT CONSOLE WITH ASPEN PFD FIGURE 95-8 EIGHT-INSTRUMENT CONSOLE WITH ASPEN PFD PITOT-STATIC SCHEMATIC Page 95.28 Chapter 95 Instrument System APR 2019...

  • Page 799: Aspen Efd500H & Efd1000H Display(S) Installation

    95-73 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).
  • Page 800 FIGURE 95-10 EIGHT-INSTRUMENT CONSOLE WITH ASPEN PFD AND MFD FIGURE 95-11 EIGHT-INSTRUMENT CONSOLE WITH ASPEN PFD AND MFD PITOT-STATIC SCHEMATIC Page 95.30 Chapter 95 Instrument System APR 2019...
  • Page 801 95-73 Aspen EFD500H & EFD1000H Display(s) Installation (continued) B. Schematics Refer to Figure 98-19 for Aspen EFD500H Display Installation electrical schematic, and Figure 98-18 for Aspen EFD1000H Display Installation electrical schematic. Refer to Figures 95-3, 95-8, and 95-9 for Aspen PFD pitot-static schematic, and Figures 95-3 and 95-11 for Aspen MFD pitot-static schematic.
  • Page 802 95-73 Aspen EFD500H & EFD1000H Display(s) Installation (continued) E. Remote Sensor Module (RSM) Antenna NOTE Do not use magnetized tools. Removal 1. Turn battery switch off and pull-out EFIS circuit breaker (7.5 amp) on circuit breaker panel. 2. Refer to § 6-80 for antenna locations. Using plastic scraper, remove B270-1 sealant from around EFIS antenna at corners where it attaches to tailcone.
  • Page 803 CHAPTER 96 ELECTRICAL SYSTEM Section Title Page 96-00 Description ..........96.1 96-10 Battery .
  • Page 804 Intentionally Blank Page 96.ii Chapter 96 Electrical System JUL 2020...
  • Page 805 CHAPTER 96 ELECTRICAL SYSTEM 96-00 Description CAUTION The installation of electrical devices can affect the accuracy and reliability of the electronic tachometer. A 28-volt DC electrical system is standard. Primary system components are a sealed lead-acid battery, a starter-generator, and a generator control unit. The battery is located beneath the left front seat or in a compartment in the left side of the baggage compartment.
  • Page 806 FIGURE 96-1A B237-7 (LEAD-ACID) BATTERY INSTALLATION Page 96.2 Chapter 96 Electrical System APR 2019...

  • Page 807: Lead-Acid Battery Installations

    96-10 Battery 96-11 Lead-Acid Battery Installations NOTE Refer to Concorde Battery Corporation's Owner/Operator's Manual, and Instruction for Continued Airworthiness for battery maintenance procedures. CAUTION B237-7 battery (19 AH) weighs 42 lb and B237-8 battery (25 AH) weighs 52 lb including electrolyte. Carefully remove/install battery using handle provided to prevent injury.
  • Page 808 FIGURE 96-1B B237-8 (LEAD-ACID) BATTERY INSTALLATION Page 96.4 Chapter 96 Electrical System APR 2019...
  • Page 809 6. Install G248-8 cover assembly; verify security. Install auxiliary fuel tank per § 28-51, as required. Close baggage compartment door. 7. a. If B237-7 battery was removed and B237-8 battery was installed: Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6 to incorporate the following data: Subtract:...
  • Page 810 Intentionally Blank Page 96.4B Chapter 96 Electrical System APR 2019...
  • Page 811 Intentionally Blank Page 96.5 Chapter 96 Electrical System JUL 2020...
  • Page 812 FIGURE 96-2 LITHIUM-ION BATTERY INSTALLATION Page 96.6 Chapter 96 Electrical System JUL 2020...

  • Page 813: Lithium-Ion Battery Installation

    The True Blue Power (a division of Mid-Continent Instrument Company) TB17 Lithium- ion battery is a 24-volt, 17 amp-hour battery, and weighs 15.6 lb. In addition to significant weight savings (the R66 standard lead-acid battery weighs 42 lb), lithium batteries feature improved starter performance as well as cooler starts.
  • Page 814 96-12 Lithium-Ion Battery Installation (continued) C. Installing and Connecting Battery 1. Remove auxiliary fuel tank per § 28-51, if installed. 2. Perform pre-installation inspection and completely charge battery per True Blue Power Installation Manual and Operating Instructions. If battery is new, also perform visual inspection, charging, capacity check, and return to service per True Blue Power Installation Manual and Operating Instructions.

  • Page 815: External Power

    96-12 Lithium-Ion Battery Installation (continued) E. Special Maintenance and Inspections No other battery maintenance other than routine maintenance specified by True Blue Power is permitted. Operators are encouraged to review important safety information regarding handling, shipping, storage instructions, estimated unit life, and disposal instructions provided in True Blue Power Installation Manual and Operating Instructions.

  • Page 816: Lighting System

    96-40 Lighting System A red anti-collision light is installed on the tailcone and is controlled by the strobe switch on the instrument console. Position lights are installed on each side of the cabin and in the tail and are controlled by the nav lights switch. A light at the top of the windshield and post lights illuminate the instrument panel.
  • Page 817 96-50 Annunciator Panel (continued) A. Description The COWL DOOR segment is illuminated when the fuel filler cowl door, the right engine cowl door (which accesses the external power receptacle), or the baggage door is not closed. The AIR FILTER segment illuminates when pressure drop across the filter opens bypass doors, allowing unfiltered air to the engine.

  • Page 818: Low Rotor Rpm Warning Unit Adjustment

    96-50 Annunciator Panel (continued) B. Troubleshooting (continued) 7. Either an open circuit exists along wire -2062 between F695-1 tester and G198-1 annunciator, or G198-1 annunciator panel is faulty. Troubleshoot beginning with Console Connector 1 (“C1”), pin 34 and verifying security of pins on both halves of connector.

  • Page 819: Engine Monitoring Unit (Emu)

    96-70 Audio System (continued) Headset jacks are located in the ceiling near each seat. Pilot and copilot intercom and transmit are controlled via trigger switches on the cyclic grips. The trigger has two detents; the first detent activates the intercom and the second detent transmits. Additional intercom buttons are located on the forward side of the rear seats and on the left forward floor.

  • Page 820: Emergency Locator Transmitter (Elt)

    96-90 Emergency Locator Transmitter (ELT) Refer to Section 25-61 for ELT programming instructions and maintenance procedures. The Emergency Locator Transmitter (ELT) installation consists of a transmitter with internal battery pack, an external antenna, and a remote switch/annunciator. The transmitter is mounted to the upper steel tube frame and is accessible through the spring loaded air intake door in the right-side cowl.
  • Page 821 96-100 Electrical Load Analysis CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT COMPONENT AMPS EACH AMPS EACH TOTAL TOTAL MAIN BUS WARNING LT PANEL 0.006 0.320 0.006 0.320 ROTOR BRAKE LT 0.044 0.000 0.044 MAPLIGHT 0.020 0.020 0.020 0.020 INTERIOR DOME LT 0.020 0.020 0.020 0.020 OAT GAGE...
  • Page 822 96-100 Electrical Load Analysis (continued) CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT COMPONENT AMPS EACH AMPS EACH TOTAL TOTAL LIGHTS BUS LANDING LT BALLAST 1.600 5.250 3.200 10.500 LANDING LT RELAY 0.060 0.060 0.060 0.060 CIRCUIT BREAKER LTS 0.001 0.001 0.001 0.001 INSTRUMENT LT 0.500 0.500 0.500...
  • Page 823 96-100 Electrical Load Analysis (continued) CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT COMPONENT AMPS EACH AMPS EACH TOTAL TOTAL TACH BUS TACH (INCL REG) 0.022 0.022 0.022 0.022 TACH @ 13.75V 0.035 0.035 ROTOR TACH (INCL REG) 0.022 0.022 0.022 0.022 ROTOR TACH @13.75V 0.035 0.035 SUBTOTAL (TACH BUS)

  • Page 824: Audio Alerts

    96-110 Audio Alerts All R66 helicopters have a low-RPM horn which sounds when rotor RPM is below 95%. The horn is muted when the collective is fully down. On earlier aircraft, the horn is provided by speakers in the side of the instrument console. On later aircraft, a tone generator in the audio system provides the horn through crew headsets.
  • Page 825 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 .
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  • Page 827: Garmin G500H Electronic Flight Instrument System (Efis) Installation

    CHAPTER 97 AVIONICS 97-10 Garmin G500H Electronic Flight Instrument System (EFIS) Installation 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 Display Unit (GDU). NOTE Refer to Garmin G500H Instructions for Continued Airworthiness.
  • Page 828 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 on circuit breaker panel. 2. Place GDC 74H air data computer on F950-2 support assembly and install screws. Verify security.

  • Page 829: Lru Installation - Grs 77H Ahrs

    97-13 LRU Installation – GRS 77H AHRS 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. The GRS 77H also utilizes GPS data forwarded from the GDU 620.

  • Page 830: Lru Installation - Gmu 44 Magnetometer

    97-13 LRU Installation – GRS 77H AHRS (continued) E. Scheduled Maintenance and Inspections Refer to Garmin G500H EFIS Maintenance Manual, Section 5 Periodic Maintenance. NOTE All factory-installed Garmin units are “on condition” and do not require scheduled periodic maintenance. Units feature a BIT (Built-In Test) function during each initial power-up that will detect internal failure(s) and alert pilot.
  • Page 831 97-14 LRU Installation – GMU 44 Magnetometer D. Installation 1. Turn battery & avionics switches off and pull out EFIS (5 amp) circuit breaker on circuit breaker panel. 2. Position MS21919WDG12 clamp on GMU 44 magnetometer connector. 3. Install hardware securing magnetometer to F950-4 bracket. Verify security. 4.

  • Page 832: Gps Installation

    97-15 GPS Installation 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. Garmin's Wide Area Augmentation System (WAAS) utilizes ground reference stations that monitor GPS satellite data and issue correction messages which are broadcast via satellite to WAAS-enabled GPS receivers, improving accuracy, integrity, and availability.
  • Page 833 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 on circuit breaker panel.
  • Page 834 97-15 GPS Installation (continued) F. Scheduled Maintenance and Inspections NOTE All factory-installed Garmin units are “on condition” and do not require scheduled periodic maintenance. Units feature a BIT (Built-In Test) function during each initial power-up that will detect internal failure(s) and alert pilot. NOTE Refer to §...

  • Page 835: Radar Altimeter Installation

    97-20 Radar Altimeter Installation 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. B.
  • Page 836 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 on circuit breaker panel. 2. Connect console harness to RAD-40 Indicator. 3. a. For Above-Console Installation: Install hardware securing B560 faceplate to indi- cator &...
  • Page 837 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 on circuit breaker panel.

  • Page 838: Garmin Gtx 33 Transponder Installation

    97-30 Garmin GTX 33 Transponder Installation 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. The GTX 33 has no control panel face; it is controlled via the Garmin GTN 600/700-series GPS navigator.
  • Page 839 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 on circuit breaker panel.
  • Page 840 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 841: Garmin Gdl 69A Xm Receiver Installation

    97-40 Garmin GDL 69A XM Receiver Installation 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. The GDL 69A has no control panel face; weather data and audio controls are displayed on the G500H EFIS MFD or by a GTN 600/700-series GPS navigator.
  • Page 842 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 on circuit breaker panel.

  • Page 843: 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 A. Description of New Features The angle of the pilot’s cyclic grip can be adjusted fore and aft relative to the cross tube. The most forward position provides the most control clearance at aft cyclic.

  • Page 844: 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 845 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 on circuit breaker panel. 2. Using plastic scraper, remove B270-1 sealant from around COM antenna at corners where it attaches to tailcone.

  • Page 846: 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 847 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 848: 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 849 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 850: 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 851 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 852 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 on circuit breaker panel. 2. Remove paint & primer from antenna mating surfaces to ensure electrical ground.

  • Page 853: 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 854 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 on circuit breaker panel.

  • Page 855: Avionics Software

    As long as RHC-installed equipment is functioning properly, there is no continuing airworthiness requirement to check or update software levels in Robinson helicopters; RHC will issue an SB (or FAA will issue an AD) for any mandatory updates.
  • Page 856 Intentionally Blank Page 97.30 Chapter 97 Avionics APR 2019...
  • Page 857 Page 98-1 R66 Electrical System (F024-2 Revision V) ..... . . 98.1 98-2A R66 Electrical System (F024-2 Revision R) ..... . . 98.2A 98-2B R66 Electrical System (F024-1 Revision J) .
  • Page 858 CHAPTER 98 WIRING DIAGRAMS (Continued) Figure Title Page 98-26 Lithium-Ion Battery Installation ....... . . 98.47 98-27 Heated Seats Installation .
  • Page 859 FIGURE 98-1 R66 ELECTRICAL SYSTEM (REVISION V) JUL 2020 Chapter 98 Wiring Diagrams Page 98.1...
  • Page 860 Intentionally Blank Page 98.2 Chapter 98 Wiring Diagrams JUL 2020...
  • Page 861 FIGURE 98-2A R66 ELECTRICAL SYSTEM (F024-2 REVISION R) JUL 2020 Chapter 98 Wiring Diagrams Page 98.2A...
  • Page 862 FIGURE 98-2B R66 ELECTRICAL SYSTEM (F024-1 REVISION J) Page 98.2B Chapter 98 Wiring Diagrams JUL 2020...
  • Page 863 FIGURE 98-3 AIR CONDITIONING INSTALLATION Page 98.3 APR 2017 Chapter 98 Wiring Schematics...
  • Page 864 Intentionally Blank Page 98.4 Chapter 98 Wiring Schematics APR 2017...
  • Page 865 FIGURE 98-4 ADF INSTALLATION Page 98.5 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 866 Intentionally Blank Page 98.6 Chapter 98 Wiring Diagrams APR 2017...
  • Page 867 FIGURE 98-5 STANDARD AUDIO INSTALLATION (NAT AA12S-600 AUDIO CONTROL) Page 98.7 APR 2017 Chapter 98 Wiring Schematics...
  • Page 868 Intentionally Blank Page 98.8 Chapter 98 Wiring Schematics APR 2017...
  • Page 869 FIGURE 98-6 DUAL AUDIO CONTROL INSTALLATION Page 98.9 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 870 Intentionally Blank Page 98.10 Chapter 98 Wiring Diagrams APR 2017...
  • Page 871 FIGURE 98-7 PA/SIREN INSTALLATION Page 98.11 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 872 Intentionally Blank Page 98.12 Chapter 98 Wiring Diagrams APR 2017...
  • Page 873 FIGURE 98-8A AUTOPILOT INSTALLATION Page 98.13 JUL 2020 Chapter 98 Wiring Schematics...
  • Page 874 FIGURE 98-8B AUTOPILOT INSTALLATION Page 98.14 Chapter 98 Wiring Schematics JUL 2020...
  • Page 875 FIGURE 98-9 GARMIN GDU 1060 INSTALLATION Page 98.15 APR 2019 Chapter 98 Wiring Diagrams...
  • Page 876 FIGURE 98-9A GARMIN GDU 620 INSTALLATION Page 98.16 Chapter 98 Wiring Diagrams APR 2019...
  • Page 877 FIGURE 98-10 GARMIN GSU 75 ADAHRS INSTALLATION Page 98.17 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 878 Intentionally Blank Page 98.18 Chapter 98 Wiring Diagrams APR 2017...
  • Page 879 FIGURE 98-11 GARMIN GDC 74H AIR DATA COMPUTER INSTALLATION Page 98.19 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 880 Intentionally Blank Page 98.20 Chapter 98 Wiring Diagrams APR 2017...
  • Page 881 FIGURE 98-12 GARMIN GRS 77H AHRS INSTALLATION Page 98.21 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 882 Intentionally Blank Page 98.22 Chapter 98 Wiring Diagrams APR 2017...
  • Page 883 FIGURE 98-13 GARMIN GTN 6XX/7XX-SERIES GPS INSTALLATION (G500H EFIS) Page 98.23 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 884 Intentionally Blank Page 98.24 Chapter 98 Wiring Diagrams APR 2017...
  • Page 885 FIGURE 98-13A AVYIDYNE IFD 4XX/5XX-SERIES INSTALLATION Page 98.24A JUL 2020 Chapter 98 Wiring Schematics...
  • Page 886 Intentionally Blank Page 98.24B JUL 2020 Chapter 98 Wiring Schematics...
  • Page 887 FIGURE 98-13B GARMIN 500 SERIES GPS INSTALLATION Page 98.24C JUL 2020 Chapter 98 Wiring Schematics...
  • Page 888 FIGURE 98-13C GARMIN 500 SERIES GPS INSTALLATION Page 98.24D JUL 2020 Chapter 98 Wiring Schematics...
  • Page 889 FIGURE 98-14 RADAR ALTIMETER INSTALLATION Page 98.25 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 890 Intentionally Blank Page 98.26 Chapter 98 Wiring Diagrams APR 2017...
  • Page 891 FIGURE 98-15 GARMIN GTX 3X5 TRANSPONDER INSTALLATION Page 98.27 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 892 Intentionally Blank Page 98.28 Chapter 98 Wiring Diagrams APR 2017...
  • Page 893 FIGURE 98-16 GARMIN GTX 33/328/330 ES TRANSPONDER INSTALLATION Page 98.29 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 894 Intentionally Blank Page 98.30 Chapter 98 Wiring Diagrams APR 2017...
  • Page 895 FIGURE 98-17 GARMIN GDL 69A XM RECEIVER INSTALLATION Page 98.31 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 896 Intentionally Blank Page 98.32 Chapter 98 Wiring Diagrams APR 2017...
  • Page 897 FIGURE 98-18 ASPEN EFD1000H DISPLAY INSTALLATION Page 98.33 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 898 Intentionally Blank Page 98.34 Chapter 98 Wiring Diagrams APR 2017...
  • Page 899 FIGURE 98-19 ASPEN EFD500H DISPLAY INSTALLATION Page 98.35 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 900 Intentionally Blank Page 98.36 Chapter 98 Wiring Diagrams APR 2017...
  • Page 901 FIGURE 98-20 GARMIN GTR 225B COM / GNC 255B NAV/COM RADIO INSTALLATION Page 98.37 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 902 Intentionally Blank Page 98.38 Chapter 98 Wiring Diagrams APR 2017...
  • Page 903 FIGURE 98-21 GARMIN GTR 225B COM RADIO INSTALLATION Page 98.39 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 904 Intentionally Blank Page 98.40 Chapter 98 Wiring Diagrams APR 2017...
  • Page 905 FIGURE 98-22 GARMIN GDL 88 ADS-B IN RECEIVER INSTALLATION Page 98.41 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 906 Intentionally Blank Page 98.42 Chapter 98 Wiring Diagrams APR 2017...
  • Page 907 FIGURE 98-23 GARMIN GTN 6XX/7XX-SERIES GPS INSTALLATION (PILOT-SIDE CONSOLE) Page 98.43 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 908 Intentionally Blank Page 98.44 Chapter 98 Wiring Diagrams APR 2017...
  • Page 909 FIGURE 98-24 F060 INTERCOM SYSTEM INSTALLATION (GARMIN GMA 350HC AUDIO CONTROL) Page 98.45 JUL 2020 Chapter 98 Wiring Schematics...
  • Page 910 Intentionally Blank Page 98.45A Chapter 98 Wiring Schematics JUL 2020...
  • Page 911 FIGURE 98-25A F060-4, -5, -6, & -7 INTERCOM SYSTEM INSTALLATION (GARMIN GMA 350HC AUDIO CONTROL) Page 98.45B JUL 2020 Chapter 98 Wiring Schematics...
  • Page 912 FIGURE 98-25B F060-1 & -2 INTERCOM SYSTEM INSTALLATION (GARMIN GMA 350H AUDIO CONTROL) Page 98.46 Chapter 98 Wiring Schematics JUL 2020...
  • Page 913 FIGURE 98-26 LITHIUM-ION BATTERY INSTALLATION Page 98.47 APR 2017 Chapter 98 Wiring Diagrams...
  • Page 914 Intentionally Blank Page 98.48 Chapter 98 Wiring Diagrams APR 2017...
  • Page 915 FIGURE 98-27 HEATED SEATS INSTALLATION Page 98.49 APR 2019 Chapter 98 Wiring Diagrams...
  • Page 916 Intentionally Blank Page 98.50 Chapter 98 Wiring Diagrams APR 2019...
  • Page 917 FIGURE 98-28 CARGO HOOK INSTALLATION Page 98.51 APR 2019 Chapter 98 Wiring Diagrams...
  • Page 918 Intentionally Blank Page 98.52 Chapter 98 Wiring Diagrams APR 2019...
  • Page 919 FIGURE 98-29 EXTERNAL LOAD CONTROLS Page 98.53 APR 2019 Chapter 98 Wiring Diagrams...
  • Page 920 Intentionally Blank Page 98.54 Chapter 98 Wiring Diagrams APR 2019...
  • Page 921 FIGURE 98-30 COPILOT INSTRUMENTS INSTALLATION Page 98.55 APR 2019 Chapter 98 Wiring Diagrams...
  • Page 922 Intentionally Blank Page 98.56 Chapter 98 Wiring Diagrams APR 2019...
  • Page 923 FIGURE 98-31 BUBBLE DOOR FANS INSTALLATION Page 98.57 APR 2019 Chapter 98 Wiring Diagrams...
  • Page 924 Intentionally Blank Page 98.58 Chapter 98 Wiring Diagrams APR 2019...
  • Page 925 FIGURE 98-32 DUAL LOW FUEL WARNING LIGHT INSTALLATION Page 98.59 APR 2019 Chapter 98 Wiring Diagrams...
  • Page 926 Intentionally Blank Page 98.60 Chapter 98 Wiring Diagrams APR 2019...
  • Page 927 FIGURE 98-33 FUEL FLOW METER INSTALLATION Page 98.61 Chapter 98 Wiring Diagrams JUL 2020...
  • Page 928 Intentionally Blank Page 98.62 Chapter 98 Wiring Diagrams JUL 2020...
  • Page 929 CHAPTER 99 SPECIAL TOOLS Section Title Page 99-10 Special Tools ..........99.1 99-20 Illustrations and Tasks .
  • Page 930 Intentionally Blank Page 99.ii Chapter 99 Special Tools APR 2017...
  • Page 931 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 APR 2017...
  • Page 932 99-20 Illustrations and Tasks Refer to Figure 99-1. Item Part Number Description Reference 1 MT054-1 Main Gearbox Drain Assembly MM § 12-11 2 MT122-6 Micrometer Assembly – Main Rotor Hub, Bolt Stretch MM § 62-10 3 MT146-4 Blocks – Swashplate Rigging (set of 2) MM §...
  • Page 933 99-20 Illustrations and Tasks (continued) Refer to Figure 99-2. Item Part Number Description Reference 1 MT352-1 Main Rotor Blade Trim Tab Gage MM § 18-13 2 MT354-4 or -7 Teeter Moment Tool MM § 62-32 3 MT357-2 0.375-inch diameter Reamer Various* 4 MT357-3 0.156-inch diameter Cobalt Steel Drill...
  • Page 934 99-20 Illustrations and Tasks (continued) Refer to Figure 99-3. Item Part Number Description Reference 1 MT384-1 Hydraulic Test Pump (U.S / Canada / Mexico – 110 V) MM § 12-33 2 MT384-2 Hydraulic Test Pump (Outside North America – 220 V) MM §...
  • Page 935 99-20 Illustrations and Tasks (continued) Refer to Figure 99-4. Item Part Number Description Reference 1 MT549-1 Spacer – Spindle Boot (set of 2) MM § 62-10 2 MT549-2 Plate – Spindle Boot MM § 62-10 3 MT556-11 Kit Tools – Tail Rotor Hub Bearing Replacement MM §...
  • Page 936 99-20 Illustrations and Tasks (continued) Refer to Figure 99-5. Item Part Number Description 1 MT850-1 Engine Stand Assembly (RR300) 2 AN970-4* Washer – Tap Test Tool 3 MT990-1 Charger Assembly (BatteryMinder – 24 VDC, 120 VAC, 50/60 Hz) MT990-2 Charger Assembly (BatteryMinder – 24 VDC, 240 VAC, 50/60 Hz) Or 1965 or later U.S.
  • Page 937 99-20 Illustrations and Tasks (continued) Refer to Figure 99-6. Item Part Number Description* 1 R6683 Tow Cart Crate (31 in. x 38 in. x 66.50 in.) 2 R5387 Windshield Box (21.75 in. x 40 in. x 66 in.; cardboard. Holds up to four windshields.) 3 R5352 Main Rotor Blade Crate (21.75 in.
  • Page 938 99-20 Illustrations and Tasks (continued) Refer to Figure 99-7. Item Part Number Description* 1 R5386 Cabin Door Crate (23.75 in. x 34 in. x 60 in.; holds [1] bubble or [2] regular doors) 2 R5388 Tailcone Crate (27.25 in. x 24 in. x 192 in.) 3 R5702 Main Rotor Blade/Tailcone Crate (28 in.
  • Page 939 CHAPTER 100 REVISION LOG Section Title Page — Revision Log ..........100.1 Page 100.i Chapter 100 Revision Log JUL 2020...
  • Page 940 Intentionally Blank Page 100.ii Chapter 100 Revision Log JUL 2020...
  • Page 941 REVISION LOG JUL 2020 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 942 REVISION LOG JUL 2020 Page Date Page Date Page Date 5.41 ..MAY 2015 5.42 ..MAY 2015 8.i ... 25 OCT 2010 12.i .
  • Page 943 REVISION LOG JUL 2020 Page Date Page Date Page Date 18.7 ..APR 2019 20.ii ..JUL 2020 20.20 ..JUL 2020 18.7A .
  • Page 944 REVISION LOG JUL 2020 Page Date Page Date Page Date 22.12 ..MAY 2015 28.ii ..JUL 2020 29.1 ..MAY 2015 28.1 .
  • Page 945 REVISION LOG JUL 2020 Page Date Page Date Page Date 32.24 ..SEP 2012 53.7 ..JUL 2020 62.17A ..JUL 2020 53.8 .
  • Page 946 REVISION LOG JUL 2020 Page Date Page Date Page Date 64.ii ..APR 2019 67.2 ..MAR 2012 71.15 ..APR 2019 64.1 .
  • Page 947 REVISION LOG JUL 2020 Page Date Page Date Page Date 90.1 ..JUL 2020 90.39 ..JUL 2020 92.16 ..JUL 2020 90.2 .
  • Page 948 REVISION LOG JUL 2020 Page Date Page Date Page Date 92.52 ..JUL 2020 95.19 ..APR 2017 97.i ..APR 2019 92.53 .
  • Page 949 REVISION LOG JUL 2020 Page Date Page Date Page Date 98.2B ..JUL 2020 98.36 ..APR 2017 99.7 ..APR 2017 98.3 .
  • Page 950 Intentionally Blank Page 100.10 Chapter 100 Revision Log JUL 2020...

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